ORGANIZATION STUDY

EXECUTIVE SUMMARY

BPSPL

As part of the course curriculum of degree of Master of Business Administration of DAVANGERE UNIVESITY. I am required to undertake an internship study in an organization in third semester. Internship training enables me to know the realities of the business and application of theoretical knowledge in practical environment. In fact the purpose of this training is to create the managers with greater adaptability and who can provide creative solution to the organization they work in, so it helps the student to become a complete manager for the industry and efficient. This internship report is an effort of mine for the fulfillment of the same.

BALAJISWAMY PREMIUM STEES PVT LTD,. Was established in the year 2005. Bellary. Purpose of the study:

BPSPL

is located in the state of Karnataka. It is located in HALKUNDI village and it is 16km far from

Firstly, the internship training was under taken to fulfill the MBA curriculum requirements of DAVANGERE UNIVERSITY. Secondly, it was under taken to study organization activities in all functional areas in the organization and relate this to theoretical knowledge acquired.

Lastly, to carry out swot analyses of the organization.

y

Sample Size

It covers all functional areas and also a survey with reference to employee satisfaction organization
y

Data source

Primary sources --Interviews Secondary source -- Broachers and annual reports of the company.

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ORGANIZATION STUDY
FORMS OF ORGANIZATION: There are two forms of organization they are

BPSPL

1. FORMAL ORGANIZATION: In this type, responsibility rights and authority are clearly defined procedure is laid down .Method are evolved discussed put before the personnel in clear term.

2. INFORMAL ORGANIZATION: In this nothing is clearly is defined or laid down it is a developing process which develops on the basis of work performed and mutual relationship between personnels jobs, duties and authority. OBJECTIVES OF AN ORANIZATION;  To serve the society in order to improve the society.  To establish healthy relationship between labour and capital.  To administer economy in production organization and system.

Now days Steel industries has been increased due to LPG. This is one of the semi product industries. The product manufactured by this company is sponge iron.

In this organization study I have studied different department in an organization and relationship between different departments duties and responsibilities, problems, conclusions, suggestions, recommdations .. And also type of organization structure.

Finally, it was a nice experience during my entire training period in BPSPL Bellary. I feel, it was a great opportunity for me to work with this company and being a part of the company.

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ORGANIZATION STUDY
INTROUDUCTION Meaning:

BPSPL

Organization is a process of dividing and combining effort of working group of making such joint effort more production effective and fruitful organization allocates duties to the managerial staff.

DEFINITION :
Organization is a group of people who are co operating under the direction of leadership for the accomplishment of a common end.

CHARATERSTICS OF ORGANIZATION:
 It is a group of individual which may be small or large.  It refers to a structure of duties and responsibilities.  It is a continuous function and is performed in varying degree by all levels of management from the.  It consists of some direction authority which controls the collective effort of the group.

OBJECTIVES OF THE STUDY

 To study about different departments like marketing, operations, finance and human resource.  To study and understand the interrelation among different departments.  To find out the roles, duties, responsibilities of each personnel in the organization.  To find out the reporting offices and subordinates of personnel in each departments.  To find out the type of organization structure.  To look out for organization problem, if any.

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ORGANIZATION STUDY
INDUSTRY PROFILE

BPSPL

The story of sponge iron also knows as Direct Reduction Iron (DRI) industries very interesting as far as India goes. The three decade old industry came into existence all of a sudden when mini steel plants where looking out raw materials randomly. Since India has coal deposits, its utilization for steel plants was considered prime importance. Production of coal based sponge iron in the beginning was taken as viable option. Sponge iron industry grew at very slow speed till the mid of 1980 due to governments strict licensing. 1985 proved to be the historical year for the industry in general and steel industry in particular. In this year the DRI production was deli censed and since then industry started growing rapidly to re ach todays level. DRI is high quality metallic product obtained from iron ore, pellets etc. as a feedstock in Electric Arc furnace (EAFs). Hot Briquetted Iron (HBI) is a denser and compacted from of sponge iron. Traditionally scrap has been the main feed for manufacture of steel. Today, steel industry is facing a situation of less generation of scrap accompanied by greater demand. Hence sponge iron is replacing as a best substituted to it. Consequently, the supply of sponge iron is expected to grow to the level of 50 MTPA in 2010 against todays level. As a result several sponge iron plants have started to come up.

THE INDUSTRY GROWTH:

Since 1980, the sponge iron took industry took a U turn and the players of the industry were very reluctant to contribute significantly for the steel making looking at the bright prospects of the steel industry in India end the neighboring countries. Sponge Iron India Ltd was the outcome of the players enthusiasm who accepted the challenges for DRI production. This was the first sponge iron in the country which was set up at Palencia in A.P with a capacity of 0.039 MTPA in 1980. Between 1980 and 1988, there were only three, plants setup namely Orissa sponge iron Ltd, capacity of 0.1 MTPA, Imitate sponge iron capacity of 0.09 MTPA and sun flag iron steel Ltd with plants were setup to produce sponge iron for captive consumption . In 1989, the first merchant sponge iron plant of Bihar sponge iron Ltd. With a capacity of 0.15 MTPA was set up. In the late 80s, domestic producers were enthused by the discoveries of natural gas. Started setting up gas based sponge iron plants. Since coal was adequately available in India, production of coal based sponge iron was considered to be the viable option later several DRI based plants came up.
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ORGANIZATION STUDY

BPSPL

The coal based on sponge iron plants has shown high growth in the last two decades with a combined present capacity of 4.5 MTPA. India, today, is highest producer if coal based sponge iron in the world. Jindal Steel & power Ltd is the largest producer of sponge iron in the Asia and second in the world. It has the worlds largest coal based sponge iron capability at its Raigarh plant with a capacity of 650000 TPA.

INCONVENIENCE FACED BY THE INDUSTERY:

The sponge iron industry in India is facing tremendous of which mounting costs of basic inputs, high costs of capacity are prime importance. The demand was in recession in the immediate past years, however, it has recovered now and the industry is enjoying a healthy demand for the last few months. But, the industry is afraid of the scenario in future as steel scrap imports-a substitute of the sponge iron is increasing voluminously.

