Professional Documents
Culture Documents
on
KHYBER CEMENTS
-BY
SOLIHA KHAN
1
INTRODUCTION
2
Cement
In the most general sense of the word, a cement is a binder, a substance that sets and
hardens independently, and can bind other materials together. The word "cement" traces
to the Romans, who used the term opus caementicium to describe masonry resembling
modern concrete that was made from crushed rock with burnt lime as binder. The
volcanic ash and pulverized brick additives that were added to the burnt lime to obtain a
hydraulic binder were later referred to as cementum, cimentum, cäment and cement.
The most important use of cement is the production of mortar and concrete—the
bonding of natural or artificial aggregates to form a strong building material that is
durable in the face of normal environmental effects.
Concrete should not be confused with cement because the term cement refers only to
the anhydrous powder substance (ground clinker) used to bind the aggregate materials of
concrete. Upon the addition of water and/or additives the cement mixture is referred to as
concrete, especially if aggregates have been added.
Early uses
3
Modern cement
Modern hydraulic cements began to be developed from the start of the Industrial
Revolution (around 1800), driven by three main needs:
In Britain particularly, good quality building stone became ever more expensive
during a period of rapid growth, and it became a common practice to construct prestige
buildings from the new industrial bricks, and to finish them with a stucco to imitate stone.
Hydraulic limes were favored for this, but the need for a fast set time encouraged the
development of new cements. Most famous was Parker's "Roman cement".This was
developed by James Parker in the 1780s, and finally patented in 1796. It was, in fact,
nothing like any material used by the Romans, but was a "Natural cement" made by
burning septaria - nodules that are found in certain clay deposits, and that contain
both clay minerals and calcium carbonate. The burnt nodules were ground to a fine
powder. This product, made into a mortar with sand, set in 5–15 minutes. The success of
"Roman Cement" led other manufacturers to develop rival products by burning artificial
mixtures of clay and chalk.
4
Portland cement. Because of the air of mystery with which William Aspdin surrounded
his product, others (e.g. Vicat and I.C. Johnson) have claimed precedence in this
invention, but recent analysis of both his concrete and raw cement have shown that
William Aspdin's product made atNorthfleet, Kent was a true alite-based cement.
However, Aspdin's methods were "rule-of-thumb": Vicat is responsible for establishing
the chemical basis of these cements, and Johnson established the importance of sintering
the mix in the kiln.
India, being the second largest cement producer in the world after China with a total
capacity of 151.2 Million Tones (MT), has got a huge cement industry. With the
government of India giving boost to various infrastructure projects, housing facilities and
road networks, the cement industry in India is currently growing at an enviable pace.
More growth in the Indian cement industry is expected in the coming years. It is also
predicted that the cement production in India would rise to 236.16 MT in FY11. It's also
expected to rise to 262.61 MT in FY12.
The cement industry in India is dominated by around 20 companies, which account
for almost 70% of the total cement production in India. In the present year, the Indian
cement companies have produced 11 MT cement during April-September 2009. It took
the total cement production in FY09 to 231 MT
Industry Background
5
The history of the cement industry in India dates back to the 1889 when a Kolkata-
based company started manufacturing cement from Argillaceous. But the industry started
getting the organized shape in the early 1900s. In 1914, India Cement Company Ltd was
established in Porbandar with a capacity of 10,000 tons and production of 1000 installed.
The World War I gave the first initial thrust to the cement industry in India and the
industry started growing at a fast rate in terms of production, manufacturing units, and
installed capacity. This stage was referred to as the Nascent Stage of Indian Cement
Industry. In 1927, Concrete Association of India was set up to create public awareness on
the utility of cement as well as to propagate cement consumption.
The cement industry in India saw the price and distribution control system in the year
1956, established to ensure fair price model for consumers as well as manufacturers.
Later in 1977, government authorized new manufacturing units (as well as existing units
going for capacity enhancement) to put a higher price tag for their products. A couple of
years later, government introduced a three-tier pricing system with different pricing on
cement produced in high, medium and low cost plants
Cement industry, in any country, plays a major role in the growth of the nation.
Cement industry in India was under full control and supervision of the government.
However, it got relief at a large extent after the economic reform. But government
interference, especially in the pricing, is still evident in India. In spite of being the second
largest cement producer in the world, India falls in the list of lowest per capita
consumption of cement with 125 kg. The reason behind this is the poor rural people who
mostly live in mud huts and cannot afford to have the commodity. Despite the fact, the
demand and supply of cement in India has grown up. In a fast developing economy like
India, there is always large possibility of expansion of cement industry
Technology Up-gradation
Cement industry in kashmir is currently going through a technological change as a lot of
upgradation and assimilation is taking place. Currently, almost 93% of the total capacity
6
is based entirely on the modern dry process, which is considered as more environment-
friendly. Only the rest 7% uses old wet and semi-dry process technology. There is also a
huge scope of waste heat recovery in the cement plants, which lead to reduction in the
emission level and hence improves the environment..
