A CASE STUDY

on

KHYBER CEMENTS

-BY SOLIHA KHAN

1

INTRODUCTION

2

Cement In the most general sense of the word, a cement is a binder, a substance that sets and

hardens independently, and can bind other materials together. The word "cement" traces to the Romans, who used the term opus caementicium to describe masonry resembling modern concrete that was made from crushed rock with burnt lime as binder. The volcanic ash and pulverized brick additives that were added to the burnt lime to obtain a hydraulic binder were later referred to as cementum, cimentum, cäment and cement.

Cement used in construction is characterized as hydraulic or non-hydraulic.

Hydraulic cements (e.g. Portland cement) harden because of hydration chemical reactions that occur independently of the mixture's water content; they can harden even underwater or when constantly exposed to wet weather. The chemical reaction that results when the anhydrous cement powder is mixed with water produces hydrates that are not water-soluble. Non-hydraulic cements (e.g. lime and gypsum plaster ) must be kept dry in order to retain its strength.

The most important use of cement is the production of mortar and concrete—the bonding of natural or artificial aggregates to form a strong building material that is durable in the face of normal environmental effects.

Concrete should not be confused with cement because the term cement refers only to the anhydrous powder substance (ground clinker) used to bind the aggregate materials of concrete. Upon the addition of water and/or additives the cement mixture is referred to as concrete, especially if aggregates have been added.

History of the origin of cement

Early uses

It is uncertain where it was first discovered that a combination of hydrated non-hydraulic lime and a pozzolan produces a hydraulic mixture (see also: Pozzolanic reaction), but concrete made from such mixtures was first used on a large scale by Roman engineers. They used both natural pozzolans (trass or pumice) and artificial pozzolans (ground brick or pottery) in these concretes. Many excellent examples of structures made from these concretes are still standing, notably the huge monolithic dome of the Pantheon in Rome and the massive Baths of Caracalla. The vast system of Roman aqueducts also made extensive use of hydraulic cement. The use of structural concrete disappeared in medieval Europe, although weak pozzolanic concretes continued to be used as a core fill in stone walls and columns.

3

Modern cement

Modern hydraulic cements began to be developed from the start of the Industrial Revolution (around 1800), driven by three main needs:

Hydraulic render (stucco) for finishing brick buildings in wet climates.

Hydraulic mortars for masonry construction of harbor works, etc ... , in contact

with sea water.

Development of strong concretes.

In Britain particularly, good quality building stone became ever more expensive during a period of rapid growth, and it became a common practice to construct prestige buildings from the new industrial bricks, and to finish them with a stucco to imitate stone. Hydraulic limes were favored for this, but the need for a fast set time encouraged the development of new cements. Most famous was Parker's "Roman cement".This was developed by James Parker in the 1780s, and finally patented in 1796. It was, in fact, nothing like any material used by the Romans, but was a "Natural cement" made by burning septaria - nodules that are found in certain clay deposits, and that contain both clay minerals and calcium carbonate. The burnt nodules were ground to a fine powder. This product, made into a mortar with sand, set in 5–15 minutes. The success of "Roman Cement" led other manufacturers to develop rival products by burning artificial mixtures of clay and chalk.

John Smeaton made an important contribution to the development of cements when he was planning the construction of the third Eddystone Lighthouse (1755-59) in the English Channel. He needed a hydraulic mortar that would set and develop some strength in the twelve hour period between successive high tides. He performed an exhaustive market research on the available hydraulic limes, visiting their production sites, and noted that the "hydraulicity" of the lime was directly related to the clay content of the limestone from which it was made. Smeaton was a civil engineer by profession, and took the idea no further. Apparently unaware of Smeaton's work, the same principle was identified by Louis Vicat in the first decade of the nineteenth century. Vicat went on to devise a method of combining chalk and clay into an intimate mixture, and, burning this, produced an "artificial cement" in 1817. James Frost, working in Britain, produced what he called "British cement" in a similar manner around the same time, but did not obtain a patent until 1822. In 1824, Joseph Aspdin patented a similar material, which he called Portland cement, because the render made from it was in colour similar to the prestigious Portland stone.

All the above products could not compete with lime/pozzolan concretes because of fast-setting (giving insufficient time for placement) and low early strengths (requiring a delay of many weeks before formwork could be removed). Hydraulic limes, "natural" cements and "artificial" cements all rely upon their belite content for strength development. Belite develops strength slowly. Because they were burned at

4

temperatures below 1250 °C, they contained no alite, which is responsible for early strength in modern cements. The first cement to consistently contain alite was made by Joseph Aspdin's son William in the early 1840s. This was what we call today "modern" Portland cement. Because of the air of mystery with which William Aspdin surrounded his product, others (e.g. Vicat and I.C. Johnson) have claimed precedence in this invention, but recent analysis of both his concrete and raw cement have shown that William Aspdin's product made atNorthfleet, Kent was a true alite-based cement. However, Aspdin's methods were "rule-of-thumb": Vicat is responsible for establishing the chemical basis of these cements, and Johnson established the importance of sintering the mix in the kiln.

William Aspdin's innovation was counter-intuitive for manufacturers of "artificial cements", because they required more lime in the mix (a problem for his father), a much higher kiln temperature (and therefore more fuel), and the resulting clinker was very hard and rapidly wore down the millstones, which were the only available grinding technology of the time. Manufacturing costs were therefore considerably higher, but the product set reasonably slowly and developed strength quickly, thus opening up a market for use in concrete. The use of concrete in construction grew rapidly from 1850 onwards, and was soon the dominant use for cements. Thus Portland cement began its predominant role.

CEMENT INDUSTRIES IN INDIA

India, being the second largest cement producer in the world after China with a total capacity of 151.2 Million Tones (MT), has got a huge cement industry. With the government of India giving boost to various infrastructure projects, housing facilities and road networks, the cement industry in India is currently growing at an enviable pace. More growth in the Indian cement industry is expected in the coming years. It is also predicted that the cement production in India would rise to 236.16 MT in FY11. It's also expected to rise to 262.61 MT in FY12.

The cement industry in India is dominated by around 20 companies, which account for almost 70% of the total cement production in India. In the present year, the Indian cement companies have produced 11 MT cement during April-September 2009. It took the total cement production in FY09 to 231 MT

5

Industry Background

The history of the cement industry in India dates back to the 1889 when a Kolkata-based company started manufacturing cement from Argillaceous. But the industry started getting the organized shape in the early 1900s. In 1914, India Cement Company Ltd was established in Porbandar with a capacity of 10,000 tons and production of 1000 installed. The World War I gave the first initial thrust to the cement industry in India and the industry started growing at a fast rate in terms of production, manufacturing units, and installed capacity. This stage was referred to as the Nascent Stage of Indian Cement Industry. In 1927, Concrete Association of India was set up to create public awareness on the utility of cement as well as to propagate cement consumption.

