ORGANIZATION STRUCTURE TRAINING

AT
ECO PLUS CEMENT & STEEL

A Report submitted in partial fulfillment of the requirements for the degree of

Master of Business Administration

By

RAJI SARVESHWARI SINGH

REGISTER NUMBER
1828636

Under the Guidance of

PROF. SATHIYASEELAN B

Institute of Management
CHRIST (DEEMED TO BE UNIVERSITY), Bengaluru

JUNE 2018
 ORGANIZATION STRUCTURE TRAINING
AT
ECO PLUS CEMENT & STEEL

A Report submitted in partial fulfillment of the requirements for the degree of

Master of Business Administration

By

RAJI SARVESHWARI SINGH

REGISTER NUMBER
1828636

Under the Guidance of

PROF. SATHIYASEELAN B

Institute of Management
CHRIST (DEEMED TO BE UNIVERSITY), Bengaluru

JUNE 2018
 Declaration

I hereby declare that the Organization Structure Training report on ECO CEMENT Ltd., has
been undertaken by me for the award of Master of Business Administration degree. I have
completed this study under the guidance of Prof. Sathiyaseelan B..

I also declare that this Organization Structure Training report has not been submitted for the
award of any Degree, Diploma, Associate ship, Fellowship or any other title, in
CHRIST(Deemed to be University) or in any other university.

Place: Bengaluru ______Signature_____________

Date: Raji Sarveshwari Singh

1828636
Certificate by Corporate in Letterhead
 Acknowledgement

I am indebted to all the people who helped me accomplish this Organisation Structure
Training successfully.

First, I thank the Vice Chancellor Dr Fr Thomas C Mathew, CHRIST (Deemed to be

University) for giving me the opportunity to do my project.

I thank Dr Suniti Phadke, Dean, Prof. Georgy Kurien, Associate Dean, Prof.
ShrikanthRao, Head of the Department, Institute of Management, CHRIST(Deemed to be
University) for their kind support.

I thank Prof. Sathiyaseelan B. for his support and guidance during my training. I
remember him with much gratitude for his patience and motivation, but for which I could not
have submitted this work.

I wish to express my sincere thanks to my corporate mentor, Mr Bipin Agarwal, Director,

ECO Cement Ltd., for giving me an opportunity to work under his guidance and successfully
complete my training.

I thank my parents for their blessings and constant support, without which this training
would not have seen the light of day.

Raji Sarveshwari Singh

1828636
Chapter Page
TABLE OF CONTENTS
No. No.
1 INTRODUCTION TO ORGANIZATION

2 SWOT ANALYSIS

3 ORGANIZATION STRUCTURE

4 FUNCTIONAL DEPARMENTS

FUNCTIONAL HIGHLIGHTS ACROSS KEY RESULT

5
AREAS

FINDINGS, RECOMMENDATIONS AND

6
CONCLUSIONS

REFERENCES / BIBLIOGRAPHY
 CHAPTER 1
INTRODUCTION TO
ORGANIZATION

Background
The groundwork was laid down in year 1998 when ECO CEMENTS LTD was
established as a producer and supplier of Ordinary Portland Cement, Portland Slag
Cement and Portland Pozzolana Cement. Later, ECO CEMENTS LTD expanded
its cement production capacity to meet the fast growing construction industry
within Uttar Pradesh and Bihar. Since its inception, the brand has been focused and
associated with quality and customer satisfaction.
Recognizing the rapid growth for Cement and Construction materials, ECO
CEMENTS LTD, in the year 2012, marched ahead and installed one 10, 00,000
MT per annum capacity state-of-the-art cement manufacturing unit for grinding
Portland Pozzolana Cement at Kulhariya, Durgawati, Bhabhua District of Bihar.
This unit was inaugurated by the Hon’ble Chief Minister of Bihar, Shri Nitish
Kumar on 5th August, 2012.
Today, with more than two decade experience in Cement Manufacturing and its
allied products, ECO CEMENTS LTD has gained unparallel expertise in the areas
of Product Quality and Human Resource, equipped with latest and advanced

technology to meet its Customer’s Full Satisfaction. Their quality products have
been backed by extensive marketing efforts, which ensure visibility & availability
of our products in the markets. It is these attributes that have earned Eco Cement,
the trust and goodwill of the construction industry and the market. Today, due to
their goodwill and commitment; ACC, India’s No. 1 Cement Brand has joined
hands with them.

MISSION/VISION

To develop novel bio-mimetic technology for enzyme-based microbial carbonate

precipitation through the revalorization of industrial waste as raw materials, in
order to produce eco-efficient environmental cement.

OBJECTIVES

The overall aim of the project is to develop an industrially suitable cost-effective

biomimetic process for the production of Eco-Cement. The project will have a
research, development and demonstrative character with the following scientific
and technical objectives:

To investigate the use of cement industry wastes, specifically solid alkaline

industrial wastes, as raw materials for the production of Eco-Cement.
To investigate
To test the Eco-Cement technology with a pilot-scale trial.
 To evaluate the potential for energy saving, waste revalorization and reduction
of emissions of Eco-Cement.

