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LETTER OF TRANSMITTAL
December 27th, 2005 Mr. Siddique Khatri College of Business Management Karachi. Dear Mr. Khatri Here is the feasibility report on Lucky Cement Limited you had asked to conduct and submit as a learning requirement for the course, Corporate Finance by December 27th, 2005. We hope it fulfills the requirements laid by the Institute of Business Management. Sincerely, Eisha Quraishi Tariq Hasan Maria Moten ID # 2002-2-7-2307 (add) (add)
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Acknowledgment
T he teachers at CBM have provided us with skills and knowledge that will go a long way as we enter this fast moving era. Thank you Mr. Siddique Khatri, for giving us an opportunity to prepare this report for you, we really hope that it meets your expectations. We would like to extend our gratitude to the wonderful people at Lucky Cement for their time and assistance. Special thanks to the Finance Manager, Mr. Aftab Ahmed at Lucky Cement for providing us with the information required to prepare this report Also, without our team effort, it would not have been possible to make this challenging project into an exciting and learning experience. We appreciate each others contribution to this group assignment. Sincerely, Eisha Quraishi Tariq Hasan Maria Moten ID # 2002-2-7-2307 (add) (add)
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TABLE OF CONTENTS
Executive Summary.....04 Introduction to Lucky Cement...05 Production and Sales..... 07 Plant Information...09 Future Prospects for Lucky Cement......11 Purpose of Our Report...........12
Analysis of Expansion Plan....13 Benefits of Expansion...13 Issues Relating to Expansion........15 Capital Budgeting Tool Application..17 NPV, IRR and Payback Calculations....18 Assumptions Made....19 Conclusion21
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Executive Summary
(Maria has to do the Executive Summary) Baig Spinning Mills Ltd is a listed textile spinning unit on the Karachi Stock Exchange and has been operating since last 32 years. Baig Spinning Mills Ltd yearns to become highly reliable source of supply of yarn by effectively fulfilling the needs of customers through an efficient use of manufacturing facilities and maximizing return to the shareholders with due consideration to their social responsibilities and obligation. The company operates 15,192 spindles and is already engaged in the gas based captive power generation. They have continuous production for 24 hours and even on Sundays they are producing, i.e. they operate continuously through out the year while giving breathing space to the production facilities occasionally for servicing. They switched over to gas based captive power generation due to the inadequate availability of gas supply, non-reliability of grid power supply, poor quality of grid supply, increasing tariff and expansion requirements compelled the company to switch over to gas based captive power generation thus saving a huge amount of money for the company. The per unit cost for KESC is calculated to be Rs 5.15/KWH while that for the gas generator is calculated to be Rs. 2.67/KWH. The difference of Rs. 2.48/KWH is the current savings per unit, however the savings per unit are projected to decrease based on our calculation incorporating the inflationary effect on the input of the gas generator and the decreasing KESC cost per unit., however for our feasibility report purpose we have assumed KESC per unit cost to be constant if not decrease further. Even the minutest of the calculations and assumptions have been taken care of, properly stated and reflected in our calculations. The Capital budgeting tools have been appropriately applied and the calculation is based on projections for 10 years at an opportunity cost of capital of 10% amounting to Rs.18.94m and the IRR is calculated to be 20% while the payback period is
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Mission Statement
The mission that drives us is ongoing and challenging; it is to maximize the value of the Company to Customers, Employees and Shareholders by producing quality products at the least possible cost and to provide our products and services to the market
Vision Statement
To build on the strength of our core business as well as our resources, by investing in areas where we see potential for strong, sustainable growth in earning
ISO CERTIFICATION: Lucky Cements plant is one of the best maintained plants of Pakistan and is managed by qualified and expert cement field specialists. The Company has also got ISO 9001:2000 certifications, for manufacture and sales of cement by UKAS Quality Management, Pakistan National Accreditation Council and Moody International.