The cement industry in India saw the price and distribution control system in the year 1956, established to ensure fair price model for consumers as well as manufacturers. Later in 1977, government authorized new manufacturing units (as well as existing units going for capacity enhancement) to put a higher price tag for their products. A couple of years later, government introduced a three-tier pricing system with different pricing on cement produced in high, medium and low cost plants

Cement industry, in any country, plays a major role in the growth of the nation. Cement industry in India was under full control and supervision of the government. However, it got relief at a large extent after the economic reform. But government interference, especially in the pricing, is still evident in India. In spite of being the second largest cement producer in the world, India falls in the list of lowest per capita consumption of cement with 125 kg. The reason behind this is the poor rural people who mostly live in mud huts and cannot afford to have the commodity. Despite the fact, the demand and supply of cement in India has grown up. In a fast developing economy like India, there is always large possibility of expansion of cement industry

The cement industry in Kashmir division is dominated by around 3 companies, which account for almost 60% of the total cement production in kashmir. In the present year, the kashmir cement companies have produced 2.5 T cement during the year 2008-2009.

Technology Up-gradation

6

Cement industry in kashmir is currently going through a technological change as a lot of upgradation and assimilation is taking place. Currently, almost 93% of the total capacity is based entirely on the modern dry process, which is considered as more environment-friendly. Only the rest 7% uses old wet and semi-dry process technology. There is also a huge scope of waste heat recovery in the cement plants, which lead to reduction in the emission level and hence improves the environment..

Cement Production and growth

The production of cement in kashmir grew at a rate of 5.1% during 2006-07 against the total production of 147.8 MT in the previous fiscal year all over india. During April to October 2008-09, the production of cement in India was 2.5T comparing to 1.5T during the same period in the previous year. During October 2009, the total cement production in India was 2 T compared to a production of 1.5 T in the same month in the previous year. The cement companies are also increasing their productions due to the high market demand. The cement companies have seen a net profit growth rate of 85%. With this huge success, the cement industry in kashmir has contributed almost 9% to kashmir's economic development.

Jobs in cement industry

If one wishes to start a wonderful career which can help him or her to climb up the path of success, then jobs in cement industry can be an ideal choice. With the growth in the infrastructure and technological projects, there has been a rise in the cement industries in the country. This has led to the high growth of jobs in cement industry and more and more people are opting for the jobs in the various companies of this field to start a wonderful career

Growth of Jobs in Cement Industry

After the open market policies undertaken by the government from the 1990s, there was a significant increase in the infrastructure and housing projects in the country to cater

7

to the growing consumer market. As a result, more and more cement companies started to set up bases in various parts of the country. The government also put emphasis on the renovation of the heritage places and set up some public cement companies as well. As these projects required plenty of manpower, there was a significant increase in the number of job opportunities.

Today, the cement industry is one of the booming sectors in the country. According to recent surveys, the industry is expected to grow at a rapid pace over the next few years to cater to the growing infrastructure and real estate projects. As a result, there will be more employment in all these sectors. In fact, working in the cement industry is also considered as a lucrative career option for the freshers and

the youngsters. More and more young people who have a craving for architecture are joining the cement industry to get good jobs

. According to the recent surveys, one metric ton of cement generates job opportunities

for around 14 lakh people. Some of the states where the cement industry is booming are Gujarat, Madhya Pradesh, and Rajasthan and Kashmir and so on . To cope up with the competition market, other states are also gearing up with a number of cement projects which will produce a favorable effect on the cement industry in the country. In the year few years, more than 25 lakh people will be employed in the cement companies.

Top Cement Companies in kashmir

Following are the list of top cement companies in Kashmir:

JK Cement Kyber cement Tci Safco Itifaaq cement

Name Jk Limited

Production 17,902

Installed Capacity 18,640

Net Profit (in 2008-2009 ) 90 lakhs

Name Kyber Cements Limited

Production 15,094

8

Installed Capacity 14,860

Net Profit (in 2008-2009) 80 lakhs

Name Tci ltd

Production 13,707

Installed Capacity 17,000

Net Profit (in 2008-09) 60 lakhs

Name Safco cements

Production 14,649

Installed Capacity 14,115

Net Profit (in 2008-09) 50 lakhs

Name itifaaq

Production 8,434

Installed Capacity 8,810

Net Profit (in 2008-09) 30 lakh

9

Chapter- 1

COMPANY PROFILE

Chapter – I

Company Profile

1.1 Profile of the organization

Origin of the Organization

The product Cement plays an important role in the economic development of the

country. Cement is been used from more than 150 year of construction. The cement

consumption determines the infrastructure strength and development of the nation.

10

Khyber Industries (P) Ltd. was incorporated by Khyber Group of company’s as

Private owned company to meet the growing demand of cement in the state and utilize

the main raw material from limestone reserves of Khonmoh area. Foundation stone for

existing 600 TPD Cement plant was laid in the year 1982 at Khonmoh area of district

Pulwama, 25 Kms away from Srinagar and commissioned in October, 1987 at a cost of

Rs.132 crore, the commercial production started in April, 1987 with the production of

OPC-Grade 33 under the bureau of Indian Standard Certification. The trademark “Khyber

Brand” is registered with trademark Registry Mumbai, Govt. of India. At present Khyber

is manufacturing OPC 43 Grade & 53 Grade under BIS certification.

Growth and Development of the Organization

KHYBER Industries (P) Ltd.is one of the modern and efficient

cement plants in Kashmir producing best quality cements. The Head office is

located at Khayyam Road, Nowpora,Srinagar. The company is providing

employment directly/indirectly to more than one thousand unskilled/skilled &

specialized category of workers. The company is playing a significant role in the

development of state by providing not only direct & indirect employment but also

major contribution in construction of major projects, like Salal Hydel USHP-1&2,

Water treatment plant, Bridges, Flyover, and Canals where the cement is used.

The company has till date contributed more than Rs. 120 crore’s towards State

and Central exchequers as revenue in the form of State Sales Tax, Excise duty and

other taxes & duties. The performance of the company over last few years has

shown encouraging results, by steady increase in production & sale of cement,

resuming of plant improvisation and stabilization process, installation of pollution

control devices for bringing down the emission levels in stacks to present prescribed

norms besides modernization and up-gradation of machinery.

1.2 Mission, Vision, and Objectives:

Mission:

11

We are engaged in cement manufacturing and are poised to grow very

rapidly into a profitable transnational corporation. We would achieve this through;

New strategic investments in core and new businesses, Strategic alliances

and partnerships with multinational and national companies, Increased presence in

high potential countries.

Vision:

Product Excellence, Hard Work, and Continuous Self Improvement to

encourage individual ability and creativity and build effective teams.

To contribute for the advancement and development of the nation and improve

human life and to become market leader by adding continuously new capacities

incorporation state of art technology to produce quality cement at least cost to the full

satisfaction of customers.

Corporate Objectives of the company

To improve effectiveness and environment.

