13134965 intrnship report on kalyani steels ltd

Organization study

EXECUTIVE SUMMARYM/s Kalyani Steels Limited (Pig Iron Division Siruguppa) are running a pig iron industry situated at Honnarhalli village, Siruguppa taluk, Bellary district. Originally, this industry was established during November 1994 by M/s Uni-Metal Is pat Ltd and since 01-11-1997 it was closed. On 23-11-2004, this industry was sold to M/s Shree Ram Electro cast Pvt. Ltd. Subsequently, on 21-04-2005 the industry was leased to M/s Kalyani Steels Limited (KSL) and since then the industry is running continuously. The industry has an installed capacity of 90000 TPA pig iron. However, the Consent for Operation from KSPCB was obtained for the production of 60 000 TPA pig iron. M/s Kalyani Steel Limited is an Indian company with worldwide refutation in steel and alloy steel manufacture. Considering huge demand in the country, the company has proposed to enhance the pig iron production capacity of the industry from 60 000 TPA to 120 000 TPA. The production capacity will be enhanced mainly by full utilization of the existing surplus plant capacity and up gradation of process technology. The expansion does not involve procurement of additional land or construction of additional buildings. The capital investment (Gross Block) of the industry for exist capacity is Rs. 2640 Lakhs. Additional investment needed for enhancement of capacity is about Rs. 60 Lakhs.

1 Govt. R.C. College of Commerce & Management

Organization study

TITLE OF THE STUDY:An Organization study at KALYANI STEELS LTD, HONNARHALLI, SIRUGUPPA (TQ), BELLARY (DST).

INTROUCTION OF THE STUDY

Practical exposureIt gives a exposure to researcher. It nurtures us to what is going on real corporate and gives a firsthand experience in real corporate world.

Industry Exposure It exposure the student to know how the industry work. It also helps to understand function of each department.

Presentation Skills Project helps in improving the presentation student. It helps the student improve their confidence and also their communication skills.

Field work It gives the opportunity to go the field to learn and collect data and learn about organization.


Organization study

OBJECTIVES OF THE STUDY: To gain the first had practical knowledge of the overall functions of the organization in terms of various functional departments. To learn about the present situation and performing of the company. To relate the classroom theories practically and analyze them to have a view of problems faced by the organization and to help them by suggestions to understand the problems of various functional departments of the organizations. To satisfy the requirements for the partial fulfillment of the post Graduate degree of master of business administration as per the syllabus of Bangalore University.

SCOPE OF THE STUDY: Useful to students to know the working setup in the organization. The study will help us to know the overall functioning of the organization in detail. It also provides a wide scope to improve the knowledge of the study undertaking the project in practical aspect.


Organization study

METHODOLOGY OF STUDY:The required information and data was assimilated through two sources:

PRIMARY DATA:-

By observing the various departments of the organization. By interacting with various employees working in the company (interview).

SECONDARY DATA:-

From the company manual. From the journals and management books. Brochures and records of the organization. Internet.


Organization study

LIMITATIONS OF THE STUDY: The study is for a short duration and hence all the aspects of all the departments were not covered. The study is limited to the organizational structure and brief details of all

the

departments. Technical details are not covered, only a brief outline available from the secondary data is reported. There has been limited access to the annual reports of the company. It is my sincere hope that in spite of all limitations, the reader finds this report comprehensive, interesting and informative. I hope that this report serves the purpose efficiently and meaningfully for which it has been intended.


Organization study

INDUSTRY PROFILE:India is gifted with large quantity of iron ore with high Ferrous content, which is the crucial raw material for producing the steel. Hence India is one of the largest producers of steel in the world. With the help of liberalization, globalization of economy in the process, there is a scope for economic development, which means there will be focus on infrastructure. This will lead to considerable demand for steel. As its main applications are in the construction, engineering and automobile sectors, which are the key elements in building infrastructure steel in universal intermediate and has very strong forward and backward linkages hence steel industry has become one of the core sector of the economy. Though India one of the large steel producers. It has low percepts consumption of steel in comparison with order developing and developed countries. As steel is on the rise we can expect good rise in consumption. India is fortunate in having intensive iron ore deposits with reserves estimated at 10.3 billion which is more than 1/4th of the world reserves. Further the average iron ore content of Indian ore is above 60% in India, the iron ore reserves are mainly found in the states Orissa, Karnataka, Bihar, MP, Goa, A.P., Rajasthan and sum parts of western Maharashtra. When we think of the Industry steel , the first thing that comes in to mind us pig iron. This is because of its name. To put in to simple words, when metal from blast


Organization study

furnace is paired in to Moulds and solidifies it assumes a shape which resembles the back of a pig. Hence name pig iron. GLOBAL SCENARIO OF PIG IRON:The demand for the international has a sharp rise, the total production of pig iron. It is estimated at 500 mt. Developed nation accounts for 45% of the total production seeing the potential demand many mills in USA such as a Nucor, Norigstar, Steel and Max steel are switching over to pig iron production. INDIAN STEEL SCENARIO:The Indian steel industry's onward journey in the recent times has been a cause of great pride to all of us. The last two years have seen the deregulated Indian steel industry performing at its peak level in almost all spheres. Steel production went up by 8 per cent to reach a level of 33 million tons in 2005-06 from 32 million tons recorded a year before. The domestic demand for steel also registered a growth rate of 6 per cent and grew from 27 million tons in 2005-06 to 29 million tons in 2005-06. The most spectacular achievement has, however, been recorded in export performance. The Exports of finished steel from India increased to a modern and globally-integrated industry in an astonishingly short span Indian steel industry's onward journey in the recent times has been the a cause of great pride to by 37 per cent and from 2.7 million tons to 3.7 million/tons. In addition, significant improvement was noted in the exports of semi-finished steel, stainless steel and pig iron. All these favorable trends have been reflected in the improved profitability of the major steel makers in both the public and the private


