Traning Report22

INDUSTRIAL TRAINING REPORT 1

CHAPTRER-1 INTRODUCTION TO CEMENT INDUSTRY IN INDIA

Cement industry in India has made significant contribution to the country’s economic development. This is obvious because most of the development activities of the country involve construction works using cement. South Indian Industry Limited installed the first cement industry in Tamil Nadu in 1904 and then onwards number of factories manufacturing cement was started. In our country there are 51 companies and 99 plants having installed capacity of manufacturing 700 million KN of cement and with this installed capacity, the Indian cement industry is the largest in the world after China, Russia, Japan and USA. It accounts of about 4% of the world’s production. Some of the important highlights of Indian cement can be summarised as follows. 1. The energy consumption is substantially higher than that in efficient plants abroad. 2. The energy protection activities require be improving and updating. 3. The new technologies i.e. high efficiency separator, roll press, vertical roller mill, pre calcinators etc, have to be improved. 4. The requirements such as better packaging materials, bulk containers and ready mix concrete technology deserve immediate attention.

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CHAPTER-2 HISTORY OF THE COMPANY

The Travancore Cement Limited was incorporated in the year 1946. The year of commencement of Grey Cement in the year 1949. The licensed capacity of the plant was 50,800 Ts of cement per annum. The master-mind behind setting up of this factory was that of late Sir. C.P.Ramaswami Iyer, the then Devan of Travancore, who had realized the vital role of cement in the industrial development of Kerala. The company was promoted by M\s. Essel Limited, Bombay and the Technology tie up made with M\s. F.L.Smith & Co. Denmark. During 1959, the company diversified into the production of White Portland Cement. The installed capacity for the production of White Cement is 30,000 Ts per annum. Till 1974, the company was manufacturing both White Cement and Grey Cement in the same plant, disturbing the production of two over certain period in a year. Since 1974, the company manufacturing white Cement alone, as the demand for white cement went up. During the last 54 years of its existence, TCL has diversified its activities to relate areas. Besides Super Shelcem brand Cement paint, the company has added to its products ranges, Sheltex Acrylic Emulsion paint for interiors and exteriors and Shelprime Cement Primer. The Travancore Cements Limited is the only manufactured, perhaps in the whole world, producing White Cement from a raw material other than conventional limestone. The main raw material of TCL is lime shell, which is dredged out of Vembanad Lake, one of the DEPT OF MECHANICAL ENGG RIT KOTTAYAM

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back waters in Kerala. The company has successfully executed a diversification project for manufacture of Grey cement during the year 2000, with a capacity of 66,000 MT per annum.

CHAPTER-3 DESIGN OF STUDY

3.1 OBJECTIVE OF THE STUDY

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To understand the functioning of organization as a whole.

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To study the organizational structure.

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To study various department of the organization and their function.

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To know the organizational objectives and scope.

3.2 SCOPE OF STUDY

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The scope of the study conducted includes the study of aims of the company, various departments and their functions, various products and their production activities, quality control procedures taken by the company and the work culture of the organization. The study of the various departments would help in improvement their overall efficiency, by way of identifying deficiencies.

3.3 METHODOLOGY This study was conducted by visiting the head office of Travancore Cements Limited at Kottayam from February 2009 to June 2009. The information’s and data’s were collected by interacting with the managers, officers and workers and also made interviews. The further details about the production were taken by the direct observation of the plant process. Also some of the data’s regarding the past performance of the organization were collected by referring the annual report of the company.

CHAPTER-4 PROFILE OF TRAVANCORE CEMENTS LIMITED 4.1 MILESTONES IN THE HISTORY OF TCL •

Standard production of Vembanad Grey cement from lime shell in August 1949.

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Standard production of Vembanad White cement from lime shell in August 1959.

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Grey cement production stopped in 1976.

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Diversified into cement paint super shelcem production in 1977.

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Celebrate Silver Jubilee in 1982.

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Become a government company in April 1989.

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Celebrate Golden Jubilee in 1997.

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Launched Shelprime Dry Cement primer in January 2000.

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Diversified into Acrylic Emulsion Paint Sheltex for interiors and Exteriors in April 2000.

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Diversified into Grey cement production from bought outclinker in 2000.

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Become an ISO 9002 company in December 2000.

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Started HRD centre in 2002. Started production of “Vembanad Wall Putty” in 2008. TCL has implemented the Quality Management System and maintain best quality

throughout the production process. The row materials are taken by verifying quality and after and every production process they are testing the quality of sample in the laboratory. Thus customers are well satisfied with the products

4.2 LOCATION OF TCL The cement plant is situated on the bank of Kodoor River and on the bank of the state highway, M.C Road, 4KM away from the town of Kottayam in Kerala. The location of plant makes it accessible by road as well as by water.

4.3 BRANCHES AND OFFICES The company has its registered office and factory at Nattakom, Kerala. Also it has another registered office in Trivandrum, it has depots at Bangalore, Coimbatore and Vijayavada.