To improve effectiveness of maintenance system.

To improve safety and hygiene.

To improve employee morale and improvement.

Develop skill up gradation program for employees.

Enhance life span of equipment by maintainability improvement.

T.P.M Policy

T.P.M stands for Total Productivity Maintenance. It deals with productivity, people

and profit. T.P.M is a powerful tool for organization and cultural transformation that

brings in total efficiency of the plant by tackling key aspects of plant utilization quality

and down time with the ultimate goal being zero breakdown, Zero Accident, Zero Defect,

Optimum inventory and clean environment with the involvement of each and every

employee right from top management to the bottom level person in the company.

The letter ‘T’ stands for Including, Increasing, and Improving respectively;

Total effectiveness by maximizing the overall efficiency.

12

Total life cycle by reducing life cycle costs.

Total employee participation by involving everyone and transfer of knowledge

to everyone.

The letter ‘P’ stands for

Product to pursue maximization of the production system by bringing all

losses to Zero, Zero Accident, Zero Defects, Zero Breakdowns.

The letter ‘M’ stands for

Maintenance in a much wider sense. It covers the entire life cycle of the

production system to maintain the individual processes, plants and production

management systems.

T.P.M aims at involving all the employees of the organization through eight pillars

of TPM.

Individual improvement

Autonomous maintenance.

Planned Maintenance

Education and Training.

Maintenance Preventive system.

Quality Maintenance.

Administration and Support.

Safety and Environment.

1.3 Products Profile

It is the highly competitive environment of cement market, the yardstick is quality

and this testified by acceptance of Khyber Industries (P) Ltd. in the prestigious market. In

a short span of time it has distinguished itself and is the most sought after brand as it offer

sterling value for money. It offers superlative qualities, unmatched particles, fineness and

faster setting which give in cement consumption.

13

Khyber Industries (P) Ltd. at present is manufacturing OPC 43 Grade under BIS

certification. Khyber Industries (P) Ltd. raises much above BIS specification and

therefore has much better acceptance in the market.

Product

43 Grade OPC

Brand Name

Khyber Brand Cement

Punch Line

Let us build together, let us build with Khyber.

Packing

Woven Polyethylene bags in packing plant

Weight

50 Kg /bag

Price / bag

Rs 230

Quality

Specification B.I.S.

General Application

43 grade OPC

Multistoried building

Underground structures

Foundation and pillars

Dams and canals

Power project

14

Large and massive water tanks

Present Status and Future Plans of the Organization

Khyber Cement Plant is located at 25 Kms, from Srinagar city of J&K state.

The company has 834 workforce of which 600 are regular employees including 10

outside state employees, 88 are regular daily wagers (R.dw) at present apart from 23

consolidated and 10 time rated labours(T.R.L.). The capacity of Unit-I is 600 tons per day

(TPD).

The company has recorded a highest turnover of 93.23 crores’ in last financial year.

Khyber Industries (P) Limited is recording profit continuously since 2003-04 and during

last year Rs. 2 crore has been achieved as profit

MANAGING DIRECTOR

D.G.M (P&A) GENERAL MANAGER

DY. MANAGER

ASSTT. MANAGER D.G.M (MINES) D.G.M (WORKS) D.G.M (M-S/PP) ASSTT. MGR

SECTIONAL OFFICER SEC. OFFICER

MANAGER

15

MGR (Engg)

FA & CAO

MGR (Fin)

D.G.M (P&P)

DY. MGR (P&P)

SUB ORDINATE STAFF SUB ORDINATE STAFF

GEOLOGIST DY. MANAGER

SR. ENGR

SR. FOREMAN

ASST. FOREMAN

OPERATORS/ OTHERS ST

1.1 Organizational Chart

16

MGR (Store)

MGR (Q&P)

MGR (P&P) SITE

Organizational Structure

The organizational structure is shown in the previous page. The company is

headed by Managing Director (M.D.) who controls the various functional departments

e.g. Finance, H.R.D, Production and Marketing which are headed by Deputy General

Manager (D.G.M).

The various D.G.M’s are:

D.G.M. Purchase and procurement

D.G.M. Mines

D.G.M .Financial Advisor and Chartered Accounts Officer

D.G.M. Quality and Process Control

D.G.M. Personnel and Administration

Under the D.G.M ., Khyber Industries (P) Limited have Managers and Deputy

Managers in all respective departments which indicates the three top, supervisory ,

middle and lower management levels.

17

1.4 Board of Directors of Khyber Industries (P) Ltd. as on 06.08.2009

The company’s board of directors consists of well known economists and other

professionalized people having expertise knowledge in the field of commerce and

industry from the state as well as from the whole country, the company’s B.O.D includes

people like:

Haji Mohammad Maqbool,

Tramboo. Managing Director

Mr. Abdul Qayoom,

Tramboo. Director

Mr. Khursheed Ahmad,

Tramboo. Director

Mr.Umar Khursheed,

Tramboo. Director

Mr. Reyaz Ahmad,

Tramboo. Director

Mr. Rauf Ahmad,

Tramboo. Director

18

Chapter- 2

Functional Departments

19

MANAGING DIRECTOR

Chapter- II Functional Departments

2.1. Human Resource Department

Chart no.2.1 Human Resource Department Chart

20

GENERAL MANAGER

DGM (WORKS) DGM (P&A) DGM (P&P)

DEPUTY MANAGER

ASSISTANT MANAGER

SUB ORDINATE STAFF

Preamble:

To be competitive in all facets of the business operation, it has become an

imperative that all employees of the company must strive towards enhancing their

operational performance and developing their potentials to add-value significantly.

Therefore, the Performance Management System (PMS) is being looked critically

by the Management.

PMS is implemented for attaining a set of objectives:

Administrative: (Decision on promotion, salary increase, placement, transfer,

discharge, etc.)

Organizational: (Human resources planning and restructuring of operations and

enhancing human resource productivity.

Motivational: (Appraisal interviews, participation in goal setting and work

planning, earning incentives/reward/stock options, self appraisal and learning etc.)

Development: (Counseling, training and development, communication).

HRM policy & Man power planning

HRM policy firmly believes in induction, orientation, training and performance

appraisal, individual rating, up-gradation of knowledge and skills for achieving

technological change, cost reduction, targeted reduction with reciprocate profit motive

and shared challenging aims of the organization.

The policy believes in give and take reciprocation, punishment and reward

promotion for long service, education and skills and for timely action with integrity and

dignity of human value.

21

Man power planning

This includes forecasting, planning, inventory, man power resources depending

upon the technology adopted, capacity of the production unit, layout of the plant, building

and machinery, time and motion studies, skill of the workman, job responsibility, role

analysis and work load, raw material supply, marketing and turnover.

Recruitment

Recruitment is a generating of application or applicants for specific jobs. Recruitment

consists of two main processes:

Identification of vacancy of staff and workman

A stock of a recruitment sources.