Organization study

sectors. The biggest success story has been that of TISCO, which has recorded an increase of 391 per cent in its profits during this fiscal year compared to the previous y

ESSAR's balance-sheet has been in the black after a long time, while other major steel makers have reduced their losses significantly. The fact that such an improvement has come at a time of intense global competition and a worrisome proliferation of nontariff barriers in the developed world, speaks volumes about the resilience, the innovativeness and, above all, the competitive spirit of the Indian exporters of steel. The dexterity, with which the Indian exporters diversified their destination markets, modified the composition of their export basket to suit the changing global demand profile, affected sizable reduction in production costs and adoption of state-of-the-art technologies provides sample testimony to the maturity of this industry. From a highly protected inward-looking industry of .the pre-liberalization years it has matured into a modern and globally-integrated industry in an astonishingly short span of time. GROWTH TREND OF PIG IRON SECTOR IN INDIA:Before liberalization the pig iron industry was monopolized by the integral steel plants to utilize the liberalization policy initiated by the Government. Decline the pig iron production and paved the way of helping the ISPs be utilize pig iron for making steel to gain value addition. The integrated steel plant (ISP), is the major supplier of pig iron. Public sector (ISP) Contributes up to 90% of the pig iron supply. According to the steel ministry report demand for pig iron is estimated to increase by a whopping 37% over next 8 years.


Organization study

Demand & availability of pig iron (units 000)Years 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 Demand 2400 2900 2700 2900 3100 3300 3600 3800 4100 4400 Availability 3224 3469 3733 4016 4322 4650 4900 5750 5233 5474

6,000 5,000 4,000 3,000 2,000 1,000 0 1996- 1997- 1998- 1999- 2000- 2001- 2002- 2003- 2004- 200597 98 99 00 01 02 03 04 05 06

Demand Availability


Organization study

Pig iron is the basic input for making iron casting which finds its application in steel industry & other sectors of the economy. It can also be used in the change mix of the electrical are furnaces (EAFs) as a partial substitute of melting scrap. Pig iron mainly classified into tow glades. Basic glade (which is used for making steel/) Foundry glade (which is used of manufacturing iron casting) S.g glade (which is used of manufacturing special steel)

ROLE:In the changed policy environment based on the tenets of economic liberalization and global integration, the role of the Ministry of Steel has also changed significantly. In the post-deregulation years, the Ministry has seen a significant expansion in its role as a nodal agency for facilitating the process of transformation of this pioneering Indian industry with a history dating back to the beginning of the last century. The Ministry of Steel has directed its efforts towards fostering the growth of this industry based on the principles of competitiveness and economic efficiency. At the same time, much of its efforts have also been directed at curbing unfair competition from domestic and overseas sources. Similarly, it has also made efforts to help the industry in overcoming the structural rigidities, the scarcities of essential inputs, infrastructure-related constraints and other market-distorting forces commonly experienced by the developing countries in the course of industrialization


Organization study

COMPANY PROFILE

KALYANI STEELS LTD [Better Steel Through, Better Technology] Kalyani Steels Ltd, is a part of the over $2.1 billion Kalyani Group. Established in 1973, Kalyani Steels Ltd is a leading manufacturer of forging and engineering quality carbon & alloy steels using the Blast Furnace route. With its corporate headquarters in Pune, Kalyani Steels Ltd. was set up to fulfill the in-house requirements of forging quality steel of the Kalyani Group In 1997, the Kalyani Group set up a new plant to manufacture steel using the less power intensive mini-blast furnace route. The new facility is at Ginigera in the Hospet - Bellary region of Karnataka state, where iron ore is abundantly available. This integrated steel complex has capacity of 400,000 tpa of carbon and alloy steels, which is being expanded to 650,000 tpa. Over the years, Kalyani Steels has been continuously upgrading its technology and infrastructure. The facilities at KSL are at par with any sophisticated steel manufacturers in the world Although the forging industry in India is the primary market for the companys products, markets of various components for commercial vehicles, two wheelers, diesel engines, bearings, tractors, turbines and rail also form a substantial part of the companys clientele. KSL has earned the status of preferred steel supplier for engineering, automotive, seamless tube and primary aluminum industry.


Organization study

B.N.KALYANI:- GROUP CHAIRMAN

Mr B N

Kalyani, Chairman of the USD 2.4 Billion, Kalyani Group is the principal driving force behind the growth and success of the Kalyani Group of Companies. An able entrepreneur and technocrat, Mr Kalyani has enriched the group with his vision of sound business governance and value driven management practices. He is the12 Govt. R.C. College of Commerce & Management

Organization study

driving force behind the company's vision, products, market direction, and company's spirit & commitment to superior quality. While he has been instrumental in elevating the company to new heights, he is responsible for the company's strategic planning, policies & corporate directions. He also inspires the company's unique culture by promoting core values that focus on people, customers, innovation, quality, integrity, fun, and profitability. With a business experience of more than 27 years, Mr. Kalyani has set the group on its growth path and is credited with the extraordinary vision for its entry into the fast emerging infrastructure development arena in India. Born on 7th January 1949, Mr. Kalyani is an Engineering Graduate from the Birla Institute of Technology, Pilani, and post graduate from the Massachusetts Institute of Technology, USA.

