Professional Documents
Culture Documents
INTRODUCTION
1
SIGNIFICANCE OF STUDY:
The study is based upon the part of financial performance that has been taken in to
consideration i.e., budgetary concepts.
2
METHODOLOGY:
The information for the study has been obtained from two sources namely.
1. Primary Data
2. Secondary Data
Primary data: The data for study has been collected from the management of the
company. The information about the industry profile and company profile was
gathered from HRD, VSP and the data about the budget and budgetary control was
gathered from Financial Department, VSP.
Secondary data: This is taken from the annual reports, websites, company journals,
magazines and other sources of information of steel plant.
LIMITATIONS:
1. The period of study that is 6 weeks was not enough to go into the detailed
aspects of the study.
2. The study is carried basing on the information and documents provided by the
organization and based on the interaction with the various employees of the
respective departments.
3. Most of the matters related to budgets were confidential. So it is not possible
to gather much information.
4. Budgeting process is very dynamic.
5. Budget that were prepared are only based upon trend at the time preparation.
6. Flexibility with in the budget is not possible.
3
CHAPTER - 2
PROFILE
OF
STEEL INDUSTRY
4
INDUSTRY PROFILE:
Though the production of steel in significant quantity started only after 1900,
the growth of steel industry can be conveniently studied by dividing the time in to pre
and post independence period.
5
Pre-independence:
1918 Initially Indian iron and steel co (IISCO) was founded and the
Bengal iron and steel co merged with it in 1926. To start with,
IISCO restricted it self for manufacturing of pig iron for export
to UK and JAP AN. It produced steel.
1940-50 Formation of the Mysore iron and steel Ltd. Presently known as
Visveswarayya Iron and Steel Ltd. (VISL) at Bhadravathi in
Karnataka owing to the pioneering efforts of Sri.
Visveswarayya. It started manufacturing Ferro alloys and Sp.
Steels.
6
Post-independence:
First five-year plan (1951 to 1956):
No new steel plant came up, as the first plan was mainly agriculture oriented.
However, IISCO was allowed to expand form IMT/year to 2 MT/year of ingots, and
from 0.5 MT/year to 1.0 MT/year of steel. And, the first five-year plan contemplated a
new steel plant to be erected in public sector.
Thus the Hindustan Steel Limited (HSL) was born on 19th Jan 1954 with the
decision of setting up three steel plants each with one million tons ingot steel per year
at Rourkela, Bhilai and Durgapur. Though TISCO and IISCO were scheduled to
expand, TISCO started its expansion program.
7
In addition to the above BSP and DSP each were having the capacity to
produce 300,000 tons of pig iron for sale.
8
Work on Salem project progressed well. Bokaro with 1.7 MT capacities
started in Feb 1978. The expansions of Bhilai steel plant form 2.5 MT to 4 MT and
Bokaro from 1.7 MT to 4.0 MT picked up momentum. The idea of setting up the 5th
integrated steel plant at Visakhapatnam took a definite shape. By the end of fifth five-
year plan the total installed capacity from six integrated plants was 10.6 MT/year.
Annual plans 1979 to 1980: various plans named above were reviewed and the
progress on different plants consolidated. Soviet - Union has agreed to help in setting
up the Visakhapatnam steel plant.
9
Tenth five-year plan (2002 to 2007):
Steel industry registers a growth of 9.9%. VSP has high regime targets.
10
Sola Name of 2007- 2008- 2009- 2010- 2011- total
no the scheme 08 09 10 11 12
1 AMR 100 100 100 100 100 500
schemes
2 Coke oven 125.56 - - - - 125.56
battery#4
3 Expansion 2700.3 2966.8 1483.6 463.3 154.4 7768.62
to 6.3 Mt 0 9 7 2 4
4 Pulvarised 87 - - - - 87
coal
injection
5 Air 36 - - - - 36
separation
plant
6 Acquisitio - 600 - - - 600
n of mines-
coal &ore
7 R&D 10 10 10 10 10 50
8 BF1 27 - - - - 27
capital
repairs
9 Spl.capex 200 175 - - - 375
value
added
products
Total 3285.8 3851.8 1593.6 573.3 264.4 9569.18
6 9 7 2 4
Global Scenario:
As per IISI
11
In March 2005 World Crude Steel output was 92.8MT when compared to
March 2004 (87.2 MT), the change in percentage was 6.5%.
China remained the world's largest Crude Steel producer in 2005 also
(27.5MT) followed by Japan (9.6MT) and USA (8.1MT). India occupied the
8th position (8.8MT)
USA remained the largest importer of semi-finished and finished steel
products in 2002 followed by China and Germany.
Japan remained the largest exporter of semi-finished and finished steel
products in 2002 followed by Russia and Ukraine.
Other significant recent developments in the global steel scenario have been
under the auspices of the OECD (Organization for Economic Co-operation &
Development) the negotiations among the major steel producing countries for
a Steel Subsidy Agreement (SSA) held in 2003 with the objective to agree on a
complete negotiating text for the SSA by the middle of 2004. It also set
subsidies for the Steel Industry of a ceiling of 0.5% of the value of production
to be used exclusively for Research & Development.
The global economy witnessed a gradual recovery from late 2003 onwards.
China has become one of the major factors currently driving the world
economy.
As a result of these economic developments IISI has projected an increase by
6.2% or 53 million metric tonnes in 2004 in the global consumption of
finished steel products. IISI has split the growth into two separate areas, China
and the Rest of the World (ROW). Steel consumption in China has been
estimated to increase by 13.1% or 31 mt in 2004.
USA has repealed the safeguard measures on import of steel as a result of a
ruling, by a WTO Dispute Resolution Panel, which held these measures to be
illegal under the WTO regime.
12
Present Scenario of Indian Steel Industry:
India is uniquely placed to become a very large producer and consumer of
finished steel products in the world. Substantial reserves of high grade iron ore, low
wage rates; technical and managerial skills of a high order have all enabled India to
gain this stature, by becoming 10th largest producer of steel in the world.
