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Project PPT RPT
Project PPT RPT
The expanding Industrial Scenario calls for efforts to tackle related problems:
Industry needs capital and technology. Since energy cost accounts nearly 25 per cent of cost of production there is an urgency to improve energy management and energy consumption. Quantum jump in production, called for by the demand projection is possible only by expansion of existing capacity and creation of additional capability. Up gradation of technology and new capacities also involve massive investment.
Use of agro residues for preparation of pulp also throws up challenges like pollution control, recycling, use of cost effective technology for utilization of agro residues, etc. 1
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Improvements of key ports, roads and railways and communication facilities. Revision of forest policy is required for wood based paper industry so that plantation can be raised by industry, cooperatives of farmers, and state government. Degraded forest land should be made available to the industry for raising plantations.
Import duty on waste paper should be reduced. Duty free imports of new & second hand machinery/equipment should be allowed for technology up gradation.
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COMPANY PROFILE
In the year 1983, the Karanja Industries Pvt Ltd. started its operation in Bidar district. Due to Backward area the government had given the subsidy to start its operations for developing this area. And the company had seen the availability of the raw material, transportation, market opportunities, cheap labor and well water resource etc. The Karanja Paper Industry was incorporated during the year of 1983 with authorized capital of Rs. 5,00,000/- under companies Act 1956 for manufacturing of white cutting duplex board with a capacity of 3000 tons per annum. After identifying the viable location the company could acquire the land of 36 acres. The company secured loans of Rs. 1.6 crores from various financial institutions during 1986 and put the plant on the stream during September 1988 with the project cost of Rs. 234 lakhs. From 1st November 1988 it has resumed the commercial production. While on 30 th November 1996 the Karanja Industry had received I. S. O. 9002 certificate by STQC Directorate Government of India New Delhi. After this they are decided for 50 ton capacity paper mill and this dream was completed in 2001, This paper use for packaging of various material, Which paper known as a Kraft paper.
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Karanja Industries (Pvt.) Ltd. PRODUCT PROFILE: The company manufactures mainly two types of paper products. One is White Duplex board and another is Kraft Paper. The raw material required mainly is only all types of old paper and imported. The required papers are brought from local and outside places like Maharashtra, Kerala, and Karnatakas various cities and America, Saudi imported. The raw material is brought from the entire place through road and rail.
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Kraft papers
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Duplex Board
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VISION, MISSION AND QUALITY OBJECTIVES: VISION: Aim to increase the production by 65 tones per day by 2009 Planning to have ISO 14000 certification for environmental management by 2012. Planning for introduce the LWC (Light Weight Coating) HWC (Heavy Weight Coating) system to the existing product by 2012. LWC Light Weight Coating upto to 10 gm / cm2 HWC (Heavy Weight Coating) means to provide upto 25 gm / cm 2 of thin layer of chemical coating.
MISSION:Karanja Industries (P) Ltd. is following the quality policy which clearly depicts the type of product and service characteristics provided by them. Shall strive to provide quality product and services at competitive price, to satisfy the requirements of the customers. Shall encourage new ideas and efforts from all levels for continuous improvement.
QUALITY OBJECTIVES : Developing at least 2 new customers a year. To achieve 5000 tons of Duplex Board and 3000 tons of Reclaimed Rubber and 14400 kraft paper. The Management will reconstruct the objectives in every Management Review Meeting as applicable depending upon the requirement.
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The area of operation of the Karanja Industries Pvt Ltd is National and Regional level only. Karanja Industries (Pvt) Ltd. has wide distribution network. The Company increased the number of dealers to push the product into the market. The following are the few dealers to whom Karanja Industries (P) Ltd. is selling their products white Duplex Board/Kraft paper.
OWNERSHIP PATTERN:
This company is owned by 46 shareholders but out of these only seven are active shareholders. The active shareholders are as follows:-
COMPETITORS:
Gramox Paper Kerala Duplex Board. Sarvalakshmi Papers Tamil Nadu Duplex Board. Murli Agro Papers Nagpur Duplex. Bedse Paper Mill Aurangabad Kraft paper. Awade Paper Mill, Sangli Kraft paper. Vijayanand Papers Andra Pradesh
Local Competitors: Gemini Graphics Industries Pvt Ltd. Bidar. Veerji Paper Mill Pvt Ltd- Bidar.