Quality Systems, Quality Products

As cement is an indispensable component of the construction industry, with

activity directly linked with people and their safety, Eco Cement makes no
compromise on the quality of our products.
With vast experience in cement manufacturing field, ECO CEMENTS LTD holds
strong positions across several key areas of the technology spectrum. In its
consistent pursuit of quality standards, ECO CEMENTS LTD successfully
acquired ISO 9001 in 2008.
At ECO CEMENTS LTD, quality control begins right from the selection of raw
materials. Clinker, granulated furnace slag and additives such as gypsum are
imported from various sources wherever these are available and meet our Product
quality is ensured, by selecting the ingredients with stringent and elaborate quality
checks, to surpass requirements laid by Bureau of Indian Standards vide IS 1489,
IS 8112 & IS 12269 for PPC, 43Gr OPC and 53Gr OPC.
ECO CEMENTS LTD has installed state of the art, Distributed Control System
(DCS) to operate the plant from Central Control Room (CCR) with latest
equipment for proportioning the ingredients and to feed the raw materials without
variation so as to have consistent product quality.
By adopted stringent quality control checks, starting from selection of the best
quality raw material as per our own internal standards and checks at every stage of
manufacturing process, till final product is pumped to cement storage silo, we
guarantee unwavering confidence to our valued customers. Quality Control
Laboratory is well equipped with X-Ray Analyzer, Particle Size Analyzer, Flame
Photometer, Heat of Hydration, Digital Compressive Testing Machine and all other
equipment which are required for testing physical and chemical characteristics of
cement.
In addition to Portland Pozzolana Cement, ECO CEMENTS LTD will shortly offer
to its valued customer special cement such as Super-Sulphated Cement. Having
wide range of quality products,

ECO CEMENTS LTD ensures meeting customer requirements under the same
roof. ECO CEMENTS LTD provides cement by 50Kg, block bottom PP Bag,
Paper Bag and Loose Cement through Bulkers.

Environmental Responsibility

Responsibility towards environment is at the forefront of ECO CEMENTS LTD

daily business operations. They recognize that their long-term success depends on
their ability to keep the environment clean and as a responsible entrepreneur this
aspect was taken care at the time of conceptualizing the unit. To maintain clean
environment ECO CEMENTS LTD have built Concrete
Storage silo for Clinker and Fly ash and Covered Storage Yard for other raw
materials and installed Bag Filters at all the material transfer and cement loading
points. This is also evident by the fact that the plant is laid-out with the Concrete
roads all over and recently completed landscaping project. They say- It is our
endeavors to maintain equipment and machineries in perfect condition by adopting
condition based and preventive maintenance philosophy. We have ensured that no
waste material is generated by the process which may cause bio- degradation and
we take pride in confirming that ECO CEMENTS LTD is Zero waste generating
factory.

Cementing the Future

At ECO CEMENTS LTD, they are focused on delivering the commitment of

providing products and services based on global expertise, trust and
professionalism–their core strengths. Operating in a highly competitive market, the
company maintains its lead by consistently engaging expert professional,
improving processes, introducing new products and employing sales people who
foster long-term relationship with customers. Believing in Human value and
developing human relation is one of their strong points. At ECO CEMENTS LTD,
their LOGO is more than an image; it is a guarantee of sustainable development to
outpace the ever-changing demands of every market they serve.
 PROFILE OF THE PRODUCTS-

ECO Plus PPC Cement

ECO PLUS is special cement, produced
by grinding Clinker with high quality
processed fly ash, based on norms set by
our R&D department. This unique, value-
added product has hydraulic binding
properties not found in ordinary cements.
This imparts a greater degree of fineness,
improved workability properties while
mixing, and makes concrete more
corrosion resistant and impermeable. All
of this confers better long-term strength
and improved corrosion resistance. This
in turn provides greater life for your
constructions.
ECO PLUS Fly-ash based PPC is Eco-
friendly cement with much lower carbon
footprint than OPC.

TMT Rebar FE 500

ECOPLUS 500 is a high strength ribbed

TMT reinforcement bar. For reference,
the strength of the rebar is 500 MPa. By
keeping the level of impurities like
Sulphur and Phosphorous to below
0.105%, the consistency in strength across
the rebar is maintained. ECOPLUS 500
conforms to the latest standards (last
 revision 2012) set by Bureau of Indian
Standards (BIS).

Eco Plus Pre-engineered

Buildings Pre-Engineered building is a steel
structure built over a structure concept
of primary, secondary members and the
cover sheeting connected to each other.
The structural members are custom
designed to be lighter in weight as well as
high in strength. Pre-Engineered
buildings are ideal for use in non-
residential, wide span low rise
buildings. PEB buildings are used for
diverse applications such as factories,
warehouses, offices, shopping malls,
schools, hospitals, community buildings
and several more.
As a leading PEB manufacturer Eco Plus
provides the complete service of
engineering and fabrication thus ensuring
better quality control at every stage of the
process. Eco Plus is a turnkey solution
Provider for all commercial and
industrial Pre-Engineered Building (PEB)
systems.
Multi-Storey Steel The supremacy of steel in the multi-story
commercial sector is based on perceptible
Construction client-related benefits including the
ability to provide column free floor spans,
efficient circulation space, integration of
building services, and the influence of the
site and local access conditions on the
construction process. In many large
commercial buildings, a two stage
construction process means that the
tenant is responsible for the servicing and
fit-out, and so the building structure has
to be sufficiently flexible to cope with
these differing requirements.
 • Columns and Pillars
• Walkways, Railings and Ladders
Steel Structure System for • Arches
• Storage Units
Other Applications • Processing Vessels
• Structural Supports
• Wall and Ceiling Panels
• Supports for reinforced concrete (i.e.,
bridge decks)
• Marine construction, piers and wharfs
• Balconies and frames for front-elevation
units
• Anchorages and any kind of joints
• Off-shore platforms
• Framers and anchorages for damp
environments, tunnels, underpasses and
subways
• Bridges, viaducts, overpasses
• Cement frameworks with magnetic
characteristics
• Frameworks which are prone to
breaking up due to frost or because of low
temperatures
• Concrete slabs for drainage in
environments with corrosive agents
• Supports/restoration for statues,
monuments, cement, stone and marble
works
Advantages of PPC Cement-
PPC is manufactured by inter-grinding 65% of cement clinker with 30% of fly ash
and 5% of gypsum in a closed circuit ball mill with a high-efficiency separator to
achieve the required fineness.