After the open market policies undertaken by the government from the 1990s, there
was a significant increase in the infrastructure and housing projects in the country to cater
to the growing consumer market. As a result, more and more cement companies started to
set up bases in various parts of the country. The government also put emphasis on the
renovation of the heritage places and set up some public cement companies as well. As
7
these projects required plenty of manpower, there was a significant increase in the
number of job opportunities.
Today, the cement industry is one of the booming sectors in the country. According to
recent surveys, the industry is expected to grow at a rapid pace over the next few years to
cater to the growing infrastructure and real estate projects. As a result, there will be more
employment in all these sectors. In fact, working in the cement industry is also considered
as a lucrative career option for the freshers and
the youngsters. More and more young people who have a craving for architecture are
joining the cement industry to get good jobs
.
According to the recent surveys, one metric ton of cement generates job opportunities
for around 14 lakh people. Some of the states where the cement industry is booming are
Gujarat, Madhya Pradesh, and Rajasthan and Kashmir and so on . To cope up with the
competition market, other states are also gearing up with a number of cement projects
which will produce a favorable effect on the cement industry in the country. In the year
few years, more than 25 lakh people will be employed in the cement companies.
JK Cement
Kyber cement
Tci
Safco
Itifaaq cement
Name Jk Limited
Production 17,902
Installed Capacity 18,640
8
Net Profit (in 2008-2009) 80 lakhs
Name Tci ltd
Production 13,707
Installed Capacity 17,000
Net Profit (in 2008-09) 60 lakhs
Chapter- 1
9
COMPANY PROFILE
Chapter – I
Company Profile
The product Cement plays an important role in the economic development of the
country. Cement is been used from more than 150 year of construction. The cement
consumption determines the infrastructure strength and development of the nation.
Khyber Industries (P) Ltd. was incorporated by Khyber Group of company’s as
Private owned company to meet the growing demand of cement in the state and utilize
the main raw material from limestone reserves of Khonmoh area. Foundation stone for
existing 600 TPD Cement plant was laid in the year 1982 at Khonmoh area of district
Pulwama, 25 Kms away from Srinagar and commissioned in October, 1987 at a cost of
Rs.132 crore, the commercial production started in April, 1987 with the production of
10
OPC-Grade 33 under the bureau of Indian Standard Certification. The trademark “Khyber
Brand” is registered with trademark Registry Mumbai, Govt. of India. At present Khyber
is manufacturing OPC 43 Grade & 53 Grade under BIS certification.
The company has till date contributed more than Rs. 120 crore’s towards State
and Central exchequers as revenue in the form of State Sales Tax, Excise duty and
other taxes & duties. The performance of the company over last few years has
shown encouraging results, by steady increase in production & sale of cement,
resuming of plant improvisation and stabilization process, installation of pollution
control devices for bringing down the emission levels in stacks to present prescribed
norms besides modernization and up-gradation of machinery.
11
Vision:
Product Excellence, Hard Work, and Continuous Self Improvement to
encourage individual ability and creativity and build effective teams.
To contribute for the advancement and development of the nation and improve
human life and to become market leader by adding continuously new capacities
incorporation state of art technology to produce quality cement at least cost to the full
satisfaction of customers.
T.P.M Policy
T.P.M stands for Total Productivity Maintenance. It deals with productivity, people
and profit. T.P.M is a powerful tool for organization and cultural transformation that
brings in total efficiency of the plant by tackling key aspects of plant utilization quality
and down time with the ultimate goal being zero breakdown, Zero Accident, Zero Defect,
Optimum inventory and clean environment with the involvement of each and every
employee right from top management to the bottom level person in the company.
The letter ‘T’ stands for Including, Increasing, and Improving respectively;
Total effectiveness by maximizing the overall efficiency.
Total life cycle by reducing life cycle costs.
Total employee participation by involving everyone and transfer of knowledge
to everyone.
The letter ‘P’ stands for
12
Product to pursue maximization of the production system by bringing all
losses to Zero, Zero Accident, Zero Defects, Zero Breakdowns.
T.P.M aims at involving all the employees of the organization through eight pillars
of TPM.
Individual improvement
Autonomous maintenance.
Planned Maintenance
Education and Training.
Maintenance Preventive system.
Quality Maintenance.
Administration and Support.
Safety and Environment.