The competitors watch each other carefully and formulate the strategies to increase their dealers.
ACHIEVEMENT / AWARDS:
The following achievements are achieved by the company in its life time. The company received on Award for Excellence for an excellent performance of the company by KSFC during 1994-95. While on 30th November, 1996 the company added one more diamond to its crown. The company received ISO: 9002 certificate by STQC Directorate Govt. of India, New Delhi.
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To open a school for companies workers children. To open a hospital in factory campus. To provide colony facilities to the workers. To expend the market area to U. P., Kolkata, Delhi, etc., i.e., through out North India. To provide better quality of product at cheapest rate. 12
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ORGANIZATIONAL STRUCTURE
Managing Director
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Q.A.I/C
Production Manager
Store Asst
Asst
Lab Asst
R/M Insp
Finishing Supr
ETP I/C
Elect Supr
Maint Engg.
Shift I/Ss
Finishers
Operators
Electricians
Fitters
Opts
Opts
MANAGER
ASSISTANT MANAGER
SUPERVISOR
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The role of the personnel management is an organization is a more valuable to achieve the organizations goals. The Personal Department will conduct the advanced technical training to develop the employees skills at the works.
Functions:1. 2. Personnel Department provides a set of techniques for handling people with professional standard. Personnel Department helps the employee to utilize their capacities to the maximum level and to attain not only individual satisfaction but also satisfaction as a part of the work group. 15
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10. Promotion. 11. Discipline & disciplinary actions. 12. Health, safety, welfare of the employee.
Apart from the above functions, the personnel department also liaison with various statutory bodies like Labour department, Factory Inspectorate department, P.F. Office etc., It is the responsibility of the department to prepare the statutory returns falls under various acts and submit the same to the concerned authority within the stipulated time.
RECRUITMENT: Recruitment is the process of stimulating the prospective candidates to apply the job.
Karanja Industries Pvt. Ltd uses the following sources to recruit the candidates. : Advertisement in news paper & electronic media. Walk in interviews
Promotion is totally based on working experience of the employees. Company believes in promoting those employees who really contributes towards the growth of the organization.
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First the applications were received, then the candidates are scrutinized, then they send call letter to the candidates, then the interview is taken by Head of the Department takes the interview & induction will be done for selected candidates. At every stage scrutinizing is there.
TRAINING AND DEVELOPMENT Company is also conducting exit interviews of separating employees by the head of HRM the out come of the exit interview is discussed in top-level meetings in order to keep pace with change due to the liberalization and globalization initiated steps are taken to upgrade the skill of the employee train them periodically, internally and if required through external programs 95% of management at staff is computer literates.
INFRASTRACTURAL FACILITIES:
The company has provided the infrastructure like building, workspace, process equipments, computers and supporting service (transport or communication etc.,) for meeting their equipments of the customer.
CANTEEN
The company is having a canteen in the factory campus only supplying the food at cheapest rate than outside, to the workers of the company.
MEDICAL TREATMENT
The company providing medical allowances about doctor fees and medical expenditure whatever paid by the worker. If the injured at the working hours all the expenses incurred are paid by the company and some extra allowances with half salary up to his injury period are paid.
TRAINING FACILITY
If some workers show some extraordinary service then for his further improvement the company may send them for training. Company gives On the Job and Off the Job training. Company sends them for attend the national level and state level seminar for managers only.
SICK ROOMS
The sick room facility is providing here to the workers during their leave hours and the sick room for visitors also available.
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PARKING FACILITY
The parking facility is provided for the employees cycles, two wheelers and four wheelers and for the trucks which bring the raw material.
ACCOUNTS DEPARTMENT
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PRODUCTION DEPARTMENT
The production department is headed by the production manager. The function of the production department is to produce our products on time, to the required quality levels, at the defined product cost. Of major concern to the production manager is monthly output. Production managers have monthly targets which they are expected to strive to meet or exceed. Production can only meet its targets if Sales secure orders. Also production costs are dependent on the price we pay for components and materials etc.