FUTURE:
Sponge iron and steel making industry go hand and hand. Hence, its quite difficult to assume the future of sponge iron without steel and vise versa. Therefore the further of DRL depends on the steel demand coupled with the availability of its substitute i.e. steel scrap, production this material saves a lot of revenue loss in the form of high foreign currency demand and long gestation period to obtain the material to the company and the country subsequently. Hence, these producers are lobbying with the government with regards to protection from liabilities and overheads.

Over View and Profile of the Industry

The sponge iron has of late come up as a major input material for steel making through electric furnace route both Electric Arc Furnace and Induction Furnace. Due to long gestation period, huge investments, dependence for coke on foreign suppliers, etc., the steel industry is slowly diverting itself from blast furnace route to electric furnace route and the requirement of Sponge Iron is increasing very fast. Another major reason is the global shortage of scrap. The steel making furnaces in the eastern region use average 70% Sponge Iron in the feed material for steel making. The future for the Sponge Iron is therefore quite bright.

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ORGANIZATION STUDY
ROLE OF DRI IN ECONOMY

BPSPL

The steel is today considered as the backbone of Indian economy. The growth of economy has a direct relation with the demand of steel. With the present steel intensity index, considering the GDP projection by the Govt. of India, growth of steel demand will be around 11% annually . Production of Steel: (figures in MT) Year 1952 2008-09 India 1.5 43 China 1.5 340

It is universally accepted that Indian economy is growing at a very high rate presently and the demand for steel is also showing an upward trend. No. of units in operation - India 330 Now DRI units have spread over the states of Orissa, Jharkhand, Chattisgarh, West Bengal, Karnataka, Tamil Nadu, Andhra Pradesh, Gujarat and Goa. India is the largest producer of Sponge Iron in the world In the year 2006    

India produced - 13.9 million ton Venezuela Iran Mexico - 6.2 million ton - 4.3 million ton - 4.5 million ton

As per the National Steel Policy issued by the Ministry of Steel India will produce 110 million tons of steel by 2020. The requirement of Sponge Iron as metallic will be 30million tons.

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ORGANIZATION STUDY
Furnace Route But availability of scrap is not likely to reach 11 million.

BPSPL

Today India produce 13.9 million tons of sponge iron, out of which 4.2 million ton is gas based and remaining 9.7 million ton is coal based.  India has a proven reserve of 410 million ton of high grade iron ore, another 440 million ton of high grade iron ore which will be established. India has total 9992 million ton of iron ore reserves (as per IBM report of 1995).  India has sufficient non-coking coal through of high ash low fixed carbon grade. Coal is used as a redundant for sponge iron making in the furnace. The availability of scrap of required quantum is unlikely and therefore scraps needs to be replaced more and more by DRI.  Local supply of scrap is diminishing as generation of scrap in India due to improvement of technology is getting continuously minimized.  As per World Steel Dynamics (WSD) the Global shortage of scrap will reach 68 million tons in the year 2010. That means the scrap price will go up and availability will be a problem. Today the international price for scrap is around US$ 390.00.  Due to soaring price of iron ore and coke, blast furnace is being set up in the countries where iron ore or coking coal is available.  With resources available in India Sponge Iron Electric Furnace Route is the most viable option for steel making.  And foreign countries are likely to invade Indian market.  We must produce steel at a cheaper cost to remain competitive and control over domestic market.

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ORGANIZATION STUDY
COMPANY PROFILE

BPSPL

BALAJISWAMY PREMIUM STEELS Pvt. Ltd,. Is the company which primarily deals with the production of sponge iron. BPSPL is situated in Halkundi of Bellary District which is in the outskirts of Bellary city. BPSPL is a company which involves in producing sponge iron as a raw material for the steel manufacturing industries. It has been established on 2005. BALAJI companies are primarily family run business which headed by Mr.Y.SRINIVASRAO, who is one of the business magnate of Bellary. BALAJI companies are also involved in maintaining cotton mill and other major companies in North Karnataka and neighboring state of Andhra Pradesh. The family business also owns a petrol

bunk and a theater in the city apart from several commercial establishments in the city. The Company is located on the main road in the outskirts of the Bellary city. It is well connected by the road and it is very near to the iron ore reserve. There is an ample land available for the unit including storage of iron ore and coal. The land is also available for further expiation of the power plant or induction furnace with the rolling mill. Bellary is the further steel city of Indian. This is stated so because there is rapid industrialization in the city. The driving factor behind this development is availability of best grade of iron ore in this area. There is huge natural wealth in this district that needs to be exploited and as a result many steel units are coming up in this district. It is this back ground that has encouraged Mr. Y.SRINIVAS RAO to take up this sponge iron plant.

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ORGANIZATION STUDY
NATURE OF THE BUSINESS CARRIED
Balajiswamy Premium Steels Pvt Ltd is producing sponge iron.

BPSPL

The raw materials required for producing sponge iron are Iron Ore, Coal and Lime stone.

VISION/MISSION AND QUALITY POLICY VISION

1. To be best global market player in the quality 2. Identify best manufacturing quality policy of the company 3. The company is planning to increase their production, presently 100 tones to 200 tons per day in future. 4. To reduce cost of production

MISSION
To manufacture good qualitative as per the demand & go in to the international market & to achieve customer delight ness through professional system & prospective in every field giving due weight age to the development of human resources available in the organization. To advance the firm with latest technology established leadership in the field & to national wealth ultimately to become one of the best sponges & iron manufacturing in India & overseas market (In terms of turnover & efficiency).

Quality Policy
The management has interested in continuous improvement and innovation to sustain leadership in the market. Customer satisfaction through quality is the top priority. They excel in their Endeavour for their qualitative performance. The quality policy of the company is as follows: Quality leading to customer satisfactions shall be our top priority.