Mr. Kalyani is Member of key Government Committees that include National Manufacturing Competitiveness Council; Board of Trade; and Development Council for Automobile and Allied Industries. He is the Member of the National Council of Confederation of Indian Industries; Chairman, Board of Governors, IIM Indore; and Chairman, Board of Governors, SGGS College of Engineering & Technology, Nanded. He is member of World Economic Forum, Switzerland; Commonwealth Business Council, UK; and India-US CEO's Forum.


Organization study

Mr Kalyani is associated with the Indian Education Initiative and has founded Pratham Pune Education Foundation, an NGO that provides primary education for underprivileged children. In 2004 Mr Kalyani was awarded "CEO of the Year" by the prestigious Business Standard newspaper. In 2005 he was recipient of "Entrepreneur of the Year (Manufacturing)" Award from Earnst & Young. In February 2006, The Jagatik Marathi Chamber Of Commerce and Industry honored him with their "Global Entrepreneur of the Year" Award. On 9th April 2006 Mr Kalyani was awarded "Rashtrabhushan" award by FIE Foundation for outstanding contribution in Industrial Globalization. The Symbiosis International University, Pune has accorded Mr B N Kalyani with 'the doctorate title' recognizing his invaluable service to the nation in putting the Indian Manufacturing industry on the Global Map. The IIMM has conferred him with the CEO of the Year Award 2006 for his outstanding achievements and contribution to Business, Industry, Society and to the Materials Management Profession at large. Mr Kalyani was recently honoured with Business Indias Businessman of the Year Award for 2006.

KALYANI GROUP:The Kalyani Group is one of the leading Industrial Houses in India, having14 Govt. R.C. College of Commerce & Management

Organization study

diverse business interests in Engineering Steel, Forgings, Auto Components, Non Conventional Energy & Speciality Chemicals. The Groups Annual Turnover is over USD 2.4 billion and has joint ventures with some of the world leaders such as ArvinMeritor, USA, Carpenter Technology Corporation, USA, Hayes Lemmerz, USA, FAWCorporation,China,etc. Bharat Forge Limited, the flagship company of the group is the second largest forging company in the world a nd the largest domestic player with a share of 80% in axle components and engine components.


Organization study

The Kalyani Group operates in four different business areas. The chart below illustrates how, in percentage terms, the Kalyani Group companies in each of these areas contribute to the overall makeup of the group. The table that follows shows the group's financial performance for the last


Organization study

Our success has been founded on a clear vision of leveraging our core competencies to maximum effect and this has been a feature of our impressive growth for some years. Our growth and the significant changes we have seen in our businesses have relied on our ability to manage the process of change in a proactive way and has17 Govt. R.C. College of Commerce & Management

Organization study

been a direct result of our ability to recognize and enhance our strengths. Careful targeting of prospective partners is a core ingredient, but it is our ability to realize the potential locked-up in alliances, which has contributed to our success. A common foundation for all our businesses has been building mutually beneficial relationships with our partners and customers and this features in all areas of our business. Our clear aim is to forge long-term, profitable alliances, be it with partners or customers. Growth is one of the leading management challenges for corporations. Our goal is to dominate each and every segment of the market where we operate. The Group's low key, but focused style of management has earned the company recognition amidst investors, employees, vendors and customers, as also worldwide recognition. The growth of the Group through the years has been influenced by a number of factors:

Focus on core businesses, to maximize immediate growth potential Aggressive cost savings programs Expand geographically to build global capability and leading positions External growth through acquisitions

VISION:Kalyani Steels sees itself as a GLOBAL ONE-STOP SHOP for Automotive & Engineering Steels.18 Govt. R.C. College of Commerce & Management

Organization study

A major gear shift to anticipate changing needs of user industries is the need of the hour. The company is already producing newer grades in Micro-alloyed steel segment. KSL intents to increase its product reach and range by continuous efforts on new product development. The company aims to augment its capacity to 1 million ton, while attaining self sufficiency for major raw materials viz. Met Coke and Iron ore.a. Coke: By adding coke oven batteries.

b. Iron Ore: By gaining controls on mining operations. & economizing the operations by... a. Generating power from flue gases of blast furnace/coke oven batteries. b. Reduce material handling losses and freight costs by building railway sidings at plants

Business strategy:To attain market leadership in value added, engineering steel segment By19 Govt. R.C. College of Commerce & Management

Organization study

Constantly upgrading manufacturing technologies & adopting cost effective methods of steel making thus enchasing shareholder value.