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ETP Section
Electrical Section
Mechanical Section
Process Sections
WATERMAN
LINEMEN
ENGEENEAR
STORKEEPER
ETP SECTION :
Effluent water is treated in ETP Plant waste water takes birth in pulping and dehydration process and washing activities is plant treatment and recycling of water for it taken to ETP (Effluent Treatment Plant). ETP contains considerable amount of waste impurities like pins, dust etc. They were neutralized by using lime water, alum and sulphuric acid after sterilization of the mixed material, the impurities will be drained and fresh water will be utilized in recycling of puling process.
ELECTRICAL SECTION:
There is one supervisor and 4 electricians working, 3 electricians in 3 shifts all the electrical work is done by this department. Any power on / off power supply, wiring, lighting, all are maintained and forward by the said department.
MECHANICAL SECTION
MECHANICAL ENGINEER
FITTER
HELPER
Interpretation:
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PROCESS SECTION:
The process starts from accepting raw materials from pulp mill where the raw materials is stored in the form of Kraft paper.
SORTING:
In this step the raw material accepted from pulp mill will sorted i.e., separated into Kraft paper, stored them differently in different 2 godowns with the capacity of 65 tons each.
PULPING:
The sorted papers were transferred to plumping process where the pulp is formed of them. The pulp is formed by mixing raw materials. Paper with required quantity of water is flowed from top and all paper is converted into pulp. The machine used for the purpose is HYDRO PULPER.
SCREENING:
Thus formed pulp is transferred to machine through pipes where the weighted substances like metals, pins, and steels, sand, soil from pulp is removed and passed is to the decter section. 24
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Then the pulp is passed through TDR (Trial Disc Refiner) where pulp is softened and ph of pulp is tested and the chemicals like Rosin, Alum, and Goargum. There are totally 5 decters for 1 pulp mill.
Thus softened pulp is passed and stored in chest box. There is 1 head box for 1 pulp. Then from head box the pulp is passed through various following machines and undergone following process.
HEAD BOX:
There is 1 synthetic wire the slurry pulp is constantly supply to synthetic wire. The basic purposes of this synthetic wire is to get the basis paper web format.
VACCUME PUMP:
There are 5 vaccume pump used for removed water from pulp, with help of synthetic wire boxes are below synthetic wire. Wire will carry slurry of pulp. Vacuumed pump queering water from pulp. Water contain in end of wire part is around 80% drying the synthetic felt. Then passed to press section.
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The moisture content of paper web is maintained and after 2 nd press in the range of 52
DRIER:
Then from press section the paper web passes to dyers through belts. The dryers are used to dry the paper web through steam generated trough boilers. In the initiation is done by drying the web slowly. When the web moves to pre-dryer where the web is dried again with high steam and when it is passes to MG Cylinder it dries out the condensed water continuously,. Then the paper web ends and the paper web is fully dried out and all content of moisture is removed finally. When the web transfers to MG Cylinder there is 35 to 40% moisture is present and which comes down to 20% when pass through past Dryer. There are totally 1 MG Cylinder and 7 pre-dryers and 4 past dry [per machines used.
POP REEL:
If the paper was ordered in reels then the paper is reeled out with the help of this machine. It is a machine which is having a round roll and which reels the paper.
REWINDER:
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FINISHING HOUSE:
After cutting the paper board they were brought to finishing house where segregation of acceptable and non acceptable paper is done by physical testing.
`The defective reels such as creasing; cocking, over dry size variations, damping and
damage reels should be rejected and kept alone. The accepted reels should checked physically may ream of 1 bundle and packed with clip, plastic sutali, pp woven, wrapper properly and paste the labels containing manufacturing date, size and number of sheets, GSM, BF and weight.The weight of each bundle 200 to 800 kg and packed in Hessian cloth and put proper identification mark and record.