Product
13
43 Grade OPC
Brand Name
Khyber Brand Cement
Punch Line
Let us build together, let us build with Khyber.
Packing
Woven Polyethylene bags in packing plant
Weight
50 Kg /bag
Price / bag
Rs 230
Quality
Specification B.I.S.
General Application
43 grade OPC
Multistoried building
Underground structures
Foundation and pillars
Dams and canals
Power project
Large and massive water tanks
14
Khyber Cement Plant is located at 25 Kms, from Srinagar city of J&K state.
The company has 834 workforce of which 600 are regular employees including 10
outside state employees, 88 are regular daily wagers (R.dw) at present apart from 23
consolidated and 10 time rated labours(T.R.L.). The capacity of Unit-I is 600 tons per day
(TPD).
The company has recorded a highest turnover of 93.23 crores’ in last financial year.
Khyber Industries (P) Limited is recording profit continuously since 2003-04 and during
last year Rs. 2 crore has been achieved as profit
MANAGING DIRECTOR
ASSTT. MANAGER D.G.M (MINES) D.G.M (WORKS) D.G.M (M-S/PP) ASSTT. MGR
MGR MGR
(Stor (P&P)
e) SITE
GEOLOGIST DY. MANAGER
15
MGR
(Q&P
)
SR. ENGR
SR. FOREMAN
ASST. FOREMAN
OPERATORS/ OTHERS ST
16
Organizational Structure
D.G.M. Mines
Under the D.G.M ., Khyber Industries (P) Limited have Managers and Deputy
Managers in all respective departments which indicates the three top, supervisory ,
middle and lower management levels.
17
The company’s board of directors consists of well known economists and other
professionalized people having expertise knowledge in the field of commerce and
industry from the state as well as from the whole country, the company’s B.O.D includes
people like:
Haji Mohammad Maqbool,
Tramboo. Managing Director
Mr.Umar Khursheed,
Tramboo. Director
18
Chapter- 2
Functional Departments
Chapter- II
19
Functional Departments
2.1. Human Resource Department
MANAGING
DIRECTOR
GENERAL
MANAGER
DEPUTY
MANAGER
ASSISTANT
MANAGER
SUB
ORDINATE
STAFF
Preamble:
20
To be competitive in all facets of the business operation, it has become an
imperative that all employees of the company must strive towards enhancing their
operational performance and developing their potentials to add-value significantly.
Therefore, the Performance Management System (PMS) is being looked critically
by the Management.
21
This includes forecasting, planning, inventory, man power resources depending
upon the technology adopted, capacity of the production unit, layout of the plant, building
and machinery, time and motion studies, skill of the workman, job responsibility, role
analysis and work load, raw material supply, marketing and turnover.
Recruitment
Recruitment is a generating of application or applicants for specific jobs. Recruitment
consists of two main processes:
Identification of vacancy of staff and workman
A stock of a recruitment sources.
Candidates called for interview will be paid to and for fare as prescribed in TA
rule according to the status and position of the post for which candidate is called for on
22
specific commitment made in the interview letter. If candidate is required to stay,
accommodation is provided in the guest house/transit hostel/hotel expenses are paid as
permitted in the rules, interview letter. All recruitments and interviews are
organized/coordinated by the personal developers.
Selection:
Selection will be done at the interview after complete verification of application blank
with passport size photo affixed, original certificates, with regard qualification,
experience last salary drawn, references etc., attached assessment form to be filled up and
signed by the interview committee. If selected the salary offered, grade, trainee or
probationer or direct employment, designation etc., offered should be mentioned for final
approval of the Managing Director (unit head) .
In case of the workers, wage board employees, staff etc., trainees, management
trainees, graduate trainees etc, the HOD of the personnel department, the department head
and subject specialist will be in the selection committee. In case of Sr. Officers, Dy.
Manager, Manager, Sr. Manager. The committee by composition, as HOD of personnel
department, and Managing Director (unit head) and for any post above Assistant.
Placement:
Depending on clear vacancies in the concerned departments/section on the basis
of sanction strength the candidates selected on the basis of qualification, experience, age,
professional requirement, etc., are placed with proper designation in the respective
department initially on probation of one year. Fresher graduate/diploma holders and ITI
and other or taken as trainees on stipend per month.
Test conducted for trainees.
Oral test.
Medical examination.
Verification of certificates and reference.
Induction.
23
A circular is issued to all departments and notice is also displayed in case when
Sr. Officers and above or newly appointed induction booklet to study the plant and
organization is issued to new entrants.
The company organizes training programme on need basis regularly for fresher’s
and for existing employees. The type of training is as under:
On the job training for all categories of employees.
