A project report submitted for the partial fulfillment of the Master In Labor Welfare semester-1 in subject of RESEARCH METHODOLOGY

Submitted by BLESSY CHACKO Roll NO [ 04 ]

MLW (SEM-1) Supervising Teacher JAYESH DESAI SIR Submitted to DEPARTMENT OF RESEARCH METHODOLOGY AND INTERDISCIPLINARY STUDIES IN SOCIAL SCIENCES VEER NARMAD SOUTH GUJARAT UNIVERSITY SURAT-393 007

PREFACE
Veer Narmad South Gujarat University, Surat is one of

the institutes providing the post graduate level course in Labour Welfare area in India. It is two year degree course.

The motive behind practical survey at the MLW level is to

make students aware of law.

have done survey in organization in UPL in ANKLESHWAR . I have prepared this report which is outcome of information received from the company.

ACKNOWLEDGEMENT

I being student of MLW (SEM-1) feel great pleasure in presenting this report as part of my practical studies. This report is prepared on the basis of survey taken at various organization of Ankleshwar.

I am thankful to our HOD Dr. KIRAN PANDYA who gave

me an opportunity for this survey. I am also thankful to our Prof. JAYESH DESAI who provided sufficient guidance to me. I feel privileged to express my deep gratitude to all the their cooperation and guidance during my survey in their organization. I wish to convey my special gratitude to under whose supervision; I completed my survey and other faculty members for providing me guidance support and information related to this survey. I also convey my sincere gratitude to my parents for their continuous love & support.

DECLARATION

I declare that the project entitled Training And Development submitted for the partial fulfillment of the semester-1 in Masters in Labour Welfare [M.L.W-Regular] in the subject of RESEARCH METHODOLOGY is my original work and carried it out at Department of Research Methodology and Interdisciplinary Studies in Social Sciences, affiliated to Veer Narmad South Gujarat University-Surat.

Signature of the student

Date : Place : Ankleshwar

CERTIFICATE
This is to certify that the project entitled submitted by BLESSY CHACKO for the partial fulfillment of the semester-1 in Master in Labour Welfare [M.L.W-Regular]. In the subjectof RESEARCH METHODOLOGY is his original work and carried it out at Department of Research Methodology and Interdisciplinary studies in Social Sciences, Veer Narmad South Gujarat University-Surat. The project or any part of it has not been previously submitted for any degree.

[Name and Designation of the Supervising Teacher] Date: Place:

CHAPTER: 1 GENERAL INFORMATION

Background Of The Company UPL was promoted by Mr. R D Shroff in 1969 to manufacture phosphorus and its compound in 1972, the company started in 1972, the company started by making red phosphorus having establishes itself as a leading producer, it subsequently added to its list of products. United phosphorus Ltd. is a leading global producer of generic crop protection products, intermediates, and other industrial chemicals. It is one of the agrochemical producers in India with a wide range of products that includes fumigants, fungicides, insecticides, rodenticides and herbicides. It ranks amongst the top eight generic agrochemical companies in the world. UPL manufactures and markets both technical and formulations. UPL has customer base in 86 countries which makes the global player of crop protection products in the world. The companys branded products are well recognized and have a reputation for quality. UPL has a worldwide network of subsidiaries, affiliates, and offices selling branded agrochemicals, bulk pesticides and industry chemicals. Having close support from on side technical services and quality control, each one operates to the strictest international quality standards. The underlying philosophy of the company is to provide cost effective, quality solution in crop protection for farmers. UPL has been able to achieve this through managing
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change and making most of the opportunities that opened up with the liberalization and globalization. A focus on core competence, a vision of being a global player and a commitment to provide cost effective solution in crop protection fro farmers, have been the driving forces of the company. UPL has constantly looking for new ways to improve their products and services and the efficient synthesis ofactive ingredients is the core of our success. UPL has started pioneered backward integration in agrochemicals and is one of the worlds few companies to manufactures complex organophosphorus compounds starting from the basic raw materials, rock phosphate. The strategy has now been extended to other products. Their main aim is to build successful long term relationship with customers to understand their needs and deliver real performance in use benefits. As a reliable and dynamic partner their area of experience covers registration manufacture and formulation, technical support and marketing. UPL is also concerned with product development and their aim is to accurately meet the needs of their markets across the world through the development and introduction of existing and new products. These products are developing to meet and exceed their customers expectation in the area of quality and performance. The quality control policy of the UPL is based on the clear target of Zero Defect. Each stage of production from raw material through manufacturing to post production is closely monitored. UPL has also committed substantial investment to maintain and improve high standards of environmental care. This concern is designed in to UPLs process and manufacturing plants at the outset to minimize effluents and energy use. Care

is taken to ensure that raw materials and energy are used efficiently across the production process. They recognize that their process may have an impact on the environment and as a result they are committed to continuously improving their environmental performance to minimize the effluent. To work closely with the custom in the market place, UPL recognizes the requirement of the support in product research, development and registration. The company has invested in research team, which undertakes extensive filed trials for developing innovative formulations. New products have been introduced every year of the companys history, in response to the specific needs of the changing market. The company is committed to maintaining and expanding its portfolio of registration throughout the world. Considerable investment has been focused on the regularity requirement for registration support. Through acquisition, subsidiaries, UPL has built a network across the globe- in Europe, America, Asia-pacific, Africa, Australia with fully ownes subsidiaries in Argentina, Bangladesh, China, Cuba, Denmark, Hong Kong, Japan, Mauritius, Mexico, Russia, South Africa, USA, UK, Zimbawe and representative officies in Srilanka and Vietnam. UPL has established a marketing and distribution network, comprising of more than 5000 dealers and 25 offices that works closely with the farmers. UPL has the commitment and capabilities to offer total solution from start to finish in the agriculture sector. All the units of UPL are certified under the ISO 9001 for quality Assurance, 14001 for environment pollution control norms and OSHAS 18001 for health and safety.

Form of Organization
There are different forms of organization like public sector, private sector, proprietorship firm, partnership firm etc. UPL is a Public Ltd. form of Company. It is a multi national Corporation with its base in India.

Vision And Mission Statement

Vision Statement * Enhancing values to our customers and other stakeholders. * Focusing on total quality, innovation of the product and responsible care toward the environment. * Caring for employee to work as a motivated team in an open & learning environment. * Setting challenging new standards of performance. Mission Statement We are in the business of * Manufacturing and supplying crop protection & Special chemicals world wide. * Providing through solution to optimize farm. Productivity for the farmers through innovative & cost effective products to provide the customer better values for money. Investment In Plant And Machinery The total investment in the plant and machinery of UPL-2 is 169490 lacs.
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Present Profile Currently united phosphorus is the largest Generic Agrochemical Manufacturing Company in the world. UPL is the largest manufacturer in the world for producing the product like Acephate. Future Expansion Plans Diversify product offerings:Company is planning for diversifications by introducing new products plan in current financial year are:1. MLNT 2. PPFS Enhance market penetration:Company is planning to expand its seed business by acquiring one of the biggest seed processing companies in Europe. After this acquisition UPL will capture major market in Europe and will become biggest player in seed business. UPL is expanding the production capacity of its two major products after which UPL will become monopoly organization in this two products, it is confidential so it is not declared. Organization Structure: In the year 2000, underwent a restructuring exercise and rolled out a process driven structure. UPL has moved towards an entirely Title based flat organization structure.

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Types Of Communication Channel There are various types of communication channels are used in the UPL-2 to ensure that smooth and effective communication in the organization. Some times dual mode of communication is used to ensure message is received by the receiver. Formal communication Formal communication is used to flow all important communication in the organization. For circulating important information formal communication is used in the company. It includes production plan of the day, daily production report, meeting agenda etc. these information are flow through various modes like e-mails, notice board, employee portal etc. Informal communication Sometimes informal communication is also used in the organization. It is used where data to be communicated are qualitative in nature rather than quantitative in nature. Some detailed which flow through formal channel of communication has to be communicated again through in formal channel of communication. It includes timing of meeting, training venue, training nominations etc. once communication is done through mail again communication is done either face to face or through telephone. Horizontal communication Communication which flows between same peer groups of different department is known as horizontal communication. The communication related to production planning, material requisition from store, daily operation meeting etc. flow through this channel.

Vertical communication

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Communication which flows from higher level to lower level is known as vertical communication. This method of is useful for handling the conflict and grievance. This method is followed for collecting the data from the subordinate, daily reporting to the superior etc. but in the UPL-2 it is not specific rule to follow hierarchy for the communication. Any employee from any level, if required, can directly communicate to any level of superior/subordinate without take in to consideration the hierarachy of levels. Verbal communication Generally in UPL-2 verbal communication is avoided to prevent rumours in organization because sometimes it leads to misunderstanding between the superior and subordinate. In case of informal communication, the method of verbal communication is used. Non verbal communication Generally in UPL non verbal communication is used. It is very necessary to adopt this method of communication when data to be communicated is either technical or quantitative in nature. For most of the formal communication, non verbal mode of communication is followed. Legal notice and memos are communicated through non verbal mode of communication. Modes Of Communication Used In UPL communication is done through several modes of communication. They are as follows: UPLONLINE.com:- employee portal Notice board Cell phones Memos PSI chart window Uniphos.com-Mail server
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 Inward-outward letters Present Product Mix UPL has three main businesses:1.Agrochemicals Agrochemicals are those chemicals which are used in field to protect the crop from the insects and unwanted grass. These products cater specifically to the domestic and international pesticides markets. They are classified on the basis of their final or end usage.
a) Insecticides

An insecticide is a pesticide whose purpose is to kill or to prevent the multiplication of insects. Some insecticides have been banned due to their adverse effect on animals and human. They are either, Parathyroid e.g. Cypermethrin (Ustaad/cyrux), AlphaCypermethrin(fastox), Fenvalerate (Fen kill), Permethrin (perkill). Organo phosphous compounds e.g. Acephate(Lancer), Dichlorvos(Doom) Monocrotophus (phoskill),phorate(Umet). b) Herbicides Herbicide is a pesticide used to kill unwanted plants. Unwanted plants include weeds, brush, unproductive trees. c)Fungicides Fungicide is a pesticide compound that kills or inhibits the growth of fungi. In Agriculture, fungicide is used to control fungi that threaten to destroy crops. The purpose of fungicide is to kill fungi in a field and to protect the crops.
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Gardeners use fungicide as household pesticides to protect plants from unwanted fungi. d) Fumigants Aluminium Phosphide (quick phos), magnesium Phosphide (MagnaPhos). e) Rodenticides Rodenticides are used to control rate and house mice in a house as well as in warehouses. These are used to protect food item such as grain (corn, wheat, and oats). These are useful in big warehouses and in a house also to protect against rats and other insects in a grain. They are used after the grains are gained and when grains are store in warehouses. Zinc phosphide (Ratol). 2. Industrial Chemicals Industrial chemicals are intermediates for a number of industries including pesticides industry. Industrial chemicals are those chemicals which are used as a raw material, intermediate for the other company or which are used for own industrial use. They can be subdivided into on the basis of their usage into: Chemicals sold to the industry for use as pesticides intermediates e.g. Trimethyl phosphate (TMP) and Phosphorous Penta Sulphide. Other industries e.g. Red phosphorous. Technical grades pesticides e.g. Monocrotophos, Acephate, Phorate, Quinalphos etc. 3. Special Chemicals Special chemicals are those chemicals which are used for particular purpose only. They can not be used as multiple
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purposes. These chemicals are used for only special purpose. E.g. red phosphorous is used to make match sticks only. These are principally pharmaceutical feedstock, like, flame retardants, plasticizers. UPL industries with a strong technical strength and wide range of special chemicals are all set to contribute in terms of export of its products. More than 20% of the total production of special chemicals from UPL industries will be exported. Competitive Scenario There are six international competitors: 1) Bayer crop science 2) Tata Rallis India 3) Syngenta-Largest player in industry 4) Monsanta 5) Du point-2nd Largest player in India 6) Dow Agro Ltd. There are four national & local competitors: 1) Pesticides India Ltd. 2) Gharda chemicals 3) Meghmani organics 4) Sudarshan chemicals Overall Organization Culture Being a chemical industry, safety is given the first preference. Every new employed person, maybe worker or employee is given safety induction. There is a well trained Emergency response team (ERT) which takes care if any kind of accident take place in Company premises. Every employee & worker of different departments and plants have good co-ordination among them. There is no sense of differentiation found in employees and workers, they are all treated as same. Each and every employee is always ready to help each other.

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Strategies For Future Growth And Development And Benchmarking The company is in the business of manufacturing of goods (chemicals) which cant be prepared without its demand. These goods cannot be stores because they would get spoiled and it will be a loss to the company. These chemicals are very dangerous to store because they are very hazardous in nature. Thus company has no any particular benchmarking for its future growth but it takes in to consideration the market demand from customers. The companys only strategy fro benchmarking is the timely delivery of the goods as per the demand of their customers. UPL As Pioneer UPL is pioneer for few things like 5s, ERT, PSR, Unit Assessments, Mutual Aid, BBSMS, Balance score card etc. Besides few companies no other company has implemented these things. UPL has adopted these things for better work environment. A brief explanation of these concepts adopted by UPL is as under. 5s-Concept of Housekeeping 5s is a Japanese concept of housekeeping. This concept has been adopted by UPL. This concept is followed so that everything is going as per the steps and this is a systematic way to maintain all the necessary files, documents etc. This Japanese concept is adopted by UPL to ensure that everything is at its place and there is allocated place os for every thing. There are five steps are followed as per the 5s.