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FINISHED SECTION
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Karanja Industries (Pvt.) Ltd. The Work Flow Model Of The Company: SORTING OF RAW MATERIALS: Responsibility : Q.A. Inspector Purpose
Instructions:
1. This procedure is restricted for white cutting material only. 2. Remove the packing of each bundle of white cutting and keep a side. The packing material shall bee considered as color record and used as raw materials for bottom layer 3. Unwanted materials such as dust, sand , rubber, plastic strips, etc. shall be removed. 4. Unwanted materials shall be collected in a drum and shall be used as a color record. 5. Sorted white cutting materials shall be stacked for further process.
Hydropulper-01 No. Sand trap 01 No. Johnson vibrating screen 01 No. Thickner 01 No. Turbo-separator- 01 No. Dry disc refiner 01 No.
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: To refine the pulp and to add chemicals to obtain the Ph properties. : Hydro pulper 01-No.
Sand trap 01-No. 3-F screen 01-No. Inclined screen 01-No. Tri- disc refiner 01-No.
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: To make the wet paper web. : Shift incharge and Mould operators.
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To dry the wet paper web and cut as per customer size.
Instructions:
1. Heat all the dryers and MG by opening the steam to all dryers and MG . 2. Pass the wet web to pre dryer group manually and adjust the steam by controlling the pressure at each dryer with the help of pressure gauges which are indicative so that the moisture contains of the web leaving pre-dryers should be 40 20%. 3. Pass the sheet to M.G so that the top surface will get glazed along with drying maintaining the moisture content of the sheet leaving the M.G in between 20 2% by controlling the steam at M.G . 4. Pass the sheet to past drying group and dry the sheet so that the moisture content of the final sheet should be 6.0% 1 % . 5. Pass the sheet through calendar to the bottom surface smooth and then feed the sheet at cutter machine to cut according to customer required size and stock it in finishing house with identification label. 6. Reel the paper in pope reel and then rewind it in re-winder as per the orders are in reel form. 33
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TRANSPORTATION :The company doesnt have its own transport vehicles. It hires the vehicles on rental and lease basis. The main transportation is done through road transport and railways.
MACHINES :The company brought machines which were installed in the company from the following companies Parason TDR, Delhi J & K Engineers Pvt., Ltd, Chennai. Machine Industries Pvt. Ltd., Kolkatta Unique Enterprises, Pune
FINISHING CLERK
PACKING SUPERVISOR
STICKING SUPERVISOR
FINISHER
The packing of the kraft, Board is done in finishing house. According to demand of the customer the krat board and pop reels are packed in various sizes with the help of clip, plastic sutali, pp woven, wrappers and the stitched. All the reeling, cutting of pop reel are done by automatic machines. The stitching pasting, weighing are done physically.
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MARKETING DEPARTMENT
Importance of Marketing
Marketing is a social process which individual and groups obtain what they want and what through creating, offering-and freely exchanging products and services of value with others. The essence of marketing is exchange or a transaction intended to satisfy human needs and wants through an exchange process. A demand is a want for which the consumer is prepared to pay a price. A want is anything or a service, the consumers desires or seeks. Wants becomes demand when backed by purchasing power.
A need is anything the consumer fells to keep himself alive and healthy. A transaction consists of value between two parties. A transaction differs from a transfer. A transfer may receive nothing in return. The aim of making is to make sales n order to earn reasonable portable profit for the producers.
Objectives of Marketing
Barker and Anshen say the end of all marketing activities is the satisfaction of human wants through the satisfaction of human wants, profits are rewarded to the business and addition benefit is the inducement of marketing. Now the time has changed and the objective of marketing is more than security profit. The following are the main objectives of modern marketing activities.
