Ashas Report

Summer Project Report 2008-2009 Organizational study CHAPTER 1 INTRODUCTION Binani Zinc Ltd.
is a pioneer in the manufacture of high grade electrolytic zinc in India. Since its inception in the year 1967, Binani Zinc has paved the way integrating systems for maintaining product quality, environmental safety, occupational health and social accountability. Binani Zinc Limited is engaged in the manufacture and sale of zinc metal and its byproducts sulphuric acid & cadmium metal. Binani Industries Limited ranks within the first 20, amongst the top 200 large public limited companies in terms of Capital Output Ratio; BIL has employee strength of around 2000 people. It was in the turbulent times of 1872, when the ancestors of Binani, Seth Pragdas & Seth Mathuradas Binani ventured into the trading of non-ferrous metals. Later on, the son of Seth Mathuradas, Seth Govardhandas, a man with profound vision, had seen great potential in manufacturing rather than just trading in non-ferrous metals. Binani Zinc is the pioneer in the manufacture of high grade electrolytic zinc in India since 1967. The reigns of this wide spreading business ere with Late Shri Ghanshyam Binani, the only son of Seth Govardhandas Binani. His individual expertise and time-honed skills steered the organization towards many milestones ahead. In the span of 1970s 80s Cominco Binani Zinc Limited upgraded its technology to be on par with the latest in the world. It also became the first plant in the country to commence production of special high-grade electrolytic zinc with 99.995% purity
M.B.A College Marampally
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Summer Project Report 2008-2009 Organizational study
Today Binani Zinc being part of Binani Industries Limited is the second largest producer of Zinc in India. The company enjoys the reputation of being a leading and most preferred supplier of pure zinc in India. It is located at a place called Binanipuram in Ernakulum, Kerala. Its corporate office is at Kolkata and has another office at Mumbai. This strategic location, named as Binanipuram, has proven ideal as it facilitates the loading and off-loading of zinc concentrate, provides cost efficient power supply, ease in transportation, abundant water and easily available resources, inclusive of a literate work force. The main product produced by Binani Zinc Limited is zinc and its bye products are sulphuric acid and cadmium, which are used by other industries. It has the Capacity of:Zinc Cadmium 38,000 MTPA 51,000 MTPA 65000 kg PA Sulphuric Acid -
OBJECTIVES OF STUDY
PRIMARY OBJECTIVE
The main objective of the study is to get an idea about the whole organization as such and to understand briefly about the nature of the industry
SECONDARY OBJECTIVES
a) b) c)
To get an organization structure of the company and to get an idea about the various departments and its functioning. To know how the key business processes are being carried out in a manufacturing industry. To know about various policies and programmes
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Summer Project Report 2008-2009 Organizational study of the company. REASONS FOR SELECTING BINANI ZINC LIMITED FOR ORGANIZATIONAL STUDY Binani Industries Limited has been a pioneer in non-ferrous metal industry in face. It is the first company to manufacture zinc in India in the private sector. They also produce Sulphuric Acid and Cadmium as by-products. The plant has the capacity to produce 38,000 MT per annum. In India, zinc is manufactured only by two companies- Binani Zinc Limited and Hindustan Zinc Limited. Hindustan Zinc Limited is the dominant player in Indian market. Binani Zinc Limited is the only Zinc manufacturing company in Kerala. Over the years, Binani Zinc limited has undergone many transformations in its capacity, technology etc. under the leadership of Sri. Ghanshyam Binani, with the stinted support of qualified and dedicated staff. It is the 1st Indian company to operate a customized zinc smelter designed for 100% imported zinc concentrate. It is the 1st Indian company to produce special high grade quality of zinc with 99.995% of purity, The 1st in the private sector and one of the two primary manufacturers of zinc in India, The only company to install a converter heat exchanger system in the acid plant designed by M/s. Lurgi, Germany for energy conservation. It is among the 1st to be recognized by the Department of Science and Technology, Government of India for its R&D facility and laboratories. The 1st to be recognized by the bureau of Industrial Cost and Prices as the Best Zinc Plant in the country for the steps taken in energy conservation. First in India and in Asia, to be certified by BVQI for the four International accreditations viz., ISO 14001:1996, SA 8000:1997 as well as OHSAS
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Summer Project Report 2008-2009 Organizational study 18001:1999 for installation and maintenance of Environmental Management System, Occupational Health and Safety Assessment Series respectively.
SCOPE The organizational study was intended to get Industrial exposure. The study intends for a period from 21th May 2009 to 18th June. The study was mainly conducted to understand the functions of different departments of the Company. Binani created a name in the world zinc industry, by pioneering the manufacture of high grade electrolytic zinc in India.
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CHAPTER SCHEME The report is prepared in five different chapters. The details of each chapter are as follows: CHAPTER 1:-The first chapter gives an introduction about the study. provides details about the planning of the study and how it is prepared. CHAPTER 2:-This chapter gives an overview about Zinc Industry as a whole and gives Industry Profile. It gives details about the major uses and applications of Zinc. It gives an overview about Zinc Industry in the world, national and state scenario. The major players of Zinc Industry in India are also discussed in this chapter. CHAPTER 3:-This chapter gives an idea about the history and explains the company profile of Binani Zinc Ltd. This also gives details about the objectives of the company, mission and vision etc. This chapter also throws light on the organization structure of the company. CHAPTER 4:-This chapter gives the departmental details of Binani Zinc Limited. The various departments are Human Resource Department, Finance Department, Materials Department, Marketing Department, Information System Department, Research & Development department, Projects & Utility services etc. It gives the functions, structures and procedures of each department in detail. CHAPTER 5:-This chapter gives SWOT analysis of the company. CHAPTER 6:- This chapter gives the findings and suggestions.
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It
includes objectives of the study, sources of data collection. This chapter also
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Summer Project Report 2008-2009 Organizational study CHAPTER 7:- Conclusion of the report.
CHAPTER 2 INDUSTRY PROFILE WORLD SCENARIO Zinc is considered to be the fourth most important metal used in the world following steel, aluminium and copper. This metal is primarily used in the steel industry for galvanizing process. The other uses include used in making coins and pennies, used in die-casting in automobile industry, making battery container parts, used as a substitute to tin and lead pipes, ingredient in water colors and paints, activator in rubber industry etc. Also because of the fact that zinc does not corrode due to the non-acidic atmospheric corrosion, it makes the metal worth to use in for extending the life of building structures and modes of transport. The metal also comes in good use as a fungicide, herbicide and rodenticide. Zinc is available in the atmosphere in large quantities. The various external sources in which zinc is concentrated in the atmosphere are electric services, petroleum refining, crude petroleum and natural gas extraction, manufacturing of fabricated rubber products and metal heating and plumbing products, production of inorganic chemicals etc. The various indoor sources for the same contribute to slightly higher zinc content in the atmosphere and include infiltration of outdoor air; smoking, cooking, etc. Zinc is extracted from zinc ores mostly sphalerite, zincite and smithsonite and the world mine production of zinc concentrate sums up to around 10008000 tons annually. The zinc concentrates are then used to produce the zinc metal and around 10319000
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Summer Project Report 2008-2009 Organizational study metric tons of metal is produced per year. China is the largest producer country of zinc in the world in context of both metal and concentrate production. The world consumption of zinc annually totals up to around 10774000 tons.
ZINC USAGE: The usage of Zinc can be detailed as below. Galvanizing Alloys Chemicals Battery Brass Miscellaneous 60% 12% 12% 5% 6% balance
Zinc is widely used metal and used in protecting steel, diecasting and also as chemical compound. While zinc was known to the ancients, its production with modern technology started in India only in 1966, with the Smelter at Debari, While the zinc production worldwide was 7.2 million tonne in 1989, the Indian production capacity of zinc was only 99,000 tonne. Zinc metal uses are based on a number of properties and these properties are being exploited for variety of applications in defence and other essential industries. The principal processes for manufacturing are horizontal retorts, electrolysis, vertical retorts, electrothermic, overpelt and blast furnace (Imperial Smelting Process). Out of these, most important processes are electrothermic and blast furnace manufacturing, covering 93% of the total zinc production in the world. The electrolytic zinc process consists of dissolving zinc bearing materials to zinc sulphate solution which is purified to satisfactory
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Summer Project Report 2008-2009 Organizational study electrolyte and recovered as metallic zinc by electrolysis. The Imperial Smelting process is pyro-metallurgical process for combined production of lead and zinc. This will include raw material handling plant, smelter and gas cleaning plant, smelting blast furnace, zinc refinery, lead refinery, and recovery of high value metals. Zinc concentrates are the raw material for zinc smelter. Zinc ore consists of sulphate, sulphide mineral with galena, chalcopyrtite and
copper sulphide minerals. Zinc concentrates from zinc-lead ores contain about 59% zinc andd complex ores have 54% zinc. The pollution control/environmental requirements in terms of water, air, sulfur dioxide emission, etc., are important. Secondary zinc production has started in India in the last few years. Secondary zinc is recycling process and thus adds to the economy. The main sources of secondary zinc are scraps, drosses and fluxes. The process of electrolyzing is similar to primary zinc products. A large number of recovery units with capacity of 1 tone per day to 15 tonne per day have started and they are importing basic raw material (zinc concentrate) from abroad.
Zinc: mine production

Annual cost (Thousand tones) 2005 Europe 1013 Africa 258 America 3744 Asia 3057 Oceania 1447 World Total 9520
2006 1007 352 3568 3507 1298 9733
2007 1057 414 3496 3832 1329 10127
2008 1035 376 3398 4220 1321 10350
Zinc: metal production

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Annual cost (Thousand tones) 2005 Europe Africa America Asia Oceania World Total 2744 197 1936 4450 553 9879 2006 2720 260 1993 4906 574 10353 2007 2559 274 1883 5057 457 1029 2008 2498 255 1845 5212 463 10273
Zinc: metal consumption

