Date post: | 04-Mar-2015 |
Category: |
Documents |
Upload: | abeyfrancis |
View: | 244 times |
Download: | 0 times |
Summer Project Report 2008-2009 Organizational study
CHAPTER 1
INTRODUCTION
Binani Zinc Ltd. is a pioneer in the manufacture of high grade
electrolytic zinc in India. Since its inception in the year 1967, Binani Zinc has
paved the way integrating systems for maintaining product quality,
environmental safety, occupational health and social accountability. Binani
Zinc Limited is engaged in the manufacture and sale of zinc metal and its by-
products sulphuric acid & cadmium metal.
Binani Industries Limited ranks within the first 20, amongst the
top 200 large public limited companies in terms of Capital Output Ratio; BIL
has employee strength of around 2000 people.
It was in the turbulent times of 1872, when the ancestors of
Binani, Seth Pragdas & Seth Mathuradas Binani ventured into the trading of
non-ferrous metals. Later on, the son of Seth Mathuradas, Seth Govardhandas, a
man with profound vision, had seen great potential in manufacturing rather than
just trading in non-ferrous metals.
Binani Zinc is the pioneer in the manufacture of high grade
electrolytic zinc in India since 1967. The reigns of this wide spreading business
ere with Late Shri Ghanshyam Binani, the only son of Seth Govardhandas
Binani. His individual expertise and time-honed skills steered the organization
towards many milestones ahead. In the span of 1970’s – 80’s Cominco Binani
Zinc Limited upgraded its technology to be on par with the latest in the world.
It also became the first plant in the country to commence production of special
high-grade electrolytic zinc with 99.995% purity
1 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
Today Binani Zinc being part of Binani Industries Limited is the
second largest producer of Zinc in India. The company enjoys the reputation of
being a leading and most preferred supplier of pure zinc in India. It is located at
a place called Binanipuram in Ernakulum, Kerala. Its corporate office is at
Kolkata and has another office at Mumbai. This strategic location, named as
Binanipuram, has proven ideal as it facilitates the loading and off-loading of
zinc concentrate, provides cost efficient power supply, ease in transportation,
abundant water and easily available resources, inclusive of a literate work force.
The main product produced by Binani Zinc Limited is zinc and its bye products
are sulphuric acid and cadmium, which are used by other industries.
It has the Capacity of:-
Zinc - 38,000 MTPA
Sulphuric Acid - 51,000 MTPA
Cadmium - 65000 kg PA
OBJECTIVES OF STUDY
PRIMARY OBJECTIVE
The main objective of the study is to get an idea about the whole organization
as such and to understand briefly about the nature of the industry
SECONDARY OBJECTIVES
a) To get an organization structure of the company and
to get an idea about the various departments and its functioning.
b) To know how the key business processes are being
carried out in a manufacturing industry.
c) To know about various policies and programmes
2 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study of the company.
REASONS FOR SELECTING BINANI ZINC LIMITED FOR
ORGANIZATIONAL STUDY
Binani Industries Limited has been a pioneer in non-ferrous metal
industry in face. It is the first company to manufacture zinc in India in the
private sector. They also produce Sulphuric Acid and Cadmium as by-products.
The plant has the capacity to produce 38,000 MT per annum. In India, zinc is
manufactured only by two companies- Binani Zinc Limited and Hindustan Zinc
Limited. Hindustan Zinc Limited is the dominant player in Indian market.
Binani Zinc Limited is the only Zinc manufacturing company in Kerala. Over
the years, Binani Zinc limited has undergone many transformations in its
capacity, technology etc. under the leadership of Sri. Ghanshyam Binani, with
the stinted support of qualified and dedicated staff. It is the 1st Indian company
to operate a customized zinc smelter designed for 100% imported zinc
concentrate. It is the 1st Indian company to produce special high grade quality of
zinc with 99.995% of purity, The 1st in the private sector and one of the two
primary manufacturers of zinc in India, The only company to install a converter
heat exchanger system in the acid plant designed by M/s. Lurgi, Germany for
energy conservation. It is among the 1st to be recognized by the Department of
Science and Technology, Government of India for its R&D facility and
laboratories.
The 1st to be recognized by the bureau of Industrial Cost and Prices
as the Best Zinc Plant in the country for the steps taken in energy conservation.
First in India and in Asia, to be certified by BVQI for the four International
accreditations viz., ISO 14001:1996, SA 8000:1997 as well as OHSAS
3 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study18001:1999 for installation and maintenance of Environmental Management
System, Occupational Health and Safety Assessment Series respectively.
SCOPE
The organizational study was intended to get Industrial exposure.
The study intends for a period from 21th May 2009 to 18th June. The study
was mainly conducted to understand the functions of different departments of
the Company. Binani created a name in the world zinc industry, by pioneering
the manufacture of high grade electrolytic zinc in India.
4 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
CHAPTER SCHEME
The report is prepared in five different chapters. The details of each
chapter are as follows:
CHAPTER 1:-The first chapter gives an introduction about the study. It
includes objectives of the study, sources of data collection. This chapter also
provides details about the planning of the study and how it is prepared.
CHAPTER 2:-This chapter gives an overview about Zinc Industry as a whole
and gives Industry Profile. It gives details about the major uses and applications
of Zinc. It gives an overview about Zinc Industry in the world, national and
state scenario. The major players of Zinc Industry in India are also discussed in
this chapter.
CHAPTER 3:-This chapter gives an idea about the history and explains the
company profile of Binani Zinc Ltd. This also gives details about the objectives
of the company, mission and vision etc. This chapter also throws light on the
organization structure of the company.
CHAPTER 4:-This chapter gives the departmental details of Binani Zinc
Limited. The various departments are Human Resource Department, Finance
Department, Materials Department, Marketing Department, Information System
Department, Research & Development department, Projects & Utility services
etc. It gives the functions, structures and procedures of each department in
detail.
CHAPTER 5:-This chapter gives SWOT analysis of the company.
CHAPTER 6:- This chapter gives the findings and suggestions.
5 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational studyCHAPTER 7:- Conclusion of the report.
CHAPTER 2
INDUSTRY PROFILE
WORLD SCENARIO
Zinc is considered to be the fourth most important metal used in the
world following steel, aluminium and copper. This metal is primarily used in
the steel industry for galvanizing process. The other uses include used in
making coins and pennies, used in die-casting in automobile industry, making
battery container parts, used as a substitute to tin and lead pipes, ingredient in
water colors and paints, activator in rubber industry etc. Also because of the
fact that zinc does not corrode due to the non-acidic atmospheric corrosion, it
makes the metal worth to use in for extending the life of building structures and
modes of transport. The metal also comes in good use as a fungicide, herbicide
and rodenticide.
Zinc is available in the atmosphere in large quantities. The various
external sources in which zinc is concentrated in the atmosphere are electric
services, petroleum refining, crude petroleum and natural gas extraction,
manufacturing of fabricated rubber products and metal heating and plumbing
products, production of inorganic chemicals etc. The various indoor sources for
the same contribute to slightly higher zinc content in the atmosphere and
include infiltration of outdoor air; smoking, cooking, etc. Zinc is extracted from
zinc ores mostly sphalerite, zincite and smithsonite and the world mine
production of zinc concentrate sums up to around 10008000 tons annually. The
zinc concentrates are then used to produce the zinc metal and around 10319000
6 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational studymetric tons of metal is produced per year. China is the largest producer country
of zinc in the world in context of both metal and concentrate production.
The world consumption of zinc annually totals up to around 10774000 tons.
ZINC USAGE:
The usage of Zinc can be detailed as below.
Galvanizing - 60%
Alloys - 12%
Chemicals - 12%
Battery - 5%
Brass - 6%
Miscellaneous - balance
Zinc is widely used metal and used in protecting steel, diecasting and also
as chemical compound. While zinc was known to the ancients, its production
with modern technology started in India only in 1966, with the Smelter at
Debari, While the zinc production worldwide was 7.2 million tonne in 1989, the
Indian production capacity of zinc was only 99,000 tonne.
Zinc metal uses are based on a number of properties and these
properties are being exploited for variety of applications in defence and other
essential industries. The principal processes for manufacturing are horizontal
retorts, electrolysis, vertical retorts, electrothermic, overpelt and blast furnace
(Imperial Smelting Process). Out of these, most important processes are
electrothermic and blast furnace manufacturing, covering 93% of the total zinc
production in the world. The electrolytic zinc process consists of dissolving
zinc bearing materials to zinc sulphate solution which is purified to satisfactory
electrolyte and recovered as metallic zinc by electrolysis. The Imperial
7 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational studySmelting process is pyro-metallurgical process for combined production of lead
and zinc. This will include raw material handling plant, smelter and gas
cleaning plant, smelting blast furnace, zinc refinery, lead refinery, and recovery
of high value metals. Zinc concentrates are the raw material for zinc smelter.
Zinc ore consists of sulphate, sulphide mineral with galena, chalcopyrtite and
copper sulphide minerals. Zinc concentrates from zinc-lead ores contain about
59% zinc andd complex ores have 54% zinc. The pollution
control/environmental requirements in terms of water, air, sulfur dioxide
emission, etc., are important.
Secondary zinc production has started in India in the last few years. Secondary
zinc is recycling process and thus adds to the economy. The main sources of
secondary zinc are scraps, drosses and fluxes. The process of electrolyzing is
similar to primary zinc products. A large number of recovery units with
capacity of 1 tone per day to 15 tonne per day have started and they are
importing basic raw material (zinc concentrate) from abroad.
Zinc: mine production
Annual cost (Thousand tones)2005 2006 2007 2008
Europe 1013 1007 1057 1035Africa 258 352 414 376America 3744 3568 3496 3398Asia 3057 3507 3832 4220Oceania 1447 1298 1329 1321World Total 9520 9733 10127 10350
Zinc: metal production
Annual cost (Thousand tones)2005 2006 2007 2008
8 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
Europe 2744 2720 2559 2498Africa 197 260 274 255America 1936 1993 1883 1845Asia 4450 4906 5057 5212Oceania 553 574 457 463World Total 9879 10353 1029 10273
Zinc: metal consumption
Annual cost (Thousand tones)2005 2006 2007 2008
Europe 2780 2837 2683 2755Africa 173 194 204 199America 1958 2126 1904 2035Asia 4664 5245 5572 5781Oceania 267 263 253 273World Total 9841 10666 10614 11043
MAJOR PLAYERS
The major Zinc players in the world market are Canada and China.