Unfortunately for the Indian steel industry, the price and distribution controls to which
it was subjected till about economic liberalization process began in the early 1990's
did not permit the large integrated steel plants to modernize their steel manufacturing
facilities or to upgrade their technologies to the state of art levels from time to time.
With the economic liberalization that was initiated in 1992, Indian steel
Industry has to accept the inevitable i.e. to appreciate the implications of low import
duty rated, face foreign competition and some how improve its strengths and
competitive edge to produce good quality products at lower prices and learn to survive
in the market place. Following liberalization, the steel Industry is well set on the path
of globalization. The dynamics of the world steel industry has a close relation with
Indian steel Industry. Presently in India, Steel products are being produced from four
different sources viz.
Integrated Steel Plants have larger capacity and produce Steel from basic raw
materials and the other three categories mentioned are characterized by low
investment and low break-even point. Characteristics of Integrated Steel Plants.
13
They have long gestation period.
Labour intensive.
They would have all facilities including raw materials resources, water supply,
power supply, testing and inspection facilities, township facilities, medical,
educational and recreational etc.
Inter dependency of all the processing units on the proceeding and succeeding
units in the path of materials flow.
A potential source for earning foreign exchange through exports.
They serve as centers for the development of ancillary industries.
They are major consumer of refractory materials.
Production:
Steel industry was de-licensed and decontrolled in 1991 and 1992 respectively.
India is the 8th largest producer of steel in the world.
In 2003-04, finished steel production was 36.193 million tonnes.
Pig iron production in 2003-04 was 5.221 million tonnes.
Sponge iron production was 80.85 million tonnes during 2003-04.
The annual growth rate of crude steel production in 2002-03 was 8% and in
2003-04 was 6%. Last 4 years production performance is as under:
14
PRODUCTION PERFORMANCE (In Million tons)
YEAR PIGIRON SPONGEIRO FINISHEDSTEEL
N
2000-01 3.39 5.44 29.27
2001-02 4.08 5.44 30.63
2002-03 5.28 6.44 33.67
2003-04 3.76 8.09 39.12
2004-05 3.18 9.93 41.15
2005-06 4.39 0.00 30.84
2006-07 3.52 0.00 31.40
2007-08 4.95 0.00 29.74
2008-09 4.95 0.00 29.74
45
40 2000-01
35 2001-02
30 2002-03
25 2003-04
20
2004-05
15
10 2005-06
5 2006-07
0 2007-08
PIGIRON SPONGEIRON FINISHED
2008-09
STEEL
15
CHAPTER -3
PROFILE
OF
VISAKHAPATNAM STEEL
PLANT
16
PROFILE OF VISAKHAPATNAM STEEL PLANT
Introduction
Origin- History of VSP
Milestones of VSP
Vision
Mission
Objectives
Core Values
Achievements & Awards
Raw Materials & Sources
Major Units of VSP
Production Performance
Product Mix
Process
Board of Directors
Organization Chart
Department Chart: Finance(Budget)
Description of Various Departments
Recent Trends
Financial Performance.
17
INTRODUCTION
18
Origin and History of the organization
19
universal beam mill were dropped. The other steel melt shop of 2.2 MTPA of
liquid steel was up rated to 3 MTPA without any additional facilities. Further the
capacities of Rolling Mills i.e. Light and Medium Merchant Mill (LMMM),
Medium merchant and structural mill (MMSM) and Wire Rod Mill (WRM) were
also up rated without any modification to make the project economically viable.
The project cost with all these modifications was brought down to about
Rs.6281 cars. However during implementation further cost escalations took place
and finally the project was implemented at a capital cost of around Rs.8500 cars.
Various operating units were commissioned one after another from 1989 onwards
and entire project was completed by July 1992. The then Honorable Prime
Minister Sri. P.V. Narasimha Rio dedicated the plant to the Nation on 1 st August
1992. Unlike other integrated steel plants in the country, new technology, large-
scale computerization and automation etc. were incorporated in the plant. To
operate the plant at international levels and attain such labor productivity, the total
manning of the organization was frozen to 17,500 employees. The plant has a
capacity of producing 3.0 MT of liquid Steel and 2.656 MT saleable steel.
20
7. 15.10.1977 Detailed project report submitted
by consultant.
9. 12.06.1979 Inter government agreement
signed between India and
Erstwhile U.S.S.R at MOSCOW
for the cooperation in the
construction of VSP.
10. 19.10.1979 Government approved setting up
of
VSP. Soviet side carries out the
revision of detailed project
report.
11. Jan. 1980 Site leveling work started.
12. 30.11.1980 M.N. Disturb & Co., principal
consultant submits the
comprehensive revised detailed
project report.
13. 01.01.1981 Export committee submits
recommendation for approval of
comprehensive revised detailed
project report with certain
modification.
14. 05.02.1981 Contract singed with Erstwhile
soviet union for preparation of
working drawings for coke
ovens. Blast furnace and sinter
plant.
15. 23.02.1981 Comprehensive revised detailed
project report along with expert
committee recommendations
approved.
16. 10.07.1981 Protocol signed with Erstwhile
soviet union for supply of
equipments and specialists.
17. 23.01.1982 Blast furnace foundation (1st
mass concreting in the project)
To
lay.
26.02.1982
18. 01.02.1982 Zero date of the construction of
the project.
19. 18.02.1982 Rashtriya Spat Enigma Ltd.
(RINL) formed.
20 29.01.1987 Commissioning of structural
shop. With this commissioning
of various auxiliary units
commenced.
21. 06.09.1989 Coke oven Battery no.1 starts
pushing of cake. With this the
21
commissioning metallurgical
unit starts.
22. 14.11.1989 Sinter plant (Machine-1)
commissioned.
23. 28.03.1990 “Godavari” the 1st blast furnace
commissioned.
24. 03.05.1990 PM dedicates “Godavari” to the
nation.
25. 06.09.1990 The 1st converter and the 1st
continuous casting machine of
the steel Melt shop starts
production.