Internal sources External sources

Circulation, advertisement

in group companies.

By internal promotion.

By internal or group

units/company

transfer/deputation’s.

By internal trainees and

apprentice.

Extension of service.

Advertisement in leading news

papers.

District and university employment

exchanges.

From institutions, university

campus recruitment.

From consultants and placement

agencies.

Form waiting list/shortlist and with

references of VIPs, known

concerned.

Applications from applicants

directly received from time to time.

Table.no.2.1 Recruitment Sources Table

22

Candidates called for interview will be paid to and for fare as prescribed in TA

rule according to the status and position of the post for which candidate is called for on

specific commitment made in the interview letter. If candidate is required to stay,

accommodation is provided in the guest house/transit hostel/hotel expenses are paid as

permitted in the rules, interview letter. All recruitments and interviews are

organized/coordinated by the personal developers.

Selection:

Selection will be done at the interview after complete verification of application blank

with passport size photo affixed, original certificates, with regard qualification,

experience last salary drawn, references etc., attached assessment form to be filled up and

signed by the interview committee. If selected the salary offered, grade, trainee or

probationer or direct employment, designation etc., offered should be mentioned for final

approval of the Managing Director (unit head) .

In case of the workers, wage board employees, staff etc., trainees, management

trainees, graduate trainees etc, the HOD of the personnel department, the department head

and subject specialist will be in the selection committee. In case of Sr. Officers, Dy.

Manager, Manager, Sr. Manager. The committee by composition, as HOD of personnel

department, and Managing Director (unit head) and for any post above Assistant.

Placement:

Depending on clear vacancies in the concerned departments/section on the basis

of sanction strength the candidates selected on the basis of qualification, experience, age,

professional requirement, etc., are placed with proper designation in the respective

department initially on probation of one year. Fresher graduate/diploma holders and ITI

and other or taken as trainees on stipend per month.

Test conducted for trainees.

Oral test.

Medical examination.

Verification of certificates and reference.

Induction.

23

A circular is issued to all departments and notice is also displayed in case when

Sr. Officers and above or newly appointed induction booklet to study the plant and

organization is issued to new entrants.

An induction schedule is prepared in personnel development giving different

period of exposure in different departments that is, Mines, Crushers, Raw mills, Kiln,

Cement mill, Workshop, Power plant, Stores, Laboratory, Packing plant, Time office,

Commercial and Sales department, Canteen, Welfare facilitation department etc. The

certified sanding orders of the cement factory or mines, Code of conduct and other rules

and regulation are also explained and such copies of manuals are given wherever

necessary

Training and Development

The company organizes training programme on need basis regularly for fresher’s

and for existing employees. The type of training is as under:

On the job training for all categories of employees.

Learning new techniques through internal training or by external agencies.

Fresher’s training and training for promotion in the organization.

Remedial training and general training in safety, discipline, culture, rules

and regulations of the company, statutory matter and procedure.

Internship training

This sort of training is important to employees who are transferred from other

units, fresher’s or to the employee promoted in new jobs. This is advanced vocational

training system.

24

External training

Every year before March annual training calendar is prepared after consulting all

the concerned departmental heads on various need based training programme on different

aspects like technical, marketing and of HRD administration to develop skills and latest

technical knowhow and same is approved by the management.

Promotions.

Procedure.

Career path.

Performance Planning

It is done from the level of Asst. General Managers and above quarterly. Major

tasks and key result areas are identified and written at the beginning of the quarter for

each person. At the end of every quarter achievement marks are given against the targets

set earlier. Marks 5 to 1 are given for various levels of achievements. Wherever the

targets are discussed during the counseling session and fresh targets are set for the next

quarter. Review of each quarter is done with the individual and factors helping/hindering

in the achievement of the targets are discussed and recorded. Assessment is done by the

immediate superior and is reviewed by the next higher-up.

Employee Motivation

Suggestion scheme, Grievance handling, Bonus, Quality Circle.

25

Employee Welfare

Dispensary

The company has provided health centre with X-ray diagnostics facility, ECG and

pathology lab to the benefit of the employees with qualified medical officers and Para

medical staff, visits of specialists are arranged regularly.

Libraries and Reading rooms

The company has provided libraries and reading rooms in the plant and also in the

head office for the benefit of employees. All kind of News papers and magazines are

made available.

Literacy Programs

The company is organizing literacy classes for the illiterate workers.

Bachelors Housing

The company provides Bachelors accommodation for the freshers who join

trainees and a staff Bachelors Mess is being run by the bachelor staff themselves.

Bus Facility

The company provides bus facility to its employees of Srinagar and other cities on

every day for its employees who are residing far from the site and its headquarters for the

benefit of the employees.

Security Department

Generally this department function under administration of personnel department

and the main function of this department are safety and security of men and material of

factory.

26

General Office Timing

--- 9.30 AM to 1.00 PM

--- 1.30 PM to 05.30 PM

Factory Timing

--- 9.00AM to 1.00PM

--- 1.30PM to 5.00PM

Shift Timings

The company runs in 3 shifts round the clock and general shift for all the

administrative works

Security and Time Office

The security at the main gate permits only those with proper ID card, Helmet,

Shoes, and Uniform.

The time office keeps record of all the employee details in 3 shifts and also General

shift. The attendance of all the employee are registered using an synel sensor punching

card reading machines which is installed to keep record of the day to day attendance of all

employees of the company in all shifts.

Employee Union

Union activities started in the factory in early 2007’s, when the employees felt the

need for organizing under a common platform so as to get speedy redressed of their

grievances regarding pay anomalies, recruitment policy, post retirement benefits, transfer,

promotion, accidental claims etc. The office bears comprises of six members

including chairman, president, secretary, general secretary, cashier, advisor. As per the

norms the elections for these posts are held after every two years through secret ballot.

The minimum eligibility for membership in the union requires regular service of one year

in the organization.

27

The cadres eligible for membership are:

For technical cadre – Below rank of engineer

For non-technical cadre – Below rank of Assistant manager.

So far the union and management has enjoyed a friendly and cooperative relation for

striving industrial peace

At present all the issues between the management and union are amicably

resolved through collective bargaining. During the negotiation the management takes a

reasonable and supportable position. Both the management and union strive to set the

solution to the critical problems faced by the factory pertaining to the efficiency of

production. There exists a mutual confidence, good faith and desire to make the collective

bargaining work. The union does not believe in resolving the issues through

undemocratic practices.

2.2. Finance Department

Chart.no.2.2 Finance Department Chart

28

General Manager

Sr. Manager

Manager Establishments

Manager Accounts

Manager Bills

Sr. Accounts

Accounts Officer

Assistant Manager

Personal Secretary

The financial year of the company starts from 1st April and closes on 31st March.

