EFFECTIVENESS OF TOTAL QUALITY MANAGEMENT IN HLL

PEROORKADA PLANT, THIRUVANANATHAPURAM

Project Report
Submitted is partial fulfillment of the requirements
For the award of the degree of
Master of Business Administration of University of Kerala.

Submitted by
ARJUN RAJEEV WARRIOR
Register Number: 59514460005
IV Semester MBA

Under the Guidance of

Dr. S.Narayenen Nair
Professor

DC School of Management and Technology

Kinfra Film and Video Park, Sainik School P.O., Kazhakuttom,
Thiuvananthapuram 695585
2016

EFFECTIVENESS OF TOTAL QUALITY MANAGEMENT IN HLL

PEROORKADA PLANT, THIRUVANANATHAPURAM

EFFECTIVNESS

OF

TOTAL
QUALITY
MANAGEMENT
PEERORKADA
PLANT

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HLL

Project Report

Submitted is partial fulfillment of the requirements

For the award of the degree of
Master of Business Administration of University of Kerala.

Submitted by
ARJUN RAJEEV WARRIOR
Register Number: 59514460005
IV Semester MBA
Under the Guidance of
Dr. S.Narayenen Nair
Professor

DC School of Management and Technology

Kinfra Film and Video Park, Sainik School P.O., Kazhakuttom,
Thiuvananthapuram 695585
2016

DECLARATION

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I hereby declare that the project report titled EFFECTIVENESS OF TOTAL QUALITY
MANAGEMENT OF HLL PEROORKADA PALNT, THIRUVANANTHAPURAM
submitted by me to the University of Kerala is based on the project work undertaken by me,
under the guidance of Dr. S.Narayayenen Nair and it is not submitted to any other University or
Institution for the award of any degree, diploma, certificate or title earlier.

ARJUN RAJEEV WARRIOR

Place: Trivandrum

Reg. No. 59514460005

Date:

IV Semester MBA

ACKNOWLEDGEMENT

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I express my sincere thanks to one and all that helped for the successful completion of my
project work. First and foremost, I praise and thank God Almighty form the depth of my heart,
which has been the source of strength in the completion of the project work.

I would like to express my sincere gratitude to the HLL Management Academy at Kowdiar as
well as the management of HLL Peroorkada Plant for allowing me to conduct the project in
their esteemed organization. I would like to acknowledge my gratitude to Mr.Venugopal S,
Deputy General Manager (P, S&E) for the guidance and useful help in completing this project.
I am deeply obliged to all the employees of HLL for their cooperation, support and help in my
endeavor. My special thanks to one and all in the production and quality control department for
their valuable support and suggestions.

I sincerely thank and record my gratitude to my faculty guide as well as our director of DC
School of Management and Technology, Trivandrum Dr.S. Narayenen Nair for guiding me
through the project, offering valuable suggestions, encouragement and providing a wonderful
opportunity for learning.

EXECUTIVE SUMMARY

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This report is a problem oriented study conducted in HLL Life care Ltd for a period of 45 days.
As the name implies HLL Life Care Ltd produces Life Care products. Their main product is
condoms. The corporate office of HLL Life Care Ltd is situated in Poojapura, Trivandrum. This
study is conducted in their first plant which is situated in Peroorkada Plant, Trivandrum.

The identified area in this organization is the relationship between the various factors associated
to the quality management system from the perspective of the employees. Thus the report is
titled as A Study on effectiveness of Total Quality Management of the HLL, Peroorkada Plant
from the perspective of the employees. There is 1 primary and 3 secondary objective behind the
study. The main objective is to determine the effectiveness of total quality management in HLL,
Peroorkada Plant from the perspective of the employees working in the organization. For this
study a sample of 60 employees were taken from a population of 600 employees through
questionnaire and schedule. Statistical tools used for the study is mainly Chi-Square test, charts
and percentage analysis.

From the analysis of the reports it is concluded that the effectives of various factors associated to
the quality management from the angle of the employees is appreciable to some extent thus has
room for further improvement in the organization. The possible suggestion for further
improvements is mentioned towards the end of the report.

LIST OF CONTENTS

CONTENTS

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Chapter I INTRODUCTION
1.1 TQM Defined
1.2 Steps for Creating TQM culture
1.3 Strategies for development of TQM
1.4 Principles of TQM
Chapter II RESEARCH METHODOLOGY
Chapter III INDUSTRY & COMPANY PROFILE
4.1 Industry Profile
4.2 Company Profile
4.3 Product Profile
4.4 Functional departments
Chapter IV DATA ANALYSIS AND INTERPRETATION
4.1 Gender of respondents
4.2 Age of respondents
4.3 Income wise classification
4.4 IMPORTANCE OF QUALITY MANAGEMENT
IMPLEMENTATION IN CREATION OF SUCESSFUL BUSINESS
STRATEGY IN HLL
4.5 ENTHUSIASM OF TOP MANAGEMENT
4.6 IMPORTANCE OF 7QC TOOLS FOR PROCESS
CONTROL AND IMPLEMENTATION IN HLL
4.7 IMPORTANCE OF STANDARDIZED
DOCUMENTATION FOR WORK METHOD AND PROCESS
INSTRUCTIONS IN HLL
4.8 IMPORTANCE OF TQM TRAINING FOR BUILDING
POSITIVE WORK CULTURE
4.9 INCREASED EMPLOYEE MORALE
4.10 QUALITY BASED SEMINARS AND PROGRAMS
4.11 PRIMARY RESPONSIBILITIES FOR QUALITY

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4.12 QUALITY SYSTEM IMPROVES ORGANIZATIONAL

PERFORMANCE AND DIRECTIONALITY TO EMPLOYEES OF HLL
4.13 REDUCE DEFECT LEVELS
4.14 TRANSPARENT AND EFFECTIVE QUALITY
SYSTEM FOR RECOGNIZING AS WELL AS DETECTING DEFECTS
4.15 IMPLEMENTATION OF QUALITY IMPROVEMENT
ACTIVITIES SUCH AS QUALITY CIRCLE, QUALITY TEAM WORK
AND SUGESSION SYSTEM IN HLL
4.16 REDUCED LABOUR TURN OVER
4.17 ENCOURAGEMENT NEEDED FOR CONTINUOUS
IMPORVEMENT FOR ALL THE PRODUCTS AND SERVICES IN
DECISION MAKING
4.18 QUALITY STANDARD A GUID FOR ACTION,
JUDGEMENT AND ATTITUDE FOR BUILDING TQM CULTURE
4.19 QUALITY INITIATIVES HELP TO KEEP
PRODUCTIVITY POSITIVE ALWAYS
4.20 PERIODIC CONDUCTION OF BENCHMARKING
WITH OTHER FIRMS
4.21 PROCESSES, WORK CULTURE AND PRATICES BY
HLL
4.22 AWARNESS OF THE EMPLOYESS BASED ON THE
FOLLOWING FACTORS
4.22.1 CERTIFICATIONS OBTAINED BY HLL
4.22.2 QUALITY PRACTICES HLL APPLYING FOR

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4.23 INCREASE IN PROFITABILITY

Chapter V HYPOTHESIS
Chapter VI FINDINGS, SUGGESTIONS AND CONCLUSION
6.1 Findings
6.2 Suggestions
6.3 Conclusion
BIBLIOGRAPHY
APPENDIX - QUESTIONNAIRE

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INTRODUCTION

INTRODUCTION

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Total Quality Management is a management approach that originated in the 1950s and has
steadily become more popular since the early 1980s. Total Quality is a description of the culture,
attitude and organization of a company that strives to provide customers with products and
services that satisfy their needs. The culture requires quality in all aspects of the companys
operations, with processes being done right the first time and defects and waste eradicated from
operations.
Total Quality Management, TQM, is a method by which management and employees can
become involved in the continuous improvement of the production of goods and services. It is a
combination of quality and management tools aimed at increasing business and reducing losses
due to wasteful practices.
Some of the companies who have implemented TQM include Ford Motor Company, Phillips
Semiconductor, SGL Carbon, Motorola and Toyota Motor Company.

TQM Defined
TQM is a management philosophy that seeks to integrate all organizational functions (marketing,
finance, design, engineering, and production, customer service, etc.) to focus on meeting
customer needs and organizational objectives.
TQM views an organization as a collection of processes. It maintains that organizations must
strive to continuously improve these processes by incorporating the knowledge and experiences
of workers. The simple objective of TQM is Do the right things, right the first time, every
time. TQM is infinitely variable and adaptable. Although originally applied to manufacturing
operations, and for a number of years only used in that area, TQM is now becoming recognized
as a generic management tool, just as applicable in service and public sector organizations. There
are a number of evolutionary strands, with different sectors creating their own versions from the
common ancestor. TQM is the foundation for activities, which include:

Commitment by senior management and all employees

Meeting customer requirements

Reducing development cycle times

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Just in time/demand flow manufacturing

Improvement teams

Reducing product and service costs

Systems to facilitate improvement

Line management ownership

Employee involvement and empowerment

Recognition and celebration

Challenging quantified goals and benchmarking

Focus on processes / improvement plans

Specific incorporation in strategic planning

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HLL

This shows that TQM must be practiced in all activities, by all personnel, in manufacturing,
marketing, engineering, R&D, sales, purchasing, HR, etc.

STEPS FOR CREATING TQM CULTURE

a)
b)
c)
d)
e)

Management action in delighting customers.

Dismantling boundaries and internal competition.
Fact based decision making.
Kaizen approach
No organizational structures of TQM

STRATEGIES FOR THE DEVELOPMENT OF TQM

a) TQM Element Approach Using TQM tools to foster improvement. i.e. quality circles,
statistical process control, six sigma and design of experiments ensures the effective
implementation.
b) The Guru Approach Use the guides of one of the leading quality thinker.
c) Organizational Model Approach The organization use bench marking as a model for
excellence.
d) Japanese Total Quality Approach Companies pursue Deming principle to follow total
quality approach and for receiving Demings prize.

PRINCIPLES OF TQM
a) Be Customer Focused: Only customers determine the level of quality.

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b) Ensure Total Employee Involvement: Proper environment is provided by empowering

employees.
c) Process Centered: Fundamental part of the TQM is to focus on process centering.
d) Integrated System: All employees must know the business mission and vision.
Modeling of integrated business system to be made.
e) Strategic and Systematic Approach: Strategy plan must integrate quality as core
improvement.
f) Continuous Improvement: Using analysis, quality tools and creating thinking to
become more effective and efficient.
g) Fact Based Decision Making: Decision making must be done only on data, not personal
or situational thinking.
h) Leadership: Leadership from top management.
i) Communication: Communicating strategy, method and timelines must be well defined.

SCOPE OF STUDY
The scope of the project study has both theoretical aspects of quality management and analyzing
its practical implications after observation and study during visits to various functional
departments.

OBJECTIVES OF THE STUDY

Primary Objective
To determine the effectiveness of total quality management in HLL, Peroorkada
Plant from the perspective of the employees working in the organization.

Secondary Objective
To study the factors underlying the implantation of total quality management in
HLL, Trivandrum

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To identify the level of employee awareness and effectiveness, regarding the total
quality management system at HLL
To identify the level of employee teamwork and rejection/defects, regarding the
total quality management system at HLL

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RESEARCH METHODOLOGY

RESEARCH METHODOLOGY
RESEARCH DESIGN
In this study, the researcher has used descriptive design as well as hypothesis for studying the
effectiveness of Quality Management of HLL, Peroorkada Plant. This research design focuses
attention on the following:
a)
b)
c)
d)

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Formulation of the objectives

Identification of the methods of data collection
Selecting a valid sample using suitable sampling technique
Collection of data by using a reliable instrument

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e) Analysis and Interpretation of the data

f) Preparation of a detailed report

SOURCES OF DATA
The sources of the project were collected through two main sources namely primary and
secondary sources.

PRIMARY DATA
Questionnaire Method Primary data was collected through a non-distinguish structured
questionnaire. Questionnaires were issued to the employees for acquiring the data. With the help
of questionnaire it was easy to determine the preference, attitude and satisfaction level of the
employees that were working in HLL.

SECONDARY DATA
The following were the secondary methods used for data collection which are as follows
a)
b)
c)
d)

Company Corporate Family Magazine

Company Magazines & Section Journals
Internet
Discussions and Personal Interaction with employees

PICTORIAL REPRESENTATION
The pictorial representation was made mainly by Histogram during the data analysis of the
project. The main factors relating to Total Quality Management focusing on Quality System
indentified are a) Increase Quality Awareness, b) Employee Effectiveness, c) Labor Turnover,
d) Improve team work, e) Reduction in Rejection/Defect Levels from which the same factors
were incorporated in the questionnaire. From the above factors five variables have been
identified in the study and two have been used for analysis.

SAMPLE DESIGN

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A sample design is a definite plan for obtaining a sample from a given population. It refers to the
technique or the procedure the researcher would adopt in selecting items for the sample. Sample
design has to be determined before the data collection.

POPULATION OF STUDY
600 employees of HLL Peroorkada Plant, Thiruvananthapuram

SAMPLING SIZE
The sample size collected for the study is 60

SAMPLING TECHNIQUE
The sampling technique adopted for selecting the representative units is Simple Random
Sampling

SAMPLE FRAME
Sl.N
o

Population

1
2
3
4
5
6
7

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Sample
Size

Department

Category

Production
Electronic Testing Department
Packaging
Quality
Material Testing and Research & Development
Finance
Human Resource
Utility
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7
4
7
6
4
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Engineering
600

60

9
10
11
12
13

Mechanical
Electrical
Instrumentation

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2
2
3

Safety
Purchase
Sales
Stores
Others

PERIOD OF STUDY

2
3
3
5
2

The period of study was 45 days i.e. from 17.05.2016 to

01.07.2016

LIMITATIONS OF STUDY

The subject of Effectiveness of Total Quality Management is quite vast and to do

justice to the subject, much more time will be needed.

Notwithstanding the above limitation, a sincere effort has been made to obtain and
observe as much information and knowledge as was possible. This has been achieving by
undertaking detailed discussions with a number of persons at various levels in the
organization so as to see the practical implementation of quality measures on the ground.

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INDUSTRY PROFILE

INDUSTRY PROFILE
Introduction
Healthcare has become one of Indias largest sectors - both in terms of revenue and employment.
Healthcare comprises hospitals, medical devices, clinical trials, outsourcing, telemedicine,
medical tourism, health insurance and medical equipment. The Indian healthcare sector is
growing at a brisk pace due to its strengthening coverage, services and increasing expenditure by
public as well private players.
Indian healthcare delivery system is categorized into two major components - public and private.
The Government, i.e. public healthcare system comprises limited secondary and tertiary care

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institutions in key cities and focuses on providing basic healthcare facilities in the form of
primary healthcare centers (PHCs) in rural areas. The private sector provides majority of
secondary, tertiary and quaternary care institutions with a major concentration in metros, tier I
and tier II cities.
India's competitive advantage lies in its large pool of well-trained medical professionals. India is
also cost competitive compared to its peers in Asia and Western countries. The cost of surgery in
India is about one-tenth of that in the US or Western Europe.

Market Size
The overall Indian healthcare market today is worth US$ 100 billion and is expected to grow to
US$ 280 billion by 2020, a Compound Annual Growth Rate (CAGR) of 22.9 per cent.
Healthcare delivery, which includes hospitals, nursing homes and diagnostics centers, and
pharmaceuticals, constitutes 65 per cent of the overall market.
Deloitte Touche Tohmatsu India has predicted that with increased digital adoption, the Indian
healthcare market, which is worth US$ 100 billion, will likely to grow at a CAGR of 23 per cent
to US$ 280 billion by 2020.
There is a significant scope for enhancing healthcare services considering that healthcare
spending as a percentage of Gross Domestic Product (GDP) is rising. Rural India, which
accounts for over 70 per cent of the population, is set to emerge as a potential demand source.
India requires 600,000 to 700,000 additional beds over the next five to six years, indicative of an
investment opportunity of US$ 25-30 billion. Given this demand for capital, the number of
transactions in the healthcare space is expected to witness an increase in near future. The average
investment size by private equity funds in healthcare chains has already increased to US$ 20-30
million from US$ 5-15 million, as per Price, Water, House and Coopers.
A total of 3,598 hospitals and 25,723 dispensaries across the country offer AYUSH (Ayurveda,
Yoga & Naturopathy, Unani, Siddha and Homoeopathy) treatment, thus ensuring availability of
alternative medicine and treatment to the people.
The Indian medical tourism industry is pegged at US$ 3 billion per annum, with tourist arrivals
estimated at 230,000. The Indian medical tourism industry is expected to reach US$ 6 billion by
2018, with the number of people arriving in the country for medical treatment set to double over
the next four years. With greater number of hospitals getting accredited and receiving
recognition, and greater awareness on the need to develop their quality to meet international
standards, Kerala aims to become India's healthcare hub in five years.