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1 . SEIRI:-(Sorting/Segregation) SEIRI means to segregate all necessary items from unnecessary once. Segregation means to segregate all wanted and unwanted things. Which ever things are wanted should be segregated properly and all the unwanted things should be remove of. As per the Japanese concept all the wanted things should be segregate en such a manner that all things should be easily available whenever needed. As per the concept all wanted things are divided in three categories as per their use:a. Immediate use:The things which are used in a daily basis these things should be segregated in such a manner that when ever it needed is should be available within 30 seconds. All the daily items like diary, pen etc come under this category. b. Use within 3 to 7 days:Things like necessary documents which are not used on daily basis, are segregated in such a way that can get in 1 minute. c. Useful within 1 to 6 month:All the necessary files and documents which are not used on routine basis they should be arrange in a manner that whenever any file or document is needed can get in 3 minutes. 2. SEITON:- (Arranging) SEITON means arrange the items in a manner that every operator can pick them up when ever necessary. After the segregation of all the things, it is necessary that all the things should be arrange in a proper way so that it should be identified by any body. To identify all the things, proper tagging system is followed by the unit. Tags are attached with the things as well as to the place where things are placed so

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that any new person can also easily find the things and the wanted things should be placed in their proper place. 3. SEISO:- (Cleaniness) SEISO means working place should clean both during and after the working. Once the things, files are attached properly in their place, than proper maintenance is also required. According to this concept regular cleanliness should be done. The main aim of this concept is cleaning of all things and all the required things should not be here and there. Tables and cupboards should be neat and clean. 4. SHITSOKE:-(Self Discipline) SHITSOKE means embedding the 4S in the organization. After the standardization is maintained, it is the responsibility of individual for the maintenance and cleanliness of all the things. Purpose Purpose of 5s is nothing but standardization in the work and visual management system is followed by the company so that any new operator or worker can know hazardous place and working style of the company. Main purpose of 5s is to save time and cost by using standard working style. 5s committee 5s committee is also organize by the company. There are some activities followed by this committee: They decide roles of the committee members, sorting the responsibility of people, periodic inspections are done, and the best work ship awards are given. ERT ( Emergency Response Team)

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Introduction:In the year 2001 there was Ammonia leakage in unit-1 at the loading point & noticed that there is no awarness in the employees that how to handle the emergency. So at that it was decided that they should have their own trained person just like common do to act immediately in case of any type of emergency. UPL falls under major accident hazards industry. They are handling hazards chemicals, if it leaks may cause fire and toxic release. So that they have decided for ERT so that in case of emergency in the company, emergency response team always ready to handle any type of emergency and they try to save the life, material, machine. For this purpose 57 members are selected from different plants. Selection of ERT members is done by safety managers as well as plant HOD. ERT members are also given training as per their schedule. Mock drill is also done in the plant area and to motivate the ERT members competition is held in different units. ERT is useful not only to handle inside emergency but also in off side emergency. Today more than 50% of employees in Unit-2 are trained ERT members. Objective:To give quick emergency response to all the emergency accidents, incidents inside and outside the factory premises. Criteria:Members need to be selected with individual personnel interviews with criteria that self interested and enthusiastic members to be select. This selection expected from safety officer and head of the plant. Training given to ERT members:Following trainings are given practically as well as theoretically. 1. What is accident-types, prevention, precaution, effects, duties and responsibility of ERT members. 2. What is fire-causes, types of fire, equipments.

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3. Hazardous chemicals handling-study of MSDS. 4. Practical fireman ship-duties and responsibility of fireman. 5. Self RESCUE from height by using Rope ladder, by ladder climbing. 6. Spillage handling & prevention and precautions & control of spillage of various solvent and materials. 7. SBA SET-types, uses, practice of wearing equipments. 8. Special fire / leakage risk-solvent fire, oil fire and control of leakages of chlorine and Ammonia gas. 9. FIRST-AID-Definition, rules, limitation of FIRST AID. 10.Discussion on off side emergency, mock drill. 11.Visit to fire station-for practical look and study of modern fire fighting equipments available in the fire bridge station. 12.Leakage handling of chlorine. PSR (Plant Safety Representative) Eight employees are selected as a plant safety representative. These representatives are selected from the different plants and departments, like they are selected from five plantsAcephate, PD, Phorate, Devrinol, ETP & one from electric department, one from store department and one from the QA department. The selection of these representatives is done by plant HOD. Two years contract is given to the representatives. After this contract if HOD feels, then he can change the representatives. There are some roles and responsibility performed by this representative, which are defined by the HOD. Following duties are performed by them. Roles and Responsibility of PSR: Promoting safety culture in their area including being catalyst in involving employees in safety activities and emphasis zero accident culture. Conducting plant safety committee meeting as per the guide lines on fortnightly basis.

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Conducting plant safety inspection once in a month, as per guide lines and submits the report to unit Head by 25th of every month. Inspection and maintaining the safety cupboards and ensuring readiness of all safety equipments Co-ordination safety activities related to their department such as safety talk and upgrading Area accident statistics board. Continuous interaction / co-ordination with safety department on behalf of the plant. Supporting investigation of accident / incident occurring in their submitting the reports, if required. To compulsory attend and deliberate the monthly safety meetings to be held in 1st week of every month. PSR is fully responsible of house keeping in their section.

Mutual Aids UPL Unit 2 is into an agreement with five companies, they are Zandu, UPL Unit-3, Kanoria, Coromandel, RPG Life Sciences. They share a concept mutual aids among them. When ever there is any emergency they help each other in terms of man power and equipment support, in case off site emergency as well as during on site emergency. One type of Agreement is prepared among them in which they have to help and give support to each other in case of any emergency in any of these five companies. UPL provide Emergency Response Team to all these company whenever there is any outside emergency as well as in side emergency and other company helps in terms of equipments. Unit Assessment UPL has adopted unit assessment system to improve the work environment of all the units of UPL. This system assessment is done for all the units of UPL which are in India. Unit assessment is done on different parameters like SHE, budget, KFA achievement (Key Focus Area), Quality, FTPR (First Time Pass
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Rate), customer complaints, service level, quality assurance, technical audit, improvement initiative, production plan v/s Actual plan. On these different parameters marking is done and based on unit assessment, efficiency and effectiveness of different units can be known. This assessment is discussed with the different units and if requires then necessary steps are also taken to improve the efficiency of the units.

BBS (Behavior Based Safety) / BBSMS Behavior based safety is a process that helps employee to identify and choose a safe behavior. This training is needed to reduce the unsafe acts in the company. In this system all the HOD of the plants have to observe the behavior of the workers and employees for their particular plant. For e.g. safety equipments are compulsory to wear for the workers and staff in the plant area so that they have to observed these things that rules are followed by them or not. Based on the observations, monthly meeting is conducted. In this meeting they prepare plan to take corrective action. If some employees do not follow the rules then he is given feedback & counseling. By this approach his behavior is targeted & tried to change. Training regarding the BBSMS also conducted. This training is provided to all the Head of Department, they are only participate in this training. HR department is responsible for the implementation of the training. Balance scorecard Balance scorecard is strategic planning and management system that is used extensively in business and industry to align business activities to the vision and strategy of the

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organization, improve internal and external communication and monitor organization performance against strategic goals. Traditional financial reporting system provides an indication of how a firm has performed in the past but offer little information about how it might perform in the future. E.g. a firm might reduce its level of customers service in order to boost current earnings but then future might be negatively impacted due to reduced customer satisfaction. It is performance measurement that added strategic non financial performance measure to give managers and executives a more balanced view of original performance. The balance scorecard has evolved from its early use as a simple performance measurement framework to a full strategic planning and management system. It provides a framework that not only provides performance measurements, but helps planner to identify what should be done and measured. The balance scorecard approach provides a clear prescription as to what companies should measures in order to balance the financial perceptive. The balance scorecard is management system that enables organization to clarity their vision and strategy and translates them in to action. It provides feedback around both the internal business process and external outcomes in order to continuously improve strategic performance and result. The balance scorecard, a performance measurement system that considers not only financial measures but also customer, business process and learning measures. The balance scorecard includes the following four perspectives. 1. Financial Perspective IT includes measures such as operating income, return on capital employed and economic value added. Timely and accurate funding data will always be a priority and managers

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will do whatever necessary to provide it. In fact, often there is more than enough processing of financial data. With the implementation of corporate database, it is hoped that more of the processing can be centralized and automated. 2. Customer Perspective Recent management philosophy has shown an increasing realization of the importance of customer focus and customer satisfaction in any business. It include such as customer satisfaction, customer retention and market share in target strategy. If customers are not satisfied, they will eventually find other supplier that will meet their needs. In developing metrics for satisfaction customers should be analyzed in terms of kinds of customers and kinds of processes for which they are providing a product or service to those customer groups. 3. Internal Business Process Perspective It includes measures such as cost throughput and quality. These are for business process such as procurement, production, and other fulfillment. This perspective refers to internal business process. Metrics based on this perspective allow the managers to know how well their business is running and whether its products and service conform to customer requirements. These metrics have to be carefully designed by those who know this process most intimately. 4. Learning and Growth Perspective It includes such as employee satisfaction, employee retention, skill sets etc. This perspective includes employees training and corporate culture attitudes related to both individual and corporate self improvement. In a knowledge based organization, people the only repository of knowledge are the main resource. In the current climate of rapid knowledge technical change, it is becoming necessary for knowledge

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workers to be in continuous learning mode. Metrics can be put in to place to guide managers in focusing training funds where they can help most. In any case, learning and growth constitute the essential foundation for success of any knowledge worker organization. Learning and growth perspective also includes things like mentors, tutors within the organization as well as that ease of communication among the workers that allows them to readily to get help on a problem when it is needed. Each perspective of balance scorecard includes objectives, measures of those objectives, target value of those measures and initiatives which are as follows: Objective: Major Objective to be achieved Measures: The observable parameters that will be used to measure progress. Targets: The specific target values for the measures. Initiatives: Action programs to be initiated in order to meet the objective.

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CHAPTER: 2 PRODUCTION DEPARTMENT

Activities Of Production Department To prepare plans for daily production. To produce the chemicals like Phorate, Devrinol, Phosphamidon and Acephate. To supervise the work if production is going on as per the plan. To provide guidance to the workers regarding the working methods. Type Of Products There are main four types of products are manufactured in unit-2. There are main four plants and there is one ETP in the UPL. 1. Phorate 2. Acephate 3. Phosphamidon 4. Devrinol Plant: Phorate In Phorate plant two products, DETA and photare are produced. DETA is the raw material for making phorate product and DETA is produced in a company itself. Specification of Phorate:Physical state-Liquid Molecular formula-C4H11O2PS2 Molecular weight-186

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Boiling point-348K Specification gravity-1.169 Vapor pressure-0.8 bar at 348K DETA Raw material used for DETA:Deta (Heel) P2S5 (Phosphorous Penta Sulfide) TEA (Tri Ethyl Amine) Alcohol The Process of DETA:First of all fall in a big reactor R-5301, some part of DETA is already remaining in the reactor which is called DETA heel which is in liquid form. In this big reactor first of all P2S5 is charged which is in solid form and TEA which is catalyst is also charged in to the reactor. TEA is very necessary to enter in this reactor because it helps to improve the quality, purity and also speed up the production of the product. After the addition of these two raw materials stirring process is done so that P2S5 which is solid product and DETA which is liquid product are mixed up properly so it becomes slurry. After the stirring of these products liquid Alcohol is entered in to this rector. This addition is done 8 for 10 hours. After this addition of the Alcohol again cooking process is done with 3 products. In this reactor cooking process is done for 2 hours. This process generates H2S gas which is converted in to by product i.e. NASH and also generates DETA in a liquid form. For converting H2S in to NASH small process is carried out i.e. in a big tank NAOH is filled up than in a big column from one side solution of NAOH is entered and from other side H2S gas is entered than in this column circulation is done and this process gives NASH which is dispatched by the company to the Dye industry. The reaction mass is cooled for 2 hours at -10 C.

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Finally DETA is transferred in filter for filtration and to remove the other impurities. Than DETA is transferred in to the storage tank and this is in liquid form. Total batch cycle time is 12 hours. Phorate The raw material used for phoratea:DETA Ethyl Mercantile Formaldehyde Water The process of Phorate:DETA is main raw material for making Phorate product and DETA is produced in a company itself. First DETA and water are charged in the reactor than alternative addition of formaldehyde and Ethyl Mercantine at 34C and atmosphere temp. at 30 to 35C generate hit, so it is necessary that reactor has to be cool so 15 to 25C cooling is maintain in this reactor by providing cool water to the reactor. After the addition, this reaction is transferred to the other reactor for cooking process. Here reaction is cooked for 18 hrs. at 25C to 30C. Here reaction is divided under two layers one is Aqueous phase and other is Organic compound. In this glass port separation is done. In this separation organic part is separated at the bottom and Aqueous is separated at the top. Than Aqueous phase is pumped to different tank and is transferred to ETP and organic phase is pumped to other reactor. In this reactor organic phase is contained Acidity so to neutralize the solution and to remove the acidity, there are two types of washing is done. 1. Caustic wash 2. Water wash

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In this reactor first caustic lye is added to remove or control the acidity. After the addition of caustic lye 2 hrs, is given for settling. After the addition of the caustic lye again this reaction is divided into two phases. One is Aqueous and anther is organic compound. In this separation caustic lye is separated at the bottom and removed as Aqueous and it is transferred to ETP and organic phase is separated at the top and it pumped to other reactor. This organic compound is contained Phorate but it is not pure. So after the separation of caustic, to neutralize the solution water washing is done and again this reaction is divided in two phases. One is Aqueous as water is separated at the top and transferred to other tank and then it is transferred to the ETP plant and organic phase which is Phorate is separated at the bottom and transferred to other reactor. This organic phase which is Phorate, it also contained some part of water so to remove the water and impurity stripping is done for 4 hrs. In the stripping process heat is given 80C temp. So through vapor water and other impurities are removed. After this process 90% quality of Phorate is obtained. 90% quality of Phorate is also dispatched by the company. Than from the striper it is transferred to TFE. To get pure Phorate further purification is done in TFE (Thin Film Evaporator) by giving 114C temp. heat. After this process 93% of quality of Phorate is obtained which is finished good of the company. At last packing is done 260 kgs drums. Plant:- Acephate Specification of Acephate:Plant capacity-450 MT / Month Physical state-solid Molecular formula-C4H10NO3PS Molecular weight-183 Melting point-93c