Annual cost (Thousand tones) 2005 Europe 2780 Africa 173 America 1958 Asia 4664 Oceania 267 World Total 9841
2006 2837 194 2126 5245 263 10666
2007 2683 204 1904 5572 253 10614
2008 2755 199 2035 5781 273 11043
MAJOR PLAYERS The major Zinc players in the world market are Canada and China. Though China was a net exporter of the metal as it is the maximum Zinc producer, but its domestic consumption demand does not allow the country to take a lead in the world exports. The major exporter countries of Zinc are Canada, Australia, Netherlands, Mexico, Norway, Spain, China, Korea, Finland, France and Japan. The world export of the zinc metal have been constantly decreasing and as there is a deficit in the world market now, the imports of the metal have become more than the export done in the world. The largest zinc market in the world is the London Metal Exchange that affects the world demand and supply
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Summer Project Report 2008-2009 Organizational study for zinc significantly. The major countries that import are USA, Germany, Italy, Singapore, Korea, China and Taiwan, Belgium, Netherlands, France and U.K
ZINC PRODUCING COUNTRIES As mentioned above zinc has been produced in the world for quite a along time and today also the zinc ores are being mined in more than 50 countries of the world. The pattern of zinc mine production in the world is not a concentrated pattern as there are over 266 mines indulging in the extraction of zinc but only around 19 mines are able to stretch their production over 100000 tons per annum. 80% of the zinc mines fall under the category of underground mines, 8% relate to the category of open mines and the remaining are a combination of both open and close mines. The total mine production of zinc ore in the world accounts up to around 10008000 metric tons with 64% share held by the underground mines. The major countries engaged in the zinc mine production are China,Australia, Canada, Peru, USA, Namibia, Ireland, Sweden.
INDIAN SCENARIO
PRODUCTION OF ZINC IN INDIA 10
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Summer Project Report 2008-2009 Organizational study India was one of the first country that started the process of extracting and smelting zinc. Though India is not the leading player in the production of zinc, it is moving in the direction to get self reliant in this context. India has approximately 4.8% share in the total zinc smelter capacity in Asia Pacific region. India is producing approximately 6 lakh tons and its consumption is 4.92 tons.
The largest zinc producing company in India is Hindustan Zinc Limited and its production capacity is 754000 tons and the turnover is 8560 crores. But now ever since the company got privatized and the Indian industry completely become in the hands of the private sector. It can be said that the zinc industry in India, after privatization is leading towards a major expansion programme. The major zinc mines in India which were under the control of the company are: Rampura agucha mine Rajpura dariba mine Zawar mines The smelting plant in India engaged in the production of zinc metal is: Chanderia lead zinc smelter

_ _ _ _
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Rajastan Rajastan Andrapradesh Kerala
Debari zinc smelter Vizag zinc smelter Binani zinc smelter
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India was one of the first countries to gain knowledge of (zinc production) extracting Zinc from Zinc ores and started the production of zinc metal. It should have been an important player in world zinc market. But this is not the current situation. Indias reputation regarding zinc is not significant as it just produces a small share of metal in the worlds production and is not able to satisfy its domestic consumption demand, making it net importer of zinc. Zinc production in India was in the hands of the government initially. As all the operations in India relating to the metal was in the hands of a public sector company-Hindustan Zinc Limited, it was the biggest company in India which took care of zinc extraction and its smelting process. But in April 2002 this company was privatized in favour of Sterlite group and after that Indian industry is in the hands of private sector completely. Zinc has major application in the galvanizing industry and battery sector together. Zinc products are mainly used by the galvanizing industry (60%), alloy making (20%), battery sector (15%) and die casting (5%).
INDIAN ZINC MARKET
The Indian zinc industry consists primarily of two players, namely Hindustan Zinc and Binani Zinc. Hindustan Zinc is an integrated producer having its own mines and has a market share of more than 60%. Binani Zinc is a custom smelting producer. All the major zinc ore mines in India viz. Rampura Agucha, Rajpura Dariba and Zawar mines are located in the state of Rajasthan and all of these are under the control of Hindustan Zinc.
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Summer Project Report 2008-2009 Organizational study The zinc production capacity in India is set to register robust growth after the government allowed privatization of the state owned company Hindustan Zinc in 2002. The total production capacity stood at around 707,000 tonnes in Financial Year 08. The zinc production has registered a strong growth in India in the last few years. It stood at around 4% of total zinc production in the world in 2007. The zinc production increased from 265,000 tonnes in 2004 to 458,000 tonnes in 2007, registering a growth of 20% CAGR.The zinc consumption has increased from 347,000 tonnes in 2004 to 470,000 in 2007, backed by demand from infrastructure and industry. Important to add that galvanizing accounted for around 70% of the total consumption. The demand for zinc is expected to remain strong in the coming years on account of growth in the key zinc consuming industries like infrastructure, realty and manufacturing. Moreover, the growth in automobile and consumer durables industry would also further aid the increase in consumption of zinc.
STATE SCENARIO
Zinc is a bluish-white lustrous metal. It is normally covered with a white coating on exposure to the atmosphere. Zinc also exists in many compounds. Zinc has a role in normal human growth, taste, and sperm development. In Kerala, the only Zinc smelter is Binani Zinc Ltd. It started on 1967 as a new step towards to zinc industry. It is a private limited company located 20 KM upstream from Cochin Air Port, 16KM by road from International Air Port, on the banks of Periyar, in the area of 136 acres at Binanipuram, Ernakulum District. Binani Industries Ltd, India's only private-sector Zinc producer, will invest $87 million to upgrade and expand its Zinc smelter at Binanipuram in Kerala state.
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Summer Project Report 2008-2009 Organizational study Zinc industry sow its seeds in the gods own country when Binani Zinc Ltd was established in Kerala. Binani Zinc Ltd is the only zinc smelter plant in the whole of Kerala. Expanding on an existing capacity is always a lot easier. The water required for a smelter plant is far more easily met in Kerala rather than the arid parts of Rajasthan and Gujarat, and, despite the soaring costs of power in the state, the unit cost is not just comparable, but still remains competitive in the state. Binani zinc Ltd is full- fledged effluent treatment adheres to environmental protection norms without disturbing the ecological balance. The State Pollution Control Board has rewarded the companys environmental protection and pollution control measures. Highly committed to energy conservation, Binani is a proud achiever of the energy conservation award from the national safety council of India for four consecutive years since 1990. It is the first zinc smelter to receive ISO 14001 for its environmental management system form Bureau Veritas Quality International (BVQI) in June 2000.
CHAPTER 3 COMPANY PROFILE

HISTORY Binani is now consolidating on its enviable track record. It was in the turbulent times of 1872, when the ancestors of Binani, Seth Pragdas & Seth Mathurdas Binani ventured into trading of non-ferrous metals. Later on the son of Seth Mathurdas, Seth Govardhandas, a man with profound vision, saw great potential in manufacturing rather than just trading in non-ferrous metals. Binani Metal Works Limited in collaboration with Multicore Solders UK came into
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Summer Project Report 2008-2009 Organizational study being in 1941. The plant was set up in Howrah, West Bengal to produce nonferrous alloys, cad, casting and powders & solder wires. Binani Metal Works Limited went public for the first time in 1953. In 1962, Binani entered into collaboration with world leaders in the field of nonferrous metals, Cominco Metals, Canada to form Cominco Binani Zinc Limited and became the first producer of primary zinc in India. In 1967 Binani create a name in the world Zinc industry, by pioneering the manufacture of high grade electrolytic zinc in India. The reigns of this wide spreading business were with Late Sree Ghanshyam Binani, the only son of Seth Govardhan Das Binani. His individual expertise and time-honed skills steered the organization towards many milestones ahead. In the span of 1970s 80s Cominco Binani Zinc Limited upgraded its technology to be on par with the latest in the world. It also became the first plant in the country to commence production of special highgrade electrolytic zinc with 99.995% purity. In 1983, a merger between Binani Metal Works Limited & Metal Distributors UK Limited took place forming Binani Metals Limited. It became one of the largest trading and intending houses for non-ferrous metals in India. On 3rd May 1991 Cominco Binani Zinc Limited was rechristened as Binani Zinc Limited. The company diversified into other prominent industrial enterprise in 1996, i.e. Binani Glass Fibre at Goa & Binani Cement Limited in Rajasthan. With such diversification of Binani enterprise it was imperative to rechristen the company as Binani Industries Limited. It now represents an amalgamation of new aspirations, new leadership and entrepreneurial skills, with innovative thinking and indigenous strategies. In 1998, following the true Binani tradition of growth and excellence, the mantle of leadership passed on to the sons of Late Sree Ghanshyam Binani, Mr.
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Summer Project Report 2008-2009 Organizational study Gokul Binani, the Caption of Binani International Operations is the Chairman and Managing Director of Metal Distributors UK, while Mr. Braj Binani, is the Chairman and Managing Director of Binani Zinc Limited in India. In tune with its inherent growth culture the Binani Industries Limited has undergone a thorough re-structuring process. All the three divisions of Binani Industries Limited i.e. Zinc, Cement and Glass Fibre have been gradually hived off as wholly owned subsidiaries.
Binani Cement Limited(Rajasthan) 1997 Glass Fibre Limited(Goa) 1999 Binani Zinc Limited(India) 2001
effective from 1st November effective from 1st December effective from 1st April
Binani Zinc is the pioneer in the manufacture of high grade electrolytic zinc in India since 1967. Today Binani Zinc being part of Binani Industries Limited is the second largest producer of Zinc in India. The company enjoys the reputation of being a leading and most preferred supplier of pure zinc in India. The main product produced by Binani Zinc Limited is zinc and its bye products are sulphuric acid and cadmium, which are used by other industries. It is located at a place called Binanipuram in Ernakulum, Kerala. Its corporate office is at Kolkata and has another office at Mumbai. This strategic location, named as Binanipuram, has proven ideal as it facilitates the loading
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Summer Project Report 2008-2009 Organizational study and off-loading of zinc concentrate, provides cost efficient power supply, ease in transportation, abundant water and easily available resources, inclusive of a literate work force.
MISSION
To forge ahead as a world-class organization in the core sector industry in India and abroad.
To explore all opportunities and to enhance its stakeholders value through ethical practices.
To relentlessly pursue in the new global movement for a "customerdriven, quality-oriented, socially-conscious" industrial corporation.
To adopt, adapt, assimilate and integrate the technologies from global giants, thereby leveraging value - addition through deployment of technology into products and services.
To adhere to the highest standards in manufacturing, beyond the stringent parameters of environmental stipulations.
To
pursue
research
and
development
activities
diligently,
consolidating on its track record of innovations and breakthroughs in manufacturing practices on a state-of-art-technology platform.
To promote human values at the forefront and nurture its people with a deep rooted sense of employee care, concern and deep-routed
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Summer Project Report 2008-2009 Organizational study commitment to people; people being considered as assets of high intrinsic value. VISION Binani Zinc has already laid out plans for increasing production capacity to 65,000MT per annum along with its own 100% captive power plant at an investment of about Rs.300 crores. The company plans to add a further 1, 00,000 Mt of Zinc production immediately after its phase of development plans. The company had already forayed into hydal power projects within the framework & guidelines of the Govt. of Kerala to tap the power resources needed for industrial development of the State. BZL has planned after a lot of deliberation and careful evaluation, Greenfield facility at Gujarat. The project envisages at 71 m2 fluid bed roasting gas cleaning and matching capacity sulphuric acid plant, modifications capacity up gradation in the existing leaching, purification and residue treatment facilities, a new 3.3m2 cathode area based super jumbo tank house with an integrated state of art melting and casting facility along with matching increase in offset and utilities capacities.
MILESTONES 1962: Binani entered into a technical and financial collaboration with Cominco Limited Canada, to form Cominco Binani Zinc Limited. 1967: The first Indian company to manufacture of high grade electrolytic zinc at Binanipuram, Kerala.
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Summer Project Report 2008-2009 Organizational study 1970: By leveraging technology and keeping up with a burgeoning market, Binani Zinc Limited successfully met the steady increase in capacity from 12 kty to 20 kty. 1980: Binani Zinc Limited further upgraded technology at par with the latest in the world with assistance from M/s. Lurgi, Germany. Binani Zinc Limited, commenced production of special high grade electrolytic zinc ingots with 99.995% purity. 1990: Cominco Limited carted off its financial support from its operations in alignment with their world policy. Cominco Binani Zinc was rechristened as Binani Zinc Limited on 3rd March 1991. 1995: Binani Zinc entered into collaboration with M/s U.M. Engineering Limited to adopt its state-of-the-art technology and increased its capacity to 30 kty. 1998: Binani Zinc receives the 'Industrial Safety Award' from the National Safety Council of India for having the second lowest frequency rate of accidents recorded in Scheme III. 2000: Binani Zinc received an ISO 14001 and an ISO 9001:2000 Certification from Bureau Veritas Quality International for their Environment Management
System and Quality Management System respectively. Binani Zinc adopted the '5s' housekeeping management practice and tagged it with the international accreditation ISO 14001:1996. 2001: Voluntary commitment to quality was demonstrated by getting the international accreditation on quality, ISO 9001:2000. Leveraging the people
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Summer Project Report 2008-2009 Organizational study potential, Binani Zinc became the first company in the manufacturing sector to go for international.
PRODUCTS
MAIN PRODUCTS
Zinc - High Grade Zinc - Special High Grade