All employees shall be systematically trained, developed and motivated to continuously improve the quality of their work. The company having fully equipped quality Assurance Laboratory managed by well trained technicians to ensure quality, continuous modernizations and timely expansion has given competitive edge and on other companies. As a result of this, the company has established itself as a leader in most of its products.
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ORGANIZATION STUDY
RAW MATRIALS:

BPSPL

The raw material used in sponge iron production is iron ore and coal. Iron ore is abundantly available in and around Bellary and coal will be sourced from other part of the country. The iron ore available in this area is best suited for the production of sponge iron because of its strength, technically the tumbler of the ore is good that ore does not break in the oxidation process, there by resulting in lesser percentage of sponge fines generation . The low ash coal is generally desired. The other raw material needed is limestone which acts as a desulphuris.

MAJOR RAW MATERIAL IS:

y y

IRON ORE COAL

Fully/Automated raw material handling system Fully computerized process control Size: lumps ---5 to 20 mm Fines ----0 to 05 mm

OTHER RAW MATERIALS:

y

LIME STONE

y CHART DUST MUD.

It purchases raw materials Iron Ore from Coal from Lime Stone - oblapuram, Sandur, Chitradurga - Africa, Madras, (Indonesia) - Kadapa

And sold its finished product sponge iron throughout the Karnataka, Andhra Pradesh, Tamil Nadu, Maharashtra and Goa.

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ORGANIZATION STUDY
Steps in the production of Sponge Iron

BPSPL

The entire process of production of sponge iron can be studied under following headings.  Filling of Raw Materials  Direct reduction  Cooling of product  After burning  Dust extraction  Magnetic separation and storage

PRODUCT PROFILE
Balajiswamy Premium Steels Pvt Ltd. produces sponge iron where the founder uses it in steel production industries. For these companies sponge iron is necessary, so it is clear that automobile industry depends on steel industry and steel industries in turn depend on sponge iron producing companies. Steel is used in producing small implements, boilers, ships, bridges, automobiles parts to heavy instruments, current rises heavy structures, buildings etc., Everywhere steel is versatile and an indispensable item.

AREA OF OPERATION
Balajiswamy Premium Steels Pvt Ltd service has been widely spread across global. It has its establishment all over the regional.

Regd.office:
Plot no.16, KIADB munddargi, 2nd phase, Bangalore Road. BLLARY-583101.

Plant site:
H.Siddapra Road, Halkundi, Bellary (D) KARNATAKA.

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ORGANIZATION STUDY
OWNERSHIP PATTERN

BPSPL

Balajiswamy Premium Steels Pvt Ltd. is promoted by Mr. Y.SRINIVAS RAO he is the sole owner of the company and the Managing Director, since the inception of the company in 2005, the managing director has successfully executed the plans of it operations in producing sponge iron.

COMPETITORS INFORMATION
y y y y y

M/s. Embitter Iron & Steel Pvt. Ltd., M/s. I S T Sponge Iron and Power Pvt Ltd M/s. Sajjala Iron & Steel Pvt. Ltd. M/s. Rayen Sponge Iron Pvt. Ltd., M/s. Hothur Iron & Steels.

INFRASTRUCTURAL FACILITIES
The company has good water facility, good canteen facility to the employees, it has sufficient of land, Different departments are constructed separately, and Plants around the company, all the departments are connected through telephone for better come coordination. Balajiswamy Premium Steels Pvt Ltd. is located in Bellary district Halkundhi village about 16 km away from the city of Bellary. Bellary is also ideally near the major power generation station, both ideal and the thermal like Kudhitini, Raichur, Munirabad, and Sharavathi and Kali nadhi. All these stations are connected to the grid at Munirabad (about 62 K.M.) from Bellary.

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ORGANIZATION STUDY
ORAGNISATION CHART ORGANIZATION STRUCTURE:

BPSPL

Basis for specialization and coordination influence primarily by strategy and by organization size and diversity. The organization structure of BPSPL is as below.

Organizational structure refers to the basic hierarchical procedure in which the organization carries out their business and accompanying baggage that shows whose tasks are divided and integrated. Pascal and Athos in their book The Art of Japanese Management says that Organization structure emphasizes that the quality of management depends on the goodness of which amongst all those key managerial dimensions.

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ORGANIZATION STUDY
Overall Organization Structure :

BPSPL

The organization objective and strategies have direct bearing on the organization structure. It is visualized that BPSPL will have the following strategic goals:

 To evolve short term and long term strategic directions and continuously reviewing them in the light of business environment  To provide high quality Sponge Iron  To satisfied customer needs through well designed strategies  To mobilize the resources from external and internal sources and to develop long term financial plans, capital investment and profit plans  To develop policies governing organization design, compensation, human resources development, human relations and human resource retention.

General Manager:
1. Overall responsibility of contract review, production and Finance Related activities. 2. To sign all the purchase order after verifying the price, delivery, terms and conditions 3. Approval of vendors 4. Approval the request for training of the employees 5. Appraisal of all training needs of all the employees

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ORGANIZATION STUDY
HUMAN RESOURCE DEPARTMENT

BPSPL

Definition: The term human resource can be thought as the total knowledge, skills, creative abilities, talents and aptitudes of organizations workforce, as well as the value, attitudes and beliefs of the individuals involved.

 An organization success depends upon the quality of its workforce identifying workforce requirement selecting the right person for the right job, at the right place, at the right time, motivating the existing employees in order to retain  Them and development the man power to adapt to the fast changing environment department.  Human Resources Management is a management is a function that helps managers to recruits, select, train and develops the required members for an organization. The personnel department in BALAJISWAMY PREMIUM

STEELS PVT.LTD,. Has one main objective that is to keep its employees happy, satisfied a disciplined.

ACTIVITES OF THE DEPARTMENT ARE:

Maintaining industrial relation Recruitment and selection Salary and wage administration Training and Development Welfare activities Health and Safety Organization Development Performances Appraisal

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ORGANIZATION STUDY
EMPLOYEE SPECIFICATION:

BPSPL

Employee specification is a statement which states the minimum acceptable educational qualification, experience, age limit that are necessary to perform the job. The exact list of human requirements will vary from company to company and according to the uses to which job specification is to be put. As far as possible the specification written for each characteristics should quantified.