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Marketing Mix Marketing mix is a term used to describe the combination of the four inputs which constitute the core of a companys marketing system. They are :1. Product 2. Price 3. Place 4. Promotion
MARKETING POLICY:
In the direction of achieving the companys mission, the marketing team- PIP endeavors for maximization of sales and realization for the company products while meeting the customers requirement to heir all round satisfaction. This department is headed by marketing manager and maintains a wide area of distribution network. The company occupied a large of market in the state as well as in other state namely Maharashtra, Tamil Nadu, Kerala etc. The company supplies it product to its main dealers, customers in various following regions. Anil Paper Board Bangalore. Nikhil Agencies Bangalore. Sushen Paper (P) Ltd. Bangalore. Laxmi Paper mart Bangalore. Deepa Packers, Mangalore Mysore Paper Corporation Secundrabad. 36
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DISTRIBUTION NETWORK:
Under the distribution method the product is sold to the dealers and consumers and consumers on consignment selling method. The advantage of consignment selling is that manufacturer runs no risk in having possession and making sales of the product through the dealers, retailers to finally consumers. Sometimes consumers directly purchase the product from the company also.
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RETAILER
CONSUMER
CONSUMER
CONSUMER
LABORATORY :
There are 3 lab assistants are for each shift the tab assistant has to check the GSM (Gram Square Meter), size, weight, thickness, Ph stiffness, ash content, consistency, BF of every paper product, the square of every paper is cutted down tested in laboratory. If lab assistant checked that the produced paper board is not of the required quality he will reject them and inform the production manger and other required quality paper board will be produced.
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QUALITY DEPARTMENT
Quality assurance division is a customers representative. This department acts as communicating channel between customers and production department. They make steel for automobile industries and also for stimulus tubes. It is also used for transportation of oil and any other fuel.
In quality assurance department, marketing department plays in important role. The orders of the customers will be received by the marketing department, then department. This process is called as Contract Review.
Then the quality assurance department translates the need of the customers to the production department. This department also inspects the cost And rolled products. It checks 39
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As there are two divisions in the company the quality department for each department is different. Quality inspection is carried out for both the incoming raw materials and out going finished goods. The raw materials should be as per the standard size, volume and with chemical composition and metallurgical composition.
QUALITY CONTROL :-
In Karanja Industry, there is a laboratory in the plant to check the quality of paper manufactured and it check the quality in every lot. It sends a report of quality of paper to quality manager, if the manager feels quality of paper dues not meet the customer requirements. Then he sends report of corrective action to be taken production manager, where in the takes proper corrective actions according to the report to meet the customer requirements and satisfaction. The rejected paper due to bad quality is reused in process in hydro pulper machine by making pulp of rejected paper so there no wastage 100% utilization takes place. Inspection of Raw materials Laboratory testing method
AIMS
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FUNCTION; 1. Adding internal/external chemistry to attain specified standard. 2. Testing the manufactured products subjects to any damage or not. 3. To check the raw materials. 4. Identifying customer 5. Indentifying needs. 6. Converting needs into specialization.
QUALITY POLICY
Karanja Industries Pvt. Ltd is committed to achieve total customer satisfaction through adoption of state of art manufacturing and processes with continual improvements. Karanja Industries Pvt. Ltd is also committed to improve the quality of work life of its employees through improved work practices.
QUALITY OBJECTIVES:
Customer Satisfaction: Maximization of Customer Satisfaction by consistent 41
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PURCHASE SECTION
PURCHASE MANAGER
ASST. MANAGER
CLEARK
The purchase department is headed by the purchase manager, who takes the responsibility of purchasing the required qualitative and quantitative raw materials. All purchases are made by the company or all requirements needed by the company will purchase through him only. If some department of the company required some any materials they have send requisition letter informing about the quantity and quality of materials required. The purchase manager after accepting the letter, he purchase and sends them to concerned 42
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The following are prices quotes in purchasing of raw materials White Record White Cutting Color Record Depend upon Market Price
STORES SECTION :It is a one where all the necessary daily-required materials are stored and are issued against requisition slip by concerned department chief. The department is maintaining Bicard MRV. (Material Receipt Voucher ledger books of every product which coming in and going out of department. MISSION MINIMIZE THE COST OF INVENTORY. VISION ATOMIZATION OF CURRENT SYSTEM.
