1

A Report on Organizational Study at

TRAVANCORE CEMENTS LTD,
NATTAKOM, KOTTAYAM
Submitted by
RUPESH JOY
Reg No. 42254
2012-2014
Under the guidance of
Ms. NAYANA S
I n partial fulfillment for the award of the degree
Of
MASTER OF BUSINESS ADMINISTRATION
Submitted to M.G University, Kottayam

Department of Management Studies
Adi Shankara Institute of Engineering and Technology, Kalady
(An ISO 9001: 2008 Certified Institution)
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DEPARTMENT OF MANAGEMENT STUDIES
ADI SHANKARA INSTITUTE OF ENGINEERING AND
TECHNOLOGY
(An ISO 9001: 2008 Certified Institution)


CERTIFICATE

This is to certify that the report entitled Organization Study is a bona fide record of
the work done by Rupesh Joy during the second Semester at Travancore Cements Ltd.,
Nattakom, Kottayam i n part i al ful fi l l ment of t he requi rement s for t he award of
t he Degree of Mast er of Busi ness Admi ni st rat i on of Mahat ma Gandhi
Uni versi t y.











Dr. S.G Iyer
Principal
Prof. Govinda Bhatt. S
Head Of the Department
Ms. Nayana. S
Faculty Guide
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DECLARATION

I, Rupesh Joy, hereby declare that the project work, An Organizational study at
TRAVANCORE CEMENTS LTD, NATTAKOM, KOTTAYAM submitted in partial fulfillment
of the award of Master Of Business Administration, Mahatma Gandhi University, Kottayam
has been carried out by me under the guidance and supervision of Ms. Nayana.S, Faculty
Member of Department of Management Studies, Adi Shankara Institute of Engineering &
Technology, Kalady.

The empirical findings in this report are based on the data collected by myself and I
also declare that the work is original and has not submitted earlier to the university and other
institution.


Place: Kalady Rupesh Joy
Date:
4


ACKNOWLEDGEMENT

The study will not be complete without acknowledging my sincere gratitude to all
persons who have helped me in the preparation of this dissertation.

I would like to thank the management and staff of different departments of
Travancore Cements Limited, Nattakom, Kottayam for their valuable help to me in
completing the organization study.

I extend my sincere thanks to Mr. Joseph Dost, Personnel manager T.C.L Ltd. for
his guidance in this organization study.

I owe a deep gratitude to our Principal Dr. S. G. Iyer and our beloved Head of the
Department, Prof. Govinda Bhat .S for permitting me to take up this study.

I am enormously indebted to my guide Ms. Nayana.S for her valuable guidance,
continuous encouragement and suggestions through the completion of the project.

My family members and friends helped me and I would like to record my special
thanks to them. I also take this opportunity to thank the Almighty God who enabled me to
successfully complete this study.



Rupesh Joy





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INTRODUCTION

Organization study is an exercise for the students who are undergoing M.B.A. program. The
objective of the study is to make the student familiar to the current industrial scenario. It
provides the student with the first hand idea on the general working of the organization. The
student gets an environment where he can actualize all the knowledge he has acquired in his
curriculum. The exercise is an opportunity for the student to understand the organizational
structure, the major departments, flow of information and various other functions in an
organization.
Organization is the backbone of the management. Organizational study is the study of how the
structure of the organization is designed to integrate people with the organization and to have
effective interface with the environment for the accomplishment of organizational goals. Or we
can say that it is a macro analysis of the organization. The proper care of the organization the
higher, middle and lower level of administration is important for any management to run the
business smoothly.
The organization selected for purpose of the study was Travancore Cements Ltd. It is a
Kerala Government undertaking company. The study is mainly based on details collected from
each department. Each and every activities of the company is studied carefully with the data
available. The data is available from various sources like past records of the organization, direct
interaction with concerned persons or by personally visiting each department. The study helps
in obtaining practical experience of the operations in an organization.












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OBJECTIVES OF THE STUDY
The organizational study was done at Travancore Cements Ltd., Kottayam was very much
helpful to achieve the following objectives.
To understand in detail about the overall working of the organization.
To study about different departments and their functioning such as Production,
To study the organizational structure of the company.

SCOPE OF THE STUDY
The study covers overall functioning of Travancore Cements Ltd. (TCL). There is a large
scope for organizational study in TCL as the company has 18 numbers of departments. Study
is mainly based upon the functions carried out by these departments. The organization
structure and working conditions in TCL definitely helped me to understand how a big
organization is functioning. Moreover its a Government of Kerala undertaking, which helped
me to understand how government is managing the company.















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INDUSTRY PROFILE
HISTORY OF THE INDUSTRY
Cement is one of the core industries which plays a vital role in the growth and
expansion of a nation. It is basically a mixture of compounds, consisting mainly of silicates
and aluminates of calcium, formed out of calcium oxide, silica, aluminium oxide and iron
oxide. The demand for cement depends primarily on the pace of activities in the business,
financial, real estate and infrastructure sectors of the economy. Cement is considered
preferred building material and is used worldwide for all construction works such as housing
and industrial construction, as well as for creation of infrastructures like ports, roads, power
plants, etc. Indian cement industry is globally competitive because the industry has witnessed
healthy trends such as cost control and continuous technology up gradation.
The word cement derived from "caementum" in Latin meaning hewn stone chips and
then started to be used in the meaning of binder. The date of the first reinforced concrete
building is 1852 but yet the use of binding agents in the construction of buildings dates back
to very old times. The first material used as binding agent is lime. Although there are no
precise findings, it is possible to say that the binding property of lime was discovered in the
early period of human history; in 2000s B.C. Examples of the use of lime as a construction
material have been encountered in different regions of the Ancient Egypt, Cyprus, Crete and
Mesopotamia. The Ancient Greeks and Romans used lime as a hydraulic binder. Architect
Vitruvius (70-25 B.C.), in his 10-volume book "On Architecture", mentions the hydraulic
properties of pozzolana and lime and even gives a mixing ratio that can be used in the
buildings to be constructed by rivers and seas.
Throughout the history, many different binding agents symbolizing the civilization of
that period were used in the Egyptian Pyramids and the Great Wall of China and in the
castles built at different times. Later on, nearly 2000 years ago, the Romans mixed hydrated
lime with volcanic ashes and afterwards with dusts obtained from fired brick and thus started
to use a hydraulic binder having properties similar to those of todays cement. The first
cement production plant in the world was founded in 1848 in England. The first German
Cement Standard was created in 1860. And, the establishment of the American Concrete
Institute (ACI) and the creation of the first American Regulations coincide with 1913.