4.4 PROMOTERS OF THE ORGANIZATION DEPT OF MECHANICAL ENGG RIT KOTTAYAM

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At first TCL was under the control of private management till 1974 subsequently the government of Kerala took over the management and now the government holding 50.13% of the equally share capital. Another 25% of shares are provided by the Pyramid group of company and the remaining shares are held by General public.

4.5 OBJECTIVES OF THE ORGANIZATION The main objective of TCL is the production of Vembanad White Portland cement. It is the first and foremost product of the company. By quality, it is the best whit cement produced in India. The company is now engaged in the production of cement paint known as ‘Super Shelcem Cement Paint’ which is available in 42 different shades.

4.6 QUALITY CONTROL POLICY TCL has implemented the Quality Management system and best quality throughout the production process. The row materials are taken by checking its quality and after each and every production process they are testing the quality of sample in the laboratory. Thus customers are well satisfied with the products.

4.7 PROBLEMS FACED BY COMPANY The main problem faced by the company is the storage of row materials. The company has serve storage of lime shell which is the major row material for both the products of the company. The difficulty in commencing mining operations for lime shell in the company’s lease hold area at Vaduthala is affecting the lime shell availability. The issue is being sorted out. Now the company is obtained lime shell from ‘Chithira’ lake. The increasing use of oil and diesel is badly affecting the profitability of the company. Surplus labour is the another major problem faced by the company.

4.8 PRODUCTS The company is producing three types of products. They are, 1. White Portland Cement under the brand name “VEMBANAD”. 2. Cement paints under the brand name “SUPER SHELSEM” in 42 different shades. DEPT OF MECHANICAL ENGG RIT KOTTAYAM

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3. Wall putty under the brand name “VEMBANAD”.

1. VEMBANAD WHITE PORTALAND CEMENT It is the first place in Indian white cement market by its excellent quality and its quality is at pas with that of the best available in the world market. As compared to others brand it accounts for its superior whiteness and maintain its quality by using lime shells instead of lime stone. The white cement is the best suited for housing and construction of industries. Vembanad White Cement is quickly drying, process high strength and superior aesthetic values. Also it is good for floor finish, plaster and ornamental works. The miscellaneous application of white cement are in swimming pools, where it replaces the use of glazed tiles with coloured shades under water, for moulding sculptures and statues, for painting furniture’s. It is also used for ready mixed concrete and precast blocks and also fixing marbles and glazed tiles. Today the company enjoys the highest 8042 e-1976 specification.

SPECIAL FEATURES  Lowest magnetic content and hence most durable white cement.  Brilliant whiteness.  High strength.  Super soundness.  Super finishing.  Excellent properties.  Ideal for manufacturing cement paints, mosaic tiles etc.

APPLICATIONS DEPT OF MECHANICAL ENGG RIT KOTTAYAM

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 Pointing brick works.  Road marking.  Cast stone finish.  External rendering.  Mosaic tiles.

 Terrazzo flooring.  Primary coat for cement paints.

2. SUPER SHELCUM CEMENT PAINT In 1977 TCL started manufacturing cement paints under the brand name “SHELCEM”. It was rebranded as “SUPER SHELCEM” in 1986. Super Shelcem is a unique technology formulation with the most durable “VEMBANAD” white cement. It is an intimate mixture of Vembanad white cement, water proofing fungicides, oxide extends, non fading oxide pigments and hardening agents. Cement paint is water biased paint widely used for painting buildings. Unlike other cement paints, Super Shelcem doesn’t require water curing after first and second coat. Only initial wetting of the surface is necessary. This makes it ideal for exteriors of multi storied buildings and sky scrapers. Also it is ideal for interiors since, tedious curing after removing furniture can be avoided which means saving of labour. Once a wall is painted with Super Shelsem , it looks and stays good for years un affected by weather and fungal attack . Super Shelsem carries ISI marks and the approval of Bureau of Indian Standards, is E-1969. It is available in a wide range of colours of total 42 different shades in the market.

SPECIAL FEATURES

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 CAPACITY: Any previous deep shade made on the surface can be effectively

hidden with a single coat of Super Shelcem. The second coat completely covers the dark patches and stains on the wall.

 COVERAGE: Super Shelcem covers greater area than any other cement paint. 1Kg

covers 100 sq feet for a single coat or 65 sq feet for two coats.

 ADHESION: Super Shelcem can be applied on a wide variety of surface like

cement plaster, concrete, brick work and plastered surface.

 DRYING: Super Shelcem dries very quickly. While other cements paints requires

16 to 24 hours waiting time for applying the second coat, Super Shelcem need only 3 to 6 hours after the first coat.