Financial management vows to the application of general management principles to a

particular finance operation. It guides investment where opportunity is the greatest

producing relatively uniform hard-sticks for judging most of the firms operations and

projects. Certain uniform norms for financial consideration have to be setup to enable an

enterprise to judge its activities properly. Financial management is the dynamic involving

or making of day to day financial decision in a business of any size. Financial

management however, should not be so planned as to contribute to project making

activities for finance cannot be generated without profits.

Financial management unlike other functional areas of a business related to the

company as on operating entity.

Functions

The function and responsibility of the finance and account wings include the

following:

Determine the financial resources required to meet the corporation operating and

capital expenditure program.

Forecast how much of there of these requirement would be met by internal

generation of funds by the corporation and will have to be obtained outside the

corporation.

Develop the best plans to obtain the external funds needed.

Establish and maintain a system of financial control governing the allocation and

use of funds.

Analyze the financial results of all operation, report the facts to management and

make recommendation concerning future operations.

Carry out special studies with a view to reduce costs, improve efficiency and

profitability.

29

The above are dealt with detail here under:

Feasibility study and project reports

In regard capital expenditure related to new project or expansions

feasibility studies and detailed projects reports are to the prepared by the management

and these should be examined by the financial wing to ensure that the capital expenditure

proposed would be in further once of the objectives for which the corporation has been

established, that the expenditure proposed to be incurred is reasonable and the

expenditure would result in ensuring reasonable profit.

Budgeting

Long term operating expenditure budget concerning a period of 10 years

indicates the likely profit/loss earned during period. Preparation of long term capital

expenditure budget covering a period of about 5/10 years and advise the arrangement in

regard to the timing of the incurrence of capital expenditure.

Capital expenditure budget is in regard to the capital expenditure that is expected

to be incurred during the year. The preparation of the arrival operating budget, the budget

returns that flow out of the comprehensive budgetary system in operating.

Cash flow statement

Based on the long term budget the financial wing would prepare a cash

flow statement indicating the inflow and outflow of cash during the period similarly it

will also prepare a details of monthly cash flow statements for the year based on the

annual budgets.

Working capital

It will also make an assessment of the working capital requirement for the

fiscal year and advice the management regarding the sources of financing the working

capital requirements.

30

Purchase

Finance wing will be associated on a matter relating to purchase of

equipments, machinery etc. it would also lay down suitable procedures for purchase to

ensure that adequate control is exercised over such purchase and that there are no un-

economic purchase.

Pricing policies

It will also advice the chief executive on pricing policies followed in the

organization in regard to the selling price of power inter departmental issues charging of

materials to jobs contract.

Service condition

It advices the management on all service matters having financial

implication such as scale of pay, clearness allowance, bonus, gratuity etc.

Accounting matters

General finance and accounts being is in charge of allows, budgets and

internal audit of the corporation. It shall maintain adequate records of assets, liabilities,

and transaction of corporation see that adequate internal audits there of the correct and

regularly made and recommended and enforce duly approved methods and procedures

where by the business of the corporation with the maximum safety efficiency and

economy. It shall examine all proposed disbursements from the corporation’s funds and

approve in advance payments required take made in accordance with the prescribed

administrative and accounting requirements and procedure.

Stores account

Finance and account wing responsible for the maintenance of adequate

system of store accounts. It would assist the management in determining the minimum,

maximum and ordering levels of various items and also be responsible for the

31

introduction and for operation of the ABC method of control with a view to reduce

the inventory holding to the optimum level.

It would also be responsible to ensure that the verification of stocks of various

items of store is carried out by ensuring:

That physical stock of selected items is verified every day.

That each item of stock is verified at least once in a year.

That the surprise elements in regard to stock verification are maintained.

Internal audit: it will organize effective internal audit departments and will

process the reports submitted by the internal audit and place the same before the

chief executive.

Annual accounts and audit: it will ensure that the annual accounts are prepared in

time according to provisions of law. It will attend to all matters relating to the

statutory audit and the audit by the controller and audit general.

Tax matters: it will be responsible for attending to all tax matters relating the

corporations.

Reporting

The following reports are taken submitted to the management

Resources employed.

Summary of cash flow for the quarter.

Forecast of cash flow for the next quarter.

Capital expenditure incurred during the quarter compared with sanctioned

amount, budget estimates etc.

Any other report prescribed by the undertakings relating financial matters.

Head Office Finances and Account Wing

The finance and accounts wing of the head office is divided into the following sections:

Establishment

Bills and banking

Management information system and financial concurrence

32

Assets accounts

Book keeping and compilation

Budget and finance

2.3 Marketing Department

Marketing is a social and managerial process by which individuals and

groups obtain what they need and want through creating, offering and exchanging

products and value with others.

Chart.no.2.3 Marketing Department Chart

Marketing Process

The marketing process consists of analyzing marketing opportunities, developing

marketing strategies, planning marketing programs and managing the marketing efforts.

33

Managing director

General Manager

Dy. General Manager

Depot Staff Site Staff Excise Staff

Analyzing market opportunities

The marketing department is continuously involved in analyzing the long-run

opportunities in this marketing fort improving the unit’s performance. These people

recognize the abundance of opportunities in the bargaining business field. The building of

the future is fast becoming a reality and high investment in this area is likely to continue

incoming decades. As it is dream of every individual in his life should own a house and it

needs cement, and also coming of many industries in the state and which require large

quantity of cement for construction purpose. This wide and constant market and

increasing demand for cement is great opportunity for Khyber Cement to launch new

products into market and to capture regular market with good quality of products.

Marketing department is responsible for monitoring of commercial market and its

components and the related technology trend never less than of competitors and the

related technology trend never less than of competitors activities for forged materials. It is

responsible for the following activities:

Market analysis and planning

Product analysis

Competition analysis

Determining customer satisfaction

Marketing department is also responsible for other internal department such as

operation, finance, purchasing etc.

Pricing and order administration

Regular customer interaction

Handling non technical customer complaint

Definition of commercial aspect of new supplier contract

Price updating

Authority and responsibility of marketing manager

Contract review and resolves the differences with customers

To release order board

Customer complaint handling

Follow-up and review payment collection

34

To coordinate for new product development activities

To study, enquiry and reply regarding feasibility

To coordinate for product price finalization

Developing marketing strategies

Khyber Industries (P) Ltd. has decided to target the home segment, Govt. and

private customers, bulk purchases. It involves a differentiating and position strategy for

the target market. This strategy includes the excellent service, pricing and distribution

policies as the state is heading towards normalcy.

Planning marketing programs

Marketing programs includes marketing mix and marketing allocations. It

includes 4P’s such as

Product - Customer needs and wants

Price - Cost to the customer

Place - Convenience

Promotion - Communication

Managing the Market segment

Organizing the market resources and then implementing and controlling the

market plan. The company has built a marketing organization that is capable of

implementing a market plan, Marketing research, Setting Advertising, Customer

servicing and so on. As marketing department is fully automated and having talented

personnel who work around the clock to achieve organizational goals and objectives

35

Functions and objective of marketing department

Marketing department has to perform following function and objectives with brief

explanation.