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CEMENT INDUSTRY IN INDIA

The cement industry presents one of the most energy-intensive sectors within the Indian
Economy and is therefore of particular interest in the context of both local and global
Environmental discussions. Increases in productivity through the adoption of more Efficient
and cleaner technologies in the manufacturing sector will be effective in merging Economic,
environmental and social development objectives. A historical examination of Productivity
growth in Indias industries embedded into a broader analysis of structural Composition and
policy changes will help identify potential future development strategies that lead towards a
more sustainable development path.
Issues of productivity growth and patterns of substitution in the cement sector as
well assign other energy-intensive industries in India have been discussed from various
perspectives. Historical estimates vary from indicating an improvement to a decline in the
sectors productivity. The variation depends mainly on the time period considered, the source
of data, the type of indices and econometric specifications used for reporting productivity
growth. Regarding patterns of substitution most analyses focus on interfuelsubstitution
possibilities in the context of rising energy demand. Not much research has been conducted
on patterns of substitution among the primary and secondary input factors: Capital, labor,
energy and materials. However, analyzing the use and substitution possibilities of these
factors as well as identifying the main drivers of productivity growth among these and other
factors is of special importance for understanding technological and overall development of
an industry.
A scenario analysis concludes the report in highlighting the energy efficiency and
productivity improvements that could be achieved by employing more efficient technologies.
The origin of Indian cement industry can be traced back to 1914 when the first unit was setup
at Porbandar with a capacity of 1000 tonnes. Today the cement industry comprises of 125
large cement plants with an installed capacity of 148.28 million tones and more than 300 mini
cement plants with an estimated capacity of 11.10 million tonnes per annum.

The financial performance of the cement industry has also recorded impressive
growth. The growth of the Indian Cement companies has also attracted global companies.
Top global companies such as Lafarge of France, Holcim of Switzerland, Italcementi of Italy
and Heidelberg Cements of Germany have entered in cement production in India. Their
investment in the Indian cement sector is also giving a boost to the Indian economy. There
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are about 11 types of cement produced in India. They are Clinker Cement, Ordinary Portland
Cement, Portland Blast Furnace Slag Cement, Portland Pozzolana Cement, Rapid Hardening
Portland Cement, Oil Well Cement, White Cement, Sulphate Resisting Portland Cement etc.

Cement is a key infrastructure industry. The performance of the industry and prices of
cement are monitored regularly. The constraints faced by the industry are reviewed in the
Infrastructure Coordination Committee meetings held in the Cabinet Secretariat under the
Chairmanship of Secretary (Coordination). Its performance is also reviewed by the Cabinet
Committee on Infrastructure

CHINA

"For the past 18 years, China consistently has produced more cement than any other country
in the world. (However,) China's cement export peaked in 1994 with 11 million tonnes
shipped out and has been in steady decline ever since. Only 5.18 million tonnes were
exported out of China in 2002. Offered at $34 a ton, Chinese cement is pricing itself out of
the market as Thailand is asking as little as $20 for the same quality."
In 2006 it was estimated that China manufactured 1.235 billion tonnes of cement, which was
44% of the world total cement production. "Demand for cement in China is expected to
advance 5.4% annually and exceed 1 billion tonnes in 2008, driven by slowing but healthy
growth in construction expenditures. Cement consumed in China will amount to 44% of
global demand, and China will remain the world's largest national consumer of cement by a
large margin."

SIZE OF THE INDUSTRY

The global industry is worth about 180 billion dollars. Its total production is about
2783 million tones.






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STRUCTURE

Two different markets are there for cement globally. It includes bulk sale for
large infrastructure projects to the government and companies and bagged products sold to
individuals for personal use in homes for local structures. Bagged cement accounts for about
65% of the worlds production. Word wide market has grown an average 44% per year for
the last 70 year. In china and Latin America, the growth rate is about 5-15% year. But in US
and Europe market growth is zero.
























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COMPANY PROFILE

HISTORY OF TRAVANCORE CEMENTS LTD

The Travancore Cements Limited was incorporated in the year 1946.The mastermind
behind setting up of the factory was late Sri.C.P.Ramaswamy Iyer Diwan of Travancore. He
realized the vital role of cement in industrial development of Kerala. The company was
promoted by the state of material other than conventional lime stone. The main raw material
is lime shell, which is dredged out of Vembanad Lake. The company was promoted by the
state of Travancore in association with Tamilnadu.Later the Govt. of Kerala acquired the
company with a share of 91% and rest by the public. The shares of the company have been
listed in the Stock Exchange of Cochin and Chennai.

The company was promoted by M/S Essel Ltd Mumbai and technology tie up was
made with M/S F.L.Smidth &Co.Denmark.The company is the premier project making
company in Kerala. It is the only public sector which manufactures and markets White
Cement and Cement Paints.

Till 1974 the company was manufacturing both white and grey cements in the same
plant. The company switched over to the exclusive manufacturing of white cement as the
demand for white cement went up and the Govt.of Kerala took over the management of the
company. The installed capacity for the production of white cement is 30,000 tonnes per
annum.
For the last 64 years of its inspection, it has diversified its activities to related areas.
Besides Super Shelcem Cement Paint, the company has added to its product range, Sheltex
Acrylic Emulsion Paint for interior and exteriors and Shelprime Cement Primer. Sheltex
Acrylic Emulsion Paint and Shelprime Cement Primer were later withdrawn.
The Travancore Cements Ltd is the only manufacturer, perhaps in the whole world,
producing white cement from raw material other than conventional lime stone. The main raw
material is lime shell, which is dredged out of Vembanad Lake, one of the most important
backwaters of Kerala.

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LOCATION

The company is situated on the banks of the Kodoor River and along the side of the
state highway, MC Road, 4 kilometers away from Kottayam town. The typical location of the
plant makes it accessible by road and water.

MILESTONES IN THE HISTORY OF TCL

Started production of Vembanad Grey Cement from lime shell in August 1949.

Started production of vembanad white cement from lime shell in August 1959.

Diversified into cement paint super shelcem production in 1977.

Celebrated silver jubilee in 1982.

Became a Government company on April 19
th
in the year 1989.

Celebrated golden jubilee in 1997.

Launched Shelprime Dry Cement Primer in 2000.

Diversified into Acrylic Emulsion Paint Sheltex for interiors and exteriors.

Conferred ISO 9001 in February 2001.

Company started HRD center in 2002.

In 2008, TCL stated the production of Vembanad Wall putty.


BRANCHES AND OFFICES

The company has its registered office and factory at Nattakam, Kottayam, Kerala. It
has a regional office at Trivandrum and depots at Bangalore, Coimbatore and Vijayawada.