Investments
The hospital and diagnostic centers attracted Foreign Direct Investment (FDI) worth US$ 3.41
billion between April 2000 and December 2015, according to data released by the Department of
Industrial Policy and Promotion (DIPP).
Some of the major investments in the Indian healthcare industry are as follows:

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Versante Software Technologies, an Indian subsidiary of US-based IT consulting and

software engineering services company Versante Technologies LLC, is in the process of
raising US$ 1 million in its first round of external funding by March 2016, the proceeds

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of which would be used for initial promotion, and pan-India marketing and distribution of
hand-held and portable patient care devices.

Abraaj Group, a Dubai based Private Equity (PE) investor, has planned to buy a majority
stake in an Indian firm Quality CARE India Ltd, which runs CARE Hospitals.

Qatar-based Non-resident Indians (NRI) including medical professionals and

businessmen, are planning to set up a huge world-class healthcare project in Kochi worth
Rs 1,300 crore (US$ 190.74 million)

American multinational technology and consulting corporation, IBM has announced that
Manipal Hospitals corporate and teaching facilities will adopt Watson for Oncology, a
cognitive computing platform trained by Memorial Sloan-Kettering that analyses data to
identify evidence-based treatment options, helping oncologists to provide cancer patients
with individualized healthcare.

Apollo Hospitals Enterprise (AHEL) plans to add another 2,000 beds over the next two
financial years, at a cost of around Rs 1,500 crore (US$ 220.08 million).
Malaysia-based IHH Healthcare Berhad has agreed to buy 73.4 per cent stake in Global
Hospitals Group, India's fourth-largest healthcare network, for Rs 1,284 crore US$
192.84 million.

Temasek Holdings Pte Limited acquired the entire 17.74 per cent stake of Punj Lloyd
Limited in Global Health Private Limited, which owns and operates the Medanta Super
Specialty Hospital in Gurgaon.

CDC, a UK based development finance institution, invested US$ 48 million in Narayana

Hrudayalaya, a multi-speciality healthcare provider. With this investment, Narayana
Health will expand affordable treatment in eastern, central and western India.

Government Initiatives
India's universal health plan that aims to offer guaranteed benefits to a sixth of the world's
population will cost an estimated Rs 1.6 trillion (US$ 23.48 billion) over the next four years.
Some of the major initiatives taken by the Government of India to promote Indian healthcare
industry are as follows:

Provisions made in the Union budget 2016-17:

o National Dialysis Services Program to be initiated to provide dialysis services in
all district hospitals to accommodate the increasing demand for dialysis session
o A new health protection scheme for health covers up to Rs 1 lakh (US$ 1,470) per
family.

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o Setting up 3,000 medical stores across the country to provide quality medicines at
affordable prices.
o Senior citizens will get additional healthcare cover of Rs 30,000 (US$ 441) under
the new scheme
o Pradhan Mantri Jan Aushadhi Yojana to be strengthened, 3000 generic drug store
to be opened

Government of West Bengal has introduced G1 Digital Dispensary, which aims to

provide people from rural areas access to primary healthcare services.

A unique initiative for healthcare 'Sehat' (Social Endeavour for Health and Telemedicine)
has been launched at a government run Common Service Centre (CSC) to empower rural
citizens by providing access to information, knowledge, skills and other services in
various sectors through the intervention of digital technologies and fulfilling the vision of
a Digital India.

India and Sweden celebrated five years of Memorandum of Understanding (MoU). The
cooperation in healthcare between India and Sweden will help in filling gaps in research
and innovative technology to aid provisioning of quality healthcare.

Mr. J P Nadda, Union Minister for Health & Family Welfare, Government of India has
launched the National De-worming initiative aimed to protect more than 24 crore
children in the ages of 1-19 years from intestinal worms, on the eve of the National Deworming Day.

Under the National Health Assurance Mission, Prime Minister Mr. Narendra Modi's
government would provide all citizens with free drugs and diagnostic treatment, as well
as insurance cover to treat serious ailments.

Road Ahead
India is a land full of opportunities for players in the medical devices industry. The country has
also become one of the leading destinations for high-end diagnostic services with tremendous
capital investment for advanced diagnostic facilities, thus catering to a greater proportion of
population. Besides, Indian medical service consumers have become more conscious towards
their healthcare upkeep.
India's competitive advantage also lies in the increased success rate of Indian companies in
getting Abbreviated New Drug Application (ANDA) approvals. India also offers vast
opportunities in R&D as well as medical tourism. To sum up, there are vast opportunities for
investment in healthcare infrastructure in both urban and rural India.
Exchange Rate Used: INR 1 = US$ 0.0147 as on March 01, 2016

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The Indian healthcare sector is expected to register a compound annual growth rate (CAGR) of
22.9 per cent during 2015-20 to US$ 280 billion. Rising income level, greater health awareness,
increased precedence of lifestyle diseases and improved access to insurance would be the key
contributors to growth.
The private sector has emerged as a vibrant force in India's healthcare industry, lending it both
national and international repute. It accounts for almost 74 per cent of the countrys total
healthcare expenditure. Telemedicine is a fast-emerging trend in India; major hospitals (Apollo,
AIIMS, Narayana Hrudayalaya) have adopted telemedicine services and entered into a number
of public-private partnerships (PPP).The telemedicine market in India is valued at US$ 7.5
million currently and is expected to grow at a CAGR of 20 per cent to reach US$ 18.7 million by
2017.Further, presence of world-class hospitals and skilled medical professionals has
strengthened Indias position as a preferred destination for medical tourism.
The Government of India aims to develop India as a global healthcare hub. It has created the
National Health Mission (NHM) for providing effective healthcare to both the urban and rural
population. The Government is also providing policy support in the form of reduced excise and
customs duty, and exemption in service tax, to support growth in healthcare.
Investment in healthcare infrastructure is set to rise, benefiting both 'hard' (hospitals) and 'soft'
(R&D, education) infrastructure.

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COMPANY PROFILE

COMPANY PROFILE
INTRODUCTION
As a condom-manufacturing company, HLL Life care started small, but dreamed big. That dream
changed lives in ways unimaginable. Soon, HLL became the go-to brand for various
contraceptives. It was only a matter of time before diversification followed, bettering the brand
with healthcare products and services. After more than 30 years of consistent quality

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performance, HLL Life care now takes on an even bigger responsibility the vaccine security of
the nation. No wonder then, at HLL work is about innovating for healthy generations, every
day.

HISTORY
HLLs first plant began operations on April 5, 1969 at Peroorkada in Thiruvananthapuram district
of Kerala. The plant was established in technical collaboration with M/s Okamoto Industries Inc.
Japan.
Today, seven manufacturing plants later, HLL has grown into a multi-product, multi-unit
organization addressing various public health challenges facing humanity. In 2003, when HLL
had a turnover of a mere INR 163 crores, it had set its sights on becoming a INR 1000 crore
company by 2010. HLL not only surpassed this figure by 2010 but also drew a clear road map to
achieve ten-fold growth by 2020.

Now, HLL is a Mini Ratna, upgraded as a Schedule B Central Public Sector Enterprise. The
company received the Prime Minister Award for being the best public sector enterprise in India.
It is also the only company in the world which manufactures and markets such a wide range of
contraceptives. Today, HLL produces 1.316 billion condoms annually, making it one of the
worlds leading condom manufacturers, accounting for nearly 10 percent of the global
production capacity.
Over the years each of the initiatives taken up by HLL have been aimed at providing quality
healthcare to every family. HLLs associate institutions, Hindustan Latex Family Planning
Promotion Trust (HLFPPT) and Life Spring Hospitals, have ensured this to the nations
underserved and vulnerable populace, at an affordable cost.
With a vast array of innovative products, services and social programs to meet the countrys
healthcare needs, HLL Life care Limited is firmly on track, with its motto of 'Innovating for
Healthy Generations'.
HLL continues to make its mark by setting new goals and taking on challenges others often view
as impossible.

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COMPANY VISION
Our vision is to become a INR 10,000 crore global healthcare company by 2020.
HLL will establish itself as a leader in its core activities through a process of continuous
innovation and technology as well as quality to be internationally competitive participatory
approach in order to:
a) Provide best value to the customer.
b) Be an employer of choice.
c) Promote the cause of family health in general and women health in particular.

COMPANY MISSION
To accomplish the corporate vision, HLL has outlined a mission to be a world class health care
company by the year 2020 with focus on five key areas namely:
a)
b)
c)
d)
e)

Business
Customer
Innovation
Employee Satisfaction
Social Sector initiatives.

COMPANY PURPOSE
The very purpose of business at HLL is to provide high-quality products and services at
affordable prices.

COMPANY VALUES
HLL has a Value Charter TTT Trust, Transparency and Teamwork. It symbolizes the
philosophy of HLL; its reason for existence, values and principles it follows in its daily
activities. It also provides a common direction for all employees of HLL; the way to conduct in
personal and professional life.

Trust

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We shall practice what we profess and thereby build trust among ourselves and all our
stakeholders.

We believe that trust creates an atmosphere of mutual respect and support.

We shall never compromise doing the right things at the right time consistently.

Transparency

We shall exhibit honesty and accountability in all our activities.

We shall encourage active participation of all stakeholders in our decision-making

process.

We shall practice Equity, Fairness and Justice at work.

Teamwork

We believe that excellent outcomes can be achieved only through teamwork.

We shall build teams committed to company goals.

We shall foster friendliness, camaraderie and selflessness.

HLL Life care Ltd. has adopted a Code of Business Conduct & Ethics for Board Members and
Senior Management, Enterprise-wide Risk Management Policy and has constituted a qualified
and independent Audit Committee of the Board of Directors. It also has a formal statement of
Board Charter that sets out the role, structure, responsibilities and operation of the Board of HLL
and its delegation of authority.

HLL GROUP COMPANIES

a)
b)
c)
d)
e)
f)

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HITES (HLL Infra Tech Services Ltd)

HBL (HLL Biotech Ltd)
HLFPPT (Partners for Better Health)
GAPL (Goa Antibiotics and Pharmaceuticals)
HMA (HLL management academy)
Life Spring (Maternity Hospital)

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QUALITY MODEL IN HLL PEROORKADA PLANT

5S - 5S engages people through the use of 'Standards' and Discipline'.
It is not just about housekeeping, but concentrating on maintaining the standards & discipline to
manage the organization - all achieved by upholding & showing respect for the workplace every
day.
The 5 Steps in 5S are as follows:

Sort: Sort out & separate that which is needed & not needed in the area.

Straighten: Arrange items that are needed so that they are ready & easy to use. Clearly
identify locations for all items so that anyone can find them & return them once the task
is completed.

Shine: Clean the workplace & equipment on a regular basis in order to maintain
standards & identify defects.

Standardize: Revisit the first three of the 5S on a frequent basis and confirm the
condition of the workplace using standard procedures.

Sustain: Keep to the rules to maintain the standard & continue to improve every day.

World Class Quality by

Eliminating Waste 5S

Customer Requirement

Customer Satisfaction

5S is an essence for growth

INTEGRATIVE SYSTEM
The company follows the concept of an integrative system which is:

ISO 9001

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ISO 18001

The ISO 9001, ISO 50001, ISO 14001 and OHSAS 18001 are integrated with triple bottom line
approach of Total Quality Management which is people, plant, profit.

QUALITY POLICY
g) Provide affordable healthcare solution focusing on inclusiveness, conforming to
international standards, enabling people to lead healthy and happy lives.
h) Achieve organizational excellence through continual improvement by adoption of
best technologies and practices in all areas.
i) Market products and services globally delivering highest value for customers
through focus on innovation, quality, R&D relationship management.
j) Be an organization meeting highest standards in Corporate Governance and
Corporate Social Responsibility.

PRODUCTION FACILITIES:
Peroorkada Factory, Trivandrum ( PFT )
The manufacturing unit at Peroorkada, in Thiruvananthapuram district of Kerala was set
up in 1969 in technical collaboration with M/s Okamoto Industries Inc., Japan. The plant
has undergone continuous modernisation over the years and has an annual production
capacity of 1600 million pieces of condoms. The facility is equipped with modern
machines and equipment for production, inspection and quality testing, conforming to
GMP and meets international standards. The unit produces many variants of condoms
with different flavours and textures. Condoms manufactured in this facility have product
certifications such as CE, KITE, SABS, NF, CMD CAS and meets a range of
international quality specifications and standards such as: WHO 2003, 510K, ISO
4074:2002,

SANS

ISO

4074,

ASTM

3492 and GOST - 4645-81. The facility has certifications under ISO 9001:2008, ISO

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14001:2004, ISO 13485:2003, OHSAS 18001:2007, WHO GMP and NABL as per ISO
17025:2005.

Akkulam Factory, Trivandrum ( AFT)

Akkulam Factory in Thiruvananthapuram district of Kerala is the state of the art facility
for manufacture of Blood Bags and other medical devices namely Surgical Sutures
(Absorbable & Non Absorbable), Intrauterine Devices (Copper T) and Mesh Implant for
Reinforcement of Connective tissue structure.
The above products are manufactured in class 10000 and class 100 Clean
room facilities maintained in a centrally air conditioned atmosphere. The products have C
E International Quality Certification and the manufacturing facility has been certified for
conformity with international quality standards-ISO 9001,WHO GMP, ISO 13485,
OHSAS 18001 and ISO 14001.
The annual production capacity of blood bags at the factory stood at 11.5
million pieces, copper IUDs - 5.5 million pieces, surgical sutures - 1,25,000 dozens and
tubal rings - 2.5 million pairs.

Kanagala Factory, Belgaum( KFB )

The Kanagala plant in Belgaum in the state of Karnataka commenced operations with the
production of condoms in 1985 using Japanese technology. This unit underwent
diversification in 1992 with the tabletting facility for birth control pills - Mala-D/N and
the formulation and tabletting of Saheli (Centchroman) the indigenous, non-steroidal
once-a-week pill. The tabletting of Emergency Contraceptive pills started in 2003.
Commercial manufacturing of women healthcare products commenced in 2006. KFB has
also added a world-class hormonal/steroidal formulation plant UNIPILL Block in 2012.
The manufacturing unit has GMP and quality management systems (QMS) like ISO
9001:2008, ISO 14001:2004, OHSAS 18001:2007 and ISO 13485:2003.

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Kakkanad Factory, Cochin( KFC )

HLLs female condom manufacturing facility at Cochin Special Economic Zone,
Kakkanad in Kerala has been set up in technical collaboration with M/s. Female Health
Company (FHC), US. It is the second generation of female condoms made from
Synthetic Nitrile latex, the product generically being termed FC2. The installed capacity
of the plant is 7 million pieces of FC2 per year. In addition, KFC has a fully automatic
testing and packing facility for male condoms with an annual capacity of 150 million.
This facility mainly caters to the export market. KFC has the ISO 9001:2008, ISO
13485:2003, CE Mark and WHO GMP certification for manufacturing female condoms
(FC2) certified by M/s DNV and ISO 9001:2008,ISO 13485:2003, CE Mark and WHO
GMP for male condom facility certified by M/S DNV.
KFC has also received the NF Mark certification from M/s LNE for male
condom facility and is also approved by many institutional buyers like IDA, Mission
Pharma and UNFPA for the supply of male condoms.
In addition to the product certification, KFC is also certified by M/s TUV,
with ISO 18001:2007 and ISO 14001:2004 certifications for safety, health and
environment compliance.

Manesar Factory, Gurgaon( MFG )

HLL has its in-vitro immuno diagnostics kit manufacturing facility at Manesar in
Gurgaon. It has an installed capacity to manufacture 26 million rapid pregnancy test kits
per year. The unit commenced operations in November 2007. The unit manufactures
rapid test kits for detection of metabolic hormones such as human chorionic gonadotropin
(hCG) in urine and prognosis of diseases such as Dengue, Malaria (different strains),
Kala-azar (leishmaniasis), TB, Chikungunya and other infectious diseases. The facility

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has Quality Management Systems like ISO 9001:2008, ISO 13485 and CE mark
according to IVD 98/79/EC directive for pregnancy test cards for professional use brands
like Makesure, P-Test and Nishchay.

Pharma Factory, Indore (PFI)

Indore, the commercial capital of Madhya Pradesh opened its doors to a pharma
production facility in 2010. The facility manufactures a range of pharma products which
include formulations such as tablets, capsules and Oral Rehyderation Salt. PFI also
supplements the existing production facility of KFB in the area of womens healthcare
products.