BY PRODUCTS
Cadmium Sulphuric Acid With leveraging technology and burgeoning market, Binani Zinc have successfully met the capacity of 10-12 to 14-20 kty and presently produces 30kty of special high grade Zinc along with Sulphuric Acid and Cadmium as by-products with a production capacity of 51kty.
PER CENT Zinc PRODUCT SPECIFICATION Impurities Limited As Under: HIGHLead GRADE ELECTROLYTIC ZINC Cadmium Iron Tin 20 0.025 Max 0.02 Max 0.01Max 0.001Max 0.002Max 0.050Max 99.95 Min
M.B.A Copper College Marampally

Total Impurities
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Table 3.1
CADMIUM PER CENT Cadmium Zinc Copper Lead Iron Nickel Antimony Arsenic 99.95Min 0.01Max 0.02Max 0.025Max 0.002Max 0.002Max 0.001Max 0.002 Max
SULPHURIC ACID
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PER CENT
Total Acidity (as H2SO4) Residue on Ignition Iron Lead Arsenic
98 Min 0.2 Max 0.05 Max 0.005Max 0.004Max
USES OF ZINC
TRADITIONAL USES OF ZINC
1)Food- fertilizers to overcome Zinc deficiency in soil and improve crop yields; animal feed supplements to improve health and performance; food supplements for human health. 2)Shelter- roofing and cladding for industrial, commercial and residential construction, rain water evacuation, heating, ventilation and air conditioning. Protecting the durability and integrity of steel infrastructure and steel infrastructure and steel goods against corrosion-such as highway barriers, guardrails, transmission towers, bridges. 3)Safety- Protecting vehicle tyres from degradation by UV rays. For hearing aids, portable computers and mobile phones; to power zero-emission batteries, electric vehicle such as buses, post vans, delivery carts and wheel chairs; to power air conditioning units on trucks so that engine idling is unnecessary.
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4)Water purification systems- zinc is alloyed with other metals for new generation water purification system. 5)Satellite-zinc compounds are used to shield the outer surface of satellites and space vehicle. 6)Varistors-zinc compounds are used in electrical systems for circuit protection against power surges and lightning strikes. 7)Undersea- zinc cladding is used to protect undersea cables and enable remote operation of cables in deep water oil wheels. Zinc is considered to be the fourth most important metal used in the world following steel, aluminum and copper. This metal is primarily used in the steel industry for galvanizing process. The other uses include: a. Used in making coins and pennies b. Used in die-casting in automobile industry c. Making battery container parts d. Used as a substitute to tin and lead pipes, ingredient in water colors and paints, activator in rubber industry etc e. The metal also comes in good use as a fungicide, herbicide and rodenticide. f. Used as pigment in paints & varnishes
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USES OF SULPHURIC ACID
a. Textiles b. Fertilizers c. Chemicals d. Dyes

USES OF CADMIUM a. Electroplating b. Alloy-making c. Battery Cells d. Dyestuffs
TECHNOLOGY
The greatest bulk of Zinc is produced in the world comes from the high productivity electrolytic process. All high grade and special high grade Zinc are produced directly from this process. The pyro metallurgical techniques are used to produce prime western Zinc and gab Zinc as a natural corollary to the ever increasing availability of electrolytic high grade Zinc London Metal Exchange has now adopted a special high grade as well as a high grade standard for trading in Zinc.
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HIGHLIGHTS: THE COMPANY HAS MANY FIRSTS TO ITS CREDIT
It is the 1st Indian company to operate a customized zinc smelter designed for 100% imported zinc concentrate. The 1st Indian company to produce special high grade quality of zinc with 99.995% of purity. The 1st to install high productivity, energy saving super jumbo cell technology. The 1st in the private sector and one of the two primary manufacturers of zinc in India.
The only company to install a converter heat exchanger system in the acid plant designed by M/s. Lurgi, Germany for energy conservation.
Among the 1st to be recognized by the Department of Science and Technology, Government of India for its R&D facility and laboratories.
The 1st to be recognized by the bureau of Industrial Cost and Prices as the Best Zinc Plant in the country for the steps taken in energy conservation.
First in India and in Asia, to be certified by BVQI for the four International accreditations viz., ISO 14001:1996, SA 8000:1997 as well as OHSAS 18001:1999 for installation and maintenance of Environmental Management System, Occupational Health and Safety Assessment Series respectively.
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Summer Project Report 2008-2009 Organizational study COMPANY POLICY

[ON QUALITY, ENVIRONMENT, SAFETY, HEALTH AND SOCIAL ACCOUNTABILITY]
1. The company considers quality of its products and services, environmental control, safety and health of its employees and social accountability as the prime management responsibility and will strive for continual improvement. 2. The company shall comply with social accountability standards, all existing national and local applicable legislation and all legal and other requirements pertaining to environment, occupational, health and safety. 3. The company shall encourage waste minimization and reutilizations as well as recovery of valuables from waste streams. 4. The company shall continuously strive for energy conservation in all its operations and processes 5. The company shall endeavor to ensure that the people and the environment are not put to unacceptable risks by adopting world class environment friendly operations and processes and by ensuring the use of relevant personal protective equipment. 6. The company shall impart training to all its employees in creating awareness to update their knowledge on all aspects of technology and plant operations quality, environment health safety and social performance. 7. The company shall interact with its suppliers on a professional and fair basis and select the basis of quality, timely delivery and cost. 8. The company shall interact with its customers to continuously asses their needs and expectations and ensure total customer satisfaction by
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9. Maintaining consistent quality of its products and services with the
involvement of its employees. 10.The company shall promote transparency and openness in its relationship with its employees and the community and treat them in fair and respectful manner. 11.The company shall display the policy in its premises and also in its brouchers published for the benefit of customers, suppliers, employees and other interested persons.
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V.P (FINANCE)
SR MANAGER MGR
DY
ORGANIZATIONAL CHART OF BINANI ZINC LTD EDAYAR
MGR
V.P (COMMERCIAL)
MTRL GM MK NG GM
SRVC
MANAGER SR MANAGER MANAGER
DY
MGR DY
PRESIDENT
SR. V.P (OPERATIONS & R&D)
R & D
SR IS DGM &MS PRJ GM M DGM ANAGER INSTR SR
V.P (ENG& PROJECTS
AVP MECH
ELECTR ICAL
MGR DY
MANAGER SR
DY MGR
A.V.P (HRD&OHS)
SR MANAGER C.M.O G.M ADMN HRD G.M MGR SAFETY D.G.M I.R & A
MGR
DY
DY MGR
MGR

