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FACT
UNDER THE GUIDANCE OF
DR.M.S JAYAMOHAN
DEPARTMENT OF
MECHANICAL ENGINEERING
R.I.T,KOTTAYAM
DEEPAK CHERIAN
Roll No : 07
S3 IEM
RIT, KOTTAYAM
FACT
To understand the various key functional
areas of the company
To get an idea about existing business
operations at FACT.
To interact with managers at various levels of
the organization hierarchy
To analyse the practical aspect in relation to
the theoretical aspect of the organization
Data collection
PRIMARY
Direct interview with the department heads
Discussion with the divisional heads
Interaction with workers in the company
Data collected by observing the function of the organization
SECONDARY
Annual reports of the company
Department manuals
Periodicals, books, etc. published materials by the company
Company website
COMPANY PROFILE
HISTORY
FACT, India's first large scale fertilizer unit was set up in
1943 1943
FACT Udyogamandal started production of Ammonium
1947 Sulphate with an installed capacity of 10,000 MT Nitrogen
1973
The Cochin Division of FACT, the 2nd production Unit was set
up at Ambalamedu
1973 The 1st phase was commissioned in 1973.
The 2nd phase of FACT Cochin Division was commissioned
in1976.
CD II Sulphuric Acid Plant commissioned
1976 CD II Phosphoric Acid Plant commissioned
CD II NPK trial run started
1977
2010
2014
BOARD OF DIRECTORS
Shri S. K.
Lohani
Director
Shri Vinod
Kumar
Thakral
Director
Shri K P S
Nair
Director
Dr. Murali S
Director
ORGANIZATION STRUCTURE
DEPARTMENTS OF FACT
FACT
Corporate
Head Office
CD
UD
PD
FEW
FEDO
CSC
MD
MDC
R&D
CENTR
E
CD Cochin Division
UD
Udyogamandal Division
PD Petrochemical Division
FEWFACT
Engineering Works
FEDOFACT Engineering and Design Organization CSCComputer
Service Centre
MD Marketing Division
MDCManagement
Development Centre
MANPOWER OF FACT
Category
Employee
HO
CD
PD
UD
group
Mark FED
FEW
Total
eting O
Managerial
Managerial
113
113
60
176
72
61
17
612
Managerial
Managerial
Managerial
Trainees
Managerial
*Managerial
deputation
116
113
60
176
72
61
17
615
Non-
Non-Managerial
19
27
33
30
117
Managerial
Non-
Clerical
Non-Managerial
14
297
99
401
12
832
Managerial
Non-
Skilled
Non-Managerial
22
119
33
178
360
Managerial
*Non-
Unskilled
55
443
134
612
46
11
1309
Managerial
Sub Layer
Sub-Layer Clerical
53
13
11
15
107
Sub-Layer
Sub-Layer Skilled
136
70
99
319
*Sub-Layer
58
149
77
110
19
426
229
705
271
898
137
76
34
2350
Total
MANUFACTURING DIVISIONS
Udyogaman
dal Division
Petrochemic
al Division
Fertilizer plants
Ammonium sulphate
plant
Sulphuric acid plant
Ammonia plant
ANONE Plant
HYAM Plant
LACTUM Plant
Captive Power
Plant
Cochin
Divisio
n
Cochin Division
Fertilizer Plants
Ammonia Plant
Sulphuric Acid
Plant
Phosphoric Acid
Plant
Phosphori
c Acid
Plant
Ammonia
Plant
Complex
Fertilizer
plant
ORGANIZATIONAL BREAKDOWN
STRUCTURE OF FACT CD
CGM
GM
Operations
DGM
(Civil)
DGM
(Mechanical)
Sr.Manager
(Civil)
AGM
Mechanical)
Dy.Manager
(Civil)
Sr.Manager
(Mechanical)
Asst.Manager
( Civil)
Asst.
Engineer/
Manager
GM
Technical
DGM
(E&I)
DGM
(Production)
AGM
Production (NP)
Sr.Manager
Production (NP)
Asst. Engineer/
Manager
AGM
Production (PAP)
Sr.Manager
Production (PAP)
Asst.
Engineer/
Manager
AGM
Production (SAP)
Sr.Manager
Production (SAP)
Asst.
Enginer/
Manager
AGM
(E&I)
Sr.Manager
(E&I)
Asst.
Manager/
Engineer
DGM
(TS)
AGM TS
(Process)
Asst.
Engineer/
Manager
DGM (P&P)
AGM TS
(Engineering)
Asst.
Engineer/
Manager
AGM (P&P)
Sr.Manager
(P&P)
Asst.