Irapuram Factory, Cochin (IFC)

Irapuram Factory, Cochin (IFC) is located at the Rubber Park near Perumbavoor, Kerala.
IFC facility is the moulding hub for male and female condoms. The installed capacity for
male condom moulding is 240 mpcs/ year and for the female condoms is 25 mpcs/year.
The total constructed area in the 306 cents plot is 4650 square metre.

CERTIFICATIONS IN HLL
a) Facility Certifications
ISO 9001 Quality certification
ISO 13485 Medical Devices Standard
ISO 50001 Energy Management System
ISO 14001 Environmental safety standard
ISO 18001 Laboratory standard (sample testing and calibration)
ISO 170025 NABL (National Accredition Board for Laboratory)

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b) Product Certifications
CE-Mark for selling in European
KITE Mark for selling in United Kingdom
SABS for selling in South Africa
NF for selling in France
CMDCAS for selling in Canada

SAFTY, HEALTH and ENVIRONMENT POLICY (SHE POLICY)

HLL lifecare limited is committed to protect environment, eliminate occupational hazards and
ensure safety of employees and subcontracts through:
a) Monitoring and control of the impact of its activities, products and services on a
b)
c)
d)
e)
f)

continual basis.
Compliance of applicable legal and other requirements.
Adopting safe operating practices with an emphasis on social accountability.
Facilitating employee training and their involvement.
Pollution mitigation through adoption of best practices.
Conserving materials, energy and reducing waste at source and encourage usage of

renewable energy sources.

g) Periodic review of safety, health and environment management system.

MAJOR CSR INITIATIVES DURING THE LAST DECADE

a) Benson Aid GLL supports HIV affected Benson with nutritious food supplements,
medicines and other care.
b) Village adoption Adopted two villages in Karakulam in Thiruvananthapuram and
c)
d)
e)
f)
g)
h)
i)
j)
k)

Kanagala in Karnataka.
Renovates and maintains two parts in Kowdiar and Poojapura in Thiruvananthapuram.
Rest House for headload workers in Akkulam.
Health awareness camps at various locations in the country.
Regular blood donation camps.
Distribution of clothes and teaching aids to poor students of government schools.
Life skill training programs.
General health check-up at Government schools.
Installation of solar street lights.
Adolescent wellbeing interventions like distribution of sanitary napkins, awareness
programs, counseling services.

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OUR PARTNERS
In its search for becoming a truly world-class provider of healthcare products and services, HLL
has been seeking to adapt knowledge from its partners. HLL has over the years been networking
with various corporate organizations, development agencies and NGOs by combining strengths
and capabilities of several world leaders. Some of them are listed below:

Okamoto Industries Inc. for male condoms.

Female Health Company (FHC) for manufacture of Female Condoms and its promotion.

Finishing Enterprises, USA for Copper T IUD.

Helm, Germany for distribution of DMPA (Depot Medroxyprogesterone Acetate) in

India.

Arya Vaidya Sala (AVS), Kottakkal, Kerala, for Natural Ayurvedic products.

Bharat Biotech International Ltd., Hyderabad for Hepatitis B and Typhoid Vaccines.

Chengdu Institute of Biological Products, China for supply of JE Vaccines to

Government of India.

Cheng Da Biotechnology (CDBIO), China for marketing of Human Anti-Rabies Vaccine

in India.

Cycle Technologies Inc., USA for manufacture and distribution of Cycle Beads in India
and abroad.

More than 300 NGOs for implementing population stabilization and HIV/AIDS
prevention and control programs.

MAJOR EXPANSION IN THE LAST DECADE

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a) Marked entry into Infrastructure Development and Procurement Consultancy in

healthcare industry and floated subsidiary HITES (HLL Infra Tech Services Limited).
b) Forayed into vaccine production, floated HLL Biotech Ltd which is implementing
c)
d)
e)
f)
g)
h)
i)

Integrated Vaccine Complex in Chengalpatto, Tamil Nadu.

Opened State of the art world class corporate R7D centre (HLL RDC).
Entered into the field of education and floated HLL Management Academy (HMA).
Opened HLL Bhawan, HLL regional offices in New Delhi and Mumbai.
Rapid Diagnostic Kits manufacturing unit at Manesar.
Started LIFESPRING mother and childcare hospital chain for the low income population.
Opened new manufacturing facility for male and female condomes in Kochi.
Forayed into retail marketing and opened exclusive condome shops under the name

MOODS planet.
j) Investment in Pharma WHO prequalified pharma manufacturing facilities in Kanagala
and acquired GAPL (Goa Antibiotics and Pharmaceuticals Ltd).
k) Investment in diagnostic services Hindlabs MRI Scan Centers.
l) Investment in retail outlets in pharmaceuticals and ophthalmic products- HLL pharmacy
and surgicals, HLL Opticals, AMRIT Pharmacy and AMRIT Clinic.

GLOBAL PERSPECTIVE
With the changing socio-political climate, global health programs are constantly seeking diverse
solutions in the areas of medicine and healthcare. HLL provides the perfect answer to many
questions that the world faces in healthcare, thanks to its extensive experience, innovative
technologies and ample resources which today reach over 115 countries spanning the seven
continents. Its consultancy services and products are part of the global healthcare packages of
international agencies such as UNPFA, UNOPS, UNHCR, WHO, PSI and IDA.

GLOBAL COMPETITORS
a)
b)
c)
d)
e)

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US surgical (USSC) which is relatively new into the industry.

ANTZ Latex Private Limited, Singapore.
ANSELL Ltd, Australia.
Sinochem Nimbo Medical Company Ltd, China.
Green Mate Corporation, South Korea.

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PRODUCT PROFILE

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PRODUCT PROFILE

DETAILED PRODUCT PROFILE

PRODUCT
Contraceptive

BRAND
Moods

Share
Nymph
Nirodh

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VARIETY
Ultrathin
Supreme Dotted
All Night
Extra Long
Scented (Rose, Musk, Jasmine)
Chocolate Flavor
Banana Flavor
Strawberry Flavor
Ribbed
Colored
Glow
Share 3S
Nymph 3S
Deluxe Nirodh
New Lubricated Nirodh
Super Deluxe Nirodh

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Rakshak

Non-Steroidal
Contraceptive
Oral Re-Hydration Salt
Blood Transfusion and
Intravenous Set
Intra-Oterine Device
Medical Plaster
Surgical Sutures

Hi-tech Hydrocephalus Shut

Needle Destroyer
Tube Sealer
Tissue Expander
Instant Needle and Syringe
Destroyer
Blood Collection
Monitor
Female Condom
Tubal Rings
CBD Herbs Berries

OF

HLL

Ustad
Crezendo
Saheli
Novex
Jal Jeevan
HLL HEAMOPACK
Preventol
T-Care
Plaster Aid
Hicon
Hisil
Hinsurg
Hincryl
Hincocryl
Hindox
Hinglact
Ceredrain
Needle Destroyer
Tube Sealer
In Care
HL SUB CUTEX
Instant Needle and Syringe
Destroyer
Hi Care

SIPPSA
Telungu
Ustad 3S
Crezendo
Saheli
Novex
Jal Jeevan
HLL HEAMOPACK
Preventol
T-Care
Plaster Aid
Hicon
Hisil
Hinsurg
Hincryl
Hincocryl
Hindox
Hinglact
Ceredrain
Needle Destroyer
Tube Sealer
In Care
HL SUB CUTEX
Instant Needle and Syringe
Destroyer
Hi Care

Confidom
Velvet
Tubal Rings
Chyauanules

Confidom
Velvet
Tubal Rings
Chyauanules

They can be further explained as follows:

HLL lifecare limited is providing wide range of products for different sections of market. The
details are given below as follows:
1. Condom
Condoms are major profit earning components of HLL Lifecare Ltd. Condoms products
are meant to prevent against sexually transmitted disease (STD) like Acquired Immune
Deficiency Syndrome (AIDS).
Different brands of condoms produced by HLL Lifecare limited are:-

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Nirodh
Deluxe Nirodh
Super Deluxe Nirodh
Moods
Moods Supreme
Rakshek
Gay
Ustad
Share

2. Contraceptive Tablets
Contraceptive tablets are taken by women to avoid unwanted pregnancy. Different brands
of contraceptive tablets produced by HLL Life are: Saheli
Mala-D
3. Blood Bags
During earlier years blood bag were imported, but HLL Lifecare started manufacturing of
blood bag from 1995 with the technical knowhow from Sree Chithra institute of Medical
Science and Technology Trivandrum. A blood bag per annum is up and running at the
Akkulam Factory. Different types of blood bag produced in HLL Lifecare Ltd are: Single
Double
Triple
Pediatric
Transfer bag
4. Copper T Intra-Uterine Device
Copper T is an IUD device used by women to protect against unwanted pregnancy. Use
of Copper-T leads to lower fertility rates in women. Commercial production of Copper-T
is installed. It has been useful for a period of 5 years.
Two brands of Copper-T products of HLL Lifecare Ltd are:T- Copper 200B
T- Copper 380A
5. Hydrocephalus Shunt
Hydrocephalus Shunt is used to regulate the pressure inside the head of children having
abnormal brain fluid condition. HLL Lifecare started the manufacture of hydrocephalus
shunt in the year 1994 at Akkulam factory.
6. Surgical and Examination Gloves
Need of total sterility is necessary in todays world of medical science. With a view of
providing this HLL Lifecare Ltd entered in to the production of surgical and examination

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gloves, both sterile and non-sterile. The gloves are of export quality and subject to ASTM
and ISO standard. It also manufactures produce free and chrome therapy gloves.
7. Survival Sutures
Aiding the heading process is a special type of thread called surgical sutures. HLL
Lifecare Ltd planned to make available the sterile eyeless needled surgical sutures which
are synthetic and surgical catgut sutures that will come in two types. Brand name,
HINCON.
8. Additional Products

Intra-Uterine-Device
Oral Rehydration Salt
Iron and Folic Acid
Medicated Plaster
Structures
Needle Destroyer

Blood Collection
monitors tissue
expander
Mediguard Surgical
Gloves (Sterile)
Blood bag tube seater

FUNCTIONAL DEPARTMENTS

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QUALITY ASSURANCE DEPARTMENT

Hierarchy of Quality Assurance Department

SENIOR MANAGER (QA)

DY. MANAGER (QA) - 2

SUPERVISOR

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a. Half Product Quality Assurance

b. Full Product Quality Assurance

Half Product Quality Assurance

Production time for a lot of 6000 pieces is 45 minutes. These lots then go
for half product testing. Half product is the product that comes out of
vulcanizing machine. This type of testing mainly consists of visual
checking. A sample of 40 randomly selected condoms from each lot is
tested for the following:

Oil
Dust
Folding
Breakage
Wrinkle
Inside Sticking
Not Uniform
Bump
Weak Spot
Scratch
Visible Hole
Edge roll
Printing not proper
Nipple cream
Foam
Water dripping
Improper Vulcanizing

Full Product Quality Assurance

DC

In this section various tests are conducted to measure strength of the

condoms, presence of holes, etc. Different types of tests are conducted in
these sections which are:

Burst Volume & Burst Pressure Test

Water Leakage Test
Package Integrity Test
Lubricant Quantity Test

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Thereafter send for quality checking. The qualities checking in HLL are of
two types:-

1. Sample Check
2. Random Check

1) Sample Check:

In sample check 60 pieces of samples are taken and checked for quality.

2) Random Check:

In random checking 40 pieces are taken and checked visually. The passed
lots are sending for 100% quality check such as:
a) Water Leakage Test
b) Burst Volume & Burst Pressure Test (Inflation Test)
c) Integrity Test
d) Lubricant Testing
e) Electronic Pinhole Testing

a) Burst Volume Burst Pressure Test

In this test the condoms are subjected to pressure. The pressure and
volume will be determined in advance normally the pressure is chosen as 1 kilo
Pascal and volume is 18.51 for 53 mm and 14.81 mm condoms. If more than 8
pieces of 310 samples are failed in this test, then the batch will be discarded.

b) Water Leaking Test

Here 40 samples are taken from each lot and 300ml of water is taken in
each sample and kept for some time. If more than 20 defects are found
information given to the inspection supervisor and information is passed to the
production department. There are mainly two types of water leakage test:
Hang and Squeeze Method
Hang and Roll Method

c) Integrity Test

Here 30 condoms are taken randomly from a pack and kept in a jar and
applying a pressure of 50+/10 Kpa. If the packs swell, it indicates that there is no
air in the pack. This means a good one if the pack doesnt swell, it indicates that
the packing is not good.

d) Lubricant Testing

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Each condom should contain minimum 200mg of lubricant, if the oil

content is less than prescribed amount, then the whole lot will be rejected.

e) Electronic Pinhole Testing

After maturation period, each condom from the lot is manually covered on
the steel moulds provided in the automatic electronic pinhole testing machines.
The steel moulds are fixed in a continuality moving conveyor. Here the electrical
resistance of the film is measured to examine the products, which are subjected to
100% electric testing to separate them with pinhole and weak spots. The good
condoms are then subjected for further quality checks.

Schematic Diagram of Quality Control

Primary Production

PPC

Half Product Inspection

ETD

Lot wise Tests and Batch wise Test after

Packing
EPTMK Testing

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Passed
Rejected

Dispatch

Documented procedure /
procedure as per customers
standard

Quality Assurance department of Peroorkada Factory is engaged with inprocess Inspection, finished product inspection, control of non-conforming
product and assignment of product identify and maintaining the quality
system at department as per requirement of various quality system
standards.

In process inspection includes half product inspection for giving feedback

to primary production department, online testing after EPT machine
checking to give feedback to Electronic testing department.

In finished product inspection each of production is tested.

INSPECTION DEPARTMENT

Inspection

Actually Inspection Department comes under the QC department

but for ensuring better quality the company management keeps the
inspection department a separate wing.

This department is in charge of inspecting the quality and durability of the

product. They check the product in the time of manufacturing and in the

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idle of process. The samples were taken in random basis from the whole
serial of production.

At the last the products are sent to final inspection department and there is
100% guaranteed electronic pinhole testing and is done through most
modern Japanese machines.

There are two types of testing for the final product:

1) Wet type test

2) Dry type test

Functions:

Incoming material inspection

In process inspection of products at various stages of production
Final product testing and assuring quality of outgoing products
Statistical Analysis
Handling of customer complaints
Maintaining of ISO 9002 quality systems
Maintaining of quality systems as per the requirements in medical service directive

ELECTRONIC TESTING DEPARTMENT (ETD)

Organization Chart

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Sr. APM / APM (Shift)

(General Shift)
Sr. APM / APM

Junior Officer / Foreman /

Supervisor

Machine Operators (VI / V

Grade)

Covers IV / III / II / I Grade

The half products are send to the inspection department, where 100%
electronic testing is done. The condoms had been tested for pinholes using
electronic pinhole testing machine. The process follows manual, electrical
and mechanical device. There are two types of pinhole testing machines:

The wet type machine is used to remove the powder, which fills the small
holes in the condoms, detects any hole in the condoms, and makes the
condom clean and dry the condom by passing it through a heating
chamber. The dry machine consists of a carbon rubber mechanism, which
is provided with a high voltage which separates the bad condoms from the
good ones. In this test, the condoms are wrapped on steel moulds and
passed through a carbon brush which has charged by electric voltage up to
1600 volts. When the mould is passed through the brushes, any pinhole on
the condom can be detected. The good condoms are sending to the packing
department.

Wet Type
Dry Type

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Functions:

The functions of ETD department are to test & roll of condoms in

Electronic Pinhole machines. ETD receives condoms manufactured by
HLL as well as bought up from other sources passed by HPQC (Half
product Quality Control) for testing in EPT (Electronic Pinhole Testing)
machines.

Material Testing (MT) & Research and Development

(R&D)

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Material Testing

To maintain high quality products providing to the society, HLL Life care
Limited has a material testing lab which checks the quality of raw
materials supplied to the company. This section keeps a consistent watch
over the inputs and reports its findings to the concerned departments. This
section also is entrusted with the design and art work of packages and
cartons to ensure that all displayed as per statutory requirements.

a) Receiving Raw Materials:

The raw material used is latex. All the raw material includes rubber and
other chemicals such as tamol, darvan-I, darvan-II, Sulphar, Zinc Oxide
are received in barrels and accepted after testing and getting clearance in
the laboratory.

b) Sample Testing:
Random sample of raw latex is taken to the laboratory here with latex is
tested for various properties like acidity, viscosity, flow rate, PH value,
mechanical stability of the latex etc. Only when all properties are satisfied,
they are taken for further processing.