26. 28.08.1990 Billet production in the light and
medium Merchant mil started.
27. 21.11.1990 Wire Rod Mill commissioned.
28. 04.03.1991 The 2nd converter commissioned.
29. 30.06.1991 Yeller Water supply scheme
made ready for supply of water
to VSP.
30. 28.10.1991 Trial production commences in
the bar mill of light and Medium
Merchant Mill.
31. 31.10.1991 Coke oven Battery No.2
commissioned.
32. 27.12.1991 Sinter Machine-2 commissioned.
33. 20.03.1992 Medium Merchant and structural
Mill commissioned.
34. 21.03.1992 “Krishna” Blast furnace-2
commissioned.
35. July 1992 Coke Oven Battery No.3
commissioned.
36. July 1992 Converter no.3of steel milt shop
commissioned. This marks the
completion of commissioning
units of the no.3 million tones
plant.
37. Aug. 1992 Dedication of the plant to the
Nation by the Prime Minister.
22
40 28.10.2005 Got of India approval ref.6 (1)
2005-vsp approval date
41 28.10.2005 Commencement date
1. Got of India approval ref: 6 (1) 2005-VSP dated 28th October 2005.
2. Commencement Date 28th October 2005
3. Main Units in Expansion
Raw Material Handling Plant
One Sinter Plant
One Blast Furnace 3.25 Mt / year Sinter
One Blast Furnace (BF-3800 C.2.50 Mt/ year Hot Metal
Claiming and Refractory Materials 12x500 t / day
One Steel Melt Shop 2.60 Mt / year Liquid Steel
Rolling Mills
Wire Rod Mill 600,000 t/ year
Light Structural Mill ( LSM) (in stage –II) 700,000 t/ year
Augmentation of existing TPP 1X67.5 MVV turbo – generator with TB
Power Plant (BOO Basis) 2x67.5 MVV capacity with all necessary facilities
Air Separation Plant (BOO basis) 2x1200 t / day Oxygen
Captive Mines Augmentation of capacities at Ashram. Jaggayyapeta
And Garb ham Mines.
Vision:
Deliver high quality and cost competitive products and be the first choice of
customers.
23
Be a respected corporate citizen, ensure clean and green environment and develop
Mission:
Objectives:
Expand plant capacity to 6.3 million ton by 2011-12 with the Mission
to expand further in subsequent phases as per the corporate plan.
Revamping existing Blast Furnaces to make them energy efficient to
contemporary levels and in the process increase their capacity by 1 Mt,
thus total hot metal capacity to 7.5 Mt.
Be amongst top five lowest cost steel producers in world by 2009-10.
Core Values:
24
AWARDS WON BY VSP
Bagged the First Steel Minister’s For being the best integrated 2009
Trophy for the year 2006-07 steel plant in the country
(Runner Up)
25
The ‘India Gandhi Rajabhasha’ For the best performance in 2009
Award Hindi implementation during
the year 2007-08 in
September.
ISPAT RAJYA BHASHA For popularizing the usage of 2009
TROPHY. Hindi.
RINL ranked No.2 globally for the Global survey by Steel guru 2009
popularity of website among the for the most popular website
global steel makers. among steel makers all over
the world
The ‘Best Place to work for- 2009’ Award given by “The 2009
Economic Times-Great Place
to Work Institute” was won by
VSP in June .
ISPAT RAJYA BHASHA For popularizing the usage of 2009
TROPHY Hindi.
VSP bags ‘top assessed’ award For 2007-08 for paying 2009
highest central excise.
Ukkuvani, the bi-monthly In-house For Employee welfare in 2009
journal was adjudged the ‘Best ‘National Awards for House
House Journal Devoted to Welfare Journals’.
of Employees’
26
“Enterprise Excellence Award Excellence in overall 2008
2007” conferred by Indian Institute performance
of Industrial Engineering (IIIE) in
May 2008.
Sri PK Bishop, CMD was awarded For his significant 2008
a Gold medal by the Hon’ble Prime achievement for ‘Sustainable
Minister, Dr.Manmmohan Singh at Development’, ‘Improving the
the 95th Indian Science Congress at quality of life in society’ and
Andhra University, Visakhapatnam ‘Supporting the cause of
Science& Technology’.
27
1st - 2006
2nd - 2005
1st - 2004
Energy efficiency (First prize
for 3 consecutive years and 1st - 2003
National Energy Conservation Award also a special award for
achieving this). This is the 7th 1st - 2002
award in a row.
2nd - 2001
Merit
Certificate-
2000
Organizational Excellence Award Efficient suggestion scheme2006, 2004
operation given by INSSAN
Environmental Conservation 2005
& Pollution Control presented
Business Achievement Award for
by Confederation of Asia
Excellence
Pacific Chamber of
Commerce & Industry
CII -GBC National Award Excellence in Energy2005
management
Energy Conservation Award by AP Best organization in Energy2005
Productivity Council conservation initiatives
Certificate of Appreciation by Excellence in energy2005
Institution of Engineers, AP conservation
chapter
National Award for Excellence in Excellence in water2005, 2004
Water Management by CII management
Leadership & Excellence Award in Excellence in SHE by CII2004
SHE (Safety, Health & South Zone
Environment)
CACCI Business Achievement For environmental2004
Award conservation & pollution
control by FICCI
World Quality Commitment Performance excellence,2004
International Star Award quality management & quality
achievement, given by
Business Initiative Directions,
Paris in the Gold category.