Karanja Industries Pvt. Ltd adopts FIFO [First in First out] method to issue the materials in order to avoid obsolescence of material and company finds this method as most 43
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Futures Growth and Prospects: As the company is committed to produce quality products, it results in attracting more number of customers and to beat the competition. As per the infrastructure is concerned Karanja Industries Pvt. Ltd has a well equipped and sophisticated infrastructure which helps the company to meet the customer demand in time. By looking at the present infrastructure, skilled workforce, technology and emerging demand condition, company is planning to put one step ahead i.e. by diversifying to steel manufacturing industry.
As the demand for the automobiles are increasing the demand for the products of Karanja Industries Pvt. Ltd is also increasing, so Karanja Industries Pvt. Ltd has got a clear and bright future
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SWOT ANALYSIS
The main Strengths, Weaknesses, Opportunities and Threats of the company which have been observed and studied in the organization are as follows:
STRENGTHS: Good cliental base. Technical and experienced manpower. Automated and highly sophisticated machines. ISO 9002 certified company. Government support acting as the backbone for the company. Well planned layout helps for the smooth functioning of work & excellent infrastructure can create better working environment.
WEAKNESSES: Less emphasis on training. Location of plant resulting in high transportation cost. Lack of motivation and creeping inefficiency. Price of goods is comparatively high.
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THREATS: Changing Government Regulations. Pollution Board Norms . New competitors like Gemini Graphics and Veerji Paper Mill are enters in market will dilute in the market share of the company. Increased transportation cost due to loading recreation & increasing fuel prices. Inconsistent power supply.
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FINDINGS: The organization is one of the major industrial setups in Bidar providing employment opportunities. It is spread in 85 acres of land including the lands and the manufacturing unit. More efforts are required in the marketing field and there is no recruitment in the company from last few years It offers employment to more than 506 no of employees at various levels and in different capacities and the mode of employment ranges from permanent contract to daily wages. Dealers are showing increased interest in purchasing the companys board because of high profit margin. Usage of modern technology. It is having centralized control system which is not useful for sudden decisions. Dealers are showing increased interest in purchasing the companys board because of high profit margin. 47
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SUGGESTIONS:Means communication should be made through telephone, internet, and websites and also through fax. Good means of combination system like transport facility should be made easy to deliver the goods in time. Keep the workers well contented and reduce labor turn over rate. Company has to improve its performance by reducing cost so that the company can able to achieve the profit in future. The company can introduce innovative quality practices to cut costs in various process of production and increase competitiveness in the market. Organization could re-design the structure as per the current environment to allow freedom and empower the management for decision making. Skills and motivation level of the employee can enhanced by providing effective training. To conclude company should minimize its overall cost and its operation for the benefit of the company. Effective, charismatic leadership is required who could steer the company towards profitability by controlling the leakage of available resources and overcoming the organizational weakness. 48
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Have to replace the new machine in place of the old machine, as replacing the new machine with the old it costs too high but it can be done as follows: Taking loan from the bank to implant the new machine. Installing new machine with the exchange of the old by deducting the depreciation and paying the remaining amount. Monitoring every month whether the machineries working fine and lubricating whenever required.
CONCLUSION
The company has to overcome the following, The main objective of the in-plant training is to gain knowledge about functions of an organization, its back ground, Nature of business, its working and analysis of various product profile of the organization. Staying in the KARANJA PAPER MILL PVT LTD factory for almost a month was a platform for me to know its business conditions in the initial stage and gradual growth. The study helped me to view the process of producing various products produced in the factory. To know the performance of KARANJA PAPER MILL PVT LTD. Produces good quality white cutting duplex paper board and Kraft paper board. Workers are highly satisfied with wage and salary administration and welfare facilities. To conclude organizational study at KARANJA PAPER MILL PVT LTD. helped me to relate the theoretical knowledge to the practical environment and enlightened me with the knowledge regarding.
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BIBLIOGAPHY
BOOKS:
Title of the Book Marketing Management. Name of the Author Philip Kotler. Title of the Book Financial Management. Name of the Author I. M. Pandey. Title of the Book Financial management Name of the Author Prasanna Chandra Title of the Book Human Resources Management Name of the Author Dr. Aswathappa By Observation & Magazines & Reports.
Website: www.karanjaindustriesltd.com
www.google.com
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