3. VEMBANAD WALL PUTTY Vembanad Wall Putty was introduced in the last year, i.e. in 2008. It is dry powder putty with Vembanad White Cement as the base. By the low content of MgO in Vembanad White Cement, the putty when applied on the cement plastered wall and ceiling will ensure durability, extra coverage and smooth finish. Vembanad Wall Putty can be applied on freshly plastered surface also. Like other products of TCL, Vembanad Wall Putty is also excellent in quality. Before applying wall putty, one or two coats of Vembanad White Cement is recommended to be applied on the newly plastered wall.

SPECIAL FEATURES  Quality tested Vembanad White cement is used for making wall putty.  Its production process goes through the strictest quality test.  It has a unique formulation. DEPT OF MECHANICAL ENGG RIT KOTTAYAM

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 It has more coverage than any other wall putty in the market.

CHAPTER-5 ORGANIZATION STRUCTURE

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The Board Directors consists of five persons of which one is full time Managing Director. Under the General Manager there are five Chief Managers, i.e. for Finance, Personal, Production maintenance, Marketing and Purchase. The maintenance manager is responsible for departments of dredger, civil and sanitary, water and general transport, workshop and electrical. The production manager is responsible for the departments of white cement plant, kilin, packing house, shelcem, lab and quality control. The purchase manager is responsible for the departments of purchase, stores and shelcem. The finance manager is responsible for the departments of accounts. Finally the personal manager is responsible for the time office, personal department, office and guest house.

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CHAPTER-6 PERSONNEL DEPARTMENT DEPARTMENT STRUCTURE

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It is the department which is connected to other departments in TCL. This department is headed by Joint General Manager. Under him Joint Chief Manager followed by Junior Executive and office assistance. The recruitment and selection of the personnel are owned by this department. Another important function of personnel department is to loot into welfare of its employees. Time office comes under this department. The function of time office is to maintain leave register, attendance making, overtime confirmation etc. The above data is forwarded to the accounts department for accounting the wages of employees.

1. EMPLOYEE POTENTIAL In TCL are totally 595 employees, which include 24 officers. The officers of the TCL are further classified into: •

General Manager

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Manager Grade

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Special Grade

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Class one Grade

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Class two Grade

People working in the office, a security and a senior employee in the plant come under the staff category. The grade of staff varies from 1 to 7. It being the lowest grade and 7 being highest grade. Workers in TCL are classified into: 1. Permanent 2. Probation 3. Temporary 4. Casual 5. Apprentice The grades of workers vary from A to E. E being the lowest grade A being highest.

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1. TIMING The office time of TCL is from 9 am to 5 pm. On Sundays the working time is from 9 am to 1 pm. The factory is working on the shift basis. 1. 3 continuous shift of 5 hours each 2. 2 special shift to 8 hours each 3. Special shift for special work of 8 hours 4. A general shift of 8 hours

3. MAN POWER PLANNING Man power planning is a key economic resource of an organization. Man power planning is the process by which a firm ensures that it has right number and right kind of peoples at right places. Man power planning includes a series of activities consisting of the following: 1. Forecasting 2. Anticipating man power status 3. Planning

4. SALARY AND WAGES Salary and wages to be paid to the employees are determined on an agreement between CMI and Trade Union. In TCL pay revision is done by every 4 years.

5. LEAVE PATTERN There are 14 days of casual leave and 12 days of sick leave. For non-staff workers 18 days of privilege leave are allowed and for officers 30 days.

6. RECRUITMENT AND SELECTION

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Recruitments is done through direct application and through employment exchange. Selection is mainly based on written test and interview. Selected person will have undergo a period of training. The training period is usually six months and for higher post it may extended to one year or more. Every worker is liable to be transferred from one department to another and one job to another according to experience of work in the factory.

7. TRADE UNIONS The recognized trade union. In the company are: 1. Travancore Cements Workers Union 2. Kerala Cement Workers Union 3. Travancore Workers Union 4. The Kottayam Cement Workers Union

8. CANTEEN A fare price canteen is operating at the premises. The employees are given Rs. 30 per day of attendance. Maximum Rs.900 per month is allowed by the company.

9. WELFARE FACILITIES PROVIDED BY THE COMPANY Uniform

3 pairs of uniform once in two years

Foot wear allowance

Every year

Umbrella

Once in two years

Rain coat

Once in three years

Washing soap

Two half bars in a month

Toilet soap

Two numbers in a month

Turkey towel

Every year

10. COMPANY SCHOLARSHIP Company is giving scholarship to the children of employees. DEPT OF MECHANICAL ENGG RIT KOTTAYAM

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For S.S.L.C, P.D.C, to Degree & Diploma Rs. 700/- for 1st highest rank. Rs 500/- for 2nd rank.

12. DEATH BENIFIT Rs. 5000/- will be given to the department of the deceased employee to meet the expenses in connection with funeral.

13. TOUR Inside Kerala and outside Kerala For staff and officers- one in an year For workers-Two each

14. TRANSPORTATION Free transportation facility provided to employees for coming and return after duty. For the children of employees for attending education institution in and around Kottayam.

