Project PPT RPT

Karanja Industries (Pvt.) Ltd.
PROMOTERS PROFILE/ COMPANY PROFILE: INDUSTRY PROFILE

Paper Industry is riding on a strong demand and on an expanding mood to meet the projected demand of 8 million tons by 2011 & 13 million tons by 2020 according to India. The Indian Paper Industry is among the top 15 global players today, with an output of more than 6 million tons annually with an estimated turnover of Rs.1,50,000 million. A large number of expansion program & expansion of capacities with an outlay of Rs. 10,000 crores have been announced covering the various sectors like paper, paperboard, newsprint. The Indian Economy is progressing well and targeting 8%+ growth. The economic reforms coupled with the liberalized Government Policies, India today offers excellent business opportunity for investments. One of the first FDI Projects may come through the proposed Finish proposal to set up a 4, 00,000 TPA capacity plant with an investment of US$240million.
The expanding Industrial Scenario calls for efforts to tackle related problems:

Industry needs capital and technology. Since energy cost accounts nearly 25 per cent of cost of production there is an urgency to improve energy management and energy consumption. Quantum jump in production, called for by the demand projection is possible only by expansion of existing capacity and creation of additional capability. Up gradation of technology and new capacities also involve massive investment.
Use of agro residues for preparation of pulp also throws up challenges like pollution control, recycling, use of cost effective technology for utilization of agro residues, etc. 1
ADMINISTRITIVE MANAGEMENT COLLEGE BANGLORE
Paper Industry in India

Paper industry in India is the 15th largest paper industry in the world. It provides employment to nearly 1.5 million people and contributes Rs 25 billion to the government's kitty. The government regards the paper industry as one of the 35 high priority industries of the country. Paper industry is primarily dependent upon forest-based raw materials. The first paper mill in India was set up at Srirampur, West Bengal, in the year 1812. It was based on grasses and jute as raw material. Large scale mechanized technology of papermaking was introduced in India in early 1905. Since then the raw material for the paper industry underwent a number of changes and over a period of time, besides wood and bamboo, other non-conventional raw materials have been developed for use in the papermaking. The Indian pulp and paper industry at present is very well developed and established. Now, the paper industry is categorized as forest-based, agro-based and others (waste paper, secondary fibre, best fibres and market pulp). In 1951, there were 17 paper mills, and today there are about 515 units engaged in the manufacture of paper and paperboards and newsprint in India. The pulp & paper industries in India have been categorized into large-scale and small-scale. Those paper industries, which have capacity above 24,000 tonnes per annum, are designated as large-scale paper industries. India is self-sufficient in manufacture of most varieties of paper and paperboards. Import is confined only to certain specialty papers. To meet part of its raw material needs the industry has to rayon imported wood pulp and wastepaper. Indian paper industry has been de-licensed under the Industries (Development & Regulation) Act, 1951 with effect from 17th July, 1997. The interested entrepreneurs are now required to file an Industrial Entrepreneurs' Memorandum (IEM) with the Secretariat for Industrial Assistance (SIA) for setting up a new paper unit or substantial expansion of the
2

Existing unit in permissible locations. Foreign Direct Investment (FDI) up to 100% is allowed on automatic route on all activities except those requiring industrial licenses where prior governmental approval is required. Growth of paper industry in India has been constrained due to high cost of production caused by inadequate availability and high cost of raw materials, power cost and concentration of mills in one particular area. Government has taken several policy measures to remove the bottlenecks of availability of raw materials and infrastructure development. For example, to overcome short supply of raw materials, duty on pulp and waste paper and wood logs/chips has been reduced. Following measures need to be taken to make Indian paper industry more competitive:

Improvements of key ports, roads and railways and communication facilities. Revision of forest policy is required for wood based paper industry so that plantation can be raised by industry, cooperatives of farmers, and state government. Degraded forest land should be made available to the industry for raising plantations.
Import duty on waste paper should be reduced. Duty free imports of new & second hand machinery/equipment should be allowed for technology up gradation.
3
4
COMPANY PROFILE
In the year 1983, the Karanja Industries Pvt Ltd. started its operation in Bidar district. Due to Backward area the government had given the subsidy to start its operations for developing this area. And the company had seen the availability of the raw material, transportation, market opportunities, cheap labor and well water resource etc. The Karanja Paper Industry was incorporated during the year of 1983 with authorized capital of Rs. 5,00,000/- under companies Act 1956 for manufacturing of white cutting duplex board with a capacity of 3000 tons per annum. After identifying the viable location the company could acquire the land of 36 acres. The company secured loans of Rs. 1.6 crores from various financial institutions during 1986 and put the plant on the stream during September 1988 with the project cost of Rs. 234 lakhs. From 1st November 1988 it has resumed the commercial production. While on 30 th November 1996 the Karanja Industry had received I. S. O. 9002 certificate by STQC Directorate Government of India New Delhi. After this they are decided for 50 ton capacity paper mill and this dream was completed in 2001, This paper use for packaging of various material, Which paper known as a Kraft paper.
5
Karanja Industries (Pvt.) Ltd. PRODUCT PROFILE: The company manufactures mainly two types of paper products. One is White Duplex board and another is Kraft Paper. The raw material required mainly is only all types of old paper and imported. The required papers are brought from local and outside places like Maharashtra, Kerala, and Karnatakas various cities and America, Saudi imported. The raw material is brought from the entire place through road and rail.
6
Kraft papers
7
Duplex Board
NATURE OF THE BUSINESS CARRIED:

The company manufactures mainly two types of paper products. One is White Duplex board and another is Kraft Paper. The raw material requires mainly is only all types of scrap paper. The required papers are brought from local and outside places like America and Saudi, Maharastra, Kerala, and
8