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MANAGEMENT OF TCL

TCL is a public sector undertaking with the Kerala government having 91% and shares. The
authorized share capital of the company amounts to Rs. 5000000. The company is headed by
the board of directors. The board of directors consists of chairman, managing director &
seven other directors.
BOARD OF DIRECTORS
SRI.ANTONY RAJU CHAIRMAN
SRI.P RAJENDRA KUMAR MANAGING DIRECTOR
SRI.JAPABALAN OLIVER DIRECTOR
SMT. M. RAGINI DIRECTOR
SRI. PAZHAKULAM SIVADAS DIRECTOR
SRI. MANARKAD KURIAKOSE DIRECTOR
SRI. V.P. IBRAHIM KUTTY DIRECTOR
SRI. RAVI MYNAGAPALLY DIRECTOR
SRI. V.V. VENUGOPALAN DIRECTOR

VISION

In the fast paced global environment as the barriers are withering away, India need proper
internal synergy creation from the manufacturing sector for which the organisation, pioneer
of the white cement manufacturing in the country, can play a remarkable role and so is
committed towards effective utilization of man, machine, material and money (4Ms).

MISSION

Having a unique role in the Heavy Industry sector of the country, the company is committed
for catering the society towards the specific need expected by producing quality product at a
customer friendly price while keeping sustained growth of the organization and total growth
of the society.

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OBJECTIVES

The main objective of the company is to engage in the production of Vembanad
White Portland Cement. It is the first and foremost product of the company which is best in
quality. Now the company is also engaged in the production of cement paint known as Super
Shelcem which is available in wide range of 40 shades.

ISO CERTIFICATION

The company has been granted ISO 9001 certification on 8
th
February 2001, by The
Bureau of Indian Standards (BIS).On behalf of the company, the certificate was received
from the Director of BIS by the late Minister for Industries and Social Welfare Smt.Suseela
Gopalan in the presence of Sri.K.M.Abraham, Chairman, Sri.George Sebastian, MD, staff
and Trade Union representatives of the company.

FUTURE EXPANSION

The company plans some diversification schemes which will be implemented in the
near future, which includes the proposal to assist setting up of Enamel paint unit and textured
coating under co-operative societies. There are proposals to start a packing unit, the venturing
of a project for the manufacture of calcium nitrate and Dicalcium phosphate, shifting of the
present technology to dry process technology, reinitialize the production of grey cement.
Other proposals include export of white Portland cement to Srilanka, Gulf countries, South
Africa and Mauritius.The company also plans to improve the quality of white cement. The
company has a bright future.

COMPETITORS

Cement industry is a highly competitive field since cement products have
manifold uses. The company is facing tough competition from domestic and international
manufactures. JK white cement, Birla white cement, Razal Kima Cement (RKC) etc are the
major competitors in white cement sector. In the cement paint sector there are about 14
brands to compete with Super Shelcem. The major competitors are Durocem, Trucem, and
Snowcem, etc.Still, the company being a pioneer concern, unique in its salient features, time
tested for six decades of credibility, this indigenous firm has bright prospect.
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PRODUCT PROFILE

The company now produces only one product.
Vembanad White Portland Cement

VEMBAND WHITE PORTLAND CEMENT

Vembanad White Portland cement is the main product of the Travancore Cements. It
is one of the only two companies in the world manufacturing white cement from a raw
material other than lime stone. The other is in South California, U.S.A. The main raw
material is lime shell which is dredged out from Vembanad Lake, one of the Back waters of
Kerala. As it does not contain Oxide, the white cement made out of lime shell is highly
durable and superior in quality. Moreover the company employs wet process technology on
the fully imported machinery of F.L.Smidth &Co. Denmark.

Vembanad enjoys the best reputation in white cement and in specifications are much
above IS 8042 E-1976.White cement is quick drying, possesses high strength and superior
aesthetic values. It is used for floor furnish, plaster works and ornamental works. The
miscellaneous application of white cement is in swimming pools, where it replaces the use of
glazed tiles with coloured shades under the water, for moulding sculptures and statues, for
painting garden furniture, etc. It is also used for ready mixed concrete and pre cast blocks and
also for fixing marble and glazed tiles.

SPECIAL FEATURES OF VEMBANAD WHITE CEMENT

Lowest magnesium oxide content hence ensures durability.
Wet processing ensures whiteness and strength.
High consistency.
Super finishing.
Ideal for manufacturing of cement paint, mosaic tiles, etc.




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APPLICATIONS
Pointing brick works.
Road marking.
Cast stone finish.
External rendering.
Mosaic tiles.
Terrazzo flooring.


















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ORGANIZATION CHART





























BOARD OF DIRECTORS
CHAIRMAN
MANAGING DIRECTOR
GENERAL MANAGER
FINANCE
MANAGER
PRODUCTION
MANAGER

MAINTENANCE
MANAGER
PERSONNEL
MANAGER

MARKETING
MANAGER
ACCOUNTS
OFFICER
MAINTENANCE
ENGINEER
DEPUTY
MAINTENANCE
MANAGER
STAFF

MARKETING
SUPERINDENT
STAFF JOINT
MANAGER
STORE
SUPERINDENT
STAFF
OBSERVATION
FOREMAN AND
WORKERS
STAFF
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FUNCTIONAL DEPARTMENTS

In Travancore Cements Ltd the work activities that are similar and logically connected are
grouped to form departments. At present there were 18 departments in the organization. They
are as follows.

Departmental details
4.1 Operations Department
1. Transportation Department
2. Dredging Department
3. Purchase Department
4. Production Department
5. Electrical Department
6. Laboratory Department
7. Packaging House
8. General stores Department
9. Material Handling Department
10. Workshop Department
11. Civil Engineering Department
4.2 Personnel Department
1. Time Office
4.3 Finance Department
4.4 Marketing Department
4.5 Miscellaneous Departments
1. Medical Department
2. Security Department
3. Sanitation Department





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4.1 OPERATIONS DEPARTMENT

Following are the departments come under Operations:-

TRANSPORTATION DEPARTMENT












TRANSPORT

Mainly water transportation facilities are used to bring lime shell from the
Vembanad Lake. The company has two dredgers of which one is hydraulic and the other is
mechanical. Dredger is used for cutting and sucking limeshell from the river bed. There are
6 Barges and the capacity of each Barge is 70 tones approximately. The Barges are used for
transporting lime shell from the Vembanad Lake to the unloading station.

The capacity of two dredgers is 30 tones per hour. The cutter of dredger is about
10m in length. The capacity of a wooden Barge is 70 tones.

GENERAL TRANSPORT

Free transportation facilities are given to the staff to come to the office. For the purpose, the
company has two buses of their own. It is available to workers in all shifts.



CHIEF MANAGER
(MAINTENANCE)
DEPUTY MANAGER
(SERVICE)
FOREMAN
TRANSP.SUPDT
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DREDGING DEPARTMENT















The main raw material for the production of Vembanad White Cement is lime shell;
an underwater deposit in the Vembanad Lake. It is dredged and brought to the company by
means of power barges. The company has two dredgers, one hydraulic dredger named
Lokanathan of 5000 gallons capacity and one mechanical dredger of 2000 gallons capacity.
The dredger can cut the lime shell around 40 ft. maximum depth. The dredger works on two
powerful engines, a dredger pamper engine and an auxiliary engine.