ICWA National Award Good performance for2004
excellence in Cost
management
Best Enterprise Award For surpassing MOU Targets,2003-04
awarded by SCOPE
28
Rolling shield for "Environmental To recognize efforts in 2002, 2003
Protection" environmental protection, by
Directorate of field publicity,
Ministry of Information &
Broadcasting
Prime Minister's Trophy Best integrated steel plant 2002-03
India Priyadarshini Vrikshmitra For massive afforestation 2002-03
Award efforts. Given by Ministry of
Environment & Forests
Best HR Practices Given by Indian Society for 2002
Training & Development
(ISTD)
Environment Excellence Award for Energy conservation by 2002
Greentech Foundation, Delhi
Best Enterprise Award, WIPS Given by SCOPE 2001-02
Award for Best Turnaround Given by SCOPE 2000-01
Best Management Award for outstanding contribution in 2000-01
management of industrial
relations, labour welfare and
productivity given by Govt. of
AP
Shield for "Best efforts in Rain AP Pollution Control Board 2001
water Harvesting"
SAIL Chairman's Silver plaque for no fatal accidents (for 2000
regular employees category)
Paryavaran Parirakshak Award in recognition of it's success in 2000
prevention of industrial
pollution and preservation of
ecological balance by
reducing pollution to the
minimum by installing
sophisticated equipment and
machinery in the factory.
Given by Rotary District 3020
International
29
Major Sources of Raw Materials:
VSP is one of the most modern steel plants in India incorporating State-of-the-
Art technology. Following are some of the modern technologies adopted:
30
7 meter tall Coke Oven Batteries with coke dry quenching.
Biggest Blast Furnaces in the country
Bell-less top charging system in Blast Furnace
100% slag granulation at the BF Cast House
Suppressed combustion- Ld gas recovery system
100% continuous casting of liquid steel
“Temporal” and “steamer” cooling process in LMMM &WRM respectively
Extensive waste heat recovery systems and pollution control methods
31
Production Performance (‘000 Tonnes):
Labour
Year Hot Liquid Saleable Productivity
Metal Steel Steel (Tonnes/man year)
1999-2000 2,943 2,656 2,382 192
2000-2001 3,165 2,909 2,507 211
2001-2002 3,485 3,083 2,757 228
2002-2003 3,941 3,356 3,056 253
2003-2004 4,055 3,508 3,169 262
2004-2005 3,920 3,560 3,173 398
2005-2006 4,153 3,603 3,237 414
2006-2007 4,046 3,606 3,290 413
2007-2008 3,913 3,322 3,074 389
2008-2009 3,546 3,145 2,701 359
4500
4000
3500
3000
Hot M etal
2500
Liquid Steel
2000
Saleable Steel
1500
Labour Produc
1000
(Tonnes/man y
500
1999- 2000- 2001- 2002- 2003- 2004- 2005- 2006- 2007- 2008-
2000 2001 2002 2003 2004 2005 2006 2007 2008 2009
32
Commercial Performance (Rs. Crs.):
12,000
10,000
8,000
Sales Turnover
6,000
Domestic Sales
Exports
4,000
2,000
0
2002-2003 2003-2004 2004-2005 2005-2006 2006-2007 2007-2008 2008-2009
33
Main Products of vsp;
STEEL BY PRODUCTS
PRODUCTS
Angles Nut Coke Granulated Slag
Billets Coke Dust Lime Fines
Channels Coal Tar Ammonium Sulphate
Beams Anthracene oil
Squares HP Naphthalene
Flats Benzene
Rounds Toluene
Re-bars Byline
Wire Rods Wash Oil
Process:
Following are the details of processes of main production units of VSP.
1. Coke ovens & Coal chemicals plant:
Coking coal after selective crushing and proper blending is subjected to
destructive distillation (heating in the absence of air) in the Coke Ovens. After
heating for nearly a period of 16-18 hours at a temperature of about 1100 Degree
Delicious, coke is obtained and is used as a fuel as well as reducing agent in the
Blast Furnace. The Coke Ovens of VSP are engineering feats by themselves.
They are the tallest ovens of 7 meter tall constructed in the country. The Plant has
3 batteries of 67 ovens each. Another feature is the dry cooling of coke carried
out by the inert gas nitrogen thus, reducing pollution considerably. In the process
considerable quantity of gas is generated which carries large number of coal
chemicals and heat value. A by-product plant is provided for each battery to
extract the coal chemicals and make the resulting gas useful for heating various
furnaces. By-products like benzene, toluene, xylem, naphthalene, coal tar,
creosote oil, pitch, and ammonium gas.
2. Sinter Plant
Iron ore fines, coke breeze, limestone and dolomite along with recycled
metallurgical wastes are converted into agglomerated mass at the Sinter Plant,
34
which forms 80 % of iron bearing charge in the Blast Furnace. The Sinter Plant
comprises of two sinter machines each having 312 square meters of grate area
with a total production capacity of 5.256 million tones per annum.
3. Blast Furnace
VSP has two Blast Furnaces with an effective volume of 3200cu.m. Each,
Which are the largest in the country? Blast Furnace is charged with coke, iron
ore, sinter and fluxes such as lime stone from the top. Hot air at very high pressure
is blown from the bottom. The iron ore and sinter charged from the top gets
reduced to hot metal by the time it reaches the hearth. Metal is tapped from the
hearth of the furnace at regular intervals. Its novel circular cast house with four tap
holes ensures continuous tapping of hot metal. Each furnace produces about 5000
tones of molten iron per day. The annual Production capacity of these Blast
Furnaces is 3.4 million tones of liquid iron. The furnace is operating at about
125% of their capacity at present.
In addition to hot metal the gang material present in the iron ore and sinter
also comes out in the form of molten slag while tapping. This molten slag is
converted to granulated slag in the slag processing plant. Granulated BF slag is
used for cement making and various other construction purposes. The hot metal
produced is carried to steel melt shop for further processing. The surplus hot metal
is taken to Pig Casting machines and cast into pig iron. The pig iron is sold to
foundries and exported to various other countries. Some pig iron is consumed in
steel melt shop also as coolant.
35
Converter gas to be used as a fuel in the plant. The entire molten steel cast at the
radial type continuous casting machines result in significant energy conservation
and better quality steel. 100% Continuous casting on such a large scale has been
conceived for the first time in India.