 Using PPC eliminates surface cracks due to low heat of hydration.

 Setting time is slightly more than OPC, which gives PPC more workable
time.
 Strength development continues even after 28 days, giving ultimate higher
strength to the concrete.
 The company’s addition of Fly Ash improves particle size distribution and
gives a perfect concrete matrix.
 PPC is less porous than OPC, making it even more resistant to chemical
attack.
 PPC is a more eco-friendly type of cement, with less production energy
required to make each ton of cement by blending in high strength Fly Ash, a
by-product from thermal power plants, which historically was disposed of
through environmentally un-friendly, long-term land-filling.

Advantages of TMT Rebar Fe500-

“Fe” remains for ferrous material i.e. iron from which the reinforcement steel bars
(TMT Bars) are produced. 500 stands for the base yield stress in N/mm2. Fe 500
evaluation TMT Bars were presented as a one stage up mechanical miracle over
standard Fe 415 evaluation item.

 This classification of steel bars indicates higher tensile strength. These steel
bars are fabricated through unique classification of billets and
fundamentally controlled warm treatment amid assembling process
 The most special property of 500D TMT bars are these are perfect item for
earthquake resistance and absolutely free of mechanical weakness.
  They additionally have lower amounts of carbon, sulfur and phosphorous,
which helps in safeguarding the steel and opposing earthquake stuns in
future.
 TMT bars can be utilized as a part of an assortment of ventures like
scaffolds, dams, flyovers, structures, railroads, and so forth. The
fundamental focal points of utilizing Fe 500D TMT steel bars are as per the
following:
A) Simple bend ability
B) Earthquake resistant
C) Unrivaled welding strength
D) Ductile and high strength
E) Opposes rust

Advantages of Pre-engineered Buildings-

 Reduced Construction time: When the foundation is being built in site, the
structural members are simultaneously fabricated in industries. Since the
erection time is also less it results in the early completion of the structure
 Less Manpower at Site: Most of the work in a PEB construction is done in
the industries thus the requirement of manpower at the site is very less
comparatively
 Reduction in Cost: Since both materials and manpower is minimized the
overall cost of construction is reduced
 Flexibility in Design: The steel structural members are designed in software
and is fabricated with machines, thus desired shape can be achieved without
any compromise. Hence the PEB can be architecturally versatile
 Scope for Future Expansion: Since bolted connections are only used, the
length wise expansion in a PEB becomes more evident
 Low Maintenance: Modern metal finishes and coatings will help the steel
panels to resist corrosion, chemical attack etc., and also the steel surfaces
can be easily repaired if damaged.

Advantages of Steel Structure Systems-

 Cost Effective and Quick to Build-Construction is quick and simple with the
FRAMECAD accurate steel frame system components. This means high
quality results anywhere, using low-cost, low-skilled labor and shorter
timeframes.
 Strong and Design-Flexible-Steel’s inherent strength enables architectural
and design flexibility – allowing long spans and curves to be easily
incorporated into functional designs.
 Durable and Safe-Thanks to exceptional resistance to fire, corrosion and
pests, steel framed buildings are the first choice for extreme environmental
conditions. Because steel doesn’t need treating with pesticides, preservatives
or glues, it’s also safer for people handling and living or working around it.
 Fire Resistant-Steel frame housing components have been tested and proven
to withstand severe bush fire temperatures of more than 1000°C.
 Earthquake Tested-The structural integrity of steel frame houses has
demonstrated in full-scale simulations that it stays straight, true and most
importantly, safe.
 Environmentally friendly

CERTIFICATIONS-
 ISO 9001-2008 CERTIFICATION FOR TMT
 ISO 9001-2008 CERTIFICATION FOR CEMENT

 COMPLAINCE CERTIFICATION
i) Discharge consent
ii) Emission consent
iii) Compliance report of Environment Clearance
Emissions Control-
Environment policy-

1. Prevent pollution and minimize fugitive emission from all the activities of the
Eco cement Plant.

2. Comply with all relevant legal and regulatory requirements.

3. Conserve key resources such as water and energy.

4. Minimize generation of solid waste and take appropriate action for reuse.

5. Continual improvement in Environmental performance.

Clean Development Mechanism-

As per this mechanism, the company aims to pursue other sources of non-
conventional green energy such as wind power, waste heat recovery, solar PV
energy, solar thermal energy and mini hydel power etc.

Water Heat recovery-

In dry process cement plants nearly 40 percent of total heat input is rejected as
waste heat from exit gases of pre-heaters and grate coolers. In most plants the
waste heat is utilized for drying raw material or pre-heating air required for coal
combustion. But even after covering these applications, there is some heat
available which can be trapped and utilized for electric power generation. Eco
cement is exploring power generation based on water heat recovery from cement
kiln and cooler gases.

Atmospheric emission control-

Sophisticated pollution control equipment and devices are provided at the Eco
cement Plant.

a) Baseline monitoring- It means measuring the environmental performance

of the plants in terms of emissions.
 b) Continuous Emission Monitoring systems- It is in process of installation
to facilitate continuous monitoring of emissions and ensure environment
compliance within the standards.

c) Monthly CO2 monitoring- The company is still working for

implementing programs and channels for CO2 monitoring.

d) Dust control- The Company has two dust control equipment. One; Gas
Conditioning tower; it is used to reduce the temperature and increase the moisture
level of the dusty exhaust from the kiln. It is called conditioning tower because it
conditions the hot gas, thus making it more suitable for the ESP or the Electrostatic
Precipitators that are used in cement plants particularly for the removal of dust
from the exit gases of the cement kilns and from the exhaust air discharged by
dryers. Two; Road sweeper cum industrial vacuum cleaner; it was first introduced
by ACC cement. This equipment helps to accumulate or suck up the dust of the
cement plant.
 CHAPTER 2
SWOT ANALYSIS

STRENGTHS-

 High selling prices and profitability levels

 Relatively low energy costs
 Favorable location having raw material site at a near distance
 Excellent innovation engineering and technological skill used for operating
activities
 Tax free environment
 Taxes and restrictions set on imported cement
 Natural hedge from outside competition arising from high transportation
costs
 Capital intensive industry with long construction periods, creating natural
barriers to new entrants.