Though China was a net exporter of the metal as it is the maximum Zinc
producer, but its domestic consumption demand does not allow the country to
take a lead in the world exports. The major exporter countries of Zinc are
Canada, Australia, Netherlands, Mexico, Norway, Spain, China, Korea,
Finland, France and Japan.
The world export of the zinc metal have been constantly decreasing and
as there is a deficit in the world market now, the imports of the metal have
become more than the export done in the world. The largest zinc market in the
world is the London Metal Exchange that affects the world demand and supply
for zinc significantly. The major countries that import are USA, Germany, Italy,
Singapore, Korea, China and Taiwan, Belgium, Netherlands, France and U.K
9 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
ZINC PRODUCING COUNTRIES
As mentioned above zinc has been produced in the world for quite a
along time and today also the zinc ores are being mined in more than 50
countries of the world. The pattern of zinc mine production in the world is not a
concentrated pattern as there are over 266 mines indulging in the extraction of
zinc but only around 19 mines are able to stretch their production over 100000
tons per annum. 80% of the zinc mines fall under the category of underground
mines, 8% relate to the category of open mines and the remaining are a
combination of both open and close mines.
The total mine production of zinc ore in the world accounts up to around
10008000 metric tons with 64% share held by the underground mines. The
major countries engaged in the zinc mine production are China,Australia,
Canada, Peru, USA, Namibia, Ireland, Sweden.
INDIAN SCENARIO
PRODUCTION OF ZINC IN INDIA
10 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study India was one of the first country that started the process of extracting
and smelting zinc. Though India is not the leading player in the production of
zinc, it is moving in the direction to get self reliant in this context. India has
approximately 4.8% share in the total zinc smelter capacity in Asia Pacific
region. India is producing approximately 6 lakh tons and its consumption is
4.92 tons.
The largest zinc producing company in India is Hindustan Zinc Limited
and its production capacity is 754000 tons and the turnover is 8560 crores. But
now ever since the company got privatized and the Indian industry completely
become in the hands of the private sector. It can be said that the zinc industry in
India, after privatization is leading towards a major expansion programme.
The major zinc mines in India which were under the control of the company
are:-
Rampura agucha mine
Rajpura dariba mine
Zawar mines
The smelting plant in India engaged in the production of zinc metal is:-
Chanderia lead zinc smelter _ Rajastan
Debari zinc smelter _ Rajastan
Vizag zinc smelter _ Andrapradesh
Binani zinc smelter _ Kerala
India was one of the first countries to gain knowledge of (zinc production)
extracting Zinc from Zinc ores and started the production of zinc metal. It
should have been an important player in world zinc market. But this is not the
11 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational studycurrent situation. India’s reputation regarding zinc is not significant as it just
produces a small share of metal in the world’s production and is not able to
satisfy its domestic consumption demand, making it net importer of zinc.
Zinc production in India was in the hands of the government initially. As
all the operations in India relating to the metal was in the hands of a public
sector company-Hindustan Zinc Limited, it was the biggest company in India
which took care of zinc extraction and its smelting process. But in April 2002
this company was privatized in favour of Sterlite group and after that Indian
industry is in the hands of private sector completely.
Zinc has major application in the galvanizing industry and battery sector
together. Zinc products are mainly used by the galvanizing industry (60%),
alloy making (20%), battery sector (15%) and die casting (5%).
INDIAN ZINC MARKET
The Indian zinc industry consists primarily of two players, namely
Hindustan Zinc and Binani Zinc. Hindustan Zinc is an integrated producer
having its own mines and has a market share of more than 60%. Binani Zinc is
a custom smelting producer. All the major zinc ore mines in India viz. Rampura
Agucha, Rajpura Dariba and Zawar mines are located in the state of Rajasthan
and all of these are under the control of Hindustan Zinc.
The zinc production capacity in India is set to register robust growth
after the government allowed privatization of the state owned company
Hindustan Zinc in 2002. The total production capacity stood at around 707,000
tonnes in Financial Year 08. The zinc production has registered a strong growth
in India in the last few years. It stood at around 4% of total zinc production in
the world in 2007. The zinc production increased from 265,000 tonnes in 2004
12 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational studyto 458,000 tonnes in 2007, registering a growth of 20% CAGR.The zinc
consumption has increased from 347,000 tonnes in 2004 to 470,000 in 2007,
backed by demand from infrastructure and industry. Important to add that
galvanizing accounted for around 70% of the total consumption. The demand
for zinc is expected to remain strong in the coming years on account of growth
in the key zinc consuming industries like infrastructure, realty and
manufacturing. Moreover, the growth in automobile and consumer durables
industry would also further aid the increase in consumption of zinc.
STATE SCENARIO
Zinc is a bluish-white lustrous metal. It is normally covered with a white
coating on exposure to the atmosphere. Zinc also exists in many compounds.
Zinc has a role in normal human growth, taste, and sperm development.
In Kerala, the only Zinc smelter is Binani Zinc Ltd. It started on 1967 as
a new step towards to zinc industry. It is a private limited company located 20
KM upstream from Cochin Air Port, 16KM by road from International Air Port,
on the banks of Periyar, in the area of 136 acres at Binanipuram, Ernakulum
District. Binani Industries Ltd, India's only private-sector Zinc producer, will
invest $87 million to upgrade and expand its Zinc smelter at Binanipuram in
Kerala state.
Zinc industry sow its seeds in the gods own country when Binani Zinc
Ltd was established in Kerala. Binani Zinc Ltd is the only zinc smelter plant in
the whole of Kerala. Expanding on an existing capacity is always a lot easier.
The water required for a smelter plant is far more easily met in Kerala rather
than the arid parts of Rajasthan and Gujarat, and, despite the soaring costs of
power in the state, the unit cost is not just comparable, but still remains
competitive in the state.
13 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
Binani zinc Ltd is full- fledged effluent treatment adheres to
environmental protection norms without disturbing the ecological balance. The
State Pollution Control Board has rewarded the company’s environmental
protection and pollution control measures. Highly committed to energy
conservation, Binani is a proud achiever of the ‘energy conservation award’
from the national safety council of India for four consecutive years since 1990.
It is the first zinc smelter to receive ISO 14001 for its environmental
management system form Bureau Veritas Quality International (BVQI) in June
2000.
CHAPTER 3
COMPANY PROFILE
HISTORY
Binani is now consolidating on its enviable track record. It was in the
turbulent times of 1872, when the ancestors of Binani, Seth Pragdas & Seth
Mathurdas Binani ventured into trading of non-ferrous metals. Later on the son
of Seth Mathurdas, Seth Govardhandas, a man with profound vision, saw great
potential in manufacturing rather than just trading in non-ferrous metals. Binani
Metal Works Limited in collaboration with Multicore Solders UK came into
being in 1941. The plant was set up in Howrah, West Bengal to produce non-
ferrous alloys, cad, casting and powders & solder wires.
Binani Metal Works Limited went public for the first time in 1953. In
1962, Binani entered into collaboration with world leaders in the field of non-
ferrous metals, Cominco Metals, Canada to form Cominco Binani Zinc Limited
and became the first producer of primary zinc in India. In 1967 Binani create a
14 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational studyname in the world Zinc industry, by pioneering the manufacture of high grade
electrolytic zinc in India. The reigns of this wide spreading business were with
Late Sree Ghanshyam Binani, the only son of Seth Govardhan Das Binani. His
individual expertise and time-honed skills steered the organization towards
many milestones ahead. In the span of 1970’s – 80’s Cominco Binani Zinc
Limited upgraded its technology to be on par with the latest in the world. It also
became the first plant in the country to commence production of special high-
grade electrolytic zinc with 99.995% purity.
In 1983, a merger between Binani Metal Works Limited & Metal
Distributors UK Limited took place forming Binani Metals Limited. It became
one of the largest trading and intending houses for non-ferrous metals in India.
On 3rd May 1991 Cominco Binani Zinc Limited was rechristened as Binani
Zinc Limited. The company diversified into other prominent industrial
enterprise in 1996, i.e. Binani Glass Fibre at Goa & Binani Cement Limited in
Rajasthan. With such diversification of Binani enterprise it was imperative to
rechristen the company as Binani Industries Limited. It now represents an
amalgamation of new aspirations, new leadership and entrepreneurial skills,
with innovative thinking and indigenous strategies.
In 1998, following the true Binani tradition of growth and excellence, the
mantle of leadership passed on to the sons of Late Sree Ghanshyam Binani, Mr.
Gokul Binani, the Caption of Binani International Operations is the Chairman
and Managing Director of Metal Distributors UK, while Mr. Braj Binani, is the
Chairman and Managing Director of Binani Zinc Limited in India.
In tune with its inherent growth culture the Binani Industries Limited
has undergone a thorough re-structuring process. All the three divisions of
15 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational studyBinani Industries Limited i.e. Zinc, Cement and Glass Fibre have been
gradually hived off as wholly owned subsidiaries.
Binani Cement Limited(Rajasthan) – effective from 1st November
1997
Glass Fibre Limited(Goa) – effective from 1st December
1999
Binani Zinc Limited(India) – effective from 1st April
2001
Binani Zinc is the pioneer in the manufacture of high grade
electrolytic zinc in India since 1967. Today Binani Zinc being part of Binani
Industries Limited is the second largest producer of Zinc in India. The company
enjoys the reputation of being a leading and most preferred supplier of pure zinc
in India. The main product produced by Binani Zinc Limited is zinc and its bye
products are sulphuric acid and cadmium, which are used by other industries.
It is located at a place called Binanipuram in Ernakulum, Kerala. Its
corporate office is at Kolkata and has another office at Mumbai. This strategic
location, named as Binanipuram, has proven ideal as it facilitates the loading
and off-loading of zinc concentrate, provides cost efficient power supply, ease
in transportation, abundant water and easily available resources, inclusive of a
literate work force.
MISSION
16 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
To forge ahead as a world-class organization in the core sector
industry in India and abroad.
To explore all opportunities and to enhance its stakeholders value
through ethical practices.
To relentlessly pursue in the new global movement for a "customer-
driven, quality-oriented, socially-conscious" industrial corporation.
To adopt, adapt, assimilate and integrate the technologies from global
giants, thereby leveraging value - addition through deployment of
technology into products and services.