)
MANAGER SR
PLANT
DGM E SR PRD MGR GM
WORKERS
MGR
MGR DY
M G R
GM
PLANNING SR
D Y
MGR DY
DY. MGR
MGR DY.
DY MGR
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DIFFERENT PHASES OF DEVELOPMENT SINCE INCEPTION 1990 The commitment of Binani Zinc towards environmental protection and its pollution control efforts are rewarded by the 'Kerala State Pollution Control Board' in 1990. 1991 Binani Zinc awarded with a 'Certificate of Merit' by the 'Kerala State Pollution Control Board' for achieving the Second place among large scale industries, in making substantial and sustained efforts in Pollution Control. 1993 Binani Zinc awarded with a Certificate of Merit by the 'Kerala State Pollution Control Board' for achieving the first place among large scale industries in making substantial and sustained efforts in Pollution Control. Binani Zinc is the proud recipient of the 'Energy Conversation Award' for five consecutive years from 1993 onwards. 1994 Binani Zinc has been awarded the second 'Jawaharlal Nehru Memorial National Award' by International Greenland Society for excellence in Indian Industries in Energy Conservation. 1995
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Summer Project Report 2008-2009 Organizational study Binani Zinc has been awarded the 'Certificate of Merit' by Govt. of Kerala in appreciation of its best effort in the field of Energy Conservation.
1996 Binani Zinc awarded the 'Certificate of Merit' by Govt. of Kerala in appreciation of its best effort in the field of Energy Conservation. 1998 Binani Zinc receives the 'Industrial Safety Award' from the National Safety Council of India for having the second lowest frequency rate of accidents recorded in Scheme III. The systematic and scientific approach throughout operations has earned Binani's Glass Fibre plant, an ISO 9002 accreditation from Bureau Veritas Quality International, (BVQI), and UK.Binani Zinc receives the 'Industry Excellence Award' instituted by The Institution of Engineers, India, Cochin Local Chapter, the first prize for excellence in Energy Conservation, and R&D efforts. 2000 Binani Zinc receives the prestigious international accreditions, 'ISO 14001' and 'ISO 9001:2000' Certification from Bureau Veritas Quality International for its Environment Management System and Quality Management System. 2001
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Summer Project Report 2008-2009 Organizational study BVQI also certified Binani Zinc to be qualified for Social Accountability Management system, SA 8000:1997 as well as OHSAS 18001:1999. Occupational Health and Safety Assessment Series.
CONTRIBUTIONS TOWARDS THE SOCIETY "It is in giving that you receive"
1. Ghanshyam Binani Foundation: From the basic needs of the poorest to educational and medical facilities, Binani has always been at the forefront in lending a helping hand to serve humanity. The legacy of caring for the underprivileged has been passed on from one generation to another at Binani. To continue on this tradition, the Binani charitable body was established by the Founder Chairman Late Seth Govardhandas Binani along with his son, former Chairman Late Ghanshyam Binani at Kolkata in 1958. The Ghanshyam Binani Foundation periodically conducts free eye camps, gives donations and provides scholarships for the needy. The Ghanshyam Binani Foundation has always come forward at the time of crisis and natural calamities. Concern for the welfare of the employees is a top priority of Binani, amply reflected with the creation of townships for employees and their families. A diagnostic health center, equipped with latest equipments and medical facilities, has been recently set up for the employees and the residents around Binanipuram. 2.Binani Bravery Award:- Binani Trust has instituted a Bravery Award for children in the age group of 5 - 16 years who have risked their own lives to save another. 3.Binani zinc multipurpose cooperative society
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Summer Project Report 2008-2009 Organizational study 4.Binanipuram high school 5.Ghanshyam binani community hall 6.Day care for the elderly
PROBLEMS FACED BY THE COMPANY
Reduction in Import Duty -The future expansion plans of Binani Zinc, is likely to be affected by the reduction in import duty on non-ferrous metals such as zinc in the recent Union Budget. The import duty had been brought down from 35 per cent to 25 per cent, and at the same time, no relief had been given on the import duties for the basic raw material such as zinc concentrate.
Power Tariff Hikes - The steep electricity tariff revision by the Kerala Government is making the operations of Binani Zinc increasing unviable
3) Shortage of Raw Material: The shortage of raw material is a major problem faced by the company. The company had to be shut down for more than hundred days because of this problem and it resulted in poor performance of the company
FUTURE PLANS The company is proceeding with the setting up of 2 Hydel power plants, with an installed capacity of 10MW, for which necessary approvals have been given by the State Government.
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Summer Project Report 2008-2009 Organizational study In view of the adverse market for coal and consequent impact on cost of generation, the company has deferred plan for setting up a thermal power plant. The company is also carrying out a series of debottlenecking exercises to maximize capacity utilization.
CHAPTER-4 VARIOUS DEPARTMENTS IN BINANI ZINC LTD 1) Human Resource Development and Occupational Health and Safety Department Human Resource and Deveopment Safety Security Occupational Health Centre 2)Commercial Department Marketing Department Material Department 1. Purchase Department 2. Stores Department 3)Research and Development 4)Information System Department
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Summer Project Report 2008-2009 Organizational study 5)Finance Department 6)Projects and Technical Services Department 7)Production Department Roaster and acid plant Leaching and Purification plant Electrolytic plant Melting plant 8)Engineering Department Electrical Department Instrumentation Department Mechanical/ Maintenance Department Utility Department
DEPARTMENTAL DETAILS 1. HUMAN RESOURCE DEVELOPMENT & OCCUPATIONAL HEALTH & SAFETY DEPARTMENT
VICE PRESIDENT (HRD, OH&S)
GENERAL MANAGER
GENERAL MANAGER 34
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(ADMINISTRATIONS) (HRD) OFFICER
MANAGER (INDUSTRIAL RELATIONS) DEPUTY MANAGER
MANAGER (SAFETY)
WELFARE OFFICER
PERSONNEL OFFICER
NON MANAGERS AND
WORKERS
HUMAN RESOURCE DEVELOPMENT DEPARTMENT FUNCTIONS Recruitment and selection Induction Training and development Public relations Industrial relations
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Summer Project Report 2008-2009 Organizational study Performance Appraisal Leave Administration Separation of employees Punishment procedure Grievance procedure Wages and salary administration Provident fund ESI Scheme Gratuity Welfare activities Medical facilities Educational facilities Assistance to distribution Promotions
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1.SELECTION AND RECRUITMENT
The department where there is a vacancy will sent a Staff Requisition to the HR Department containing the job requirements. A fixed time will be allotted for the receipt of application. The application received will be scrutinized and shortlisted. Hence the final interview and medical check up will be carried out and it will be shortlisted. In case of vacancies the first preference will be for lateral transfer and then for promotion. The first scrutiny and short listing will be done by HRD. But the final scrutiny and fixing of interview date will be done with the consent of the General Manager of the department. The final appointing authority will be the President and the interview is rest to him. Then the offer letter will be sent for the medical exam.
2.INDUCTION
Induction will help in familiarizing with the working environment. The training period for the managerial staff is 1 year and that for workmen is 2 years. The probation period is 6 months.
3.TRAINING AND DEVELOPMENT
Manufacturing of zinc has undergone revolutionary changes both conceptually and technologically. In the view of high technology employed in the manufacture of zinc the company is giving various training and development programs for its employees.
OBJECTIVE
To continuously develop competence and skill of its employees
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TRAINING PROCEDURE
Training needs of employees knowledge, skill, attitudinal and behavioral traits are assessed every year. Gap analysis of employees is made in each department facilitated by HRD Department. Resource persons in the company and external are identified and training calendar is prepared for the year. Methodologies adopted are lectures, discussions, interactive sessions, group work, case studies etc. Training effectiveness are assessed and evaluated at the end of each in house programme by using the feedback form (PM 16). Binani Zinc is an organization following 3 TIER SYSTEM. Either a centrally organized training will be provided or specific programs conducted by resource persons from outside will be organized. This may include Individual Employee Contact Programme, which is conducted for identifying the strengths and weaknesses in the employees and also to understand their perception about the management. Also Knowledge and Skill Upgradation Program is conducted for nonmanagerial staff for occupying the higher position in the management category in terms of knowledge, skill and behavior. Cross Functional Exposure Program is a training program intended for management staff for career development. Also Learning Center Initiatives are taken in which one among a group will take a session for the group. This is done in order to create an informal learning atmosphere.
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4.PUBLIC RELATIONS
Planned and sustained effort is taken to establish and maintain goodwill and mutual understanding between an organization and its public. It includes the relation with the employees, community nearby and government. The programs like Deepawali celebrations , Founders day celebrations (May 3rd) is informed to the employees and the family members. Also it plays a major role in internship of new employees, helping them to fit into the organization. As part of public relations, whenever mock drills are conducted the near by communities are informed about it, so that they do not get panic at the siren given at the mock drill. The financial assistance is provided for religious and social institutions. Also the medical camps being conducted are informed to the public. But the company does not give much priority to the media relations, and responds only to the media publications made about it. The public relations office is concerned with the publication of Binani home journal and also with the subscription of other dailies, magazines and journals. All advertisements about the company in magazines, the financial assistance given to various institutions, the letters to the government, the company sponsorship offered by the company, goodwill letters, thank you letters, clarification letters, etc are forwarded through the PRO.
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5.INDUSTRIAL RELATIONS
There exists cordial relationship between the trade unions and the management and hence the industrial relations is very smooth. There exists three unions in Binani Zinc Ltd. namely Cominco Binani Zinc Employees Union Cominco Binani Zinc Employees Association Cominco Binani Zinc Employees Organization
Each of these trade unions has secured 20 % and more in the referendum conducted.
6.PERFORMANCE APPRAISAL
For the trainees and probationaries , there is a monthly evaluation of performance. In case of confirmed employees, the evaluation is on an yearly basis. There is no performance appraisal for the workmen.
7.LEAVE ADMINISTRATION
For workmen, the leave administration is as per the long term settlement ie., casual leaves shall be granted to permanent workmen at the rate of 10 days in a calendar year. Also privilege leaves shall be granted. Sick leave shall be granted to those who are not
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Summer Project Report 2008-2009 Organizational study covered at the ESI scheme at the rate of 7 days with pay in a calendar year. Medical certificate should be provided for more than 2 days of sick leave. Compensatory off should be granted within the same month or within 2 months immediately following the month in which the office work. For management staff, there are 11 casual leaves and 30 privilege leaves. Also there is leave application book for each employees.
8.SEPARATION OF EMPLOYEES
The separation of employees can be through resignation or retirement. In case of resignation the person has to give one month notice (for GMs and above 3 months notice). In case of retirement character certificate, clearance certificate, service certificate, etc are issued. All the benefits are given on the retirement day itself.
9.PUNISHMENT PROCEDURE
For workmen, the whole procedure is as per the standing order. Before taking action, the concerned union members is always unlimited. The management staff, especially in case of theft, it is direct termination, if the crime is proved.
10.GRIEVANCE PROCEDURE
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Summer Project Report 2008-2009 Organizational study Most of the grievances are settled in the department itself. The unions will nominate representative in departments and forward the list to the management.
The grievances reported will be sent to the department head in writing in prescribed Grievance form.
If there is no reply or if the reply is not satisfactory within 48 hours, then the employee can submit a copy to the concerned functional manager. If there is no response within another 48 hours, then the complaint could be forwarded to the Personnel Department. In case of lack of response even after 72 hours, the complaint shall be forwarded to the President. After waiting for 2 more weeks the complaint could be forwarded to the State Labour Department.
11.WAGES AND SALARY
The wages and salary is determined based on the attendance record provided by the time office. The time office keeps the punching of the workmen. By the starting of each month, a shift schedule is prepared and programmed. Any change in the shift has to be reported to the time office. At the end of each month, the time office gives record of leaves, attendance, over time, off days or holiday work and depending on this the wages are computed.
The pay slip will contain all the details of allowances, deductions and total pay of employees. The over time rate is twice in plant and for managerial staff it is
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Summer Project Report 2008-2009 Organizational study one and a half times. The wages and salary are given on or before 5 th of every month. Also Binani Zincs time office is the Keralas first computerized time office.
12.PROVIDENT FUND
Binani Zinc Ltd is an exempted organization and looks after the provident fund administration by itself. An account for provident fund is in the bank and after the expenses the balance is invested as per the ruling of the Ministry of Labours. To be eligible for provident fund benefits, one days work is enough. Also there is provision for voluntary provident fund. But there is a limit on the amount that can be surrendered.
13.ESI SCHEME
Only very few employees at BZ are under the ESI scheme. But for contract workers, it is made compulsory for ESI scheme on Life Insurance Scheme.
14.GRATUITY
Gratuity is a benefit that is given to the employees at the time of retirement. If a person complete service for more than 5 years, he is eligible for this.
15.WELFARE ACTIVITIES
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Summer Project Report 2008-2009 Organizational study The welfare measures adopted by BZL can be classified into statutory and non-statutory measures.
Statutory measures includes canteen providing subsidized food, rest room with various facilities, 24 hours working first aid unit, etc. Non-statutory measures includes uniform/foot wear, one umbrella per year, recreational facilities, Founders day, Deepawali celebrations, etc.
16.MEDICAL FACILITIES
The following are the medical facilities provided by BZL: i. ii. iii. iv. Construction of hospital building at Binanipuram. Health campaign for public. Awareness programmes. ESI dispensary at Binanipuram.
17.EDUCATIONAL FACILITIES
i. ii. iii.
Lower primary school in Binanipuram. Class room furniture for other neighbouring school. Binani Library of UC College Alwaye.
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18.ASSISTANCE TO DISTRIBUTION
i.
Rent free accommodation for Binanipuram police Station and Post Office.
ii. iii.
Branch of UBI at Binanipuram. Traffic island, Bus shelter and Sodium vapour lamps at nearby tri-junctions.
iv.
Binani hall of kaula management association .
19. PROMOTIONS MANAGERIAL STAFF:
Promotion will be at the sole discretion of management Depending upon the promotions/vacancies promotion will be given anytime during the year. The concerned department head and concerned MCs recommendation has to be forwarded to HRD Department.
NON MANAGERIAL STAFF:
For the purpose of promotion workmen will be considered under 3 groups. 1. Production/operations All production plants, water treatment, effluent treatment, R&D and auxiliary boiler.
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Summer Project Report 2008-2009 Organizational study 2. Services Maintenance, captive power plant, crane/fork lift operators, drivers, compressor operators. 3. Office/administration Administration, security, occupational health, technicians, sweepers. The promotion will be effected on a 3-tire system as follows: If suitable candidates are available within the group the promotion will be given to worker in the same group. If suitable workmen are not available in one-group suitable workmen from any other group will be granted the promotion. If no suitable candidates are available in any of the 3 groups recruitments from outside will be made. DIFFERENT TRAINING SCHEMES IN BINANI
1. IN HOUSE TRAINING:
After assessing training needs, external faculties are identified and brought into the company premises and conduct classes for target groups.
2. EXTERNAL TRAINING:
Employees are nominated on selective basis for external training programmes, seminars and conferences. Concerned MC will recommend the employees. Top executives are sent to advanced management programs organized by institutions like XLRI, ASCI etc.
3. CROSS FUNCTIONAL EXPOSURE PROGRMME:
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Summer Project Report 2008-2009 Organizational study This program is developed for young professionals in the managerial staff. Duration is 3 to 4 months. Employees in the main stream will be trained in the supporting functions and employees in the supporting stream will be trained in the main stream.
4. SKILL DEVELOPMENT PROGRAMMES:
This programme is mainly for the non managerial staff in the company. Trainees are identified by the MC classes are addressed by internal as well as external trainers. Classes are conducted on every Monday, Wednesday and Friday between 2 pm to 6 pm.
SAFETY Safety is the keyboard at Binani Zinc Ltd. The use of Personal Protective Equipment (PPE) is compulsory for each and every employee. If an employee is found without PPE a Red Card is issued. As the first step he is not given the prize on safety day. If he is again spotted without PPE, there is a cut in his salary. There is an OHS committee set up to occupational health, safety and housekeeping practices. The members are executive Vice President, Manager Safety, three members representing the three recognized unions, senior engineers (environment) and The chief Managerial Officer. The committee carries out regular inspections and make necessary recommendations.
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Summer Project Report 2008-2009 Organizational study In order to promote safety house keeping the Japanese 5S concept is practiced in all departments at BZ
1. 2. 3.
Sirie Seiton Seiso -
Segregation, Sorting
Arrangement Cleaning
4. Seiketsu 5.
Standardization, maintenance, control Training, Discipline, continous improvement
Shitsuke -
There is a safety management system to ensure safety and healthy environment. Periodical Monitoring of dust, noise, illumination, etc is carried out. There is a safety suggestion scheme in which employees can make suggestion and the best suggestion is given award. There is a safety and housekeeping notice board to display notices and messages regarding it. There is a safety mock drills carried out twice a year. Competition are held as a part of Safety Day Celebrations(March 4th) , Fire Safety audit and
electrical safety. Audit are conducted by external agencies and their decisions are implemented. The company is giving safety training on a regular basis and it has an Onside Emergency Plan detailing the responsibilities of various functionaries in case of an accident.
OCCUPATIONAL HEALTH CENTRE Clean environment, safety practices and good health are the major ingredients of Binani Zinc vision. To achieve good health of all its
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Summer Project Report 2008-2009 Organizational study employees the company has set up an occupational health center in the name of Ganashyams Binani Health Center . The Centre emphasizes on the preventive aspects and its main objective are protecting workers, health, promoting physical, mental and social well being of workers and minimizing the consequences of occupational hazards, accidents and diseases. The centre has the most sophisticated instruments with facility for audio testing, vision testing, ESU, checking of lungs and also a biochemistry and haematology lab. A doctor is available from 8:30 am to 5:00 pm. The first aid units functions for 24 hours and for all 7 days in a week. There is one ambulance to evacuate people in case of serious injuries.
The primary function of the center is providing total health cure to all its employees from the time of recruitment. Each employees has to undergo thorough medical check up right at the time of recruitments and from then he has to undergo annual medical clean up every year. The center maintains a personal file for each employees free of cost. All the facilities and services of the center are accessible to their families for a normal fees. The community people can make use of center on Tuesdays and Wednesdays.
The center also organized health check ups, diabetics detection camp, eye camps, etc. Training programs on first aid is given regularly to employees. The center also focuses on health counseling, use of personal protective equipments, occupational hygiene, etc.
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Summer Project Report 2008-2009 Organizational study SECURITY
The security function is concerned with the security of personnel as well as property. The security looks into the arrivals and departure of employees, their punchings , control of shift buses , allotment of out pass, visitors pass, etc. Punching is permitted within 30 minutes, permission is to be sought from the concerned department. If the punching system fails the security personnel note the timing and hand it over to the time office. The siren system is also included in security function. Normally sirens are given at the beginning and end of the shift hours. During emergency wailing alarm is given. Other security functions include checking of workmen of departure, attending incoming calls and transferring them. At most care is taken during transport of product and each vehicle for transport of Zinc, Cadmium and H2SO4 is thoroughly checked for damage and leakage. The license of driver, documents of the vehicle and the load carried is checked. The vehicle essentially must contain a first aid box. The security office maintains files, registers and documents carrying information about personnel, about material, pass challans, monthly report about fire fighting equipments, interdepartmental sports and games etc. The security also collects information in the area of industrial relation, employee welfare, etc that may assist the management in taking decision.
2. COMMERCIAL DEPARTMENT
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Summer Project Report 2008-2009 Organizational study The commercial department handles activities related to materials handling and marketing of products. It is major functional area of the company where most vital transactions are taking place. The commercial department can be divided into mainly two parts. They are Marketing and Materials departments. Materials department consist of stores and purchase department.
COMMERCIAL DEPARTMENT
MARKETING
MATERIALS
STORES
PURCHASE
STRUCTURE OF COMMERCIAL DEPARTMENT 51
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VICE PRESIDENT (COMMERCIAL)
GENERAL MANAGER (MARKETING)
ASST.GENERAL MANAGER (MATERIALS)
DEPUTY MANAGER (MARKETING)
Sr. MANAGER (MARKETING)
Sr.MANAGER (MATERIALS)
OFFICER
PURCHASE Sr.OFFICER (PURCHASE)
STORES Sr.OFFICER (STORES) STORES STAFF
(MARKETING)
PURCHASE STAFF
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Summer Project Report 2008-2009 Organizational study PURCHASE DEPARTMENT