Karnatakas various cities. The raw material is brought from the entire place through road and rail.
VISION, MISSION AND QUALITY OBJECTIVES: VISION: Aim to increase the production by 65 tones per day by 2009 Planning to have ISO 14000 certification for environmental management by 2012. Planning for introduce the LWC (Light Weight Coating) HWC (Heavy Weight Coating) system to the existing product by 2012. LWC Light Weight Coating upto to 10 gm / cm2 HWC (Heavy Weight Coating) means to provide upto 25 gm / cm 2 of thin layer of chemical coating.
MISSION:Karanja Industries (P) Ltd. is following the quality policy which clearly depicts the type of product and service characteristics provided by them. Shall strive to provide quality product and services at competitive price, to satisfy the requirements of the customers. Shall encourage new ideas and efforts from all levels for continuous improvement.
QUALITY OBJECTIVES : Developing at least 2 new customers a year. To achieve 5000 tons of Duplex Board and 3000 tons of Reclaimed Rubber and 14400 kraft paper. The Management will reconstruct the objectives in every Management Review Meeting as applicable depending upon the requirement.
9
AREA OF OPERATION: (National/Regional):
The area of operation of the Karanja Industries Pvt Ltd is National and Regional level only. Karanja Industries (Pvt) Ltd. has wide distribution network. The Company increased the number of dealers to push the product into the market. The following are the few dealers to whom Karanja Industries (P) Ltd. is selling their products white Duplex Board/Kraft paper.
OWNERSHIP PATTERN:
This company is owned by 46 shareholders but out of these only seven are active shareholders. The active shareholders are as follows:-
SRI. JAGAN LACHUREY SRI B.S KUDRE
CHAIRMAN MANAGING DIRECTOR 10

SRI. H.S BIRADAR SRI. V.S. CHILLARGI SRI. VIJAYKUMAR PATIL SRI. PANDURANG BIRADAR SRI. SHARANAPPA PATIL DIRECTOR EXECUTIVE DIRECTOR EXECUTIVE DIRECTOR DIRECTOR DIRECTOR
COMPETITORS:
Gramox Paper Kerala Duplex Board. Sarvalakshmi Papers Tamil Nadu Duplex Board. Murli Agro Papers Nagpur Duplex. Bedse Paper Mill Aurangabad Kraft paper. Awade Paper Mill, Sangli Kraft paper. Vijayanand Papers Andra Pradesh
Local Competitors: Gemini Graphics Industries Pvt Ltd. Bidar. Veerji Paper Mill Pvt Ltd- Bidar.
The competitors watch each other carefully and formulate the strategies to increase their dealers.
ACHIEVEMENT / AWARDS:
The following achievements are achieved by the company in its life time. The company received on Award for Excellence for an excellent performance of the company by KSFC during 1994-95. While on 30th November, 1996 the company added one more diamond to its crown. The company received ISO: 9002 certificate by STQC Directorate Govt. of India, New Delhi.
11

On march 2003 the company has switched over to ISO: 9001-2000 version which is in upgraded version Further in appreciation of the excellent performance of the company. The M/s KSIDC Bangalore allotted Excellent Track Record AAA for best performances and also allotted the Health Code No. 1 for working capital operator limit efficiency by Canara bank. In addition to the above achievements the following awards were conferred on the M.D. of the company for excellent performance. Award for excellence by KSFC Bangalore. Vijayshree by International Friendship Society of India, New Delhi. Udyog Excellence Award by Industrial Economic Forum Mumbai. Bharat Gaurav Award by Council for National Develop, New Delhi. Indira Gandhi: Priyadarshini Award by All India National Unity Conference New Delhi. Bharat Udyog Ratana Award by Indian Economic Development and Research Association New Delhi. Industrial Excellence Award by Industrial Exhibition Committee, New Delhi. Rastriya Nirman Award and national Goldstar Award by Forum for 21 st century Development, New Delhi. Rajeev Gandhi Shiromani by Global Economic Council, New Delhi.
FUTURE GROWTH AND PROSPECTS:
To open a school for companies workers children. To open a hospital in factory campus. To provide colony facilities to the workers. To expend the market area to U. P., Kolkata, Delhi, etc., i.e., through out North India. To provide better quality of product at cheapest rate. 12

Effected treatment plant: The industry having good water management to reuse or recycle the waste water within the system it self having a good E.T.P. Company plan is to increase production by 10 to 15 MT modification in production unit. They are supplies their product to I.T.C and pass India ltd. They try to get more and more supply with quality and quantity to customers.
ORGANIZATIONAL STRUCTURE
Managing Director
13

General Manager Factory Manager Paper Division
Asst. Stores Mgr
Time Office In charge
Q.A.I/C
Production Manager
Store Asst
Asst
Lab Asst
R/M Insp
Finishing Supr
ETP I/C
Elect Supr
Maint Engg.
Shift I/Ss
Pulp Mill I/C
Finishers
Operators
Electricians
Fitters
Opts
Opts
FUNCTIONAL AREAS HUMAN RESOURCE DEPARTMANT
MANAGER
ASSISTANT MANAGER
SUPERVISOR
14

H uman resources management involves recruiting and addressing staffing needs, hiring and training the best employees and making sure that these employees turn out to be out standing performers. It also includes dealing with performance issues and ensuring employees personnel and management practices conforms to various regulations. Any organization with manpower as its chief capital is a treasure of talent. It is the HR department which acts as the key to unlock, identify, develop and utilize employee skills and talents to further individual as well as organizational goals. The chief functions of the HR department Training and Development change the management, salary and benefits, industrial and employee relations and performance appraisal. The HRM department here at Karanja Industries Pvt.Ltd consideration the employee the foremost and major resources of the company upliftment of employees growth are at the center of organization philosophy of growth, which aims at providing a career in which the individual can make at the same time better standard.
The role of the personnel management is an organization is a more valuable to achieve the organizations goals. The Personal Department will conduct the advanced technical training to develop the employees skills at the works.
Functions:1. 2. Personnel Department provides a set of techniques for handling people with professional standard. Personnel Department helps the employee to utilize their capacities to the maximum level and to attain not only individual satisfaction but also satisfaction as a part of the work group. 15