WEAKNESS-

 High oil prices, significantly increasing production and transportation costs

 Proximity to lower cost export markets in Indian subcontinent, Egypt and
Turkey, increasing competition in both local and export markets.
 Fragmented regional industry with no economies of scale
 Non-optimal capital structure driven by the relatively low debt levels
maintained by most companies in the region

OPPORTUNITIES-

 Construction boom in all GCC countries that is expected to continue in the

short to medium term
 Innovation opportunities
 A number of M&A transactions might take place in the near future
 Possible entries of MNCs , increasing efficiency and opening new export
routes
THREATS-

 Several capacity upgrades are planned, raising the possibility of over-supply

situation
 Increased competition in local markets post joining WTO and/or Opening up
for foreign investments
 Further hikes in oil prices could negatively affect companies profitability if
they cannot pass increasing production costs onto customers
 Change in government policies
 Exchange rate fluctuations
 CHAPTER 3
ORGANIZATION
STRUCTURE/DESIGN

An organization can be structured in many different ways, depending on their

objectives. The structure of an organization will determine the modes in which it
operates and performs. Organizational structure allows the expressed allocation of
responsibilities for different functions and processes to different entities such as
the branch, department, workgroup and individual.

Organizational structure affects organizational action in two big ways. First, it

provides the foundation on which standard operating procedures and routines rest.
Second, it determines which individuals get to participate in which decision-
making processes, and thus to what extent their views shape the organization’s
actions.

An organizational chart displays in a graphic format the roles of each position in

the company and the name of the employee that fills the role. Organizational charts
can be assembled in various formats. One of these formats is by function, which
organizes the positions within the company by the purpose of the job or position.

By laying out the levels of the company in a functional organization chart, it

allows the creator of the chart to assign precise and clear roles to each department
in the company and to each individual that works in each department. It allows the
viewer of the functional organization chart to easily see the positions in the
business and what specific purpose or function each area fulfils.
It may seem as if a functional organization chart is separated into departments,
such as marketing, human resources, operations, sales and research and
development. This is precisely how these types of organizational structures work.
It devotes one aspect of the business to an entire department, so that the marketing
department and the roles within the marketing department all work toward the
common goal of promoting and marketing the company.

The benefit of organizing a functional organization chart is that it makes it simple

for all of the employees working for the company to understand. This type of
structure also focuses the objective or purpose of the function, role or department
to be clear and precise to those working in and out of the department.

In other words, employees working in the marketing department know and

understand their role in the company. Within the functional organization chart,
there may also be subcategories or subspecialties that fall within the function.
Using the marketing department, one employee may focus on print marketing,
while another focuses on social media marketing. Individual employees in the
marketing department may even focus on a specific product or product line.

The primary drawback with a functional organization chart is that it can create
dividing lines between departments and employees. Rather than having everyone
work for the common goal of making the company successful, the “that’s not my
job” mentality can creep into the minds of employees. In turn, this can cause a
conflict between departments.
STRUCTURE OF THE ORGANISATION

ORGANIZATION DESIGN FACTORS & APPROACH

The factors which influenced ECO cement to adopt a functional approach to

structure their organization are:

 Powerful Top Level :

Functional organizations contain specialized units that report to a single

authority, usually called top management. The main power vests with the top
management. A functional structure allows easy and focused dissemination
of information to and from the top layers of the organizational structure

 Scope for Growth of Employees:

The Company believes in molding and growing from within. Functional

structure makes that simple by promoting the visibility of individual skills,
thereby aiding coaching and climbing the hierarchical ladder.
 Optimum Utilization of limited Resources:

Sub-organization leaders are experts both in their field and in the resources
available, which allows each unit to reach its greatest potential and prevents
over-use of limited resources.
 CHAPTER 4
FUNCTIONAL
DEPARTMENTS

Production department- This department’s main responsibilities are:

 production planning and scheduling

 control and supervision of the production workforce

 managing product quality (including process control and monitoring

 maintenance of plant and equipment

 control of inventory

 Deciding the best production methods and factory layout.

Research & Development department- The Research and Development (R&D)

function is concerned with developing new products or processes and improving
existing products/processes. R&D activities must be closely coordinated with the
organization’s marketing activities to ensure that the organization is providing
exactly what its customers want in the most efficient, effective and economical
way.

Marketing department- Marketing is concerned with identifying and satisfying

customers’ needs at the right price. Marketing involves researching what customers
want and analyzing how the organization can satisfy these wants. Marketing
activities range from the ‘strategic’, concerned with the choice of product markets
(and how to compete in them, for example, on price or product differentiation) to

the operational, arranging sales promotions , producing literature such as . and so

on. A fundamental activity in marketing is managing the Marketing Mix consisting
of the ‘4Ps’: Product, Price, Promotion and Place.

Product: Having the right product in terms of benefits that customers value.

Price: Setting the right price which is consistent with potential customers’
perception of the value offered by the product.

Promotion: Promoting the product in a way which creates maximum customer

awareness and persuades potential customers to make the decision to purchase
the product.

Place: Making the product available in the right place at the right time –
including choosing appropriate distribution channels.

Human Resource (HR) department- The Human Resources function is

concerned with the following:

 Recruitment and selection: Ensuring that the right people are recruited to the
right jobs.

 Training and development: Enabling employees to carry out their

responsibilities effectively and make use of their potential.