Research & Development (R&D)

HLL Life care Limited gives more importance to Research and

Development department. As the company is in contraceptive and
healthcare industry, which is highly consumer sensitive industry, more
care has to be given to research and development activities. During the
year the company proposes direct investment to strengthen its R&D.
R&D is the main centre in corporate head office which keeps the presence
of their product alive in the market.
The R&D is concerned with the development of new and innovative
products. It conducts frequent test to analyze and ensure the quality of the
chemicals used for the condom production and also finished products.

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Objectives:-

a) Development of new products

b) Development of new technologies
c) Absorption / adaptation / assimilation of new technologies

Functions:a) Identification of alternative source for product chemicals both imported and indigenous is
being carried out.
b) Quality parameters of products at various levels of production are being checked.
c) Modification work of Bio-Gas plant.
d) Development of packing machines.
e) Modification of effluent treatment plant for further refinement of treated water.

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SAFETY & SECURITY DEPARTMENT

The company integrates safety and environment protection as a

policy along with the production quality related activities.

Organization Chart

Chief Emergency Controller

Additional Emergency Control (GM)(O)

Security & Fire Coordinator

(Security Inspector)

Finance Coordinator
Manager (F)

Transport / Welfare / Medical

Coordinator

Engg. Coordinator

(AGM) (ENGG)

Safety Coordinator
Manager (Safety)

DC

The company has a well established safety, occupation and environment

policy that ensure safety of public, employees, plant and equipment.

The Peroorkada plant complies with all statutory rules and regulations basis.

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It imparts training to its employees as per the training calendar, carrying out statutory safety
audits of its facilities as per legal requirements.
It conducts regular medical checkup of its employees and promoting eco-friendly activities.
It carry outs hazard identification and risk assessment.
It takes various measures to avoid the fire hazard.
Air pollution management
Waste water management
Solid waste management
Forestation activities

5 S

a)
b)
c)
d)
e)

Seiri
Seiton
Seiso
Seiketsu
Shitsuke

Integrated Japanese concept for work place management by five

steps of Housekeeping viz. Organizing, neatness, cleaning, standardization
and discipline. Each S stands for:
-

Sort out
Set in Order
Shine
Standardize
Sustain

It is an important management philosophy towards high level of process,

accuracy, dust free atmosphere, proper maintenance, clean habits,
understanding proper training, better human relationship etc.

Functions of 5 S:

DC

A frame of mind
Improves quality of human behavior
Team work
Starts with each individual practicing it
For total employees involvement
Reduces time for searching materials
Marks area and cautions
Keeps things in the best way
Minimizes inventory
Improves work place utilization
For total quality environment
A basic step towards total quality management
Creates proper storage of hazardeous material
Gives proper care for emergency equipments
Eliminates unsafe situation
Organizes all cleaning aids

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Helps operator for doing autonomous maintenance

Reduce wastages, defects and breakdowns
Calls for regular inspection and feedback
Assign roles and responsibilities
Stepping stone for world class productivity

Strategy for World Class Management [Balance Score

Card Principle]

HLL
P World Class
Manufacturing
Strategy
WCP CUF
C

Waste Elimination, Work Environment

Classic Quality

Productive & Predictive Maintenance

Customer Driven Approach

Learning and growth, Loss Control

Internal perspective, International control Information flow

Financial perspective

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Safe forum is a media for implementation of 5 S within the factory. It is a three

tier scheme with Safety Committee as the axis linking management review

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meeting and quality circle at Grass Root Level. Safe forum is introduced recently
in HLL to ensure involvement of people at all the levels of an organization by
assigning responsibility towards safety & environment protection.

Organization Chart

Safety Committee

Safe Forum (Dept - Level)

Dy. Leader
(Safety)

Dy. Leader
(Work
Improvement)

Dy. Leader
(Emergency
Conservation
Trainee)

Dy. Leader
(House
Keeping)

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PRODUCTION DEPARTMENT

The production department processes and tracks all of the drawings for
any given project once they are released from the design department. HLL
has today five state of the art manufacturing facilities. HLL commenced
its commercial operations on April 5, 1969 at Peroorkada in
Thiruvannthapuram in the state of Kerala. Together with the
manufacturing facility at Peroorkada, HLL today has five state of the art
manufacturing facilities at:

a) Kanagala near Belgaum (1985) for contraceptives and pharmaceutical products

b) Akkulam in Thiruvananthapuram (1994) for hospital products
c) Kakkanad in the Cochin Special Economic Zone (2004) for female condoms and male
condoms for export
d) Manesar in Gurgaon (2007) for rapid in-vitro diagnostic test kits.

I.
II.

All these units have ISO 9001, ISO 14001 quality and environmental
management system certifications.

The corporate vision of achieving the production department has a vision

of achieving a target production of 1 billion pieces as a first step towards
corporate vision. HLL has recorded a high productivity and profitability
progressively over the years. It is because of the implementation of very
efficient and effective manufacturing process with the technical help from
Japan.

The production department is divided into two. They are:

Primary Production
Secondary Production

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PRIMARY PRODUCTION

The manufacturing process of condoms in the primary production

department can be broadly classified into three main operations, viz.

A. Compounding

Compounding is done to make the latex suitable for molding operations and for
making the final product in conformity to requirements of the user. This is achieved
by the addition of fixed quantity of liquid compounding chemicals followed by
compounding chemicals dispersion to roll latex into mixtures. The dispersion is
prepared by using ball mill/sound grinder/pearl mill/attrite mill. After this the
mixtures heated and then called for pre-vulcanization. Then the pre-vulcanized
compound is transferred to the molding section after the aging period.
B. Molding

In this section highly automated condom shaped moulds are mounded on dual line
chain and are by two motor.
Mould washing
Mould drying
First dipping
Drying
Second dipping and drying
Edge rolling (beading)
Drying and vulcanization
Dipping is swelling solution tank
Dipping in anti-sticking solution
Stripping
This cycle is continuous round the clock and fully automatic setup.

C. Vulcanizing

It is the process of cross-linking modules to make the material harder, less soluble
and durable. It is also called curing. Vulcanizing operations are done in automatic
vulcanizing machines in order to improve the physical properties of the products. The
condoms from the molding section are sent to the vulcanization machines. The
condoms are vulcanized at the same time the powered in these machines and are
collected in crates. The production lots are transferred to quality control half product
without losing identity.

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MANUFACTURING PROCESS

Collecting of Raw Materials

Compounding

Storage

Dipping

Drying

Tumbling / Edge Rolling

Testing

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COLLECTING THE RAAW MATERIALS

Rubber latex is obtained from the milky fluid produced b various

tropical plants. Latex is actually an emulsion or dispersion of tiny rubber
particles in water and ingredients added to the latex must be able to attach
to the rubber particles during compounding.

COMPOUNDING

Next the chemical additives are mixed to from a paste. This paste
is then blended with the liquid latex in a process called compounding.

STORAGE

The latex and chemical compound is then unloaded into drums for
storage, where it remains for approximately seven days. During this
period, vulcanization chemically strengthens the bond of the rubber. The
storage time also allows any air, which might have been trapped in the
mixture during compounding to escape.

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The compound is then added to the dipping or condom forming

machine. The dipping machine is a long, hooded machine approximately
100 feet (30.5m) in length. Thick tempered glass rods move along a closed
belt between two circular gears. The belt drags the rods, which are called
mandrels, through a series of dips into the latex compound. The mandrels
rotate to spread the latex evenly. Several coats are required to build the
condom to its required thickness. Between each dip, the latex is hot air
dried.

After the final dipping and drying, the condoms automatically roll off the
mandrels. A machine shapes and trims the ring of latex at the n=base of
each condom.

TUMBLING

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The condoms are put in a tumbling machine, where they are coated
with talc or another similar powder to prevent the rubber from sticking to
itself.

TESTING

After a curing period of several days, the condoms are sampled by

batch and tested for leaks and strength. The first such test is the inflation
test, in which the condom beyond 1.5 cubic feet, about the size of a
watermelon, before bursting. This test is considered most important
because the elasticity of the condom keeps it from tearing during
intercourse.

In water leakage test, the condom is filled with 10 ounces (300ml) of

water and inspected for pin-sized holes by rolling it along blotter paper.

Condoms are also tested electronically. This involves mounting each

condom on a charged stainless steel mandrel. The mandrel is passed over
by a soft, conclave brush. If pin holes are present, a circuit will be
established with the mandrel, and the machine will automatically reject the
condom.

PACKAGING

Condoms that have successfully passed these tests are rolled by a machine.
Rolling the condom makes it easier to package and use. Lubricant and
spermicidal may be applied by a metering pump just before the top wrap is
added in the foiling process.

HIERARCHY OF PRIMARY PRODUCTION DEPARTMENT

GROUP HEAD

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DGM

SENIOR MANAGER

MANAGER

DEPUTY MANAGER

OFFICER/JUNIOR
OFFICER/SUPERVISOR

II.

SECONDARY PRODUCTION

Secondary production department consists of the following departments

Quality Assurance Department
Electronic Testing Department
Packing Department

PRODUCTION PLANNING & CONTROL

DEPARTMENT

Organization Chart

GM (O) / UNIT
CHIEF

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MANAGER (PPC &

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GRADUATE
TRAINEE

SG4

Production, Planning and Control (PPC) prepares production schedule to

meet the overall objectives in terms of quantity, quality and delivery of
products. The functions of PPC are as follows:

Interact with departments of production, quality control, MPC, Sales, Stores, marketing
etc for the effective achievements of the organizational growth.
Preparation with social marketing organization and marketing department to affect the
order efficiency
Sending monthly production data to DGTD through company secretary
Renewal of licenses related to drugs, sulphur, rubber, diesel, furnace oil, rectified sprit
and ammonia by interacting with Drug Control Board, Rubber Board etc.
Monitoring and review of production effectiveness

Major Customers of HLL

a) Major customers of HLL in domestic market are Ministry of Health & Family welfare,
SMOs (Social Marketing Organizations) and Marketing division of HLL.

b) Major customers of HLL in International market are UNFPA, IDA, IPPF, Mission
Pharma, etc.

c) HLL also caters to the requirements of Middle East countries, African countries, Russia,
Europe and Asian countries.

ACTIVITIES OF PPC DEPT

a) Planning and monitoring of condom production as per the requirement based on orders.

b) Interaction with external agencies for maintaining the statutory requirements of PFT.
c) Preparation of Monthly/ quarterly/ annual report to evaluate the planning and scheduling
of condom production.

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MATERIAL PLANING AND CONTROL DEPARTMENT

ED & GH (C & MCG)

M (PPC & MPC)

JR. OFFICERS

GRADE EMPLOYEE /
GRADUATE TRAINEE

Objectives

Proper planning of procurement of raw materials, chemicals & packing

materials as per the production plan and packing plan. Control of
inventory to keep optimum stock, to avoid stock out situation &
unnecessary inventory campaign.

ACTIVITIES
a) Preparing for annual budget for production and packing materials based on annual plan
meet/ marketing projections/ production and packing plan.
b) Material required along with specification and quantity is forwarded to purchase to
facilitate purchase department to obtain the rates and identify the vendor.
c) PRs are given subsequently, with schedule of supply according to the indication from
production/ marketing/ orders etc. Considering the norm, present stock/ FG stock and on

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order quantity for items not covered under MRP. For all materials covered under MRP
based on MRP run PRs will be generated automatically.
Periodic monitoring and review of material stock position and providing feed back to
purchase department to ensure supply.
Raising stock transfer P.Os for receiving materials from other units and corresponding
with other units for the material required by them.
Raising subcontracting PRs for printing on foil/ wallets/ cartons and PRs for printing of
consignee address stickers for export orders.
Dealing with SMO supplied products.
Dealing with specifications of materials with MT/ stores etc.

ENGINEERING DEPARTMENT

In HLL, Engineering department is responsible for the installation, proper

maintenance and upkeep of all factory structures and equipments and in maintaining the
optimum of condoms.

There are mainly four sections in engineering department, they are:

1. Mechanical section
2. Utility section
3. Instrumentation section

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4. Electrical section

1) Mechanical Section:

CO (ENGG)

CO (ENGG)

SAPM/APM (MECH)

JO/EM/SUP

FM/SUP
(M/M)

(M/S)

JO/FM/SUP
(M/W)

Mechanics/Filt
Mechanics/
Mechanics/Filt
Tradesman

er
Filter
er

Description:

JO
:
Junior Officer

FM
:
Forman

M/S
:
Mechanical Shift

MM :
Mechanical Maintenance

It plays a key role as a service section to keep the plant and

machinery in satisfactory condition according to the standards set by the management.

Functions:
Mechanical maintenance of the plant & machinery
Inspection of the all incoming materials/spare/equipments.
Modification, new installation, technology, up gradation and continual improvement
of equipment / machinery.

Objectiveness of Maintenance:

Increase the productivity equipments.

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Decrease the overall cost of production

Safeguard the equipment by minimizing the rate of deterioration of assets.

Types of Maintenance:

Maintenance is subdivided into two main categories:

a) Preventive maintenance
b) Breakdown maintenance

A) Preventive Maintenance:

Activities carried out to prevent failure or detect failures before it develops in

to breakdown. The preventive maintenance adopted in HLL includes lubrication,
plant or over hauls regular cleaning adjustment etc.

B) Breakdown Maintenance:

Activities carried out to correct the failure or breakdown after the occurrence
of breakdown.

2) Utility Section:
CO(ENGG)

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SAPM / APM (U)

a)
b)
c)
d)

JO/FM/SUP
General Shift U

Mechanic &
other Trade

man

JO/FM/SUP
Shift (Mech)

JO/FM/SUP
Shift (Boiler)

Chiller /
Compressor pump
Operator

Boiler
Operator

Description:
JO
FM
M/S
MM

:
:
:
:

Junior Officer
Forman
Mechanical Shift
Mechanical Maintenance

Functions:

The main function of utility section is the maintenance of machinery

which incudes:

Chiller
Boiler
Compressor
Pipeline maintenance

A) Chiller

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Chillers are used for cooling. There are five chillers in the organization.
They are used for process cooling and two are used for refrigeration.
Process cooling means the cooling of mould and condoms during
production process. Refrigeration includes air conditioners and other
coolers like water coolers in the organization.

B) Boiler

Boilers are used for supplying steam to provide required temperature

during drying process. There are 3 boilers in total.

C) Compressor

Compressor is used to provide air flow for condom stripping. It is also

used in vulcanizing process. There are three compressors in the plant.

3) Instrumentation Section:

CO (ENGG)

DM (ENGG)

SAPM / APM
(Inst)

JO (I)

JO (I)

SUP

Technicians

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Description:

JO
:
Junior Officer

FM
:
Forman

M/S
:
Mechanical Shift

MM :
Mechanical Maintenance

The instrumentation section consists of:

a) Electronic workshop
b) Calibration Lab

a) Electronic Workshop

It deals with motor and other electronic equipments.

b) Calibration Lab

The main function of calibration lab is the testing of equipments used in

process control such as ammeter, voltmeter and other sensitive instruments.
Standard device is placed in the lab and reading of devices during production
process must match the reading of standard device.

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Electrical Section:

CO (ENGG)

DM (ENGG)

SAPM / APM (E)

JO (E) General I

JO (E) General - 2

SUP (E) Shift

Technicians

Technicians

Technicians

This section plays a key role in the service section regarding the power
receiving and distribution system and to keep the plant and machinery in
satisfactory condition according to the standards set by the management.

Functions:

Power receiving & distribution

Preventive maintenance
Breakdown maintenance
Winding and over hauling of motors
Inspection of incoming electrical materials
On the job training to all electrical technicians

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The task of maintenance is to keep production and testing machinery,

service equipments, building & grounds in good working condition with
sufficient safety provisions.

PACKING DEPARTMENT

Organization Chart

Unit Chief (PFT)

Head of Production
Department
Controlling Officer
(Packing)
Head of Packing
Department

Section Head of Primary

Packing

Section Head of
Secondary Packing

ET / APM
/ SAPM / DM

ET / APM / SAPM / DM
(PKG)

Supervisor
/ Foreman /
Junior
Officer

Supervisor / Foreman /
Junior Officer

Grade I - VI

Grade I - VI

Trainees / Contract
Personnel
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Naked condoms from Quality Control Finished Product are received batch
wise and scheme wise, foils, silicon oil, pouches wallet, cartons boxes
etc after passing the incoming inspection are received from store
department. Naked condoms are issued to packing machine for strip
packing in foils as per packing schemes. Required quantity of silicon oil is
closed in strip as part of machine operation. Quality of silicon oil closed is
as per customers standard. Strips are packed in to pouches and wallets
and then in to cartons & boxes as per customer requirements.