Price fixation

Based on prevailing marketing conditions

As per with the other main competitors

Sales Promoters

Appointed at all major distributors with security deposit ranging from Rs.1

Lakh to Rs.10 Lakhs. Interest paid is 14% per annum. The main functions are:

Sales promotion and market survey.

Price fixation.

Appointment of authorized stockiest.

Timely disposal of stocks.

Timely delivery of material to dealers.

Timely collection of payments.

Collection of confessional forms.

Transportation Bill passing procedure

The transportation bills are passed on weekly basis.

The transportation bills are checked thoroughly with the acknowledgment

received and advice is sent to account for releasing payment.

Shortage/Damages if any reported, the cost of the same is deducted from the

transporters bill and credited to sales expense account.

The information about pending LRs is monitored regularly.

Centralized Invoicing

Total invoicing is centralized at Srinagar.

Depot sends challans to site twice a week.

36

On receipt of challans, checking is dine immediately and fed into computer and

invoices are sent to Depots/parties.

When the loaded trucks report back the excise invoices are issued based on the

data from booking file and handed over to the truck driver immediately.

Loading

Co-ordination with packing plant personnel, for destination wise loading of

cement grade wise as per distributors/dealers requirement.

Frequent weight checking of loaded cement bags is being carried out at packing

plant to ensure accurate loading. In case of any variations it is being informed to

technical person for attending the same.

Dispatches

Monthly cement dispatches are planned at the site Road based on the required

cement grade wise by all the distributors/orders on hand.

All the distributors are informed well in advance about monthly cement

dispatches planning.

Road Dispatches

Truck booking are computerized and once the data is delay into the computer for

booking the Lorries, the same data is used for taking out excise invoice.

Truck booking goes on round the clock.

For truck booking transporters have to collect taken Nos. from security gate.

The trucks are allowed serially inside the factory for loading.

Road shortages are booked on monthly basis.

Sales Department

The sales department of this organization mainly concerned with sales, sales

promotion activities, distribution networking, marketing research activities and handling

consumer grievance. The total number of personnel employed included site, depot and

37

exercise staff is 42. The total area covered under sales is mainly different cities itself

in the state like Srinagar, Baramulla, Kupwara, Pulwama & Anantnag..

Sales Record of Previous 3 Years

Year 2006 :

1 Lakh 40 Thousand Metric Tons (M.Ts.)

Year 2007 :

1 Lakh 60 Thousand Metric Tons (M.Ts.)

Year 2008 :

1 Lakh 51 Thousand Metric Tons (M.Ts.)

(1Metric Ton = 20 Cement Bags,1 Bag = 50 KG)

Sales classification

Direct sales

Government projects

Private projects.

Sales through stockiest

Distributors

Customers

The total number of stockiest of company will be around 20 located in

different districts. The key competitors to this content are industries like TCI. ,

Saifco Cement etc. the motivation factors plays on vital role in sales because it

reduces distributors to sell more and indirectly it helps the organization to

increase its profits. The motivation to dealers is done in many ways they

include:

Meeting of all distributors in company office every year.

Three shields to maximum sellers etc.

Dairies to distributors and to permanent customer.

Calendar to customers.

Key chains to customer

38

Current market situation

Competition:

There is neck to neck competition between Khyber Industries (P) Limited and other private brands, the other brands are

J & K Cements.

Saifco Cements.

Trumboo Cements Industries ( TCI ).

Ambuja Cements.

Even Though the Khyber Cements are above the Jhelum Brand Cements(JKCements)

Saifco Cement Brands but it is registering top most sales since its incorporation.

Last year Khyber Cements registered round about 75% of the total sales in Srinagar

Ambuja Cement Brand is mostly used outside the Kashmir Division mostly in Ladakh

Region being the coldest region in the state. Therefore, 53 Grade Cement is used

there. The higher the grade the more is the strength of the cement. Most of the

Competition is seen between Khyber and Jhelum brand of cements.

Market situation:

Target market – House-holds, Government contractors, Semi-government

departments, and Private firms.

Competitive situation – The competitors are Khyber cements and Saifco cements.

Distribution situation – Distribution takes place through depots and retailers.

Product situation – There is only one product namely 43grade.

39

Advertising

Advertising is one of the most common tools which companies use to direct

persuasive communications to target buyers and public. We define advertising as follows:

Advertising is any paid form of non-presentation and promotion of ideas, goods or

services by an identified sponsor. Organization handles their advertising by someone in

the sales or marketing department who works with an advertising agency.

Modes of Advertising

Wall Paintings.

Hoardings.

Dealer Boards.

Neon Glow Sign Dealer Boards.

Bus Panels.

Bus Shelters.

Stickers (English, Urdu).

Posters.

Calendars and Diaries.

Telephone Index.

Gift Articles (Cash bags, Pen stand, Key chains, Wall clocks, Diaries, Flask, and Pens

etc.)

40

2.4. Production Department

MANAGING DIRECTOR

GENERAL MANAGER

(WORKS)

DGM (WORKS)

MANAGER RD&QA

DY. MANAGER

CHIEF CHEMIST

SENIOR CHEMISTS

CHEMISTS & TESTE

Chart.no.2.4 Production Department Chart

41

Nature of Production

Production is the process by which, raw material and other input are converted

into finished products. The other word synonymously used with production is

manufacturing. Some people try to draw distinction between the two terms:

Manufacturing is understood to refer to the process of producing only tangible goods,

where as production includes creation of both tangible goods as well as intangible

services.

Important of Production Functions

It needs no exaggeration to say that production makes significant contribution to

society’s well being. The standard of living of people depends on production of goods

and services. More the production, higher is the standard of living of the people.

Methods of production

The raw materials are carefully proportioned to provide the desired amount of

lime, silica, aluminum oxide iron oxide. They are then mixed and grounded either in a

wet or in a dry condition accordingly. The process is known as “wet” or “dry” process,

modern plants use the “Dry” process. The ground materials are bed into a long rotary

kiln, which is maintained at a temperature around 1400 C. The raw material when burnt

at that temperature react chemically, to form pellets which are known by the name

clinkers, After the discharge from the kiln, the clinker is cooled and then grounded to a

fine powder, during the grinding process few percentage of dry gypsum is added to

control the rate of setting. Cement is supplied in Bags or in bulk.

42

Material Requirements

The following materials required.

Lime stones.

Sand stone.

Hematite/Late rite (Iron ore).

Pet coke

Gypsum.

Clay

Routing Scheduling

As pre plant is running round the clock shift system requires. In this plant the

schedule areas under:

“A” Shift 6.00AM to 2.00PM

“B” Shift 2.00PM to 10.00PM

“C” Shift 10.00PM to 6.00PM

General shift 8.00AM to 5.00PM

(Half hour lunch)

Material Handling System

The material handling systems are as follows:

Belt convey or

Pay loader

Tipper

Dozer

Safety Standard/Norm

The company is following the I.S.I, also factory act code and other relevant code

pertaining to safety.