5. Rolling Mills:
The cast blooms from continuous casting department are heated and rolled
in the three high speed and fully automated rolling mills namely Light & Medium
Merchant Mill, Wire Rod Mill and Medium Merchant & Structural Mill, to
produce various long products like Reinforcement bars, rounds, squares, flats,
angles, channels, billets, wire rods etc. Rolling Mills adopt steamer cooling
process to get high quality products. VSP
Enjoys very high reputation for the quality of their products both in the domestic
and export markets.
36
Board of Directors:
BOARD OF DIRECTORS
37
Department chart- Finance (Budget):
38
ED(F&A)
(Budget)
Mgr (F&A)
(F&A(F&A)
AM(F&A) (Budget)
To carry out the major functions of Visakhapatnam steel plant following core
departments exist:
1) Marketing Department
2) Works Department
3) Materials Management Department
4) Finance and Accounts Department
5) Personal and Administration Department
6) Corporate strategic Management Department
7) Management services Department
8) Mines Department
39
Recent Trends:
Considering the Turn Around and the excellent physical and financial
performance in the last 4 years VSP has been awarded MINIRATHNA STATUS
by the GOI in the month of May 2006. This confers more DOP and AUTONOMY
to VSP Management in financial and policy matters. The BOD also will be
strengthened with more independent non-executive DIRECTORS.
VSP has undertaken expansion of capacity from 3-million tone liquid steel
to 6.3 million tone liquid steel at a cost of Rs.8692cr. Their entire expansion work
is to be completed within a period of 4 years from October 2006. The honorable
Prime Minister Of India has inaugurated the expansion project by laying
foundation stone on 20th May 2006. VSP will be producing special grade long
products required for automobile, railways and other special applications in the
new mills which are going to be installed. Further VSP will be producing
Seamless tubes of 3 lakh tones which are presently imported.
Joint Ventures:
VSP does not own any mines for extracting much required iron ore and
low ash metallurgical coal for its production. VSP depends on M/S.NATIONAL
MINERAL DEVELOPMENT CORPORATION for meeting its iron ore
requirements and import sources (Australia) for low ash metallurgical coal. These
sources have been increasing their prices disproportionately in recent times due to
very high demand because of capacity additions taking place in large scale. In
order to have raw material security and control over prices VSP has embarked
upon acquiring interest in coal mines and iron ore mines through joint ventures in
India and abroad.
40
VSP Has Been Allotted Mining Rights In Mahal Coal Block:
GOI has allotted mining rites in Mahal Coal Block for VSP after
continuous persuasion relentless efforts. VSP has started exploratory work in
Mahal coal block to ascertain the feasibility and project cost for opening up a
mining unit in this place.
Conservation of Water:
41
FINANCIAL PERFORMANCE (Rs.Crs)
4000
3500
3000
2500
500
-500
2000- 2001- 2002- 2003- 2004- 2005- 2006- 2007- 2008-
2001 2002 2003 2004 2005 2006 2007 2008 2009
42
Demand - Availability Projection:
Location:
The plant is located on the coast of Bay of Bengal, 16Kms to the
southwest of the Visakhapatnam Port. It lies between the northern boundary of the
national highway No.5 from Chennai to Kolkata, and 7Kms to the southwest of
Howrah Chennai Railway line. The decision of Govt. of India to setup an integrated
steel plant with an annual capacity of 3 MT of liquid steel and 2.656 MT of saleable
steel at Visakhapatnam in AP is yet another step towards the country’s steel
production redefining steel imports and removing the regional imbalances in the
development.
43
CHAPTER – 4
CONTROL
44
BUDGET:
Introduction
Definition
Need of budget
Essentials of budget
Advantages of budget
Limitation of budget
Types of budget
BUDGETARY CONTROL:
Key factor
45
BUDGET
Introduction:
Definition:
46
Need of budget:
To forecast and to plan for the future to avoid losses and maximize profits
i.e. to help in planning.
To bring about coordination’s between different function of an enterprise i.e., to
help in co-ordination.
To control actual actions by ensuring that actual are in tune with target i.e.,
to help in controlling.
Essentials of budget:
Advantages of budget:
47
It highlights upon the in efficiency in the business and thus helps the
Management to take remedial actions.
Types of budget:
The Budgets are usually classified according to their nature. The following are the
types of budgets, which are commonly used.
48
known to lower levels of management's. Long-term time budgets are prepared for
some sectors of the concern such as capital expenditure research and development.
Long term finances etc these budgets are useful for those industries where
gestation period is long i.e. machinery, electricity, and organization.
2) Short Term Budgets -These budgets are generally for one or five Years and
are in the form of monetary terms. The consumer’s goods industries like sugar,
cotton, textiles, etc. use short-term budget.
(2) Financial Budget: - Financial Budget are concerned with cash receipts and
disbursements, working capital. Expenditure, financial position and result of
business operations. The commonly used financial budgets are:
a. Cash Budget
b. Working Capital Budget
c. Capital Expenditure Budget
d. Income Statement Budget
49
e. Statement of Retained Earnings Budget
f. Budget Balance sheet or position statement Budget
(3) Master Budget: - Various functional budgets are integrated into master
budget. This budget is prepared by the ultimate integration of separate function
budgets. According to I.C.W.A. London. "The master budget is the summary
budget in corpora-ting its functional budgets". Master budget is prepared by the
budget officers remained with the top-level management. This budget is used to
co-ordinate the activities of various departments and also to help as a control
device.
50
BUDGETARY CONTROL
Introduction:-
Budget is formal plan of future course of action. When the budget is use to
evaluate the actual performance it is known as budgetary control.
51
It acts as yardstick with which actual are compared and necessary
corrections can be made so that it promotes efficiency and there by helps the
management for taking future courses of action.
Co-ordination is established among the different departments and
individuals through planning policy and control.
Limiting factors can be utilized properly by the application of this system.
Otherwise less important factors can pay the most significant role without,
however, utilizing the scarce sectors, which should have been used in view of
their importance. As a result, there may be loss instead of profit.
The budgetary control systems are however not free from short coming
which are as follows;
This system proves useless in that firm where policies, processes,
techniques, etc., are frequently changing since it does not take into account
such changes.