3. 4. 5. 6. 7. 8. 9. Manpower planning. Recruitment and Selection. Introduction of the newly recruited employee. Training and development of the employee. Motivation/Counseling. Grievance handling. In time communication to the employee.
10. Promotion. 11. Discipline & disciplinary actions. 12. Health, safety, welfare of the employee.
Apart from the above functions, the personnel department also liaison with various statutory bodies like Labour department, Factory Inspectorate department, P.F. Office etc., It is the responsibility of the department to prepare the statutory returns falls under various acts and submit the same to the concerned authority within the stipulated time.
RECRUITMENT: Recruitment is the process of stimulating the prospective candidates to apply the job.
Karanja Industries Pvt. Ltd uses the following sources to recruit the candidates. : Advertisement in news paper & electronic media. Walk in interviews
Promotion is totally based on working experience of the employees. Company believes in promoting those employees who really contributes towards the growth of the organization.
16

SELECTION PROCESS
First the applications were received, then the candidates are scrutinized, then they send call letter to the candidates, then the interview is taken by Head of the Department takes the interview & induction will be done for selected candidates. At every stage scrutinizing is there.
TRAINING AND DEVELOPMENT Company is also conducting exit interviews of separating employees by the head of HRM the out come of the exit interview is discussed in top-level meetings in order to keep pace with change due to the liberalization and globalization initiated steps are taken to upgrade the skill of the employee train them periodically, internally and if required through external programs 95% of management at staff is computer literates.
INFRASTRACTURAL FACILITIES:
The company has provided the infrastructure like building, workspace, process equipments, computers and supporting service (transport or communication etc.,) for meeting their equipments of the customer.
PRIVIDEND FUND AND GROUP INSURANCE:

Under this benefit, monthly deductions from the employees salary are made. The employer contributes an equivalent amount. At the time of retirement, death the full balance of his / her credit with interest is payable. And the company also provides group insurance to their employees. 17
Karanja Industries (Pvt.) Ltd. WAGES SYSTEM

Time wage system / Fixed wage system is practiced in the organization because measurement of each employees outputs are very difficult.
CANTEEN
The company is having a canteen in the factory campus only supplying the food at cheapest rate than outside, to the workers of the company.
MEDICAL TREATMENT
The company providing medical allowances about doctor fees and medical expenditure whatever paid by the worker. If the injured at the working hours all the expenses incurred are paid by the company and some extra allowances with half salary up to his injury period are paid.
TRAINING FACILITY
If some workers show some extraordinary service then for his further improvement the company may send them for training. Company gives On the Job and Off the Job training. Company sends them for attend the national level and state level seminar for managers only.
SICK ROOMS
The sick room facility is providing here to the workers during their leave hours and the sick room for visitors also available.
18
Karanja Industries (Pvt.) Ltd. BONUS

The company is providing Bonus to employees is 8.33% based on workers salary. Promotion facilities available in this company.
GOOD VENTILATION, LIGHTING

For better environment conditions to the workers in the factory good ventilation and soft lighting are used to maintain the workers health in the production area.
UNIFORM, SHOES, HELMETS

For every worker working permanently in the company could get factory uniforms, shoes, helmets and safety measures every year.
PARKING FACILITY
The parking facility is provided for the employees cycles, two wheelers and four wheelers and for the trucks which bring the raw material.
ACCOUNTS DEPARTMENT
ACCOUNT MANAGER ASSI.A/C MANAGER SUPERVISOR
19
Karanja Industries (Pvt.) Ltd. CASHIER

The accounts are maintained in the double entry system of book keeping. The basic documentation is done through chequs, vouchers, receipts, bill invoice and journal voucher. The accounts department is headed by internal auditor of the company. All the accounts are computerized. Tally accounting software is in use. The total expenditure of the company of Rs.3 crores per month. The total monthly salary of workers of Rs.16 lakhs. The company maintains a clean and perfect Accounting system. The main activity of the Account Department is Working Capital Management. Preparation of financial statements such as Balance Sheet, Profit & Loss Account etc is also the activities of the Finance Department. Secretarial works relating to Board comes under the review of this Department. Most of the activities carried out by the Account Department pertaining to long-term and short-term requirement of the operation using Purchase Bill maintaining the accounts of contractors, sub-contractors, Income Tax deductions, salary, discrepancy, dealing with the financial institutions with imports and exports are also the functions of the Account Department.
Functions of Account Department:

1. Funding Activity Banks provide both long-term and short-term funds. Long-term funds like debentures, term loans, etc are used for project financing. Short-term loans are taken to meet the working capital requirement. Commercial banks help in providing short term funds.
20

The account department will be having the continuous communication with the head office, so that the corporate office can transfer the funds to its unit. This is called as Fund transfer booking. 2. Treasury Function They will maintain cash or bank balance book for any payment. They will use only cheques for making transactions. 3. Book Keeping A company should maintain books of accounts. There is an own built computerized system including the accounts of sale, purchase, cash/bank, stock, tax, fixed assets, etc. The department has to disclose the information by closing the books monthly. The books disclose the information to the share holders of the company.
PRODUCTION DEPARTMENT
The production department is headed by the production manager. The function of the production department is to produce our products on time, to the required quality levels, at the defined product cost. Of major concern to the production manager is monthly output. Production managers have monthly targets which they are expected to strive to meet or exceed. Production can only meet its targets if Sales secure orders. Also production costs are dependent on the price we pay for components and materials etc.
21