 Employee relations: Including negotiations over pay and conditions.

 Grievance procedures and disciplinary matters: Dealing with complaints from

employees or from the employer.

 Health and Safety matters: Making sure employee(s) work in a healthy and safe
environment.
  Redundancy procedures: Administering a proper system that is seen to be fair to
all concerned when deciding on redundancies and agreeing redundancy
payments.

Development Cell-

The company’s policy is to measure the actual performance. The company

basically believes in sustainable development strategy. In this they measure their
success on the basis of three approaches-

1. Economic Prosperity

2. Contribution to the well-being and preservation of the plant and its

people.

3. Social and Local well being

Accounting & Finance department- The Accounting and Finance function is

concerned with the following:

 Financial record keeping of transactions involving monetary inflows or

outflows.

 Preparing financial statements (the income statement, balance sheet and cash
flow statement) for reporting to external parties such as shareholders. The
financial statements are also the starting point for calculating any tax due on
business profits.

 Payroll administration: Paying wages and salaries and maintaining

appropriate income tax and national insurance records.

 Preparing management accounting information and analysis to help

managers to plan, control and make decisions.

Below is the list of the Technical departments of a cement plant, starting from
raw material to finished product.
Safety Department: They are the eyes of the factory, they make sure all the work
is carried out in a safe manner, and they follow some industrial norms, advisories
and guidelines to protect the workers and employees.

Mines Department: They are responsible for taking large mine-able land lease, as
well as mining the proper grade and quality of limestone (in few cases coal,
bauxite, gypsum, etc. too) as recommended by the plant's requirements.

Quality Department: They check the chemical and physical parameters of almost
every material at any point in the process flow, starting from limestone, to clinker,
additives, fuel, and conduct mandatory laboratory testing to meet government
standards.
Process Department: They are responsible for maintaining the plant's process
parameters (heat flow, mass flow, air flow and other utilities) and suggest changes
to accommodate some failures/breakages during plant operation, while minimizing
cost.
Maintenance Department (Mechanical): They are responsible to conduct regular
inspection of the plant equipment, design methods and planning for spares and
execution of jobs to improve/repair certain parts, as well as fix the parts during a
breakdown or shutdown. It consists of Methods and Execution department.

Maintenance Department (Electrical and Electronics): Their primary role is the

maintenance of the electrical equipment in the plant (Substation and Main
Receiving Station), power transmission as well as control system design using
software.
Environment Department: Their major task is to ensure regular monitoring of
plant emissions, making sure they are in accord with the compliance of the Govt.
regulatory bodies as well as suggesting measures to reduce environmental damage.

New Works and Civil Department: They are the ones who take charge of any
new line/project/equipment that needs to be installed in the plant. Generally
consists of expert engineers. (Civil/Electrical/Mechanical)
Operations Department: This department ensures the supply chain from raw
materials import to packaged cement export is done in the optimum manner with
respect to time and money. Warehousing, Truck loading, connectivity of markets,
etc. is done by them.
Drawing Department: They are the library of the plant and store, create or modify
the drawings of all major and minor equipment of the plant.

Purchase Department: They make sure the right materials (be it raw materials,
mechanical equipment or even a tea maker) are purchased through the best market
and price. They are also responsible for storing and issuing of the materials.

HR POLICY

Management at ECO CEMENT is committed to-

 Empower People
 Honor individuality of every employee
 Develop competency
 Employees shall be given enough opportunities for betterment
 None of the person below the age of 18 years shall not be engaged for work
 Standard labor practices shall be followed
 Observance of Business ethics and professional code of conduct will be
appreciated
 Safety, Health, Quality, Environment and Energy policies to be followed

Grievances Handling Techniques-

Grievance cell is functioning under the HRM department wherein the grievances of
the employees are heard and solutions are found. Some of the methods for
grievances handling and reducing are-

1. Enabling employee communication

2. Complaint Box
 3. Employee satisfaction survey wherein the survey is taken to find out-
People are treated fairly regardless of caste and religion, Company is a safe place
to work, Employees feel good about the company’s contribution to the society,
Management has a positive approach, Employees are proud to tell that I work here.

Time Keeping Department-

A. This department too comes under the HR Department. The main objectives of
this department are-

1. To facilitate preparation of pay roll if wages are paid on time basis.

2. To maintain discipline in attendance.

3. To calculate overtime and shift management.

4. To control labor cost and to introduce incentive plans.

B. Factory timings- General Shift: 9am to 5pm

“A” Shift : 2pm to 10pm

“B” Shift : 10pm to 6am

Lunch Break: 12.30pm to 1.45pm (Only for general shift)

C. Attendance procedure- Employees should report for his duty on time as per the
shift schedule. If any employee reports for his duty 20 minutes late, for every three
such late coming ½ (half) leave gets deducted for maintaining the discipline among
the employees.

D. Leave Rules- All confirmed employees are eligible for leave, after completing 6
months of continuous service as detailed below:

a) Privileged Leaves 30 days in a calendar year

b) Casual Leaves 08 days in a calendar year

 c) Sick Leaves 12 days in a calendar year

Training and Development-

This Company’s HR policies are directed towards enhancing knowledge,

experience and skill of its people and retain a skilled workforce. Various multi
skills training programs are arranged to acquire cross-functional expertise. These
are put to use through job enlargement and increase responsibilities. It leads to an
all-round development of the employees, such programs benefits the company
through cost reduction, improved processes and overall enhanced productivity.
Employees also gain through knowledge enrichment and career progression.

Creating leaders at every level-

ECO CEMENT emphasizes on creating leaders not just at the organizational apex
but at each and every level which results in strong sense of emotional ownership.
Thus the employees are delegated with responsibility and authority to adopt energy
conservation and more effective and efficient ways of production.