The operations involved can be broadly classified into two categories:

1) Primary Packing Operations

2) Secondary Packing Operations

1) Primary Packing Operations

In primary operations, the major input to the process is tested and rolled
condoms which are received from QA department. Foils, lubrications, fragrances
and flavors are the other major department that the Primary packing operation
involves. Strip packing of condoms using packing machines i.e. tested and rolled
condoms are packed as strips with lubricants / fragrances flavors in aluminum
foils.

2) Secondary Packing Operations

In the SPO the major input to the process is strip packed condoms from
the primary packing section. Secondary packing materials such as pouches,
wallets, cartons, leaflets and boxes are received from stores department. After
completion of secondary packing of a batch, the quantity is offered to Quality
Assurance department for FG (finished goods) inspection. The Quality Assurance
passed filled boxes will be transferred to depot section after box strapping
operations.

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Flow Chart of Packing Operations

Organization Chart

Secondary packing

material storage

Stamping

Store

Strip Packing

Material
Storage

Strip Packing

Strip Storage

Secondary
Packing

Q/A

Condom
Storage

Depot

There are two types of packing:

1) Squeeze packing
2) Square packing

1) Squeeze Packing:-

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Less lubrication oil is used to lubricate the condoms compare to

square packing. This is for domestic market and the expiry period is 3
years.

2) Square Packing:

These condoms are more lubricated and more foil is used to pack.
This is for international markets and its expiry period is 5 years. The final
product in cases manually and from there the sales department will take
for sales.

Lubricant Quality Table

Sl
N
o

DC

Type of
Pack

Squeeze
rectangular (Govt.
supplies & SMOs)

Square
(Export)

Square (SMO
brand)

Square pack
(Domestic)

Square pack
(Domestic)

Square pack

SCHOOL

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Eg. Of
Scheme of Pack

Free supply,
Delux, Sawan, Milan,
Zaroor, Mithun,
Ahsaus, New
lubricated, Rakshak,
Trill, Muktha etc.

UNFPA, IPPF,
IDA, Moods, export
etc.

Masti

Moods
branded varieties

Moods all
right

Astha

MANAGEMENT

AND

Range
Min
Maxim
of Silicon Oil
imum
um Range
quantity
Range
(mg)
(mg)
(mg)

280 +/10

270

290

460 +/10

450

470

280 +/10
410 +/10
460 +/10
560 +/-

270

290

400

420

450

470

510

530

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(Domestic)

FINANCE AND ACCOUNTS DEPARTMENT

Organization Chart

DGM (F)

DM (F)

SAM (F)

JO

Supt

Employees

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Description:

DGM

Deputy General Manager

DM

Deputy Manager

SAM

Senior Assistant Manager

JO

Junior Officer

Supt

Superintendent

The company reinvests the profits to meet the working capital. This
enables the company to operate without outside borrowing. A separate file
is maintained for every supplier. In case of extra item supplied by the
supplier, purchase department sends an amendment order to finance
department on bills are prepared accordingly and a copy will be send to
stores section. If the supply is less than the order placed no payment is
made unless and until full quantity of material is supplied. The types of
payment made to suppliers are:

1. Advance payment
2. Payment against credit
3. Payment through bank

Functions:

Suppliers Bill / Party Bill section

Payroll Section
Internal Audit Section
Costing Section
Ledger Section
Cash Section
Finalization of Accounts
Working Capital

Suppliers Bill / Party Bill Section

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This section is concerned with matters relating to purchase of

goods and raw materials. The Material Receipt Report (MRR) prepared by
the stores department is send to this section during the purchasing
function. The MRR in addition to the suppliers invoice sends a copy of the
purchase order is to be send to be maintained by this section in order to
send the suppliers bills.

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PAYROLL SECTION

This section deals with salary computation with respect to

attendance, overtime work, leave and recoveries in accordance with time
office and personal department. Vouchers have been sanctioned and
cash/cheque issued from the cash section. Salary account is prepared
monthly. Advance amount is given to employees are recovered from next
months salary. Allowance like festival allowance, house rent allowance,
medical allowance and dearness allowances etc are given to the
employees.

The details regarding attendance of the employees are received from the
Time Officer and an Accountant of the information received and taking in
to consideration statutory deduction; loan and the salary bills are prepared.
This section also deals with TA bills, medical advance settlements etc.

INTERNAL AUDIT SECTION

Scrutinizing of all personal files of all employees of the unit

relating to annual increment, promotion, transfer etc. Scrutinizing all
purchase proposals, comparative statements connected with supply order
and purchases. Scrutinizing pay fixation statements, arrears pertaining to
pay provision and other connected work of all employees. Securitizing of
several specific cases apart from the above work as directed by top
authority

COSTING SECTION

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Information required for costing is obtained from systems through

the report generated by MIS report includes closing stock, production,
conception etc. The costing done here is process costing and prime costing
is obtained.

The new variances that add to cost are identified and there costs are
ascertained. This section prepares monthly / quarterly financial reports. In
addition to those they also prepare variance reports which show the

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deviation in quantity and cost which is used to check and regulate the
consumption of such items.

LEDGER SECTION

This section is concerned with the maintaining of ledger accounts.

CASH SECTION

This section deals with all payment to be made to parties in the

form of cash or Cheques. It further deals with the payment of the salaries
and wages of the employees and workers.

Finance department undertakes the budget preparation for the

organization. The budget is prepared considering the budgetary needs and
requirements made by all departments and section. The budget proposals
are put forward to the Board of Directors for sanction.

FINALIZATION OF ACCOUNTS

The section deals with preparation. Co-ordination & assists in the

preparation of final accounts of the company. It is also used to assist the
statutory auditors of the company.

WORKING CAPITAL

HLL Life Care Ltd. Kept 10 crore rupees as working capital. This amount
is kept in State Bank of India. The amount will issue based on inventory,
credit ratio etc.

HUMAN RESOURCE DEPARTMENT

Organization Diagram

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DGM (HR)

DM

MT - HR

MED
OFFICER

C & GC C1
C2

SG 5 - 2

O 5 - 4

SG 4 - 1

MG 6 - 1

O3-2

Nurse Staff (4) and

CONTRACT

MG 4 - 2

SG 3 - 1

S1

MG 1 - 1

1.
2.
3.
4.
5.

DC

The main functions are:

General Administration
Wages and Salary
Training and Development
Performance Management
Industrial Relations

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6. Labor Welfare
7. Estate Management
8. Implementation of official language

I.

GENERAL ADMINISTRATION
a) Time Keeping
HLL is a company that works around the clock and has 3 shifts:
i. 06:00 am 02:00 pm
ii. 02:00 pm 10:00 pm
iii.
10:00 pm 06:00 am
iv. General shift 09:15 am 05:15 pm

Time office maintains all attendance records of employee. An unauthorized

absence is reported to appropriate section. It maintains records of any medical leave,

compensatory leave, overtime offs, breaks more than half hour, on duty leave etc. It gives
sufficient attendance list, which helps in wage calculation. Time offices use punching
system for entry and exist of workers. Late attendance up to 15 minutes the concerned
department should five a written consent to the employee because the punching system
will cut off automatically after 15 minutes. Punching 2 cards by the same person is
prohibited. The late minutes are added up for one month and are deducted from salary or
wages, however 2 late purchases per month are allowed.
b) Employment Administration

Maintaining details of agreed strength and actual strength

Statistical data related to employees
Sending report relating to the manpower
Maintaining seniority list and roster position

c) Maintenance of Personal Records

HLL has got a prompt management information system, which feeds data every

day, LAN helps the MIS to update data of every department regularly, and this helps the
management to have a detailed data about personal records. MIS helps in knowing the
demand and supply of labor and in creation of manpower plan. Maintenance of such
records helps the personal department is new recruitment, promotions and internal
transfer according to the need.

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Contract Labor Management

This includes registration and timely renewal of license
Inviting tenders as per the requirement of the user department
Certification of license, commencement / competition report
Maintaining records & registration, annual returns as per contract labor Act
Administration of quality management system and OHSAS
Formulating HR policies and procedures
Issue office orders, notice and circulars
Administration of various schemes and agreement

II.

WAGES AND SALARY ADMINISTRATION

III.

Pay fixation as per the long term settlement

Annual increment
Parity determination
Gratuity and other retirement benefits

TRAINING AND DEVELOPMENT

HLL follows continuous training programs for employees for their

effectiveness.
Training helps to increase the knowledge and skill of an employee for
doing a particular job. Training and development in HLL is categorized

IV.

DC

into:
Executive Development Program
Supervisory Development Program
Seniority
Reservation list
Performance appraisal
Pay fixation and grade seniority list

PERFORMACE MANAGEMENT

Performance evaluation is done annually for workers, supervisors and executive

separately.
Factors affecting the key performance indicators of each job are identified and evaluated

as per the importance.

Each factors has five descriptions

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The evaluator selects the best one that describes the factor of performance of each

employee
The employees who get excellent rating on 2 continuous appraisals will be
recommended for the fast track promotion and also if an employee gets very poor
rating for two consecutive periods, he will be recommended for termination.

V.

INDUSTRIAL RELATIONS

Industrial Relations (IR) as it is today all embracive and people involved.

IR is also integral part of social, political and economic conditions
prevailing the scope of present day. IR has widened and embraced
functional interdependent complexities, involved not only matters to
wages and allowances, grades, promotions, transfer etc. People tend to
respond differently in different subjects even though issues are raised.

At HLL, employees are considered an asset and their value is appreciated

through continued improvement. Its philosophy itself as to relieve and
trust our employees, so any grievances are met with utmost importance
and necessary actions are taken. HLL is domestic in approach towards
employee trade unions. A present HLL recognizes three employee trade
unions:

1. HLL Life Care Ltd. Employees Union (CITU)

2. HLL Life Care Ltd. Workman Congress (INTUC)
3. HLL Life Care Ltd. Labor Union (AITUC)

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All grievances handling procedures are handled through union only.

Disciplinary procedures are also taken in consultation with unions. Unions
are also mediating bodies of collective bargaining. Apart from there; waste
disposal, dispatch estate, cleaning and maintenance duties are done by
union members.

VI.

WELFARE SECTION

In the case of HLL Life care Ltd, they have offered many employees
welfare schemes that is provided to both salaried staffs and daily paid
workers.

1. Provident Fund Scheme

PF will be deducted from all the employees at 12% of basic wages i.e.
basic pay and DA per month.
2. Employee State Insurance Scheme
3
3
Under this scheme, 1 4 % from the total wages of workers and 4 4
% from other employees are taken as insurance. For availing its benefits
employees have to visit E.S.I dispensaries at respective places.
3. HLL Welfare Fund
For this scheme, Rs 2 is collected from the wages and salaries of all the
employees of the organization.
4. HLL Workers Relief and Welfare Fund
Rs 1 are collected from all the employees wages and salaries for this
scheme.
5. Bonus

Usually the organization provides 21

1
2

% bonus to factory workers.

Employees are also eligible for bonus. The bonus to employees is usually
provided in a way of 3 month and 7 days salary which is fixed by HLL
relations committee (HLRC) 2010.
6. Canteen

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Company provides canteen facilities to all employees. It is not fully

subsidized. It provides breakfast, lunch, dinner and break time tea at Rs 70

/- per day. Canteen is based on basis of annual contract.

7. Safety of Employees
7.1 Fencing of Machinery: All dangerous and moving parts of machinery are
securely fenced. Screws, bolts and teeth are completely encased to prevent
danger.
7.2 Work on or near Machinery in motion: Only a specially trained adult male
worker does lubrication or other adjusting operation on the moving
machinery.
7.3 Employment of young Person on Dangerous Machines: No young person
is allowed working on any dangerous machine (so prescribed by the state
government) unless he is sufficiently trained or is working under the
supervision of knowledgeable person.
7.4 Device for Cutting off Power: Suitable device for cutting of power in
emergencies are provided.

8. Employee Insurance
Employees are insured under the Employees State Insurance Scheme
(ESI). ESI is a self financing social security and health insurance scheme
for Indian workers. For all regular employees earning less than Rs
15,000 /- per month salary, the employer contributes 4.75 % and employee
contributes 1.75 %, total share 6.5 %.

9. Recreation Club
A recreation club for all employees provides all facilities for arts and
sports. In every year, there was an annual program. Program includes
entertainment programs, athletics, parties etc.

VII. TRADE UNION DETAILS AND FUNCTIONS

HLL has five important trade unions:
1. Employee Association: It is an independent union, but the majority of the members
in it believe in the Marxist ideology.
2. HLL Employee Union: It is affiliated INTUC (Indian National Trade Union
Counters)

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3. HLL Thozhilali Union: It is an independent union, but majority of the members

believed in the ideology of Muslim league. Now BMS (Bharatiya Majdoor Sangh)
with them.
4. HLL Staff and Workers Association: It is affiliated to AITUC (All India Trade
Union Counters). It is the only unrecognized union in HLL.

Purpose of Trade Unions

Employment protection and job creation

Economic protection
Social Status and identity
Democratic institution
Transformation
Sustainable development
Greater bargaining power
Minimize discrimination
Sense of security
Sense of participation
Platform for self expression
Betterment of relationships

Specific Functions of Unions

Wages and salary bargaining

Fight for continuous improvement in employee benefits
Improving working conditions at work place
Improving welfare, healthcare and recreation facilities as well as leisure at workplace
Increasing rest periods, holidays, paid leave and time offs.

VIII. ESTATE MANAGEMENT

The internal & external mails, office memos, registered mails etc. are
received in this section and corresponding entries are made in the dispatch
register before sending them to the concerned parties. The General
maintenance of HLL also comes under this section.

DC

Modification and maintenance of company premises

Housekeeping of all sections / departments
Waste Management

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IX.

OFFICIAL LANGUAGE IMPLEMENTATION

HLL Life Care Ltd has an efficient security system for safeguarding &
preventing pilferage. The force has strength of more than 40. A
superintendent of police is appointed as the security & vigilance officer.

Being a central government undertaking HLL is committed to promote the

national language. The Hindi section under an assistant manager is
responsible for this all orders and records are translated in Hindi. The
library is also functioning under the personnel department.

SALES DEPARTMENT

Organization Chart

Deputy General
Manager (Commercial)

Manager (Stores &

Sales)

Deputy Manager (Sales

& Store)

Junior
Officer - I

Junior
Officer - I

Junior
Officer - I

SUPDT

Asst

SR. STENO

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Dy GM

- Deputy General Manager

Mgr

- Manager

JO

- Junior Officer

SR. STENO

- Senior Steno

OF

HLL

Purpose:

Execute the supply orders issued from Government of India,

Ministry of Health & Family Welfare and carryout execution of orders
against domestic supply condoms as well as export condoms as advised
from the HLLs marketing department.

Scope:-

In addition to the above main task, sales department arrange for the
disposal of no conforming products and sales of miscellaneous scraps like
metal scrap. Foil waste, card board waste, plastic waste, empty barrels etc.
after complying necessary formalities with regard to the scale of these
items.

Responsibility:

DC

MGR (stores, sales) here in after referred as controlling officers of

sales, senior assistant manager under the guidance of the deputy manager
is responsible for the implementation of this procedure. The orders are
placed in the following details.

Orders Number and Date

A/C no and Date
Item Distribution
Quality order
Unit
Rate per Unit
Total cost price
Address of consignee
Date of delivery to each consignee
Details of inspecting authority

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Terms of delivery
Mode of delivery

STORES DEPARTMENT

Organization Chart

Unit Chief

DGM (Commercial)

MGR (Stores & Sales)

DM (Stores & Sales)

DC
SCHOOL
SSK
SSK
(Local
(FG

Purchase)
Store)

OF

MANAGEMENT
SK & SK

(Engg & Store)

AND

TECHNOLOGY,
SK & SK

(Stationary)

TRIVANDRUM
SK
JO (Chem. &

PM Store)
store)

Page
SSK86
2I

(Receipt)

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Description:

GM
General Manager
DGM
Deputy General Manager
MGR
Manager
SSK
Senior Store Keeper
SK
Store Keeper
JO
Junior Officer
FG Store
Finished Goods Store
PM Store
Packing Material Store

HLL consists of 5 sections:

1) Receipt store
2) Chemical & packing material store
3) Engineering store
4) Stationary store
5) Finished goods store

1) Receipt Store

All purchased goods arrive at the receipt store. Inward register book is
maintained and MAN (Material Arrival Note) is issued. Then the testing
department issues MRR (Material Receipt Report) if the goods are accepted of
MRN (Material Rejection Note) if materials are rejected.

2) Chemical Store

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Here the latex, chemical and packing materials are stored.

3) Engineering Store

All engineering goods are stored here.