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Process of Acephate:First step is Isomerisation, in this step DMPAT, DMC, MDC are entered in to the reactor R-1081A, it become reaction, in this reaction DMPAT is main or key raw material, DMS is catalyst, DMS is very necessary to add in the reaction because it helps to increase the speed of production and MDC is solvent for the reaction. First, DMPAT and DMS are entered in to the reactor. By this reaction heat is generated at 42 to 50C so that to control heat MDC as solvent is entered in to the reaction. By this reaction we get MMD which is in intermediate form. After the Isomerisation reaction, MMD is transferred to other reactor R-1021B. In this reactor , Sulphuric Acid and Acetic Anhydrine are entered in to MMD reaction. Here Sulphuric Acid works as a catalyst. By this addition of MMD, Sulphuric Acid and Acetic Anthydrine we get Acephate in a product form. By this reaction Acidic Acid is also generated so that it is transferred to other reactor R-1021A for neutralization. In R-1021A neutralization is done. In this reactor the solution should be neutral at 7 PH. So that to neutralize the solution(reaction), Liquid Ammonia is of 18 to 20% entered in to the reaction. So it helps to neural the solution and remove the Acidic Acid which is generated in Acetylation reaction and salt is also generated. The mixture or reaction in this reactor is neutral and contain crude Acephate and other impurities. This mixture is then pumped to tank T-911 where two phases are obtained. The upper phase is Aqueous and lower phase is organic phase. This operation is known as a separation. In the separation, first organic phase is pumped in to tank T1061, T-1062, T-1063 so in this tank only Aqueous is remaining. So Aqueous is pumped to other reactor R-1031. This Aqueous is contained 7 to 8% Acephate so to get this Acephate from the Aqueous, it transferred to vessel V-7002 with this Vessel, pump is connected and this pump is

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also connected to extraction column. Aqueous is pumped from the vessel to extraction column. MDC from storage tank is also fed to extraction column. In this extraction column circulation is done between Aqueous and MDC and from this process Acephate is obtained which is collected in a tank and Aqueous is transferred to ETP. In this process salt is also removed. The organic phase is contained 18% Acephate and MDC is pumped in to tank T-1061, T-1062, T-1063. Than this organic phase transferred to MDCFFE-8081 to remove the MDC from the organic phase. To remove the MDC heat is generated from the bottom of MDCFFE. By providing the heat to the MDCFFE, MDC become vapor and remaining mixture fall down in a collection port with the help of gravity. Then vapor of MDC which is obtained from the evaporator and remaining vapor of MDC from the pot are collected in a vapor liquid separator. Vapor which is obtained from the separator and evaporator is combined in a condenser. In the condenser cooling water treatment is given to vapor of MDC so MDC become in a liquid form and transferred to the MDC storage tank. Then mixture of liquid Acephate is pumped in to reactor R1041B where addition of Ethyl Acelate is done in the mixture from the top of the reactor. Ethyl Acelate is solvent and for dilution, it is entered in the mixture. It is soluble with the MDC. In this stage again heat is generated to remove the remaining MDC from the mixture. The boiling point of MDC is 39c. So MDC is converted in a vapor form and this vapor fed in to condensers. In the condensers vapor of the MDC contact with the chilled water and MDC liquid is obtained then MDC liquid is transferred to R-1081A in the first stage or which ever stage it is needed. In this process crude Acephate is obtained and it is done for purification. This operation is called MDC recovery. The crude Acephate from R-1041B is pumped to the crystallizer. In the crystallizer process crystallizer jacket is provided from the outside through with chilled water is passed and in this process temp is maintain of -5c, so that liquid

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Acephate become in a crystal form and because of the contact with the chilled water crystals of Acephate are obtained. Crystals of Acephate along with the mother liquor is then transferred to the ANF (Agitated Nuch Filter) for filtration. In this ANF crystals of Acephate are separated from mother liquor and solid Acephate is separated at the bottom and remaining liquid portion is fall down at the bottom. By this way pure Acephate is obtained in a solid form. Plant:- Phosphamidon (PD) Specification of PD:Plant capacity-100 MT / Month Physical state-liquid Molecular formula-C10H19CLNO5P Molecular weight-400 Melting point- -45c Specific gravity-1.2132 Vapor pressure-0.00002 micron Hg at 293K Raw material used:DEAA (Dye Ethyl Acito Atthiile) Chlorine Soda Ash MCB (Mono Chloro Benzene) TMP (Tri Mithyl Phosphate) Caustic Lye EDC Process of Phosphamidon:First step is chlorination, in this step DEAA, EDC, Cl2, water are the raw material entered in to big reactor R-3001. DEAA is the main raw material in this process and EDC is solvent in the mixture and it is used to control the hit which is generated during the addition of DEAA and Cl2. By this reaction we get

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DEACl2 and HCI is byproduct. The quality of the DEACl2 should be 0.5% so it is tested in the lab. In the next step by taking this mixture neutralization is done. Reaction should be 6.5 to 7 PH so to neutralize the solution (mixture) soda Ash and water entered in to the reactor. After the neutralization process Phosphamidon is generated but it is not pure because it includes the EDC solvent and other impurities. From this stage separation process is also done and aqueous phase is transferred to other tank than it is transferred to ETP plant and organic compound is transferred to other reactor. EDC recovery is done in this reactor, in this stage from the reactor EDC which is solvent, is removed of. To remove the solvent hit is generated. In recovery stage hit is provided in the reactor so that EDC becomes vapor and through the condensers it is again become liquid and entered in reactor-1. After the EDC recovery Perkow reaction is done. In this step try methyl phosphate and mono chloro benzene are added in to reaction, this experiment is done by the Perkow scientist so it is called Perkow reaction. In this reaction there should not be any water part so that it removes the moisture effect from the reaction. So by this reaction we get crude PD. In this stage reaction is transferred to TFE for purification. In this process EDC, MCB, TMP are removed. With the help of TFE, EDC and other impurities are also removed by giving heat but some part of EDC is still remaining in the reaction so it transfer for further purification. In this step again purification is done and remaining EDC is also removed so that pure PD is obtained. After the purification, pure PD is obtained which the finished good of the company. Than PD is transferred to other tank for packing. PD is packed in drums of 225 kg of each.

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Plant:- Devrinol Specification of Devrinol:Plant capacity-240 MT / Month Physical state-solid Molecular formula-C7H21NO2 Molecular weight-271.4 Melting point-68 to 70C Raw material used:EDTA DEA Caustic lye Toluene-solvent Alpha napthol Water Process of Devrinol:First step is done in two reactors R-2002B and R-7002. In the first step DEA, EDTA, Toluene, water, caustic, lye are entered in to these reactors. After addition is done of all these material we get CPC. With the CPC cooking is done and then setting process is done. Then this mixture is pumped to another tank where separation is done and two phases are obtained, one is Aqueous phase and other is organic phase. The lower phase is Aqueous and upper phase is organic. Water and other impurities which are Aqueous pumped to other tank. By this reaction, we get CPAM which is organic part. This reaction is called CPC to CPAM. CPAM is pumped to other reactor R-2002A and CPAM is washes by H20 and then recovery is done. In the recovery stage heat is generated so that toluene

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and un reacted DEA are removed. The boiling point of toluene is 110c, so after toluene is removed CPAM which is main organic phase is pumped to reactor R-2007 and T-1031. In the CPAM, Alpha napthol and caustic lye are entered and addition is done of these materials. After the addition we get Devrinol in a liquid form. This reaction is called CPAM to Devrinol reaction. Then the Devrinol is transferred to other reactors R-1501 and R-2008 where hot water and toluene are used for purification and again impurities are washed i.e. removed from the organic phase and it is pumped to TFE (Thin Film Evaporator). To remove the toluene from the organic (devrinol) phase, heat is generated at the bottom of the evaporator so that toluene become vapor and with the contact of chilled water in the condenser vapor is converted in a liquid form and it is transferred to the which ever stage it is needed. Till some part of toluene is remained in the organic phase. After removing toluene, organic part is pumped to stripper and in the stripping process toluene is fully removed and with the help of vaquem other impurity is also removed. After this process we get pure Devrinol with 94% of quality. Then Devrinol is pumped to flaker. In the flaking process hot is entered in it and devrinol is collected in crystal form. After flaking, it is crushed in to crusher. In the crushing process it is converted in to small pieces. Then in the hammer mill small pieces are converted in to powder form and finally packing is done in 600 kg, 50 kg and 100 kg jumbo bags. Plant:- ETP(Effluent Treatment Plant)

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Effluent is liquid waste of the company which occurs during the production. The reason of the all the effluent in the industry are leakage and spillage of the chemicals from the pipes, pumps, during the material handling, storage etc. The other sources of the wastages or effluent are canteen, bathrooms, during the manufacturing of the product, washing and cleaning of the equipment. The effluent comes from the plant include various hazardous and dangerous chemicals as well as liquid hazardous wastages. Company can not directly discharge as it is very hazardous in nature. If the effluent directly discharged to anywhere or in river, well then these chemicals present in the effluent may cause various dangerous problems to environment, animals and human being. So it is very necessary to treat this effluent before discharging to remove the hazardous chemical from it. This treatment is given in a separate plant and that plant is called as effluent treatment plant Process of ETP plant Capacity of the ETP plant is 250MT/day. Effluent comes from all the plants like Acephate, Phorate, Devrinol, PD and from the other sources like bathroom, canteen are fed in ETP plant for removing the hazardous chemicals from the effluent before discharging outside. These effluent contains oil, grease, paper ,plastic, lubricant and other liquid waste. All these effluent fed into oil separator tank. In this plant treatment is given to the effluent to remove the oil and the wastages. This separation is done in oil separator tank. It is necessary to remove this wastages because presence of solid or liquid wastages may choke up the pipe lines. In this oil separator solvent are removed and effluent is pumped to the equalization tank. In the oil separator only oil solvent are removed but in the equalization tank all the hazardous chemical present are equalized because effluent comes from all the plants are hazardous in nature . They have to be equalized in this tank and the effluent is transferred to neutralization tank.

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In the neutralization tank acidity of effluent is neutralized by adding lime solution and ph is maintained between 7-8. From this tank effluent is transferred to flocculate. In the flocculating process Alum is used to settle the inorganic impurities. The resident time is given for 4-5 hours. From the flocculate effluent is pumped to primary settlement tank where the entire inorganic particle is settle down and resident time is given 2-3 hours. This treatment is known as primary treatment. In primary all the inorganic particles are settled down and clear water is overflowed and is fed to TSDF where water is separated in two layers. One layer is sludge and the other layer is clean water. Sludge is settled at the bottom , is dried and sent to disposal for land filling. Then clear water is overflowed and fed in aeration tank .In this tank 1.5-3% is fed. Living bacteria diates the biomass organic part which is presented in effluent and again clear water is overflowed and aerated effluent is introduced into secondary setting tank. From the aeration tank with the clear water, living bacteria is also fed in to secondary settling tank. In this tank bacteria will diate the organic part from the effluent. Similar process is followed in the second aeration tank and secondary settling tank. By this way all organic part is consumed by the bacteria and then an effluent from the second aeration tank is pumped to second secondary tank where remaining organic impurities are removed by adding fresh air to tank from bottom of tank. In this treatment effluent become free from all biological impurities and clear effluent is then fed to carbon filter. In this treatment 80 to 90% of BOD is removed. This treatment is known as secondary treatment. In the carbonic filter, carbon is fed in to this filter. In this filter tertiary treatment is given to clear effluent to remove the color

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from effluent and further purification is done in this filter and finally clear water is discharged to GIDC outlet. Types Of Material Handling Equipment Used There are many equipments are used for handling the material in the plant area. Fork lift Stacker Hand trolley Wooden palate Manually Pipe lines Vapor lines Tanks Pump Cranes Drums For handling the material big reactors are used. In these reactors all the chemical reactions are done. The raw material in the reactors is filled by using the pipe lines. Co-Ordination Between:a. Stores and production:Store and production departments are closely related to each other. When ever there is need arise of raw material, it prepares material requisition note and send to the store department through SAP system, in this material requisition note all the things like quantity, specification of the product is described. The store department than receive this material requisition note through SAP and will send the raw material to the production department as per their requirement. b. Purchase and production:-

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Whenever purchase department needs any new type of raw material than this department have to inform to purchase department. They have to provide the particular product specification like color, quality, name, of the product to the purchase department can purchase the material as per their specification.

c. Production and dispatch:As the production is going on, along with it packing of the finished goods on the other side is also carried out. As per material packed in the drums and bags they are sent to the dispatch department and finally dispatched finished goods. Dispatched department is arranged the goods as per the goods are produced. d. Production and engineering:During the production process many tools and spares and nut bolds are needed. When ever there is any break down occurs in the plant, the supervisor of the particular plant sends the requisition of spares through the SAP system to the engineering department. And engineering department send the requisition to the store department and the store department get an approval from the production manager. Than the required spares are send to the plant. Micro motion study of reactor:This is the micro motion study for reactor in which neutralization and separation process for Phorate product is done. This process includes various steps like addition of NAOH and water, stirring, QA analysis etc. and each step takes some time to complete this process. The whole process completes within 13 hours and 45 minutes. Quality Assurance At The Time Of Production Process

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Quality assurance is carries out during the production process to conform all the production is carries out properly or not and to get desired quality of the product. First, raw material is checked before it enters in the plant. During the production process after the addition of all the raw materials acid is generated in the reactor so that for neutralize the solution, it is checked by the QA department and after some addition of raw material quality of the product is also checked. During the every stage impurity and purity of the product is also checked by QA department. Purification is done to maintain the quality of the product. Many products in unit-2 are produced in batch process like Phorate, Acephate. So quality assurance is taken care of after the batch is completed. Quality assurance is also taken care for finished goods before dispatching the goods to the customers.