BALAJISWAMY PRIMUM STEELS PVT.LTD:

Has a motivated work force and is an Employee runs company. BALAJISWAMY PREMIUM STEELS PVT.LTD,. Employee people who are technically sound, highly capable and versatile and who are adapting to change. The internal development of core competencies and continuous process of improvement make BPSPL on the most of the existing engineering companies to work for. This excitement and motivation permeates right down to the shop floor. Attrition and union activism is almost unheard of at BPSPL. The average age of each employee is 35 years. BPSPL major strength is its employees whom the management recognizes and nurses accordingly.

MAN POWER PLANNING:

Classification of workman in BPSPL: 1. Staff 2. Commercial Trainee 3. Permanent worker 4. Temp.operator (ITI) 5. Temp.helper 6. Contract labour 7. Group 4 flak security.

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ORGANIZATION STUDY
TRAINING: INTRODUCTION:

BPSPL

India is passing through convulsive changes due to the advancement in science and technology, but at the same time, millions of people of our country are caught in the twilight zone of development. Till the sixties training activity in most of the Indian organization was withering totally absent or party present in a rudimentary form. However in seventies the Indian organization became aware of the need for the development of the managers for better management of the organization. Thus began the executive development programs started mostly by a few educational institutions like the administrative Staff College in Indian and the institute of Management. It is only after the former Prime Minister late Rajeev Gandhis stress on HRD that training has taken a front seat in the national economy. He had even established a separated ministry for HRD in November 1985.

IMPORTANCE OF TRANING:
 Training is the systematic process of enhancing the job related skills attitudes and knowledge of personnel for the purpose of improving individual and organizational performance. It is fundamentally important for the continued growth and development of both the individual employee and the organization. Training shortens the time required for employee and the organization. Training shortens the time required for employees to reach peak efficiency level. The cost of training is considerably less than the cost of gaining experience particularly, in the content of advanced technology and expensive equipment.

 Essentially training constitutes significantly in increasing the quantity of work processed and reducing waste and idle time. Training is the corner stone of sound management, for it makes employees more effective and personnel or managerial activities functionally inter-related.

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ORGANIZATION STUDY

BPSPL

 Training is a practical and vital necessity because apart from other advantages it enables employees to develop and rise within the organization and increase their market value earning power and job security. It enables management to resolve sources of friction arising from parochialism, to bring home to the employees the fact that the management is not divisible. Training is widely accepted solving device.  Over and under-emphasis on training system largely from inadequate recognition and determination of training needs and objectives. Training and development has also become a vehicle of communication to reach out to employees and to educate them not only to be productive employees but also to become socially responsible members of the society  Emphasis is placed not only in the use of state art technology but to use technology to meet up with the competition and to stay in tandem with international hospitality expectations. Training presentation use computer technology for high impact results.  To fulfill our customers perceived expectations we see the integration of people versus technology skills are the hallmark to achieving our business and competitor differentiation in the industry for competitive advantage. In order to achieve to this, training and development must be viewed in the development of soft and hard skills so that our employees from the basis of a knowledgeable organization.

TRAINING AND DEVELOPMENT FORMAT:

The format lies in identifying the training needs of our employees and analyzing the type of programs, which will help in development the skills required to conduct our operations within our infrastructure of meeting customers expectations and career development of our employees. As such we have explored into three broad levels of categorizing are optimized for value added service. In our pursuit of this end we have categorized our Training and Development format into the following: 1. External consultants for In-house trainers and on the job training 2. External courses 3. In-house classroom trainings by in-house trainers and on the job training.

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ORGANIZATION STUDY

BPSPL

TRAINING METHODS AT BALAJISWAMY PREMIUM STEELS PVT.LTD

1. Case Study 2. Role playing 3. Distance learning and videoconferencing 4. Business game 5. Videotapes 6. Job rotations.

WELFARE MEASURES: Leaves:

The company provides the leave annually as under Privilege Leaves Annually all the permanent employees will get 30 days leaves Casual leave Per year 12 days casual leave will be provided. This leave cannot be carried forward and automatically laps at the end of the year Sick Leave An employee is entitled for 6 days of sick leave per year.

WORKING HOURS:
General shift 9.00a.m to 1.00p.m 2.00p.m to 6.00p.m.

A 6.00a.m to 2.00p.m B 2.00p.m to 10.00p.m C 10.00p.m to 6.0

8x3shifts=24hrs

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ORGANIZATION STUDY
RECRUITMENT AND SELECTION:

BPSPL

The company recruits and selection the manpower based on the requirement of the individual units following is the process of recruitment

1. Advertisement 2. Training satisfaction 3. Performance appraisal 4. Conformation of the employee.

EMPLOYEES MOTIVATION:
y y y y y

Insurance Bonus Internal awards Cricket matches Suggestion scheme.

UNIFORAM AND SHOES:

The company provides uniform each year and also provides shoes for each employee and also provides helmet and nose masks to the employees who work in the plant.

TRAVELING FACILITY:
Since the company is located 8 kilometers away from the town. The company is providing bus facility for their employees.

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ORGANIZATION STUDY
SAFETY AND HEALTH:

BPSPL

The company provides all the satisfactory requirements pertaining to health and safety provide under the factories act 1948. So as part of these employees are given safety shoes, hand gloves and first aid boxes in main places of the shop floors. This company provides pure drinking water facilities etc.

SECURITY:
The company appointed security manager to look after the contract labor and visiting persons. The security managers have adopted first come serves method for the truck loading.