Rewards and Recognition-

The management believes in the self-actualization of its employees by injecting the

concept of Human Resource Development in all its policies and strategies. By
reward and recognition the employees are motivated to give their best in the

interests of the organization in particular and for the society in general.

According to the company’s MD, morale management is considered to be more

challenging than material management. According to him it is really important to
keep walking around and congratulating the teams for their small efforts and
victories. Employees are rewarded for doing exemplary work in the field of
reducing/eliminating breakdowns, in-house developments, better house-keeping,
and reduction in raw material, fuel, power and wastage. Cash awards and
certificates of honor are too given to the deserving employees.
 Manufacturing Process-

Incoming Raw materials-

 Limestone- Received from-------- Quality of limestone is monitored by

analyzing quality of crushed lime sample collected from crusher department.

 Bauxite/ Laterite / Fluoric sludge (Alumina as Silica) - It is used in raw

mill as a corrective material for required alumina content. Source wise daily
average samples are analyzed for acceptability.
  Iron Ore (Fez03) - Mill scale/ Iron ore is used in raw mill as corrective
material for required iron content. Quality Control Department analyzes the
source wise daily average samples for acceptability.

 Gypsum- It is used in required proportion in cement mills. Quality Control

Department analyzes the source wise daily average samples for acceptability
or quality assurance.

 Fly Ash- It is used as a pozzolanic material in manufacture of Portland

Pozzolana Cement (PPC) in cement mills procured from established sources.

 Coal/Lignite/Alternative Fuel

CEMENT MANUFACTURING PHASES-

CEMENT MANUFACTURING PROCESS PHASE 1: RAW MATERIAL

EXTRACTION

Cement uses raw materials that cover calcium, silicon, iron and aluminum. Such
raw materials are limestone, clay and sand. Limestone is for calcium. It is
combined with much smaller proportions of sand and clay. Sand & clay fulfill the
need of silicon, iron and aluminum.

Cement plants are fixed where the quarry of limestone is near bye. This saves the
extra fuel cost and makes cement somehow economical. Raw materials are
extracted from the quarry and by means of conveyor belt material is transported to
the cement plant.

There are also various other raw materials used for cement manufacturing. For
example shale, fly ash, mill scale and bauxite. These raw materials are directly
brought from other sources because of small requirements.

CEMENT MANUFACTURING PROCESS PHASE II: PROPORTIONING,

BLENDING & GRINDING

The raw materials from quarry are now routed in plant laboratory where, they are
analyzed and proper proportioning of limestone and clay are making possible
before the beginning of grinding. Generally, limestone is 80% and remaining 20%
is the clay.

Now cement plant grind the raw mix with the help of heavy wheel type rollers and
rotating table. Rotating table rotates continuously under the roller and brought the
raw mix in contact with the roller. Roller crushes the material to a fine powder and
finishes the job. Raw mix is stored in a pre-homogenization pile after grinding raw
mix to fine powder.

CEMENT MANUFACTURING PROCESS PHASE III: PRE-HEATING

RAW MATERIAL

After final grinding, the material is ready to face the pre-heating chamber. Pre-
heater chamber consists of series of vertical cyclone from where the raw material
passes before facing the kiln. Pre-heating chamber utilizes the emitting hot gases
from kiln. Pre-heating of the material saves the energy and make plant
environmental friendly.
Figure: Preheating of raw material/ vertical cyclone

CEMENT MANUFACTURING PROCESS PHASE IV: KILN PHASE

Kiln is a huge rotating furnace also called as the heart of cement making process.
Here, raw material is heated up to 1450 ⁰C. This temperature begins a chemical
reaction so called de-carbonation. In this reaction material (like limestone) releases
the carbon dioxide. High temperature of kiln makes slurry of the material.

Figure: Rotary Kiln

The series of chemical reactions between calcium and silicon dioxide compounds
form the primary constituents of cement i.e., calcium silicate. Kiln is heating up
from the exit side by the use of natural gas and coal. When material reaches the
lower part of the kiln, it forms the shape of clinker.

CEMENT MANUFACTURING PROCESS PHASE V: COOLING AND

FINAL GRINDING

After passing out from the kiln, clinkers are cooled by mean of forced air. Clinker
released the absorb heat and cool down to lower temperature. Released heat by
clinker is reused by re-circulating it back to the kiln. This too saves energy.Final
process of 5th phase is the final grinding. There is a horizontal filled with steel
balls. Clinker reach in this rotating drum after cooling. Here, steel balls tumble and
crush the clinker into a very fine powder. This fine powder is considered as
cement. During grinding gypsum is also added to the mix in small percentage that
controls the setting of cement.

Figure: Rotating ball mill

CEMENT MANUFACTURING PROCESS PHASE VI: PACKING AND

SHIPPING
Figure: Transportation of cement from silos

Material is directly conveyed to the silos (silos are the large storage tanks of
cement) from the grinding mills. Further, it is packed to about 20-40 kg bags. Only
a small percent of cement is packed in the bags only for those customers whose
need is very small. The remaining cement is shipped in bulk quantities by mean of
trucks, rails or ships.

Figure: MANUFACTURING PROCESS FLOW

TMT MANUFACTURING PROCESS-

 STAGE 1: Conversion of Iron ore to molten iron

A. Sourcing and B. Beneficiation, C. Iron making

processing of raw material Agglomeration &
Conversion of coke to
coal

STAGE 2: Conversion of Molten Iron to Steel and continuous casting

A. Pretreatment and B. Secondary steel C. Continuous Casting

primary steelmaking making

STAGE 3: Hot rolling and Thermo Mechanical Treatment

A. Quenching B. Self-Tempering C. Atmospheric Cooling

Packaging the CEMENT BAGS-

Cement is packed in HDPE (High Density Polyethylene) / PP(Poly Propylene)

woven sacks and in paper bags conforming to companies specification formulated
by Material Management Division (MMD) of corporate office.