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CHAPTER:3 HUMAN RESOURCE DEPARTMENT/ PERSONNEL DEPARTMENT

Human Resource Department is the heart of the organization. Without employees and workers, the existence of the organization cant be imagined. All the other departments are directly or indirectly linked with the Human Resource Department, Human Resource Department play an important role in maintaining the proper manpower in the company. Human Resource Department play important role in development of employees as well as organization. Human Resource Department is mainly concerned with all the activity related to the human in the organization. This department is important as it gives life to non-living machines. In UPL, Human Resource Department is divided in to two parts as: Human Resource Department Personnel Department The activities are also divided among these departments and hence the company is able to get more effective management related to human activities. Activities Human Resource Department: Human resource planning Recruitment Selection Performance Appraisal Training and Development
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Wages and salary Organization development activity Coordinal environment Employee engagement program

Human Resource Planning Human Resource Planning is carried out in UPL on yearly basis. The meeting for Human Resource Planning is carried out in March in the Head office. Human Resource review is done and then gap of human resource is calculated. For calculation the gap of the Human Resource they use manmachine chart, with the use of this chart they come to know the gap of manpower. Expansion and diversification of the product they have to make Human Resource planning. The requirement of the manpower is approved by the CEO concerned. Then the Human Resource Department gets the man power requisition and the concerned department or the plant Head has to fill the man power requisition form. Human Resource planning helps in recruiting the required number of employee with needed skill and at the right time in the organization. Recruitment And Selection HR Department is responsible for getting the right candidate with knowledge and skill as per the requirement of the position of the company. The whole recruitment and selection process is done through HR Department. Manpower is the most important resource in the organization and with out the manpower organization can not be thought of. To run and to handle all other resource manpower is most important resource in the organization. Employees are the real asset of the company so it is requires to get most effective and suitable candidate for the company.
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The profitability and productivity of the company is depends upon the effective workforce. If the company is able to get wellmotivated candidate, then company can achieve its desired target and make the organization more effective. At UPL, recruitment and selection process is done very carefully. When ever there is any vacant position in the organization, recruitment is done in the company. Retirement, retrenchment, resignation, death of the employees are the main reason of the recruitment. Sources of Recruitment At UPL, two types of sources are used to recruit the candidate. 1. Internal 2. External Recruitment is done internally as well as externally but they prefer to recruit the candidate by using the internal sources like employee reference, existing employees, promotion, transfer of the employee because employees are already familiar with the company and company has also all the details of the employees and it also saves the cost and time for induction program. But to bring the new talent and skill in the company, they also recruit the candidate by externally.
Internal recruitment is done by following ways:-

1. Employee reference 2. Existing employees 3. Promotion 4. Transfer

For External recruitment following sources are used:-

1. Employment exchange 2. Consultancy

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Within Ankleshwar: Ankleshwar Employment service Perfect placement Oxford placement Rapid placement

Outside Ankleshwar: India placement service Havoc placement service Fact personnel Omkar placement Friends placement

Recruitment And Selection Process The process of recruitment starts from the nanpower planning and manpower assessment. Based on existing as well as future business need of the company, they forecast manpower requirement.
Each

department or functional head has to prepare proposal for the requirement of additional manpower. Manpower requirement is raised in case of any position is vacant in any department. The reason of requirement will be raised in manpower requisition form. This form mentions job description, job specification and justification for particular level. They defined the factors which are needed and helpful to select the candidate. This form is filled by HOD and job description is also prepare by the HOD then it send to Chief Operating Officer for approval.

After the Form approved by COO, HR department will start approaching various internal and external sources to fill the requirement of the manpower. From this stage selection process will start. To fill the requirement of

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manpower for particular position. HR department first prefer to get the candidate from the internal sources like through promotion, transfer and through employee reference because it is cost saving and beneficial for the organization. If HR department is not able to get desired candidate from the internal sources then they start approaching various external sources like passing job description to various external agencies, posting on websites. The HR department collects the c.v.s from different sources and then c.v.s are screening by HR department with the help of screening process. C.V. which are not as per the job description are rejected and other c.v.s which are as per the defined factors are collected and those selected candidates undergo for further process. The outstation candidates are reimbursed for their travel expenditure by train.

First of all they do telephonic conversation with selected candidate. Telephonic conversation is done to check their communication skill. After this round some of the candidates are rejected and selected candidates are called for the personal interview with the HR department then technical interview is taken by the head of the concerned department. Some of the candidates are rejected in this stage and suitable candidates will undergo for the final round of interview which is taken by senior management. After the final round only suitable candidate is selected. The candidate who has cleared the final round of interview an offer letter is given to him detailing the terms of employement and other terms and conditions. If candidate is not agree with the terms of employment then candidate may reject the offer letter and then again screening process is done by the HR department and
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similar procedure is followed to find the suitable candidate. If candidate accept the offer letter then candidate is required to undergo for a medical examination in a company authorized medical center. The medical examination once conducted the reports are sent only to the HR department and not to be discussed with the candidates. If candidate is fail in the medical examination then candidate is rejected and candidate clear this examination then appointment letter is given to him. In this letter date of joining is mentioned and he is asked to resign from his current organization and joint the company as per the joining date. He is also asked to bring necessary documents with him at the time of joining and finally position is closed. By this way recruitment and selection procedure is carried out in the UPL Performance Appraisal System:Performance appraisal is a management tool designed to encourage communication in the organization, improve quality of work produced and promote individual accountability. Objectives of the Appraisal System: Open two way communication between the immediate superior and the subordinate. Provide an opportunity for the superior to give positive and constructive feedback to his team. Set mutually acceptable and achievable goals and objectives. Provide a platform for the HOD to discuss how the team/department objectives align with the strategy of the company.
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Develop personal growth and career development strategies for the individual team members. Provide a basis for rewards and benefits. Policy:The performance management system at UPL provides a structured and formal platform for interaction in order to obtain a review of goals and objectives set by individual and teams. Types of appraisal in UPL:1) Annual Performance Appraisal 2) Quartely Appraisals Annual Performance Appraisal Purpose To review employee performance and provide feedback so as to facilitate employees overall growth and development. To decide the rewards (i.e. annual increment and incentive) that would accrue to the employee. Period of Review and Timing The annual performance appraisal reviews an individual for the financial year for e.g. April 2006-March 2007. The review is done during the month of April. The annual performance review is done for all employees who have completed a minimum of 6 months in the organization and have been confirmed. Process The appraisal and Quartely review process follow a similar pattern. The process begins with the employee filling up his self review stating the achievement in the key result areas and process areas. The process can be jointly done with the HOD or
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may be first done by the employee and then appraised by the immediate superior. For all those employees who have preset objectives, the appraisee would enter the ratings against the preset objectives after discussion with the concerned employee. For all those employees whose objectives have not been preset the appraiser could evaluate the performance of the employee for his contribution in result areas, based on: Quantity of work handled Quality of output Timeliness with which the job is done ( These are general guidelines, which may be used to set a framework for the appraise). The completed appraisal form is then sent to the next Reviewer for his/her comments, who could then forward the same to HR. This entire process is to be completed before the 15th of April. Quarterly Reviews:Purpose Quarterly reviews are meant to be specific, measurable, achievable, result oriented and time-bound. To set goals/objectives keeping in view the focus of the organization in view of changes in the organizational direction, time/resource availability. To decide the incentive amount an individual is entitled to. Period of Review The quarterly review is done for an individual for every quarter in the financial year i.e. Quarter 1: April-June, Quarter 2: July-September
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Quarter 3: October-December Quarter 4: January-March. Process The quarterly review process begins at the start of the quarter, where the team members discuss the team strategy at the onset of the quarter along with the H.O.D. They then set their goals or targets for the quarter a review of achievements against the set targets is carried out and based on this review a ranking is given to the individual. This ranking decides the incentive amount an individual receives. The final rankings should reach HRD by the 10th day of the month immediately succeeding the quarter. In order to make the KPI system more reward oriented while constantly endeavoring for higher standards of performance, we have defined the metrics of evaluation. This will enable an individual to be able to earn up to 120% of his KPI in each quarter. Keeping the above in mind, the new system for setting the goals and the system of evaluation will be as follows: The targets set in every quarter should be much focused and the number of targets taken would vary depending on the different focus areas. The weight age for each target would depend on the level of priority up to a maximum score of 100. A level of difficulty will be defined at the end of all the targets. Level of difficulty is the extent to which the targets set for the quarter are difficult to achieve. The range should be between 0.7 to 1.2, where 0.7 would be a fairly low level of difficulty in achieving the goal. The level of difficulty is agreed upon mutually by the subordinate and superior. The level of difficulty will be decided at the beginning of the quarter.

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The evaluation of the targets at the end of the quarter would be scored on the following methodology; Table No: 5 Goals Target Target Target Target Total 1 2 3 4 Results Achieved Weightage 30 25 25 20 100 Achieved 25 20 24 17 86

The level of difficulty set for the above was 1.2. The person has achieved a score of 86 points. The score for actual achieved is arrived at by multiplying the level of difficulty with the achieved score. Hence the score would be 103.2. The criterion for scoring is as follows: Table No:6 Grade Z+ Z A B C D Range 111-120 101-110 90-100 75-89 60-74 59 below Percentage earned 120 110 100 85 70 0 Criteria for scoring Sets more than benchmarks At least 2 benchmarks Achieves more than targets Achieves set targets Slightly below target Unacceptable For Employees And 2

set

Types Of Training Programs Vocational Trainees:-

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There are many types training programs are conducted at UPL:-

ISO training is compulsory for all the employees as well as new joiners. EMS (Environment Management System), QMS (Quality Management System), and IMS (Integrate Management System) are the ISO training which are provided to new joiners in the organization. ISO training is provided at every quarter in order to improve the knowledge about the ISO. According to ISO, it is compulsory that what ever is written in the form of documents it must be done in the organization. E.g. types of training are written in the document than it should be followed in the organization. If is not done in the organization than non compliance is given to the organization and it adversely affects the goodwill of the company and certificate of the company will be taken. Induction training:At UPL, induction training is conducted for 3 days. It is compulsory for all the new joiners in the organization. It is provided to make familiar him/her with the organization. Safety training:Safety training is compulsory provided to all employees as well as new joiners. There are many hazardous chemicals produced in the company. So safety training is very important to protect from these hazardous chemicals. 4 days safety training is conducted for every joiners and every month safety training is provided to the workers on different topics like fire safety, mock-drill, emergency response safety, drum handling and hazardous material handling. To create the awareness about the safety, different safety talk is conducted on various topics like necessary to wear helmet, gloves, safety goggles, shoes etc. exposure safety is also provided to all workers and staff at UPL.

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SAP training:At UPL, SAP system is used to maintain data and report of the different department. Thus to make every one aware about the SAP system, this training is given to all the employees. At UPL, every quarter SAP training is provided to all new joiners and refresher training is also conducted for existing trainees. IT training:IT training is conducted at provided to all the employees the computer and internet knowledge and skill and to environment. Soft skill training:Every employee should not have only technical skill but they should also have soft skill. Soft skills include training regarding the leadership, communication training, team building are provided to employees. It is off job training and provided by the external faculty in order to develop the personality and behavior of the employee. BBSMS training:It is new concept which UPL has taken up in order to improve safety system at UPL. After continuous training the system has been implemented and to sustain the system regular training are provided at UPL. Vocational training Induction training Orientation training Safety training
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regular intervals in UPL. It is to upgrade the knowledge about etc. IT helps to improve the be more competent in todays

Training needs which are identified by the employees ASPEAN software:It is useful for simulation of chemical process. If they want to implement some innovative procedure in the plant area which might be reduce the cost and improve the quality. But this process directly can not be implemented in the plant because it is too risky and hazardous and also huge amount is needed for investment. That is why they implement and experiment this process in the ASPEAN software and it will give the result whether this method should be implemented or not. This software also gives the calculation so they can make the judgement about the implementation of the process in the plant area. Knowledge of utility operation:Training is given to the trainee about the chilled water in the plant area, how to run the cool water plant, about the boiled water, training is also given about the utiltity equipment for e.g. how to provide the utility to the plant like steam, air, water, gas etc. Process design and calculation:Training is given to the trainee that how to bring innovation in the production process which can improve the quality of the product and reduce the cost. This training is given so that they can become innovative and it also helps to the company as it improves the productivity and profitability by bringing the new process design and calculation which can reduce the production cost. Energy conservation:This training is provided for saving the energy. Training is given about how to save the energy like electricity, water etc.

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Emergency rescue training:This training is provided to save the man, machine, material. They are trained when ever there is any emergency in the plant than how to save the life which is most important in the part of training, how they can save the material and equipments. OPE calculation:OPE is known as overall plane efficiency. This training is given to the employees of the Max pro department. To check and improve the overall plant efficiency this training is very important. In this training they are taught that how to check the purity, maintain the purity and improve the purity and reduce the cost. In short this training is provided to improve the plant efficiency and productivity. For example:If the purity of particular chemical should be 98% and if the purity comes 97.5% than they will think how to improve the purity of this chemical and if the purity is 98.5% than they try to maintain the purity at this level. Advance chemical equipment design and material and emergency balance:Training is provided so that standard procedure is followed by every one. This training is given to maintain the standard purity and quality by every one. Suppose the different procedure is followed by the different operators so to maintain the purity of the product standard procedure is followed in the company and this training is provided to follow the standard process. 5s:-

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This is the Japanese concept for house keeping. This training is also provided to the workers so that systematic method is followed and all things are maintained in a proper way.

Supervisor training:This is succession planning for the employees. Supervisory training is provided to all the level because they can always ready for taking the responsibility for the higher post. In this training they are prepared for future succession like promotion. This training is compulsory so that when ever any need arise and if a person is promoted for higher person than he is always ready for higher responsibility. Internal auditor certificate training:Company have also internal auditor to check the quality, quantity of the product so auditing training is also provided to the trainee. Vibration analysis:If any machine or equipment is vibrating then analysis is done through vibration machine to know in what extent machine is vibrating. This training is also given. Time management:Training is given to the workers, employees how they should utilize the time. So time management training is also given to save the time. System automation:Some work is done through manually and some work is done through machine. So training is given to the workers how they should operate the machine.