Four important sections of the Production Department. PRODUCTION MANAGER
ETP Section
Electrical Section
Mechanical Section
Process Sections
WATERMAN
LINEMEN
ENGEENEAR
STORKEEPER
ETP SECTION :
Effluent water is treated in ETP Plant waste water takes birth in pulping and dehydration process and washing activities is plant treatment and recycling of water for it taken to ETP (Effluent Treatment Plant). ETP contains considerable amount of waste impurities like pins, dust etc. They were neutralized by using lime water, alum and sulphuric acid after sterilization of the mixed material, the impurities will be drained and fresh water will be utilized in recycling of puling process.
TREATMENT OF WASTE MATERIAL :

22

The main advantage of the company is 100% use of waste material because the basic raw material used is any kind of papers thus waste paper in various processes, cut downs, on sized papers, defective quality of papers all are reused, they were stored at one place and passed to pulp mill were they used for pulping process and water which is waste again reused by purifying then at ETP Plant.
ELECTRICAL SECTION:
There is one supervisor and 4 electricians working, 3 electricians in 3 shifts all the electrical work is done by this department. Any power on / off power supply, wiring, lighting, all are maintained and forward by the said department.
MECHANICAL SECTION
MECHANICAL ENGINEER
FITTER
HELPER
Interpretation:
23

There are 3 mechanical engineers, 6 fitters and 9 helpers working in 3 shifts. The maintenance of all machines in the organization is to be maintained by the said department. If some mechanical trucked the concerned in charge has to inform the mechanical engineer. He will make repair it. If not possible by him the specialist will be called from outside.
PROCESS SECTION:
The process starts from accepting raw materials from pulp mill where the raw materials is stored in the form of Kraft paper.
SORTING:
In this step the raw material accepted from pulp mill will sorted i.e., separated into Kraft paper, stored them differently in different 2 godowns with the capacity of 65 tons each.
PULPING:
The sorted papers were transferred to plumping process where the pulp is formed of them. The pulp is formed by mixing raw materials. Paper with required quantity of water is flowed from top and all paper is converted into pulp. The machine used for the purpose is HYDRO PULPER.
SCREENING:
Thus formed pulp is transferred to machine through pipes where the weighted substances like metals, pins, and steels, sand, soil from pulp is removed and passed is to the decter section. 24
Karanja Industries (Pvt.) Ltd. THICKENER:

Thus purified pulp transferred to decter machines where dehydrating is done i.e., the water is removed from pulp and that water transfers for the further use in hydro pulper. The water content removed with the help of 3 f screen, magnet valve and sandraf.
Then the pulp is passed through TDR (Trial Disc Refiner) where pulp is softened and ph of pulp is tested and the chemicals like Rosin, Alum, and Goargum. There are totally 5 decters for 1 pulp mill.
Thus softened pulp is passed and stored in chest box. There is 1 head box for 1 pulp. Then from head box the pulp is passed through various following machines and undergone following process.
HEAD BOX:
There is 1 synthetic wire the slurry pulp is constantly supply to synthetic wire. The basic purposes of this synthetic wire is to get the basis paper web format.
VACCUME PUMP:
There are 5 vaccume pump used for removed water from pulp, with help of synthetic wire boxes are below synthetic wire. Wire will carry slurry of pulp. Vacuumed pump queering water from pulp. Water contain in end of wire part is around 80% drying the synthetic felt. Then passed to press section.
25
Karanja Industries (Pvt.) Ltd. PRESS SECTION:

There are two different press machines for 1 pupl to form one single paper web. The web board contains 1 layer of a pupl. In this section, the moisture content present in the paper web is also removed.
The moisture content of paper web is maintained and after 2 nd press in the range of 52
3% by applying pneumatic load at both the press roles.
DRIER:
Then from press section the paper web passes to dyers through belts. The dryers are used to dry the paper web through steam generated trough boilers. In the initiation is done by drying the web slowly. When the web moves to pre-dryer where the web is dried again with high steam and when it is passes to MG Cylinder it dries out the condensed water continuously,. Then the paper web ends and the paper web is fully dried out and all content of moisture is removed finally. When the web transfers to MG Cylinder there is 35 to 40% moisture is present and which comes down to 20% when pass through past Dryer. There are totally 1 MG Cylinder and 7 pre-dryers and 4 past dry [per machines used.
POP REEL:
If the paper was ordered in reels then the paper is reeled out with the help of this machine. It is a machine which is having a round roll and which reels the paper.
REWINDER:
26

It is a machine which cuts the paper reels into required sizes. The reels are cuter by circular knives. Breaks and core knives.
FINISHING HOUSE:
After cutting the paper board they were brought to finishing house where segregation of acceptable and non acceptable paper is done by physical testing.
DUTIES AND RESPONSIBILITIES:
`The defective reels such as creasing; cocking, over dry size variations, damping and
damage reels should be rejected and kept alone. The accepted reels should checked physically may ream of 1 bundle and packed with clip, plastic sutali, pp woven, wrapper properly and paste the labels containing manufacturing date, size and number of sheets, GSM, BF and weight.The weight of each bundle 200 to 800 kg and packed in Hessian cloth and put proper identification mark and record.
WORK FLOW MODEL PROCESS FLOWCHART
27