Bags are checked for the following parameters-

 Length and width of bag

 Length of valve
 Weight of bag
 No. of stitches/decimeter
 Tensile strength for length, width, top seam and bottom seam
 Taper test for branding

In case of paper bags following checks are made-

 Length and width of paper bag

 Length and width of valve
 Weight of bag

In Process Materials-

 Crusher Department-
The output of the crusher department is limestone. The quality check is carried out
by samples collected from product belt conveyor.

 Raw Mill Department-

The input of this department is crushed limestone, ground in raw mills along with
required quantity of corrective materials and water for producing low grade slurry.

 Ball Mill and Floatation Department-

The input of this department is crushed limestone which is grounded in closed

circuit ball mills. The quality control function involved in this process is to check

the quality and fineness of slurry which is the final out from the ball mill and also
the quality of enriched slurry which is fed to thickener as quality of reject
generated from the floatation process.

 Kiln Department-

The Corrected slurry in Mixer basin 1 & 2 of raw mill department is pumped to
mixer basin no. 3 & 4 of Kiln department where from it is fed to the slurry filters.

 Kiln Feed-

Corrected slurry available in mixer basin 3 & 4 which is ready for feeding to the
slurry filters is called Kiln Feed. It is samples from the point of over flow from
constant head tank located at the top of slurry filtration plant. About 1-1.5 liters of
sample is collected twice a shift and checked for quality moisture and fitness.

 Filter Cake-

The slurry filter drums filter out the water from the kiln feed and cake produced is
dislodged over the belt conveyors for feeding to the kiln system. About 1/2kg
sample of cake is collected from common belt conveyor once in a shift and tested
for moisture content.

 Fine Coal-
Coal which is used as a fuel is finally ground in a mill for firing to the kiln system.
About 1/2kg of fine coal sample is collected for discharge point of screw
conveyors for kiln once in a shift and tested for moisture, ash and fineness.

 Clinker-

The output from kiln system is clinker, which comes out from cooler discharge
point. About 5 kg sample is drawn every 2 hours and part of sample of sieved for
liter weight determination and another part is kept separately for preparation of
daily average composite samples. The spot clinker samples are also analyzed for
quality.

 Cement Grinding-

The clinker so produced is ground along with gypsum or gypsum and fly ash for
manufacture of OPC or PPC, as the case may be, in cement mills. The QC function
involves in this process are to check the fineness, setting time and specific
chemical parameters on periodic samples collected from each mill separately.

 Grade Analysis-

In this stage only grade test is also conducted for the final product i.e. cement
undergoes physical test as per which specific grade is fixed for each type of
cement. This grade acts as a representative symbol of quality and strength of final
product in front of customers. Under this quality grade is fixed by undergoing
queering process.

Queering process is a process of keeping cement cake/concrete produced in mold

with water and sand in it in a certain pre-fixed proportion for a period of 24 hours.

After the period of 24 hours, the Quality Control department will apply certain
level of pressure to the molded cement cake if it withstands pressure up to the stage
of 16 mega Pascal then concrete is good otherwise bad in quality.
Marketing and Distribution

Distribution: Key Cost Drivers

Channel of distribution-
After production, the next problem faced by a producer is that of selling
distribution because production is made to satisfy the needs of the customers, so it
must reach to the customers for whom it is made. The way through which the
goods flow from the producer to the consumer is called the channel of distribution.

The channel is as follows-

 Manufacture
 Direct consumer regional sales officer
 Sub officer
 Dealer
 Consumer sub dealer
 Consumer

LEVELS OF DISTRIBUTION-

ZERO level distribution- Producer Consumer

ONE level distribution- Producer Retailer Consumer

TWO level distribution- Producer Wholesaler Retailer

Consumer

THREE level distribution- Producer Agent Wholesaler Retailer

Consumer

Sales Promotion-

Sales promotion is an activity which aims at sales expansion. It’s basic objective is
to increase sales through special efforts, proper selection of them, provision of their
training attempts to improve relation with distributors and consumer advertising
etc. are the activities which essentially aim at increasing sales promotion refer to
all activities for enhancing the total sale and demand.

Eco Cement adopts various types of sale promotion tools like discounts, gifts, and
some other incentives and sometimes company sends their dealers and distributors
on tours.
Eco cement has 3 levels of sale promotion-

 At a dealer level
 At a salesman level
 At a consumer level

Thus we can say that sales promotion is not expenditure; it is an investment which
provides a lot of rich dividend. Thus it is an integral part of manufacture in efforts.

Marketing Research-

Marketing is the systematic gathering of information, recording and analysis of

data, to problem concern with market. Marketing Research is basic thing needed
for the company. Without marketing research the company will not be able to know
which pattern, size, colors of products are in demand by the customers.

Eco Cement has an open market to sell their products in market thus there is an
immense requirement for market research. They have a special marketing segment
for the same.

Marketing Mix
 PRODUCT- PRICE-
-Variety of products List Price
Discounts
-Brand name
-Pacakaging

Marketing
PLACE- mix PROMOTION-
Coverage Sales promotion
Channels Advertising
Transport Public Relation

Customer Relations-

The company is known to promote ethical and fair practices in its supply chain.
The company’s commercially terms, procedures are professional and transparent.
Their marketing and sales practices envisage the promotion and encouragement of
all dealers including small traders and retailers.

They reach to their customers in the following ways-

1. Regular Interactions – The Company has a regular practice of interacting with

the customers and end users as well as members of their distribution channels such
as dealers, sub-dealers, and retailers.

2. Surveys – Market surveys are organized at regular intervals to ascertain

perceptions about Eco cement’s brand image, marketing and distribution
procedures, and their sale force, channel management and relationships with
customers, dealers and influencers.