It is very costly in case of small firm and serves no purpose in the
event of abnormal situations, such as strikes, lockouts etc.
There are many factors over which the management has no control but
the budgetary control depends on them. In that case, if its is prepared, it may
be inaccurate and fails to serve the purpose for which it is meant.
52
The targets of the budgets should be realistic; if the targets are difficult to be
achieved then they will not ensure the persons concerned.
A good system of accounting is also essential to move the budgetary
successful.
The budgeting system should have a whole-hearted support of the top
management.
1. Clarifying Objectives:
The budgets are used to realize objectives of the business. The objectives must
be clearly spelt out so that budgets are properly prepared. In the absence of
clear goals, the budgets will also be unrealistic.
53
4. Budget Education :
The employees should be properly educated about the benefits at budgetary
system. They should be educated about their role in the success of this system.
The employees may not take budgetary control only as a control device but it
should be used as a tool to improve their efficiency.
6. Flexibility :-
Flexbility in budgets is required to make them suitable under changed
circumstances – Budgets are prepared for the future, which is always
uncertain. Even though budgets are prepared by considering the future
possibilities but still some occurrences late on may necessitate more
appropriate and realistic.
Managing Director
Chief Executive
Organization chart for budgetary control:
Budget Committee
Budget Officers
Productio
Sales Purchase Personnel Developme 54
Accounta
n
Manager Manager Manager nt Manager nt
Manager
Key fa
The factor that sets a limit to the total activity is known as key factor
which influence budgets. It is also called limiting factor or governing factor
principal budget factor. For example, there may be a high demand for a particular
product but due to non-availability of the supply of raw materials, production may
have to be destructed and this factor is known as key factor.
The following are examples of key factor.
55
Bottleneck incretion key processes;
iv)
5 MANAGEMENT : I) Shortage of efficient executive ness;
. ii) Insufficient capital
The key factor does not create any permanent problem in the business
operations since it is possible to solve any problem with proper management
action in figure.
56
57
CHAPTER – 5
CONTROL IN VSP
Every organization prepares budgets so that it can plan for its future and meet
any unforeseen contingencies and Visakhapatnam. Steel plant is no exception to
this rule. In many organizations, the budgetary process is taken up by any senior
executive of finance department. Since Visakhapatnam Steel Plant is a large
organization it has a separate budget section in the finance department, which
takes care of the budgetary process.
58
Objectives of preparing budget in Visakhapatnam Steel Plant:
59
Department will consolidate the department projection and prepare over all
company budget which indicate the Company projected Financial. The
budgets after being approved by the C.M.D. are placed before the Board of
directors (which includes C.M.D.). It is the board of directors, who approves
the budget for Budget Period (usually coming financial year).
Board of directors
Chairman-cum-managing Director
Budget Committee
60
This department is headed by the General Manger (Corporate Planning) and is
responsible for drawing up the policy to be followed by the company.
b) Medical Department:
Headed by the chief medical officer, this department is responsible for
maintaining the health of the employees of the company and their department.
c) Marketing Department:
Headed by General Manager (Marketing) this department is responsible for
procuring orders for the company and selling the goods produced by
Visakhapatnam Steel Plant
d) Works Department:
Headed by Director (Operation), this is the life and flood of the company as
this department is responsible for manufacturing the various items.
61
Headed by the Chief Town Administrator, this department is responsible for
maintaining the Steel Plant township and meeting its requirements.
j) Personnel Department :
Headed by Director (Personnel), this department is responsible for maintaining
employee records.
k) Commercial Department:
Headed by Director (Commercial), this department is responsible for material
management in the company.
l) Project Division :
n) Training Department :
This department is responsible for providing on the job training and off the job
training for fresh recruits.
o) Finance Department :
Headed by Director (Finance) this department is responsible for per forming
the various financial activities at the company. It also prepares the pay rolls.
Budget Manual :
62
budgetary control Visakhapatnam Steel Plant also has a well laid out budget
manual which enlists the responsibilities of different managers and Headed of
Department of various budget centers.
Budget Committee :
Budget Period :
It refers to the period for which the budget is prepared and employed. There is
no fixed time for budget period. The length of the period depends on.
Key Factor :
The factor, which sets a limit to the total activity, is known as the key factor
due to difficult and the high costs involved in the procurement of raw
materials and also due to less demand for the product.
63
Operation Budget
A) Capital Budget :
Capital Budget deals with the new schemes to be implemented during the
current year and also with the completion of schemes already implemented. It
is prepared and approved by Visakhapatnam Steel Plant and sent to ministry of
Finance to incorporate the projected capital expenditure in the over all Planned
expenditure of GOI.
COB-4
B) Operations Budgets :
This is the main budget prepared by Visakhapatnam Steel Plant. This budget
deals with the cash from operations of various items produced by the steel
plant. Operations budget is a short term budget and is prepared for a period of
one year. It is fixed budget there is periodic review of the budget to check
whether the actual figures match the budgeted figures. It may be as follows:
64
Step – I The Chairman-cum-Managing Director at Visakhapatnam Steel
Plant in consultation with the board at Directors decides the
production schedule for a particular year.
Step – III The need of each of the 19 budget centers then presents the
budget for his center to CMD’s approval.
Step – IV After discussions with the head of each center with some
modification if necessary is approved.
Step –VI The master budget is then circulated to all the department.
Step – VII The budget at each budget center and the master budget are
reviewed frequently, some times even daily, using a
computerized monitoring system in case Administrative
Expenditure.
65
PROCESS FOR PREPRATION OF MONTHLY WORKING
RESULTS IN RINL(VSP):
Introduction:
66
24. By Product Prices Mktg Deptt
The General Format of MWR:
67
Computation of Items in MWR:
(i) Gross Sales: This item is derived directly from the data
fed from monthly NSR report given by the Branch sales A/cs.
(ii) Net Sales: This item also derived from the Data fed from
Monthly NSR report given by the branch Sales A/cs
68
consumption quantities includes Handling loss, Transit losses, Moisture
loss etc.