ENVIRONMENTAL MATTERS:
Companys operation and properties are subject to a wide variety of increasingly complex and stringent environment laws. As such, the nature of the companys operations exposes it to the risk of claims with respect to such matter and there can be no assurance that material costs or liabilities not be incurred in connection with such claims. The company believes its operation and properties are in substantial compliance with such environmental laws. The company understands its obligation towards the society, is planning for electrostatic precipitator through which the carbon monoxide liberated from the kiln will be purified , cooled and thereafter left in the atmosphere, however the energy will be positively used for generation of electricity. The waste heat from the kiln inform of gases will be used for production of steam and subsequent generation of electric power.

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ORGANIZATION STUDY

BPSPL

FINANCE DEPARTMENT
The lifeline of any organization is the finance. It flows through every department and helps in carrying the vital element throughout the organization thus ensuring the survival of the organization. The main functions of the finance and accounts department in Balajiswamy premium are as follows;

1. Generation and proper utilization of funds 2. Working capital management 3. Cost control and reduction 4. Maintain the book of accounts 5. Preparation of financial statements

THE SUB DEPARTMENTS UNDER THIS DEPARTMENT: 1. Accounts:

Accounts handles finance function concerning arranging of finance, payment to suppliers, collecting of money from customer and accounting all the transaction related to the above activities

2. Internal Audit:
This department plays the important role of watch dog of the companys assets And money resources.

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ORGANIZATION STUDY
They are responsible for  Per audit payment  Checking of branch accounts  Verification of inventories  Verification of credit  Verification of assets from time to time

BPSPL

3. Secretarial:

 Secretarial is compact selection, which takes care of the companys secretarial function. This selection also handles pay roll of management staff.

4. Sales Accounting
 Sales accounting includes analysis of the dispatches of stocks, accounting of bills and collection of receivables. comprises of the following activities  Preparation of invoices  Receiving and issuing of sales tax forms as per procedure  Verifications of invoices  Accounting for collections  Debit and credit notes as per procedures The greatest challenge posed to the finance department is that of working capital management receivables management, payables managements and cash management from the core of the finance departments. Sales accounting

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ORGANIZATION STUDY
MARKETING DEPARTMENT

BPSPL

DEFINITION OF MARKETING
Marketing is a social process by which individuals and groups obtained what they need and want through creating, offering and freely exchanging products and services of value with others.

AIM OF MARKETING
To know and understand the customer so well that the product or service first him and sells itself. Ideally marketing should result in customer who is ready to buy. All that should be needed then in to make the product or service available.

BACKGROUND
During the early 90s, sponge iron industry emerged to provide an alternative to steel melting scrap which was increasingly becoming scarce. Special benefits were provided at required level by the government to encourage the production of sponge iron in India. Today, India is the largest producer of sponge iron in the world. The production of sponge iron in country as also resulted in providing an alternative feed material to steel melting scrap which was hitherto imported in large quantities by the electric arc furnace unit and the induction furnace unit. This has resulted in considerable saving in foreign exchange. The present capacity of sponge iron (both gas and coal based) in India is of the order of over 6.5 million tones surpassing that of Venezuela which is around 5.0 million tones. Major part of metallic requirement by the secondary steel sector is mostly dependant on sponge iron, as availability of indigenous melting scrap is limited coupled with shortage of imported scrap. The imported scrap prices are spiraling day by day and have increased from US$ 260 to US$ 325 presently.

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ORGANIZATION STUDY
OBJECTIVES OF MARKETING

BPSPL

y y

To take care of the sales and dispatching them properly To look after the central excise matters pertaining to the sales of the department.

POLICIES:

1. Keep a watch on the market conditions. 2. Branch officials and agents should always be in touch with customer. 3. BPSPL always prefer to have direct contact with the plot owners for timely supply of raw materials. 4. Orders are always taken on first cum first basis and credit sales are negotiated only after knowing buyers credibility and prior approved of management. 5. The transporter approaches marketing section for billing and other various document required as per government rule.

PRACTICES/PROCEDURE:

1. Only those employees who know the local language are sent to the customers. 2. Marketer makes the customer to know the quality checks done at BPSPL. 3. The customers financial strength and weakness and requirements are known to the branch officers and agents.

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ORGANIZATION STUDY
MARKETING MIX OF BPSPL

BPSPL

1. PRODUCT : Sponge iron Quality : High quality

Branding: BPSPL Packing Colour : Not required : ash

After sales service: Good.

2. PRICE Cash transaction: As Price is fixed by the sponge iron association it cant be changed. It is useful to maintain good and healthy relation with competitors. Cash discount: It is left to the company weather to discount or not if it is paid from cash. Credit period: 30 to 45 days.

3. PROMOTION Public relation: Good relationship Advertising & publicity: Not needed

4. PLACE Channels of distribution: Direct selling and commission agents. Mode of transport : By truck only

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ORGANIZATION STUDY
MARKETING REASEARCH:

BPSPL

DEFINITION OF MR American Marketing Association defines marketing research as the systematic planning, gathering, recording, analyzing and interpreting of data for application of specific marketing decisions.

Learning the wants and needs of buyers by using such sources is:
y y

Primary sources Secondary sources

PRIMARY SOURCES The data collected through the observation, by personally asking

questions to managers, workers and others.

SECONDARY SOURCES The data also collected through the company Manuals.

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ORGANIZATION STUDY
MATERIAL DEPARTMENT

BPSPL

For all stock items initiative would be taken by materials department as per ROS list and laves fixed. As and when taken the stock level touches the ordering level procurement action would be taken by raising ROS for non-stock items respective intending departments would raise purchase requisition these requisitions are approved by department heads these requisitions are sent to purchase sections. This formal posses present stock quality to procure with full description and sizes on receipt of these ROS and enquiries obtaining quotations making proposals and releasing purchases orders. After obtaining quotations from available sources on competitive basis comparative statement of offers (price details) would be and send for indenters recommendations along with all quotations for quality specification and also for price awareness as per indenters recommendations purchase proposals would be made and send for future approvals.

Approvals Purchase Proposals Materials Dept: Office asst Manager Intending Dept: A.G.M/G.M. Manager Finance Dept: Manager (F & A)/ D.G.M/Manager (F & A) Manager: for stock items up to Rs.50,000/D.G.M (F & A) for all items above Rs.50,000 to 1.00 lack M.Ds Approvals : all proposals valuing Rs.1.00 Lack and above After the proposal is duly approved purchase order would be made and signed by the head of the department and to release. Stores material handling.