VICE PRESIDENT (COMMERCIAL)
ASST.GENERAL MANAGER (MATERIALS)
SR. MANAGER (MATERIALS)
PURCHASE
SR.OFFICER (PURCHASE) PURCHASE STAFF
WORKMEN
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Summer Project Report 2008-2009 Organizational study FUNCTIONS OF PURCHASE SECTION Procurement against purchase order Emergency collections Bills settlement Vendor development Vendor rating Contracts PURCHASE PROCEDURE
i. PURCHASE REQUISITION
Procurement shall be effected against authorized /approved purchase order through online integrated system. The PR is processed online .The PR initial entry is made by the intending department through the system. The entered PR is to undergo 1st level authorization by concerned manager and 2nd level authorization by concerned DGM and a 3rd level authorization by the concerned MC committee member. The PR are then converted to intents in the stores and processed through the system by purchase department.
ii. ENQUIRY
After the PR is converted to intents at stores, enquiry processed online in the prescribed format, is issued to active vendors by purchase department. Where such lists are not available in the vendor master, enquiries are sent to vendors recommended by the user department or newly developed vendors.
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Summer Project Report 2008-2009 Organizational study Enquiry form contains following information Material description Quantity General terms and conditions Statement on QMS/OHSAS/SA compliance of the vendor.
iii. COMPARATIVE STATEMENT/PROPOSAL
On receipt of quotation, comparative statement shall be prepared and sent to user departments. Comparative statement is prepared through the system and normally contains the following information Indent no. And date Enquiry no. And date Vendors name Materials description Price basis Delivery schedule Payment terms Total value for approval
iv. APPROVAL FOR PURCHASE
No purchase shall be effected without prior approval. Purchase/contract approval shall be made as under. DGM MC MEMBER VICE PRESIDENT PRESIDENT M.B.A College Marampally <= >
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10,000 10,000 - 50,000 50,000-100,000 100,000 M.E.S
v. PURCHASE ORDER
Purchase order shall be issued on evaluation of comparative statement and approval of purchase by concerned personnel P.O shall be issued only after getting appropriate approvals and will be signed by the DGM (materials). Average internal lead-time shall be 15 days for routine items. External lead time shall comprise of transit time and delivery lead time of the vendor VENDOR EVALUATION The following are considered in evaluating a vendor VRC Product catalogue /specification Technical suitability of the product Credentials of the vendor Capacity, turn over, previous orders executed Third party report General financial and performance evaluation. VENDOR RATING In Binani zinc vendor rating is applicable only for purchase budget items with a yearly purchase value above 4 lakhs. And rating is done on a yearly basis.
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Vendor rating is done for the following Checking consistency of the vendor Comparison of vendors Selection of appropriate vendors Good relationship with the vendor VENDOR RATING PARAMETERS Right Time Delivery Conformance Of Product Specification Quantity Quality Mangement System
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STORES DEPARTMENT
VICE PRESIDENT (COMMERCIAL) ASST.GENERAL MANAGER (MATERIALS) SR. MANAGER (MATERIALS) STORES SR.OFFICER (STORES) STORES STAFF WORKMEN
The stores department in the Binani zinc is guided by the principle Must have optimum inventory of what we need. This means that the company should have sufficient inventory to meet the needs whenever it arises. The stores department mainly deals with consumables and spares. The raw materials and finished goods are dealt with separately at the production department. The raw materials are imported and minimum stock is maintained. And in case of finished gods one days production is kept as the stock.
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INVENTORY MANAGEMENT SYSTEM To eliminate rare and non-moving items binani zinc has adopted a systematic approach for managing their inventory. STAGE I Stage I deals with the classification of inventory their categorization, policy making for each category etc. the following are steps involved. Identify appropriate parameters for classification like SDE, XYZ, Insurance spares, general purpose spares etc Develop decision rules for each category Meaningful analysis to check whether company is holding what it need Disposal of obsolete and surplus items STAGE II The second stage deals with the creation of central information pool for managing inventory. The steps involved are: Data acquisition to create central information pool can easily be done in a networked environment Dynamic cataloguing ensures traceability of all design or specification charges. STAGE III
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Summer Project Report 2008-2009 Organizational study This stage depicts the parties for replacement of inventory, their purchase etc. Policy for initial provisioning. Regulation of future purchases. Emergency purchase to be avoided totally. FUNCTIONS OF STORES SECTION
1. RECEIPT AND INSPECTION OF ITEMS
The goods are received at the main gate .the security staff at the main gate physically verify the quantity by comparing it with P.O. after receiving the goods and after verifying the quantity and quality of material an inspection document is prepared at the stores and sent to concerned user department. The user department conducts inspection and results will be passed on to stores. This information will be incorporated in final document namely G.R generated at the stores. GR is sent to the purchase department for payment.
2. STORAGE AND PRESERVATION
Materials are mainly stored in racks and bins. Each rack is coded in order to identify the items. For instance the equipment required by the roaster plant are kept in one rack and rack is named R. items are stored in each shelf of that rack. Each shelf is numbered as 1, 2, 3 etc, the storekeeper identifies items by the rack symbol. Items of common use are kept together. Chemicals are stored in separate room which requires particular range of temperature. Instruments are kept in separate dust proof room.
3. ISSUE OF MATERIALS
After the introduction of ERP system at binani recording and documentation of materials are done online. Once the user department
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Summer Project Report 2008-2009 Organizational study recognizes the need for materials it places an authorized requisition online. The storekeeper identifies the material at store after comparing the material code in the system with that in the rack. The material is issued to the user department and necessary updating will be automatically done by the system. FIFO method is followed in the issue of materials.
4. STOCK TAKING
Binani zinc follows an up to date stock taking system. Stock taking will starts at 3:00 pm every day. The staff in the stores department verifies the stock and reports it to the officer in charge. In case the quantity of stock in stock does not tally with that in the records, causes for the same will be found out and necessary steps for rectification will be taken after reporting to the higher authorities.
STORES PROCEDURE
Receipt of Materials
Automation indent for items that reach the recorded level
-Verification of stores -Generation of SIR
Issue of material on production of MR
-Inspection of items -Accepted quality -Identified by tags -Store in respective location -Costing of SIR
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Summer Project Report 2008-2009 Organizational study MARKETING DEPARTMENT This department also comes under the commercial department. This department handles marketing of BZL products and by-products. Also deals with customer care. Binani Zinc Limited is an industrial firm. It has got
regular customers to buy the products. And also, there are only two major producers in India- Hindustan Zinc Limited and Binani Zinc Limited. So the Marketing Department in this organization does not have much to do with advertising, but sales. Zinc is the main product and the annual production is now 32,500MT. The by-products are sulphuric acid and cadmium, which are produced annually at a rate of 47,000MT and 70MT respectively. Binani Zinc Limited sells zinc all over India except north. It is because Hindustan Zinc Limited dominates in north. The customers of Binani Zinc are mainly from Kerala, Tamilnadu and Pondicherry. Cadmium is sold all over India. The customers for cadmium are mainly from North India. And, the customers for sulphuric acid are mainly from Tamilnadu.
STRUCTURE OF MARKETING DEPARTMENT
VICE PRESIDENT (COMMERCIAL) GENERAL MANAGER (MARKETING)
DEPUTY MANAGER (MARKETING) 62
Sr. MANAGER (MARKETING)
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OFFICER (MARKETING)
FUNCTIONS OF MARKETING SECTION Finalization of Sales policy formulation Finalization of new/continuation of current selling agency agreements for zinc and cadmium. Dispatch of zinc and cadmium. Dispatch of sulphuric acid. Interaction of customers. Transportation contract SALES PROMOTION: Promotion of the products does not take place through media or any other way. Customers of the firm are huge companies. These prospective customers act as the sale promoters of the company. These companies share their experience of using the products of Binani zinc with other companies. There is only one competitor for the company .due to these reasons no additional cost for sales promotion is to be incurred by the company. SALES:
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Summer Project Report 2008-2009 Organizational study Sale of cadmium, zinc and sulphuric acid is done directly by the company. The sale is done directly from the plant and also from the various depots situated in Mumbai, Chennai etc. Sale of zinc and cadmium is determined directly on the basis of level of production. Sale of sulphuric acid is fixed in advance and only a specific number of customers can be supplied. Sale is also carried out through sales agents.
MARKETING PLAN It is taken care of during the formulation of sales policy and long term contract booking for whole financial year. Marketing budget forms the major financial resource planning for each year, which is carried out at the beginning of the each financial year. PRICING OF BINANI ZINC PRODUCTS
ZINC AND CADMIUM
Price is based on import/local prices Fluctuations in the import prices. Prizes are set in line with HZL prices. Price of zinc concentrate.
SULPHURIC ACID
Acid supply and demand Pricing depends on sterlite/sulphur prices MARKET INFLUENCING FACTORS Level of stocks with London Metal exchange. Fluctuation in worldwide demand of zinc. Growth rate of zinc producing countries.
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Summer Project Report 2008-2009 Organizational study Funds in zinc sector CUSTOMERS
ZINC
Everady Industries Limited Souther Metals And Alloys Limited Phonix Indstries Meta Dust Ganga Jamuna Limited
SULPHURIC ACID
Hindustan News Print Limited Reliance Dye Chemicals Limited Narmada Chemicals Limited
CADMIUM
Anil Metal Company Southern Metals S.K.Chemicals Ltd
COMPETITORS Hindustan Zinc Ltd is the only competitor of BZL. Hindustan Zinc Ltd. was created from the erstwhile Metal Corporation of India (MCI) on 10th January 1966 as a Public Sector Undertaking. Its registered office is situated at Udaipur. In April 2002, Sterlite acquired a 46% interest in HZL from the Government of India and the open market, and it became a part of the Sterlite group. Since then HZL has been growing from strength to strength.HZL produces Zinc, Lead and by-products viz. Sulphuric Acid and Silver. HZL
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Summer Project Report 2008-2009 Organizational study achieved an all-time high production output of 283,698 tonnes Zinc and a record production of 889,007 tonnes of Zinc concentrate during 2005-06.
3. RESEARCH & DEVELOPMENT DEPARTMENT The backbone of any manufacturing organization is its Research and Development department. All major research is done at the R&D. when concentrate reaches the company R&D department takes samples and check the content of zinc in raw materials. R&D department has all the mini type of automatic advanced machinery. They do the process initially and identify the purity of the zinc. R&D has three sections. They are: Development section Assay section Environmental section FUNCTIONS DEVELOPMENT SECTION The activities of the development section are as follows: Zinc concentrate evaluation Voltage measurement and anode correction in cell house Acid to concentrate measurement
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Summer Project Report 2008-2009 Organizational study Taking up of process/product development studies Preparation of control charts for critical operating parameters and analytical values ASSAY SECTION The activities of the assay section are as follows: Bulk chemical sampling and analysis Analysis of samples at different stages of process Analysis of products Viz zinc ingots, cadmium, sulphuric acid
Analysis of samples for recovery calculation and extraction efficiency calculation Preparation and issue of various reagents required by control laboratories in plants ENVIRONMENTAL SECTION The activities of the environmental section are: Monitoring of effluents emissions Sending statutory reports Monitoring of hazardous waste quantity, storage and disposal Monitoring of various activities in the plant for the control of pollution Maintenance and improvement of environmental management system.
STRUCTURE OF RESEARCH AND DEVELOPMENT
VICE PRESIDENT 67
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SENIOR MANAGER
ADVISOR
MANAGER
OFFICER R&D
OFFICER ENVIRONMENT
ENGINEER R&D
BENEFITS OF R&D DEPARTMENT Treatment of zinc bearing secondary materials had improved capacity utilization. Value addition and waste minimization. Improvement in anode life. Improvement in process efficiency. Over all extraction of zinc has been considerably improved and purity of zinc ingots is considerably maintained.
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4. INFORMATION & MANAGEMENT SYSTEM DEPARTMENT This is the service department of the company. It works on Oracle platform-Oracle developer 2000. The company has 85 PCs connected to main server- 1 BM. Operating system for the server is Windows2000, and for the other systems Windows XP, 98, 2000 etc. Separate Enterprise Resource Planning (ERP) pack for each department is maintained. The department was formed in 1982 with a single PC and data entry machine. The ERP model was established in the year 2001. Up gradation happens every 5 year. A mini E R P system operates Binani Zinc Limited. It does not use a standard ERP system. The company uses an integrated online system called CKN.all the functions in the company are carried through this system. The company is following a punch card system and employees have to punch their cards while entering into the company and going out of the company. Managerial staff has to mark their attendance by login into the system. The leave application is also processed through online system. Various operations of the stores department like preparing purchase requisition, purchase order,
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Summer Project Report 2008-2009 Organizational study inspection note etc are done with the ERP system. ERP was made by an outside company in Kadavanthra. There is Annual Maintenance Contract for all systems. All functions are computerized for example leave applications, all functions of HR, Finance etc.
STRUCTURE OF INFORMATION SYSTEM DEPARTMENT
GENERAL MANAGER (MANAGEMENT SYSTEMS)
SENIOR MANAGER (INFORMATION AND SYSTEMS)
DEPUTY MANAGER (INFORMATION SYSTEMS)
FUNCTIONS OF THE DEPARTMENT a. IT plan formulation