3. Interactive website

4. Complaint Handling
5. Suggestion Boxes – Sales office maintains a suggestion box in which the
customers and suppliers of the company can put their suggestions to improve the
service of the company.

Supply chain management and Logistics-

A supply chain is an integrated manufacturing process wherein raw materials are

converted into final products, then delivered to customers. At its highest level, a
supply chain is comprised of two basic, integrated processes:

 The Production Planning and Inventory Control Process, and

 The Distribution and Logistics Process.

These Processes, illustrated below in Figure, provide the basic framework for the
conversion and movement of raw materials into final products.

Suppliers
Distribution
centers

Manufacturing Storage facility Transport vehicle

facility

Retailer Customer

Figure: The supply chain process

The Production Planning and Inventory Control Process

The Production Planning and Inventory Control Process encompass the

manufacturing and storage sub-processes, and their interface(s). More specifically,
production planning describes the design and management of the entire
manufacturing process (including raw material scheduling and acquisition,
manufacturing process design and scheduling, and material handling design and
control). Inventory control describes the design and management of the storage
policies and procedures for raw materials, work-in-process inventories, and
usually, final products.

The Distribution and Logistics Process

The Distribution and Logistics Process determines how products are retrieved and
transported from the warehouse to retailers. These products may be transported to
retailers directly, or may first be moved to distribution facilities, which, in turn,
transport products to retailers. This process includes the management of inventory
retrieval, transportation, and final product delivery. These processes interact with
one another to produce an integrated supply chain. The design and management of
these processes determine the extent to which the supply chain works as a unit to
meet required performance objectives.

Types of process of Supply Chain Practices-

Supply Chain Management in Cement Company is the management of upstream

and downstream relationships with and customers to deliver superior customer
value at less cost to the supply chain as a whole. A supply chain is the process of
moving goods from the customer order through the raw materials stage, supply,
production and distribution of products to the customer. All organizations have
supply chains of varying degrees, depending upon the size of the organization and
the type of product manufactured. The cement companies has to understand the
requirements of the customers, define core competencies and roles the companies
are going to play to fulfill the requirements of the customers and finally develop a
SC capabilities to support the roles of company has chosen

There are eight processes of Supply chain. The processes and their functions are
described as follows:

(a) Customer Relationship Management: Provides structure to customer

relationship and how such relationships are developed, maintained, and managed.
Identifies target customer groups as part of the business mission and develops
agreements with key accounts. Performance reports also measure profitability and
financial impact for key customers.

(b) Customer Service Management: Provides customer information such as

shipping dates, product availability, and real-time information between customers
and the firm.

(c) Demand Management: Balances the customers’ requirements with the firm’s
supply capabilities. This would include forecasting demand and managing the
demand in production, procurement, distribution, and in all other outputs of the
company.

(d) Order Fulfillment Management: Provides integration of the firm’s

manufacturing, logistics and marketing plans. This would require the management
of partnerships maintained by the company to meet customer requirements.

(e) Manufacturing Flow Management: Helps to manufacture products and

establishes the manufacturing flexibility required to service target markets.
Requires management of product flow and maintaining the flexibility established.

(f) Supplier Relationship Management: Defines how a company interacts with

its suppliers. Similar to customer relationship management, partnership
management is required to develop key relationship with core suppliers potentially
providing a competitive advantage.
(g) Product Development and Commercialization: Provides the development of
new products by integrating customers and suppliers in reducing time to market.
Timely development of new products and services are keys to firm’s success.

(h) Returns Management: Provides a critical component of sustained competitive

advantage for the firm. Allows firm to monitor productivity improvements and
identify valuable projects related to products or services.

CHAPTER 4
FINANCIAL HIGHLIGHTS OF THE
ORGANIZATION

Balance sheet for the year 2015:

Balance sheet for the year 2016:
Balance sheet for the year 2017:
Profit and Loss Statement for the year 2015:
Profit and Loss Statement for the year 2016:
Profit and Loss Statement for the year 2017:
CHAPTER 5
 SUGGESTIONS AND
RECOMMENDATIONS

SUGGESTIONS AND RECOMMENDATIONS

 Decentralizing of Power:

At Eco Cement, decentralization of power must be diminished. Centralization of

powers restricts ideas and innovations from lower level. The power will be
concentrated with the top management. This could prove to be a burden to the
managers. Since talent would be spread across the organization, a platform to
showcase such talent must also be provided.

 Diversity:

Bringing about a diversity of people in the organization by recruiting outsiders for

valuable posts, ensures that there are a variety of ideas and suggestions for the
company , which will help them to innovate, grow and succeed.

 Diversification and Modernization:

The company must lay emphasis on its modernization and diversification of its
products.

Modernization is important in today’s market as it will help the organization to

remain up to date with technology and provide better quality products. Product
diversification will help the organization to meet the fast changing requirements of
the markets and keep on the competition.

 Usable and Visible Website:

An attractive, up-to-date and informative website is very essential for businesses

today, as they not only improve and enhance visibility, they also help create an
image and help target wider range of audiences. After all, whether or not the
business is online, the potential customer always is.

 Reward System:

At Eco cement, the reward system is strict and rigid. There is no flexibility in its
reward and performance appraisal system. The most important source of
motivation in an organization is benefits and rewards to its employees. Hence, the
firm must focus on its rewards system.
 REFERENCES/BIBLIOGRAPHY
About Eco Plus Cement (n.d.). Retrieved May 30, 2018, from http://ecocement.in/

(n.d.). Retrieved June 30, 2018, from http://www.google.com/

http://www.wikipedia.org/

REPORTS

Director, Eco Plus Cement and Steel

Finance Department, Eco Plus Cement and Steel