Académique Documents
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ACKNOWLEDGEMENT
We have taken efforts in this project. However, it would not have been possible without the kind support and help of many individuals and organizations. We would like to extend our sincere thanks to all of them. We are highly indebted to Mr. N. Venkat Raju, AVP Works for his guidance and constant supervision as well as for providing necessary information regarding the project & also for his support in completing the project. We would like to express our gratitude towards our parents & member of Anjani Portland Cement for their kind co-operation and encouragement which helped us in completion of this project. We would like to express our special gratitude and thanks to industry persons for giving us such attention and time. Our thanks and appreciation also goes to people who have willingly helped us out with their abilities in developing our project.
INDEX
A glimpse on cement industry Contribution of various sectors towards demand of cement Excise duty on cement Research and Development About Anjani Portland Cement Ltd. Process Mining Highlights of Anjani Cement Corporate Social Responsibilities Environmental Responsibilities Pollution Control Measures Objectives of the report Learnings
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Today cement industry comprises of 183 cement plants and more than 360 mini cement plants. 98% of the capacity is in the private sector and the rest in public sector. Global cement production has expanded at an average rate of 6.4% in the last five years from 2568 million tonnes to 3294 million tonnes. China and India have been the drivers of growth in global cement output. India is the second largest cement producer in the world after China. The turnover of cement industry was found to be nearly US $25billion in 2010-11. Cement being a low value high volume output has a very limited international trade.
The Government of India decided to increase its investment in infrastructure to US $1trillion in the 12th five year plan as compared to US $514billion in the 11th five year plan.
Infrastructure15%
Roads-5%
Housing-53% Irrigation-23%
HISTORY: Anjani Cement Portland Limited (APCL) is a decade old company. The genesis of Anjani
was inspired and motivated by the pioneer in cement industry Padma Bhushan Dr.BV Raju.
It took over an ailing company called M/S Shez Cement Pvt. Ltd. In 1999 and set the
beginning of its onerous journey to the top.
COMPANY PROFILE:
It is a popular brand in South India. Started with an initial production capacity of 0.3 million tonnes per annum and has now achieved a quantum shift in its production capacity to 1.2 million tonnes per annum.
VISION:
Vision is to achieve a production level of 3.5 million tonnes per annum by 2015. MISSION: To be among the top five market leaders in South India. To establish a dominant position in the neighboring states
VERTICALS OF APCL:
o Hitech Print Systems o Vennar Ceramics
PRODUCTS OF APCL:
o o o o OPC 43 Grade OPC 53 Grade PPC Test Certificate
PROCESS
MINING:Started Lease Area Area used : : : 1999 142.14 acres 25 acres (till now) 20years Chintalapalem Mellacheruvu Nalgonda
In mines, the procurement of limestone is done through benches. There are 4 benches now and the height of each bench is about 6 metres, arranged in three steps. From mines to factory, each lorry carries around 17.5 tonnes. Shavel is used to load the material into tipper. Dumpers are used to load heavy, bulk materials. Safety equipment is provided to the workers.
Blasters:
Electrical Detonators are used for blasting. The length of a detonator is usually 33-55mm. The diameter of detonators: Inner diameter 3mm and Outer diameter 9mm. A Detonator is made up of PETN [PENTA ERYTHRIDO TETRA NITRATE]. Detonators are of two types : Milliseconds Electrical Prime Detonators use Boost Katali, in which Ammonia Nitrate is used. For 100kgs ammonia nitrate, 7 litres of diesel is mixed. Now a days, latest blasters used are: Defies reel coil Non- electrical detonators
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PROCESS
The cement manufacturing process begins in the mines where the raw material, i.e. Limestone is collected and then transported to the factory. Next in the factory, the limestone is crushed in the primary and secondary crusher and sent to the raw mill. The raw mill carries nearly 130 tonnes of material, where the crushed material is converted into raw meal (i.e., semi-powder). This raw meal is then transferred to the pre-heater, which has 5 cyclones, each with different temperatures. From the pre-heater, the material is passed into kiln which is 48 metres long. Here the material is heated up at 1400C by using coal and oil resources. Then the material turns into a larva which is further passed in to the cooler. The cooler has nine fans which together cool the larva from 1300-1400C to 100C. The cool material is then passed to the cement mill. The Cement mill carries about 80 tonnes of material. Here the material is converted into fine powder called cement. In the mill, along with the material, about 3% gypsum is added for all grades of cement. If it is PPC, fly ash is added directly in the cement mill. Then cement thus formed is stored as a stock pile, from where cement is passed into the packing plant. From this plant, cement bags are dispatched.