MILESTONE:-

1973 1997 2004 2005 2005 2007

Setting of KSL, Pune Facility Setting of Ginegera Plant Setting up of Bharat NRE Coke, Dharwad Commencing KSL, Siruguppa Operations Commissioning of Captive Power Plant at Ginegera Acquisition of SJK Steel Plant, Tadipatri

About Kalyani Steels Ltd (Pig Iron Division), Siruguppa:Year of establishment: November 1994

Sales turnover 2007-08: 10,000 tons No. of employees: Business area:Pig Iron 386

M/S KALYANI STEELS LIMITED (LESSEE)20 Govt. R.C. College of Commerce & Management

Organization study

(PIG IRON DIVISION) (Operator and Producer)

M/s Shree Ram Electro Cast Pvt. Ltd (LESSOR) Kolkata At: Honnarhalli, Post: Hatcholli, Taluk: Siruguppa, District: Bellary, Karnataka State 583 114 RegisteredOffice, KalyaniSteelsLimited, Mundhwa, Pune411036

INTRODUCTIONPREAMBLE:M/s Kalyani Steels Limited (Pig Iron Division Siruguppa) are running a pig iron industry situated at Honnarhalli village, Siruguppa taluk, Bellary district. Originally, this industry was established during November 1994 by M/s Uni-Metal Is pat Ltd and since 01-11-1997 it was closed. On 23-11-2004, this industry was sold to M/s Shree Ram Electro cast Pvt. Ltd. Subsequently, on 21-04-2005 the industry was leased to M/s Kalyani Steels Limited (KSL) and since then the industry is running continuously. The industry has an installed capacity of 90000 TPA pig iron. However, the Consent for Operation from KSPCB was obtained for the production of 60 000 TPA21 Govt. R.C. College of Commerce & Management

Organization study

pig iron. M/s Kalyani Steel Limited is an Indian company with worldwide refutation in steel and alloy steel manufacture. Considering huge demand in the country, the company has proposed to enhance the pig iron production capacity of the industry from 60 000 TPA to 120 000 TPA. The production capacity will be enhanced mainly by full utilization of the existing surplus plant capacity and up gradation of process technology. The expansion does not involve procurement of additional land or construction of additional buildings. The capital investment (Gross Block) of the industry for exist capacity is Rs. 2640 Lakhs. Additional investment needed for enhancement of capacity is about Rs. 60 Lakhs.

NEED FOR THE EXPANSION:Pig iron is basically used as a raw material in the production of cast iron products, steel, alloy steel and cast iron. The iron/alloy and steel plants are the essential for the growth of manufacturing and engineering industries, construction activities and infrastructural development. Since 1998, the consumption of steel in the country has increased by about 12 % per year. In view of the present encouraging industrial and economic growth in the country, which is likely to continue in future, M/s Kalyani Steels Limited has proposed to enhance the production capacity of its pig iron plant at Siruguppa. Bellary region in Karnataka state is a potential zone for establishment of iron and steel industries because of its accessibility to natural resources including water and raw material like rich iron ore, dolomite, manganese ore


Organization study

etc. Further, it helps to enhance the status of this underdeveloped rural area through improvement in roads, communication, job opportunities and other infrastructural facilities. The Government of Karnataka envisaged the policy to encourage iron and steel industries in the state. LOCATION DETAILS:The site is located adjacent to the district road joining Siruguppa and Hatcholli village and is about 6 km from Hatcholli and 16 km from Siruguppa. The nearest villages to the site are, Honnarhalli: 2km N, Chikkabellary: 3km NE, Chigaragadde: 3 km E, Kurudahal : 4 km S and Hatcholi:6 km NE. The location is basically rural and agrarian. Iron ore, the main raw material for pig iron is abundantly available in Bellary district and other raw materials are also available from near by places. The perennial rivers Thungabhadra and Hagari are about 3 km WN and 5 km SW from the site. The region has plain lands gradually sloping towards the rivers. Paddy is the main crop with sugar cane, sun flower, chilli are the other crops. Rice mill is the only industrial activity in the region and these are located (24 Nos) located at Siruguppa town and surrounding region. Environmental sensitive locations such as archeological structures, protected forests etc. are not present. However, rivers including Tungabhadra and Hagari are flowing in the study area.

DESCRIPTION OF ENVIRONMENT:-


Organization study

Base line environmental data were collected primary and secondary sources for the study area 10 km region from the site. The environmental parameters studied were weather, air, water, soil, ecology and socio-economical status. The region experiences tropical climate with hot summer and moderately cold winter. Monthly mean of maximum temperature during summer and minimum temperature during winter rises up to 41.2 0C and falls to 10.7 0C, respectively. Annual average relative humility is about 65 %. Rain is received from SW monsoon (June-September) and N-E monsoon (September-November). Average annual rain fall is 645 mm and most of the precipitation occurs during May to November. Winds are moderate and predominant wind speed are in the range of 2 to 19 km/hr. Major wind direction are W to E and E to W. education status. Ambient air samples were collected from 10 different locations within and outside the factory premise and tested for their quality. The quality of air in the region appears to be within the CPCB standards for the rural and industrial area.

Surface water samples were collected from Tungabhadra and Hagari rivers and groundwater samples were collected from 10 bore wells located in the region. Surface Water is almost neutral and its salinity is low. However, it contains turbidity, suspended solids and coli form organisms. It is suitable for drinking after conventional treatment and disinfection. TDS and total hard ness of ground water are moderate to high and they are in the range of 680-1048 mg/l and 320- 526 mg/l, respectively. The quality of bore well water in general is within the permissible limits for drinking and domestic uses. Soil samples were collected from six different locations in the region and tested for their quality. Soil in the region is clay loamy to sandy loam in structure. Concentration of soluble salts & plant nutrients are moderate in all the soil samples. The soil in general is suitable for agriculture.