43

Cement Manufacturing Process

The process of manufacturing cement involves basically the following sequential unit

operation and processes.

Limestone mining.

Limestone crushing.

Stacking and reclaiming.

Raw material grinding.

Storage and homogenization of raw metal in continuous blending silo.

Coal grinding.

Clinkerisation - (kiln feed, preheating, kiln and cooler).

Cement grinding, storing.

Cement packing and dispatches

Limestone Mining: is the first phase of cement manufacturing process. The

company is open cast, mechanized mining. After removing 2 to 3mts of over burden

clay grades will be classified (1st bench low grade 8 to 10mts in depth, II and III

bench high grade 10 to 12mts in depth) then drilling and blasting will be done. The

material will be loaded by shovels and transported to Crusher by Dumpers having a

capacity of 30 MT in the required ratio.

Limestone crushing: Crushing of limestone is carried in single stage by

HAZEMAG IMPACT CRUSHER having a capacity of 800 PPH. The feed size of

the material is maximum 1.6 Cu. meters and product size maximum 80mm the

material, which is entering the crushing chamber, encounters the impact by blow

bars mounted on the rotor and revolving at a circumferential velocity of 44 m/sec.

The fragments are flung against upper and lower bars. This process is repeated until

they have been sufficiently crushed to pass through the blow bars. Grinding path

(blow bars) can be adjusted if the output material size is more than 80mm the crushed

material will be transported to Stacker by means of Belt Conveyors.

44

Stacking and reclaiming: For stacking crushed limestone Belt Type Boom

Stacker is in operation, which is having capacity of 800TPH. The boom stacker has

been conceived for material stacking on Chevron Method. In this method the

stacker travels to and fro on a runway between two detained limits, while building

up stock pile. The materials are always discharged constants above the middle of

the stockpile. With this method piling can be done uniformly with required grades.

Four stock piles of 130mtrs long and approximately 25000 MT capacities each can

be made, by turning the boom to the opposite direction.

Reclaiming:

For this Bridge Scraper is in operation. A triangular structure called harrows move to and

for across the stock pile width and scraps the material. Scrapped materials slides done

from face of the stockpile to get blended limestone. The blended limestone which slides

down is scrapped and conveyed by buckets to belt conveyor, which in turn will be

transported to Raw Mill Hoppers. By means of stacking and reclaiming the

homogenization of limestone will take place

Raw material grinding: Grinding operation is the second stage of operation in

unit operation after crushing stage. In this stage, crushed material is to be grounded

into finer material. The raw materials (Blended limestone, Corrective limestone,

Laterite and Bauxite) are fed to the hoppers by belt conveyers. The material from

hoppers, fed to the mill in required proportion by weight feeders as pre-redesigned

by Quality Control Department. In between the grinding table and rollers grinding

take place by hydraulic pressure on rollers. The ground material is conveyed

outward over the edge of grinding bowl, entrained by the air steam emanating from

the nozzle ring conveyed to the Electrostatic Precipitator through the Static

separator of Unit-I and a dynamic separator of Unit-II is built above the chamber.

The separator separates the ground material into the finished product (product

fineness about 30% on 90 micron sieve) and coarse material. The coarse material

drops back to the middle of grinding bowl; while fines are carried by the air steam

to the E.S.P will be transported through Bucket Elevator or by Airlift to Blending

Silo. The hot gases coming out of the Kiln are being utilized for drying the material

and entrainment of raw meal at required temperature. To control the outlet

temperature of the mill and to maintain constant material bed on the grinding table

water spraying system is provided inside the mill.

45

Continuous Storage and Homogenization of Raw Meal in Blending Silo:

Continuous flow into the silo (Capacity 12000 MT for each unit) is being used for

storage and blending of Raw Meal. Continuous homogenization can be performed

in this Silo to maintain uniform desired quality.

Coal Grinding: The Raw Coal, received by road is stored in Coal yard is crushed

to 30mm size by Reversible Impact Hammer and four roll crushers. Crushed raw

coal is fed to the vertical coal mill for grinding before firing in the kiln and

precalciner.

The coal grinding takes place inside the mill under grinding rollers and

grinding table. The ground material (fine coal) is carried by the hot gases drawn by

C.A. fan. The hot gases are used to remove the moisture form coal. The ground coal

is carried by hot gas steam through static separator in which coarse material will be

returned to the mill and fines will be conveyors.

Clinkerisation: It is combined process made of Pre-heating, Calcining, burning

and cooling operation. Rotary kiln is the main equipment for Clinkerisation. The

company has a dry process plant consisting of Dopol Kiln

After blending and homogenization process, the Raw Meal is conveyed to

the Pre-heater through Poldos system (Poldos/solid flow meter system is for

weighing and feeding the raw meal) and bucket elevator/air lift from C.F. Silo. Kiln

Feed is fed into the Cyclones IV gas duct. Preheating and Calcinations takes place

in various stages of cyclones due to heat transfer

Fine coal is fired at kiln outlet end through a Burner pipe. Pneumatic screw

pumps in Unit-I and Poldos-SC in Unit-II are used for main firing and precalciner

firing. The hot gases generated due to fine coal firing are taken out by Dopol

Fan/ESP Fan through Pre-heater, Raw Mill and ESP.

Heat transfer takes place in Pre-heater as Kiln Feed moves downward and

flue gases move upwards causing co-current flows in gas ducts. Kiln feed after

preheating (around 90% calcined material) enters at kiln inlet. Then such

decarbonised material will to the Burning Zone due to the inclination and rotation of

46

the rotary kiln in the direction of hot zone (burning zone). The temperature of the

Burning Zone is maintained at about 1400 deg. C for proper Clinkerisation. After

this stage the material is known as Clinker. This clinker gets cooled in the cooling

zone and falls into Jet Stream Plate Cooler for Unit-II where it cools down from

1250deg. to 100deg. temperature by cold incoming air from the cooling fans

connected to the grate cooler. Finally clinker will be conveyed to the stock yard by

DPC (Deep Pan Conveyor).

Cement Grinding: Cement grinding is the final unit operation of cement making

process. We have a tube mill of grinding capacity 115 TPH length 16mtrs x 4.4mtrs

dia. The material to be ground is extracted in desired proportions of clinker and

gypsum from storage hoppers by means of Weigh Feeder and fed to the mill by

conveying belt.

In cement mill the material will ground into fine material by means of

impact and attrition. The material is pre-crushed in I chamber and fine ground in II

chamber. The product i.e., Cement will be conveyed to the silos either by Air Lift or

through bucket elevator. Recently close circuiting of this mill is carried out and

output increased from 115 TPH to 140 TPH. Unit-II cement mill is a closed circuit

mill with Roller Press of 280TPH capacities. Its length is 14.5mtrs x 4.6mtrs Dia.