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Summer Project Report 2008-2009 Organizational study b. Finalization of AMC c. Development /modifications of software d. Provide MIS reports wherever necessary e. Installs programs in various departments. f. Different slots for net serving
5. FINANCE DEPARTMENT
Finance is regarded as the life blood of any business. The finance department maintains or keeps data regarding all financial transactions that are taking place in an organization. The finance function is under pressure to enhance its value contribution to the company, deliver information and maintain effective controls in line with ever changing governance needs.
STRUCTURE OF FINANCE DEPARTMENT MANAGER (FINANCE)
DEPUTY MANGER
DEPUTY MANGER
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OFFICER OFFICER
NON-SUPERVISORY OFFICER
CASHIER
FUNCTIONS a. Monthly accounting statements b. Sales accounting, budgets etc are prepared. c. Department wise capital expenditure is prepared. d. Raw material accounting: - Raw materials are imported from various places come in ship to the port. The material is unloaded using barges to a space that is rented by the company for temporary storage of material. e. HRD Package: - The main purpose is to take care of the salary payment to the employees. It makes use of a payroll package in association with the HRD. f. Corporate office set up:-It takes care of the cash and bank operations and with the statutory remittance like sales tax, Income tax, ESI, PF etc
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6. PROJECTS AND TECHNICAL SERVICES DEPARTMENT
VICE PRESIDENT GENERAL MANAGER SENIOR MANAGER/MANAGER/DEPUTY MANAGER SENIOR ENGINEER/ENGINEERS ASSISTANT
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Summer Project Report 2008-2009 Organizational study Projects and technical Services Department is the department which leads to the technical development of the company. Introduction and execution of long term projects come under this department. Major repairs of the plants and other departments, green field project and expansion of the company are dealt by this department. The new project of the BZL is Waelz Plant, which will produce zinc from zinc concentrate by vapourising.
LAST YEARS PROJECTS JAROFIX PLANT- It was 10 crore project and has capacity of 100 tonnes per day. It has purchased technology from Canada. WAELZ PLANT Till 1982 residue contained 18% zinc. It recovers the zinc from the residue. It is a 5 crore project and has capacity of 100 tonnes per day. ONGOING PROJECTS ZINC DUST PLANT To develop fine Zinc dust. It currently has a Zinc Dust Plant but the quality of existing plant is less. The cost of it is around 1.75 crores.
FUTURE PROJECTS
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Summer Project Report 2008-2009 Organizational study Sewage Treatment Plant ETP underflow filteration systems Heat exchangers for acid wash section New technology to produce zinc dust of superior quality Modification in the neutral leach stream line
7. PRODUCTION DEPARTMENT
STRUCTURE OF PRODUCTION DEPARTMENT
DEPUTY GENERAL MANAGER FLM (MANAGER, DEPUTY MANAGER, SHIFT IN CHARGE)