Organization study

The region is basically agrarian and crops cultivated are paddy, maize, sun flower,Cotton and sugarcane. No forests or thick plantations in the region except the Vegetation observed at the banks of river and streams. The region is relatively backward with respect to education, communication and education status. PROJECT DESCRIPTION:MANUFACTURING PROCESS:The raw materials iron ore, coke, limestone, dolomite, manganese ore and quartz are charged into top of the furnace through conveyors. Atmospheric air is heated in Metallic blast furnace and then blown into the bottom of the blast furnace. Raw Materials descending from top of the furnace come in contact with hot air. The carbon in coke reduces iron ore to molten Iron (hot metal). The hot metal is collected at the bottom of the furnace. The impurities in the ore form slag. Slag being lighter floats on the hot metal. Hot metal and slag are removed separately from the furnace. The hot metal after solidification is cooled in to iron castings by spraying with water. The pig iron castings are then transferred to finished product yard. The hot slag is cooled and granulated into powder form by spraying with water. This slag along with water is collected in atank.BF gas which comes out of the blast furnace contains suspended solids. This is treated in an efficient gas cleaning unit consisting of dust catcher, two stage venturi scrubber, saturator and dry cyclone separator. B.F gas contain good amount of heat (600-700kcal/Nm3). The clean and cooled BF gas is then used as fuel in metallic blast pre-heater and boiler.


Organization study

RAW MATERIALS AND PRODUCTS Pig iron is the product from the industry. Pig iron production capacity will be increased from the existing 60000 TPA to 120000TPA.The raw materials are mainly iron ore, coke and limestone. The requirement of these raw materials for the existing capacity is 136 140 TPA, 46 680 TPA and 11 160 TPA, respectively. After enhancement of capacity the requirement of raw materials will be doubled. The iron ore mines are present in Bellary- Hospet region. Limestone is to be brought from Bagalkot (approx. 200 km) by road. Coke is mostly imported and transported from nearest port by road. Except coke, all other raw materials are locally available. Means of raw material transportation is by road.

LAND UTILIZATION The total land area is 116A -17G acres. Out of this 38A -00G is the factory premises covered with plant facilities and green belt. The balance of 78.17 acres is open area around the factory premise. Production enhancement will be achieved in the existing plant facilities and no additional is required for the purpose.

MAN POWER


Organization study

Man power in the industry is 351. After enhancement of production the man power will be increased to 386. More than 80 % of the manpower is recruited from the local area.

POWER PLANT The existing plant is already having a 2.5 M.W. power plant. The power plant consists of high pressure boiler a turbo generator. Blast furnace gas is used as fuel in the boiler. The existing power plant has adequate capacity to meet the power requirement even after enhancement of the pig iron manufacturing capacity. The power requirement of the industry is fully met from captive source. Only during the emergency of power shortage from captive source, the power will be drawn from KPTCL (950 KVA) or diesel generators (1250 KVA each 2 Nos.).

WATER REQUIREMENT Water requirement to the industry is met from Tungabhadra River. The fresh water Requirements to the industry for its present and expanded capacities is 862 m3/d and1157 m3/d, respectively. Government of Karnataka has sanctioned the industry to draw24000 m3/d water from the river. The industry has constructed a water reservoir of about 100 000 m3 capacity. This tank is filled up during rainy season. During lean flow in the river water will not be drawn from the river. During such period water from the reservoir will be utilized to meet water requirement in the industry.


Organization study

ENVIRONMENTAL IMPACTS AND MITIGATION MEASURES Pollution is likely to be caused mainly due to the discharge of waste products to the environment. Waste products from the industry are, i. Gaseous emissions from boiler and air pre-heater. ii. Fugitive emission from solid handling points and vehicular movement iii. Solid waste disposal The environmental parameters such as air, water and land are likely to be affected by the discharges of gaseous, liquid and solid wastes. The environmental impacts and their mitigation measures are given below.

AIR ENVIRONMENT:Blast furnace gases are used as fuel in boiler and air pre heater furnace. These gases are contaminated with suspended particles and therefore cleaned in a gas cleaning plant before being used as fuel. Flue gases from boiler and air pre-heater are vented through stacks of adequate height. Flue gases contain pollutants such as SPM, SO2 and NO2.The concentration pollutants in flue gases are within the permissible limits and will not affect the air environment. Fugitive emissions are likely to be present at solid handling locations such as loading and unloading points, solid storage yards and roads.


Organization study

Water spraying and sprinkling is practiced at these locations to control fugitive emissions in the industry.

WATER ENVIRONMENT:After enhancement of capacity a total of 1157 m3/d of water will be utilized in the industry. A water reservoir of about 3 months capacity is constructed in the industry for use in summer months. During lean season water will not be drawn from the river. Water is used in the industry for cooling, quenching and dust suppression applications. These water streams are totally re-circulated and only the makeup water is added to the system. Water requirement is mainly to meet evaporation losses in cooling water systems and dust suppression. There are no industrial effluents from the industry. Domestic effluent (36 m3/d) from the industry is small in quantity. It is treated in septic tank and discharged through soak pits.