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Types Of Training Aids Used in UPL There are three types of training Aids are used in UPL-2. 1) Audio-visual Aids 2) Visual Aids 3) Others/ Audio Aids While identifying training needs of the employees. HR department also identify training aids i.e. they also have to identify which are the training aids are required to conduct training programs. As per the training needs identified by the employees, they decide the priority that which trainings are conducted in quarter 1,2 or 3 and based on the training schedule that have to identify that which are training aids are needed. E.g soft skill trainings required Audio Aids like oral presentation, case study. Here visual Aids are not useful. On the other hand if technical trainings are identified by the employees then Audio-visual Aids are more effective. Three types of training Aids are used in UPL which are described as follows: Visual Aids:Visual Aids help our presentation make things happen. Visual Aids help to reach our objectives by providing emphasis to whenever is being said. Clear picture multiply the audiences level of understanding and they should be used to reinforce the message clarity points and create excitement. Visual Aids involve the audience and use of visual aids then it is mutually beneficial to the audience. With the help of visual aids increase the understanding of the audience and retention level. Visual Aids are subdivided in four categories. a. Over Head projectors/ transparencies
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Over head projector is useful for audience settings of 20 to 50 people and can be used quickly, easily and inexpensively. Any charts, illustration or diagrams can be made in to transparencies. b. Charts/flipcharts/peg boards Flip charts are quick, inexpensive visual aids for briefing small groups. The charts, felt-tip markers and graphics materials are readily available and with a modest ability at lettering the presenters can compose the desired visual aid in house. c. Posters Posters are prepared graphic devices that can be made of verify of materials and media. Photographers, diagrams, graphs, word message or a combination of these posters work best in smaller audience size. d. White boards/black boards It is the most common visual aid available to the presenter. When using blackboard, some points should be kept in mind. Chalks, pens are used for writing necessary points in a black boards as well as white board. e. Chalks/ pens/ markers These are also used as training aids. Audio Visual Aids Audio Visual Aids include video tapes, LCD projector, computers/laptop. They can be used to provide a wide range of realistic example of job conditions and situation in the condensed period of time. Further, the quality of presentation can be controlled and will remain equal for all training groups. But, audio visual aids constitute a one way system of communication with no scope for the audience to raise doubts for clarification.

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Audio visual Aids include a wide variety of io aids communication products. Audio visual aids are divided in following categories. a. Video tapes/CD Video tape carries both a picture and sound track. feature of sound, movement, color and variety hold audiences attention. Video tape can be used in program entire presentation or to support a speakers remarks highlighting certain points. b. LCD projectors c. Computer/ laptops Its an an by

Others/audio aids Audio aids are also subdivided in following ways a. Audio taps b. Oral presentation c. Questionnaires/case study are used Audio aids The experimental psychologists have found that three days after an event, people retain 10% of what they heard from an oral presentation, 35% from visual presentation and 65% from visual & oral presentation. Training and Development Activities At UPL, training and development activities are given very importance because it helps to improve the growth of the employees as well as organization. Training helps to upgrade the skill and knowledge of the employees and developmental activities improves the behavior and personality of the employees. Purpose of providing Training & Developmental activities is to improve the growth of overall organization and besides this trained employees are very helpful whenever there are any changes take place in the market. Training & Development activities are carried out so that accidents are minimizes, wastage of the material is also minimizes and it also helps to reduce the supervision cost. Productivity and
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profitability employees.

also

increase

with

the

help

of

trained

At UPL, training is need based i.e. training is not compulsory for all the employees. Training need assessment is done by the employees and for the workers training need is assessed by the superior. For identification of the training need of the employees, form is given to each and every employee of each department. In this form they have to fill up the area, type of training in which they need training. After this form will verify and signed by the concerned HOD. All these activities are handled by the HR person so that this form will send to the HR department and it is signed by the concerned person of the HR department and than training program will be implemented. After the completion of the training program, training evaluation is done by giving the feedback forms to the trainees where they have to mention that they are satisfied or not by the training. In these feedback forms they have to give feedback regarding the training topics, training facility, training aids and performance of the training faculty. Than for evaluation of effectiveness of the training, feedback form is filled and signed by the concerned HOD. It is done for all individual trainees. For personality and behavior development of the employees development activities like seminar, personality development program are carried out by the HR department. Responsibility Responsibility for training needs assessment will be as follows: For managers, staff and workers by the respective immediate superior/HOD of plant and functional area.

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 For Sr.managerial staff like Sr. manager and above by GM. HOD/ superior will decide the competency requirement for each position. Unit-head will responsible and authorized for approval of the training, plan, training resource. HOD of HR department is responsible for implementation of this procedure. HOD is responsible for reviewing effectiveness of the training procedure. HOD of respective plants/sections is responsible and authorized to implement this procedure as desired in section description. Way To Identify Training Needs The competencies for respective positions in the organizations and those working on its behalf shall be determined by HOD and unit head. The gap analysis shall be done based identified competencies and actual competencies performance in their work. The identification of competency shall take in to consideration of job description, skill requirement, level of responsibility, ability, language skills and literacy and risk. The training needs shall be based on gap analysis and when a person joins or some one is transferred from one department to another department. The gap analysis i.e. training need shall be done by HR department/ functional Head. The training need on the basis of actual or potential of their work, activities and behavior. Wage And Salary Structure

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In the past, grade system is followed by the UPL. But now flat organization structure is followed by the UPL. In UPL wage and salary is distributed by following way:Monthly: Basic HRA(House Rent Allowances) Transport Education Special Allowances Monthly Gross Yearly: Bonus Providend Fund Medical LTA Performance incentive Superannuation (for managers and above post) Conveyance (for assistant manager and above post) Annual gross The negotiation are done on the cost to the company. Organizational Developmental Activities It is the responsibility of the HR Department to carry out organizational developmental activity in the organization to motivate the employee. HR department carried out the activity related to provide the training to the employee, to held the safety week for 7 days, to celebrate the environment day in a company to create the awareness among the workers. For the development of the employee they try to identify the training need of employee and provide training so that employee can come over from their weakness and identify
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their strength. HR department tries to improve their knowledge and skill by providing magazines, by providing library facility where employees can read some books in their rest time. For the development of the employees the activity related to changing the work culture are also been carried in the organization. They are so concerned about the development of the employees and organization as they believe that trained employees are real assets of the company. Transfer Policy There is no any particular transfer policy is followed at UPL. There is no any policy of job rotation or compulsion of transfer for any employees. Here transfer is not given as a punishment. Transfer is totally need based of the employees. HR person are constant contact with the different units of the UPL. When there is any need arise in any unit or any vacancy arise in the unit, interested person are asked for transfer and among them suitable employees is transferred. Employee can also demand for transfer. Suppose if employees wants to transfer his native place and if he is suitable for a particular unit, he will transfer to a place. Reason for transfer:Position vacant Demand of the employee Housing for transferred employees:Where an employee is transferred to any place in India, he will be provided company accommodation. In case the employee avails company accommodation, 10% of his basic salary will be deducted as house rent and if the HRA is more than the amount is deducted, is shall be paid as house maintenance allowance. Promotion Policy

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Promotions are in UPL are given on merit basis only. Any employee becomes eligible for the promotion, if he has achieved at least two benchmarks from his set target. Promotions are the result of annual performance appraisal. Before the restructuring of the organization, the promotions were based on the grading system. e.g. if an officer was earning 5000 Rs. Per month and as a result of increment his salary reaches to 8000 Rs. Per month, then he was automatically promoted to executives. This was the grading system which is not followed now. Now the performance is measured and then the promotions are given. If the employee is covering his target (KPI), then PI (performance incentive) is added to his salary quarterly. Activity Carried Out Towards Organization Development The HR department looks after the all activity regarding the organization development. Development center:Generally development centers are outside the work place. It is a place where the employees who need similar type of training are grouped together and provide training relating to communication skill, team building training, leadership training as per the need of the group. It is a place where person receives the knowledge and skill so trained and skilled employee are ultimately beneficial to the organization. Excellence Awards:It is one of the activities for the organization development and to motivate the employee to hard work. It is an event which held once in a year. It is held to appreciate the efforts put by the different person of UPL and to recognize & reward the individual and team performers which are bench mark. Here different awards and reorganization are given to the different person for their achievement in a organization.

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Parivartan Magazine:UPL has introduce its own magazine named parivartan which helps the employees to abreast with the latest events, products, new initiatives with respect to domestic marketing and sales. Techno savvy(SAP):UPL keeps itself abreast with the latest technology. UPL has successfully implemented SAP across all the functions. UPL provides the SAP training the employees for the organizational development. Learning and development:For the development of the organization UPL held the safety week, environment day in the organization. For learning purpose they provide training regarding the SAP etc. so that workers can learn something and get the knowledge. Mentoring:It is done for new joinee in the organization. Any new joinee is given 7 days induction training by the any person from ay department. This person become mentor and looks after all his activity and provide training to him. Mentor with the experience and knowledge of any department train the person and make him familiar with the company and other person of the company. Mentor at UPL facilitates people of UPL to Learn new concepts and techniques Know where the opportunities are and steer clear of the pitfalls. Appreciate your own shortcomings. Understand the intricacies of the knowledge economy of 21st century. Share, anticipate and provide feedback.

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Personnel Department Departmental Structure:

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GM (Works)

DGM(personnel & Administration)

Assistant Manager (Personnel & Administration) Senior Executive/ Executive

Officers

Trainees

Activities Personnel Department Time office

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Detail in employees personnel file Welfare activities Industrial relation Administrative activities Resolving the disputes of the employees Co-ordination with factory inspector

Details In Personal File: Manpower requisition form signed by HR department and approval of COO. Employee personal data Application Form Salary structure Curricular vitae Application form for loan purpose Appointment letter Negotiation letter Medical insurance policy proposal Gratuity form Employee provident fund organization Employee confidential information Certification of all educational organization Leaving certification of last organization Transfer letter if any Promotion letter if any Increment letter of every year

Function Of Time Office Time keeping All factories operate six days a week. The shifts and timings are:-

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General shifts: 9:00 A.M to 5:30 P.M. 1st shift: 7:00 A.M. to 3:00 P.M. 2nd shift: 3:00 P.M. to 11:00 P.M. 3rd shift: 11:00 P.M to 7:00 A.M. In UPL punch card system is used for recording the in-out timing of the employees, but very soon they will adopt biometric system for recording purpose. For new entrance, till the punch card is provided to them, they are required to sign in the muster table, their arrival and departure time. This muster kept in the personnel department. The timings are recorded for salary calculation and leave of the employees. Leave Management Leave is calculated on working days. It will not include weekly offs and public holidays. Company takes in to consideration 24 days for salary calculation of the employees i.e. they take average 29 days as working days and 4 or 5 Sundays in a month. The leave balance card score card is provided by the company twice in a year i.e. in January and July. Employee have to fill this leave card before he/she take a leave, but in case of sick leave, employees have to feel this card after he/she take leave. The leave balance score card include name of the employee, reason for the leave, number of days for the leave, duration of the date for the leave. There are three types of leave, they are as follows: Privilege Leave (PL):This leave is available for 21 days in a year. P.L. can be taken for minimum 3 or 4 days i.e if any employee wants to take leave for more than 3 days, it will take into consideration as a privilege leave. It can be accumulated to the next year. Casual Leave:-

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Employees get 7 casual leave in a year. C.L. can be taken for maximum 3 days. This leave cannot be accumulated and converted. Sick Leave:Sick leave is available for 9 days in a year. Employee can take maximum 3 days for sick leave. These leave will be accumulated and converted in the privilege leave in a next year. Average Training Man-days/ Hours Per Employee Total training provided to employees=757 man days Numbers of employees=81 Average training man day=Total training provided Number of employee = = 1 day= 8 hours = 9.34* 8 = 74.76 = 75 man hours/employee Welfare Activities The welfare activities are carried out so that the employees feel that the company is taking care of them. The purpose of providing welfare activity is to provide satisfaction to the employee so that they can work smoothly in the company without any negative feelings towards the management and the company. UPL offers various activities to the workers and employees. Medclaim It is different for different levels in the company Canteen
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757 81 9.34 man days

This facility is provided to all employees and workers with nominal rate Raincoat It is provided to all employees & workers in every 2 years. Uniform for workers It is provided to all the workers in every two years. Civil shoes, Gum boots for workers It is provided to all the workers. Education for employees children This facility is provided to worker for their children for further study. Workers have to see certain documents to the company. UPL colonies (bachelors quarters, Family accommodations, guest houses) Company provides this facility to the executives & senior executives otherwise HRA is provided to them. UPL library This facility is for all the employees Provident fund It is the statutory facility. Statutory Benefits Provident fund and employee pension:It is compulsory contributory fund for the future of the employee after his retirement or for his dependents in case of early death. The employee and employer contribute equally towards the provident fund that is each one of them contributes 12% of the basic salary. The employees pension envisages providing monthly pension to employee on superannuation, pension to dependents in unfortunate event of death. Employee state insurance:The employee who received gross salary below and up to 7500/- per month excluding conveyance eligible for ESIC coverage. ESIC(employee state insurance corporation) provide the employee with medical relief
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and sickness cash benefits. The employer is required to contribute at the rate of 4.75% of the gross salary paid. The employees are also requires to contribute at the rate of 1.75% of the gross salary. Bonus:The company pays bonus to every employee at the rate of 8.33% of the basic salary drawn by employee. Gratuity:Gratuity is paid as per the payment of gratuity Act, 1972. An employee who completes five year of service in the company is eligible for payment of gratuity. The rate of payment is 15 days for every year of service completed. It is paid after the retirement of the employee. Non Statutory Benefits Med claim policy:Med claim is an paid an ensure policy, which covers medical expenses on hospitalization. For UPL United Insurance Corporation covers it. The employee is eligible for this policy from the date of joining. Employee has to submit the bills to the company and personnel department will submit this bill to the insurance company. There is a waiting period of 2 months to avail of this benefit which starts after the submission of med claim by the personnel department to the insurance company. The cash will credited to the account of the employee. General personnel Accident policy:It is a group policy which covers any personnel loss due to any injury caused to employee during course of employment. The company pays the premium for all the employees covered under this scheme. In UPL, United Indian Insurance Company Ltd. covers this policy. In case of death, employees family get 100 times of his/her basic salary. In case of disablement, employee will get reimbursed for number of days he

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was on leave. In addition, he will get 50% of above mentioned salary as medical reimbursement. Industrial Relations The word Industrial Relations means the nature of relation between the employee and employer in the organization. It is necessary to maintain industrial relation between the workers and the management. It helps to increase the productivity and profitability of the organization. When willing co-operation is available from employees and workers for the achievement of the organizational goals, it is said as company is having sound industrial relations. UPL has achieved this kind of sound relationship with the workers. UPL is providing fair and conductive environment for working. Trade Union Personnel department is of the view that the company should have harmonious relationship with the workers. In UPL, the workers have formed their Trade Union which is not affiliated to any outside committee. The mane of the Trade Union is UPL Kamdar Sang. This union is common for all the units which are located in the Gujarat. The main activity of this union is salary negotiation with the management. There is a settlement system between management and worker level. Meeting is held between the HOD and members of the trade union once in every 4 year. It is done in the month of January. In this meeting union demands for increase in salary for the workers and negotiations is done with the workers and management. So activity is carried out smoothly and industrial disputes are not found much as workers and employees are satisfied. The participation in this Union is Voluntary i.e. no compulsion to be part of this union. Administration Activities

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Administration activities include activities like house keeping of the premises, travel arrangement and ticket booking, guest house arrangement and their maintenance, allocation of personnel like office assistants and cleaners and handlings of security, corporate communication and organizing conference also fall in this portfolio. These activities are carried out by the personnel department. The administration activities is carried out in this department are as follows:House Keeping House keeping is one of the main activities carried out by the administration department which involves the cleaning of roads, canteen area, administration building, other offices, gardening and sanitation. All such activities are carried out through workers on daily basis and for which annual budget is approximately above 1 lakh p.a. excluding the materials used. House keeping in plant area is basically done by well trained workers as other technical knowledge is required to work in the plant area. Canteen Handling The main aim of canteen handling is to provide good quality and quantity of food to employees from the canteen contractors. Also the house keeping in the canteen area is taken good care, as cleanliness is very much required in such places. Transportation This transportation carried out by the administration department is for the employees on Duty. This facility is provided for official purpose only. This basically involves two Maruti Vans in the company premises or the traveler expenses are duly paid. Ticket Booking

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Ticket bookings for railway reservation, general reservation in railways, bus tickets and air tickets for the employees who have to go on official tour are done by the administration department. The tickets are been booked taking in to consideration the designation of the employee. Hotel Booking Booking in Hotel or guest house is basically done by the company for its visitors, as per the visitors requirement. The grade of service is maintained as per the persons designation. Computer Application In HR Softwares Used To Assist In HR Management Function In UPL the Microsoft office i.e. Microsoft Word and Microsoft Excel is used in the HR department and personnel department. SAP payroll module is used by personnel department for salary and wages administration. HR department has also implemented SAP module for recruitment, selection, performance management and training records.