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Summer Project Report 2008-2009 Organizational study CHIEF OPERATOR SENIOR OPERATOR OPERATOR GENERAL WORKMEN GENERAL WORKMEN (TRAINEE)
There are 4 mangers in the production department. Zinc is produced by hydro metallurgical route, which includes the following plants. Roaster and acid plant Leaching and purification Electrolytic plant Melting plant ROASTER PLANT
MANAGER SHIFT IN CHARGE CHIEF OPERATOR OPERATOR

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Summer Project Report 2008-2009 Organizational study BOILER OPERATOR WORKMEN Zinc is present as zinc sulphate in zinc concentrate. Zinc concentrate is roasted in a Lurgi fluidized bed roaster in the presence of air .In roaster zinc sulphide is converted to calcine and sulphur di oxide. The roasting process is exothermic. The roaster reaction takes place at 900-950 degree. Calcine and hot laden gases are the roaster products. Calcine comes out as furnace overflow and it is cooled in a roto cooler, powdered in a ball mill and pneumatically conveyed to storage sitos. The hot dust laden gas passes through a series of equipments for gas cleaning. The gas cleaning equipments are: Waste heat boiler Cyclone Hot gas precipitator Star cooler
Wet gas precipitator The coal, cleaned gas goes to acid plant where sulphur di oxide is converted to sulpur tri oxide. And it is absorbed in absorbing acid to produce sulphuric acid. LEACHING PLANT MANAGER SHIFT IN CHARGE
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Summer Project Report 2008-2009 Organizational study CHIEF OPERATOR SENIOR OPERATOR JUNIOR OPERATOR GENERAL WORKMEN The aim of leaching is to dissolve maximum of zinc and valuable elements such as cadmium fro calcine obtained from roaster. The zinc in calcine is under easily soluble oxide form. Leaching is carried at neutral condition ie return sulphuic acid coming from cell house and calcine are mixed in such a way that system never goes to acidic condition. During this process of neutral leaching hydrolysable impurities get hydrolyzed and removed. Iron present as ferrous get oxidized with air. After leaching the slurry goes to a thickener where the sulphuric acid solution is separated from the residue. Impurities like insoluble sulphates and hydrolyzed impurities are
removed through under flow of thickener and over flow is sulphuric acid solution with soluble impurities. The impure sulphuric acid solution goes to purification section. PURIFICATION In purification elements like copper ,cadmium ,cobalt, nickel etc which are more electro positive than zinc are displaced from the solution by the addition of zinc dust. There are two stages of purification.
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Summer Project Report 2008-2009 Organizational study Cold purification: this is carried at 55-60 degree by using zinc dust by a process called cold purification cake leach. Cadmium is replaced at this stage. Hot purification: Filtrate after cold purification pass through a heat exchanger to heat up to 75 degree in hot purification. Fine zinc dust is added to sponge out nickel and cobalt. Hot purification cake is leached at controlled activity to recover excess zinc dust present and it is filtered. The over flow of clarifier, pure sulphuric acid solution is sent to cell house for electrolysis. ELECTROLYTIC PLANT (CELL HOUSE) The electrolytic plant involves the cell house. Here the purified zinc is separated as sheets by the electrolysis process. The faradays Laws of electrolysis is being followed in this plant. The main process of electrolysis is to produce special high grade zinc from the zinc sulphate solution received from the purification section. Electrolyte : Anode Cathode : : Pure Zinc Sulphate Lead Aluminium
There are 32 cells in cell house. Each cell contains 84 cathodes and 85 anodes. Cell feed is cooled in a cooling tower and sent to cells where DC current is applied from a pair of silicon rectifiers. Individual cell voltage is about 3.3V and current density is 450 A/m2. Zinc deposited cathodes are transported to shipping machine using cell crane. Deposits on each side of the cathode are stripped of using automatic stripping machine. The deposition time of the zinc is about 40 hours. At the end the zinc will be deposited at the cathode and the manganese dioxide will be deposited at the anode. The cell house consumes
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Summer Project Report 2008-2009 Organizational study about 4 lakh units of electricity per day. This amount constitutes of about three fourth of total power consumption of the company. Also certain reagents are added into the electrolyte in order to arrest the acid fumes formed out of the reaction MELTING PLANT MANAGER SHIFT IN CHARGE
SENIOR OPERATOR
OPERATOR
FORK LIFT OPERATOR GENERAL WORKMAN GENERAL WORKMAN (TRAINEE)
Melting Plant is the final step in the extraction process. And the final product is divided into 99.99% high grade zinc and 99.995% special high grade zinc ingots are obtained. Cathode zinc is melted in an induction furnace of 30 MT holding capacity and 8 MT/Hr melting capacity. Molten zinc is pumped from furnace to cast moulds where approximately 25Kg zinc slabs are casted and stacked with the help of stacking machine
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Summer Project Report 2008-2009 Organizational study The performance of the company was adversely affected due to the non availability of raw material. The non availability of zinc concentrate led to the shutdown of factory for 131 days. This led to low capacity utilization of 59 % in the production. With effect from 31st march 2006 the production capacity of zinc has been increased to 38000mt and production capacity of Sulphuric acid has been increased to 53063 mt and the production capacity of cadmium has been increased to 80287 kg.
PRODUCTION FLOW DIAGRAM
Concentrate (ZnS)
Fluidized Bed Roaster

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DCDA Acid Plant
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Summer Project Report 2008-2009 Organizational study H2SO4 (98%) Calcine Residue
Leaching
Residue Treatment
Opportun Solution
Cold Purification Cu and Cd Cake Cu-Cd Re-leaching
Solution
Hot Purification Co and Ni Purified ZnSO4 Solution Cell House Cadmium Section Co-Ni Re-leaching Residue for disposal/sales
Melting Complex
99.99% pure Zinc Ingots
99.95%pure Cadmium
8. ENGINEERING DEPARTMENT The engineering department of the company includes instrumentation, electrical and maintenance.
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Summer Project Report 2008-2009 Organizational study ELECTRICAL DEPARTMENT