SORTING OF RAW MATERIALS
Moisture test
STOCK PREEPARATION OF BOTTOM LINEAR PULP

Freeness test, consistency , & PH
STOCK PREPARATION OF TOP LINEAR NO.1 PULP

STOCK PREPARATION OF TOP LINEAR NO.2 PULP

PAPER MACHINE WET END SECTION

Consistency test Moisture test
DRY END SECTION

Consistency test Final test
FINISHED SECTION
28
Karanja Industries (Pvt.) Ltd. The Work Flow Model Of The Company: SORTING OF RAW MATERIALS: Responsibility : Q.A. Inspector Purpose
To segregate the unwanted materials
Instructions:
1. This procedure is restricted for white cutting material only. 2. Remove the packing of each bundle of white cutting and keep a side. The packing material shall bee considered as color record and used as raw materials for bottom layer 3. Unwanted materials such as dust, sand , rubber, plastic strips, etc. shall be removed. 4. Unwanted materials shall be collected in a drum and shall be used as a color record. 5. Sorted white cutting materials shall be stacked for further process.
STOCK PREPARATION IF BOTTOM LINEAR PULP: Purpose

: Slushing, Screening, Refining, & Chemicals mixing of the pulp.
Responsibility : Pulp mill operators. Machineries
Hydropulper-01 No. Sand trap 01 No. Johnson vibrating screen 01 No. Thickner 01 No. Turbo-separator- 01 No. Dry disc refiner 01 No.
29
Karanja Industries (Pvt.) Ltd. Instructions:

1. Feed the back water form E.T.P to hydro pulper upto th level and starts the motors. 2. Feed the acceptor raw materials through the converter. 3. Pump the slushed pulp to sand trap and allow the pulp to flow through the sand trap. The dense particles , sand, grit and iron particles are settled down. Clean the sand trap once in 15 days for better result. 4. Clean the hydro pulper once in a shift. 5. Pump the sand trap accept to turbo-seperator. The accepted stock passes to thickner and rejects will again feed to Johnson vibrating screen. 6. Collect the thickner accepts in chest No.2 and start the empty tri-disc refiner and pass the pulp through a pump. Apply the load upto 75 5 ampsin order to achieve the required freeness. 7. Take a refined pulp to chest no.4. Add chemicals as per annexure-1 till obtaining the Ph. In between 4.0 to 4.5 and pump to chest no. for machine use. 8. Keep the surrounding area always clean. 9. Check the consistency performance of the machine chest pulp once in 4 hours and maintaining 3.0 0.5%.
STOCK PREPARATION IF TOP LINEAR NO.1 PULP: Purpose
: To refine the pulp and to add chemicals to obtain the Ph properties. :
Responsibility : Pulp mill operation. Machineries

Hydropulper 01 No. Tri-disc refiner -01 No. Inclined screen -01 No.
30

1. Fill the hydro pulper with fresh water up th level. 2. Start the hydro pulper motor and put the sorted white cutting raw materials slowly and uniformly. 3. Take the slushed pulp to chest no.1 through pump. 4. Pass the pulp to chest no.2. 5. Start the tri-disc refiner apply the load 75 5 amps. And recalculate the pulp to the same chest for 2 to 2:30 hours in order to achieve the required freeness value. 6. Add the chemicals as per the annexure-1 till obtaining the Ph 4 to 4.5. 7. Pulp the pump to chest no.3 for machine use. 8. Check the consistency of the machines chest pulp once in 4 hours by consistency meter and maintain in between 2.5 0.5%.
STOCK PREPARATION IF TOP LINEAR NO.2 PULP: Purpose
: To refine the pulp and to add chemicals to obtain the Ph properties. : Hydro pulper 01-No.
Sand trap 01-No. 3-F screen 01-No. Inclined screen 01-No. Tri- disc refiner 01-No.
Responsibilities : Pulp mill operators Machineries
31

1. Start the hydro pulp motor and back water pump and fill up to 50% level and put the sorted white record material slowly and uniformly. 2. Pump the slushed material to chest No.4 through the sand trap add the bleaching powder as per annexure-1 and wash the pulp thoroughly by re circulating the pulp through the inclined screen. Clean the sand trap once in 15 days. 3. Start the 3-F screen and back water pump and pass the pulp to chest No.5 . Add the chemicals as per annexure-1 till obtaining the Ph in between 4.0 to 4.5. 4 . Start the try disc refiner apply the load 75 5 amps and re circulate the pulp to the same chest for 2 to 2:30 hours in order to achieve the required freeness value. 5 .Pump the pulp to chest No.3 for machine use . 6.Check the consistency of the machine chest pulp once in 4 hours by consistency meter and maintain in between 2.5 0. 5% .
PAPER MACHINE WET END SECTION: Purpose Responsibility Instructions:

1. Fill the back water tanks with fresh water (or) E.T.P recycled water. 2. Start the empty machine by starting the D.C variable motor. 3. Start the fan pumps which pumps pulp and water to centric cleaners. 4. See the whirling action at all nozzles. 5. Tate the accepts of centric cleaners pump to individual dilution tanks and add back water through a separate pump. 6. 6.Adjust the edge cutter as per the required size 7. Keep the mould showers always clean .
: To make the wet paper web. : Shift incharge and Mould operators.
32

8. See all the layers that are formed at separate mould are become a single wet sheet, which is carried by an end less bottom pick up felt to press section. 9. Adjust the pneumatic loads at 1 and it press so that the moisture % of the wet web living 2nd press should bee 58 3%.
PAPER MACHINE DRY END SECTION: Purpose Responsibility Machineries
To dry the wet paper web and cut as per customer size.
: Shift incharge and steam operators. : Dryers