To adhere to the highest standards in manufacturing, beyond the
stringent parameters of environmental stipulations.
To pursue research and development activities diligently,
consolidating on its track record of innovations and breakthroughs in
manufacturing practices on a state-of-art-technology platform.
To promote human values at the forefront and nurture its people with
a deep rooted sense of employee care, concern and deep-routed
commitment to people; people being considered as assets of high
intrinsic value.
VISION
Binani Zinc has already laid out plans for increasing production capacity
to 65,000MT per annum along with its own 100% captive power plant at an
investment of about Rs.300 crores. The company plans to add a further 1,
17 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study00,000 Mt of Zinc production immediately after its phase of development plans.
The company had already forayed into hydal power projects within the
framework & guidelines of the Govt. of Kerala to tap the power resources
needed for industrial development of the State.
BZL has planned after a lot of deliberation and careful evaluation,
Greenfield facility at Gujarat. The project envisages at 71 m2 fluid bed
roasting gas cleaning and matching capacity sulphuric acid plant, modifications
capacity up gradation in the existing leaching, purification and residue
treatment facilities, a new 3.3m2 cathode area based super jumbo tank house
with an integrated state of art melting and casting facility along with matching
increase in offset and utilities capacities.
MILESTONES
1962: Binani entered into a technical and financial collaboration with Cominco
Limited Canada, to form Cominco Binani Zinc Limited.
1967: The first Indian company to manufacture of high grade electrolytic zinc
at Binanipuram, Kerala.
1970: By leveraging technology and keeping up with a burgeoning market,
Binani Zinc Limited successfully met the steady increase in capacity from 12
kty to 20 kty.
1980: Binani Zinc Limited further upgraded technology at par with the latest in
the world with assistance from M/s. Lurgi, Germany. Binani Zinc Limited,
commenced production of special high grade electrolytic zinc ingots with
99.995% purity.
18 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study1990: Cominco Limited carted off its financial support from its operations in
alignment with their world policy. Cominco Binani Zinc was rechristened as
Binani Zinc Limited on 3rd March 1991.
1995: Binani Zinc entered into collaboration with M/s U.M. Engineering
Limited to adopt its state-of-the-art technology and increased its capacity to 30
kty.
1998: Binani Zinc receives the 'Industrial Safety Award' from the National
Safety Council of India for having the second lowest frequency rate of
accidents recorded in Scheme III.
2000: Binani Zinc received an ISO 14001 and an ISO 9001:2000 Certification
from Bureau Veritas Quality International for their Environment Management
System and Quality Management System respectively. Binani Zinc adopted the
'5s' housekeeping management practice and tagged it with the international
accreditation ISO 14001:1996.
2001: Voluntary commitment to quality was demonstrated by getting the
international accreditation on quality, ISO 9001:2000. Leveraging the people
potential, Binani Zinc became the first company in the manufacturing sector to
go for international.
PRODUCTS
MAIN PRODUCTS
Zinc - High Grade
19 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
Zinc - Special High Grade
BY PRODUCTS
Cadmium
Sulphuric Acid
With leveraging technology and burgeoning market, Binani Zinc have
successfully met the capacity of 10-12 to 14-20 kty and presently produces
30kty of special high grade Zinc along with Sulphuric Acid and Cadmium as
by-products with a production capacity of 51kty.
PRODUCT SPECIFICATION
HIGH GRADE ELECTROLYTIC ZINC
20 M.B.A M.E.S College Marampally
PER CENT
Zinc 99.95 Min
Impurities Limited As Under:
Lead 0.025 Max
Cadmium 0.02 Max
Iron 0.01Max
Tin 0.001Max
Copper 0.002Max
Total Impurities 0.050Max
Summer Project Report 2008-2009 Organizational study
Table 3.1
CADMIUM
SULPHURIC ACID
USES OF ZINC
21 M.B.A M.E.S College Marampally
PER CENT
Total Acidity (as H2SO4) 98 Min
Residue on Ignition 0.2 Max
Iron 0.05 Max
Lead 0.005Max
Arsenic 0.004Max
PER CENT
Cadmium 99.95Min
Zinc 0.01Max
Copper 0.02Max
Lead 0.025Max
Iron 0.002Max
Nickel 0.002Max
Antimony 0.001Max
Arsenic 0.002 Max
Summer Project Report 2008-2009 Organizational study
TRADITIONAL USES OF ZINC
1)Food- fertilizers to overcome Zinc deficiency in soil and improve crop yields;
animal feed supplements to improve health and performance; food supplements
for human health.
2)Shelter- roofing and cladding for industrial, commercial and residential
construction, rain water evacuation, heating, ventilation and air conditioning.
Protecting the durability and integrity of steel infrastructure and steel
infrastructure and steel goods against corrosion-such as highway barriers,
guardrails, transmission towers, bridges.
3)Safety- Protecting vehicle tyres from degradation by UV rays. For hearing
aids, portable computers and mobile phones; to power zero-emission batteries,
electric vehicle such as buses, post vans, delivery carts and wheel chairs; to
power air conditioning units on trucks so that engine idling is unnecessary.
4)Water purification systems- zinc is alloyed with other metals for new
generation water purification system.
5)Satellite-zinc compounds are used to shield the outer surface of satellites and
space vehicle.
6)Varistors-zinc compounds are used in electrical systems for circuit protection
against power surges and lightning strikes.
7)Undersea- zinc cladding is used to protect undersea cables and enable remote
operation of cables in deep water oil wheels.
22 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study Zinc is considered to be the fourth most important metal used
in the world following steel, aluminum and copper. This metal is primarily used
in the steel industry for galvanizing process. The other uses include:
a. Used in making coins and pennies
b. Used in die-casting in automobile industry
c. Making battery container parts
d. Used as a substitute to tin and lead pipes, ingredient in water colors
and paints, activator in rubber industry etc
e. The metal also comes in good use as a fungicide, herbicide and
rodenticide.
f. Used as pigment in paints & varnishes
USES OF SULPHURIC ACID
a. Textiles
b. Fertilizers
c. Chemicals
d. Dyes
USES OF CADMIUM
a. Electroplating
b. Alloy-making
23 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
c. Battery Cells
d. Dyestuffs
TECHNOLOGY
The greatest bulk of Zinc is produced in the world comes from the high
productivity electrolytic process. All high grade and special high grade Zinc
are produced directly from this process. The pyro metallurgical techniques are
used to produce prime western Zinc and gab Zinc as a natural corollary to the
ever increasing availability of electrolytic high grade Zinc London Metal
Exchange has now adopted a special high grade as well as a high grade standard
for trading in Zinc.
HIGHLIGHTS: THE COMPANY HAS MANY FIRSTS TO ITS CREDIT
It is the 1st Indian company to operate a customized zinc smelter
designed for 100% imported zinc concentrate.
The 1st Indian company to produce special high grade quality of zinc
with 99.995% of purity.
The 1st to install high productivity, energy saving super jumbo cell
technology.
The 1st in the private sector and one of the two primary manufacturers
of zinc in India.
24 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
The only company to install a converter heat exchanger system in the
acid plant designed by M/s. Lurgi, Germany for energy conservation.
Among the 1st to be recognized by the Department of Science and
Technology, Government of India for its R&D facility and
laboratories.
The 1st to be recognized by the bureau of Industrial Cost and Prices as
the Best Zinc Plant in the country for the steps taken in energy
conservation.
First in India and in Asia, to be certified by BVQI for the four
International accreditations viz., ISO 14001:1996, SA 8000:1997 as
well as OHSAS 18001:1999 for installation and maintenance of
Environmental Management System, Occupational Health and Safety
Assessment Series respectively.
COMPANY POLICY
[ON QUALITY, ENVIRONMENT, SAFETY, HEALTH AND SOCIAL
ACCOUNTABILITY]
1. The company considers quality of its products and services,
environmental control, safety and health of its employees and social
accountability as the prime management responsibility and will strive for
continual improvement.
2. The company shall comply with social accountability standards, all
existing national and local applicable legislation and all legal and other
requirements pertaining to environment, occupational, health and safety.
25 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
3. The company shall encourage waste minimization and reutilizations as
well as recovery of valuables from waste streams.
4. The company shall continuously strive for energy conservation in all its
operations and processes
5. The company shall endeavor to ensure that the people and the
environment are not put to unacceptable risks by adopting world class
environment friendly operations and processes and by ensuring the use
of relevant personal protective equipment.
6. The company shall impart training to all its employees in creating
awareness to update their knowledge on all aspects of technology and
plant operations quality, environment health safety and social
performance.
7. The company shall interact with its suppliers on a professional and fair
basis and select the basis of quality, timely delivery and cost.
8. The company shall interact with its customers to continuously asses their
needs and expectations and ensure total customer satisfaction by
9. Maintaining consistent quality of its products and services with the
involvement of its employees.
10.The company shall promote transparency and openness in its relationship
with its employees and the community and treat them in fair and
respectful manner.
11.The company shall display the policy in its premises and also in its
brouchers published for the benefit of customers, suppliers, employees
and other interested persons.
26 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
ORGANIZATIONAL CHART OF BINANI ZINC LTD EDAYAR
27 M.B.A M.E.S College Marampally
PRESIDENT
A.V.P (HRD&OHS)
V.P (ENG& PROJECTS
)
SR. V.P (OPERATIONS
& R&D)
V.P (COMMERCIAL)
V.P (FINANCE)
G.M
HR
D
C.M
.OG
.M
AD
MN
GMIS
&M
S
SR
MG
R
DG
M
PR
JG
M
ME
CH
AV
P
EL
EC
TR
ICA
L
GM
SR
VC
E DG
M
PR
D
R&D
GM
MT
RL
GM
MK
NG
Summer Project Report 2008-2009 Organizational study
DIFFERENT PHASES OF DEVELOPMENT SINCE INCEPTION
1990
The commitment of Binani Zinc towards environmental protection and its
pollution control efforts are rewarded by the 'Kerala State Pollution Control
Board' in 1990.
1991
28 M.B.A M.E.S College Marampally
SR
MG
R
SA
FE
TY
D.G
.M
I.R&A
SR
MA
NA
GE
RS
R
MA
NA
GE
RS
R
MA
NA
GE
R
DY
MG
RD
Y
MG
R
PL
AN
T
MA
NA
GE
R
SR
MAN
AG
ER
DG
M
INS
TR
DY
MG
R
DY
.