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ORGANIZATION STUDY
STOCK HOLDING SECTION:

BPSPL

Material arrived at stores would be checked up with P.O and purchase intenders at stores after verification materials would be checked up with packing list, delivery reports would be circulated among departments. Based on the arrival report concerned intenders departments would inspect the materials (receipt) at stores after inspection accepted material would be sent to holding stores (stores section) and update stock records copies of these S.Rs (accepted) would be sent to finance department, intender department and for records and accounting copies of these S.Rs would also be sent to purchase section for necessary entries and follow up for payment as per P.O terms. Accepted stocks would be preserved safely in stores and made available for issuing to shop floor against specific material requisition notes. This requisition would be signed by shop floor shift in charge Manager/ Department head on receipt of the materials requisition (issue notes) stores would issue the material accordingly. Other production materials are issued against bill of materials the issues are strictly be made under the supervision of and consumption to avoid waste.

FOLLOWUP FOR PAYMENTS:

If materials are procured against 30 days credit basis, payment would be due dates automatically by advises to accounts as per P.O terms from time to time I.e. advance payment and release of bank documents and payments against Performa invoice.

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ORGANIZATION STUDY
INVENTORY LEVELS:

BPSPL

Stores items are of two kinds one is stock items and the other is non-stock items. Stock items are called ROS items (replenishing of stock) generally shop floor authorities and intimate stores to keep minimum stock of these items like consumable required very frequently out this list is called ROS list (minimum maximum stocks) since these are general consumable required almost every day shop floor people need not take initiative for procurement every time as per the ROS list procurement has to be made to stores. Stores have to maintain consumption. Qualities are calculated and noted in bin cards ad per levels fixed as and when the stock level touches ordering level of these consumable is very less when compared to total annual consumption of all items considering the monthly consumption availability of material I.e. locally nearby sources 3 months taking the lead time into account levels are fixed as under to avoid stock outs.

Minimum maximum stock levels

Ordering levels -------------- 3 months requirements

Minimum level ---------------2 months requirements

Maximum level----------------6 months requirements

(Ordering quantity) by the time the new receipts come minimum stock outs can be avoided and see smooth flow of operation.

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ORGANIZATION STUDY
NON STOCK ITEMS:

BPSPL

These are spares components and bulk requirements consumption values these items are not regular and uncertain and some of the items are periodically required for these items would be intending departments duly approved by the departments head sand send to materials departments for taking further procurements actions materials departments would process these requisitions.

BILL OF MATERIALS:
Bill of materials is the list of items required for fulfilling a specific job/work. These are regular production consumables such as raw materials and refractory, these items are quite specific and of very high separate list are made as per the Bill of materials. The bill of materials would be approved by the departments head of intending department (both stores and purchase sections) for taking procurement action as per the Bill of material procurement would be made in accordance with production tempo and stock level however clearance from time to time depending on payments and stock positions since these productions items are of high value only minimum stocks would be strictly made in view, the funds utilization effective any how procurements would be strictly made as per present stock available and requirements time to time. from

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ORGANIZATION STUDY

BPSPL

PRODUCTION DEPARTMENT
RAW MATERIAL STORAGE AND HANDLING

Sized iron ore, sized coal and sized limestone will be received from the mines/suppliers directly by road unloaded and stacked in the raw material yard. The material will be withdrawn by means of pay loader and tippers and unloaded into the ground hoppers. From the ground hoppers, the materials would be conveyed to respective vibrating screens by means of belt conveyors and ultimately the sized material would be stored in the earmarked day bins. One road weight bridge would be provided for weighing all the incoming materials to the storage yard and outgoing materials from the storage yard.

STOCK HOUSE

Pic no: 1

The reduction plant would have a stock house housing the day bins for storing sufficient requirements of various raw materials. Here, sized iron ore, sized fine coal, sized feed coal and limestone will be stored in separate RCC bins. Weigh feeders will be provided to the raw material bins for withdrawing predetermined quantities of iron ore, coal and limestone from the bins which will be conveyed to the kiln feed building by means of belt conveyor.

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ORGANIZATION STUDY

BPSPL

KILN AND COOLER

Pic no: 2 For Direct Reduction of Iron ore, two rotary kilns which is the main/major facility. The kiln feed from the charging end will consist of screened iron ore, feed coal and limestone. A portion of fine coal will be injected from the discharge end of the kiln. Inside the kiln, the raw materials will be dried and heated to the reduction temperature of approximate 1000 degree centigrade. The iron oxides of the ore will be reduced to metallic iron by carbon monoxide generated inside the kiln. The heat required for the process will be supplied by controlled combustion of carbon and volatiles in the kiln. Thermocouples will be located along the length of the kiln shell for temperature measurement in various zones. The temperature will be

regulated by controlling the amount of combustion air admitted into the kiln through fans mounted on the kiln shell. A variable speed main drive has been provided to rotate the kiln at desired speeds. For initial starting and during emergency operation an auxiliary drive has been provided which will rotate the kiln at a constant RPM. The inside of the kiln will be lined with special high alumina refractory. Light diesel oil or H.S.D oil will be used for initial heating of the kiln during start-up and during disturbed operation of the kiln. No fuel oil will be required in normal operation. However, in the event of any thermal imbalance occurring during operation, fuel oil will required to be used for correcting the imbalances in the shortest possible time. The product from the kiln will be cooled in a Rotary Cooler by means of indirect spray of water. Arrangement for by passing the product will be provided at the discharge end of the cooler for any emergency discharge of materials.

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ORGANIZATION STUDY

BPSPL

The cooled product will be conveyed to the screening and magnetic separation building by a system of belt conveyors. The cooling water will be collected in troughs below the cooler and pumped to the cooling tower for cooling and recycling after adding the required make up water.