4) Stationary Store

The stationary goods are stored here. All those stores are computerized
and issue material on receipt of intent or material requisition from used
department. The store is based FIFO system i.e. first in first out. The items that
are coming first are to be dispatched first. ABC analysis is used in the store.

5) Finished Goods Store

Finished goods are stored in the department as custodian or finished

goods.

PURCHASE DEPARTMENT

Organization Chart

Unit Chief

DGM [C]

PA to DGM (C)

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AM [P-1]

SAM AM [P-II]

SAM [P-III]

Jos / Superintendent
[SPDT/S]

Grade IV

Description:-

DGM
SAM
PA
JO
AM
SPDTs

: Deputy General Manager

: Senior Assistant Manager
: Personal Assistant
: Junior Officer
: Assistant Manager
: Superintendent

Objectives

The objective is to ensure that materials and services are made

available to have uninterrupted production and packing as per plan.

Purchase department is called up on to purchase the right type of goods at

the right time, from the right suppliers and at the right price. The
machineries, tools, raw-materials, packing material, sanitary items etc
which is required for the operation in the factory are brought by the
purchase department as and what required. Therefore the deputy manager
has to deal with the procurement of raw materials, packing materials etc.

Purpose: - To give introduction and describe the objective with regards

to the functions of purchase department.

There are two tenders:

1. Open Tenders
2. Limited Tenders

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1) Open Tenders:
Value is exceeding 30 lakhs in the case of consumable and recording expenditure and
value exceeding Rs 50 lakh in case of capital goods / works. Tenders are floated in reading
news paper / website.
The purchase function includes:
a) Source Identification
b) Source Selection
Source identification involves the identification of suppliers looking into past
experience, trade journals etc.

Source selection is determined by obtaining the desired quality price and service.

The other functions are:

i)

Maintain continuity in respect of supply of materials to support the production

schedule and the co-operations.
ii)
Doing the above with the minimum investment consistent with the economic
advantage.
iii)
Avoiding duplication wastage and obsolescence with respect to materials.
iv)
Developing goods and reliable relationship with the suppliers.
v)
Procuring material at the lowest cost consistent with the quality.
vi)
Maintaining standards in quality of materials based on suitability for use.

2) Limited Tenders:

Limited Tenders are floated in the following cases:i)

For consumable items whose total value is less than Rs.3000000/ii)
Capital goods/work contracts whose value is below Rs.5000000/-. Limited tenders
have only price bid.

Suppliers Rating

Done based on the following:-

1. Quality of the product

2. Functional performance

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3. Adherence to delivery schedule

INFORMATION TECHNOLOGY DEPARTMENT

Organization Chart

Junior Officer
-2

Superintendent

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Trainees

1)
2)
3)
4)

This department provides the resulting service and support for hardware,
networking and security services required for the company. The support
includes the development/ maintenance of various software services like
eIMIS, Intranet site mailing service, Website etc. The eIMIS is a software
application developed for the organization having modules for production,
purchase, store, sales, marketing, finance and engineering.

Software support includes development/maintenance of various software

applications like:-

INTERNET
MAILING SERVICE (WAN)
COMPANY WEBSITE
EIMS (Enhanced Integrated Management Information System)

1) INTERNET

It is the network connection between the entire computer of the

Peroorkada factory for data and resource sharing.

2) MAILING SERVICE

The WAN (Wide Area Network) is the network of all computer of

Hindustan Latex Limited (HLL) worldwide. Internet connection is provided from
BSNL.

3) COMPANY WEBSITE

The company website opened in 2000 (www.hindlatex.com)

4) EIMIS (Enhanced Integrated Management Information System)

EIMIS has developed in 1997. It makes the daily operations smooth and
fast. It certain records of attendance, employee salary, leave details etc.

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EMIS is customized application with ORACLE database. 10G form

EIMIS maintains all the data for functioning of production on QC. Finance ETD,
Store, purchase etc. Internet connects the networks with in the organization. The
WAN (Wide Area Network) connects all the function and officers of HLL across
the world. Company website provides in information about the organization for
the public. Operating system Linux is used in HLL. It is graphical user interface.

For communication purpose HLL is suing IP (Internet Protocol) phones

and messaging purpose IP messenger is used.

COUNSELING AND GUIDANCE CENTRE

DC

SCHOOL

OF

Counseling and guidance centre was started in Peroorkada Factory

(PFT) in the year 2005. It has completed its third year of service. During
the 3 years, it has extended its wings to confidently take up and organize
newer initiation with a view to enhance its wings to confidently take up
and organize newer initiation with a view to enhancing the physical,
mental and psychological aspects of health. The counseling centre
functions with 2 full time social workers & a consultant psychologist.

MANAGEMENT

AND

TECHNOLOGY,

TRIVANDRUM

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QUALITY
MANAGEMENT
PEERORKADA
PLANT

OF

HLL

Mission

To promote lifelong learning, build cooperative working

relationship for a satisfying personal and professional development.

The individual counseling is done and the activities are as followed:-

1. Counseling & Guidance

2. Mukha Mukham

Awareness on legal rights of women at work place

Awarness on Chikungunya as well as other viral fevers

Awareness and screening of diabetic retinopathy

Financial Management
3. Summer Camp for employee children
4. Kudumba Sangamam
5. Sayahna Sangamam
6. Observance of World Mental Health Day
7. Short term spoken English Courses
8. Skin care & medical camps
9. Observance of World AIDS Day
10. Alcoholic de addiction

PROJECT DEPARTMENT

Organization Chart

GM

DC

SCHOOL

OF

MANAGEMENT

DGM (Project Head)

AND

TECHNOLOGY,

TRIVANDRUM

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QUALITY
MANAGEMENT
PEERORKADA
PLANT

OF

HLL

SAPM (Project)

Staff

1.
2.
3.
4.
5.
6.
7.

Description:

GM
DGM
SAPM

General Manager
Deputy General Manager
Senior Assistant Plant manager

The main function of project department is implementation of

major projects of HLL. The software is used in this department is Ms
Project. The activities of this department are as follows:

Understanding the requirements

Preparing the project proposal based on the requirement
Project cost estimation and feasibility study
Project report
Approvals from the authority
Implementation of the project
Project completion

DC

SCHOOL

OF

MANAGEMENT

AND

TECHNOLOGY,

TRIVANDRUM

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QUALITY
MANAGEMENT
PEERORKADA
PLANT

OF

HLL

DATA ANALYSIS
AND
INTERPRETATION

GENDER OF RESPONDENTS
Table No: 4.1

DC

SCHOOL

OF

MANAGEMENT

AND

TECHNOLOGY,

TRIVANDRUM

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OF

TOTAL
QUALITY
MANAGEMENT
PEERORKADA
PLANT

GEND
ER

FREQ
UENC
Y

MALE

OF

HLL

PERC
ENTA
GE %

41

FEMA
LE

TOTA
L

19

32

60

68

100

Chart No: 4.1

Gender Ratio
80
70
60
50
40
30
20
10
0

MALE

FEMALE

DC

SCHOOL

OF

MANAGEMENT

AND

TECHNOLOGY,

TRIVANDRUM

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OF

TOTAL
QUALITY
MANAGEMENT
PEERORKADA
PLANT

OF

HLL

Interpretation:

Out of total respondents surveyed, 68% were male employees and 32%
were female employees. This shows that in the firm majority workers are
the male employees, considering the fact that its a manufacturing plant it
is an obvious that males are more as they can endure more physical stress
that is needed in a production facility.

AGE OF RESPONDENTS

Table No: 4.2

AGE

Below
25
25 40
40 45
Above
55
Total

FREQ
UENC
Y
15

PERC
ENTA
GE %
25

23
12
10

38
20
17

60

100

Chart No: 4.2

DC

SCHOOL

OF

MANAGEMENT

AND

TECHNOLOGY,

TRIVANDRUM

Page 98

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OF

TOTAL
QUALITY
MANAGEMENT
PEERORKADA
PLANT

OF

HLL

Age of Employees
40
35
30
25

Column1

20
15
10
5
0

Below 25

25 40

40 45

Above 55

Interpretation:

Out of total respondents surveyed, most of the respondents i.e. 38% are
from the age group of 25 40, 25% of the respondents are below the age
of 25, 20% are between the age of 40 and 45. The remaining 17% are
above 55 years of age. This means that around 60% of the employees
working at the plant are young and dynamic which makes the production
facility all the more productive as the youthful employees can produce
greater output within short period of time and can also work long and
hectic schedules to fulfill their targets.

INCOME WISE CLASSIFICATION

Table No: 4.3

INCO
ME

DC

SCHOOL

OF

MANAGEMENT

FREQ
UENC

AND

TECHNOLOGY,

PERC
ENTA

TRIVANDRUM

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OF

TOTAL
QUALITY
MANAGEMENT
PEERORKADA
PLANT

OF

HLL

Y
LESS
THAN
15000
15000
30000
30000
45000
Above
45000
Total

GE %

12

20

23

38

16

27

15

60

100

Chart No: 4.3

Monthly Income
40
35
30
25

Column1

20
15
10
5
0

LESS THAN 15000

15000 30000

30000 45000

Above 45000

Interpretation:

DC

SCHOOL

OF

Out of the total respondents surveyed, 38% of the respondents draws

salary between Rs. 15000/- and Rs. 30000/-, 27% draws salary between
Rs. 30000/- and Rs. 45000/-, 20% draw salary less than Rs. 15000/- and
15% of the employees draw salary above Rs. 45000/-.

MANAGEMENT

AND

TECHNOLOGY,

TRIVANDRUM

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OF

TOTAL
QUALITY
MANAGEMENT
PEERORKADA
PLANT

OF

HLL

This shows that the employees are well compensated for the services that
they provide to the organization based on their grade as well as based on
their performance. This also indicates that the income is appreciably
satisfactory when compared to other organizations of similar stature.

IMPORTANCE
OF
QUALITY
MANAGEMENT
IMPLEMENTATION IN CREATION OF SUCESSFUL
BUSINESS STRATEGY IN HLL

Table No: 4.4

Indica
tor

Frequ
ency

Very
Importa
nt
Importa
nt
Neutral
Less
importa
nt
Not
importa
nt
Total

Perce
ntage
%

32

53

16

27

7
5

12
8

60

100

Chart No: 4.4

DC

SCHOOL

OF

MANAGEMENT

AND

TECHNOLOGY,

TRIVANDRUM

Page 101

EFFECTIVNESS

OF

TOTAL
QUALITY
MANAGEMENT
PEERORKADA
PLANT

OF

HLL

QUALITY MANAGEMENT IMPLEMENTATION FOR SUCESSFUL BUSINESS STRATE

60
50
40
30
Column1

20
10

po
rt
an
t
N

im
Le
ss

ot
im

po
rt
an
t

eu
tr
al
N

po
rt
an
t
Im

Ve
ry

Im

po
rt
an
t

Interpretation: Out of the total respondents surveyed, 53% of the

employees responded that quality management is very important for the

companys strategy development, 27% of them feel that it is important,
12% are neutral about it and remaining 8% feel it to be less important.
This shows that about 80% of the employees have a strong belief as well
as experience that by implementing TQM it would definitely aid and help
in developing HLLs business strategy to a great extent.

ENTHUSIASM OF TOP MANAGEMENT

Table No: 4.5
Indica
tor

DC

SCHOOL

OF

No of
Respo
ndents

Very
Importa

MANAGEMENT

AND

Perce
ntage

28

TECHNOLOGY,

TRIVANDRUM

47

Page 102

EFFECTIVNESS

OF

TOTAL
QUALITY
MANAGEMENT
PEERORKADA
PLANT

nt
Importa
nt
Modera
tely
Importa
nt
Less
Importa
nt
Not
Importa
nt
Total

OF

HLL

17

28

15

10

60

100

Chart No: 4.5

Enthusiasm of Top Management

50
45
40
35
30
25
20
15
10
5
0
ot
Im
po
rt
an
t

po
rt
an
t

Im
M
od
er
at
el
y

Ve
ry

Im

po
rt
an
t

Column1

DC

SCHOOL

OF

Interpretation:

MANAGEMENT

AND

TECHNOLOGY,

TRIVANDRUM

Page 103

EFFECTIVNESS

OF

TOTAL
QUALITY
MANAGEMENT
PEERORKADA
PLANT

OF

HLL

Out of the total respondents surveyed, 47% of the employees strongly

responded that it is based on the enthusiasm shown by the top
management, the quality management has implemented in the
organization, 28% find it to be important, 15% find it to be moderately
important and the last 10% find it to be less important.

IMPORTANCE OF 7QC TOOLS FOR PROCESS

CONTROL AND IMPLEMENTATION IN HLL

Table No: 4.6

Indica
tor

No of
respon
dents

Very
Importa
nt
Importa
nt
Modera
tely
Importa
nt
Less
Importa
nt
Not
Importa
nt
Total

Perce
ntage

28

47

18

30

10

17

60

100

Chart No: 4.6

DC

SCHOOL

OF

MANAGEMENT

AND

TECHNOLOGY,

TRIVANDRUM

Page 104

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OF

TOTAL
QUALITY
MANAGEMENT
PEERORKADA
PLANT

OF

HLL

IMPORTANCE OF 7QC TOOLS

50
45
40
35
30
25
20
15
10
5
0
po
rt
an
t
N

ot
Im

Im
M
od
er
at
el
y

Ve
ry

Im

po
rt
an
t

po
rt
an
t

No of respondents2

Interpretation: Out of the total respondents surveyed, 47% responded that 7QC tool is very

much important for process control as well as implementation, 30% of the respondents feel it is
important, 17% feel it to be moderately important and remaining 6% feel it to be less important
comparatively. Around 77% feel its absolute importance as most of the tools in it help them to identify
a problem or defect in the various processes in the various production phases. It is especially vital in
the quality assurance department, also the ETD section and even the packaging department.

IMPORTANCE
OF
DOCUMENTATION FOR WORK
PROCESS INSTRUCTIONS IN HLL

STANDARDIZED
METHOD AND

Table No: 4.7

Indica
tor

DC

SCHOOL

OF

No of
respon
dents

Very
Importa
nt
Importa
nt

MANAGEMENT

AND

Perce
ntage

14

23

22

37

TECHNOLOGY,

TRIVANDRUM

Page 105

EFFECTIVNESS

OF

TOTAL
QUALITY
MANAGEMENT
PEERORKADA
PLANT

Neutral
Less
Importa
nt
Not
Importa
nt
Total

OF

HLL

17
7

28
12

60

100

Chart No: 4.7

IMPORTANCE OF STANDARDIZED DOCUMENTATION IN HLL

40
35
30
25
20
15

Column1

10
5
po
rt
an
t
N

Le
ss

Im

ot
Im

po
rt
an
t

eu
tr
al
N

Im
po
rt
an
t

Ve
ry

Im

po
rt
an
t

Interpretation:

DC

SCHOOL

OF

Out of total respondents surveyed, 23% responded that standardized

documentation is a very important factor for process instruction as well as
work method. 37% feel it to be important, 28% feel it to be neutral and
remaining 12% feel it to be less important. It shows that 60% believe that
a set of well recorded documents are essential not only to solve daily

MANAGEMENT

AND

TECHNOLOGY,

TRIVANDRUM

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OF

TOTAL
QUALITY
MANAGEMENT
PEERORKADA
PLANT

OF

HLL

hindrances if any in operational processes but also for guiding the nonactive employees or trainees of the plant regarding various aspects.

IMPORTANCE OF TQM TRAINING FOR BUILDING

POSITIVE WORK CULTURE
Table No: 4.8
Indica
tor

No of
Respo
ndents

Very
Importa
nt
Importa
nt
Modera
tely
Importa
nt
Less
Importa
nt
Not
Importa
nt
Total

Perce
ntage

25

42

18

30

13

22

60

100

Chart No: 4.8

DC

SCHOOL

OF

MANAGEMENT

AND

TECHNOLOGY,

TRIVANDRUM

Page 107

EFFECTIVNESS

OF

TOTAL
QUALITY
MANAGEMENT
PEERORKADA
PLANT

OF

HLL

IMPORTANCE OF TQM FOR POSITIVE WORK CULTURE

45
40
35
30
25
20
15
10
5
0
ot
Im
po
rt
an
t

po
rt
an
t
Im

M
od
er
at
el
y

Ve
ry

Im

po
rt
an
t

Column1

Interpretation:

Out of the respondents surveyed, 42% of employees responded that the

TQM training is very important factor that leads to positive work culture
in HLL. 30% of the respondents feel it to be important, 22% feel it to be
only moderately important and remaining 6% feel it to be less important.
There are around 70% of the employees who feel strongly about TQM
training like the 5S that aids the organization in developing a positive
work culture by various conducting various skits and plays in each
department.