QUALITY MANAGEMENT: Lucky Cement always gives major emphasis to manufacture of high quality cement through stringent quality control techniques and computerized control systems using advance state of the art sophisticated equipments like Distributed Control System (DCS), Programmable Logic Controllers (PLCs) and on line X-Ray Analyzers. The Company has got one of the best equipped laboratories, having all facilities for the analysis of raw material, semi furnished product, furnished product and fuel, to ensure the supply of high quality product to market. The quality of Companys cement has been tested and found to be superior in many respects to the specifications mentioned in revised edition of Pakistan Standard PSS 232-1983(R) and British standard BS 12:1978
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PRODUCTS: The following premium brands are available throughout the country:
1. 2. 3. Lucky Gold Brand Lucky Brand Lucky Star Brand
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SUPERIOR STRENGTH: The Compressive Strength is a very important quality factor of Cement. The Portland Cement achieves its maximum strength in 28 days. The Pakistan Standard PSS 2321983(R) & British Standard BS 12 : 1978 provides for 28 days strength of 5,000 Psi and 5,950 Psi respectively for mortar cubes. As compared to this Lucky Cement has a 28 days compressive strength of more than 7,000 Psi to bear heavy loads. OPTIMUM SETTING TIME: Optimal initial & final setting times are ensured by adopting special production parameters using most modern control techniques. SOUNDNESS: By using most modern Kiln feeding system, it is ensured that lime entering into the Kiln should be in such a proportion that it should totally combine with oxides during the burning process. The result is that the free lime content is very low and soundness of Lucky cement is less than 1 mm which is far better than 10 mm prescribed by Pakistan Standard PSS 2321983(R) and / or British Standard BS 12 : 1978. CEMENT EXPORTS: The Lucky Cement has exported 277,268 Tons cement during the financial year ended on 30th June, 2005 with a share of 17.7% in the total exports of Pakistan. This shows a growth of 137% over the exports made by the company during last the preceding financial year. Aggressive marketing and entrepreneurial thinking has made the Company a leading exporter of cement from Pakistan. The Company has already made its strong existence in Afghanistan and in other countries in the Middle East. The Company is striving hard to increase its exports to Middle East, Bangladesh and other neighboring countries.
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Plant Information:
The plant has been set-up in Pezu which is an under developed area. This factor has generated employment opportunities in that area which is further helpful in improving and strengthening the economic situation of the country. The plant is being managed by qualified and expert cement field specialists, with proper technology transfer to junior engineers and workman. Major emphasis is being given to ensure better quality of Cement through stringent quality control and to the training of plant personnel through senior management with proper and well planned training programs, to develop even high level of professionalism and dedication to respective jobs. The 1.26 million tpa plant's major features are listed below :
Control System Process Type Environmental Impact Distributed control system along with Programmable Logic Controllers (PLCs.) Dry process Negligible dust emission limited up to Nm 100 mg /
The Company successfully completed up gradations and modernizations program in early 2001 after more than 2 years of continuous efforts. As a result the production capability of each line was increased to almost 2400 tons of clinker per day as against the original minimum designed capacity of 2000 tons per day. Simultaneous improvement in the production capability of raw mill and cement mill was also made to feed and to grind the increased clinker production capability.
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Power Supply
A 36.72 MW Power plant, Setup in Pezu to supply uninterruptible power to Lucky Cement
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Summary of Projected Capital Outlay for Remaining Line at Karachi & Pezu
1. Existing Site at Pezu Cement Plant 2. New Project at Karachi Cement Plant Power Generation Plant Rs.5.50 billion Rs.1.20 billion Total Rs.3.00 billion
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Gain Market Share With the expansion, Lucky Cement aims to gain a larger share of the local and also possibly the international market. This way it will achieve more sales and increasing profits as compared to its competitors.
Flexibility Along with economies of scale, Lucky cement is also able to benefit from the expansion by being more flexible. It can increase/decrease its production according to sudden changes in demand.
Experience With a lot of past experience in cement production inefficiencies are minimized. Similar equipment, machinery, work procedures and skills will be required. Since Lucky Cement has been in the business for a long time now, it has an edge over other local cement companies.
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Continued
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e) Environmental aspects Lucky cements activities follow all required environmental control regulations. f) Interest charges Lucky Cement has taken loans worth Rs.7.4 billion. Recent loan taken by lucky cement is @ 10% because of IRS- Interest Rate Swap. And at the other end they had taken loans years ago at interest rates as low as 4% which they plan on paying back as soon as income is generated to avoid any additional interest costs. Since Lucky Cement has a high credit rating, it does not want to risk its reputation and credibility by defaulting. g) Tax Charges Lucky Cement pays 15% sales tax and 10% income tax on its investment cost. The Tax charges will be capitalized along with the investment cost.
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Ye ar 1 R s.
Ye ar 2 R s.
Ye ar 3 R s.
Year 4 R s.
Year 5 R s.
Year 6 R s.
Year 7 R s.
Year 8 R s.
Year 9 R s.
Ye ar 10 R s.