M.G Calendar Cutter and Rewinder
Instructions:
1. Heat all the dryers and MG by opening the steam to all dryers and MG . 2. Pass the wet web to pre dryer group manually and adjust the steam by controlling the pressure at each dryer with the help of pressure gauges which are indicative so that the moisture contains of the web leaving pre-dryers should be 40 20%. 3. Pass the sheet to M.G so that the top surface will get glazed along with drying maintaining the moisture content of the sheet leaving the M.G in between 20 2% by controlling the steam at M.G . 4. Pass the sheet to past drying group and dry the sheet so that the moisture content of the final sheet should be 6.0% 1 % . 5. Pass the sheet through calendar to the bottom surface smooth and then feed the sheet at cutter machine to cut according to customer required size and stock it in finishing house with identification label. 6. Reel the paper in pope reel and then rewind it in re-winder as per the orders are in reel form. 33
TRANSPORTATION :The company doesnt have its own transport vehicles. It hires the vehicles on rental and lease basis. The main transportation is done through road transport and railways.
MACHINES :The company brought machines which were installed in the company from the following companies Parason TDR, Delhi J & K Engineers Pvt., Ltd, Chennai. Machine Industries Pvt. Ltd., Kolkatta Unique Enterprises, Pune
PACKAGING SECTION :PACKAGING / FINISHING INCHARGE
FINISHING CLERK
PACKING SUPERVISOR
STICKING SUPERVISOR
FINISHER
The packing of the kraft, Board is done in finishing house. According to demand of the customer the krat board and pop reels are packed in various sizes with the help of clip, plastic sutali, pp woven, wrappers and the stitched. All the reeling, cutting of pop reel are done by automatic machines. The stitching pasting, weighing are done physically.
34
MARKETING DEPARTMENT
Importance of Marketing
Marketing is a social process which individual and groups obtain what they want and what through creating, offering-and freely exchanging products and services of value with others. The essence of marketing is exchange or a transaction intended to satisfy human needs and wants through an exchange process. A demand is a want for which the consumer is prepared to pay a price. A want is anything or a service, the consumers desires or seeks. Wants becomes demand when backed by purchasing power.
A need is anything the consumer fells to keep himself alive and healthy. A transaction consists of value between two parties. A transaction differs from a transfer. A transfer may receive nothing in return. The aim of making is to make sales n order to earn reasonable portable profit for the producers.
Objectives of Marketing
Barker and Anshen say the end of all marketing activities is the satisfaction of human wants through the satisfaction of human wants, profits are rewarded to the business and addition benefit is the inducement of marketing. Now the time has changed and the objective of marketing is more than security profit. The following are the main objectives of modern marketing activities.
35
Marketing Mix Marketing mix is a term used to describe the combination of the four inputs which constitute the core of a companys marketing system. They are :1. Product 2. Price 3. Place 4. Promotion
MARKETING POLICY:
In the direction of achieving the companys mission, the marketing team- PIP endeavors for maximization of sales and realization for the company products while meeting the customers requirement to heir all round satisfaction. This department is headed by marketing manager and maintains a wide area of distribution network. The company occupied a large of market in the state as well as in other state namely Maharashtra, Tamil Nadu, Kerala etc. The company supplies it product to its main dealers, customers in various following regions. Anil Paper Board Bangalore. Nikhil Agencies Bangalore. Sushen Paper (P) Ltd. Bangalore. Laxmi Paper mart Bangalore. Deepa Packers, Mangalore Mysore Paper Corporation Secundrabad. 36

Sai Baba Paper Mart, Hyderabad. Vishwa Kutumb Pvt Ltd Hyderabad. Goli Iswariah Hyderabad Direct Consumer Reliance Packaging Industry Chennai. Jahan Enterprises, Shivkashi. Krishna Enterprises, Chennai Adhunic Packaging. Paper Combasins Kerala. Shreerang Agency Mumbai. Vishwas Trading Company Pune. Candid Paper Mumbai
DISTRIBUTION NETWORK:
Under the distribution method the product is sold to the dealers and consumers and consumers on consignment selling method. The advantage of consignment selling is that manufacturer runs no risk in having possession and making sales of the product through the dealers, retailers to finally consumers. Sometimes consumers directly purchase the product from the company also.
VARIOUS ADVANTAGES OF THIS CHANNEL :

Helps in production function. Matching demand and supply gap. Stabilizing the prices. Promotional activities. Consumer will get goods at cheaper price.
37
DISTRIBUTION NETWORK OF THE COMPANY

MANUFACTURER
DISTRIBUTOR DEALER DEALER RETAILER

WHOLESALER RETAILER
RETAILER
CONSUMER
CONSUMER
CONSUMER
LABORATORY :
There are 3 lab assistants are for each shift the tab assistant has to check the GSM (Gram Square Meter), size, weight, thickness, Ph stiffness, ash content, consistency, BF of every paper product, the square of every paper is cutted down tested in laboratory. If lab assistant checked that the produced paper board is not of the required quality he will reject them and inform the production manger and other required quality paper board will be produced.
38

The following machines were used in the testing process. : BF Tester Hot air oven Weight Machine Physical balance. Consistency tester. Essae digit Freeness tester. Cob tester. Ash tester Ph tester.
QUALITY DEPARTMENT
Quality assurance division is a customers representative. This department acts as communicating channel between customers and production department. They make steel for automobile industries and also for stimulus tubes. It is also used for transportation of oil and any other fuel.
In quality assurance department, marketing department plays in important role. The orders of the customers will be received by the marketing department, then department. This process is called as Contract Review.
Then the quality assurance department translates the need of the customers to the production department. This department also inspects the cost And rolled products. It checks 39

the materials before it is taken for production and also tastes the products before dispatching to the customers. Ever since the procurement of the raw material till the dispatch of the final product the function of observation and examination of the quality control department is keen and careful.
As there are two divisions in the company the quality department for each department is different. Quality inspection is carried out for both the incoming raw materials and out going finished goods. The raw materials should be as per the standard size, volume and with chemical composition and metallurgical composition.
QUALITY CONTROL :-
In Karanja Industry, there is a laboratory in the plant to check the quality of paper manufactured and it check the quality in every lot. It sends a report of quality of paper to quality manager, if the manager feels quality of paper dues not meet the customer requirements. Then he sends report of corrective action to be taken production manager, where in the takes proper corrective actions according to the report to meet the customer requirements and satisfaction. The rejected paper due to bad quality is reused in process in hydro pulper machine by making pulp of rejected paper so there no wastage 100% utilization takes place. Inspection of Raw materials Laboratory testing method
AIMS
40