INCREASED EMPLOYEE MORALE

Table No: 4.9
Indica
tors

DC

SCHOOL

OF

MANAGEMENT

No of
respon
dents

AND

TECHNOLOGY,

Perce
ntage
%

TRIVANDRUM

Page 108

EFFECTIVNESS

OF

TOTAL
QUALITY
MANAGEMENT
PEERORKADA
PLANT

Strongl
y Agree
Agree
Modera
tely
Agree
Disagre
e
Strongl
y
Disagre
e
Total

OF

HLL

12

20

13
23

22
38

12

20

60

100

Chart No: 4.9

Increase Employee Morale

40
35
30
25

Column1

20
15
10
5
0

Strongly Agree

Agree

Moderately Agree Disagree Strongly Disagree

Interpretation:

DC

SCHOOL

OF

MANAGEMENT

AND

TECHNOLOGY,

TRIVANDRUM

Page 109

EFFECTIVNESS

OF

TOTAL
QUALITY
MANAGEMENT
PEERORKADA
PLANT

OF

HLL

Out of the total respondents surveyed, 20% of employees strongly stated

that quality management system has moderately increased the morale of
the employees, 22% agreed with the statement above, 38% moderately
agreed with the statement and rest 20% disagreed to this statement. This
shows that quality management system in the organization is effective to
some extent for increasing the employee morale of the organization.

QUALITY BASED SEMINARS AND PROGRAMS

Table No: 4.10
Indica
tor

No of
Respo
ndents

Very
Importa
nt
Importa
nt
Modera
tely
Importa
nt
Less
Importa
nt
Not
Importa
nt
Total

Perce
ntage

28

47

17

28

15

10

60

100

Chart No: 4.10

DC

SCHOOL

OF

MANAGEMENT

AND

TECHNOLOGY,

TRIVANDRUM

Page 110

EFFECTIVNESS

OF

TOTAL
QUALITY
MANAGEMENT
PEERORKADA
PLANT

OF

HLL

QUALITY PROGRAMS
50
45
40
35
30
25
20
15
10
5
0
ot
Im
po
rt
an
t

po
rt
an
t
Im

M
od
er
at
el
y

Ve
ry

Im

po
rt
an
t

Column1

Interpretation:
Out of the total respondents surveyed, 47% of the employees think quality
based seminars and programs are very important, 28% feel it to be
important, 15% feel it to be only moderately important and the rest 10%
feel it as less important.

PRIMARY RESPONSIBILITIES FOR QUALITY

Table No: 4.11
Categ
ory

DC

SCHOOL

OF

No of
Respo
ndents

Top

MANAGEMENT

AND

Perce
ntage

14

TECHNOLOGY,

TRIVANDRUM

23

Page 111

EFFECTIVNESS

OF

TOTAL
QUALITY
MANAGEMENT
PEERORKADA
PLANT

Manage
rs
Quality
Control
Team
Line
Manage
rs
All
Employ
ees
Total

OF

HLL

15

25

26

43

60

100

Chart No: 4.11

50
45
40
35
30
25

Column1

20
15
10
5
0
Top Managers Quality Control Team Line Managers

All Employees

Interpretation:

DC

SCHOOL

OF

Out of total respondents surveyed, 43% of the employees responded that

all employees have the primary responsibility for quality in the
organization. 23% of the employees respond that top managers have the

MANAGEMENT

AND

TECHNOLOGY,

TRIVANDRUM

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QUALITY
MANAGEMENT
PEERORKADA
PLANT

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HLL

responsibility, 25% respond that quality control team has the primary
responsibility for quality in the organization and only 8% feel that the
responsibility is with line managers.

QUALITY SYSTEM IMPROVES ORGANIZATIONAL

PERFORMANCE
AND
DIRECTIONALITY
TO
EMPLOYEES OF HLL
Table No: 4.12
Indica
tors

No of
respon
dents

Strongl
y Agree
Agree
Modera
tely
Agree
Disagre
e
Strongl
y
Disagre
e
Total

Perce
ntage
%

25

42

17
18

28
30

60

100

Chart No: 4.12

DC

SCHOOL

OF

MANAGEMENT

AND

TECHNOLOGY,

TRIVANDRUM

Page 113

EFFECTIVNESS

OF

TOTAL
QUALITY
MANAGEMENT
PEERORKADA
PLANT

OF

HLL

QS IMPROVES ORGANIZATIONAL PERFORMANCE AND DIRECTIONALITY TO EMPO

45
40
35
30
25

Column1

20
15
10
5
0

Strongly Agree

Agree

Moderately Agree Disagree Strongly Disagree

Interpretation:

Out of total respondents surveyed, 42% employees strongly agreed that

quality system improves organizational performance and directionality to
employees, 28% agreed to this statement and the remaining 30%
moderately agreed to this statement. Thus quality system not only
increases the efficiency of the production but also acts like a direction tool
for all the employees.

REDUCE DEFECT LEVELS

Table No: 4.13
Indica
tors

DC

SCHOOL

OF

No of
respon
dents

Strongl

MANAGEMENT

AND

Perce
ntage
%

25

TECHNOLOGY,

TRIVANDRUM

42

Page 114

EFFECTIVNESS

OF

TOTAL
QUALITY
MANAGEMENT
PEERORKADA
PLANT

y Agree
Agree
Modera
tely
Agree
Disagre
e
Strongl
y
Disagre
e
Total

OF

HLL

21
14

35
23

60

100

Chart No: 4.13

Reduce Defect Levels

45
40
35
30
25

Column1

20
15
10
5
0

Strongly Agree

Agree

Moderately Agree Disagree Strongly Disagree

Interpretation:

DC

SCHOOL

OF

MANAGEMENT

AND

TECHNOLOGY,

TRIVANDRUM

Page 115

EFFECTIVNESS

OF

TOTAL
QUALITY
MANAGEMENT
PEERORKADA
PLANT

OF

HLL

Out of the total respondents surveyed, 42% of the employees strongly

agreed that the defect levels had reduced due to the implementation of
Total Quality management system in the organization, 35% of the
respondents agreed with the statement and the remaining 23% moderately
agreed. Hence, it can be seen that on the manufacturing side, the quality
management is effective.

TRANSPARENT AND EFFECTIVE QUALITY SYSTEM

FOR RECOGNIZING AS WELL AS DETECTING
DEFECTS
Table No: 4.14
Indica
tors

No of
respon
dents

Strongl
y Agree
Agree
Modera
tely
Agree
Disagre
e
Strongl
y
Disagre
e
Total

Perce
ntage
%

12

20

13
23

22
38

12

20

60

100

Chart No: 4.14

DC

SCHOOL

OF

MANAGEMENT

AND

TECHNOLOGY,

TRIVANDRUM

Page 116

EFFECTIVNESS

OF

TOTAL
QUALITY
MANAGEMENT
PEERORKADA
PLANT

OF

HLL

TRANSPARENT AND EFFECTIVE QS

40
35
30
25

Column1

20
15
10
5
0

Strongly Agree

Agree

Moderately Agree Disagree Strongly Disagree

Interpretation:

Out of the total respondents surveyed, 20% of employees strongly agree

that transparent quality management system is essential for recognizing
and detecting defects, 22% of the respondents agreed to this statement,
38% moderately agreed to this statement and the remaining 20% disagreed
with this statement. Although there are a good majority of employees who
agree with this statement but still there are some who dont feel so in
comparison.

IMPLEMENTATION OF QUALITY IMPROVEMENT

ACTIVITIES SUCH AS QUALITY CIRCLE, QUALITY
TEAM WORK AND SUGESSION SYSTEM IN HLL
Table No: 4.15
Indica
tors

DC

SCHOOL

OF

MANAGEMENT

No of
respon

AND

TECHNOLOGY,

Perce
ntage

TRIVANDRUM

Page 117

EFFECTIVNESS

OF

TOTAL
QUALITY
MANAGEMENT
PEERORKADA
PLANT

OF

HLL

dents
Strongl
y Agree
Agree
Modera
tely
Agree
Disagre
e
Strongl
y
Disagre
e

Total

15

25

31
14

52
23

60

100

Chart No: 4.15

Improve Team Work

60
50
40
Column1

30
20
10
0

Strongly Agree

Agree

Moderately Agree Disagree Strongly Disagree

Interpretation:

DC

SCHOOL

OF

MANAGEMENT

AND

TECHNOLOGY,

TRIVANDRUM

Page 118

EFFECTIVNESS

OF

TOTAL
QUALITY
MANAGEMENT
PEERORKADA
PLANT

OF

HLL

Out of the total respondents surveyed, 25% strongly agreed that quality
improvement activities such as quality circles, quality team work and
suggestion system are essential in HLL. 52% of the respondents agree
with the given statement and the rest 23% moderately agreed to this. Thus
the employees feel greatly about the implementation of quality
improvement activities in the plant.

REDUCED LABOUR TURN OVER

Table No: 4.16

Indica
tors

No of
respon
dents

Strongl
y Agree
Agree
Modera
tely
Agree
Disagre
e
Strongl
y
Disagre
e
Total

Perce
ntage
%

13

22

16
24

77
40

12

60

100

Chart No: 4.16

DC

SCHOOL

OF

MANAGEMENT

AND

TECHNOLOGY,

TRIVANDRUM

Page 119

EFFECTIVNESS

OF

TOTAL
QUALITY
MANAGEMENT
PEERORKADA
PLANT

OF

HLL

Reduced Labour Turn Over

90
80
70
60
50

Column1

40
30
20
10
0

Strongly Agree

Agree

Moderately Agree Disagree Strongly Disagree

Interpretation:

Out of the total respondents surveyed, 22% of the employees strongly

agreed that there is a reduction in the labor turnover due to the
implementation of quality management in the organization, 77% of the
respondents agreed with the above statement, 40% moderately agreed with
the statement and only 12% of the employees disagreed to this statement.
This means quality management does have much effect in reducing labor
turnover.

ENCOURAGEMENT NEEDED FOR CONTINUOUS

IMPORVEMENT FOR ALL THE PRODUCTS AND
SERVICES IN DECISION MAKING
Table No: 4.17
Indica
tors

DC

SCHOOL

OF

MANAGEMENT

No of
respon

AND

TECHNOLOGY,

Perce
ntage

TRIVANDRUM

Page 120

EFFECTIVNESS

OF

TOTAL
QUALITY
MANAGEMENT
PEERORKADA
PLANT

OF

HLL

dents
Strongl
y Agree
Agree
Modera
tely
Agree
Disagre
e
Strongl
y
Disagre
e
Total

13

22

16
24

77
40

12

60

100

Chart No: 4.18

ENCOURAGEMENT NEEDED FOR CONTINUOUS IMPORVEMENT

90
80
70
60
50

Column1

40
30
20
10
0

Strongly Agree

Agree

Moderately Agree Disagree Strongly Disagree

Interpretation:

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Out of the total respondents surveyed, 22% of the employees strongly

agreed that there is a need of encouragement for continuous improvement
for all products and services in decision making, 77% of the respondents
agree with the statement, 40% moderately agree with the statement and
remaining 12% disagree with the statement. Hence there is need of
encouragement for continuous improvement for all products and services
in decision making process.

QUALITY STANDARD A GUID FOR ACTION,

JUDGEMENT AND ATTITUDE FOR BUILDING TQM
CULTURE
Table No: 4.19
Indica
tors

No of
respon
dents

Strongl
y Agree
Agree
Modera
tely
Agree
Disagre
e
Strongl
y
Disagre
e
Total

Perce
ntage
%

17

28

23
13

38
22

12

60

100

Chart No: 4.19

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Reduce Absenteeism
40
35
30
25

Column1

20
15
10
5
0

Strongly Agree

Agree

Moderately Agree Disagree Strongly Disagree

Interpretation:

Out of the total respondents surveyed, 28% of employees strongly agreed

to the statement that quality is indeed a guide for action, judgment as well
as attitude for building TQM culture in HLL. 38% of the respondents
agreed to this statement, 22% of them moderately agree to this and the
remaining 12% of the employees disagreed to the statement.

QUALITY INITIATIVES HELP TO KEEP

PRODUCTIVITY POSITIVE ALWAYS
Table No: 4.20
Indica
tors

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No of
respon
dents

Strongl

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AND

Perce
ntage
%

16

TECHNOLOGY,

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y Agree
Agree
Modera
tely
Agree
Disagre
e
Strongl
y
Disagre
e
Total

OF

HLL

24
17

40
28

60

100

Chart No: 4.20

QUALITY INITIATIVES
45
40
35
30
25

Column

20
15
10
5
0

Strongly Agree

Agree

Moderately Agree Disagree Strongly Disagree

Interpretation:

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Out of the total respondents surveyed, 27% of the employees strongly

agreed that quality based initiatives help in keeping the productivity
positive. 40% of the respondents agreed with the statement, 28%
moderately agreed to this and the rest 5% of the employees have shown
disagreement to this statement.

PERIODIC CONDUCTION OF BENCHMARKING

WITH OTHER FIRMS PROCESSES, WORK CULTURE
AND PRATICES BY HLL
Table No: 4.21
Indica
tors

No of
respon
dents

Strongl
y Agree
Agree
Modera
tely
Agree
Disagre
e
Strongl
y
Disagre
e
Total

Perce
ntage
%

25

42

21
14

35
23

60

100

Chart No: 4.21

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PERIODIC CONDUCTION OF BENCHMARKING

45
40
35
30
25

Column1

20
15
10
5
0

Strongly Agree

Agree

Moderately Agree Disagree Strongly Disagree

Interpretation:

Out of the total respondents surveyed, 42% of the employees strongly

agreed that there should be benchmarking with other firms periodically.
35% of the respondents agreed to this statement and the rest 23%
moderately agreed to this. Hence, it can be seen that benchmarking is an
essential concept for a firm to develop an edge over the market
competitors.

AWARNESS OF THE EMPLOYESS BASED ON THE

FOLLOWING FACTORS
CERTIFICATIONS OBTAINED BY HLL
Table No: 4.22.1
Indica

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No of

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Perce

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tors

OF

HLL

respon
dents

ISO
9001
ISO
18001
ISO
50001
ISO
13485
ISO
17025
Total

ntage
%

22

37

13

22

10

16

13

12

60

100

Chart No: 4.22.1

CERTIFICATIONS
40
35
30
25

Column

20
15
10
5
0

ISO 9001

ISO 18001

ISO 50001

ISO 13485

ISO 17025

Interpretation:

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Out of the total respondents surveyed, 37% of the employees who are
from all departments mostly know about ISO 9001, 22% know about ISO
18001, 16% know about ISO 50001, 13% know about ISO 13485 and
12% of the employees know about ISO 17025.

QUALITY PRACTICES HLL APPLYING FOR

Table No: 4.22.2
Indica
tors

No of
respon
dents

QUALI
TY
CIRCL
E
ISO
14000/
EMS
SA
8000
5S
GMP
Total

Perce
ntage
%

15

12

20

11

18

13
15
60

22
25
100

Chart No: 4.22.2

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QUALITY PRACTICES BEING APPLIED FOR

30
25
20
15
Column1

10
5

G
M
P

5S

80
00
SA

14
00
0/
EM
S
IS
O

Q
U

AL
IT
Y

CI
RC
LE

Interpretation:

Out of the total respondents surveyed, 15% of the employees know about
QUALITY CIRCLE, 20% know about ISO 14000/EMS, 18% know about
SA8000, 22% know about 5S and the rest 25% know about GMP. This
mostly shows that finance department, quality assurance department and
engineering department know well about this aspect when compared to
other departments.

INCREASE IN PROFITABILITY
Table No: 4.23
Indica
tors

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No of
respon
dents

Strongl
y Agree

MANAGEMENT

AND

Perce
ntage
%

25

TECHNOLOGY,

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Agree
Modera
tely
Agree
Disagre
e
Strongl
y
Disagre
e
Total

OF

HLL

19
14

32
23

60

100

Chart No: 4.23

Increase in Profitability
45
40
35
30
25

Column

20
15
10
5
0

Strongly Agree

Agree

Moderately Agree Disagree Strongly Disagree

Interpretation:

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Out of the total respondents surveyed, 42% of the employees strongly

agreed that the profitability had increased due to the implementation of

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quality management in the organization, 32% of the respondents agree

with the statement and only 23% of the employees moderately agreed to
the statement.

HYPOTHESIS

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SAMPLE SIZE

The population consists of 600 employees from which 60 were identified

for the sample size. The employees were from various departmental
sections in HLL Life care limited Peroorkada plant.

FORMULA

It is applicable for sample size less than 100 such that n = N (1 +

0.0025N) where N is the population size.