(ix) Stores & Consumables; This item is derived based on
stores JV details obtained from stores accounts. And also from General
accounts voucher details.
69
VISAKHAPATNAM STEEL PLANT (RINL)
70
VISAKHAPATNAM STEEL PLANT (RINL)
71
Net Profit 754.26 2253.77 1734.16 1889.66
72
Cash Profit 2065.02 2606.019 1926.86 3481.86
Depreciation & DRE 374.34 361.600 317.87 486.50
Net Profit 1690.65 2244.40 1608.99 1942.74
Income
Gross Sales 10500.46 10407.94 10353.82 7546.88
Net Sales 8801.88 8839.16 9254.83 6701.29
73
Other Expenses 351.44 341.07 414.58 260.40
Total Expenditure 7101.85 8379.32 8663.11 6243.68
Gross Margin (net) 2300.00 2355.51 970.05 961.44
Interest 35.00 88.14 84.50 58.71
Cash Profit 2264.50 2267.37 885.55 902.73
Depreciation & DRE 306.41 240.78 0.00 0.00
Net Profit 1958.09 2026.59 418.40 721.91
74
Power, Fuel & 226.84 200.99 25.85 25.85
Water
Other Expenses 185.03 216.67 31.64 31.64
Total 3039.89 3030.11 9.78 9.78
Expenditure
Gross Margin 781.60 1055.00 273.40 273.40
(net)
Interest 227.50 123.19 104.31 104.31
Cash Profit 554.10 931.81 459.94 459.94
Depreciation & 469.48 454.61 14.87 14.87
DRE
Net Profit 84.62 477.20 392.58 392.58
75
Repair & 93.00 84.48 8.52 8.52
Maintenance
Power, Fuel & 195.17 220.04 24.87 24.87
Water
Other Expenses 198.21 209.05 10.84 11.74
Total Expenditure 3228.91 3392.88 163.97 163.97
Gross Margin 850.82 1937.9 1087.08 1087.08
(net)
Interest 164.37 49.05 115.32 115.32
Cash Profit 686.45 1888.85 1202.4 1202.4
Depreciation & 464.20 476.47 12.27 12.27
DRE
Net Profit 222.25 1412.38 1190.13 1190.13
76
Remuneration
Repair & 99.00 89.33 9.67 9.67
Maintenance
Power, Fuel & 311.56 224.22 87.34 87.34
Water
Other Expenses 192.34 189.00 3.34 3.34
Total 3465.33 4313.17 847.84 847.84
Expenditure
Gross Margin 1251.01 3271 2019.98 2019.98
(net)
Interest 32.24 11.11 21.13 21.13
Cash Profit 1218.77 3259.89 2041.12 2041.12
Depreciation & 464.51 1006.12 541.61 541.61
DRE
Net Profit 754.26 2253.77 1499.51 1499.51
77
Consummates
Employees 585.44 572.34 13.1 13.1
Remuneration
Repair & 141.51 97.24 44.27 44.27
Maintenance
Power, Fuel & 328.03 235.10 92.93 92.93
Water
Other Expenses 301.30 191.10 110.2 110.2
Total 5642.01 5019.35 622.66 622.66
Expenditure
Gross Margin 2232.74 2368.95 136.21 136.21
(net)
Interest 24.58 31.00 6.42 6.42
Cash Profit 2208.16 2337.95 129.79 129.79
Depreciation & 474.00 448.29 25.71 25.71
DRE
Net Profit 1734.16 1889.66 155.15 155.15
78
Stores, Spares 460.06 357.27 102.79 102.79
&
Consummates
Employees 633.55 746.940 113.39 113.39
Remuneration
Repair & 137 109.70 27.3 27.3
Maintenance
Power, Fuel & 322.68 257.650 65.03 65.03
Water
Other Expenses 266.07 243.580 22.49 22.49
Total 5817.8 5604.18 213.52 213.52
Expenditure 9
Gross Margin 2100.6 2654.95 554.33 554.33
(net) 2
Interest 35.60 48.94 13.34 13.34
Cash Profit 2065.0 2606.01 540.99 540.99
2
Depreciation & 374.34 361.600 12.74 12.74
DRE
Net Profit 1690.6 2244.41 553.73 553.73
8
79
Income
Sale of Power 3.13
Total Income 8195 9574.36 1379.36 1379.36
Expenditure
Raw Material 4103.3 4280.22 176.91 176.91
1
Stores, Spares 475.00 364.06 110.94 110.94
&
Consummates
Employees 812.05 1030.72 218.74 218.74
Remuneration
Repair & 129.23 125.79 3.44 3.44
Maintenance
Power, Fuel & 350.46 281.80 68.66 68.66
Water
Other Expenses 373.25 321.51 51.74 51.74
Total 6243.3 6060.93 182.37 182.37
Expenditure
Gross Margin 1951.7 3513.43 1561.73 1561.73
(net)
Interest 24.84 31.57 6.73 6.73
Cash Profit 1926.8 3481.86 1555 1555
6
Depreciation & 317.87 486.50 168.63 168.63
DRE
Net Profit 1608.9 1942.74 333.75 333.75
9
GROSS SALES
80
2006-2007 8748.84 9150.57 401.73 401.73
GROSS SALES
12000
10000 Series1
8000
Series2
6000
4000 Series3
2000 Series4
0 Series5
-2000
NET SALES
81
2004-2005 4528.63 6987.09 2458.46 2458.46
TOTAL INCOME
82
2004-2005 4716.34 7584.17 2867.83 2867.83
TOTAL INCOME
TOTAL INCOME
12000 BUDGET
10000
8000 TOTAL INCOME
ACTUALS
6000
4000 TOTAL INCOME
2000 VARIANCE
0 TOTAL INCOME
-2000 FAVOURABLE
TOTAL INCOME
ADVERSE
TOTAL EXPENDITURE
83
2005-2006 5642.01 5019.35 622.66 622.66
2006-2007 5817.79 5604.18 213.52 213.52
2007-2008 6243.03 6066.93 176.37 176.37
TOTAL EXPENDITURE
10000
TOTAL EXPENDITURE
8000 BUDGET
TOTAL EXPENDITURE
6000
ACTUALS
4000 TOTAL EXPENDITURE
VARIANCE
2000 TOTAL EXPENDITURE
FAVOURABLE
0 TOTAL EXPENDITURE
ADVERSE
-2000
GROSS MARGIN
84
2005-2006 2232.74 2368.95 136.21 136.21
2006-2007 2100.62 2654.95 554.33 554.33
2007-2008 1951.7 3513.43 1561.73 1561.73
GROSS MARGIN
GROSS MARGIN
4000 BUDGET
3500
3000 GROSS MARGIN
2500 ACTUALS
2000 GROSS MARGIN
1500 VARIANCE
1000
500 GROSS MARGIN
FAVOURABLE
0
GROSS MARGIN
ADVERSE
INTEREST
85
BUDGET ACTUALS VARIANCE FAVOURABLE ADVERSE
INTEREST
100 BUDGET
80
60 ACTUALS
40
VARIANCE
20
0
FAVOURABLE
-20
-40 ADVERSE
CASH PROFIT
86
BUDGET ACTUALS VARIANCE FAVOURABLE ADVERSE
CASH PROFIT
4000
3500
3000
CASH PROFIT
2500 BUDGET
2000
CASH PROFIT
1500 ACTUALS
1000
CASH PROFIT
500 VARIANCE
0
CASH PROFIT
FAVOURABLE
CASH PROFIT
ADVERSE
0.