GENERAL MANAGER (O)
CHIEF MANAGER
(MAINTENANCE)
JUNIOR MANAGER
(DREDGER)
FOREMAN
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PURCHASE DEPARTMENT



















FUNCTIONS OF PURCHASE DEPARTMENT
Placing order
Inviting quotations
Correspondence


GENERAL MANAGER
(OPERATION)
JUNIOR CHIEF MANAGER
(PURCHASE)
JUNIOR MANAGER
(PURCHASE)
JUNIOR EXECUTIVE
OFFICER
FOREMAN
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To perform the functions effectively, the purchase department is guided by the
following procedure.

PURCHASE REQUISITIONS

The purchase officer does not initiate any action for purchasing of materials on
his own accord. With the help of purchase requisitions, the purchase officer comes to know
the types of materials needed by the organization. A purchase requisition is a form used as a
formal request for the purchasing department to purchase materials.

EXPLORING THE SOURCES OF SUPPLY & SELECTING THE
SUPPLIER

The source of supply of materials is to be selected after the receipt of purchase
requisition. The process of choosing the supplier is not a hard task. The store keeper
generally mentions the name of current suppliers, their price quotations and the purchase
department also has a series of good suppliers. Choosing the right supplier from the
suppliers list involves a process of comparison of statement of purchases. It is prepared by
the purchase department.

PURCHASING ORDER

After choosing the supplier, the purchase department prepares the order for the
supply. The order is a written authorization to the supplier to supply the particular material
or materials. It is the documentary evidence between the buyer and the supplier having the
terms and conditions of the purchasing order.

RECIEVING & INSPECTING MATERIALS

In large concerns, a separate receipt & inspection department independent of stocking
location should be set up to receive and inspect the materials. But in small concerns, the
work is done by the store keeper. In TCL, the stores department effects the general
purchase. When goods are received in stores, the consuming department is informed and its
personnel inspect the quality, quantity etc.

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CHECKING & PASSING BILLS OF EXCHANGE

The payment terms of the company are

Against invoice or acceptance of stock a minimum 15 days credit
In case of monopoly suppliers, payment is made through banks.

VENDOR SELECTION

The company has a list of suppliers for all its purchases. The company invites tenders
through advertisements in newspapers. The suppliers tender quotations and after a detailed
study of the concerned department, the supplier is selected and the order is placed.

VENDOR RATING

A vendor is rated according to his monopoly in the market, brand equity of the
products, his established dealings with other reputed organizations. There is a vendor
evaluation committee for the vendors. The committee consists of officers from concerning
finance and material departments. The vendors rated below 50% are removed from the lists.
Vendors rated between 50% & 75% are advised to improve their quality.

CONDITIONS REGARDING RECEIPT OF GOODS

If the suppliers are within Kerala, goods are to be received within 15 days of
sending/inviting quotations.

For outside suppliers of Kerala it is 20 to 30 days.
The companys local purchases are through its agents within 2 to 3 days.








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PURCHASE LIMITS

The company follows an authorized purchasing system. The purchase units are as follows:

Below Rs.25, 000, purchases are authorized to Store Manager and sanctioned by
Chief Manager.
From Rs.25, 000 to Rs.1, 00,000, Chief Manager should sanction.
From Rs.1, 00,000 to Rs.10, 00,000 should be signed and approved by the
Managing Director.
Above Rs.10, 00,000 should be approved by the Board Of Directors













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PRODUCTION DEPARTMENT

























GENERAL MANAGER
(OPERATIONS)
CHIEF MANAGER
DEPUTY MANAGER
JUNIOR CEMENT
PAINT MANAGER
JUNIOR
PRODUCTION
MANAGER
JUNIOR MANAGER
(KILN)
Jr. EXCECUTIVE
FOREMAN
FOREMAN
CHIEF
BURNER
26

The production department is the heart and soul of the organisation.Vembanad
White Portland Cement is its main product.

RAW MATERIALS

LIME SHELL

Vembanad White Portland Cement has the distinction of being the only cement in
the whole world produced from lime shell, an underwater deposit. Lime shell is the purest
source of calcium carbonate and best suited for white cement manufacture. Moreover, the wet
process, though expensive, is retained to ensure perfect quality. Lime shell is obtained from
TV Puram area (near vaikom).

WHITE CLAY

White clay or crude China clay is obtained from TECHNOPARK AREA,
TRIVANDRUM. These white clay deposits of southern Kerala are famous for their purity
and high ceramic properties. The milky white clay, which is in a paste form, which goes
through the manufacturing process of Vembanad white cement, is almost 85% pure Hydrated
Aluminum Silicate.

WHITE SAND

The white sand is obtained from the BRITISH INDIA COMPANY (their waste
product) purity up to 95%.

CRYSTAL GYPSUM

Crystal Gypsum is obtained from Tuthukudi, Tamil Nadu and maintains 98% purity.







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MACHINERY AND EQUIPMENTS

DREDGING AND STORING OF LIME SHELLS
Dredger
Diluting pump
Gravel pump
Receiving tank
Rotary filter
Conveyors
Storage tanks

PROCESSING OF LIME SHELL, SAND AND CLAY
Water pump
Wash mill
Clay pump
Ball mill
Elevators
Lifting device
Slurry pump
Slurry silos

PROCESSING OF CLINKER
Rotary kiln
High pressure screw pump
Hammer crusher
Shaking and bucket elevators
Clinker silos




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PROCESSING OF CEMENT
Cement mills
Belt and screw conveyors
Cyclone separators
Dust collectors
Air compressors
Cement silos, packing machines.

PRODUCTION STAGES
Slurry preparation
Clinker making
Clinker grinding

The different processes under these stages are:

Dredging
Unloading station
Wash mill
Shell sand grinding (Ball mill)
Slurry making (Raw mill)
Slurry section
Clinker making (Rotary kiln)
Clinker grinding (cement mill)
Packing and dispatching

DREDGING

The main raw material, lime shell, an underwater deposit in the Vembanad Lake is
dredged and brought to the company by means of power barges. The company has two
barges, hydraulic and mechanical.


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DREDGER OPERATION

The dredger is placed anywhere in the Lake using spud. The cutter is placed downwards
by using a winch when spud 1 is centered. The cutter moves anticlock wise direction and cut
the shell. After primary washing, the shell is transferred to the barge.