To inspect the quality of raw material and finished products and to maintain the grades as per the customers requirement.
FUNCTION; 1. Adding internal/external chemistry to attain specified standard. 2. Testing the manufactured products subjects to any damage or not. 3. To check the raw materials. 4. Identifying customer 5. Indentifying needs. 6. Converting needs into specialization.
QUALITY POLICY
Karanja Industries Pvt. Ltd is committed to achieve total customer satisfaction through adoption of state of art manufacturing and processes with continual improvements. Karanja Industries Pvt. Ltd is also committed to improve the quality of work life of its employees through improved work practices.
QUALITY OBJECTIVES:
Customer Satisfaction: Maximization of Customer Satisfaction by consistent 41
supply of Quality Kraft & Duplex Paper.

Supplier Quality Assurance: Provide technical support and guidance to our suppliers through Quality Assurance Programmes to ensure highest Quality of purchased materials. Supplier is a critical link in our Quality System. Employee Development: Development and motivation of all employees by providing
necessary training and support to bring out their full potential.
PURCHASE SECTION
PURCHASE MANAGER
ASST. MANAGER
CLEARK
The purchase department is headed by the purchase manager, who takes the responsibility of purchasing the required qualitative and quantitative raw materials. All purchases are made by the company or all requirements needed by the company will purchase through him only. If some department of the company required some any materials they have send requisition letter informing about the quantity and quality of materials required. The purchase manager after accepting the letter, he purchase and sends them to concerned 42

departments. The purchase manager has to maintain day-to-day purchase records and same and to be reported to the M.D. Daily 50 tons of paper has to purchased day-to-day purchased by him to run the machines of pulp mill.
The following are prices quotes in purchasing of raw materials White Record White Cutting Color Record Depend upon Market Price
STORES SECTION :It is a one where all the necessary daily-required materials are stored and are issued against requisition slip by concerned department chief. The department is maintaining Bicard MRV. (Material Receipt Voucher ledger books of every product which coming in and going out of department. MISSION MINIMIZE THE COST OF INVENTORY. VISION ATOMIZATION OF CURRENT SYSTEM.
Karanja Industries Pvt. Ltd adopts FIFO [First in First out] method to issue the materials in order to avoid obsolescence of material and company finds this method as most 43

convenient to handle the inventory. Store department is a common department both pig iron and foundry division but it maintains different documents for each division.
Futures Growth and Prospects: As the company is committed to produce quality products, it results in attracting more number of customers and to beat the competition. As per the infrastructure is concerned Karanja Industries Pvt. Ltd has a well equipped and sophisticated infrastructure which helps the company to meet the customer demand in time. By looking at the present infrastructure, skilled workforce, technology and emerging demand condition, company is planning to put one step ahead i.e. by diversifying to steel manufacturing industry.
As the demand for the automobiles are increasing the demand for the products of Karanja Industries Pvt. Ltd is also increasing, so Karanja Industries Pvt. Ltd has got a clear and bright future
44
SWOT ANALYSIS
The main Strengths, Weaknesses, Opportunities and Threats of the company which have been observed and studied in the organization are as follows:
STRENGTHS: Good cliental base. Technical and experienced manpower. Automated and highly sophisticated machines. ISO 9002 certified company. Government support acting as the backbone for the company. Well planned layout helps for the smooth functioning of work & excellent infrastructure can create better working environment.
WEAKNESSES: Less emphasis on training. Location of plant resulting in high transportation cost. Lack of motivation and creeping inefficiency. Price of goods is comparatively high.
OPPORTUNITIES:45

Growing Demand for Kraft & Duplex products. Easy availability of human resource according to the requirement. Opportunity to tap national market. Opportunities exist for the company in cutting the cost of production and thereby to gain untapped market opportunities. Due to innovation and advancements in technology, there is a scope for recruiting and retaining the specialized employee for the specific job.
THREATS: Changing Government Regulations. Pollution Board Norms . New competitors like Gemini Graphics and Veerji Paper Mill are enters in market will dilute in the market share of the company. Increased transportation cost due to loading recreation & increasing fuel prices. Inconsistent power supply.
46
FINDINGS AND SUGGESTIONS
FINDINGS: The organization is one of the major industrial setups in Bidar providing employment opportunities. It is spread in 85 acres of land including the lands and the manufacturing unit. More efforts are required in the marketing field and there is no recruitment in the company from last few years It offers employment to more than 506 no of employees at various levels and in different capacities and the mode of employment ranges from permanent contract to daily wages. Dealers are showing increased interest in purchasing the companys board because of high profit margin. Usage of modern technology. It is having centralized control system which is not useful for sudden decisions. Dealers are showing increased interest in purchasing the companys board because of high profit margin. 47