PRODUCT SEPARATION

Pic no: 3 The cooler discharge consisting of sponge iron (lumps and fines) which are magnetic and char and dolochar which are non magnetic will be conveyed to magnetic separators. Magnetic fraction of + 3mm will be conveyed to sponge iron storage bin. The non magnetic fraction of +3mm will be stored in char bin. Similarly -3mm sponge iron fines and char fines (dolochar) are also separated and stored separately in different bins.

WASTE GAS HANDLING SYSTEM

The waste gases from the kiln flowing in counter current to raw materials will pass through a dust settling chamber where heavier dust particles settle down due to sudden decrease in velocity of gases. Thereafter, the flue gases pass through an after burning chamber where any un-burnt carbon monoxide present in the gases will be completely burnt by blowing excess air. The completely burnt gases will then pass through a down duct into an evaporation cooler where the temperature is brought down and then through an E.S.P where balance dust particles are separated. Now the waste gases free from any dust particles and at a temperature of about 140 degree centigrade is let out into the atmosphere through an RCC stake of 40 meter high.

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ORGANIZATION STUDY
STORAGE SHED:

BPSPL

Sponge iron from the product separation unit will be conveyed to sponge iron bin of about 180 tones capacity. In the normal course, it is envisaged that customers trucks will be directly loaded from the sponge iron bin. However, in case the bin is full sponge iron from the bin will be transported to a covered shed for storage. A centralized control room is provided with metering and control instruments besides interlocking and protection schemes. The room will be centrally air-conditioned.

INDUSTRIAL WATER SUPPLY:

There is a hot well and cold well of supply and return water storage from cooler where sponge iron is cooled separately. Pumps are provided for circulation, cold water to cooler and hot water through cooling tower. The other requirements like for cooling compressor etc. is met from the ground water reservoir directly. An overhead tank is provided in the plant to meet the water requirement for about half an hour during emergency, like power failures, fire etc. This overhead tank has one separate compartment to store and supply drinking water to the plant personnel.

COMPRESSED AIR FACILITIES:

To meet the demand of compressed air, two water cooled compressor of 400 cfm and at a discharge pressure of 6 kg/cm sq is installed. This compressed air is used for operating the grease pumps and the pneumatic seals to kiln and cooler. For distribution of compressed air to different consuming points, an adequate distribution net work of pipelines has been provided.

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ORGANIZATION STUDY
LABORATORY FACILITIES

BPSPL

Laboratory equipments required are jaw crusher/roll crusher, disc, pulverize, muffle furnace, drying cabinet, rotary sieve shaker, C and S apparatus, satmagan, electronic balance and glassware.

VENTILATION AND AIR CONDITIONING FACILITIES

The main system of ventilation for most of the buildings is naturally ventilated. Mechanical ventilation is provided in such premises where natural ventilation cannot provide the desired effect. The control room shall be centrally air conditioned. Local exhaust fans are provided where necessary for removing objectionable fumes and vapors. De-dusting system has been considered for removing dust generated at transfer points in the handling, transportation of raw materials and finished products. Exhaust ventilation are provided for the switch gear room of the main step down sub-station, transformer station, store room and toilets.

CENTRAL STORES
One central store is provided to store various materials consumables and spares viz, equipment, conveyor belts, grease, lubricants and refractors to meet operation requirement of the plant.

POLLUTION CONTOL FACILITIES AIR POLUTION CONTROL

The air over a Sponge Iron Plant area and beyond its boundaries tends to get polluted with gases and dust particles emanating from the stack, transfer points of conveying and handling equipment. The major atmospheric pollutants in a Sponge Iron plant are waste gases mainly consisting of carbon dioxide, sulphur dioxide, nitrogen, iron ore dust, coal fines, ash, limestone fines,etc. Exhaust from both technological and ventilation equipment would be treated and let off to atmosphere at a height according to air pollution control norms.

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ORGANIZATION STUDY

BPSPL

The stack height will be chosen as to ensure that ground level concentration of pollutants remains within the permissible limits ensuring that the chimney height is at least 2m above the top most point of the adjacent tallest building. The off gas from the rotary kiln containing combustibles like carbon particles and carbon monoxide apart from oxides of sulphur and fines of iron ore, coal and limestone are completely burnt in the after burning chamber and the waste gas is passed through gas cleaning plant consisting gas conditioning tower and EP to make free from any hazardous elements before being let out into the atmosphere through a 40 m high stack.

WATER POLLUTION
Adequate effluent handling, treatment and disposal measures have been taken to conform to prescribed norms. The waste water after treatment would be discharged into the storm water drainage system, chemical wastes from laboratory, will be neutralized before discharging into the sanitary sewerage treatment system.

NOISE POLLUTION CONTROL

Due to technological reasons, it may not be practicable to entirely eliminate the noise. However, noise levels could be brought down to the acceptable level wherever possible. The major equipment of high noise production can be identified as ID fan, de-ducting fan of Sponge Iron Various measures like reduction of noise at source, providing acoustic lagging for the equipment, isolating the noise producing equipment etc would be adopted to reduce the noise pollution from this equipment. The compressors in the compressed air station would be provided with suction side silencers. Ventilation fans would generally be installed in enclosed premises. Supply ducts and grills on the ventilation and air conditioning system would be suitably sized for minimum noise level.

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ORGANIZATION STUDY
WATER GAS EMANATING POINTS AND CONTROL

BPSPL

DUST EMISSIONS AND CONTROL

From the transfer points at crushing, screening, cooler discharge and product separation, some quantity of dust is eliminated. To avoid the pollution of the environment, the de-dusting points are provided at these three places. In this system, the suction ducts are provided at various points and connected to a bag filter house. One ID fan is used to create suction and the dust particles collected in the hopper are drawn out with the help of a rotary valve, for humidifying the dust to avoid flying of the same.

ELECTRICS DEPARTMENT

POWER REQUIREMENT
The power requirement of the proposed Sponge Iron Plant is estimated at 1500 KVA on 30 minute maximum demand arsis with an annual energy consumption of 5 million KWH. HT power shall be made available at plant site by KEB.