SOLID WASTES:Solid wastes such as Iron ore fines, Coke fines, B. F. Slag, GCP Dust and GCP Sludge are produced in the industry. These are sold to cement plants, sintering plants for their reuse. No solid wastes are disposed to environment. In view of the waste management and pollution control measures as above the environment including air, water or land environment is not affected by the activities of the industry. ENVIRONMENTAL MANAGEMENT PLAN:-


Organization study

A comprehensive environmental management plan is adopted for the protection of environment. In addition to pollution control the plan consists of following measures. 1. Environmental Cell under the chairmanship of Factory Manager is created in the industry to plan and effectively manage the environmental activities. 2. Environmental Department is formed under environmental and safety officer to implement the activities of environmental management plan. It has overall responsibility of environmental protection and pollution control, including the maintenance of pollution control facilities, laboratories, self monitoring and also to maintain operational statutory records. 3. A monitoring system is established in the industry to test the quality of environmental parameters such as air, water and noise on regular basis as indicated below to ascertain pollution status within and around the plant. 4. Storm water gutters and storm water reservoir are constructed in the premise. Bunds and soak pits are provided for harvesting of rain water. 5. Green belt and greenery is development in and around the factory premise. 6. Roads in the premise are finished with paving and lining to avoid dust emission 7. Water spraying and sprinkling is practiced at loading and unloading points and solid storage yards to control fugitive emissions in the industry. 8. Occupational safety and health care systems and emergency management plan are followed in the industry.


Organization study

PROJECT BENEFITS:1. The industry is established in backward region of the state. The presence of the industry helps to develop road and transportation facilities in the region and also to improve the economic status of this rural underdeveloped region. 2. After enhancement of capacity, more than 800 persons will be engaged in the factory activities including direct and indirect employment in terms of factory employment, transportation, vehicle maintenance, etc. 3. The industry has the potential to curtail the export of iron ore and utilize the same in the country for production of steel. This will reduce the import of steel. Thus the industry has the advantage to improve foreign exchange position and the economic status of the country.

PRODUCT PROFILEThe Pig iron manufacturing unit (called as Pig iron SBU Strategic Business Unit). The process starts with the manufacture of pig iron. The pig iron division consists of 1 Mini blast furnace of 175 M3 working volume. The raw material for blast furnaces (iron ore, Coke, quartzite, dolomite, manganese and Lime stone) are fed to the furnace. The blowing system absorbs atmospheric air and blows it to the preheating section at a pressure of 1.25 Kg/cm2 and a volume of approximately 35000 Nm3/hr. This air is preheated in the preheated section to a temperature of 700 750oC. This hot high pressure air is then blown into the furnace. The air is blow from bottom, while the raw material is fed from top. Because of the hot air following in the counter flow direction,


Organization study

reduction of iron ore takes place. The coke in the raw materials acts as the main fuel to accelerate reduction of iron ore to iron in the form of liquid metal at 1500oC. The molten metal is then tapped out of the furnace and cast in the form of bricks called as pig. This casting process is carried out in the pig casting machine, where the molten metal is poured onto moulds and sprayed with water, for fas7ter solidification of iron.

Pig Iron

ORGANSATION CHART

VICE-PRESIDENT

Assistant FINANCE MANAGER Manager Accounts Officer Sr. Supervisors Supervisors Officer (Excise) Dispatch Supervisors Dispatch Govt. Assistants

PRODUCTIO N MANAGER Shift Engineers Junior Engineers Supervisors Sr. Supervisors Cast House

HR & ADM MANAGER

STORES MANAGER Junior Officers Sr. Supervisors Supervisors Asst. Stores Keepers Junior Clerks Assistants

PURCHASE MANAGER

MIS MANAGER

Q.C & PROCEES MANAGE R Sr. Chemist

SAFETY MANAGER

Sr. Assistants Assistants Time Keepers

Purchase Engineers Purchase Assistants

Research & Development

Shift Chemist Chemists Junior Chemist Trainee Chemist Sampler

Junior Officer Medical Assistants

32

R.C. Operator College Foreman

of Commerce & ManagementData Entry Operators

Organization study

Functional Departments of the Company:a. Human resource Department. b. Production Department c. Quality Assurance Department. d. Finance & Accounts Department e. Management Information System Department. f. Purchase Department.


Organization study

g. Stores Department. h. Safety department.

Human Resource Department:The Human resource Department is a part of the management function. Primarily these departments will deal with human relationship within & outside the organization and department will maintain WE feeling in the organization and make the employee/individual to contribute to the effective working of the undertaking. The Human resource Department will co-ordinate with all the departments to maintain a harmonious industrial relationship in the industry. The Human resource Department in fact more than equipment, machinery, building, furniture and fixtures and organization identity and purpose which mainly depended on the human resource which it can procure, maintain develop and utilize to accomplish the organizations goal. The management of human resource is more likely to be known as Human resource Management.


Organization study

The role of the Human resource management in an organization is more valuable to achieve the organizations goals. The Personal Department will conduct the advanced technical training to develop the employees skills at the works.

DEPARTMENT STRUCTURE OF FINANCE:-

Vice-President VicekkHR&Admn Manager

Senior Asst

Asst

Time Keepers


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Core responsibilities of HR & Administration1. Recruitment and selection: Analyzing the human resource requirement for the different projects, in coordination with the project managers.

Co-ordinate and set up the team for technical interviews.

Conducting initial HR interview rounds with the candidate and issue offers to the short listed/ selected candidates.

Suggesting an appropriate salary by referring to the salary bands and consulting with the concerned manager and top management.