Learning new techniques through internal training or by external agencies.
Fresher’s training and training for promotion in the organization.
Remedial training and general training in safety, discipline, culture, rules
and regulations of the company, statutory matter and procedure.
Internship training
This sort of training is important to employees who are transferred from other
units, fresher’s or to the employee promoted in new jobs. This is advanced vocational
training system.
24
External training
Every year before March annual training calendar is prepared after consulting all
the concerned departmental heads on various need based training programme on different
aspects like technical, marketing and of HRD administration to develop skills and latest
technical knowhow and same is approved by the management.
Promotions.
Procedure.
Career path.
Performance Planning
It is done from the level of Asst. General Managers and above quarterly. Major
tasks and key result areas are identified and written at the beginning of the quarter for
each person. At the end of every quarter achievement marks are given against the targets
set earlier. Marks 5 to 1 are given for various levels of achievements. Wherever the
targets are discussed during the counseling session and fresh targets are set for the next
quarter. Review of each quarter is done with the individual and factors helping/hindering
in the achievement of the targets are discussed and recorded. Assessment is done by the
immediate superior and is reviewed by the next higher-up.
Employee Motivation
Employee Welfare
25
Dispensary
The company has provided health centre with X-ray diagnostics facility, ECG and
pathology lab to the benefit of the employees with qualified medical officers and Para
medical staff, visits of specialists are arranged regularly.
The company has provided libraries and reading rooms in the plant and also in the
head office for the benefit of employees. All kind of News papers and magazines are
made available.
Literacy Programs
The company is organizing literacy classes for the illiterate workers.
Bachelors Housing
The company provides Bachelors accommodation for the freshers who join
trainees and a staff Bachelors Mess is being run by the bachelor staff themselves.
Bus Facility
The company provides bus facility to its employees of Srinagar and other cities on
every day for its employees who are residing far from the site and its headquarters for the
benefit of the employees.
Security Department
Generally this department function under administration of personnel department
and the main function of this department are safety and security of men and material of
factory.
26
General Office Timing
--- 9.30 AM to 1.00 PM
--- 1.30 PM to 05.30 PM
Factory Timing
--- 9.00AM to 1.00PM
--- 1.30PM to 5.00PM
Shift Timings
The company runs in 3 shifts round the clock and general shift for all the
administrative works
The time office keeps record of all the employee details in 3 shifts and also General
shift. The attendance of all the employee are registered using an synel sensor punching
card reading machines which is installed to keep record of the day to day attendance of all
employees of the company in all shifts.
Employee Union
Union activities started in the factory in early 2007’s, when the employees felt the
need for organizing under a common platform so as to get speedy redressed of their
grievances regarding pay anomalies, recruitment policy, post retirement benefits, transfer,
promotion, accidental claims etc. The office bears comprises of six members
including chairman, president, secretary, general secretary, cashier, advisor. As per the
norms the elections for these posts are held after every two years through secret ballot.
The minimum eligibility for membership in the union requires regular service of one year
in the organization.
27
The cadres eligible for membership are:
For technical cadre – Below rank of engineer
For non-technical cadre – Below rank of Assistant manager.
So far the union and management has enjoyed a friendly and cooperative relation for
striving industrial peace
At present all the issues between the management and union are amicably
resolved through collective bargaining. During the negotiation the management takes a
reasonable and supportable position. Both the management and union strive to set the
solution to the critical problems faced by the factory pertaining to the efficiency of
production. There exists a mutual confidence, good faith and desire to make the collective
bargaining work. The union does not believe in resolving the issues through
undemocratic practices.
General
Manager
Sr.
Manager
Manager
Manager
Manager Establishm
Accounts
Bills ents
Assistant Accounts
Sr.
Manager Officer
Accounts
Personal
Secretary
28
The financial year of the company starts from 1st April and closes on 31st March.
Financial management vows to the application of general management principles to a
particular finance operation. It guides investment where opportunity is the greatest
producing relatively uniform hard-sticks for judging most of the firms operations and
projects. Certain uniform norms for financial consideration have to be setup to enable an
enterprise to judge its activities properly. Financial management is the dynamic involving
or making of day to day financial decision in a business of any size. Financial
management however, should not be so planned as to contribute to project making
activities for finance cannot be generated without profits.
Financial management unlike other functional areas of a business related to the
company as on operating entity.
Functions
The function and responsibility of the finance and account wings include the
following:
Determine the financial resources required to meet the corporation operating and
capital expenditure program.
Forecast how much of there of these requirement would be met by internal
generation of funds by the corporation and will have to be obtained outside the
corporation.
Develop the best plans to obtain the external funds needed.