They are having good and excellent infrastructure and ultra-structure facilities. The employees employer relationship is very good. .
SUGGESTIONS:Means communication should be made through telephone, internet, and websites and also through fax. Good means of combination system like transport facility should be made easy to deliver the goods in time. Keep the workers well contented and reduce labor turn over rate. Company has to improve its performance by reducing cost so that the company can able to achieve the profit in future. The company can introduce innovative quality practices to cut costs in various process of production and increase competitiveness in the market. Organization could re-design the structure as per the current environment to allow freedom and empower the management for decision making. Skills and motivation level of the employee can enhanced by providing effective training. To conclude company should minimize its overall cost and its operation for the benefit of the company. Effective, charismatic leadership is required who could steer the company towards profitability by controlling the leakage of available resources and overcoming the organizational weakness. 48

The company had to capture local market to satisfy the local customers.
Have to replace the new machine in place of the old machine, as replacing the new machine with the old it costs too high but it can be done as follows: Taking loan from the bank to implant the new machine. Installing new machine with the exchange of the old by deducting the depreciation and paying the remaining amount. Monitoring every month whether the machineries working fine and lubricating whenever required.
CONCLUSION
The company has to overcome the following, The main objective of the in-plant training is to gain knowledge about functions of an organization, its back ground, Nature of business, its working and analysis of various product profile of the organization. Staying in the KARANJA PAPER MILL PVT LTD factory for almost a month was a platform for me to know its business conditions in the initial stage and gradual growth. The study helped me to view the process of producing various products produced in the factory. To know the performance of KARANJA PAPER MILL PVT LTD. Produces good quality white cutting duplex paper board and Kraft paper board. Workers are highly satisfied with wage and salary administration and welfare facilities. To conclude organizational study at KARANJA PAPER MILL PVT LTD. helped me to relate the theoretical knowledge to the practical environment and enlightened me with the knowledge regarding.
49
BIBLIOGAPHY
BOOKS:
Title of the Book Marketing Management. Name of the Author Philip Kotler. Title of the Book Financial Management. Name of the Author I. M. Pandey. Title of the Book Financial management Name of the Author Prasanna Chandra Title of the Book Human Resources Management Name of the Author Dr. Aswathappa By Observation & Magazines & Reports.
Website: www.karanjaindustriesltd.com
www.google.com
50
Karanja Industries (Pvt.) Ltd. Website: www.karanjabidar@yahoo.com
51

Project PPT RPT

Transféré par

Informations du document

Description originale:

Titre original

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

Project PPT RPT

Transféré par

Droits d'auteur :

Formats disponibles

Karanja Industries (Pvt.) Ltd.

PROMOTERS PROFILE/ COMPANY PROFILE: INDUSTRY PROFILE

Karanja Industries (Pvt.) Ltd.

Paper Industry in India

Karanja Industries (Pvt.) Ltd.

Karanja Industries (Pvt.) Ltd.

Karanja Industries (Pvt.) Ltd.

Karanja Industries (Pvt.) Ltd.

Karanja Industries (Pvt.) Ltd.

NATURE OF THE BUSINESS CARRIED:

Karanja Industries (Pvt.) Ltd.

Karanja Industries (Pvt.) Ltd.

AREA OF OPERATION: (National/Regional):

SRI. JAGAN LACHUREY SRI B.S KUDRE

CHAIRMAN MANAGING DIRECTOR 10

ADMINISTRITIVE MANAGEMENT COLLEGE BANGLORE

Karanja Industries (Pvt.) Ltd.

Karanja Industries (Pvt.) Ltd.

FUTURE GROWTH AND PROSPECTS:

Karanja Industries (Pvt.) Ltd.

Karanja Industries (Pvt.) Ltd.

Asst. Stores Mgr

Time Office In charge

Pulp Mill I/C

FUNCTIONAL AREAS HUMAN RESOURCE DEPARTMANT

Karanja Industries (Pvt.) Ltd.

Karanja Industries (Pvt.) Ltd.

Karanja Industries (Pvt.) Ltd.

PRIVIDEND FUND AND GROUP INSURANCE:

Karanja Industries (Pvt.) Ltd. WAGES SYSTEM

Karanja Industries (Pvt.) Ltd. BONUS

GOOD VENTILATION, LIGHTING

UNIFORM, SHOES, HELMETS

ACCOUNT MANAGER ASSI.A/C MANAGER SUPERVISOR

Karanja Industries (Pvt.) Ltd. CASHIER

Functions of Account Department:

Karanja Industries (Pvt.) Ltd.

Karanja Industries (Pvt.) Ltd.

TREATMENT OF WASTE MATERIAL :

Karanja Industries (Pvt.) Ltd.

Karanja Industries (Pvt.) Ltd.

Karanja Industries (Pvt.) Ltd. THICKENER:

Karanja Industries (Pvt.) Ltd. PRESS SECTION:

3% by applying pneumatic load at both the press roles.

Karanja Industries (Pvt.) Ltd.

DUTIES AND RESPONSIBILITIES:

WORK FLOW MODEL PROCESS FLOWCHART

Karanja Industries (Pvt.) Ltd.

STOCK PREEPARATION OF BOTTOM LINEAR PULP

STOCK PREPARATION OF TOP LINEAR NO.1 PULP

STOCK PREPARATION OF TOP LINEAR NO.2 PULP

PAPER MACHINE WET END SECTION

DRY END SECTION

To segregate the unwanted materials

STOCK PREPARATION IF BOTTOM LINEAR PULP: Purpose

Responsibility : Pulp mill operators. Machineries

Karanja Industries (Pvt.) Ltd. Instructions:

STOCK PREPARATION IF TOP LINEAR NO.1 PULP: Purpose

: To refine the pulp and to add chemicals to obtain the Ph properties. :

Responsibility : Pulp mill operation. Machineries

Karanja Industries (Pvt.) Ltd. Instructions:

STOCK PREPARATION IF TOP LINEAR NO.2 PULP: Purpose