MG
R
DY
.
MG
RM
GR
DY
MG
RD
Y
MG
R
DY
MG
RD
Y
MG
R
DY
MG
R
SR
MA
NA
GE
R
MG
R
PL
AN
NIN
GS
R
MA
NA
GE
R
DY
MG
R
SR
MA
NA
GE
R
DY
MG
R
DY
MGR
WORKERS
Summer Project Report 2008-2009 Organizational study Binani Zinc awarded with a 'Certificate of Merit' by the 'Kerala State
Pollution Control Board' for achieving the Second place among large scale
industries, in making substantial and sustained efforts in Pollution Control.
1993
Binani Zinc awarded with a Certificate of Merit by the 'Kerala State
Pollution Control Board' for achieving the first place among large scale
industries in making substantial and sustained efforts in Pollution Control.
Binani Zinc is the proud recipient of the 'Energy Conversation Award' for five
consecutive years from 1993 onwards.
1994
Binani Zinc has been awarded the second 'Jawaharlal Nehru Memorial
National Award' by International Greenland Society for excellence in Indian
Industries in Energy Conservation.
1995
Binani Zinc has been awarded the 'Certificate of Merit' by Govt. of Kerala
in appreciation of its best effort in the field of Energy Conservation.
1996
Binani Zinc awarded the 'Certificate of Merit' by Govt. of Kerala in
appreciation of its best effort in the field of Energy Conservation.
1998
29 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study Binani Zinc receives the 'Industrial Safety Award' from the National
Safety Council of India for having the second lowest frequency rate of
accidents recorded in Scheme III. The systematic and scientific approach
throughout operations has earned Binani's Glass Fibre plant, an ISO 9002
accreditation from Bureau Veritas Quality International, (BVQI), and
UK.Binani Zinc receives the 'Industry Excellence Award' instituted by The
Institution of Engineers, India, Cochin Local Chapter, the first prize for
excellence in Energy Conservation, and R&D efforts.
2000
Binani Zinc receives the prestigious international accreditions, 'ISO
14001' and 'ISO 9001:2000' Certification from Bureau Veritas Quality
International for its Environment Management System and Quality
Management System.
2001
BVQI also certified Binani Zinc to be qualified for Social Accountability
Management system, SA 8000:1997 as well as OHSAS 18001:1999.
Occupational Health and Safety Assessment Series.
CONTRIBUTIONS TOWARDS THE SOCIETY
"It is in giving that you receive"
1. Ghanshyam Binani Foundation: From the basic needs of the poorest to
educational and medical facilities, Binani has always been at the forefront in
lending a helping hand to serve humanity. The legacy of caring for the
30 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational studyunderprivileged has been passed on from one generation to another at Binani.
To continue on this tradition, the Binani charitable body was established by the
Founder Chairman Late Seth Govardhandas Binani along with his son, former
Chairman Late Ghanshyam Binani at Kolkata in 1958. The Ghanshyam Binani
Foundation periodically conducts free eye camps, gives donations and provides
scholarships for the needy. The Ghanshyam Binani Foundation has always
come forward at the time of crisis and natural calamities. Concern for the
welfare of the employees is a top priority of Binani, amply reflected with the
creation of townships for employees and their families. A diagnostic health
center, equipped with latest equipments and medical facilities, has been recently
set up for the employees and the residents around Binanipuram.
2.Binani Bravery Award:- Binani Trust has instituted a Bravery Award for
children in the age group of 5 - 16 years who have risked their own lives to save
another.
3.Binani zinc multipurpose cooperative society
4.Binanipuram high school
5.Ghanshyam binani community hall
6.Day care for the elderly
PROBLEMS FACED BY THE COMPANY
Reduction in Import Duty -The future expansion plans of Binani Zinc, is
likely to be affected by the reduction in import duty on non-ferrous metals such
as zinc in the recent Union Budget. The import duty had been brought down
31 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational studyfrom 35 per cent to 25 per cent, and at the same time, no relief had been given
on the import duties for the basic raw material such as zinc concentrate.
Power Tariff Hikes - The steep electricity tariff revision by the Kerala
Government is making the operations of Binani Zinc increasing unviable
3) Shortage of Raw Material: The shortage of raw material is a major problem
faced by the company. The company had to be shut down for more than
hundred days because of this problem and it resulted in poor performance of the
company
FUTURE PLANS
The company is proceeding with the setting up of 2 Hydel power plants,
with an installed capacity of 10MW, for which necessary approvals have
been given by the State Government.
In view of the adverse market for coal and consequent impact on cost of
generation, the company has deferred plan for setting up a thermal power
plant.
The company is also carrying out a series of debottlenecking exercises to
maximize capacity utilization.
CHAPTER-4
VARIOUS DEPARTMENTS IN BINANI ZINC LTD
1) Human Resource Development and Occupational Health and Safety
Department
Human Resource and Deveopment32
M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
Safety
Security
Occupational Health Centre
2)Commercial Department
Marketing Department
Material Department
1. Purchase Department
2. Stores Department
3)Research and Development
4)Information System Department
5)Finance Department
6)Projects and Technical Services Department
7)Production Department
Roaster and acid plant
Leaching and Purification plant
Electrolytic plant
Melting plant
8)Engineering Department
Electrical Department
Instrumentation Department
Mechanical/ Maintenance Department
Utility Department
DEPARTMENTAL DETAILS
1. HUMAN RESOURCE DEVELOPMENT & OCCUPATIONAL HEALTH & SAFETY DEPARTMENT
33 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study VICE PRESIDENT
(HRD, OH&S)
GENERAL MANAGER GENERAL MANAGER CHIEFMEDICAL
(ADMINISTRATIONS) (HRD) OFFICER
MANAGER MANAGER
(INDUSTRIAL RELATIONS) (SAFETY)
DEPUTY MANAGER
WELFARE OFFICER PERSONNEL OFFICER
NON MANAGERS AND WORKERS
HUMAN RESOURCE DEVELOPMENT DEPARTMENT
FUNCTIONS
Recruitment and selection
Induction
34 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
Training and development
Public relations
Industrial relations
Performance Appraisal
Leave Administration
Separation of employees
Punishment procedure
Grievance procedure
Wages and salary administration
Provident fund
ESI Scheme
Gratuity
Welfare activities
Medical facilities
Educational facilities
Assistance to distribution
Promotions
1.SELECTION AND RECRUITMENT
The department where there is a vacancy will sent a Staff
Requisition to the HR Department containing the job requirements. A fixed
time will be allotted for the receipt of application. The application received will
35 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational studybe scrutinized and shortlisted. Hence the final interview and medical check up
will be carried out and it will be shortlisted. In case of vacancies the first
preference will be for lateral transfer and then for promotion.
The first scrutiny and short listing will be done by HRD. But the
final scrutiny and fixing of interview date will be done with the consent of the
General Manager of the department. The final appointing authority will be the
President and the interview is rest to him. Then the offer letter will be sent for
the medical exam.
2.INDUCTION
Induction will help in familiarizing with the working environment. The training
period for the managerial staff is 1 year and that for workmen is 2 years. The
probation period is 6 months.
3.TRAINING AND DEVELOPMENT
Manufacturing of zinc has undergone revolutionary changes both
conceptually and technologically. In the view of high technology employed in
the manufacture of zinc the company is giving various training and
development programs for its employees.
OBJECTIVE
“To continuously develop competence and skill of its employees”
TRAINING PROCEDURE
Training needs of employees – knowledge, skill, attitudinal and
behavioral traits are assessed every year.
36 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
Gap analysis of employees is made in each department facilitated by
HRD Department. Resource persons in the company and external are
identified and training calendar is prepared for the year.
Methodologies adopted are lectures, discussions, interactive sessions,
group work, case studies etc.
Training effectiveness are assessed and evaluated at the end of each in
house programme by using the feedback form (PM 16).
Binani Zinc is an organization following 3 TIER SYSTEM. Either a
centrally organized training will be provided or specific programs conducted by
resource persons from outside will be organized. This may include Individual
Employee Contact Programme, which is conducted for identifying the strengths
and weaknesses in the employees and also to understand their perception about
the management.
Also Knowledge and Skill Upgradation Program is conducted for non-
managerial staff for occupying the higher position in the management category
in terms of knowledge, skill and behavior. Cross Functional Exposure Program
is a training program intended for management staff for career development.
Also Learning Center Initiatives are taken in which one among a group will
take a session for the group. This is done in order to create an informal learning
atmosphere.
4.PUBLIC RELATIONS
37 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study Planned and sustained effort is taken to establish and maintain
goodwill and mutual understanding between an organization and its public. It
includes the relation with the employees, community nearby and government.
The programs like Deepawali celebrations , Founder’s day celebrations (May
3rd) is informed to the employees and the family members. Also it plays a
major role in internship of new employees, helping them to fit into the
organization. As part of public relations, whenever mock drills are conducted
the near by communities are informed about it, so that they do not get panic at
the siren given at the mock drill. The financial assistance is provided for
religious and social institutions. Also the medical camps being conducted are
informed to the public.
But the company does not give much priority to the media
relations, and responds only to the media publications made about it. The public
relations office is concerned with the publication of Binani home journal and
also with the subscription of other dailies, magazines and journals. All
advertisements about the company in magazines, the financial assistance given
to various institutions, the letters to the government, the company sponsorship
offered by the company, goodwill letters, thank you letters, clarification letters,
etc are forwarded through the PRO.
5.INDUSTRIAL RELATIONS
There exists cordial relationship between the trade unions and
the management and hence the industrial relations is very smooth. There exists
three unions in Binani Zinc Ltd. namely
Cominco Binani Zinc Employees Union
Cominco Binani Zinc Employees Association
Cominco Binani Zinc Employees Organization
38 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study Each of these trade unions has secured 20 % and more in the referendum
conducted.
6.PERFORMANCE APPRAISAL
For the trainees and probationaries , there is a monthly evaluation
of performance. In case of confirmed employees, the evaluation is on an yearly
basis. There is no performance appraisal for the workmen.
7.LEAVE ADMINISTRATION
For workmen, the leave administration is as per the long term
settlement ie., casual leaves shall be granted to permanent workmen at the rate
of 10 days in a calendar year. Also privilege leaves shall be granted. Sick leave
shall be granted to those who are not
covered at the ESI scheme at the rate of 7 days with pay in a calendar year.