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CHAPTER:-4 FINANCE DEPARTMENT

Finance department plays an important role in the company. For purchase of raw material, finished goods, packing material finance is needed. Finance is needed at every stage whether in case of revenue or capital expenditure. Without finance presence of company cannot imagine. In succession of any industry or business finance is important equipment of business. Financial planning is the process of estimating the financial requirement of the business. It follows of following procedure in the organization. To determine the need of working capital and fixed assets. To determine the method of rising funds. To have control over entire funds

Activities:The major activity includes collection of the funds through various sources like term loan, debentures, preferences shares etc. and utilize these funds in the optimal way. Finance department is responsible for all the activities related with the utilizing & receiving funds. Finance department aims at borrowing the funds at the cheapest / lowest interest rates monitoring funds, liaison with the banks, bringing packing credit at lowest interest rates against export order.

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 It deals with preparation of cheques, DDs, and it is responsible for maintaining of accounts. Foreign exchange management is also done by this department. Budgetary Control System Budget Budget is prepared by all the departments. All the departments estimate their requirement and they prepare the budget as per their requirement for their particular department. They divided all the revenue expenditure and capital expenditure. Budget is prepared on the basis of last three years budget of the company. First, yearly budget is prepared by all the department by the discussion with the HOD of their department. Based on yearly budget, they prepare budget for every month and on the basis of monthly budget daily budget is prepared by all the departments. This budget is prepared for only revenue expenditure. This budget contains only day to day expenditure. For capital expenditure, CAPAX system is used by UPL. Capital expenditure includes the expansion plan for future, new machinery installation, purchase the mechanical equipment etc. Budget Control Budget for all the departments is prepared and final report of the budget is then sent to the Head Office at Mumbai. Then budget is approved by the Head Office and transferred as per their monthly requirements. Budget Period In UPL, the budget period is based on financial year i.e. 1st April to 31st March.
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Principal Budget Factor There are some main factors which take in to consideration while preparing the budget, they are as follow: Manpower planning Capacity planning Production planning Budget Centers (Cost Centers) Budget is prepared by all the departments as per their requirement. There are 32 budget centers in UPL Unit-2. These budget centers are as follows: Devrinol Phorate DETA DTP Oryzalin Alcohol Acephate Water Steam Cooling water DG House Nitrogen Chilled water Compressed Air Engineering Mechanical Engineering Electrical Engineering Instrument Engineering Civil Stores Commercial Administration Security Personnel
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IT Welfare and Canteen QC Lab Safety Max Pro ETP Incinerator Chemical House Stand still

Accounting Method/System All the details are maintained in a SAP system. Double entry book keeping system is used to record all transaction. This system is used by all the units of UPL. Ratio Analysis:Liquidity and Solvency Ratio: 1. Current Ratio: Current ratio (2006-07) = = (2007-08) = = 2. Liquid Ratio: Liquid ratio= (2006-07) = = 231410 69852 3.31:1 248434 78944 3.15:1 Current Assets-Stock Current liability-bank overdraft 231410-25942 69852 205468 69852 = Current Assets Current Liabilities

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= (2007-08) = = =

2.94:1 248434-30227 78944 218207 78944 2.76:1

3. Capital Gearing Ratio:Capital gearing ratio= Debenture + preference share Equity share (2006-07) = 6000+14000+500 5500 = 3.73:1 (2007-08) = = 4. Quick Ratio:Quick ratio = (2006-2007)= = = (2007-2008)= = = 5. Proprietary Ratio:Proprietary ratio = (2006-2007) = 1000+14500 15500 1 Current Assets-stock debtors Liquid liability 231410-25942-38056 69852 167412 69852 2.40:1 248434-30227-49852 78944 168355 78944 2.13:1 Proprietary Fund x 100 Total Tangible Assets 128925 x 100

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= (2007-2008) = = Profitability Ratio: 1. Net Ratio:Net Profit Ratio = (2006-2007) = = (2007-2008) = =

327598 39.35% 195918 x 100 399284 49.07%

NPAT x 100 Net sales 10,882 x 100 145094 7.50% 9252 x 100 159089 5.82%

2. Return On Capital Employees:ROCE = EBIT x 100 Capital Employee (2006-2007) = = (2007-2008) = = 16166 x 100 161836 9.99% 9441 x 100 213558 4.42%

3. Return On Equity Share Holder Fund:ROESHF = NPAT- Preference dividend x 100 Equity Share Holder Fund

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(2006-2007) = 10882-1 x 100 114425 = 10881 x 100 114425 = 9.51% (2007-2008) = 9252-0 x 100 181418 = 9252 x 100 181418 = 5.10% Costing Of The Main Product There are some factors which affect while fixing the cost of the main product. Costing of the main product is done by take in to consideration following factors: Cost of raw material Wages of the company labor Cost of packing material Contract labor Direct cost Indirect cost

Types Of Taxes Two types of taxes are paid by the UPL Unit-2. 1. Excise-14% 2. Sales tax-4% Movement Of Pricing During The Last One Year On A Monthly Basis:Table No: 7 Month July 08 August 08 September 08
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Price 270.75 312.9 335.5

October 08 November 08 December 08 January 09 February 09 March 09 April 09 May 09 June 09

235 96.2 78.9 118.5 92.4 74.8 104.6 125.8 163.75

Financial MIS (Management Information System) It is prepared by all the departments on monthly basis. Quantitative data are installed in the MIS. Monthly meeting is conducted among the HOD to check and discuss the MIS prepared by all the departments. If MIS give positive result then they discuss how to maintain this level and if it is negative result then they try to achieve positive result. It includes: Product costing Overhead budget Key performance data Non moving & slow moving inventory Cost sheet Summary & cumulative variance

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CHAPTER: 5 MARKETING DEPARTMENT

Marketing department is heart of the company. It helps to survive in a competitive market. It helps to the company to achieve its desired goal by introducing and promoting the products in such a way that customers attract towards the products and purchase more products. Marketing department play important role in market research and it helps to know demand of the product and also helps to know the position of the company. If marketing department perform well than company can achieve its desired goal by meeting the sales target. Profitability of the company can also improve by increasing the sales of the product with better quality and with the help of promotional activity. Activities Of Marketing Department Prepare sales target To attract the customer for purchase the product by introducing attractive scheme. With the help of market research identify the demand of the products and keep necessary information regarding the competitive company. To promote and introduce the brands and products of UPL by using necessary promotion tools like advertisement in T.V, radio, posters etc. Product launching and pricing sales promotion Domestic registration Prepare budget for their department. Connected with production department by describing them total market demand of the products which help them to prepare production target.

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List Of Competitors Following are international competitors of UPL: Syngenta TATA Rallis India Monsanto Buyer Crop Science Du point Dow Agro Science. Following are the national and local competitors: Pesticides India Limited Sudarshan Chemical Gharda Chemical Meghmani Organics. Division Of The Products As per the profitability of the products, UPL has divided its products in to three categories i.e. Golden products, Silver products and Bronze products. The products which give maximum profit, they are known as Golden products in UPL. The products which are less profitable as compared to Golden product, they are known as Silver products in UPL. These are the products which neither give very high profit nor very low profit. These products give profit higher than Bronze products and lower than Golden products and Bronze products give less profit as compared to Golden products and silver products. Golden products: i.e. Acephate Silver products: i.e. Devrinol Bronze products: i.e. Entracol

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Distribution Channel Of The Company The final users of the products are farmers. Products which are produced in the company are to be sent to the farmers who are the end users of the company so to reach the produced goods to the end users easily they have to follow distribution channel. Some of the products which are manufactured in Unit-2 become raw material for the other units of UPL and some of the chemicals which are hazardous in nature they have to send for formulation process to other units of units like unit-3, Vapi. For captive there is no distribution channel is follow and for export also there is no any distribution channel is follow. For domestic distribution of produced goods, company has to follow distribution channel. First the goods which are produced in a factory are to be sent to all the deports which are divided in six zones. From the deports produced goods are sent to distributors and than sent to dealers and finally goods are reached to the end users i.e. farmers who are the final customers of the company. Distribution System Distribution channel of UPL is segregated in to 6 zones in India which are as follows: Chandigarh Sarkhej Bellary Andhra Pradesh Calcutta Lucknow There is co-ordination among 6 zones. When ever there is over stock at any zone then other zone where stock is needed, it can collect from that zone. By this way they are co-ordinate. To provide better service to customer and to cover maximum market, UPL has 28 deports in India. These
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deports are covered all most all the area in India so that it can cover maximum customer and better service can provide to the customer. Marketing department is considered with the innovative and unique idea to attract more customers and to provide best service to its customers. Target Market Target market of UPL is only farmers because in UPL agro chemicals are produced which are useful only to farmers to kill the insect and unwanted grass in a field. So farmers are only customers of these chemicals and products like industrial chemicals and specialty chemicals are used in various manufacturing industry as a raw materials. Market Share With revenue of 180 crores in last year, UPL has captured total more than 20% of Agro Chemical Market. Promotional Measures For introducing the new product and create awareness among the people some promotional measures are used in UPL, which are as follows: Sample distribution Farmers meetings Dealers meetings Campaign programs Field activity by field officer LCD project Position Of The Companys Products In PLC Because of global recession, the company is currently in a slow down phase. Thus its position in PLC is declining/ recession stage.

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Sales Volume / Revenue Table No: 8 Accounting Year 2003-2004 2004-2005 2005-2006 2006-2007 2007-2008 Competitive Approach UPL produces wide range of products and it has stock keeping units in 2600 packing sizes. Marketing department of UPL always come up with innovative and unique ideas to provide best and better services to its customers. To survive in the competitive world, it makes superior quality products. R&D is involved in developing new products. R&D play an important role to develop innovative & new products. Because of efforts of the R&D department, marketing department launch and introduce the new products. Sales Revenue 1054 1356 1669 2311 3516

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CHAPTER:6 PURCHASE AND STORE DEPARTMENT

Purchase Department The raw materials and other tools and spares are purchase through Purchase Department at unit-1. First, monthly production target is prepared by the production department and based on this target list of requirement of material is made and then this list is send to the Purchase Department at unit-1. Company is receiving raw material, packing material and spares as per the requirement from the unit-1. Purchase of the following products is also done through Purchase Department at unit-1. Imported raw material Other raw material Mechanical Equipments Spare parts Fuel Activities Perform By Purchase Department Receive the list of the purchase requisition from different departments and verify the list before purchase order is made. Prepare the plan for purchase of material as per the purchase requisition list. Purchase raw material as per the requirement of the production department. Invite the quotations by sending inquiry. Evaluate vendors. Prepare comparative statement. Select the vendor for purchase order. Send the terms and conditions to the vendor. Prepare the order. Place the order to the selected vendor.
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Purchase Process Following is the purchase process for the approved vendors: User First step is user will identify the material and spare parts which are needed in a particular plant. Then plant supervisor prepare a list of required and necessary things. This list is prepares in a SAP system. PR(Purchase Requisition) The next step is purchase requisition list is prepared by user with the help of SAP system. The department, plant which needs materials, equipments, spare parts or any other equipment mentioned in the PR. This PR included name, quantity, vendor name, specification of the products and the rate of the products. Released by the HOD Once the PR is prepared by user, it will send to the HOD and PR is approved only after verification and it released by the HOD. Purchase Department After PR is released by the HOD, it will receive by the purchase department. Then purchase department will check the quality of the material, reliability of the supplier, past experience. Timely delivery, image of the supplier in the market. Purchase order After verifying all the aspects, PO is placed by purchase department to the approved vendor. With placing the order certain terms and conditions are cleared with the vendor that is delivery date, item description, quality and quantity aspect, packing aspect, payment details, place of receive the material etc. Follow up

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Follow up is necessary after placing the order to the vendor. Reminder is sent to the vendors place to check the quality of the product, to remind the date of delivery etc. pre dispatch inspection is done at vendors warehouses. Send material When goods are ready then on delivery date goods are dispatched through vendor with the copy of challan. Quality of material used, date of delivery, name of the vendors is mentioned in this receipt. Gate Entry Before enter goods in the factory premises, GIR is given to driver then only vehicle enter in the factory premises. Quality control After goods are enter in the factory premises quality of material is checked by QA department and give okay certificate. Store Store person will, make entry in a SAP of the receipt of the material. SAP will generate total quantity of material lying in warehouses. User Then store department will send the material to the Production Department as per the requirement of the user. By this way purchase procedure is followed in UPL-2. STORE DEPARTMENT Store department is important in a manufacturing unit. It is used to store raw material, finished goods, packaging material of the company. It is useful to store engineering items like nut, bolds etc. It is useful to store electrical items like fuels etc. it also contain safety items like helmets, gloves, shoes.