UNLOADING STATION

The shell brought by barge from lake is unloaded here. Shell in barge is diluted with about
60% of water by means of a diluting pump for easy sucking. A sucking pump draws water
along with the shell to the receiving tank near the rotary grill of the screening plant. The shell
is then passed through the rotary grill and the waste materials are washed out during its
rotation. Cleaned shell is either passed to the belt conveyors through hoppers or stored
outside.

WASH MILL

Prior to the process, clay is mixed with water in a wash mill. Clay is put into the mill
and about 65% of water is added during grinding. During the process in the wash mill, clay
is made to slurry and is pumped to storage tank known as silo. From silo, it is taken when it
is required.

SHELL-SAND GRINDING MILL(BALL MILL)

Slurry preparation is the fourth stage in the production process of white cement.
Slurry is a mixture of shell, sand and clay with around 40% of water. For slurry- preparation,
two grinding mills are used.
Roughing mill known as Ball mill
Finishing mill known as Raw mill

Ball mill is a cylindrical shell of welded metal plates. The shell along with required
amount of white sand and water is fed to the ball mill by a rotating feed table. When the mill
rotates, the materials are crushed down to small particles while it passes-through the ball. The
materials coming out the ball mill is diverted to a hammer screen by means of slurry elevator.
30

Fine material which comes out of the hammer screen is fed to the raw mill. The coarse
material is returned to the ball mill for further grinding.

SLURRY MAKING(RAW MILL)

The fine materials discharged from ball mill and clay pumped from clay silo are
finally ground and comes out as a party material known as slurry which flows to the slurry
pit.

SLURRY SECTION

Slurry discharged from the raw mill is stored in silos by means of pumps. The
chemical composition of slurry will be adjusted at this stage. There are three silos for storing
the slurry. From these silos, slurry is pumped to the slurry basin. In the basin slurry is
constantly agitated with compressed air & stirring mechanism. From this basin, slurry is
taken for burning in the kiln.

CLINKER MAKING (ROTARY KILN)

Kiln is a cylindrical steel shell lined with refractory bricks mounted at an angle of six
degree to base on roller supports, so that it can be rotated. The kiln is having a length of 285
feet. Its diameter varies from 250 cm to 300 cm. The corrected slurry is injected at the upper
end of the kiln. Hot gases or flames are forced through the lower end of the kiln.
During the burning process slurry passes through three stages:
Drying zone
Calcinations zone
Burning zone

CLINKER GRINDING (CEMENT MILL)

Clinker as obtained from rotary kiln is carried by conveyors into the cement mill.

There are three cement mills A, B and C with clinker grinding capacity of tones 60,
50 and 50 respectively. During grinding, small quantity about 3% to 4% gypsum is added.
The gypsum controls the initial setting time of cement. The gypsum added acts as a retorted
31

and it delays the setting actions of cement. It thus permits cement to be mixed with
aggregates and to be placed in positions.

PACKING AND DISPATCHING

The white cement stored in the silos is packed in paper bags in the packing house.
Compressed air is used for free flow of cement from the silo and hopper located above the
packing machine. When the bag is filled with 50 kg material from the spout it is
automatically transferred to truck through a fixed point belt conveyor and a movable belt
conveyor. The wire net conveyor receives the filled bags and is transferred to trucks through
a fixed-point belt conveyor and a movable belt conveyor.

ROLES AND RESPONSIBILITIES OF PRODUCTION EXECUTIVE
1) Forecasting the requirements of the production in order to achieve the production
target.
2) Making most efficient utilization of the available sources for production.

3) Deals with reducing material handling cost, which generally is achieved by the use
of efficient material handling system and also by using plant layouts which must be
developed in a proper or correct way.
4) Reducing the quality cost with the help of analysis of non conformances on periodic
basis and also by following suitable actions (both corrective and preventive).
5) Building team spirit among the workmen and also motivating by means of personal
involvement. This task of motivation can also be achieved by designing and
implementing suitable financial incentive schemes.



32

CHIEF MANAGER
NEXT IN CHARGE
ELECTRICAL DEPARTMENT







FOREMAN


CHARGE HANDS


SENIOR ELECTRICIANS










This department deal with all the works connected with the electrical equipment, power
linked and other allied activities. The total number of employees working in this section is
24, out of which 12 employees are concerned with the electrical maintenance of the plant and
the rest undertake the maintenance work of the power plant. The company has its own
substation for power supply. In order to ensure the safe and smooth operation of electrical
machinery and equipments, a three tier system of electrical maintenance is practiced here.


ELECTRICIAN 1
ELECTRICIAN 2
33

DAILY INSPECTION AND CHECKING

Heavy electrical machineries like transformers, mill motors, compressor motors etc.
are checked by Chief Electrician, on a daily basis before it starts functioning. Minor faults
are dealt with himself and others are brought to the attention of the Electrical Department.

PERIODICAL INSPECTION AND CHECKING

All the electrical equipments and machineries are checked periodically in order to
ensure the safety of workers and also for the smooth functioning of the plant.

BREAKDOWN MAINTENANCE

In case of any breakdown of the machineries in the production department, it will be
informed to the maintenance department, and subsequently maintenance workers are sent to
production department to solve the machine failure.

PREVENTIVE MANITENANCE

Under this system a team of maintenance workers is sent directly to the production
plant to find out whether there is any failure or fault in the functioning of the machinery.

SHUT DOWN MAINTENACE

When the plant is to be shut down due to failures, the production department informs
the maintenance department to solve the problem.






34

LABORATORY DEPARTMENT




There are three levels of testing conducted in the laboratory as follows

RAW MATERIAL TESTING

Raw materials are tested to ensure the quality of final products.

INTERMEDIATE TESTING

In this testing, slurry is tested for finding out whether it contains right proportion of lime
shell, sand, clay and water.

FINAL PRODUCT TESTING

Final product testing is done before the grinding of lime shell, sand and clay.



35

PACKING HOUSE

Here cement is drawn from storage spoils and packed in the paper bags by automatic
machines and dispatched.
Packing house is situated just opposite to the plant. There is a conveyor belt connected from
the plant for the smooth transfer of cements from the plant to the silo. One silo is there in the
packing house for storing the cements from the plant. From silo bucket elevators are there for
making the cements storing into the godown or in bag. A small conveyor belt is there in the
packing house for loading the cement packets into the truck.

The main function of packing house is loading and unloading of cements into trucks
with minimum time and without any destruction of packets. In addition to that, sales
interaction, how many vehicles loaded, and dispatching etc are dealt in this department.


The Packing House is dealing with,
50 kg- automatic packing

The packing house is providing a paper bag for packing purpose. Godown is situated
near to the packing house.
The minimum dispatch is 120 tones per shift.







36

GENERAL STORES DEPARTMENT





LOCATION AND LAYOUT

The location of stores department should be carefully planned out and it should be
housed in a position which is very near to the receiving department, so that transportation
charges are at a minimum.