Medical certificate should be provided for more than 2 days of sick leave.
Compensatory off should
be granted within the same month or within 2 months immediately following
the month in which the office work. For management staff, there are 11 casual
leaves and 30 privilege leaves. Also there is leave application book for each
employees.
8.SEPARATION OF EMPLOYEES
The separation of employees can be through resignation or
retirement. In case of resignation the person has to give one month notice (for
GM’s and above 3 months notice). In case of retirement character certificate,
clearance certificate, service certificate, etc are issued. All the benefits are given
on the retirement day itself.
39 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study9.PUNISHMENT PROCEDURE
For workmen, the whole procedure is as per the standing order.
Before taking action, the concerned union members is always unlimited. The
management staff, especially in case of theft, it is direct termination, if the
crime is proved.
10.GRIEVANCE PROCEDURE
Most of the grievances are settled in the department itself. The unions will
nominate representative in departments and forward the list to the management.
The grievances reported will be sent to the department head in
writing in prescribed Grievance form.
If there is no reply or if the reply is not satisfactory within 48
hours, then the employee can submit a copy to the concerned
functional manager.
If there is no response within another 48 hours, then the complaint
could be forwarded to the Personnel Department.
In case of lack of response even after 72 hours, the complaint shall
be forwarded to the President.
After waiting for 2 more weeks the complaint could be forwarded
to the State Labour Department.
11.WAGES AND SALARY
The wages and salary is determined based on the attendance record
provided by the time office. The time office keeps the punching of the
workmen. By the starting of each month, a shift schedule is prepared and
programmed. Any change in the shift has to be reported to the time office. At
the end of each month, the time office gives record of leaves, attendance, over
time, off days or holiday work and depending on this the wages are computed.
40 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational studyThe pay slip will contain all the details of allowances, deductions and total pay
of employees. The over time rate is twice in plant and for managerial staff it is
one and a half times. The wages and salary are given on or before 5 th of every
month. Also Binani Zinc’s time office is the Kerala’s first computerized time
office.
12.PROVIDENT FUND
Binani Zinc Ltd is an exempted organization and looks after the
provident fund administration by itself. An account for provident fund is in the
bank and after the expenses the balance is invested as per the ruling of the
Ministry of Labours. To be eligible for provident fund benefits, one day’s work
is enough. Also there is provision for voluntary provident fund. But there is a
limit on the amount that can be surrendered.
13.ESI SCHEME
Only very few employees at BZ are under the ESI scheme. But for
contract workers, it is made compulsory for ESI scheme on Life Insurance
Scheme.
14.GRATUITY
Gratuity is a benefit that is given to the employees at the time of
retirement. If a person complete service for more than 5 years, he is eligible for
this.
15.WELFARE ACTIVITIES
The welfare measures adopted by BZL can be classified into
statutory and non-statutory measures.
41 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study Statutory measures includes canteen providing subsidized food, rest room with
various facilities, 24 hours working first aid unit, etc.
Non-statutory measures includes uniform/foot wear, one umbrella per year,
recreational facilities, Founders day, Deepawali celebrations, etc.
16.MEDICAL FACILITIES
The following are the medical facilities provided by BZL:
i. Construction of hospital building at Binanipuram.
ii. Health campaign for public.
iii. Awareness programmes.
iv. ESI dispensary at Binanipuram.
17.EDUCATIONAL FACILITIES
i. Lower primary school in Binanipuram.
ii. Class room furniture for other neighbouring school.
iii. Binani Library of UC College Alwaye.
18.ASSISTANCE TO DISTRIBUTION
i. Rent free accommodation for Binanipuram police
Station and Post Office.
ii. Branch of UBI at Binanipuram.
iii. Traffic island, Bus shelter and Sodium vapour lamps at
nearby tri-junctions.
iv. Binani hall of kaula management association .
42 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
19. PROMOTIONS
MANAGERIAL STAFF:
Promotion will be at the sole discretion of management
Depending upon the promotions/vacancies promotion will be given
anytime during the year.
The concerned department head and concerned MC’s
recommendation has to be forwarded to HRD Department.
NON MANAGERIAL STAFF:
For the purpose of promotion workmen will be considered under 3
groups.
1. Production/operations
All production plants, water treatment, effluent treatment, R&D
and auxiliary boiler.
2. Services
Maintenance, captive power plant, crane/fork lift operators,
drivers, compressor operators.
3. Office/administration
Administration, security, occupational health, technicians,
sweepers.
The promotion will be effected on a 3-tire system as follows:
If suitable candidates are available within the group the
promotion will be given to worker in the same group.
If suitable workmen are not available in one-group suitable
workmen from any other group will be granted the promotion.
If no suitable candidates are available in any of the 3 groups
recruitments from outside will be made.
43 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
DIFFERENT TRAINING SCHEMES IN BINANIDIFFERENT TRAINING SCHEMES IN BINANI
1. IN HOUSE TRAINING:
After assessing training needs, external faculties are identified and
brought into the company premises and conduct classes for target groups.
2. EXTERNAL TRAINING:
Employees are nominated on selective basis for external training
programmes, seminars and conferences. Concerned MC will recommend the
employees. Top executives are sent to advanced management programs
organized by institutions like XLRI, ASCI etc.
3. CROSS FUNCTIONAL EXPOSURE PROGRMME:
This program is developed for young professionals in the managerial
staff. Duration is 3 to 4 months. Employees in the main stream will be trained
in the supporting functions and employees in the supporting stream will be
trained in the main stream.
4. SKILL DEVELOPMENT PROGRAMMES:
This programme is mainly for the non managerial staff in the
company. Trainees are identified by the MC classes are addressed by internal as
well as external trainers. Classes are conducted on every Monday, Wednesday
and Friday between 2 pm to 6 pm.
44 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
SAFETY
Safety is the keyboard at Binani Zinc Ltd. The use of Personal
Protective Equipment (PPE) is compulsory for each and every employee. If an
employee is found without PPE a Red Card is issued. As the first step he is not
given the prize on safety day. If he is again spotted without PPE, there is a cut
in his salary.
There is an OHS committee set up to occupational health, safety
and housekeeping practices. The members are executive Vice President,
Manager Safety, three members representing the three recognized unions,
senior engineers (environment) and
The chief Managerial Officer. The committee carries out regular inspections
and make necessary recommendations.
In order to promote safety house keeping the Japanese 5S concept is
practiced in all departments at BZ
1. Sirie - Segregation, Sorting
2. Seiton - Arrangement
3. Seiso - Cleaning
4. Seiketsu - Standardization, maintenance, control
5. Shitsuke - Training, Discipline, continous improvement
There is a safety management system to ensure safety and healthy
environment. Periodical Monitoring of dust, noise, illumination, etc is carried
out. There is a safety suggestion scheme in which employees can make
suggestion and the best suggestion is given award. There is a safety and
housekeeping notice board to display notices and messages regarding it.
There is a safety mock drills carried out twice a year. Competition are
held as a part of Safety Day Celebrations(March 4th) , Fire Safety audit and 45
M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
electrical safety. Audit are conducted by external agencies and their decisions
are implemented. The company is giving safety training on a regular basis and
it has an Onside Emergency Plan detailing the responsibilities of various
functionaries in case of an accident.
OCCUPATIONAL HEALTH CENTRE
Clean environment, safety practices and good health are the
major ingredients of Binani Zinc vision. To achieve good health of all its
employees the company has set up an occupational health center in the name of
Ganashyam’s ‘Binani Health Center’ . The Centre emphasizes on the
preventive aspects and its main objective are protecting workers, health,
promoting physical, mental and social well being of workers and minimizing
the consequences of occupational hazards, accidents and diseases. The centre
has the most sophisticated instruments with facility for audio testing, vision
testing, ESU, checking of lungs and also a biochemistry and haematology lab.
A doctor is available from 8:30 am to 5:00 pm. The first aid units functions for
24 hours and for all 7 days in a week. There is one ambulance to evacuate
people in case of serious injuries.
The primary function of the center is providing total health cure to all its
employees from the time of recruitment. Each employees has to undergo
thorough medical check up right at the time of recruitments and from then he
has to undergo annual medical clean up every year. The center maintains a
personal file for each employees free of cost. All the facilities and services of
the center are accessible to their families for a normal fees. The community
people can make use of center on Tuesdays and Wednesdays.
46 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
The center also organized health check ups, diabetics detection camp,
eye camps, etc. Training programs on first aid is given regularly to employees.
The center also focuses on health counseling, use of personal protective
equipments, occupational hygiene, etc.
SECURITY The security function is concerned with the security of personnel
as well as property. The security looks into the arrivals and departure of
employees, their punchings , control of shift buses , allotment of out pass,
visitors pass, etc. Punching is permitted within 30 minutes, permission is to be
sought from the concerned department. If the punching system fails the security
personnel note the timing and hand it over to the time office.
The siren system is also included in security function. Normally
sirens are given at the beginning and end of the shift hours. During emergency
wailing alarm is given. Other security functions include checking of workmen
of departure, attending incoming calls and transferring them.
At most care is taken during transport of product and each
vehicle for transport of Zinc, Cadmium and H2SO4 is thoroughly checked for
damage and leakage. The license of driver, documents of the vehicle and the
load carried is checked. The vehicle essentially must contain a first aid box. The
security office maintains files, registers and documents carrying information
about personnel, about material, pass challans, monthly report about fire
fighting equipments, interdepartmental sports and games etc. The security also
collects information in the area of industrial relation, employee welfare, etc that
may assist the management in taking decision.47
M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
2. COMMERCIAL DEPARTMENT
The commercial department handles activities related to materials
handling and marketing of products. It is major functional area of the company
where most vital transactions are taking place. The commercial department can
be divided into mainly two parts. They are Marketing and Materials
departments. Materials department consist of stores and purchase department.