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Carrying out reference checks for each candidate and immediately raising a concerned to the manager (if any)

2. Induction: Ensuring the completion of joining formalities.

Giving new employees a presentation on the company, orientation and basic

office information.

Maintaining employee data.

3. Training and Development: Collection of tech/non tech training needs and sending the information to the management.

Preparing the training Plan and Budget.


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Setting up a team of house trainers.

Organizing and felicitating the training.

4. Employee Relation.

Clarifying the employees queries about the HR policies.

Creating a HR manual/ Policies/Fitment-Increment.

Understanding employees concerns, escalating to appropriate levels and ensuring

resolution of the concerns.

5. Appraisal Process:Initializing the appraisal at different intervals for different employees in conjunction with concerned managers.

Clarification and Co-ordination for smooth flow of the process.

Exit interviews: - Conduct one to one discussions with separate employee to find the issues. This would lead to the separation. Provide appropriate feed back to concerned person of the concerns emerging from the exit interaction.


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6. Employee MIS:-

Maintaining employee master data.

Preparing joining, Head count, attrition MIS.

Provide compensation details to the accounts department for salary processing.

Should be responsible for training and managing staff activities (Projects,

internships and etc).

Office administration.

Handling the PR activities. Interacting with the villagers and land losers.

7. Payroll and Compensation Benefits & Statutory: Processing of payroll every month.

Updating of new joiners/ full and final settlements.

Maintain and prepare the standard of salary structure,

track all the details of

salary and prepare MIS report.


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Track leave records on daily basis and monthly basis.

8. Administration and Time office: Attendance / Muster Roll.

Front office administration.

Vehicle management, Guesthouse security Etc.

Superannuating & P.F:The employees in the grade of engineers and are covered under the superannuating scheme. All the employees are covered by P.F.

Communication:-


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The telephone exchange of the company works round the clock. The senior officers and essential service engineers are provide with phones and mobile phones to communicate effectively.

Canteen facility:The company has provided canteen facility to its employee and contract workers. Tea, coffee, breakfast, lunch, &dinner is provided for the employees at concessional rates. In case of the spot wherever necessary. In night shift, tea coffee & buns are provided.

Leave Facility/Holidays:All employees are entitled for a weekly off and are eligible for 9 paid holidays and 1 restricted holiday in a calendar year. They are also eligible for 24 days earned leaves & 8 days casual leaves in a calendar year.

Attendance and Identity card:Every employee of the company is provided with an identity card and daily the attendance also taken.

Gate pass for Official/ Personal work:-


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Every employee of the company will have to submit gate pass for official/ personal work going out of the factory. Salary Payments:Salary is paid to all the employees normally by seventh day of every month and through syndicate and State Bank of Mysore. LTC:LTC amount is paid to the eligible employees once in a year normally along with the salary payable for the month of April. An employee will be eligible for LTC only after completion of one year of service.

Discipline:All employees are governed by Certified Standing Order of the Company and also as per terms of their appointment letter. The Certified Standing Order of the company has been displayed on notice board & also available at Human Resources Development for ready reference.

Safety:The safety department conducts safety training programs for employees and gives the guidance regarding dos 7 donts .

Annual Appraisal System:The company has annual appraisal system. The employees joining the duties between January & June get their increment in April and the employees between July & December get their increment in October subjected to satisfactory performance. The42 Govt. R.C. College of Commerce & Management

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increment is given only after completion of one year service. Promotions are also given in the deserving cases. Promotion cannot be claimed as a matter of right and it is a prerogative of the management.

Retirement:The age of retirement is 58 years, in case of permanent employees.

Resignation/ Separation:One months notice, as the case may be, as specified in the appointment letter or payment in lieu of notice will be necessary for termination of service from either side.

TIME OFFICE It is a branch of Human resource Department. Time office is a key to Human resource Office. The primary function of time office is to maintain the attendance register of the employees and leave register and wage and salary exemption of all employees. Every employee of the company will be provided with an identity card, production of which is mandatory to gain, attendance into the company premises during the assigned shift. Every employee shall on demand by authorized persons, shall produce the card. Failing to produce the card will debar the employee from work for the day and also make him liable for disciplinary action. The Identity Card cannot be transferred and in the event of loss of identity card, the employee shall immediately report the loss to security and Human resource department. The employees shall bear the entire cost of


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reassurance, discharge retirement etc., the employee shall return the badge to the issuing authority. The employee should produce the Identity Badge to. To watch and ward staff when entering. To the wages / salary disbursement clerk, cashier or any other officer of the company while receiving wages/salary and allowances or On demand by an officer of the company. Any employee who is found to have entered the company premises without badge, issued to him will be liable to be sent out and will be treated as absent.

Production Department:-

The vision of the Kalyani Group is to be recognized globally as leaders through engineering excellence, providing diverse skills to all its existing and emerging businesses. It is our mission to provide responsive, valued and critical manufacturing technologies and engineering expertise in support of worldwide goals. Our objectives are to meet/exceed customer expectations, utilize the best applicable technology, and continuously improve our overall effectiveness as a high-


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performance, learning-based operation. For more than 35 years, Manufacturing Technology Strategies have been leading the way in helping corporations of all shapes and sizes improve their efficiencies and bottom line. We help our managers in manufacturing plants achieve their business goals through technology and people development. Today's ultra-competitive automotive marketplace demands superior product, process and technology. It requires people with in-depth technical know-how and a spirit of innovation. The results are world-leading processes, components, and continual increase in manufacturing efficiency and productivity.