37

In TCL stores department is near to the consumable department. The layout of the
stores department needs careful consideration. The centralized store is divided into racks,
which is further divided into small spaces. All these spaces are known as bins.

STORES RECORDS

BIN CARD

A bin card makes a record of the receipt and issue of materials and is kept for each
item of stores it carries. Quantity of stock received and issued is recorded in the respective
columns of the bin card and the balance is readily available. A bin card is usually hung up or
placed in a shelf, rack or bin where the materials are kept.

KARDE-X CARD

This card is used by stores keeper in addition to the bin cards for storing list of stock
of items. The company does not maintain a stores ledger, instead of this all the details are
stored using software in the computer. The existing system is FoxPro based system.

ADVANTAGES OF CENTRALIZED STORES IN TCL

Better control can be exercised over stores since all stores are housed in one
department.
Better layout of stores is possible.
Investment in stock is minimized.
Economical.
Economy in staff and concentration of experts in one department will lead to
development in high technical skills.
Facilitates inventory checking as all the stores are located in one place.




38

MATERIAL HANDLING DEPARTMENT

The Material Handling Department is mainly dealing with the loading and
unloading of raw materials. There are 36 workers working under the material handling
department. The helpers in this department are diverted to work in the mill section of the
plant. This department is located near the Cement Plant.

The structure of this department is,




The main functions of the Material Handling Department are the unloading of raw
materials from the truck and handling of machineries used in the cement plant department.
There are so many earth moving equipments are under this department. In some emergency
situations the helpers of this department is diverted to do duties of production departments
like mill house dust cleaner.


39

WORKSHOP DEPARTMENT


40

The main function of workshop department is maintenance. All maintenance of
transport, material and plant is under this department. The main sections of this
department are,

Mechanics section
Filters section
Blacksmith section
Runners and machine operators section
Welders section
Khalasi ( persons used at time of accidents) section
Cockers and carpenters section
Automobile section

Total number of workers in mechanical section is 75, out of which 4 are charge hands
assisted by a foreman and an attender. The rest include the officers and other skilled workers.


CIVIL ENGINEERING DEPARTMENT

This department is mainly concerned with the civil engineering works, manufacturing
and controls of various machines etc .There are 4 employees working in this department.







41

4.2 PERSONNEL DEPARTMENT















FUNCTIONS
To maintain good relationship between the employees
To look into the welfare of the employees
To maintain leave register
Attendance marking
Overtime confirmation

This department is interconnected to all other departments.The department is headed by
Senior Manager followed by Deputy Manager and then Assistant Manager.



MANAGING DIRECTOR
GENERAL MANAGER
CHIEF MANAGER
DEPUTY MANAGER
JUNIOR MANAGER
(IR)
JUNIOR MANAGER
(PERSONNEL)
42

ROLES AND RESPONSIBILITIES OF HR EXECUTIVE
Involvement in the strategic planning process.
Forecasting the labor requirement.
Recruitment
Selection
Induction
Training
Motivation
Performance Appraisal
Managing Redundancy
Managing employee grievance
Managing complains about employees

EMPLOYEE POTENTIAL

In Travancore Cements Limited there are totally 480 employees. The employees of
the company are classified into three categories.
Officers
Staff
Workers

OFFICERS

The officers are further classified into five
General Manager grade
Manager grade
Special grade
Class one grade
Class two grade

43

The classification is made according to the decision of the management. The different
grades are fixed on the basis of the experiences and merit of the employees.

STAFF

People working in the office, security and senior employee in the plant comes under
the staff category. The grade of staff varies from 1 to 7. 1 being the lowest grade and 7 being
the highest grade.

WORKERS

The workers in the company are classified into A-E. The highest grade is A and E the
lowest grade. The five categories of workers are:
Permanent
Probation
Temporary
Casual
Apprentice

TIMING

The office time of the company is from 9.00 AM to 5.00 PM on all working days from
Monday to Friday. On Saturdays office time is till 1.00 PM and the factory is working on
shift basis.
12am to 8am
8am to 4pm
4pm to 12am

RECRUITMENT AND SELECTION

Recruitment is done through direct and through employment exchange. Selection is
mainly based on written test and interview. Selected person will have to undergo a period of
training. The training period is usually six months and for higher post it may extend to one
44

year or more. Every worker is liable to be transferred from one department to another and one
job to another according to the experience of work in the factory.

SALARY AND WAGES

The salary is fixed for the officers and staff according to KSR rules. The salary is
revised in every four years. The provisions of Cement Manufactures Association (CMA)
determine the workers salary.

LEAVE PATTERN

Casual leave
Sick leave
Privilege leave

TRADE UNIONS

The recognized trade unions in the company are
The Kerala Cement Labour Union-CITU
The Travancore Cement Workers Union-AITUC
The Kottayam Cement Employees Union-INTUC
The Travancore Cement Workers Union-INTUC

WELFARE FACILITIES PROVIDED BY THE COMPANY

They were provided with the following benefits:
Uniform
Footwear allowance
Umbrella
Raincoat
Washing soap & toilet soap
Turkey towel
Medical reimbursement
45

Company scholarships
Tour programmers
Factory day compliment
Special advance
Two wheeler / Cycle loan
Car/ computer loan

Method of Appraisal of Employees

For Freshers
The freshers are appraised on the basis of their performance in the probation period. Usually
the probation period is from one to two years. If the performance of the employees in their
probation period is not satisfactory then probation period will be extended.
For existing employees
When there is a vacancy in a particular post, internal appraisal is done in order to fill that
post. Promotion is also provided to the employees by appraising their performance.

TRAINING AND DEVELOPMENT

There are both internal and external training for workers and employees, and it is
conducted by the HRD centre under the supervision of the personnel department. Job rotation
is allowed only for officers. Conferences, talks, workshops, etc are considered as part of
training and development.

PROVISIONS REGARDING HEALTH OF THE EMPLOYEES

Cleanliness is maintained.
Wastes and effluents are disposed properly.
Proper ventilation and temperature is maintained.
Masks are provided for protection against dust.
Cold water facilities are provided.
46

Proper lighting is maintained.

Working Conditions

Proper working conditions are maintained. Facilities like bathroom, toilets are provided at
all plants and in offices. Rest rooms and seating facilities are also provided.
Canteen

A fair price canteen is operating at the premises. The employees are given Rs 25 per day of
attendance as canteen allowance and maximum of Rs 750 per month.
Transportation

Free transportation facility is provided to employees for coming and returning after duty.
Transportation facility is also provided to the children of the employees for attending the
educational institutions in and around Kottayam.
Educational Allowance

The company provides this facility for the children of permanent employees. They are getting
an amount of Rs. 300 a month.
ESI Benefits

ESI Benefits are provided to those employees who having salary below 15,000. For ESI
1.75% is deducted from the salary of the employees and 4.75% is contributed by the
employers.