COMMERCIAL DEPARTMENT
MARKETING MATERIALS
STORES PURCHASE
48 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
STRUCTURE OF COMMERCIAL DEPARTMENT
VICE PRESIDENT (COMMERCIAL)
GENERAL MANAGER ASST.GENERAL MANAGER
(MARKETING) (MATERIALS)
DEPUTY MANAGER Sr. MANAGER Sr.MANAGER
(MARKETING) (MARKETING) (MATERIALS)
OFFICER PURCHASE STORES
(MARKETING)
Sr.OFFICER Sr.OFFICER
(PURCHASE) (STORES)
PURCHASE STAFF STORES STAFF
49 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
PURCHASE DEPARTMENT
VICE PRESIDENT (COMMERCIAL)
ASST.GENERAL MANAGER
(MATERIALS)
SR. MANAGER
(MATERIALS)
PURCHASE
SR.OFFICER
(PURCHASE)
PURCHASE STAFF
WORKMEN
50 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
FUNCTIONS OF PURCHASE SECTION
Procurement against purchase order
Emergency collections
Bills settlement
Vendor development
Vendor rating
Contracts
PURCHASE PROCEDURE
i. PURCHASE REQUISITION
Procurement shall be effected against authorized /approved
purchase order through online integrated system. The PR is processed
online .The PR initial entry is made by the intending department through the
system. The entered PR is to undergo 1st level authorization by concerned
manager and 2nd level authorization by concerned DGM and a 3rd level
authorization by the concerned MC committee member. The PR are then
converted to intents in the stores and processed through the system by purchase
department.
ii. ENQUIRY
After the PR is converted to intents at stores, enquiry processed online in
the prescribed format, is issued to active vendors by purchase department.
Where such lists are not available in the vendor master, enquiries are sent to
vendors recommended by the user department or newly developed vendors.51
M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
Enquiry form contains following information
Material description
Quantity
General terms and conditions
Statement on QMS/OHSAS/SA compliance of the vendor.
iii. COMPARATIVE STATEMENT/PROPOSAL
On receipt of quotation, comparative statement shall be prepared and
sent to user departments. Comparative statement is prepared through the system
and normally contains the following information
Indent no. And date
Enquiry no. And date
Vendors name
Materials description
Price basis
Delivery schedule
Payment terms
Total value for approval
iv. APPROVAL FOR PURCHASE
No purchase shall be effected without prior approval.
Purchase/contract approval shall be made as under.
DGM < = 10,00052
M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
MC MEMBER - 10,000 - 50,000
VICE PRESIDENT - 50,000-100,000
PRESIDENT > 100,000
v. PURCHASE ORDER
Purchase order shall be issued on evaluation of comparative
statement and approval of purchase by concerned personnel
P.O shall be issued only after getting appropriate approvals and
will be signed by the DGM (materials).
Average internal lead-time shall be 15 days for routine items.
External lead time shall comprise of transit time and delivery
lead time of the vendor
VENDOR EVALUATION
The following are considered in evaluating a vendor
VRC
Product catalogue /specification
Technical suitability of the product
Credentials of the vendor
Capacity, turn over, previous orders executed
Third party report
General financial and performance evaluation.
VENDOR RATING
53 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study In Binani zinc vendor rating is applicable only for purchase budget
items with a yearly purchase value above 4 lakhs. And rating is done on a
yearly basis.
Vendor rating is done for the following
Checking consistency of the vendor
Comparison of vendors
Selection of appropriate vendors
Good relationship with the vendor
VENDOR RATING PARAMETERS
Right Time Delivery
Conformance Of Product Specification
Quantity
Quality Mangement System
54 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
STORES DEPARTMENT
VICE PRESIDENT
(COMMERCIAL)
ASST.GENERAL MANAGER
(MATERIALS)
SR. MANAGER
(MATERIALS)
STORES
SR.OFFICER
(STORES)
STORES STAFF
WORKMEN
The stores department in the Binani zinc is guided by the
principle “Must have optimum inventory of what we need”. This means that the
company should have sufficient inventory to meet the needs whenever it arises.
The stores department mainly deals with consumables and spares. The raw
55 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational studymaterials and finished goods are dealt with separately at the production
department. The raw materials are imported and minimum stock is maintained.
And in case of finished gods one day’s production is kept as the stock.
INVENTORY MANAGEMENT SYSTEM
To eliminate rare and non-moving items binani zinc has adopted a systematic
approach for managing their inventory.
STAGE I
Stage I deals with the classification of inventory their categorization,
policy making for each category etc. the following are steps involved.
Identify appropriate parameters for classification
like SDE, XYZ, Insurance spares, general purpose
spares etc
Develop decision rules for each category
Meaningful analysis to check whether company is
holding what it need
Disposal of obsolete and surplus items
STAGE II
The second stage deals with the creation of central information pool for
managing inventory. The steps involved are:
Data acquisition to create central information pool
can easily be done in a networked environment
Dynamic cataloguing ensures traceability of all
design or specification charges.
56 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study STAGE III
This stage depicts the parties for replacement of inventory, their purchase
etc.
Policy for initial provisioning.
Regulation of future purchases.
Emergency purchase to be avoided totally.
FUNCTIONS OF STORES SECTION
1. RECEIPT AND INSPECTION OF ITEMS
The goods are received at the main gate .the security staff at the main
gate physically verify the quantity by comparing it with P.O. after receiving the
goods and after verifying the quantity and quality of material an inspection
document is prepared at the stores and sent to concerned user department. The
user department conducts inspection and results will be passed on to stores.
This information will be incorporated in final document namely G.R generated
at the stores. GR is sent to the purchase department for payment.
2. STORAGE AND PRESERVATION
Materials are mainly stored in racks and bins. Each rack is coded in
order to identify the items. For instance the equipment required by the roaster
plant are kept in one rack and rack is named R. items are stored in each shelf of
that rack. Each shelf is numbered as 1, 2, 3 etc, the storekeeper identifies items
by the rack symbol. Items of common use are kept together. Chemicals are
stored in separate room which requires particular range of temperature.
Instruments are kept in separate dust proof room.
3. ISSUE OF MATERIALS
57 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study After the introduction of ERP system at binani recording and
documentation of materials are done online. Once the user department
recognizes the need for materials it places an authorized requisition online. The
storekeeper identifies the material at store after comparing the material code in
the system with that in the rack. The material is issued to the user department
and necessary updating will be automatically done by the system. FIFO method
is followed in the issue of materials.
4. STOCK TAKING
Binani zinc follows an up to date stock taking system. Stock taking
will starts at 3:00 pm every day. The staff in the stores department verifies the
stock and reports it to the officer in charge. In case the quantity of stock in
stock does not tally with that in the records, causes for the same will be found
out and necessary steps for rectification will be taken after reporting to the
higher authorities.
STORES PROCEDURE
Receipt of Materials
-
58 M.B.A M.E.S College Marampally
Automation indent for items
that reach the recorded level
Issue of material on production of MR
-Verification of stores-Generation of SIR
-Inspection of items-Accepted quality-Identified by tags-Store in respective location-Costing of SIR
Summer Project Report 2008-2009 Organizational study
MARKETING DEPARTMENT
This department also comes under the commercial department.
This department handles marketing of BZL products and by-products. Also
deals with customer care. Binani Zinc Limited is an industrial firm. It has got
regular customers to buy the products. And also, there are only two major
producers in India- Hindustan Zinc Limited and Binani Zinc Limited. So the
Marketing Department in this organization does not have much to do with
advertising, but sales.
Zinc is the main product and the annual production is now 32,500MT.
The by-products are sulphuric acid and cadmium, which are produced annually
at a rate of 47,000MT and 70MT respectively.
Binani Zinc Limited sells zinc all over India except north. It is because
Hindustan Zinc Limited dominates in north. The customers of Binani Zinc are
mainly from Kerala, Tamilnadu and Pondicherry. Cadmium is sold all over
India. The customers for cadmium are mainly from North India. And, the
customers for sulphuric acid are mainly from Tamilnadu.
STRUCTURE OF MARKETING DEPARTMENT
VICE PRESIDENT (COMMERCIAL)
GENERAL MANAGER
(MARKETING)
59 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
DEPUTY MANAGER Sr. MANAGER
(MARKETING) (MARKETING)
OFFICER
(MARKETING)
FUNCTIONS OF MARKETING SECTION
Finalization of Sales policy formulation
Finalization of new/continuation of current selling agency
agreements for zinc and cadmium.
Dispatch of zinc and cadmium.
Dispatch of sulphuric acid.
Interaction of customers.
Transportation contract
SALES PROMOTION:
Promotion of the products does not take place through media or any
other way. Customers of the firm are huge companies. These prospective
customers act as the sale promoters of the company. These companies share
their experience of using the products of Binani zinc with other companies.
There is only one competitor for the company .due to these reasons no
additional cost for sales promotion is to be incurred by the company.
60 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational studySALES:
Sale of cadmium, zinc and sulphuric acid is done directly by the
company. The sale is done directly from the plant and also from the various
depots situated in Mumbai, Chennai etc. Sale of zinc and cadmium is
determined directly on the basis of level of production. Sale of sulphuric acid is
fixed in advance and only a specific number of customers can be supplied. Sale
is also carried out through sales agents.
MARKETING PLAN
It is taken care of during the formulation of sales policy and long
term contract booking for whole financial year. Marketing budget forms the
major financial resource planning for each year, which is carried out at the
beginning of the each financial year.
PRICING OF BINANI ZINC PRODUCTS
ZINC AND CADMIUM
Price is based on import/local prices
Fluctuations in the import prices.
Prizes are set in line with HZL prices.
Price of zinc concentrate.
SULPHURIC ACID
Acid supply and demand
Pricing depends on sterlite/sulphur prices
MARKET INFLUENCING FACTORS
Level of stocks with London Metal exchange.
Fluctuation in worldwide demand of zinc.61
M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
Growth rate of zinc producing countries.
Funds in zinc sector
CUSTOMERS
ZINC
Everady Industries Limited
Souther Metals And Alloys Limited
Phonix Indstries
Meta Dust
Ganga Jamuna Limited
SULPHURIC ACID
Hindustan News Print Limited
Reliance Dye Chemicals Limited
Narmada Chemicals Limited
CADMIUM
Anil Metal Company
Southern Metals
S.K.Chemicals Ltd
COMPETITORS
Hindustan Zinc Ltd is the only competitor of BZL. Hindustan Zinc Ltd.
was created from the erstwhile Metal Corporation of India (MCI) on 10th
January 1966 as a Public Sector Undertaking. Its registered office is situated at
Udaipur. In April 2002, Sterlite acquired a 46% interest in HZL from the
Government of India and the open market, and it became a part of the Sterlite
group. Since then HZL has been growing from strength to strength.HZL
produces Zinc, Lead and by-products viz. Sulphuric Acid and Silver. HZL
62 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational studyachieved an all-time high production output of 283,698 tonnes Zinc and a
record production of 889,007 tonnes of Zinc concentrate during 2005-06.