Now the sample size can be computed as follows:

Total Number of employees in HLL Life Care Limited, Peroorkada

Factory (N) = 600

Sample size of the employees taken for study based on the formula = 600
(1 + 0.0025 600) = 60

MAJOR FACTORS

a)
b)
c)
d)
e)

The major factors that were identified for the hypothesis were:

Employee Quality Awareness

Employee Effectiveness
Labor Turnover
Team Work
Rejections/Defects

The variables used were:

a) Strongly Agree
b) Agree

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Out of 5 only two variables were used since majority of the respondents
supported these variables as per the identified factors.

I.

CHI-SQUARE ANALYSIS

Null Hypothesis Ho: There is no significant relation between the quality

awareness and employee effectiveness.

Alternative Hypothesis H1: There is significant relation between the

quality awareness and employee effectiveness.

Table

Table No:

St

30

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38

Observation Table
Table No:

4.

0.6

1.0

1.3

4.

2.3

(OE)2

(OE)
E

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(OE)2
E

= 5.4042

Degree of Freedom = (C-1) (R-1)

= (2-1) (2-1)

=1

Level of significance = 0.05

Table value of Chi-square for degree of freedom 1 and level of

significance 0.05 is 3.841

INTERPRETATION

Since the calculated value is greater than the table value, null hypothesis
Ho is rejected. Hence the alternative hypothesis H1 is accepted.

That means there exists a significant relation between the quality

awareness of the employees and the employee effectiveness.

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II.

CHI-SQUARE ANALYSIS

Null Hypothesis Ho: There is no significant relation between the quality

awareness and labor turnover.

Alternative Hypothesis H1: There is significant relation between the

quality awareness and labor turnover.

Table

Table No:

St

10

14

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24

Observation Table
Table No:

0.

0.0

0.0

0.0

0.

0.0

(OE)

(OE)2
E

(OE)
E

= 0.0395

Degree of Freedom = (C-1) (R-1)

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= (2-1) (2-1)

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=1

Level of significance = 0.05

Table value of Chi-square for degree of freedom 1 and level of

significance 0.05 is 3.841

INTERPRETATION

Since the calculated value is less than the table value, null hypothesis Ho
is accepted. That means there does not exist a significant relation between
the quality awareness and the labor turnover.

III.

CHI-SQUARE ANALYSIS

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Null Hypothesis Ho: There is no significant relation between the team

work and rejections/defects.

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Alternative Hypothesis H1: There is significant relation between the

team work and rejections/defects.

Table

Table No:

St

34

38

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Observation Table

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Table No:

0.2

0.4

1.2

2.

2.1

(OE)2

(OE)
E

(OE)
E

= 4.2323

Degree of Freedom = (C-1) (R-1)

= (2-1) (2-1)

=1

Level of significance = 0.05

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Table value of Chi-square for degree of freedom 1 and level of

significance 0.05 is 3.841

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INTERPRETATION

Since the calculated value is greater than the table value, null hypothesis
Ho is rejected. Hence the alternative hypothesis H1 is accepted.

That means there does exist a significant relation between the team work
and rejections/defects.

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FINDINGS
SUGESSIONS
AND
CONCLUSION

FINDINGS

I.

HLL is an efficient, profit making and well organized industrial concern. It carries a good
reputation in the Indian as well as the foreign markets. In its quest for improvement, it is
working towards modernization and is also marching towards obtaining total quality

II.

environment.

Quality of the product is one of the major concerns of the company. Consequently it is
paying adequate attention to the aspect of industrial safety and hygiene. It has formulated
a well defined quality policy, has constituted a committee where daily meetings are held.

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All statutory provisions are being followed as also a number of non-statutory provisions
are also incorporated to improve professional environment.

III.

The company has comparatively higher percentage of educated and skilled workers, and
by implementing and updated industrial standards, there have been no major faults in

IV.

production so far.

The firm has over 40 years of experience in the manufacture of latex based products and
over the past decade polymer based products, with a highly proficient expert team of
technical and other personnel to envision and implement any task at hand.

V.

VI.

Though no major loss has taken place in the plant so far, the management at HLL is still
vigilant and has kept all options of improving the industrial quality and production.

Quality Assurance performance makes the product process more valuable also the
company is using manual and electronic quality checking method for achieving utmost

VII.

quality standard product.

HLL has developed a strong support from not only the State Government and the Central
Government but also valuable patronage of millions of customers within the domestic

VIII.

and global markets.

Ethicon, Mapper company (China), JK groups and polar lates are the major competitors

IX.

of the company.

Job satisfaction is relatively high among the workers in HLL the prominent reasons being

X.

job security, better wages, value creation but most importantly a solid working culture.

The company provides welfare facilities such as bus facility, medical check-up,

XI.

restrooms, etc. to their employees.

Even though HLL Life care is a Public sector company it functions more like a Private
sector company with special emphasis to the work environment and dedication of the top
management of the organization.

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XII.

Thoroughly modernized its existing manufacturing units indigenously utilize the

XIII.

expertise of its own technical personnel.

Setup indigenously world class production facilities for the manufacture of Condoms,

XIV.

Blood Transfusion Bags, Hydrocephalus shunt and copper-Ts.

The major departments of the company such as production, quality testing, store work for
24 hrs with three shifts throughout the year where the application of energy conservation

XV.

methods, advanced effluent treatment system is done effectively.

The company has been a consistent performer in delivering world class product without
any hindrance from trade unions for the past few years. Its productivity rate as well as
profitability sets it apart from other typical public sector companies like Keltron or even
Air India.

Employee Responses:
1) 82% of the employees say that they satisfied with the salary
2)
3)
4)
5)

68% of the employees say that their supervisor does his work competently.
54% of the employees say that they are satisfied with the benefits received from HLL.
42% of the employees say that they receive recognition for doing a good job.
52% of the employees say that the policies of the company do not affect their job

performance.
6) 86% of the employees say that they like their subordinates in HLL.
7) 66% of the employees say that their supervisor behaves fairly with them.
8) 90% of the employees say that they receive very good benefits from HLL.
9) 82% of the employees are satisfied with the rest room and sitting facilities.
10) 90% of the employees are satisfied with uniform, protector and safety equipments.
11) 62% of the employees are satisfied with canteen facilities
12) 80% of the employees are satisfied with education loan and allowances for education.
13) 90% of the employees are satisfied with the accommodation facilities and transport
facilities.

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RECOMMENDATIONS & SUGGESTIONS

The recommendations as well as suggestions has been discussed with the

sample respondents covered regarding their satisfaction level focusing on
five major aspects namely: Quality Management System, Place of work
and work itself, amenities provided, Rewards as well as Recognition and
Opportunities for growth in oneself.

Employees working in the administration are housed in a separate

building, where all the amenities are made available to the employees.
Similarly the company has also a technically drawn HR policy which as
consolidated manpower management issues, such as reward system,
suggestion scheme, promotion policy and facilities etc. Yet certain amount
of discontent has been noticed in the employees regarding certain aspects
of their work life, which in-turn influence on their job satisfaction.

1. 5S practices must be practiced in form of plays, lectures, presentations or even mimes

for keeping the employees more effective.
2. DMAIC approach can also be of great help to the organizational for its standard operating
procedures (SOPs) and procedures around the quality subsystem, and create a simple
checklist accordingly.
3. Mutual coordination between the employees and executives will improve the Total
quality management as well as the work culture in the plant.
4. Build quality testing into your processes -- not at the end when it is more expensive to
fix. Perform testing on an iterative basis. Resolve defective component problems as you
encounter them without waiting for the entire testing cycle to complete. Implement
automated testing if possible, because it executes without human intervention and results
in a pass or fail outcome that is easy to interpret and act upon.
5. Value employee, customer, supplier and business partner feedback and input regarding
solving product or service problems. Measure quality and productivity gains by increases
in customer satisfaction. Use customer feedback to improve current products and

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influence the design of new ones. Leveraging customer requirements in your process
redesign efforts can help you focus your efforts on the most lucrative areas of business in
your industry. For example, conduct surveys or focus groups to gather information to
resolve top issues with your product or service. Prepare a report summarizing findings,
and distribute the report throughout your organization to improve quality and
productivity.
6. Use business strategies such as Six Sigma to improve quality and productivity and Create
projects that define a problem, measure the current process, gather relevant data and
analyze the data to validate the cause-and-effect relations.
7. In the quality assurance department where water leakage is tested it is recommended to
renovate the machine that is being used because the results being given off are of varying
nature.
8. More importance should be given for introducing new concepts as well as about the
ongoing concepts in the plant about Total Quality Management with new trainees during
the recruitment as well as training sessions.
9. The quality management should think about implementing more of the control charts
especially in the area of operation.
10.
Employees should be provided with an adequate as well as detailed performance
so that the management as well as the particular employee can have a track of the job
profile and this totally will help in improving the Quality Management of the
organization.
11.
If the efforts of the employees are channelized systematically with a long term
vision then there can be great improvement in the Total Quality Management culture in
the plant.
12.
The firm should encourage problem solving approach through team work.
13.
Quality equipments are needed as in the Instrumentation section there are tools
that experience frequent breakdowns hence the employees time, effort and the firms
money, inventory space is wasted as a result.
14.
Channelized and systematic efforts with a long term vision will improve the
quality culture of the organization.
15.
In the ETD and QA section there can be usage of plastic crates instead of plastic
bags as it can help in reducing the damage in condoms like overlapping and also the
minimal use of excess light plastic whose disposal maybe a issue as it cannot be easily
recycled.

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Having sound communication strategy training among the managers as well as the

employees in how to communicate effectively can help in creating an even better

workplace as well as higher satisfaction regarding the internal coordination of the
organization and also for attaining an appreciable job satisfaction among the employees.
17.
The concept of Quality Management can be very much productive if it is applied
in the non-production functions of HLL in the plant.
18.
Efforts should be taken by the management of HLL to introduce periodic
competitions among the employees so as to keep up their working spirit high as well as
develop the Quality Culture.
19.
Timely awareness training should be given to the employees of the plant
regarding the benefit of a sound Quality Management System in an organization such that
how the companys mission and strategic goals can be achieved accordingly.
20.
In the color coding system the drinking water indicator should be different since
the plant is dealing with many chemicals that are toxic to human health thus for the safety
of the employees.
21.
Based on the Unit/ Department/ Section awareness on imparting quality
management systems should be provided to all the employees of the organization
respectively.
22.
For improving the process control in the plant, the implementation of the 7
Quality Control tools would be recommended in all the areas of the plant.
23.
There should be frequent conduction of benchmarking studies with respect to the
corresponding business practices especially with the best companies to improve the
performance of the plant as well as to boost the Total Quality Management culture.
24. The employees of the Quality team should be respected and looked upto for guidance by
other departmental employees for their roles as well as contribution in developing and
maintaining the Quality culture among the employees as a whole in the plant.
25. The documentation of the various work instructions as well as functioning of the
departments should be standard comprehensive as well as clear in the relevant areas of
the plant.

CONCLUSION

HLL has come from a long way since inception and through
diversification, has developed enviable manufacturing infrastructure, by

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virtue of which the company has come a leading manufacturer of health

care products and control devices. It has recorded consistently excellent
working results. High productivity and good work atmosphere have also
led to the reduction of rejections and wastage at different levels of
production. Therefore the company seems to have prosperity in the future.

The project study is about Effectiveness of Total Quality Management in

HLL Peroorkada Plant, Trivandrum. The study was conducted for 45
days. HLL Lifecare Limited is the only company in the world
manufacturing and marketing widest range of contraceptives. It is unique
in providing a range of condoms, including female condoms, Intra Uterine
Devices, Oral Contraceptive Pills-Steroidal, non-steroidal and emergency
contraceptive pills; and Tubal Rings. HLL today process 1.316 billion
condoms making it one of the worlds leading manufacturer of condoms,
accounting for nearly 10% of the global production capacity.

Quality system is one of the most important departments of every

organization because the process of quality management is in a cyclic
manner. The main benefits of a solid quality system are greater teamwork,
reduction in defects, reduction of waste of raw materials, maximum
productivity, employee awareness and efficiency also to reduce the cost
and provide quality products at reasonable price to the consumers.

At last this project helped to understand the relationship between various

factors that are associated to quality management in the organization. To
conclude, HLL is truly on its way to achieve greater heights along with
releasing its motto Innovating for Health generation by giving
importance to their quality management system.

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HLL

BIBLIOGRAPHY

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BIBLIOGRAPHY

1. Books Referred

a) Jay Heizer and Barry Render (2006), Principles of Operations Management,

Pretice Hall.
b) Dr.K.G.C Nair, Prof. P . Haridas, Prof. K. Vijayakumar, Dr. Johnson (2005), A
Systematic Approach to Costing, Trivandrum : Chand Publications.
c) Dr. M.M. Varma and R.K. Agarwal (1999), Financial Management, New Delhi :
King Books.
d) Department Records of HLL Lifecare Limited
e) Annual Reports of HLL

2. Journals

a) Hines, P., Holwe, M., & Rich, N. (2004). Learning to evolve: A review of
contemporary Quality thinking. International Journal of Operations & Production
Management, 24 (9/10), 994-1011.
b) Womack, James, Jones Daniel and Ross, Daniel; 1990; The machine that changed
the world; The story of quality production. New York: Rawson Associates.

Online Sources

http://www.lifecarehll.com
http://www.wikipedia.com
http://www.google.com

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APPENDIX

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QUESTIONAIRE
Effectiveness of Quality Management of HLL Peroorkada
Plant, Thiruvananthapuram

This questionnaire is essential for the primary data as part of my MBA

program; the information collected will be kept confidential and will be
used for the purpose of the project work only. I will be extremely grateful
if you take some time to fill this up.

1. Name
:
2. Gender
:
3. Age
:
4. Grade
:
5. Department :
6. Monthly Income

Male
Below 25

Female
25-40

40-55

Less than Rs. 15000

Rs. 30000 - Rs. 45000

Above 55

Rs. 15000 - Rs. 30000

Rs. 45000 and above

7) Does the Implementation of Quality standards aid in the creation of successful Business
Strategy in HLL?

Strongly Agree

Agree

Disagree

Strongly Disagree

neither Agree nor Disagree

8) Is Quality the standard to guide action, judgment as well as attitude for building the TQM
culture in HLL?

Strongly Agree

Agree

Disagree

Strongly Disagree

neither Agree nor Disagree

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9) Is the 7QC tool needed for process control and implementation in HLL?
Strongly Agree

Disagree

Agree

neither Agree nor Disagree

Strongly Disagree

10) Is encouragement needed for continuous improvement for all the products and services in
decision making process?

Strongly Agree

Agree

Disagree

Strongly Disagree

neither Agree nor Disagree

11) How much should the implementation of Quality improvement activities such as quality
circles, quality team work and the suggestion system be in HLL?

Great Extent

No Extent

Some Extent

Little Extent

12) Tick the appropriate certification obtained by HLL

ISO 9001
ISO 9002
ISO 18001
ISO 50001

ISO 9003
QS 9000
ISO 13485
ISO 170025

The year in which it got first certified.

13) What other quality practice(s) is HLL applying for?

Quality Circle
ISO 14000/EMS
SA8000

HACCP
GMP
5S
Other quality practice if any then please mention them too
14) If HLL develops its TQM further then which model do you think would be most appropriate?

MBNQA Model
ISO 9004
EFQM Model
No specified model
Other model if any then please specify.

15) Does the Quality system help to improve the organizational performance and provide a
common direction for the employees of HLL?

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Strongly Agree

Agree

Disagree

Strongly Disagree

OF

HLL

neither Agree nor Disagree

16) Should there be training for TQM for all employees for building a positive attitude so that
they start caring for the organization?

Strongly Believe

Believe

Ignore

Dismiss

Neither Believe nor

17) How much is the importance for the availability of standardized and clear documentation for
the work method and process instructions in HLL?

Strongly Agree

Agree

Disagree

Strongly Disagree

neither Agree nor Disagree

18) Do you believe in the transparent and effective Quality System for recognizing and detecting
defects in the products of HLL?

Strongly Agree

Agree

Disagree

Strongly Disagree

neither Agree nor Disagree

19) Will the Quality based initiatives help in keeping the productivity positive always?

Strongly Agree

Agree

Disagree

Strongly Disagree

neither Agree nor Disagree

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20) Should there be periodic conduction of benchmarking with other firms, their processes, work
culture and practices by HLL?

Strongly Agree

Agree

Disagree

Strongly Disagree

neither Agree nor Disagree

21) Six Sigma focuses on improving quality and reduce waste by helping organization so as to
service better, faster and cheaper. Do you think, it is the most effective technique of the
Quality management in HLL?

Yes
No
Dont Know

If No then which is the most effective technique being used

currently.

Thank You

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