Establish and maintain a system of financial control governing the allocation and
use of funds.
Analyze the financial results of all operation, report the facts to management and
make recommendation concerning future operations.
Carry out special studies with a view to reduce costs, improve efficiency and
profitability.
29
The above are dealt with detail here under:
Budgeting
Long term operating expenditure budget concerning a period of 10 years
indicates the likely profit/loss earned during period. Preparation of long term capital
expenditure budget covering a period of about 5/10 years and advise the arrangement in
regard to the timing of the incurrence of capital expenditure.
Capital expenditure budget is in regard to the capital expenditure that is expected
to be incurred during the year. The preparation of the arrival operating budget, the budget
returns that flow out of the comprehensive budgetary system in operating.
Working capital
It will also make an assessment of the working capital requirement for the
fiscal year and advice the management regarding the sources of financing the working
capital requirements.
30
Purchase
Finance wing will be associated on a matter relating to purchase of
equipments, machinery etc. it would also lay down suitable procedures for purchase to
ensure that adequate control is exercised over such purchase and that there are no un-
economic purchase.
Pricing policies
It will also advice the chief executive on pricing policies followed in the
organization in regard to the selling price of power inter departmental issues charging of
materials to jobs contract.
Service condition
It advices the management on all service matters having financial
implication such as scale of pay, clearness allowance, bonus, gratuity etc.
Accounting matters
General finance and accounts being is in charge of allows, budgets and
internal audit of the corporation. It shall maintain adequate records of assets, liabilities,
and transaction of corporation see that adequate internal audits there of the correct and
regularly made and recommended and enforce duly approved methods and procedures
where by the business of the corporation with the maximum safety efficiency and
economy. It shall examine all proposed disbursements from the corporation’s funds and
approve in advance payments required take made in accordance with the prescribed
administrative and accounting requirements and procedure.
Stores account
Finance and account wing responsible for the maintenance of adequate
system of store accounts. It would assist the management in determining the minimum,
maximum and ordering levels of various items and also be responsible for the
31
introduction and for operation of the ABC method of control with a view to reduce
the inventory holding to the optimum level.
It would also be responsible to ensure that the verification of stocks of various
items of store is carried out by ensuring:
That physical stock of selected items is verified every day.
That each item of stock is verified at least once in a year.
That the surprise elements in regard to stock verification are maintained.
Internal audit: it will organize effective internal audit departments and will
process the reports submitted by the internal audit and place the same before the
chief executive.
Annual accounts and audit: it will ensure that the annual accounts are prepared in
time according to provisions of law. It will attend to all matters relating to the
statutory audit and the audit by the controller and audit general.
Tax matters: it will be responsible for attending to all tax matters relating the
corporations.
Reporting
The finance and accounts wing of the head office is divided into the following sections:
Establishment
Bills and banking
Management information system and financial concurrence
32
Assets accounts
Book keeping and compilation
Budget and finance
Managing
director
General Manager
Dy. General
Manager
Marketing Process
The marketing process consists of analyzing marketing opportunities, developing
marketing strategies, planning marketing programs and managing the marketing efforts.
33
Analyzing market opportunities
The marketing department is continuously involved in analyzing the long-run
opportunities in this marketing fort improving the unit’s performance. These people
recognize the abundance of opportunities in the bargaining business field. The building of
the future is fast becoming a reality and high investment in this area is likely to continue
incoming decades. As it is dream of every individual in his life should own a house and it
needs cement, and also coming of many industries in the state and which require large
quantity of cement for construction purpose. This wide and constant market and
increasing demand for cement is great opportunity for Khyber Cement to launch new
products into market and to capture regular market with good quality of products.
Marketing department is responsible for monitoring of commercial market and its
components and the related technology trend never less than of competitors and the
related technology trend never less than of competitors activities for forged materials. It is
responsible for the following activities:
Market analysis and planning
Product analysis
Competition analysis
Determining customer satisfaction
Marketing department is also responsible for other internal department
such as operation, finance, purchasing etc.
Pricing and order administration
Regular customer interaction
Handling non technical customer complaint
Definition of commercial aspect of new supplier contract
Price updating
Authority and responsibility of marketing manager
Contract review and resolves the differences with customers
To release order board
34
Customer complaint handling
Follow-up and review payment collection
Khyber Industries (P) Ltd. has decided to target the home segment, Govt. and
private customers, bulk purchases. It involves a differentiating and position strategy for
the target market. This strategy includes the excellent service, pricing and distribution
policies as the state is heading towards normalcy.