The fines are separated in the separator in its circuit. The final product i.e., Cement

is conveyed to the Cement

Silos by Bucket Elevator and stored for packing. Total 6 nos. of storage silos

are there (3for each unit).

To manufacture Portland Pozzolana cement and to meet the marketing

requirement, 1000 MT capacity fly ash silo with storage and feeding arrangement

has been installed and commissioned in 2006..

Packing and Dispatch: Cement is extracted from the silo filled in Packer Hoppers,

from where the material will flow to the Packer Machine through bucket elevator

and air slides. Six numbers of electronic packers of 120 TPH capacities in Unit-I

and II are installed for the packing purpose. They have high degree of accuracy.

Finally the 50 kg. Cement bags is transported by belt conveyor and stacked inside

the Wagon/truck with help of Wagon Loading and Truck Loading Machines.

47

Chart.no.2.5 Cement Manufacturing Process Chart

48

Limestone

Mines

Limestone Stock Piles (Stacker reclaimers)

Raw Mill (vertical

Roller Mill)

Bauxite & Hematite

Processing (Pre-heaters, Kiln, Coolers)

Clinker Stock pile

Polycom/ Cement Mill

GypsumCoal Mill

Coal Stock

Cement Silos

Packing Plans

Dispatch

Chapter-3

SWOT Analysis

49

Chapter- 3

SWOT Analysis

Strengths:

Abundance availability of limestone, which is the important raw material for

cement.

Low cost of Production.

Financially sound.

Weaknesses:

High Labour turnover ratio.

Lack of Co-operation between the departments.

Lack of Skilled Labours.

Failure in penetraring to the new markets.

Less advertisement.

Opportunities:

Cement is a core commodity essential for infrastructure development

especially in the state as it is heading towards normalcy.

The expansion of the plant will be beneficial in the long run for the development

of state and can become the top leader in the cement production.

Threats:

The industry may face stiff competition in the near future due to installation / coming up of new cement plants in the state.

Rapid changes in market expectation. Rapid duplication of the pricing strategies by the competitors.

50

Chapter- 4

Learning Experience,Findings, Suggestions and Conclusion

Chapter- 4

51

Learning Experience Findings, Suggestions, and Conclusion

Learning Experience

Exposure at Khyber Cements for a month gave me a new experience of corporate

world

I learnt proper time management and resource management in my project training

in the said organization

I gained much knowledge about the entire production process of the organization

I learned to communicate with the top level , middle and lower management

I came to know the level of the job satisfaction of the employee in the

organization

In marketing department of the Khyber Industries (P) Ltd. I gained knowledge

about the strategies adopted by the company in different situation and also I came

to know how to tackle the problem in the marketing

In human resource department I gained knowledge about how to tackle employees

and customers , I also came to know the recruitment process adopted by the

organization

In finance department I gained knowledge about the function of the finance

manager and the department

In safety department I gained knowledge about the health safety environment

Company books and records were relied upon

Findings

The problem faced by the company in the present situation is that, under today’s

circumstances/ competitive age and the price index of raw materials the technology used

is almost obsolete before 4-5 years.

Spare parts of the plant are not available in the local market, almost company have to

buy small pity things from Delhi and other parts of the country and it takes lot of time and

cost.

Production is given more preference. There is no question that production is order

of day but the Industry should not neglect its employees.

52

They do not have well organized marketing channels to distribute their product

outside the state.

In this competitive world, it is very difficult to run a business no matter what the

business might be, competition is in every field. People residing over there are not fully

aware of Khyber brand as it is been used In full fledged Work for Govt settlements.

Khyber Industries (P) Ltd. have a very poor leads upon advertising setups so the brand

awareness has not been settled properly till now. The unawareness of Khyber brand

doesn’t make it surround all over the regions of Kashmir. A survey on 25 employees of the company was done to find the production efficiency.

Chart.no.4.1 Responses of company employees in the form of a chart

53

0

10

20

30

40

50

60

70

80

90

100

1 2 3 4 5 6 7 8 9

QUESTIONS

PERC

ENTA

GE

Positive Response

Negative Response

Suggestions

Company should face competition with changing technology; it is very difficult to

stay ahead in present competitive environment in terms of quality commercial

viability and demanding ecological factors.

It is desirable to produce white Cement in future. As it is more impermeable than

other type of cements.

As per welfare measures facilities in the canteen should be improved.

The mining of lime stones is to be carried out scientifically.

The imported equipments eliminate drilling and blasting and provided scope for

selective mining.

They should introduce Just in Time (JIT), Economic Order Quantity (E.O.Q)

approaches.

The no. of the employees is 834 so the no of doctors and

medical staff at present is not adequate.

The safety masks and uniform should be of good quality and they should be

provided more in number.

The pits should be covered in the factory premises.

54

There are inadequate washing facilities. At only 3 places the washing facilitiesare

provided, which is felt inadequate by the large number of workers

Extra electrostatic precipitators should be used to reduce pollution as there is a

dusty atmosphere in the factory premises

Conclusions

The company produces quality cement OPC (Ordinary Portland Cement) in the

grade of 43 & 53 under the” Khyber brand “ to meet the growing needs of customers

although the company’s cement is best in the quality and meet the requirements of

Bureau of Indian Standards ( B.I.S)

Based on the analysis and discussion made in the study, the overall performance

of the company in the recent years is satisfactory. Compared to its past records it has a

good control over the market and has been able to utilize the opportunities and its

strengths to topmost level. It has achieved a new mile stone by conserving the energy at

all levels. The company is achieving increase in cement production every year. With the

establishment of the second unit the company is going to achieve more production and a

fittest competitor in the market. Environmental improvement has been a continuing

mission with Khyber Industries (P) Ltd.,with respect to the operational and the

technological aspects, apart from material conservation and ecological balance.

55

Bibliography and Appendix

56

Bibliography

Websites ;

1) www.goggle.com2) www.greaterkashmir.com3) www.Khybercements.com4) www.kashmiruzma.com

Books:

1) Principles of Marketing (Kotler S. Philip 11th Edition)2) Marketing Management (Saxena, Rajan, Tata McGraw

Hill)3) Case Studies in Marketing(Srinivas, Prentice Hall of India) 4) Human Resource and Personal Management (Ashwathapa)5) Managing People(Rao, V.S.P)6) Human Resource Management(Irwin)7) Financial Management(Chandra, Prasanna,TMH)8) M.Y.Khan,and P.K Jain(Tata McGraw Hill)

9) Financial Management(I M Pandey)

More information gathered from the material given by the

company for study purpose like company profile, annual reports.

57

Appendix

Chart.no.4.1 Month wise production plan

58

0

2

4

6

8

10

12

14

APRIL MAY JUN JULY AUG SEP OCT NOV DEC

MONTHWISE PRODUCTION PLAN ON 100% SALES YEAR 2007 - 2008

59