Bharat Forge Ltd., the flagship company of the Kalyani Group is the largest forging company in Asia and one of the three largest and most technologically advanced commercial forge shops in the world. BFL has been leveraging technology in its endeavor to transform itself into a world class manufacturing company. It has, over the years, been investing in technology to enhance efficiencies, production quality and design capabilities. IT tools are being used extensively for product development, compressing production and product development time, supply chain management and product marketing. Our objective is to eliminate all non-value added processes, thereby reducing cycle times in all facets of our business.


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Our world class manufacturing is supported by corporate research including R&D, engineering support, advanced metallurgical analysis, and cutting edge testing facilities. This support structure, coupled with outstanding manufacturing capabilities, allows us to consistently provide our customers with the highest quality products and ensure our world-class status in this global marketplace. Our ability to penetrate foreign markets and increase global clients reflects the companys high technological capabilities.

Kalyani Steels Ltd (Pig Iron Division), Honnarhalli, Siruguppa.

Pig casting machine

Pig- Iron (10,000 tons per annum)

Process Flow Diagram for Pig-Iron Plant

Liquid Metal Mini Blast Furnace Pre-Heater Blast furnace Flue Gas Hot Blast Air (740c)

46

Govt. R.C. College of Commerce & Management

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High pressure Blast

Raw Material Handling System

Blowing System (High Pressure fans)

Steam Turbo-Generator Set AerometerTurbin e

OBJECTIVES OF PRODUCTION DEPARTMENT: Keep constant HBT 750oC. Avoid break down/Blast- leakage. Reduce consumable cast. Optimum utilization of F/C & M.C. Reduce coke rate. Maintain minimum power cost/unit.47 Govt. R.C. College of Commerce & Management

Atmosphere cdmosccc Air

Boiler

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Co/co2 Ratio =1.15 to 1.20. Reduce the skull generation in PCM & cast house. Improve Hot-metal yield. Give PCM for maintain in every shift. Co-ordinate with others department. Keep housekeeping.

MANUFACTURING PROCESS:The raw materials iron ore, coke, limestone, dolomite, manganese ore and quartz are charged into top of the furnace through conveyors. Atmospheric air is heated in metallic blast furnace and then blown into the bottom of the blast furnace. Raw materials descending from top of the furnace come in contact with hot air. The carbon in coke reduces iron ore to molten Iron (hot metal). The hot metal is collected at the


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bottom of the furnace. The impurities in the ore form slag. Slag being lighter floats on the hot metal. Hot metal and slag are removed separately from the furnace. The hot metal after Solidification is cooled in to iron castings by spraying with water. The pig iron castings are then transferred to finished product yard. The hot slag is cooled and granulated into powder form by spraying with water. This slag along with water is collected in a tank. BF gas which comes out of the blast furnace contains suspended solids. This is treated in an efficient gas cleaning unit consisting of dust catcher, two stage venturi scrubber, saturator and dry cyclone separator. B.F gas contain good amount of heat (600-700kcal/Nm3). The clean and cooled BF gas is then used as fuel in metallic blast pre-heater and boiler.

PRODUCTION FUNCTION:Equipment processes personnel are qualified to perform the required operations respective department reports qualified records objectives evidence of conformance to specified requirements.

Product identification traceability:-


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Purpose: to provide guidelines for establishment procedure fir identifying the product by suitable mesons respect during stages of production to delivery.

Method: pig iron:Incoming raw materials shall be identified by location marked for supplier wise storage other materials are identified by any of the following means tag location for storage point marks pencils marks name plates boards sticker. Quality system:To provide guidelines to establish. Document & maintaining a quality a means to ensure that product conformance to requirements. To outline structure of documentation in quality systems. Trade line document the quality planning is done to meet the requirements of product.

Method Quality assurance manual (QAM) The top ties document prepared primarily conveying the organization commitment to quality & maximizing customer satisfaction


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Common procedure manual (CPM) This is second ties document prepared by Mr Issues these to all department heads for common procedure. Divisional procedure manual.(DPM) This is also second ties document prepared by divisional heads dealing how a job is done with responsibility specified department procedure of HRM & TRG are prepared by respective department heads. Work instruction This is third ties document primary to operate with specify work details there are generally issued by document or sectional heads & when required they translated in vernacular language (Kannada).

Forms/ formats Standards check seats supporting documents etc these are primarily designed by departments taking into consideration the procedures/ work instruction details.

Pig Iron :51 Govt. R.C. College of Commerce & Management

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The specifications of the various grades of Pig Iron produced at KFIL are as follows:-

PIG IRON GRADES Foundry Grade

Carbon (%) Silicon (%) 3.80 4.20 3.80 4.20 3.80 4.20 3.80 4.20 3.80 4.20 3.80 4.20 2.00 2.50 1.80 1.99 1.51 1.79

Manganese (%) 0 50 0.90 0.50 0.90 0.50 0.90

Sulphur (%) Phosphorous (%) 0.06 Max .06 Max 0.06 Max 0.09 Max 0.09 Max 0.09 Max 0.09 Max 0.09 Max 0.09 Max

Basic Grade

13134965 intrnship report on kalyani steels ltd

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