Organizing the market resources and then implementing and controlling the
market plan. The company has built a marketing organization that is capable of
implementing a market plan, Marketing research, Setting Advertising, Customer
servicing and so on. As marketing department is fully automated and having talented
personnel who work around the clock to achieve organizational goals and objectives
35
Functions and objective of marketing department
Marketing department has to perform following function and objectives with brief
explanation.
Price fixation
Based on prevailing marketing conditions
As per with the other main competitors
Sales Promoters
Appointed at all major distributors with security deposit ranging from Rs.1
Lakh to Rs.10 Lakhs. Interest paid is 14% per annum. The main functions are:
Sales promotion and market survey.
Price fixation.
Appointment of authorized stockiest.
Timely disposal of stocks.
Timely delivery of material to dealers.
Timely collection of payments.
Collection of confessional forms.
36
Centralized Invoicing
Total invoicing is centralized at Srinagar.
Depot sends challans to site twice a week.
On receipt of challans, checking is dine immediately and fed into computer and
invoices are sent to Depots/parties.
When the loaded trucks report back the excise invoices are issued based on the
data from booking file and handed over to the truck driver immediately.
Loading
Co-ordination with packing plant personnel, for destination wise loading of
cement grade wise as per distributors/dealers requirement.
Frequent weight checking of loaded cement bags is being carried out at packing
plant to ensure accurate loading. In case of any variations it is being informed to
technical person for attending the same.
Dispatches
Monthly cement dispatches are planned at the site Road based on the required
cement grade wise by all the distributors/orders on hand.
All the distributors are informed well in advance about monthly cement
dispatches planning.
Road Dispatches
Truck booking are computerized and once the data is delay into the computer for
booking the Lorries, the same data is used for taking out excise invoice.
Truck booking goes on round the clock.
For truck booking transporters have to collect taken Nos. from security gate.
The trucks are allowed serially inside the factory for loading.
Road shortages are booked on monthly basis.
37
Sales Department
The sales department of this organization mainly concerned with sales, sales
promotion activities, distribution networking, marketing research activities and handling
consumer grievance. The total number of personnel employed included site, depot and
exercise staff is 42. The total area covered under sales is mainly different cities itself
in the state like Srinagar, Baramulla, Kupwara, Pulwama & Anantnag..
Sales classification
Direct sales
Government projects
Private projects.
38
increase its profits. The motivation to dealers is done in many ways they
include:
Meeting of all distributors in company office every year.
Three shields to maximum sellers etc.
Dairies to distributors and to permanent customer.
Calendar to customers.
Key chains to customer
Competition:
There is neck to neck competition between Khyber Industries (P) Limited and other
private brands, the other brands are
J & K Cements.
Saifco Cements.
Ambuja Cements.
Even Though the Khyber Cements are above the Jhelum Brand Cements(JKCements)
Saifco Cement Brands but it is registering top most sales since its incorporation.
Last year Khyber Cements registered round about 75% of the total sales in Srinagar
Ambuja Cement Brand is mostly used outside the Kashmir Division mostly in Ladakh
Region being the coldest region in the state. Therefore, 53 Grade Cement is used
there. The higher the grade the more is the strength of the cement. Most of the
Market situation:
Target market – House-holds, Government contractors, Semi-government
departments, and Private firms.
Competitive situation – The competitors are Khyber cements and Saifco cements.
Distribution situation – Distribution takes place through depots and retailers.
39
Product situation – There is only one product namely 43grade.
Advertising
Advertising is one of the most common tools which companies use to direct
persuasive communications to target buyers and public. We define advertising as follows:
Advertising is any paid form of non-presentation and promotion of ideas, goods or
services by an identified sponsor. Organization handles their advertising by someone in
the sales or marketing department who works with an advertising agency.
Modes of Advertising
Wall Paintings.
Hoardings.
Dealer Boards.
Neon Glow Sign Dealer Boards.
Bus Panels.
Bus Shelters.
Stickers (English, Urdu).
Posters.
Calendars and Diaries.
Telephone Index.
Gift Articles (Cash bags, Pen stand, Key chains, Wall clocks, Diaries, Flask, and Pens
etc.)
40
2.4. Production Department
MANAGING DIRECTOR
GENERAL MANAGER
(WORKS)
DGM (WORKS)
MANAGER RD&QA
DY. MANAGER
CHIEF CHEMIST
SENIOR CHEMISTS
41
CHEMISTS & TESTE
Nature of Production
Production is the process by which, raw material and other input are converted
into finished products. The other word synonymously used with production is
manufacturing. Some people try to draw distinction between the two terms:
Manufacturing is understood to refer to the process of producing only tangible goods,
where as production includes creation of both tangible goods as well as intangible
services.