EMERGENCY POWER SUPPLY

One set of 500 KVA rating at 415 V, 50 Hz is provided to cater to the emergency power requirement of vital units of the plant requiring uninterrupted power supply. The DG set will be complete with auxiliaries like AMF panel, day oil storage with transfer pumps etc, and necessary instrumentation. Job: mechanical shift in -charge The job holder is head of the production department and report to plant-in-charge and has yard supervisor, injection coal feeder and kiln mechanic as subordinates. The duties that are to be performed by the job holder include monitoring feed rate of ore and coal, temperature of kiln and pressure of inlet and outlet of kiln.
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ORGANIZATION STUDY

BPSPL

The qualities needed to carry out this job are good interpretation skills, ability to detect deviations in production process. The suitable qualification for this job is Diploma or B.E in mechanical stream with experience of 3 year for degree holder and 5 years for diploma holders. The error in work results in providing wrong feedback to subordinates, quality department, plant-in-charge, spoil interdepartmental relations which in turn leads to lowering of the revenues.

Job: yard Supervisor This job holder reports to mechanical department shift-in-charge. The duties to be performing are segregation of lumps, dislodging of coal and iron ore. The qualities required for this job are mechanical strength and ability to withstand stress, exposure to coal and iron ore. The job required the job holder to have at least one year of experience in similar job. The error in the work result in improper supply of ore and coal to bunkers improper burning of mixture, overloading on conveyors and rollers by which production gets hampered.

Job: injection coal feeder

y y

The job holder reports to mechanical department shift-in-charge. The duties to be performed are segregation of lumps, dislodging and spreading of injection coal.

The qualities required for this job are mechanical strength and ability to withstand stress, exposure to coal and iron ore. The error in the work results in creation of confusion in the department. Loss in credibility of superiors. Due to the error in the work product will not be spongy.

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ORGANIZATION STUDY
SWOT ANALYSIS

BPSPL

STRENGHS: 1. Own dolomite mine provides the required raw materials. 2. Ideal location, providing easy access for outgoing materials. 3. Time tested skill and dedicated manpower. 4. Customer satisfaction. 5. Monopoly in providing different finished products. 6. Well-equipped chemical and metallurgical laboratories. 7. Producing 700 varieties of alloy & special steels.

WEAKNESSESS:

1. Purchasing coal for high price. 2. Outdated technology. 3. Inefficiency of management in some areas. 4. Lack of proper infra structure. 6. Lack of technological knowledge up to the desired level. 7. Poor management information system.

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ORGANIZATION STUDY

BPSPL

OPPORTUNITIES:

1. Supply of products in specific length and specification. 2. Regularizing rolling of some specific section. 3. Products are acceptable to most of the leading clients. 4. Monopoly in those markets that will be a great help to exports. 5. Efforts are on for reducing the power cost, which is key element in the process of sponge manufacture. 6. Since BPSPL has wide network of traders, it can supply its product directly to customers without any difficulty.

THREATS:

1. Competition with AGRWAL STEELS, ISPAT, HOTUR STEELS, NDPL and other companies. 2. No modernization of plant because of which other steel plants take away most of the orders. 3. As it is a government company everyone is very reluctant in his or job. 4. They cannot change the selling price of the product as it is fixed by Sponge Iron Association.

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ORGANIZATION STUDY

BPSPL

FINDINGS
    There is no good infrastructure facility within the organization. There is no good maintainenes of cleanness in the organization.

There is no effective utilization of available resources in the organization.

There is no safety & security precaution regarding the welfare of the workers.

 

There is no canteen facility within the organization.

There is no sufficient plantation layout within the organization to control the environment.

  

There is no proper training & development for the employees.

There is no medical facility within the organization to safeguard the employees. There is no entertainment given to the employees other than work.

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ORGANIZATION STUDY

BPSPL

SUGGESTIONS
 There should be good infrastructure facilities such as  Maintains of the plantation to the environment.  For prevention of dust water should be sprit to the ground.  Vehicles parking facilities should be there is within organization there should be shod to vehicle.

 There should be proper good maintenances of cleanness in the organization such as  There should be used dustbin in order to keep clean.  Prevent the dust they should sprit the water to the ground in order to keep clean.  To prevent the dust they should put concert to the ground within the organization for the transport of the vehicle.  There should be a security labor for the maintenances of cleanness.

 There should be maintenances of medical facilities  There should Ambulances facilities.  Doctors should be there in the organization.

 To maintenances of safety & security precaution regarding the welfare of the workers in order to safe guards the employees  They should be wear helmet, glues & shoes.  There should be safety manger in order to safeguard the workers.

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ORGANIZATION STUDY

BPSPL

CONCLUSION
BPSPL produces special steels and it has carved a niche for itself in its field by ensuring quality steel production matching international standards. It is setup in Bellary Karnataka in , 2005 to produce sponge iron, the plant has been producing to conclude discussion on inventory control, it is noticed that, inventories generally represent a very significant proportion of total assets. Hence, the importance of inventory control cannot be over emphasized. The steel is today considered as the backbone of Indian economy. The growth of economy has a direct relation with the demand of steel. The Company also has a good production deportment, sales force and has been applying the marketing information system to some extent. The company can improve many terms like infrastructure, technology, public relation and also its distribution channel. The company has a good future as the small scale industries are developing more and more.

So this company has to give more preference to quality of the product, safety And welfare of these employees.

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ORGANIZATION STUDY

BPSPL

BIBILIOGRAPHY

1. BOOKS:
 Human Resource Management
o P.Subba Rao 3rd Edition ,Himalaya Publishers.

 Financial Management
o Prasanna Chandra, 6th Edition, Tata McGraw Hill Publishing Co. Ltd.

 Financial Management
o I.M.Panday 9th Edition, Vikas Publishers.

 Marketing management
o Philip kotler.

WEB SITES:
www.steelscenario.com www.spongeiornindialtd.com

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