R s. 2 ,0 0 0 ,0 0 0 ,0 0 0 6 5 6 ,5 0 0 ,0 0 0 3 ,5 0 0 ,0 0 0 5 0 0 ,0 0 0 ,0 0 0 3 ,1 6 0 ,0 0 0 ,0 0 0
Fi n a n ci a l C o s t: L o a n In s ta l l m e n t 1 In te r e s t ( O n In s ta l l e d 1C o s t)
2 In s u r a n c e Ex p e1n s e
2 0 0 ,0 0 0 ,0 0 0 2 0 0 ,0 0 0 ,0 0 0 2 0 0 ,0 0 0 ,0 0 0 2 0 0 ,0 0 0 ,0 0 0 2 0 0 ,0 0 0 ,0 0 0 2 0 0 ,0 0 0 ,0 0 0 2 0 0 ,0 0 0 ,0 0 0 2 0 0 ,0 0 0 ,0 0 0 2 0 0 ,0 0 0 ,0 0 0 2 0 0 ,0 0 0 ,0 0 0 9 ,9 5 4 ,0 0 0 9 ,9 5 4 ,0 0 0 9 ,9 5 4 ,0 0 0 9 ,9 5 4 ,0 0 0 9 ,9 5 4 ,0 0 0 9 ,9 5 4 ,0 0 0 9 ,9 5 4 ,0 0 0 9 ,9 5 4 ,0 0 0 9 ,9 5 4 ,0 0 0 9 ,9 5 4 ,0 0 0
2 0 ,0 0 0 ,0 0 0 2 0 ,0 0 0 ,0 0 0 2 0 ,0 0 0 ,0 0 0 2 0 ,0 0 0 ,0 0 0 2 0 ,0 0 0 ,0 0 0 2 0 ,0 0 0 ,0 0 0 2 0 ,0 0 0 ,0 0 0 2 0 ,0 0 0 ,0 0 0 2 0 ,0 0 0 ,0 0 0 2 0 ,0 0 0 ,0 0 0
To t a l Ex p e n d i tu r e
3 8 0 ,0 0 0 ,0 0 0 4 3 7 ,0 0 0 ,0 0 0 5 0 2 ,5 5 0 ,0 0 0 5 7 7 ,9 3 2 ,5 0 0 6 6 4 ,6 2 2 ,3 7 5 7 6 4 ,3 1 5 ,7 3 1 8 7 8 ,9 6 3 ,0 9 11 ,0 1 0 ,8 0 7 ,5 515,1 6 2 ,4 2 8 ,6 818,3 3 6 ,7 9 2 ,9 9
3 1 6 ,0 0 0 ,0 0 0 3 1 6 ,0 0 0 ,0 0 0 3 1 6 ,0 0 0 ,0 0 0 3 1 6 ,0 0 0 ,0 0 0 3 1 6 ,0 0 0 ,0 0 0 3 1 6 ,0 0 0 ,0 0 0 3 1 6 ,0 0 0 ,0 0 0 3 1 6 ,0 0 0 ,0 0 0 3 1 6 ,0 0 0 ,0 0 0 3 1 6 ,0 0 0 ,0 0 0
3 N P V @ 8 1%
3 ,4 2 9 ,8 9 2 ,5 9 4 .0 2 26% 5 y r s a pp r o x
IR R P a y ba ck P e ri o d
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3. The Maintenance spares cost is assumed to increase at an annual rate of 5% while the rupee-dollar parity is assumed to be same @ Rs.59 per US $. As the installed plant is new so minimum maintenance cost is taken for the first year. 4. The cost of operation and maintenance labor is assumed to increase at an annual rate of 8% p.a. *(inflation rate taken as base ) 5. The average interest on loan is fixed @ 10% p.a. based on interest rate swap, 6-mth KIBOR is taken as the benchmark. 6. The opportunity Cost of capital for Lucky cement Ltd is identified to be 8%. 7. Depreciation for the plant is calculated on the basis of unit production method and 1,124,000 metric tons is taken as the estimated useful life. 8. The insurance estimate is based on straight line method on the installed cost with no salvage value for a 10 year period. The Insurance estimated is that of a normal fire policy covering damage, malicious damage, explosion, impact damage, aircraft damage and earthquake fire and shock. Working for insurance is shown below:
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Installed Cost = 3,160,000,000 Per year Allocation @ 10% of the Installed Cost Insurance charges are as follows: Fire Premium = 3% A.S.C. 5% Sub Total F.I.F. 1% C.E.D. 3% Net Premium
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Capital Budgeting
The Capital budgeting tools have been appropriately applied to analyze the investment made by Lucky Cement and the calculations are based on the projected of cash flows for 10 years. The Net Present Value (NPV), which amounts to Rs.3429.9 million, is calculated by discounting cash flows at an opportunity cost of 8%. Whereas the Internal Rate of Return (IRR) is calculated to be 26%. Finally, the payback period was also calculated and it amounts to approximately 5 years. Huge NPV positive amount will add value to the shareholders wealth thus achieving the objective of the company while the IRR also seems to be attractive and the payback period of around 5 years is a reasonable tenor, so by all means the companys decision of plant expansion sounds favorable according to our analysis.