Methods of production
The raw materials are carefully proportioned to provide the desired amount of
lime, silica, aluminum oxide iron oxide. They are then mixed and grounded either in a
wet or in a dry condition accordingly. The process is known as “wet” or “dry” process,
modern plants use the “Dry” process. The ground materials are bed into a long rotary
kiln, which is maintained at a temperature around 1400 C. The raw material when burnt
at that temperature react chemically, to form pellets which are known by the name
clinkers, After the discharge from the kiln, the clinker is cooled and then grounded to a
fine powder, during the grinding process few percentage of dry gypsum is added to
control the rate of setting. Cement is supplied in Bags or in bulk.
42
Material Requirements
The following materials required.
Lime stones.
Sand stone.
Hematite/Late rite (Iron ore).
Pet coke
Gypsum.
Clay
Routing Scheduling
As pre plant is running round the clock shift system requires. In this plant the
schedule areas under:
43
Pay loader
Tipper
Dozer
Safety Standard/Norm
The company is following the I.S.I, also factory act code and other relevant code
pertaining to safety.
The process of manufacturing cement involves basically the following sequential unit
operation and processes.
Limestone mining.
Limestone crushing.
Stacking and reclaiming.
Raw material grinding.
Storage and homogenization of raw metal in continuous blending silo.
Coal grinding.
Clinkerisation - (kiln feed, preheating, kiln and cooler).
Cement grinding, storing.
Cement packing and dispatches
44
the material is maximum 1.6 Cu. meters and product size maximum 80mm the
material, which is entering the crushing chamber, encounters the impact by blow
bars mounted on the rotor and revolving at a circumferential velocity of 44 m/sec.
The fragments are flung against upper and lower bars. This process is repeated until
they have been sufficiently crushed to pass through the blow bars. Grinding path
(blow bars) can be adjusted if the output material size is more than 80mm the crushed
material will be transported to Stacker by means of Belt Conveyors.
Stacking and reclaiming: For stacking crushed limestone Belt Type Boom
Stacker is in operation, which is having capacity of 800TPH. The boom stacker has
been conceived for material stacking on Chevron Method. In this method the
stacker travels to and fro on a runway between two detained limits, while building
up stock pile. The materials are always discharged constants above the middle of
the stockpile. With this method piling can be done uniformly with required grades.
Four stock piles of 130mtrs long and approximately 25000 MT capacities each can
be made, by turning the boom to the opposite direction.
Reclaiming:
For this Bridge Scraper is in operation. A triangular structure called harrows move to and
for across the stock pile width and scraps the material. Scrapped materials slides done
from face of the stockpile to get blended limestone. The blended limestone which slides
down is scrapped and conveyed by buckets to belt conveyor, which in turn will be
transported to Raw Mill Hoppers. By means of stacking and reclaiming the
homogenization of limestone will take place
45
The separator separates the ground material into the finished product (product
fineness about 30% on 90 micron sieve) and coarse material. The coarse material
drops back to the middle of grinding bowl; while fines are carried by the air steam
to the E.S.P will be transported through Bucket Elevator or by Airlift to Blending
Silo. The hot gases coming out of the Kiln are being utilized for drying the material
and entrainment of raw meal at required temperature. To control the outlet
temperature of the mill and to maintain constant material bed on the grinding table
water spraying system is provided inside the mill.
Coal Grinding: The Raw Coal, received by road is stored in Coal yard is
crushed to 30mm size by Reversible Impact Hammer and four roll crushers.
Crushed raw coal is fed to the vertical coal mill for grinding before firing in the kiln
and precalciner.
The coal grinding takes place inside the mill under grinding rollers and
grinding table. The ground material (fine coal) is carried by the hot gases drawn by
C.A. fan. The hot gases are used to remove the moisture form coal. The ground coal
is carried by hot gas steam through static separator in which coarse material will be
returned to the mill and fines will be conveyors.
46
Fine coal is fired at kiln outlet end through a Burner pipe. Pneumatic screw
pumps in Unit-I and Poldos-SC in Unit-II are used for main firing and precalciner
firing. The hot gases generated due to fine coal firing are taken out by Dopol
Fan/ESP Fan through Pre-heater, Raw Mill and ESP.
Heat transfer takes place in Pre-heater as Kiln Feed moves downward and
flue gases move upwards causing co-current flows in gas ducts. Kiln feed after
preheating (around 90% calcined material) enters at kiln inlet. Then such
decarbonised material will to the Burning Zone due to the inclination and rotation of
the rotary kiln in the direction of hot zone (burning zone). The temperature of the
Burning Zone is maintained at about 1400 deg. C for proper Clinkerisation. After
this stage the material is known as Clinker. This clinker gets cooled in the cooling
zone and falls into Jet Stream Plate Cooler for Unit-II where it cools down from
1250deg. to 100deg. temperature by cold incoming air from the cooling fans
connected to the grate cooler. Finally clinker will be conveyed to the stock yard by
DPC (Deep Pan Conveyor).