3. RESEARCH & DEVELOPMENT DEPARTMENT
The backbone of any manufacturing organization is its Research and
Development department. All major research is done at the R&D. when
concentrate reaches the company R&D department takes samples and check the
content of zinc in raw materials. R&D department has all the mini type of
automatic advanced machinery. They do the process initially and identify the
purity of the zinc. R&D has three sections. They are:
Development section
Assay section
Environmental section
FUNCTIONS
DEVELOPMENT SECTION
The activities of the development section are as follows:
Zinc concentrate evaluation
Voltage measurement and anode correction in cell house
Acid to concentrate measurement
63 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
Taking up of process/product development studies
Preparation of control charts for critical operating parameters and
analytical values
ASSAY SECTION
The activities of the assay section are as follows: Bulk chemical sampling and analysis
Analysis of samples at different stages of process
Analysis of products Viz zinc ingots, cadmium, sulphuric acid
Analysis of samples for recovery calculation and extraction efficiency
calculation
Preparation and issue of various reagents required by control
laboratories in plants
ENVIRONMENTAL SECTION
The activities of the environmental section are:
Monitoring of effluents emissions
Sending statutory reports
Monitoring of hazardous waste quantity, storage and disposal
Monitoring of various activities in the plant for the control of
pollution
Maintenance and improvement of environmental management system.
STRUCTURE OF RESEARCH AND DEVELOPMENT
VICE PRESIDENT
64 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
SENIOR MANAGER ADVISOR
MANAGER
OFFICER OFFICER ENGINEER R & D ENVIRONMENT R & D
BENEFITS OF R&D DEPARTMENT
Treatment of zinc bearing secondary materials had improved capacity
utilization.
Value addition and waste minimization.
Improvement in anode life.
Improvement in process efficiency.
Over all extraction of zinc has been considerably improved and purity of
zinc ingots is considerably maintained.
65 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
4. INFORMATION & MANAGEMENT SYSTEM DEPARTMENT
This is the service department of the company. It works on Oracle
platform-Oracle developer 2000. The company has 85 PCs connected to main
server- 1 BM. Operating system for the server is Windows2000, and for the
other systems Windows XP, 98, 2000 etc. Separate Enterprise Resource
Planning (ERP) pack for each department is maintained. The department was
formed in 1982 with a single PC and data entry machine. The ERP model was
established in the year 2001. Up gradation happens every 5 year.
A mini E R P system operates Binani Zinc Limited. It does
not use a standard ERP system. The company uses an integrated online system
called CKN.all the functions in the company are carried through this system.
The company is following a punch card system and employees have to punch
their cards while entering into the company and going out of the company.
Managerial staff has to mark their attendance by login into the system. The
leave application is also processed through online system. Various operations of
the stores department like preparing purchase requisition, purchase order,
66 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational studyinspection note etc are done with the ERP system. ERP was made by an
outside company in Kadavanthra. There is Annual Maintenance Contract for
all systems. All functions are computerized for example leave applications, all
functions of HR, Finance etc.
STRUCTURE OF INFORMATION SYSTEM DEPARTMENT
GENERAL MANAGER
(MANAGEMENT SYSTEMS)
SENIOR MANAGER (INFORMATION AND SYSTEMS)
DEPUTY MANAGER DEPUTY MANAGER DEPUTY MANAGER (INFORMATION (INFORMATION (INFORMATION SYSTEMS) SYSTEMS) SYSTEMS)
FUNCTIONS OF THE DEPARTMENT
67 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
a. IT plan formulation
b. Finalization of AMC
c. Development /modifications of software
d. Provide MIS reports wherever necessary
e. Installs programs in various departments.
f. Different slots for net serving
5. FINANCE DEPARTMENT
Finance is regarded as the life blood of any business. The finance
department maintains or keeps data regarding all financial transactions that are
taking place in an organization. The finance function is under pressure to
enhance its value contribution to the company, deliver information and
maintain effective controls in line with ever changing governance needs.
STRUCTURE OF FINANCE DEPARTMENT
MANAGER
(FINANCE)
DEPUTY MANGER DEPUTY MANGER
68 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
OFFICER OFFICER
NON-SUPERVISORY OFFICER
CASHIER
FUNCTIONS
a. Monthly accounting statements
b. Sales accounting, budgets etc are prepared.
c. Department wise capital expenditure is prepared.
d. Raw material accounting: - Raw materials are imported from various
places come in ship to the port. The material is unloaded using barges to
a space that is rented by the company for temporary storage of material.
e. HRD Package: - The main purpose is to take care of the salary payment
to the employees. It makes use of a payroll package in association with
the HRD.
69 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
f. Corporate office set up:-It takes care of the cash and bank operations and
with the statutory remittance like sales tax, Income tax, ESI, PF etc
6. PROJECTS AND TECHNICAL SERVICES DEPARTMENT
VICE PRESIDENT
GENERAL MANAGER
SENIOR MANAGER/MANAGER/DEPUTY MANAGER
SENIOR ENGINEER/ENGINEERS
ASSISTANT
70 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
Projects and technical Services Department is the department which leads to
the technical development of the company. Introduction and execution of long
term projects come under this department. Major repairs of the plants and other
departments, green field project and expansion of the company are dealt by this
department. The new project of the BZL is Waelz Plant, which will produce
zinc from zinc concentrate by vapourising.
LAST YEARS PROJECTS
JAROFIX PLANT- It was 10 crore project and has capacity of 100 tonnes per
day. It has purchased technology from Canada.
WAELZ PLANT – Till 1982 residue contained 18% zinc. It recovers the zinc
from the residue. It is a 5 crore project and has capacity of 100 tonnes per day.
ONGOING PROJECTS
ZINC DUST PLANT – To develop fine Zinc dust. It currently has a Zinc Dust
Plant but the quality of existing plant is less. The cost of it is around 1.75
crores.
71 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
FUTURE PROJECTS
Sewage Treatment Plant
ETP underflow filteration systems
Heat exchangers for acid wash section
New technology to produce zinc dust of superior quality
Modification in the neutral leach stream line
7. PRODUCTION DEPARTMENT
STRUCTURE OF PRODUCTION DEPARTMENT
DEPUTY GENERAL
MANAGER
FLM (MANAGER, DEPUTY MANAGER, SHIFT IN CHARGE)
72 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study CHIEF OPERATOR
SENIOR OPERATOR
OPERATOR
GENERAL WORKMEN
GENERAL WORKMEN (TRAINEE)
There are 4 mangers in the production department. Zinc is produced by
hydro metallurgical route, which includes the following plants.
Roaster and acid plant
Leaching and purification
Electrolytic plant
Melting plant
ROASTER PLANT
MANAGER
SHIFT IN CHARGE
CHIEF OPERATOR
OPERATOR
73 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study BOILER OPERATOR
WORKMEN
Zinc is present as zinc sulphate in zinc concentrate. Zinc concentrate
is roasted in a Lurgi fluidized bed roaster in the presence of air .In roaster zinc
sulphide is converted to calcine and sulphur di oxide. The roasting process is
exothermic. The roaster reaction takes place at 900-950 degree.
Calcine and hot laden gases are the roaster products. Calcine comes out
as furnace overflow and it is cooled in a roto cooler, powdered in a ball mill and
pneumatically conveyed to storage sitos. The hot dust laden gas passes through
a series of equipments for gas cleaning. The gas cleaning equipments are:
Waste heat boiler
Cyclone
Hot gas precipitator
Star cooler
Wet gas precipitator
The coal, cleaned gas goes to acid plant where sulphur di oxide is converted to
sulpur tri oxide. And it is absorbed in absorbing acid to produce sulphuric acid.
LEACHING PLANT
MANAGER
SHIFT IN CHARGE
CHIEF OPERATOR
74 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
SENIOR OPERATOR
JUNIOR OPERATOR
GENERAL WORKMEN
The aim of leaching is to dissolve maximum of zinc and valuable elements
such as cadmium fro calcine obtained from roaster. The zinc in calcine is under
easily soluble oxide form. Leaching is carried at neutral condition ie return
sulphuic acid coming from cell house
and calcine are mixed in such a way that system never goes to acidic condition.
During this process of neutral leaching hydrolysable impurities get hydrolyzed
and removed. Iron present as ferrous get oxidized with air. After leaching the
slurry goes to a thickener where the sulphuric acid solution is separated from
the residue. Impurities like insoluble sulphates and hydrolyzed impurities are
removed through under flow of thickener and over flow is sulphuric acid
solution with soluble impurities. The impure sulphuric acid solution goes to
purification section.
PURIFICATION
In purification elements like copper ,cadmium ,cobalt, nickel etc which
are more electro positive than zinc are displaced from the solution by the
addition of zinc dust. There are two stages of purification.
Cold purification: this is carried at 55-60 degree by using zinc dust by a process
called cold purification cake leach. Cadmium is replaced at this stage.
75 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational studyHot purification: Filtrate after cold purification pass through a heat exchanger to
heat up to 75 degree in hot purification. Fine zinc dust is added to sponge out
nickel and cobalt. Hot purification cake is leached at controlled activity to
recover excess zinc dust present and it is filtered. The over flow of clarifier,
pure sulphuric acid solution is sent to cell house for electrolysis.
ELECTROLYTIC PLANT (CELL HOUSE)
The electrolytic plant involves the cell house. Here the
purified zinc is separated as sheets by the electrolysis process. The faraday’s
Laws of electrolysis is being followed in this plant. The main process of
electrolysis is to produce special high grade zinc from the zinc sulphate solution
received from the purification section.
Electrolyte : Pure Zinc Sulphate
Anode : Lead
Cathode : Aluminium
There are 32 cells in cell house. Each cell contains 84 cathodes and 85 anodes.
Cell feed is cooled in a cooling tower and sent to cells where DC current is
applied from a pair of silicon rectifiers. Individual cell voltage is about 3.3V
and current density is 450 A/m2. Zinc deposited cathodes are transported to
shipping machine using cell crane. Deposits on each side of the cathode are
stripped of using automatic stripping machine. The deposition time of the zinc
is about 40 hours.