MINES
PRIMARY CRUSHER
SECONDARY CRUSHER
KILN PRE-HEATER
RAW MILL
COOLER
CEMENT MILL
PACKING PLANT
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o 1st Prize for Publicity & Propaganda for Anjani Limestone Mines. o 1st Prize for Water Quality Management for Anjani Limestone Mines. The Construction World Award - "Fastest Growing Cement Company" Anjani is ranked as 'Numero Uno' in a study conducted by ASAPP, and was awarded the "Fastest Growing Cement Company" in India at 7th Construction World Annual Awards 2009 Mumbai. The Award was given away by Hon'ble Union Minister for Roads, Transport & Highways Shri. Kamal Nath, at the function held at Mumbai on the 8th of October 2009. 225th Position amongst Indias 500 best-performing Anjani Portland Cerment Limited awarded Certificate of Acheivement for, Demonstrating Exceptional innovation and Perseverance in attaining the 225th Position amongst Indias 500 best-performing mid-sized Enterprises by Inc. India (9.9 Media Initiative) and the award was received by Sri. PS Raju (Group General ManagerHR&MS) in New Delhi.
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Anjani is most popular with the working community of Nalgonda the cement district of AP for its community services to all Anjani employees and in all the neighboring villages.
Donated for the cause of poor, rupees one crore worth of cement towards construction of houses under Indiramma Housing Scheme. The company spends more than 10 crores for the development of villages in the neighborhood of Anjani cement plants at Nalgonda District. Comprehensive community development always takes precedence in the activities of Anjani management. Anjani is a responsible corporate with 'Best Employee Practices'. Anjanis trees shelter more than 400 happy families and considers their health education and development as its priority. The company constructed Smt. Sita Memorial School near the factory for the children of employees and neighboring villages. The children are being happily educated from preprimary to class X.
ENVIRONMENTAL RESPONSIBILITY
Environmental Commitment is no more a neighborhood issue; it is a global concern where every organization in some way has become environmentally more responsible. For Anjani Cement, Environmental Responsibility is not merely a concept to enhance the brand equity; it is a commitment. Anjani has taken an oath to protect the environment, in and around the cement plant and ever since, has never stepped back.
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Optimum use of natural resources is the companys top priority. Persistent efforts are made to restore and maintain the eco-balance and greening process. The RABH technology is used here to maintain dust and pollution free atmosphere. Efforts are also being made towards greening the environment by planting and nurturing trees and other flora in the cement plant vicinity.
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LEARNINGS
SOFTWARE:
Siemens PCS7 is the software used to control the plant activities. It is used to contol temperatures at various stages of manufacturing and also to detect errors in the process immediately.
LOGISTICS:
It is a part of supply chain management. It is defined as the flow of goods, information and money. It is of 3 types 1) Inbound Logistics 2) Manufacturing Logistics and 3) Outbound Logistics. 1) Inbound Logistics: It involves the transportation of company requirements like raw materials, shoes to employees etc. 2) Manufacturing Logistics: It involves the transportation required during manufacturing process. 3) Outbound Logistics: It involves the transportation of output.
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HR ACTIVITIES:
1) SELECTION AND RECRUITMENT 2) TRAINING AND DEVELOMENT 3) PERFORMANCE APPRAISAL 4) EMPLOYEE RETENTION 5) EXIT INTERVIEWS 6) HEALTH AND SAFETY 7) PAY STRUCTURE 8) COMPENSATION AND BENEFITS
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PERFORMANCE APPRAISAL:
It is a method of evaluating the behavior of employees in work spot, normally including both the quantitative and qualitative aspects of job performance. It can also be defined as the systematic description of an employees job relevant strengths and weaknesses. 360 degree feedback: It is also known as 'multi-rater feedback'. It is the most comprehensive
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appraisal where the feedback about the employees performance comes from all the sources that come in contact with the employee on his job.
360 degree appraisal has four integral components: 1. Self appraisal 2. Superiors appraisal 3. Subordinates appraisal 4. Peer appraisal.
180 Degree feedback: It is one of the method by which feedback of an employee can be judged and measured. Here two people are involved in the feedback process; one is the employee himself and his immediate boss. Anjani cements follow this type of appraisal. 90 Degree feedback: 90 degree = one person review (self or another, e.g., the boss)
EMPLOYEE RETENTION:
Employee retention refers to the ability of an organization to retain its employees. Employee retention can be represented by a simple statistic (for example, a retention rate of 80% usually indicates that an organization kept 80% of its employees in a given period). However, many consider employee retention as relating to the efforts by which employers attempt to retain employees in their workforce. In this sense, retention becomes the strategies rather than the outcome. In order to retain employees and reduce turnover managers must meet the goals of employees without losing sight of the organization's goals, thereby creating a "win-win" situation. Valance and expectancy theories provided some of the earlier guidance for retaining employees.
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EXIT INTERVIEWS:
An exit interview is an interview conducted by an employer of a departing employee. They are generally conducted by a relatively neutral party, such as a human resources staff member, so that the employee will be more inclined to be candid, as opposed to worrying about "burning bridges". Exit interviews are conducted by paper-and-pencil forms, telephone interviews, in-person meetings, or online through exit interview management systems. Some companies opt to employ a third party to conduct the interviews and provide feedback.
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