47
Packing and Dispatch: Cement is extracted from the silo filled in Packer
Hoppers, from where the material will flow to the Packer Machine through bucket
elevator and air slides. Six numbers of electronic packers of 120 TPH capacities in
Unit-I and II are installed for the packing purpose. They have high degree of
accuracy. Finally the 50 kg. Cement bags is transported by belt conveyor and
stacked inside the Wagon/truck with help of Wagon Loading and Truck Loading
Machines.
Limestone
Limestone Stock
Piles (Stacker Coal Mill Gypsum
reclaimers)
Packing
Plans
Dispatch
48
Chapter-3
SWOT Analysis
49
Chapter- 3
SWOT Analysis
Strengths:
• Abundance availability of limestone, which is the important raw material for
cement.
• Low cost of Production.
• Financially sound.
Weaknesses:
• High Labour turnover ratio.
• Lack of Co-operation between the departments.
• Lack of Skilled Labours.
• Failure in penetraring to the new markets.
• Less advertisement.
Opportunities:
• Cement is a core commodity essential for infrastructure development
especially in the state as it is heading towards normalcy.
50
• The expansion of the plant will be beneficial in the long run for the development
of state and can become the top leader in the cement production.
Threats:
• The industry may face stiff competition in the near future due to installation /
coming up of new cement plants in the state.
• Rapid changes in market expectation.
• Rapid duplication of the pricing strategies by the competitors.
Chapter- 4
Learning
Experience,Findings,
Suggestions and Conclusion
51
Chapter- 4
Learning Experience Findings,
Suggestions, and Conclusion
Learning Experience
52
• Company books and records were relied upon
Findings
The problem faced by the company in the present situation is that, under today’s
circumstances/ competitive age and the price index of raw materials the technology used
is almost obsolete before 4-5 years.
Spare parts of the plant are not available in the local market, almost company have to
buy small pity things from Delhi and other parts of the country and it takes lot of time and
cost.
Production is given more preference. There is no question that production is
order of day but the Industry should not neglect its employees.
They do not have well organized marketing channels to distribute their product
outside the state.
In this competitive world, it is very difficult to run a business no matter what the
business might be, competition is in every field. People residing over there are not fully
aware of Khyber brand as it is been used In full fledged Work for Govt settlements.
Khyber Industries (P) Ltd. have a very poor leads upon advertising setups so the brand
awareness has not been settled properly till now. The unawareness of Khyber brand
A survey on 25 employees of the company was done to find the production efficiency.
53
GE
100
PERCENTA
90
80
70
60
50
40
30
20
10
0
1 2 3 4 5 6 7 8 9
QUESTIO
NS
Positive Response
Negative Response
54
Suggestions
• The imported equipments eliminate drilling and blasting and provided scope for
selective mining.
• They should introduce Just in Time (JIT), Economic Order Quantity (E.O.Q)
approaches.
• The safety masks and uniform should be of good quality and they should be
provided more in number.
55
• There are inadequate washing facilities. At only 3 places the washing facilitiesare
provided, which is felt inadequate by the large number of workers
Conclusions
The company produces quality cement OPC (Ordinary Portland Cement) in the
grade of 43 & 53 under the” Khyber brand “ to meet the growing needs of customers
although the company’s cement is best in the quality and meet the requirements of
Bureau of Indian Standards ( B.I.S)
Based on the analysis and discussion made in the study, the overall performance
of the company in the recent years is satisfactory. Compared to its past records it has a
good control over the market and has been able to utilize the opportunities and its
strengths to topmost level. It has achieved a new mile stone by conserving the energy at
all levels. The company is achieving increase in cement production every year. With the
establishment of the second unit the company is going to achieve more production and a
fittest competitor in the market. Environmental improvement has been a continuing
mission with Khyber Industries (P) Ltd.,with respect to the operational and the
technological aspects, apart from material conservation and ecological balance.
56
Bibliography and Appendix
57
Bibliography
Websites ;
1) www.goggle.com
2) www.greaterkashmir.com
3) www.Khybercements.com
4) www.kashmiruzma.com
Books:
Appendix
58
MONTHWISE PRODUCTION PLAN ON 100% SALES
YEAR 2007 - 2008
14
12
10
8
6
4
2
0
APRIL MAY JUN JULY AUG SEP OCT NOV DEC
59
60