Manager/
Engineer
organization in India
Major works include :Design
Engineering
Implementation of projects in process,
petrochemicals, fertilizers
ISO 9001: 2008 certified company
Process
Engg
Civil
Engineering
Mechanical
Piping
Process
Combustion
Equipments
Machinery and
Material
Handling
Construction
Electrical
Project
Management
Instrumentation
Quality
Management
Inspection
ORGANIZATIONAL BREAKDOWN
STRUCTURE
COO
CGM
GM
GM
(Process)
GM
(Engineering
Project
Constuction)
DGM
(Drawings)
DGM
(Civil)
DGM
(Electrical)
DGM
(Instrumentation
)
DGM
Commercial
DGM
(Mechanical)
DGM
(Piping)
AGM
Commercial
AGM
(Drawings)
AGM
(Civil)
AGM
(Electrical)
AGM
(Instrumentation
)
AGM
(Mechanical)
Engineer/
Manager
Engineer/
Manager
Engineer/
Manager
Engineer/
Manager
DGM
(Process)
AGM
(Process)
AGM
(Piping)
Engineer/
Manager
Engineer/
Manager
DGM
(HR)
Engineer/
Manager
Engineer/
Manager
FEDO continued.
Softwares used
STAADPRO, ETABS, AUTODESK
INFRASTRUCTURE DESIGN SUITE, AUTODESK
BUILDING DESIGN SUITE, AUTOCAD, CAESARII, ASPEN HTFS, PIPENET, PPS, CAD WORX etc.
Project planning softwares like Primavera P6
and MS Project 2007 Professional
Works done
Mechanical piping
Mechanical (M & MH)
Mechanical (PCE)
Clientele of FEDO
Oil and Gas
Indian Oil Corporation Limited
BPCL, Kochi Refinery(KR)
Oil and Natural Gas Corporation Limited
Gas authority of India Limited
Hindustan Petroleum Corporation Limited
Bharat Petroleum Corporation Limited
IBP Co. Limited
Chennai Petroleum Corporation Limited
Oil India Limited
Clientele of FEDO.
Fertilizer
National Fertilizers Limited(Panipat, Bathinda and
Nangal)
Krishak Bharti Co-operative Limited
Madras Fertilizers Limited
Paradeep Phosphates Limited
Indo Gulf Fertilizers and Chemicals Corporation
Limited (Hindalco, Dahej)
Oswal Chemicals and Fertilizers Limited (IFFCO
Paradeep)
Gujarat State Fertilizer Corporation
Gujarat Narmada Valley Fertilizer Corporation Limited
Clientele of FEDO.
Infrastructure
GIDA( Goshree Islands Development
Authority)
KINFRA( Kerala Infrastructure Development
Corporation)
KSIDC( Kerala State Industrial Development
Corporation)
RBDCK( Roads and Bridges Development
Corporation Kerala)
DGM
(Shops)
DGM
(Projects)
Manager
(Commercial)
AGM
(Design)
AGM
(Planning &Projects)
Design Engineer
Project Manager/
Engineer
Drafting section
Planning and
Projects
Department
AGM
(shops)
Shop Engineers
Technitians
AGM
(Materials)
DGM
(Inspection)
Senior Officer
(Administration)
Inspection
Department
FEW continued.
Staff strength
GM-1 , DGM-2, AGM-4, Engineers-6,
Others: Technical-15, Non-Technical-11,
Contract Employees-65
Total strength 104
Annual Capacity of shop
Annual capacity= 1000 tons*(*excluding
external jobs/projects)
HR Department
Vigilance department
Headed by C.V.O
Adopted preventive vigilance as the main theme
Providing Transperency and accountability in the
working of the company
to new
fertilizer formulations and value additions of
existing product lines in the organization
Developing dye for coloring Zinc fortified Factamfos
Quality control cell
Bio fertilizer production by utilizing raw materials
from Coir fed.
Conservation of energy and technology absorption
Alkaline scrubbing of gaseous effluents.