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There are main four go dawns in unit-2 for storing the raw material and finished goods. It is important to meet the demand of the customer, so storing of goods is essential. 1. Raw material and packaging material:This is where the raw material which is used in the plant area and packing materials are stored. Turbophate, DETA, metamitron, oryrydone are the raw material which are store in the raw material storage. Cable tie for packing jumbo bags and fiber drum, seal for packing drums are store in the packing material storage. There are two types of packing material are stored. - Logo with the UPL - Nutral 2. Engineering store:This is where critical engineering items like pipe & pipe fittings, Gaskets, Barings, Welding materials, compressor spares, switch gear and spares, safety items, instrument items etc. are stored. 3. Finished Goods store:Finished goods like Acephate, phorate, Devrinol, PD are stored in this store. Finished goods of the company made for dispatch to the customers or for transfer to another stock point or distribution centre are kept here. Hydrozen perocside is stored in a open area. Material handling In Stores Material handling in stores is done by using the equipments. Following are the material handling equipments used. Fork lifts:It is used in a store department to handle the material and for the movement of the material from the storage to the plant area. It is also useful to carry drums. It is useful where material are stored on a racks from 20 to 25 feet high.

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Stacker:It is used in the storage area for handling the material and movement of the material within the storage area. It is not permissible to use stackers outside the storage area. It is useful to handle or carry material which are stored on a rack at very high feet which is more than 20 to 25 feet high. Hand Trolley:It is useful in the plant area for the movement of the material. Lifts:It is also useful in the plant area. Stores Procedure:UPL follows systematic procedure for storing the material. Receipt:Job of store department is started when the job of the purchase department is over. First of all store department receives the goods. This vehicle of goods cannot entered in the factory premise without checking. The vehicle has to pass through the security entry. First the driver will give the receipt to the security and than security sends the information to the store department about the receipt of the vehicle. Store conforms the purchase order and than inform to the security to enter the vehicle in the factory premises. There after vehicle is entered in the premise and security will send the receipt to the store department. Than store person verify the lorry receipt, raw material which is received and the nature of the material. There store department sends vehicle to the weight bridge, where the weight of vehicle is checked. The vehicle is weighted on the scale. After the weight is checked and gross weight is noted by the store department, it sends the report to the QA department for inspection of the quality of the goods. Vehicle will be unloaded only after the approval of the QA department.
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 After the approval from the QA department, vehicle is taken to the storage area for unloading the goods. Store person fills up the voucher and prepare GIR for registering the goods in the SAP system. Then LR copies are stamped and signed by the store department and copies are returned to the truck driver before release the truck. Aft then, store department gives an acknowledgement to the person who has brought the material in a good condition and if not than remarks are written on the copy. Storage: After receipt of goods second work of the store department is to store the goods in a proper manner in a companys storage. After receipt of material, the material is unloaded at the store and then the store keeper segregates the material and arranges the material as their proper place. In the storage also FIFO method is used for storing the materials. After vehicles is loaded, it is again taken to the weight bridge and store department again take weigh of the vehicle to ascertain the net weight. Issue:At UPL for issuing the material only one method is used i.e. FIFO When there is any need arise in any plant, material is issued by the store department regularly. The user will send a note describing material of what quality is needed. The note will be signed by the officer handling that particular material. After the note is signed by the officer and the material is issued by the store keeper. Material Coding System In UPL the stores are being maintained for raw materials, engineering spare parts, finished goods and packing materials.

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For engineering and electrical parts codification is done by using the numeric as the code number. Numbers are written on the racks, on a packing of the material. For all types of products numbers are used for identify their products. For all the materials codification is done through SAP. It records the date of manufacturing, issue, receipt, packing and type of the materials. In UPL engineering material is given 7 digits number e.g. Barining-9003263 and RM/PM, finished goods are given 6 digits number e.g RM-Ethilin diamine-706102 for PM- Drum HMHDPE202264 for FG-acephate-410003. Inventory Management System Inventory Management For Raw Material:In UPL SAP system is used for inventory management. The minimum-maximum stock levels are maintained here. Stock level in store is automatically known with t he help of SAP system and minimum level is also automatically checked by the SAP system and if the stock is at the minimum level, the purchase requisition is generated by SAP system. They have to maintain stock of all the raw material and spares parts, tools tec. E.G. safety equipment like helmet, gloves, shoes have to be maintained and whenever the stock reaches below the re-order level, SAP system will automatically generate the purchase requisition. In UPL, FIFO method is used for storing the material. They handle the stock of raw material by using FIFO method. Inventory Management For Finished Goods:Finished goods are manufactured as per the market demand because these goods cannot be stored for long period of time as they can be spoiled and these goods have limited life. Finished goods are stored in a warehouse only after these goods are approved by the QA department. So first a fall the

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goods are stored in a open yard. QA department will take sample from these goods and checked the quality of goods. If it is approved by the QA department, then only these goods are stored in the companys warehouse with the batch number, manufacturing date and the order number. In UPL, FIFO methd is followed for handling the inventory.

Stock Verification The stock verification is done physically by the different department. SAP system is also used to check the quantity of the stock on the particular day. In UPL the stock verification is done on monthly basis by some other department and annually stock is verified by third party e.g. this month stock is verifying by the max pro department, in the next month, persons from the HR department or any other department will verify the stock.

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CHAPTER: 7 QUALITY ASSURANCE DEPARTMENT

Activity Performed By The QA Department UPL is concerned with the quality of the products whether it is in form of raw material, finished goods. UPL has received the ISO 9001 certificate for the quality of their products. There is a separate QA department in the UPL-2, which consist of well trained and experienced laboratory technicians. In UPL laboratory are classified in to two categories, there are classical lab and instrument lab. Activities performed by the classical laboratory are:_ Wet analysis test Moisture in the chemical Toxicity in the waste water which is disposed in drain. Measurement of the melting of the chemicals. They do the clarity test to know what the clarity of liquid chemical is.

Activities performed by the instrument laboratory are: They test the purity and impurity of the chemical Color measurement is also done in this lab To check the incoming materials, liquid or solid To check the outgoing materials, as per the government norms. To check the quality of the product which are in process. Types Of Instrument Used And Their Utility There is a more accuracy in the instrument lab than the classical lab. Classical lab takes more time in analysis than the instrument lab because in instrument lab latest instrument are used for checking the parameters of the chemicals.

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There are several instrument are used for checking the parameters of the chemicals. These instrument are with the latest technology. The instrument used are as follows: PH meter: - To check the acidity and alkanity of the solution - PH measurement - Conductivity measurement Melting point: - For melting measurement for solid product. - To check in which temperature solid product is melted. Auto titration: - For acidity measurement of solution - To check the purity - To know the hardness of the product. Alpha meter/ Hazen meter: - For color measurement. To check the color of liquid, it obtains the range of color. Karl Fischer Instrument: - To check the moisture in solid, liquid material. For moisture analysis of the product i.e. it is used to check the water contain in the product. LOD (loss on drying): - To know the weight of the product after drying the produce i.e. after drying the material, to check the loss on drying of solid material. Incubator: - For keeping the product in stable temperature. - To check heat stability of the material, one product is kept in heat for 15 days to check the changes in color.

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Gas Liquid Chromatography: - To check purity of the product. High performance Liquid Chromatography: - To know purity and impurity of the product. - Thermal sensitive product. UV spectrophotometer: - To know purity of the product - For color measurement Turbidity meter: - For turbidity measurement of the material. Viscometer: - For the viscosity measurement to check the flow of the material like oil. Methods Of Calibration Calibration is nothing but, it is the process of checking the condition of the instruments. If the condition of the instrument is not good, then it sends to the manufacture of the instruments for repairing purpose. A list of instruments, which affect the quality of the product, is taken for the calibration. There are following methods of calibration. Calibration Of Glass wares: Butters, Vol. pipettes, graduated pipettes, Vol. Flanks to be received of only A class. Glass wares having certificate of calibration only will be received and used in lab. If they receive B class Glass wares, then they have to do calibration by their own. At every month calibration is done. Calibration Of The Thermometers: Thermometers having certificate of calibration only will be received and used in lab. Daily calibration is done.
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Calibration Of Hydrometers: Hydrometer is usd to know the density of the liquid. Hydrometer having certificate of calibration only will be received and used in lab. Calibration Of PH meter: At every one month calibration is done and acceptance criteria are PH of Buffer 7.0 & 9.2 PH. Calibration of weighing Balance: Once in a month calibration is done. Acceptance criteria are 0.0001 gm. Weighing balance used in lab having auto calibration facility, However it is to be calibrated with standard weight up to 1 mg and this is done because it will not affect the final result. Calibration Of Rota meter: Rota meter of the required instrument are get calibrated from the authorized organization once in a year and certificate should be available. It is use for checking flow of material. Parameters Tested In The Lab The various parameters are tested in laboratory scale are as follows: Appearance of product is main parameter test in lab Percentage of purity in the product The impurities present in semi-finished and finished product. Percentage of the alkalinity in product. Moisture contain in powder product. Melting point of the solid product Boiling point of liquid product Color measurement of the product. LOD test( loss on drying) of the solid product. Size of the product.

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CHAPTER: 8 DISPATCH AND LOGISTICS DEPARTMENT

Modes Of Dispatch And Logistics At UPL, there are two modes of transport are being used for transporting the goods. At UPL, goods are dispatched through roadway and waterway. Roadway is used for dispatching the goods in the local market and to other units of UPL which are located in India. Waterway is used for dispatching the goods to the other countries like Japan, Australia, U.S.A etc. While dispatching the goods through the roadway, dispatch department send the certain documents like Duplicate transport copy, certificate of QA analysis, lorry receipt and trump card with the driver. While exporting the goods, company has to submit the shipping bill and bills of loading to the custom department at Bombay within the period of 6 months. These documents are as a proof of export. Sources Of The Mode Dispatch At UPL goods are displaced through Trucks as a source of mode and ships are used for exporting the goods to the different countries. UPL does not have their own vehicles for dispatching the goods. All the vehicles are hired by the company. UPL uses hired vehicle for the dispatching the goods on an annual rate contract. This contract is given to the transport company for
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the transportation from the head office. For local transport, the local transport companies are approached.

Name Of The Transport Company V trans safe express Patel roadways Process Of Dispatch Explanation:Security entry The first step of the dispatch process is the security entry. The empty vehicles have to pass from security check before entering in the premises of the UPL. Here the security conforms to the dispatch department about the receipt of the vehicle. Information to the security Here dispatch department conforms the sale order, vehicle number and informs the security to send the vehicle in side the premise. Entry chit is given to the driver at the gate for the security entry and than vehicle is entered in the premises. Weight bridge entry After the security checking is done, the vehicles are taken to the weight bridge for taking the weight of the empty vehicle and weight is noted by the dispatch clerk. Approval from the QA department After the empty vehicle is weighted, dispatch department report the QA department for checking the quality of the goods, QA department will check the quality of batch which is going to be loaded in the vehicle. Only after the approval from the QA department vehicle is ready for the loading.

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In dispatch department, the driver will hand over the entry chit and lading chit to be concerned officer and both the chits are signed by the concerned officer of the dispatch department, than only the vehicle is ready for loading. Loading Loading is done in the store area. When driver gives the loading chit to the officer than only go down operator and dispatch clerk will load the vehicle with the help of Dispatch and logistic department After the completion of the loading again same is certified by the QA department and then vehicle is taken to dispatch and Logistics department. Here, things are again checked and verified that the materials are loaded accordingly. Weight bridge After the verification is done by the dispatch for taking weight of the loaded vehicle. Security Check After taking the weight of the loaded vehicle, the vehicle moves to the security gate an d finally vehicle is released by giving proper document to the driver.

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CHAPTER: 9 SAFETY DEPARTMENT

Introduction Safety is self protection. They believe that safety is internal protection & security is external safety. They differs safety & security. Safety is given prime importance by the management. There is a separate safety department for the safety of the workers and employees. They take many corrective steps for providing safety to their workers and employees by improving the awareness among the workers. Safety meetings are conducted frequently in the company. Steps are taken by the safety department to improve the awareness among the workers about the hazards & provide safety to protect against such hazards. They provide training to the (ERT), provide information & safety equipment to the workers. Mock-drill of an on-site emergency is carried out regularly. Chlorine kit demonstration is done every month. This demonstration helps the workers to take an on-side emergency action in case of chlorine leakage. Vision Of The Safety Department There are some visions of the safety department: Zero on job injuries Zero off job injuries Zero environmental incidents Activities Of The Safety Department There are following activities performed by the safety department: They conduct BCA test of the worker at every week. They check whether BCA of all the employees is in between the range of 62.5% to 75%. If BCA of some worker is not match with this standard, they provide rest to that worker

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at the company premises itself, till the BCA is match to the standard(75%). They conduct safety talk every day in the morning to create safety awareness among the employees about the necessary of the safety & safety equipments in the plant area. It is conducted by the different employees of the safety department about various safety talk topics. They provide the protection equipment to the workers like boiler suit, shoes, helmet, goggles etc. Functions Of The Safety Department To highlight unsafe act and unsafe situation To follow legal requirement like: Periodically check up of the employ. Pre-employment check up of the employ. Plan inspection Training to the ERT members Prepare a mock-drill report Factory license Permit system that is for any non routine work workers have to take permission from the Assistant manager of the safety department. It includes work permits like: Cold work permits Hot work permits Vessel and confined space entry Temporary electrical connection To conduct safety committee in every three months To create awareness among the workers they celebrate fire day, national safety day etc. To create motivation among the ERT they conduct competition among the different ERT of the different units of the UPL. To create awareness among the workers they provide first aid training to all the employees. Health related training programmed also held time to time. To provide the information regarding the hazards in the lab and plant area because of the Toxic materials,
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flammable materials and Hazards related communication to an site contractors. General Safety Rules Safety spectacles must be worn at all the necessary time. Safety shoes, helmet, suit must be worn at all time. Smoking & carrying match box or cigarette lighter or any other sources which may create a flame is strictly prohibited. Only authorized personnel may operate mobile or camera in the company. For all the employees who are working in the plant area, it is compulsory to wear required PPE like goggles, dust mask, gloves whenever and wherever required to avoid the eye, head and hand injuries. Know the location of the extinguisher and fire exit. It is compulsory to report about all the incident which are take place in the plant area. Photography is strictly on permission. There are certain site traffic control rules like vehicle entry pass, driver license, speed limit, no smoking in vehicle. Health, Safety, Environment Policy Following are the HSE policies of the UPL: Drive organizational towards zero accident across the site. Drive organization towards zero occupational Health related cases. To improve unsafe conditions resulting out of unsafe actions by driving safety culture through behavior based safety management system. To strengthen the emergency preparedness services across the site. Improve infrastructure related to safety and environment a. To convert manual packing to auto/ mechanized packing for;
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Acephate product Devrinol product To develop greenbelt across premises by 20% To ensure compliance of SHE aspect during the management of change processes. To drive the site towards conservation of; Raw materials by 2% against budget for 2009-2010 Utilities(steam & power) by 15% against budget for 2009-2010. Provide 1- man-day minimum training on SHE to companys and contractor employees.