47

TIME OFFICE


CHIEF TIME KEEPER

SENIOR TIME KEEPER

TIME KEEPER



The main function of the time office is the Attendance Data Management of all the
employees. In the time office, there is a Chief Time Keeper and 5 time keepers are under him.
The employees of the Travancore Cements Ltd provided with a Time Rating Card. They have
to punch-in their cards while entering the organization and punch-out the cards before leaving
the company. Officers and staffs having the card.

There are two shifts of employees,

General Shift: - the working time for the employees in the general shift is 7hours from
9 am to 5 pm. They have a lunch time from 12 pm to 1pm in the noon. For employees
in the workshop department have to work from 8am to 5pm.And for the employees in
the packing department and cement paint have to work only from 8am to 4pm.
Rotation shift: - mostly the workers in the production department are having the shift.
Three times of shift, Ist shift starts from 12 midnight to 2am, then from 8 am to 4pm,
and the last one is from 4pm to 12midnight. They have to work for 8hours.





48

Salary and Leave Structure of the employees

There must be a time keeper in the time keeping room for monitoring who all are
entering the company and maintaining the punching of cards.

Every 21
st
date of previous month is considered for the calculation of salary. The font
side of card contains 1 to 16 days of the current month and the backside contains 17 to 20 of
current month and from 21
st
to 30 or 31
st
days of previous month. Now the salary is
computerized work, earlier it was done manually.

The leave for staff category is,
Casual Leave-14
Sick leave-12
Privileged leave( PL)-30

If the employee is attending all the days in a month, he or she is eligible for getting 2.5
days compensatory leave. In a month a staff can get 30 leaves.

9 minutes more is allowed after the usual for entering, if it is 10 minutes, then the one fourth
portion is cut.










49

4.3 FINANCE DEPARTMENT













DUTIES OF FINANCE DEPARTMENT
Overall financial control.
Monetary decision making in consultation with the Managing director.
Finalization of accounts.
Budget preparation.
Control over all matters relating to finance in the organization.


The accounts and finance departments ensure that the salaries to the employees are
paid in time. The department is also concerned with the preparation of budget and budgetary
control of the concern. The departments ensure that all the entries are properly posted in the
books of accounts.




GENERAL MANAGEER (F)
CHIEF MANAGER (F&A)
ASSIST.MANAGER
JUNIOR
MANAGER
(CASH)
.SUPERINTENDENT
JUNIOR MANAGER
(FINANCE)
50

There are mainly three sections in the finance department of the company

Accounts section
Finance section
Cash section

ACCOUNTS SECTION

The most important function in accounts section is the recording of day to day
accounts. Routine accounting functions like sales tax payment, receipts and payments of
cash; cheques etc come under the preview of the accounts section. The employee Payroll
function is also undertaken by the accounts section.

FINANCE SECTION

Finance section is mainly concerned with the maintenance of accounts. The various
financial statements are recorded in the computer as well as in the manual form.

CASH SECTION

The cash section is concerned with the disbursement of cash. There are thirteen
employees working in the finance department.
The accounts of the company are prepared in accordance with the accounting policies
generally accepted in India and in line with the relevant laws as well as the guide lines
prescribed by the department of company affairs and the Institute Of Chartered Accountants
Of India and in accordance with section 211 (3C) of the companies Act 1956.

SYSTEM OF ACCOUNTING

The company adopts the accrual system of accounting.




51

FIXED ASSETS

Fixed assets are capitalized at cost inclusive of expenses. Depreciation is provided on all
fixed assets except machinery for erection and free hold land, on reducing balance method.

INVENTORIES

Raw materials, stores, spares and work in progress are valued at cost. Finished goods
are valued at cost or market price, whichever is less and does not include excise duty, except
in the case of stock at depots.

SALES

Sales are inclusive of excise duty and sales tax.

TREATMENT OF GRATUITY

The company has formed a Gratuity Trust and taken group gratuity policy of Life
Insurance Corporation of India.

ROLES AND RESPONSIBILITIES OF FINANCE EXECUTIVE
Working Capital and Cash Management decisions
Dividend Decisions
Investment Decisions
Portfolio Management
Risk Management
International Financial Decisions
Inventory Management
Budgeting





52

4.4 MARKETING DEPARTMENT

















Structure of marketing department

Functions of marketing departments
To identify the needs and want of consumers.
To meet the demands of consumers.
Developing new and better product.
Successful distribution of the product.
Improving the quality of the product or service


GENERAL MANAGER
(marketing)
CHIEF MANGER
Jr.MANAGER (SALES AND
MARKETING)
SALES
SUPERINTENDENT.
53

MARKETING ACTIVITIES

The company has a well established marketing department. There is an efficient
sales force under the Marketing Manager. The whole system comes under the General
Manager. TCL has got 14 sales representatives throughout Kerala.

MARKETING DISTRIBUTION CHANNELS

Company Depots Stockist Dealers Customers


NUMBER OF DEALERS AND STOCKISTS IN KERALA

Stockist 25
Dealers 2500

NUMBER OF DEALERS AND STOCKISTS IN TAMIL NADU

Stockist 6
Dealers 300

Marketing Mix

Marketing mix means set of marketing tools the firm uses to pursue its marketing objectives
in the target market. It includes four Ps that is product, price, promotion and place.

SALES PROMOTION

Other promotional activities include conducting dealers meetings once in two years. In
addition to these the company offers various incentive schemes for its dealers according to
their sales performance. Due to very low advertisement budget the company does not engage
in any large scale advertisement activities.



54

PLACE

The company has its registered office and factory at Nattakom, Kottayam, Kerala. It has a
regional office at Trivandrum and depots at Bangalore, Coimbatore and Vijayawada .The
location is ideal for a cement factory as easily accessible by road and water.

PRODUCT

The Travancore Cements Limited is the only manufacturer, perhaps in the whole world,
producing white cement from a raw material other than conventional lime stone. The main
raw material of TCL is the lime shell, which is dredged out of Vembanad Lake.

PRICING OF VEMBANAD PORTLAND WHITE CEMENT

Kerala MRP 50 kg Rs.1115
Outside 50 kg Rs.1250

MARKETING CHANNELS AND PRACTICES

WHITE CEMENT

The company has got six sales representatives throughout Kerala. White cement is
produced only in Kottayam. It is having sales offices and god owns at Bangalore,
Coimbatore, Kolkata and Delhi. Transportation is conducted by trucks and railway wagons to
distant places. The Regional office is at Trivandrum.

MARKET SHARE

Today out of the total production of white cement in India, the market share of
Vembanad white cement is 20%.