At the end the zinc will be deposited at the cathode and
the manganese dioxide will be deposited at the anode. The cell house consumes
about 4 lakh units of electricity per day. This amount constitutes of about three
fourth of total power consumption of the company. Also certain reagents are
76 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational studyadded into the electrolyte in order to arrest the acid fumes formed out of the
reaction
MELTING PLANT
MANAGER
SHIFT IN CHARGE
SENIOR OPERATOR
OPERATOR
FORK LIFT OPERATOR
GENERAL WORKMAN
GENERAL WORKMAN (TRAINEE)
Melting Plant is the final step in the extraction process.
And the final product is divided into 99.99% high grade zinc and 99.995%
special high grade zinc ingots are obtained. Cathode zinc is melted in an
induction furnace of 30 MT holding capacity and 8 MT/Hr melting capacity.
Molten zinc is pumped from furnace to cast moulds where approximately 25Kg
zinc slabs are casted and stacked with the help of stacking machine
77 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
The performance of the company was adversely affected due to the non
availability of raw material. The non availability of zinc concentrate led to the
shutdown of factory for 131 days. This led to low capacity utilization of 59 %
in the production.
With effect from 31st march 2006 the production capacity of zinc has
been increased to 38000mt and production capacity of Sulphuric acid has been
increased to 53063 mt and the production capacity of cadmium has been
increased to 80287 kg.
PRODUCTION FLOW DIAGRAM
Concentrate (ZnS)
H2SO4 (98%)
78 M.B.A M.E.S College Marampally
Calcine
Fluidized Bed Roaster
DCDA Acid Plant
Summer Project Report 2008-2009 Organizational study
Residue
SolutionCake
Solution
Residue for disposal/sales Purified ZnSO4 Solution
99.99% pure 99.95%pure Zinc Ingots Cadmium
8. ENGINEERING DEPARTMENT
The engineering department of the company includes
instrumentation, electrical and maintenance.
79 M.B.A M.E.S College Marampally
Leaching Opportun
Cold Purification Cu and Cd
Hot Purification Co and Ni
Cell House
Residue Treatment
Cu-Cd Re-leaching
Co-Ni Re-leaching
Cadmium Section
Melting Complex
Summer Project Report 2008-2009 Organizational studyELECTRICAL DEPARTMENT
STRUCTURE OF ELECTRICAL DEPARTMENT
ADVISOR
SENIOR MANAGER
DEPUTY MANAGER
ENGINEERS/OFFICERS
CHARGEMEN
ELECTRICIAN
GENERAL WORKMEN
PROBATIONARIES
GENERAL WORKMEN (TRAINEES) FUNCTIONS OF ELECTRICAL DEPARTMENT
The main function of Electrical department is the overall controlling and
maintenance of the electrical problem of the company and up keep of electrical
system/subsystems in the company including preventive, shutdown and
opportunity maintenance. Other functions are:- 80
M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
a. Take up development and modification jobs
b. Liaison with Electrical Inspectorate for statutory inspections
c. Co-ordination with KSEB for electrical power availability
d. Implement energy conservation activities
e. Carry out periodic calibration of selected measuring and relaying
equipment.
f. Inventory management and spares planning
g. Budget planning and monitoring
As the company is very crucial to have continuous flow of current, there are
three sources of electrical energy:
KSEB Edayar: There is a 110 KV substation at Edayar. There are 2
feeders there.
The 110 KV current received at the company is step down to different
voltages as per requirement.
Captive Power Plant: There are two diesel generators available each
producing 5MW and 5.3MW respectively. This plant uses furnace oil for
its functioning.
81 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
Turbo generator: The turbo generator available in the company
produces .5MW of electricity. The turbo generator uses the steam
produced at various stages during the processes.
OBJECTIVES
a)To manage electrical energy effectively by creating energy forecasts.
b)To maximize the utilization of assets.
c)To maintain the safety devices for protecting men and material.
d)To analyze costs, performance and technical factors.
FACTORS AFFECTING DECISIONS:
a)Imposed power cuts by KSEB
b)Government and Board orders
c)Electricity tariffs and concessions
Three types ofMaintenance functions are carried out; Running maintenance,
Annual maintenance, and Breakdown maintenance.
INSTRUMENTATION DEPARTMENT
Instrumentation department are concerned with the repairs and
maintenance of all instruments and accessories in the company. Their main
objective includes automation of skimming operation in Melting Plant, keeping
the productive asset in working condition for effective utilization of assets and
maintains safety devices and also analyzes cost, performance and technical
factors. Any false information in these items will cause high expenditure. So the
workers must be careful. The crew of this department is 14.
82 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study STRUCTURE OF INSTRUMENTATION DEPARTMENT
GENERAL MANAGER
DEPUTY GENERAL MANAGER
MANAGERS
DEPUTY MANAGER
OFFICER
INSTRUMENT MECHANIC
GENERAL WORKMEN
PROBATIONARY INSTRUMENT MECHANIC
GENERAL WORKMEN (TRAINEE)
MAINTENANCE DEPARTMENT
83 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study The total crew of this department is 39. The maintenance
department is highly critical in ensuring the smooth and continuous operations
of the production process. It plays a supportive role to the production
department and in turn is supported by the purchase and stores department. The
maintenance department in BZL covers the following three functional areas:
Mechanical maintenance and Utility
Electrical maintenance
Instrumentation
The purpose of this department is to define, document and communicate
the roles, responsibilities and authority of persons who verify, manage and
perform activities.
STRUCTURE OF MAINTENANCE DEPARTMENT
84 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study GENERAL MANAGER
SENIOR MANAGERS
MANAGERS
DEPUTY MANAGERS
MECHANIC (GRADE 1, 2, 3)
PROBATIONARY MECHANIC
GENERAL WORKMEN
GENERAL WORKMEN (TRAINEE)
UTILITY DEPARTMENT
The main purpose of Utility department supply all the necessary materials
needed for the smooth working of the organization. Optimization of all
necessary materials is carried out.
Main plants in the company for this purpose are:-
1)Captive Power Plant – To generate power.
They go for this when there is power failure from the board or when the
power cost of K.S.E.B goes high.
85 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
2) Water Treatment Plant
Process water - It process water from periyar river for the production
process.
Boiler Water – It has the capacity of 550 meter cube per day.
Demineralise water
Cooling water – To cool equipments
Cooling towers cool and recycle water for further use. Cooling
chemical is added to prevent choking inside the pipe.
3) Compressor
- Service air
- Automated air
- Instrument
Two types of compressor
-Lubricating compressor –use refrigerated drier
-Non Lubricating compressor –use clean air drier
4) Effluent Treating Plant
- capacity of 450 meter cube per day
CHAPTER 5
86 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
SWOT ANALYSIS OF BINANI ZINC LIMITED
STRENGTH
As BZL is the only one Zinc producing company in kerala. Its position is so
high in the business history of Kerala.
It is the first Indian company having four international certification i.e;
ISO 9000
ISO 14001
SA 8000
OHSAS 18000 and follows 5s housekeeping practice.
The company is committed to environment protection and the Pollution
control board has rewarded its pollution control efforts. It got excellance
award for its pollution control efforts in 2009 from state pollution
control
board, among the large scale industries.
It is the first Indian company to produce special high grade Zinc. BZL
has proved its efficiency in its productivity by acquiring 38000MT zinc
per annum during the year only with 355 employees. The company is
blessed by hard working and efficient employees. Here the labour
turnover is very low.
The company has a very cordial relationship with the employees union
and there was no strike after 1996.
WEAKNESS87
M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
The main weakness of BZL is the absence of mines.
Another weakness of BZL is that its maximum production capacity is
only 38000MT. It is nothing when compared to its competitor HZL
High dependence on imported zinc concentrate. Due to unavailability of
zinc concentrate company was forced to close down for 131 days in
2006.
Under utilization of capacity. Only 59 % and 88 % of total capacity was
utilized the past years.
OPPURTUNITIES
The demand projections for the coming years indicate a higher potential
growth pattern for zinc consumption. Demand for zinc in India is
expected to grow at 10-12% in the coming years.
The demand for recycled zinc is increasing and the company can explore
the secondary zinc market.
Company is going for vertical integration. The company is planning to
set up three captive mines project. They are Basantgarh mines in
Rajasthan, RBG Minerals Industries Limited, Ambaji mines.
THREATS
88 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational studyThe main threats or risks of BZL occurs from the external factors. The major
external factor that can have a significance bearing on the company’s
performance are
Fluctuation in zinc prices at London Market Exchange(LME)
Enhanced metal supply in market
Low treatment charges
Competition from secondary zinc manufactures
Import duty reduction of zinc metal to 7.5%.
Shortage in the availability of raw material especially zinc concentrate
CHAPTER 6
89 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
FINDINGS AND SUGGESTIONS
FINDINGS
1) BZL follows an open door policy.
2) Internet and intercom facility makes access to information easier.
3) Each and every function is carried out in a systematic manner.
4) House keeping is practiced in each and every department.
5) The company is committed to environmental protection, pollution
contol efforts,etc
6) BZL maintains a balance between business profits and social responsibility.
SUGGESTIONS
The following are the suggestions to make the Binani Zinc Ltd perform in
better ways:
1) As the BZL has only one competitor in India, it has to take certain steps
which will help to catch maximum market share.
2) The BZL has to draw a comprehensive plan to initigate the perceived threats.
3) As the prices are expected to remain volatile, the BZL must be more
conscious in undertaking hedging activities as a protection against wide
fluctuation in zinc prices.
4)Always make sure that the required concentrate is available .Also there
should not be any wastage of money due to non-productive inventory.
90 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
CHAPTER 7
CONCLUSION
Binani Zinc was the first to set up a primary zinc smelter in India.
They are the first to produce special grades of zinc of purity 99.99% and
99.995%. And now a singular achievement is that it is the first company in
India to obtain four international certifications and demonstrated its abiding
commitment to be among the best in dealing with social, environmental,
quality, occupational health and safety matters. So we can say that BZL became
an inevitable part of Indian business history.
91 M.B.A M.E.S College Marampally
Summer Project Report 2008-2009 Organizational study
BIBLIOGRAPHY
1. www.binaniindustries.com
2. www.binanizinc.net
3. www.zincworld.com
4. Company personnel manual
5. Records of different departments
92 M.B.A M.E.S College Marampally