15. FACTORY DAY COMPLIMENT Every year

16. SPECIAL ADVANCE For medical treatment up to maximum Rs. 15000/- is allowed for all members and for marriage expense up to maximum Rs. 25000/- is allowed.

17. LOAN SCHEME Two wheeler/cycle loan is allowed for all employees and car/computer loan is allowed for all officers.

18. COMPANY’S PPRODUCT AT CONCESSIONAL RATE Super shelcem cement paint and Emulsion paint are sold to employees at factory gate price.

19. QUARTERS FACILITY DEPT OF MECHANICAL ENGG RIT KOTTAYAM

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A limited number of employees are provided with quarters with free electricity and water.

20. RECREATION FACILITY Recreation facility for indoor games, reading rooms with newspaper and periodicals, T.V with cable facility.

21. TRAINING AND DEVELOPNENT There are both internal and external training for workers and employees, and it is conducted by the HRD centre under the supervision of the Personnel Development. Job rotation is allowed only for officers. Conference, talks, workshops, etc. Are conducted as part of training and development.

22. WELFARE FUND SUBSCRIPTION Company is contributing Rs. 10/- per member towards monthly subscription.

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CHAPTER 7 PURCHASE DEPARTMENT DEPARTMENT STRACTURE

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The purchase and store department plays an important role in the proper functioning of the entire organization. This department comes under the material management. It has a common department head and he look after all the activities relating to raw materials and other general consumer thing.

ADVANTAGES OF PURCHASE DEPARTMENT IN TCL 1. Because of centralized purchasing of materials, favourable terms, eg. Trade discounts or economic in transportations can be obtained because quality will be large. 2. The purchasing department can be staffed with highly paid officials who are experts in the art of purchasing the materials. Specialized knowledge and skill of this persons can be utilized. 3. All records with regard to purchase are kept at one place under the supervision of

the purchase officer. 4. Helps in achieving following uniform purchasing policies, practices and procedures. 5. It avoids duplication of efforts and is helpful in achieving standard products.

1. FUNCTIONS OF PURCHASE DEPARTMENT IN TCL The main functions of purchase department are  Placing order  Inviting quotations  Correspondence Following steps are taken to perform the above functions

STEP 1: Purchase requisitions or indenting for materials

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The purchase officer does not initiate any action for purchase of materials on his own record. With the help of purchase requisitions the purchase officer come to know the types of materials needed by the organization. A purchase requisition is a formal request for the purchasing department to purchase materials.

STEP 2: Exploring the sources of supply and selection the supplier A source of supply materials is to be selected after the receipt of purchase requisition. In TCL, the process of choosing the supplier is not a hard task. The shopkeeper generally mentions the name of the current suppliers, their price quotations, and the purchase department also has a series of good suppliers. Choosing the right supplier from the suppliers list involves a process of comparative statement of purchases. It is a statement prepared by the purchase department.

STEP 3: Purchasing order After choosing the supplier, the purchase department prepares order of the supply of sores. The order is a written authorization to the supplier to supply the particular material or materials. It is the evidence between the buyer and the supplier having the terms and conditions of the purchasing order.

STEP 4: Receiving and inspecting materials In large concerns, a separate Receipt and Inspection department independent of stocking location should be set up to receive and inspect the materials. But in small concerns this work is done by the stock keeper. In TCL, the stores department makes the general purchase only. This contains 22 classes of items needed for various consumable departments. When goods are received in stores the consuming department is informed and the personnel’s form this department come to stores and inspect the quality etc.

STEP 5: Checking and passing bills of changes After checking the bills are passed. Generally the payment terms of TCL are,  Against invoice or acceptance of stock a minimum 15 days credit.

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 In case of monopoly suppliers, they are sent/paid through banks.

2. CONDITIONS REGARDING RECEIPT OF GOODS  If the suppliers are within Kerala a time within 15 days of sending/inviting quotations.  If supplies are outside Kerala a period within 20 to 30 days  The company makes local purchase itself within 2 to 3 days.

3. PURCHASE LIMITS In TCL, they followed an authorized purchasing system. The purchase units are as follows 1) Below and up to Rs.5000, purchases are maintained by Junior Manager and sanctioned by Chief Manager Purchase in charge. 2) Rs.5000 to Rs100000, Chief Manager should sanction it. 3) Rs.100000 to 5000000, it should be signed and approved by Managing Director. 4) Rs.5000000 and above, approved by sub Committee/Board of Directors.

4. STORE LOCATION LAYOUT The location of stores department could be carefully planned out and it should be housed in a position which is very near to receiving department so that transportation charges at a minimum. In TCL, stores department is very near to the consumable department.

5. STOCK LEAVEL In stores, items are divided into three levels namely

1) Maximum level This represents the maximum quality of materials which must be maintained in hand at all items. While fixing this level, TCL considers following facts  Rate of consumption of materials.  Amount of capital available. DEPT OF MECHANICAL ENGG RIT KOTTAYAM

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 Storage space of available.  Cost of maintaining store.  Risk of obsolescence.  Re-Order quantity.