Limiting phosphate to 4mg/liters, fluoride to
2ppmand ammonia to 5ppm
PRODUCT PROFILE
PRODUCT PROFILE
Finished Products
Ammonium sulphate Udyogamandal Division
Ammonium Phosphate/ Complex fertilizers/
Factamfos Udyogamandal Division and Cochin
Division
Caprolactum Petrochemical Division
Biofertilizers Research & Development Division
Exported Products
Caprolactum Petrochemical Division
Ammonium Sulphate Udyogamandal Division
Byproducts
Nitric Acid & soda Ash Petrochemical Division
Gypsum Udyogamandal Division & Cochin
Division
Carbon Dioxide Gas Udyogamandal
Intermediary Products
Ammonia- Udyogamandal & Cochin Division
Synthesis Gas Udyogamandal Division
Sulphuric Acid Udyogamandal & Cochin Division
Oleum Udyogamandal Division
SO22 Gas Udyogamandal Division
Phosphoric Acid Udyogamandal & Cochin division
Straight Fertilizers
Ammonium sulphate Containing 20.6% N in
Ammonical form and 24% sulphur, an important
secondary nutrient
Complex Fertilizers
Factamfos 20:20:0:15- NPK complex fertilizer
Factamfos or Ammonium Phosphate contains 20% N in
ammonical form, 20% P in water soluble form and 15%
sulphur; a secondary plant nutrient, which is now
attaining great importance in agriculture. Factamfos
also can be used for foliar spraying.
NPK Mixtures
NPK Mixtures FACT prepares crop specific standard mixtures for all
crops in Kerala and also special NPK mixtures for plantation crops
like Tea, Coffee, Cardamom, Rubber etc.
Chemicals
Anhydrous Ammonia FACT produces Ammonia of over 99.96%
purity.
Sulphuric Acid FACT has one of the largest plants in Asia and it
manufactures Sulphuric acid of 98% purity.
Caprolactum It is the raw material for Nylon-6.The product quality
of FACT Caprolactum is among the best available in the world.
Nitric acid and Soda Ash Small quantities of these are obtained
from Caprolactum plant as byproduct with capacity of 3800 TPA and
4750 TPA respectively.
Competitors of FACT
SPIC Southern Petrol Industrial Chemicals ( Products-
NP
Sul. Acid
Phos. Acid
BUSINESS PORTFOLIO
900000
800000
700000
Tonne
s
600000
500000
Production
Sales
400000
300000
200000
100000
0
Fertilizers
FINANCIAL
PERFORMANCE
350000
Rs. in Lakhs
300000
250000
200000
2011-2012
2012-2013
2013-2014
2014-2015
2015-2016
150000
100000
50000
0
-50000
-100000
Turn over
Profit/Loss
Weakness
Strength
SWOT
Analysis
Opportunities
Threat
Weakness
Strength
1.Premium
1.Premium product
product in
in the
the complex
complex fertilizer
fertilizer
segment
segment
2.Production
2.Production of
of caprolactum
caprolactum
3.High
3.High level
level of
of capacity
capacity utilization
utilization
4.Land
4.Land and
and other
other infrastructure
infrastructure facilities
facilities
5.Strong
5.Strong market
market network
network
6.Strong
6.Strong manpower
manpower utilization
utilization with
with respect
respect to
to
higher
productivity
higher productivity
7.Good
7.Good quality
quality and
and environmental
environmental
policy
policy
1.Working
1.Working capital
capital management
management is
is not
not
effective
effective
2.Lack
2.Lack of
of younger
younger manpower
manpower teams
teams
3.Possible
3.Possible ineffectiveness
ineffectiveness of
of practical
practical
management
management
4.Production
4.Production downfalls
downfalls
5.Energy
5.Energy consumption
consumption is
is high
high
6.Over
6.Over dependence
dependence on
on import
import of
of raw
raw
materials
and
the
logistics
materials and the logistics
SWOT
Opportunities
1.Possibilities
1.Possibilities of
of export
export
2.Product
2.Product diversification
diversification
3.Regular
3.Regular safety
safety and
and energy
energy audits
audits
4.Availability
4.Availability of
of land
land resources
resources for
for generating
generating
additional
revenue
additional revenue
5.New
5.New recruitments
recruitments
6.Availability
6.Availability of
of RLNG
RLNG at
at Kochi
Kochi
Threats
1.Non-availability
1.Non-availability of
of sufficient
sufficient quantity
quantity of
of
certain
raw
materials
certain raw materials
2.
2. Price
Price fluctuations
fluctuations
3.Unfavourable
3.Unfavourable policies
policies of
of government
government
4.Severe
4.Severe competition
competition
5.Existing
5.Existing dept
dept
FINDINGS
FACT has been facing huge loss due to the use of Naphtha as feed stock
structure.
The authority and responsibility is clearly defined in this organization.
organization.
Employees are well qualified, skilled and dedicated to the
organization.
FACT conducts training programs for employees for the
purpose of increasing their efficiency.
The organization always keeps a good communication system.
There are strict rules and procedures followed by FACT for
issuing quotations.
FACT gives more importance to their employees safety and
safety measures.
RECOMMENDATIONS
FACTS products has already captured south Indian market
CONCLUSION
The production process in FACT was studied
The various functional departments in the
REFERENCE
www.fact.co.in
Company Brochures
Annual report
FACT NEWS