STRUCTURE OF ELECTRICAL DEPARTMENT
ADVISOR
SENIOR MANAGER DEPUTY MANAGER ENGINEERS/OFFICERS CHARGEMEN ELECTRICIAN GENERAL WORKMEN PROBATIONARIES GENERAL WORKMEN (TRAINEES) FUNCTIONS OF ELECTRICAL DEPARTMENT The main function of Electrical department is the overall controlling and maintenance of the electrical problem of the company and up keep of electrical system/subsystems in the company including preventive, shutdown and opportunity maintenance. Other functions are:83
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Summer Project Report 2008-2009 Organizational study a. Take up development and modification jobs b. Liaison with Electrical Inspectorate for statutory inspections c. Co-ordination with KSEB for electrical power availability d. Implement energy conservation activities
e.
Carry out periodic calibration of selected measuring and relaying equipment.
f. Inventory management and spares planning g. Budget planning and monitoring As the company is very crucial to have continuous flow of current, there are three sources of electrical energy: KSEB Edayar: There is a 110 KV substation at Edayar. There are 2 feeders there. The 110 KV current received at the company is step down to different voltages as per requirement.
Captive Power Plant: There are two diesel generators available each producing 5MW and 5.3MW respectively. This plant uses furnace oil for its functioning.
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Summer Project Report 2008-2009 Organizational study Turbo generator: The turbo generator available in the company produces . 5MW of electricity. The turbo generator uses the steam produced at various stages during the processes. OBJECTIVES a)To manage electrical energy effectively by creating energy forecasts. b)To maximize the utilization of assets. c)To maintain the safety devices for protecting men and material. d)To analyze costs, performance and technical factors. FACTORS AFFECTING DECISIONS: a)Imposed power cuts by KSEB b)Government and Board orders c)Electricity tariffs and concessions
Three types ofMaintenance functions are carried out; Running maintenance, Annual maintenance, and Breakdown maintenance.
INSTRUMENTATION DEPARTMENT Instrumentation department are concerned with the repairs and maintenance of all instruments and accessories in the company. Their main objective includes automation of skimming operation in Melting Plant, keeping the productive asset in working condition for effective utilization of assets and
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Summer Project Report 2008-2009 Organizational study maintains safety devices and also analyzes cost, performance and technical factors. Any false information in these items will cause high expenditure. So the workers must be careful. The crew of this department is 14.
STRUCTURE OF INSTRUMENTATION DEPARTMENT
GENERAL MANAGER DEPUTY GENERAL MANAGER MANAGERS DEPUTY MANAGER OFFICER INSTRUMENT MECHANIC GENERAL WORKMEN PROBATIONARY INSTRUMENT MECHANIC GENERAL WORKMEN (TRAINEE)
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Summer Project Report 2008-2009 Organizational study MAINTENANCE DEPARTMENT The total crew of this department is 39. The maintenance department is highly critical in ensuring the smooth and continuous operations of the production process. It plays a supportive role to the production department and in turn is supported by the purchase and stores department. The maintenance department in BZL covers the following three functional areas: Mechanical maintenance and Utility Electrical maintenance Instrumentation The purpose of this department is to define, document and communicate the roles, responsibilities and authority of persons who verify, manage and perform activities.
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STRUCTURE OF MAINTENANCE DEPARTMENT
GENERAL MANAGER SENIOR MANAGERS MANAGERS DEPUTY MANAGERS MECHANIC (GRADE 1, 2, 3) PROBATIONARY MECHANIC GENERAL WORKMEN GENERAL WORKMEN (TRAINEE)
UTILITY DEPARTMENT The main purpose of Utility department supply all the necessary materials needed for the smooth working of the organization. Optimization of all necessary materials is carried out. Main plants in the company for this purpose are:-
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Summer Project Report 2008-2009 Organizational study 1)Captive Power Plant To generate power. They go for this when there is power failure from the board or when the power cost of K.S.E.B goes high. 2) Water Treatment Plant Process water - It process water from periyar river for the production process. Boiler Water It has the capacity of 550 meter cube per day. Demineralise water Cooling water To cool equipments Cooling towers cool and recycle water for further use. Cooling chemical is added to prevent choking inside the pipe. 3) Compressor - Service air - Automated air - Instrument Two types of compressor -Lubricating compressor use refrigerated drier -Non Lubricating compressor use clean air drier 4) Effluent Treating Plant - capacity of 450 meter cube per day
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CHAPTER 5 SWOT ANALYSIS OF BINANI ZINC LIMITED

STRENGTH As BZL is the only one Zinc producing company in kerala. Its position is so high in the business history of Kerala. It is the first Indian company having four international certification i.e; ISO 9000 ISO 14001 SA 8000 OHSAS 18000 and follows 5s housekeeping practice.
The company is committed to environment protection and the Pollution control board has rewarded its pollution control efforts. It got excellance award for its pollution control efforts in 2009 from state pollution control board, among the large scale industries.
It is the first Indian company to produce special high grade Zinc. BZL has proved its efficiency in its productivity by acquiring 38000MT zinc per annum during the year only with 355 employees. The company is blessed by hard working and efficient employees. Here the labour turnover is very low.
The company has a very cordial relationship with the employees union and there was no strike after 1996.
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WEAKNESS
The main weakness of BZL is the absence of mines.
Another weakness of BZL is that its maximum production capacity is only 38000MT. It is nothing when compared to its competitor HZL
High dependence on imported zinc concentrate. Due to unavailability of
zinc concentrate company was forced to close down for 131 days in 2006.
Under utilization of capacity. Only 59 % and 88 % of total capacity was
utilized the past years. OPPURTUNITIES The demand projections for the coming years indicate a higher potential growth pattern for zinc consumption. Demand for zinc in India is expected to grow at 10-12% in the coming years. The demand for recycled zinc is increasing and the company can explore the secondary zinc market. Company is going for vertical integration. The company is planning to set up three captive mines project. They are Basantgarh mines in Rajasthan, RBG Minerals Industries Limited, Ambaji mines.
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THREATS The main threats or risks of BZL occurs from the external factors. The major external factor that can have a significance bearing on the companys performance are Fluctuation in zinc prices at London Market Exchange(LME) Enhanced metal supply in market
Low treatment charges
Competition from secondary zinc manufactures Import duty reduction of zinc metal to 7.5%. Shortage in the availability of raw material especially zinc concentrate
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CHAPTER 6 FINDINGS AND SUGGESTIONS FINDINGS 1) BZL follows an open door policy. 2) Internet and intercom facility makes access to information easier. 3) Each and every function is carried out in a systematic manner. 4) House keeping is practiced in each and every department. 5) The company is committed to environmental protection, pollution contol efforts,etc 6) BZL maintains a balance between business profits and social responsibility.
SUGGESTIONS The following are the suggestions to make the Binani Zinc Ltd perform in better ways: 1) As the BZL has only one competitor in India, it has to take certain steps which will help to catch maximum market share. 2) The BZL has to draw a comprehensive plan to initigate the perceived threats.
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Summer Project Report 2008-2009 Organizational study 3) As the prices are expected to remain volatile, the BZL must be more conscious in undertaking hedging activities as a protection against wide fluctuation in zinc prices. 4)Always make sure that the required concentrate is available .Also there should not be any wastage of money due to non-productive inventory.
CHAPTER 7 CONCLUSION
Binani Zinc was the first to set up a primary zinc smelter in India. They are the first to produce special grades of zinc of purity 99.99% and 99.995%. And now a singular achievement is that it is the first company in India to obtain four international certifications and demonstrated its abiding commitment to be among the best in dealing with social, environmental, quality, occupational health and safety matters. So we can say that BZL became an inevitable part of Indian business history.
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BIBLIOGRAPHY
1. www.binaniindustries.com 2. www.binanizinc.net 3. www.zincworld.com
4. Company personnel manual 5. Records of different departments
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Summer Project Report 2008-2009 Organizational study CHAPTER 1 INTRODUCTION Binani Zinc Ltd.

M.B.A College Marampally

Summer Project Report 2008-2009 Organizational study

M.B.A College Marampally

M.B.A College Marampally

M.B.A College Marampally

Summer Project Report 2008-2009 Organizational study

M.B.A College Marampally

M.B.A College Marampally

M.B.A College Marampally

Zinc: mine production

2006 1007 352 3568 3507 1298 9733

2007 1057 414 3496 3832 1329 10127

2008 1035 376 3398 4220 1321 10350

Zinc: metal production

M.B.A College Marampally

Summer Project Report 2008-2009 Organizational study

Zinc: metal consumption

2006 2837 194 2126 5245 263 10666

2007 2683 204 1904 5572 253 10614

2008 2755 199 2035 5781 273 11043

M.B.A College Marampally

PRODUCTION OF ZINC IN INDIA 10

M.B.A College Marampally

Rajastan Rajastan Andrapradesh Kerala

Debari zinc smelter Vizag zinc smelter Binani zinc smelter

M.B.A College Marampally

Summer Project Report 2008-2009 Organizational study

M.B.A College Marampally

M.B.A College Marampally

CHAPTER 3 COMPANY PROFILE

M.B.A College Marampally

M.B.A College Marampally

M.B.A College Marampally

M.B.A College Marampally

M.B.A College Marampally

M.B.A College Marampally

Zinc - High Grade Zinc - Special High Grade

M.B.A Copper College Marampally

Summer Project Report 2008-2009 Organizational study

M.B.A College Marampally

Summer Project Report 2008-2009 Organizational study

Total Acidity (as H2SO4) Residue on Ignition Iron Lead Arsenic

98 Min 0.2 Max 0.05 Max 0.005Max 0.004Max

M.B.A College Marampally

Summer Project Report 2008-2009 Organizational study

M.B.A College Marampally

Summer Project Report 2008-2009 Organizational study

USES OF SULPHURIC ACID

a. Textiles b. Fertilizers c. Chemicals d. Dyes

M.B.A College Marampally

Summer Project Report 2008-2009 Organizational study

HIGHLIGHTS: THE COMPANY HAS MANY FIRSTS TO ITS CREDIT

M.B.A College Marampally

Summer Project Report 2008-2009 Organizational study COMPANY POLICY

M.B.A College Marampally

Summer Project Report 2008-2009 Organizational study

M.B.A College Marampally

ORGANIZATIONAL CHART OF BINANI ZINC LTD EDAYAR

MANAGER SR MANAGER MANAGER

Summer Project Report 2008-2009 Organizational study

SR. V.P (OPERATIONS & R&D)

SR IS DGM &MS PRJ GM M DGM ANAGER INSTR SR