2) Minimum level This represents the minimum quantity of materials which must be maintained in hand at all items. This quantity is so fixed that the production may not be held up due to shortage of materials. While fixing this level, TCL considers the following.  Normal rate of material consumption.\  Lead time.  Re-Order level.

3) Re-Order level It is the point at which the stock of particular material reaches the re-order quantity. The storekeeper should invite the purchase requisition for fresh suppliers of that material. While fixing this leave TCL considers following factors,  Maximum delivery time  Maximum rate of consumption  Minimum level

6. FUNCTION OF STORE KEEPER One of the duties of the store keeper is to send requisition for materials for replenishment in time so that the production may not hamper for want of materials. The store keeper

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requisites the items need which are generally depending on the consumption pattern of various departments.

7. ADVANTAGES OF CENTRALIZED STORES 1. Better control can be exercised over stores because all stores are housed in one department. 2. Better layout of stores is possible. 3. Investment in stock is minimized. 4. Economy in cosy 5. Economy in staff and concentration of experts in one department will leda to development in high technical skill. 6. Less botherisation Inventory checking are required,

8. STORES RECORD The Bin card and Karde-X card are the two important stock records that are kept in TCL for making a record of various stores.

9. BIN CARD A bin card makes a record of the receipts and issue of materials and is kept for each item of stores carries. Quantity of stores received are entered in the receipt of stocks are recorded in the issue column of the bin card is usually hangs up or placed in shelf, rack, or bin where the materials have been kept.

10. KARDE-X CARD DEPT OF MECHANICAL ENGG RIT KOTTAYAM

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This card is used in TCL by store keeper in addition to the bin cards for storing list of stock of items. TCL does not maintain a store ledger, instead of this all the details are stored using software in computer. The existing system is a FoxPro biased system.

CHAPTER 8 PRODUCTION DEPARTMENT DEPARTMENT STRACTURE

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The production and service department control and coordinate the production process can be mainly divided into three stage; they are slurry preparation, clinker making, and clinker grinding. The total numbers of workers in these three stages are 75 with 17 employees in a shift.

1. PROCESS OF MANUFACTURING DEPT OF MECHANICAL ENGG RIT KOTTAYAM

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The two main process of Travancore Cements Ltd. Are Vembanad White Portland Cement and Super Shelcem Cement Paint. Here we are discussing the manufacturing of Vembanad White Cement and Super Shelcem Cement Paint. The TCL produces Vembanad White Cement using the Rotary kiln and wet process technology which is patented by F.L Smidth and company Denmark.

2. RAW MATERIALS Vembanad White Cement is manufacturing from natures gift of rare raw materials which are unique in consistent purity. The company is using high quality raw materials and wet process in order to maintain the quality of its products. The main raw materials are lime shell, white clay, white sand and Crystal gypsum. a. LIME SHELL Lime shells are found as under water depots in the Vembanad lake. Chemical analysis of lime shells reveals that almost 99% accounts for calcium carbonate (CaCo3). While the presence of usual impurities like iron and magnesium compounds are negligibly insignificant. Vembanad white cement has the distinctive feature of being only cement that is manufactured form lime shell. b. WHITE CLAY white clay are crude china clay is obtained from southern parts of Kerala, particularly from Trivandrum district. These white clay depots of Southern Kerala are famous for their purity and high ceramic properties. The milky white clay, which is in paste form, go into the manufacturing process of Vembanad White Cement, is almost 85% pure Hydrated Aluminium Silicate. c. WHITE CLAY The white sand is obtained from the coastal areas of Chertala in Kerala, which is accounts of purity up to 95%. d. CRYSTAL GYPSM

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PRODUCTION PROCESS OF VEMBANAND WHITE CEMENT The basic cement making process consist of collecting the row materials, grinding them to a fine stage, blending them to a uniform composition and heating them to the point of sufficient fusion when the cement compounds are formed. Portland cement is the product obtained by cooling and grinding the clinker thus formed with gypsum to a fine powder. Production process can be mainly divided into three stages: •

Slurry preparation

•

Clinker making

•

Clinker grinding

The different processes under these main stages are: 1. Dredging 2. Unloading station 3. Wash mill 4. Shell-sand grinding(Ball mill) 5. Slurry making(Raw mill) 6. Slurry section 7. Clinker making(Kiln) 8. Clinker grinding(Cement mills)

1. DREDGING The main raw material for the production of Vembanad White Cement is lime shell an underwater deposit in Vembanad Lake, is dredge and brought and brought to the company by means of power bargers. The company has two dredgers, one hydraulic dredger and one mechanical dredger. The capacity of two dredgers may about 30 tonnes/hour. The dredger can cut the lime shell DEPT OF MECHANICAL ENGG RIT KOTTAYAM

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around 40 feet maximum depth. The dredger works on two powerful engines, a dredger pamper engine and an auxiliary engine.