Personal Protective Equipments (P.P.E) There are two types of personal protective equipments: Respirator type Non respirator type.
Respirator type:Sr. no Parts protected 1. Body protection Body protection Name of the safety equipment SEBA( self contained breathing Apparatus Bubble hood Uses & hazards protection against

It is used where there is toxic environment It is protected where there is deficiency of oxygen & high concentration of toxic or any other type of harmful gas. It is used at the time of vessel entry. It provides the fresh air and filter the air. It helps to protect against the spillage & leakage of the gas. It is used where the concentration of air have higher value than TLV and protection against the hazardous chemicals.

2.

3. 4.

Nose protection Nose protection

Vapor mask Dust mask

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Non Respirator Type:1. Head protection 2. Eyes protection

3. 4.

Ear protection Body protection

5.

Face protection

Helmetfiber The purpose is to protect and plastic the head from any object falling from the top floor. Safety goggles- It is used to protect the (3) types. eyes from any type of spillage and sprays. PVC transparent It covers both sides and type goggles thus protects the complete eyes from the liquid chemicals and any flying object. Plastic goggles This goggles will protect complete eyes when operation is pressurized. Laser safety Protection against the goggles sparks generated during the welding and cutting operation. Ear plugs/muff Protection against the high noise which damage the hearing system Apron-(4) types The purpose is to reduce the impact of any spillage to the skin. Plastic PVC It is used in handling of hot aprons water or liquid material and protection against the electric shock and any skin diseases Asbestos aprons Normally used for protection in the area where there is heavy heat. Padded Lather, Normally used in hard fiber, protection stomach & metallic aprons other sensitive parts of body Cotton apron It is used in laboratory while doing light function. Face shield The purpose of face protection device is to

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Radiation proof glass 6. 7. Foot protection

8.

Safety shoes/Gum boots Hand protection Hand gloves-(3) The purpose is to reduce types the impact of any spillage to the skin Surgical hand It is used for house gloves keeping and handling the liquid material as chemicals are easily splashes from this type of gloves. Leather Protection from the spark generated during the welding & cutting operation. PVC Protection against the hazardous liquid & powder material. Falling from the Safety belt Protection from falling height while working at high elevation area, entering in to the tanks and other closed vessel.

protect the face from the impact of any spray or heat Used for protection against the spark generated during the welding or cutting. Protection against falling heavy material on feet.

Safety Talk Topics Safety talk is conducted daily in the morning. It is held by the different supervisor of the safety department about various protective equipment and their uses. Safety talk topics are written on the board with the time and name of the supervisor who is going to held the safety talk. It is conducted to create awareness among the workers about hazards in the plant area and to protect against such hazards. They provide the information about various uses

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and necessary, importance of the personal protective equipment. All the workers are gathered in particular place where safety talk is conducted, it is called safety talk area. Following are the safety talk topics; Permit to work system Why nose mask should be used Why plastic buckets should be banned from the plant area Difference between on side and off side emergency On side emergency: The emergency is controlled by own sources The affected area only is the factory area External agency not involved like district, local government, police, neighboring factories. Off side emergency: The emergency cannot be controlled by own sources The affected area can involve outside of factory area External agency help is needed Controlling action will be done by off side team. Precautions during temporary connections ( electrical as well as mechanical connection) Content of safety cupboard. LD 50 (Lethal does) Why BCA test is needed for person who are working in the plant area. Purpose of the first aid box. Confined space(work permit is required for any type of confined space work) Manual handling of hazardous chemicals(they should know hazardous properties of chemicals) Types of aprons and their use Face protection devices and their purpose Head protection devices and their purpose

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Necessity of clean dress and clean hand before meal Necessity to wear safety goggles Why bath is necessary at the end of shift Necessity to wear air line mask Effect of tobacco in industry Types of hand protection devices.

CHAPTER: 10 Research And Development Department

Research and development department is working closely with the customers in market place. UPL recognizes the requirement for the highest level of support in product research, development and registration. Registration activity of the products is also done by this department. Capability in applied R&D is one of UPLs major corporate strengths. R&D strategy is to continue to invest in innovative formulations that are environment and user friendly and which are essential to the growth of agro chemical companies. Most importantly, UPL is wholly committed to maintaining and expanding its portfolio of registration globally. Considerable investment has been focused on the regularly requirements for registration support. R&D department is very necessary and important department of the company to be stable in a competitive market. To improve the overall efficiency and effectiveness of the company R&D play most important role in the company. It is also involved in developing new techniques which helps to be capable in a competitive market by producing the goods with minimum cost.

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The main aim of R&D department is to develop such an innovative process which can reduce the cost of manufacturing the product and give maximum throughput. Most important role of R&D is to research a new molecular which can give more profit. R&D is concerned with research of formulas, product, techniques and the development of new process which can reduce the cost of production process and give more output with less cycle time and with better quality of the product. There are some key activities performed by the R&D department which are as followed: Development of innovative & cost effective manufacturing process of near off patent molecules:R&D department involves in developing some new products under the patent. They have authority to replace the existing process with the other innovative manufacturing process. They done analysis of the existing manufacturing process in terms of cycle time, total output, cost of production process etc and try to implement innovative process which can reduce the cost as well as the maximize the profit. The ultimate goal of this department is to maximize the profit with better quality of the product. They are also considered with the maximum the throughput. Support to registration activity:After research and development of new product or the process, they have to register in a Head office. Then only they can implement the new process and product because they are mainly involve in hazardous chemical process and it may risky to implement the new process and product so that all this registration activities are performed by the R&D department. While registration of the product the effectiveness of the product and its stability are also sent to HO. A detail of all these things are sent.

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 Support to plant for process improvement for:a) cost & waste reduction:They are not only considered with to bring new process but they are also considered with the cost effectiveness i.e. reduce the cost of production as we as reduce the waste so that maximum output can be achieved. b) capacity enhancement:They are involved in utilize the capacity of the plant properly. c) Ease of operation:They try to provide easy operation so that plant supervisor can devote their time to other innovative activity and they can bring innovative ideas. They are also involved in other functions which are as follows: Cost effectiveness study Effluent minimization study Professional study of the production process Toxicology study of different products Inspection of raw material, finished goods and semifinished goods. Sending samples to HO. The R&D department in Ankleshwar, unit-1 is working for all the units in Ankleshwar and for the units in Halol and Jhagadia. The R&D department can be said as the chemical department.

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CHAPTER: 11 MAX PRO DEPARTMENT

Main motto of max pro department is maximum profit. The main aim of this department is to maximize the profit by finding alternative ways. They are involved in improvements in resources utilization to reduce cost. They are always involved in bringing and developing the innovative idea to improve the profitability and productivity of the company. Max pro department technically support to the company. They try to bring innovative production process which can reduce the cost of production as well as speed up the production. To achieve the organizational goal they do experiment to bring innovative production process and every month meeting is conducted among them. In this meeting all the members bring new ideas and discuss their views on the topic. They adopt and implement new technology so that company can survive in a competitive field. They are involved in challenging task and most intelligent employees of the company are working in this department because they do challenging task to maximize the profit. Max pro department is the department working on continues improvement of the existing and running process in the organization. To maximize the profit they try to reduce the cost of production and also reduce the raw material consumption to upgrade the out put with less production cycle time. They try to find alternative process if some process take more time and give more wastages then this department finds alternative ways to implement innovative process through which they can get more throughput, reduce the
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wastages, reduce the cost and ultimately to maximize the profit. To implement new process, they invite the suggestion from the workers, plant supervisor, find out the problems in the existing process, give their views, discuss with the plant manager and management, prepare plan accordingly and after the evaluate the alternative process and finally implement the best process. Function Of The Max Pro Department There are some functions carried out by the Max pro Department: Innovative approach and doing challenging things. Discuss the problems at all inter department levels like plant, QC, R&D. Computational skill, technical process evaluation, process engineering, identifying cost saving stages, data collection and processing. Invite suggestions from every department, plants. Discuss the new plans with the plant manager. Conducting meeting and discuss their views with the management. Start implementation along with the users. Methodology There is some methodology used by Max pro department to maximize profit and to achieve this goal of profit maximization they follow certain methodology which are as follows: Improve plant efficiency Improve yield Finding the alternative process Optimize utilities and auxiliaries Improve the work practice Improve the throughput Finding theoretical limits Benchmarking against good industry practice.
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 Minimize waste Everything is open to question. Need Of Max Pro Department: To survive in competitive field To withstand in the globalize market To implement new technology Process intensification Technical up gradation MAX PRO+ DEPARTMENT Max pro+ department is an important department for the company as it helps to company to survive in a competitive field. Most talented, intelligent and experienced person are selected for this job. The main motto of Max pro+ department is to maximize the profit and productivity by changing the working condition. Data analysis is done by them. Their main goal is with minimum investment how to maximize the yield and through put. They are mainly concerned with reduce the cycle time and to get maximum output with minimum investment. They collect the data of the whole process in a step wise. They find out the time which is spent for each operation and also find out the reason for variability in time. They also find out the reason for breakdown. The main activity is to improve the plant efficiency and upgrade the overall performance of the company and to find out the standard time for doing different operation, for this purpose data analysis is done by them and reason for variability in timing and then standard time is followed by every operator. Break down analysis is done by them. Monthly production target is given to the production department. If they do not fulfill the target then they also find out the reason for production loss. They done analysis from the data and find out if there is any break down of equipment during the production,
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unavailability of man power or raw material, gap analysis is also done by them. By this way they improve the output with minimum time. The main functions of Max pro+ department are as follows. OPE (Overall Plant Efficiency):Their main activity is to improve the efficiency of the plant and to improve the plant efficiency analysis of plant capacity is done by them, they give monthly production target to production department by the discussion with the plant manager in a meeting, then analysis is done by them if there is any production loss then they find out where they are lacking, the reason for production loss and how to minimize the production loss. To improve the efficiency, they calculate batch cycle time with the help of flow diagram and they also calculate the output of each stage and then with the help of data analysis, they try to improve the capacity of the plant and if there is any production loss and target is not achieved, they do analysis for breakdown and any other reason for production loss like non availability of man power and raw material. e.g. if max pro+ department gives the target to produce 600 MT in a month and if production department produce only 500 MT, then they find the reason for production loss of 100 MT, reason for production loss may be breakdown of equipment, non availability of the manpower or raw material. After finding such reason then also result is not satisfied then they do analysis and there may be another reason like speed loss, find out reason of the speed loss and bottleneck situation for production loss. To improve the output with minimum batch cycle they also taken care of quality of the product. There should not be any quality loss of the product. Variability:116

With the help of data analysis they prepare a graph to see the variability in the timing of production. They fix the standard level. They are involved in reducing the variability in production. Performance dialogue:It is the similar activity as variability; this activity is done to find out the bottleneck situation which is in the cause for production loss.

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FINDINGS
Limitation Of The Study Workers Training need identification is not identified in the prescribed format because of time limitation. Many employees were unavailable because of shift working in plants. Availability of the HODs was also sometimes difficult because of their working schedule. For 2 GMs the training need has not been identified as their reporting is in head office. For employees in MaxPro, MaxPro + & other departments who are in Unit 2 on special deputation Training needs have not been identified as their reporting is also not at Unit 2 & they are here only for special projects. For employee who have not yet completed 6 month in the organization. Training needs have not been identified as it is too early to judge their training needs by HODs. Conclusion Out of this project done on Training and Development for employees we can conclude that training and development can help organization to achieve employees aspiration goals as well as organizational goals. Bibliography References from books as well as internet have been taken to undertake this project. The following is the list of books and websites referred for the same: o Human Resource Management- By K Ashwatthapa o www.citehr.com

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o www.teambuildinginc.com

o www.wikipedia.com

BACKGROUND OF THE STUDY

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What is Training Training is a learning process that involves the acquisition of knowledge, sharpening of skills, concepts, rules, or changing of attitudes and behavior to enhance the performance of employees. Training is a process through which employees can learn new things and get extra knowledge and skill which can improve their performance and remove their weakness. With the help of training employees can fill their competence gaps. What is Development Development refers broadly to the nature and direction of change induced in employees, particularly managerial personnel, through the process and educative process. National Industrial Conference Board has defined development as follows: Management development is all those activities and programmes when recognized and controlled, have substantial influence in changing the capacity of the individual to perform his assignment better and in doing so are likely to increase his potential for future assignments. TRAINING METHODS On the job Training Demonstration Job Instruction Training Vestibule Training Apprenticeship Coaching Job Rotation Participation in Deliberations Lectures and conferences
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Syndicate Simulation Training Role Playing In-basket Exercise

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United Phosphorus Limitd Unit 2, Ankleshwar Internal/In-house/Induction Training Attendance Sheet

Topic :

Faculty : Time : Date:

Reference : Sr. No. Name of Participants Dept. Emp. No. Sign

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