BPCL REFINERY

Product

range: - Petrol, Diesel, Kerosene, Lubricants, LPG, Methyl Tertiary Butyl Ether (MTBE), Aviation Turbine Fuel (ATF) and Lube Base Oils. Average production: - 12.52 MMT Per year. Plant Capacity: - 12 MMTPA.
Area where Company products are sold: - All Over the Country.

Basis of Production Planning: As per forecast provided by sales department.

 Flexibility

in Production Planning: Changes in Model Mix.

Material

Purchase

y Use of A, B, C categorization of bought out

material Raw material / C / Consumables: No. y Purchased material: - Crude Oil. y Criteria for quantity to be ordered: - To meet Companys Inventory target.

Receipt / Storage / Quality

y System of receiving bought out material: - By Pipelines. y Quantity Checks: - By Oil Sensors. y Quality:- By Quality Control Department.

y Storage area: - Containers.

Emphasis on Quality
y How to ensure required quality of purchased material: - By

transferring to control department for checking. y Does the Company have TQM: - Yes.

Total Quality management department is an integral and most important part for any organization. Each petroleum product has a fixed quality grading. The crude oil is brought through pipelines for fractional distillation. After that, each separate product is repeatedly refined until they achieve the required grade which is then sent to different depots for distribution.

PIPELINES AND RAILINES

LUB GODOWN/ ENCLOSURE- 150 KLS CAPACITY EACH

Get details of Maintenance practices

y Criteria for deciding maintenance schedule: - As given in the

companys manual. y Is there a maintenance schedule for each machine: - Yes. y Maintenance is carried out :- Every Year and also in case

of emergency.

Inventory Management System

y Is there a Target for: - Yes (at regular orders and festivals).

y For Finished Goods / Raw Material / Components /

WIP
y What is the Actual Inventory Vs Target: - It is flexible, when it

is special then actual inventory does not achieve its target.

Action plans for reduction of Inventory for all categories No.

 Logistics y Company collects from suppliers and Supplier

delivers directly to company. y Logistics for Finished Goods: - Finished products are stored in containers where 20% is kept as safety stock. Finished goods are brought at the distribution centers as per the requirement.
Use of IT y Company uses SAP 9.0 version for purchasing

requisitions, opening and closing of tenders, Stock levels, creating purchase orders, sales orders, move orders, invoices, etc.

y Monitorial plan Vs Actual production Vs

Actual Daily.

y Transit time for both Inbound / out bound: - Yes. y Product wise costing :-

1) Diesel- 42.06 Rs. per Ltr.

2) Petrol- 63.08 Rs. per Ltr. 3) Speed 97 - 70 Rs. Per Ltr. 4) Hi Speed- 44 Rs. Per Ltr. 3) Auto gas- 40.21 Rs. Per Ltr. 4) LPG- 348.45 Rs. Per 14.2 Kg cylinder. 5) ATF- 49046.00 Rs. Per Kl. 6) Kerosene- 12.27 Rs. Per Ltr.

Improvement Area
Company has coordination meeting between Sales / Mktg and Production plan / manufacturing.