2. UNLOADING STATION The shell brought by Barger from lake is unloaded here. Shell in barger is diluted with about 60% of water by means of diluting pump for easiness of sucking. A sucking pump draws water along with the shell to receiving tank near the rotary grill of screening plant. The shell is then passed through the rotary grill and waste materials are washed out during its rotation. Cleaned shell is either passed through the belt conveyors through hoppers or stored out. There are two rubber conveyors (Conveyor 1-short and straight, conveyor 2long and inclined) for conveying the shell to the ball

3. WASH MILL Before actually used for the process clay is mixed with water. This work is done in a clay wash mill. Clay is put into the mill and about 65% of water is also added during the grinding. During the hammering action of the weights provided in the wash mill clay is made to slurry is pumped to the storage tank known as silo. From silo, it is taken for process when required.

4. SHELL-SAND GRINDING Slurry preparation is the fourth stage in the production process of whit cement. Slurry is a mixture of shell, sand and clay with around of 40% of water. For slurry preparation two grinding mills are used: •

Roughing mill known as ball mill

•

Finishing mill known as row mill

Ball mill is a cylindrical shell of welded metal plates. The shell around required amount of white sand and water is fed to the ball mill by rotating feed table. When the mill rotates the materials are crushed down to the small particulars while it passes through the ball. The materials coming out of the ball mill is diverted to a hammer

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screen by means of slurry elevator. Fine material come out of the hammer screen is fed to the row mill. The coarse material return to the ball mill for further grinding.

5. SLURRY MAKING The row mill is hollow cylindrical shell, the inside of which is line with flint blocks. The shell lining are avoided to reduce the contamination of slurry by iron. The grinding media is used is Flint Pebbles. The mill is rotated by a motor at constant speed while passing through the mill, the fine materials discharged from ball mill and clay pumped from clay silo are finally ground and comes out as a party material known as slurry which then flows to slurry pit.

6. SLURRY SECTION Slurry discharged from the row mill is stored in silos by means of pipes. The chemical composition of the slurry will be adjusted by this stage. There are three silos for storing the slurry. From these silos slurry is pumped to the slurry basin. In the basin slurry is constantly agitated with compressed air and stirring mechanism. From the basin, slurry is taken from burning in the kiln.

7. CLINKER MAKING kiln is a cylindrical steel lined with refractory bricks mounted at an inclination of 30˚ on roller supports. The kiln having a length of 285 feet with diameter of about 9 feet and is rotated at about 1rpm by an electric motor. During the process of slurry passes through three stages: 1. Drying zone 2. Calcinations zone 3. Burning zone In the drying zone about 99% of water content in the slurry will removed. In the calcinations zone the removal of CO2 take place. After that the materials enters the burning zone. The clinker is formed in the burning stage by fusing Diclacium Silicate, Tricalcium silicate, and Tera calcium Alumino Ferrite at about 400˚ C. There after the clinker is cooled by flow of air. Clinker come out of the cooler will be usually in the modular form. DEPT OF MECHANICAL ENGG RIT KOTTAYAM

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8. CILNKER GRINDING The cooled clinker is grinded is very finely to make white cement. Clinker grinding take place in the cement mill. There are cement mill A,B&C with clinker grinding capacity of 60 tonnes, 50 tonnes, 50 tonnes respectively. The mills B&C are identical in nature. During grinding, small quantity about 3% to 4% Gypsum is added. The Gypsum controls the initial setting time of cement. If gypsum is not added, the cement wouldn’t set as water is added. The gypsum act as retarder and it delays the setting action of cement. It thus permits cement to be mixed with aggregate and to be placed in the position. The cement coming out of the mill is conveyed to claufies by means of bucket elevator. In the separator, causes particles are separated and they flow to the mill while fine particles flow to the Flaxo pump, which is operated by compressing air. Using Flaxo pump cement is transferred to the cement silo located at the packing house.

9. PACKING AND DISPATCHING The white cement stored in silos is packed in paper bags in the packing house. Compressed air is used for the free flow of the cement from the Silo and hopper located above the packing machine. While the bag is filled with 50Kg materials discharges from the spout is automatically transferred to truck through a fixed point belt conveyer and a movable belt conveyer. The filled bags fall down from the spout to the wire net conveyor and are transferred to truck through a fixed point belt conveyer and a movable belt conveyer .