NET PROFIT
87
BUDGET ACTUALS VARIANCE FAVOURABLE ADVERSE
NET PROFIT
2500
2000
NET PROFIT
BUDGET
1500
NET PROFIT
ACTUALS
1000 NET PROFIT
VARIANCE
NET PROFIT
0 ADVERSE
88
GROSS SALES
GROSS SALES
12000 Series1
10000 Series2
8000 Series3
6000 Series4
4000 Series5
2000
0
-2000
5
9
00
00
00
00
00
-2
-2
-2
-2
-2
04
05
06
07
08
20
20
20
20
20
89
NET SALES
90
TOTAL INCOME
BUDGET ACTUALS VARIANCE FAVOURABLE ADVERSE
TOTAL INCOME
TOTAL INCOME
12000 BUDGET
10000
8000 TOTAL INCOME
ACTUALS
6000
4000 TOTAL INCOME
2000 VARIANCE
0 TOTAL INCOME
-2000 FAVOURABLE
TOTAL INCOME
ADVERSE
91
TOTAL EXPENDITURE
TOTAL EXPENDITURE
10000
TOTAL EXPEN
8000 BUDGET
TOTAL EXPEN
6000
ACTUALS
4000 TOTAL EXPEN
VARIANCE
2000 TOTAL EXPEN
FAVOURABLE
0 TOTAL EXPEN
ADVERSE
-2000
92
GROSS MARGIN
GROSS MARGIN
GROSS MARGIN
4000 BUDGET
3500
3000 GROSS MARGIN
2500 ACTUALS
2000 GROSS MARGIN
1500 VARIANCE
1000
500 GROSS MARGIN
FAVOURABLE
0
GROSS MARGIN
ADVERSE
93
INTEREST
INTEREST
100 BUDGET
80
60 ACTUALS
40
VARIANC
20
0
FAVOURA
-20
-40 ADVERSE
94
CASH PROFIT
95
CASH PROFIT
4000
3500
3000
CASH PROFIT
2500 BUDGET
2000
CASH PROFIT
1500 ACTUALS
1000
CASH PROFIT
500 VARIANCE
0
CASH PROFIT
FAVOURABLE
CASH PROFIT
ADVERSE
NET PROFIT
96
NET PROFIT
2500
2000
NET PROFIT
BUDGET
1500
NET PROFIT
ACTUALS
1000 NET PROFIT
VARIANCE
NET PROFIT
0 ADVERSE
97
CHAPTER- 6
If we look at the Stores, R&M, Power & Other expenses it was increased.
Continuously.
While look at the financial results about employee remuneration
expenditure was observed that the total employee remuneration expenditure was
increased. Continuously from 2004-2005. Therefore the HRD department should
concentrate on this issue although the employee satisfaction is important but
employee performance must be increased to increase the production and reduce the
cost of production.
In the recent years the demand for the steel is rapidly increasing. Even if
the market survey has been done properly, it is only valid for some period and it is
hard to estimate for whole year. Assuming the market changes budgets should
therefore be revised each and every time there is a change.
Port is situated at 18 kms from the plant and transportation cost, which is
paid, is as some as 50 kms distance. Talks should be initiated to downstream the
costs.
The power export variance also informed that the actual were less than the
budgets from last two years therefore the top management should take care about
the misuses of power and should motivate the employees at all levels for proper use
of power.
Conclusion:
The Visakhapatnam Steel Plant has been dedicated to nation in 1992 and
it is one of the major steel plants in the Asia and having much more capital
might have long gestation period and while establishing the Visakhapatnam Steel
Plant so much of lands were taken from the local people and provided the jobs to
them in VSP thought they may not skillful. But the top management of VSP
performance, not only this but also frequent technological changes due to the above
factors in the initial stage. The VSP incurred some losses but with the remedial
measures taken by the top management the past scenario was changed and the
organization was stepped towards the profits and recorded 449.66 crores as a profit
for the year 2002. However the top management must take care to improve the
profitability and must try to reduce / remove the accumulated losses, which is
REFERENCE:
FINANCIAL MANAGEMENT: I M PANDEY
JOURNALS
SOURCE:
ANNUAL REPORT OF VSP 2008-09.
VSP PUBLISHED JOURNALS AND MAGAZINES
THE MANAGEMENT ACCOUNTS JOURNALS
WEBSITES:
www.vizagsteel.com
www.jpcindiansteel.org