CEMENT PAINT DEPARTMENT Paint is a surface coating which decorates and protects the surface on which it is applied. Paint is a mixture of four elements they are: 1. Solvents 2. Binders 3. Pigments 4. Additives The total paint market is broadly categorized into four segments: 1. Architectural finish or decorative paints DEPT OF MECHANICAL ENGG RIT KOTTAYAM

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2. Industrial finish-general industrial sector automobile sector 3. Heavy duty coatings 4. Marine paints Decorative paints are largest market segment and constitute around 75% of the market share. Super shelcem is self curing cement paint manufactured by TCL. It is an inmate mixture of White Portland Cement, water proofing compounds as oxide extender, non fading oxide pigments hardening agent and fungicide. Super Shelcem unlike other cement paints does not require water curing after first and second coats. Unlike other paints, metal primer is no require while using the paint. Only initial willing of the surface is necessary. This makes Super Shelcem ideal for exteriors of multi storied building and sky scrappers. For interior too Super Shelcem is ideal. It carries ISI marks and is available in a wide range of colours-40 shades to be precise. Now wall putty is also produced in this department, but the major production is in Chertala unit.

CHAPTER 9 MARKETING DEPARTMENT DEPT OF MECHANICAL ENGG RIT KOTTAYAM

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DEPARTMENT STRACTURE

INTRODUCTION

DEPT OF MECHANICAL ENGG RIT KOTTAYAM

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Marketing is defined as the process of identifying the needs and wants of the consumer and producing goods and services to satisfy their needs and wants. The marketing department of TCL is concerned the marketing of it s various products. The department has various techniques to market their products. This department is headed by general Manager Marketing, under him Junior Manager in marketing, superintendent followed by sales superintendent and sales representatives.

MARKETING DISTRIBUTION CHANNEL Company

Depots

Stockiest

Dealers

Customers

TCL have 40 stockiest of white cement, 300 dealers of paint, 2000 dealers for white cement in Kerala and 70 stockiest and 50 dealers for white cement in Tamil Nadu.

MARKETING ACTIVITIES TCL has a well established marketing department. There is an efficient sales force which is under marketing. The whole system comes under the General Manager, TCL has got 14 sales representatives throughout Kerala

PRODUCTS The company produces two products and they have good markets. They are: 1. Vembanad white Cement 2. Super Shelcem Cement Paint These products are well established and have good demand in the market. Vembanad White cement has 70% market share and Super Shelcem Cement Paint has 30% market share in Kerala. Vembanad white cement is also transported to Tamil Nadu. A sales representative goes around the state for collecting the order than the networks. TCL also supplies to various government agencies like PWD, FACT etc at special rates

PRICING OF PRODUCT DEPT OF MECHANICAL ENGG RIT KOTTAYAM

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The price for 1Kg of Vembanad White Cement is Rs.11.90/-. For 50Kg of white cement is Rs.580. For Super Shelcem Cement Paint 5Kg is priced at Rs. 114.25/- and for jute bag Rs.60.80/-. These products are priced very high mainly because the raw materials particularly lime shell and white clay is scared.

SALES PROMOTION TCL has an advertisement budget of 25 lakhs per annum. Since the amount is too small the company is advertising at a low level. Other promotional activities include, conducting dealers meeting once in two years. In addition to these the company offers various incentive schemes for its details according to their sales performance. Due to very low advertisement budget the company does not engage in any large scale type of advertisement activities. The company occasionally engages in advertisement through news papers, magazines etc. the main modes of advertisement are displaying boards which are positioned where they get maximum attention. They also use Asianet cable vision, wall painting etc.

DISCOUNT ALLOWED BY TCL TCL gives trade discounts of 10% and each discount of 4% for purchase of 250Kg and above. The company allows 3% discount on freight allowances and 3% on special discount. In every three months, the company gives 1% quantity discount for 200Kg, 2% for 500Kg. They also give annual discount of 3%.

MARKET SHARE The cement paint industry is divided into organized and unorganized sectors. The major players are in the organized sector, however major of the brands come from unorganized sector. TCL has 40% of market share of white cement and 33% for Super Shelcem Paint in the cement industry of Kerala.

COMPETITION The company is facing through competition from white cement from internal manufacturers and also from imported white cement, JK White, Birla, RKC, etc. are the major competitors in white cement sector. In the cement paint sector there are about 14 brands to compete with Super Shelcem. The major competitors are Durocen, Trucem, Snowcem etc. DEPT OF MECHANICAL ENGG RIT KOTTAYAM

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CHPTER 10 FINANCE DEPARTMENT DEPT OF MECHANICAL ENGG RIT KOTTAYAM

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DEPARTMENT STRACTURE

There are mainly three sectors in the finance department of TCL namely accounts section, finance section and cash section.

ACCOUNTS SECTION DEPT OF MECHANICAL ENGG RIT KOTTAYAM

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The most important task done by account section is the recording of day to day accounts. Routine account functions like sales tax payment, receipts and payment of cash, cheques etc. come under the preview of the accounts section. The employee payroll function is also undertaken by the accounts section of finance department.

FINANCE SECTION Finance section is mainly concerned with maintenance of accounts. The various functional statements are kept in the computer as well as in the manual form.

CASH SECTION The cash section is connected with the disbursement of cash.

ACCOUNTS POLICIES The accounts of TCL are prepared in accordance with the accounting policies accepted in India and in line with the relevant laws as well as the guidelines prescribed by the department of company affairs and the Institute of Charted Accounts of India and in accordance with section 211(3c)

SYSTEM OF ACCOUNTING The company adopts the accrual basic in the preparation of the accounts.

FIXED ASSETS Fixed assets are capitalized at coast inclusive of expenses. Depreciation is provided on all fixed assets except machinery for erection and free hold land, on reducing balance method.

INVENTORIES Raw materials, stores and spares and work in progress are valued at coast. Finished goods have been valued at coast or market prise whichever is less and does not include excise duty, except in case of stock at depots.

SALES Sales are inclusive of excise duty and sales tax and are net of trade discount. DEPT OF MECHANICAL ENGG RIT KOTTAYAM

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TREATMENT OF GRATUITY The company has formed a Gratuity Trust and taken group gradually policy of Life Insurance Corporation of India w.e.f.28/03/1995.

PROVIDENT FOUND Contribution to P.F. are made monthly in accordance with the Employees Provident Fund and Miscellaneous Provision Act 1952.

CHAPTER 11 MAINTENANCE DEPARTMENT DEPT OF MECHANICAL ENGG RIT KOTTAYAM

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ELECTRICAL SECTION The total number of employees working in the electrical maintenance section is 24, out of which 12 employees are concerned with electrical maintenance of the plant and other 12 undertake the maintenance work of the power plant. The company has its own substation for power supply. The main activities undertaken in the electrical section of the maintenance department can be discussed as follows. The electrical section is undertaking mainly three types of maintenance works, they are: •

Breakdown maintenance

•

Preventive maintenance

•

Shutdown maintenance

1. BERAKDOWN MAINTENANCE In case of any breakdown maintenance in the production departments, information’s regarding the breakdown is given to the maintenance department, and subsequently maintenance workers are sent to the production department to solving machine solving the machine failures.

2. PREVENTIVE MAINTENANCE Under this activity, a team of maintenance workers is sent directly to the production plants to check out whether there is any failure in the machinery or not.

3. SHUTDOWN MAINTENANCE When the plant is shutdown the employees in the production department sent a letter to the maintenance department and successive steps are taken by maintenance department to solve the failures.

MECHANICAL SCETION All mechanical works are undertaken by the mechanical section of the maintenance department. The company the company has a workshop under the control of this department. There are nine sub divisions for the mechanical section. They are: DEPT OF MECHANICAL ENGG RIT KOTTAYAM

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1. Fitter 2. Automobile section 3. Diesel machine section 4. Welder 5. Turner 6. Blacksmith 7. Carpenter 8. Khalasis 9. Tool section Total number of workers in the mechanical section is 72, out of which 4 are changed hands and foreman and an attender. The rest include the officers and other skilled workers.

CHAPTER 12 OTHER DEPARTMENTS Instead of the above discussed TCL have some other departments. They are: 1. Laboratory department 2. Transportation department 3. Workshop department 4. Dredger department 5. Time office department 6. Civil engineering department 7. Security department

1. LABORATORY DEPARTMENT

DEPT OF MECHANICAL ENGG RIT KOTTAYAM

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TCL has its own laboratory which continuously striving to maintain the quality of the products. There are three levels of testing conducted in the laboratory. They are:

a. RAW MATERIALS The row materials are tested for ensuring the quality of the product even before manufacturing.

b. PROCESS TESTING Process testing is done before the grinding of lime shell, sand and clay.

c. INTERMEDIATE TESTING In this level the slurry is tested for finding that whether it contains the right propotion of lime shell, sand and clay. Then the slurry is taken to the kilin for burning.

2. TRANSPORTATION DEPARTMENT Mainly water transportation facilities are used for bringing lime shell from Vembanad Lake. The company has two dredgers for which one is hydraulic and other is mechanical. There are six wooden bargers. Capacity of a barger is 70 tonnes approximately. Dredger is used for cutting and sucking lime shell for the river bed. The bargers are use for transporting lime shell to the unloading station. There are four workers in a darger, a foreman, a change hand and two operators. The capacity of two dredger is about 30 tonnes/hour. The cutter of the dredger is about 10 meter in length. There are six workers in a barger, a srank, a lasker, and four helpers. Tthe company has six steel bargers. The capacity of wooden barger is 70 tones and the steel barger is 400 tonnes.

3. WORKSHOP DEPARTMENT The company has one workshop under the control of the mechanical maintenance department. All machinery works and repairs are undertaken in the workshop. 76 memberes are in the workshop.

4. DREDGER DEPARTMENT

DEPT OF MECHANICAL ENGG RIT KOTTAYAM

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The dredging of lime shell from Vembanad Lake is controlled by the dredger department. There are 67 employees in this department.

5. TIME OFFICE

DEPT OF MECHANICAL ENGG RIT KOTTAYAM