55

PROCEDURE FOR MARKETING AND DISTRIBUTION

The company has been carrying out production oriented strategy because of the
monopoly of the Vembanad brand. With the entry of competitors a marketing oriented
strategy is formulated. The company depends on distributors in various regions.

The payment is to be made in advance by demand draft in the case of white cement
and by cheque in the case of cement paint. The company offers commission in the form of
trade discounts to their stockists.

DISCOUNT ALLOWED BY TCL

The company gives trade discount of 10% and cash discount of 4% for purchase of
250 kg and above. The company allows 3% discount on freight allowances and 3% on special
discount. In every three months, the company gives 1% quantity discount for 200kg, 2%
discount for 50kg. They also give an annual discount of 3%.

REASONS FOR HIGH PRICE

The production process of the company is very old, known as wet process .It is very
expensive. This is the only company which uses the old wet process. The other companies
use dry process which is comparatively less expensive and hence their price is low. But in the
case of TCL products, the raw materials particularly lime shell and white clay is scarce. So
these products are priced very high.

COMPETITION
The company is facing tough competition from the white cement from internal
manufacturers and also from imported white cement. JK white, Birla, RKC etc. are the major
competitors in the white cement sector. In the cement paint sector, there are about 14 brands
to compete with super shelcem. The major competitors are Durocem, Snowcem etc. The
companys new product Sheltex Acrylic Emulsion Paint has only 5%market share and facing
competition from majors like Apex, Excel etc.

56

ROLES AND RESPONSIBILITIES OF MARKETING EXECUTIVE
Understanding current and potential customers
Managing the customer journey (customer relationship management)
Developing the marketing strategy and plan
Management of the marketing mix
Managing agencies
Managing budgets
Ensuring timely delivery
Developing guidelines
Making customer focused decisions


















57

4.5 MISCELLANEOUS DEPARTMENT
Following are the departments come under miscellaneous department:

MEDICAL DEPARTMENT











This department provides medical aid to both permanent and temporary employees.
The medical leave of the employees is recorded and sanctioned by this department.











GENERAL MANAGER (O)
MEDICAL OFFICER
PHARMIST
58

SECURITY DEPARTMENT

Security department is concerned with the security and control of the company
.There is 24 people working on shift basis.

SANITATION DEPARTMENT

This department is concerned with the cleanliness of the company .It also undertakes
proper maintenance of premises of the company.

















59

SWOT ANALYSIS

It is a tool that identifies the Strengths, Weaknesses, Opportunities and Threats of an
organization. Specifically, SWOT is a basic, straightforward model that assesses what an
organization can and cannot do as well as its potential opportunities and threats.

STRENGTH

Travancore Cements Ltd (T.C.L) is the only Indian Made Foreign Liquor (IMFL)
manufacturer in the central Travancore.

As T.C.L is a government owned firm, it enjoys all privilege granted by the
government.

The standard quality of their products is their great strength.

Trade unions are a vital part of any organization. T.C.L experience good cooperation
from the various trade unions present there.

Good organizational climate also adds to the strength of T.C.L.

Efficient quality control systems also add to its strength.

Employees are maintaining good relation with each other.

Maximum utilization of resources.

Employees are very efficient and hardworking.

Availability of raw materials in the nearby areas

It is an eco friendly firm. Pollution is fully controlled.

60

WEAKNESS

Excess manpower is the major weakness of the company. The company at present has
more employees than required. Wastage of money through the payment of salary and other
things to this excess supply of manpower.

Lack of modern technology is another weakness of the company. They are still using the
out dated machinery and technology. The technology now followed by them is 24 years old.


As the finished products are directly given to KSBC, company cannot enjoy the full
benefit derived from the products.

Unnecessary influence on the part of government and the political parties.

Higher cost of the products compared to the competitors product.

There is no proper mechanism to handle the grievances of the customers.

Absence of computerization is also another weakness of the company.

Unnecessary formalities cause a delay in business decisions.

Lack of raw materials cause a disruption in the production process.

Outdated salary package.

Lesser chance of promotion for employees.

o High maintenance cost
o High cost drudging mechanism
o Inflated price of furnace oil
61

o Insufficiency of lime shell
o No young blood in the organization. Employees are almost above 50.
o Employees in the office are not at all active. I found many officers wasting
time unproductively.
o Company still uses the outdated technologies. it is not at all computerized.


OPPORTUNITY

The budget amount should be used wisely so as to get maximum visibility for the product.

Company introduces promotional programmes.

The company should opt for psychographic segmentation of the market. Where more
stress should be given for the quality and fitness of the product.

It should expand the distribution network to that place where the product is less available.

It should switch on to newer technologies in order ro reduce its cost price.

Expanding to north indian markets and introducing their products to overseas.

If there is government initiative to improve the firm, it will be a great
advantage for the company as well as employees.
Since there is widespread land area coverage and availability of water, there
are opportunities for amusement parks or IT firms. Expansion of the company
is also possible.






62

THREAT

Scarcity of raw materials is the major threat faced by the company.

Out-dated techniques are still being followed.

Presence of numerous competitor brands.

Hike in price of raw materials.

Time to change in government policies.

Increase in the labor cost is one of the important threats to the company.

The price of natural spirit, which is the main raw material for the manufacture of the
product, is increasing to a very high extent. It leads to increase in the production cost.

The customers requirements are changing day by day. It is another threat to the
company.

The governments policies towards sales tax and other taxes are changing every time







63

OBSERVATIONS

1. Travancore Cements is the only one company producing White cement from the lime
shell.
2. The company is providing good working conditions.
3. The unique method of WET process is used for the white cement production.
4. There is no proper planning and control of the inventory.
5. The process of control and monitoring is not efficient.
6. Not given adequate training.
7. There is not fully fledged Research and development department.
8. Workers health and safety are given prime importance.
9. The quality of the products manufactured in the company is very high.
10. The decisions are taken after consulting with the employees.















64

CONCLUSION

TCL Kottayam is the pioneer in the white cement industry. It is an ISO 9002 certified
company, which was certified by Bureau of Indian Standards (BIS). This shows companys
consciousness towards high quality production. I am happy that I could spend one month in
this great institution. The study provided useful insights into the company and its functioning.
It is worth that the company has done a great task in the provision of cement products to cater
the needs of construction in a big way. The Vembanad White Cement is the forerunner
among other cements. The vision of the founders and the commitment of the workers led the
TCL ahead. One should be proud to have Kerala in the industrial map of India.

It is true that the TCL faces very stiff competition. But it can surely overcome by
innovative strategies by making TCL products available everywhere.

The bright prospects of The TCL lies in implementation of new technology,
improving market strategy, optimum utilization of employee potential and welfare of the
employees.












65

BIBLIOGRAPHY

Books
1) Arun Kumar and Meenakshi, (2006), - marketing management, second edition, vikas
publishing house pvt ltd New Delhi.
2) Gary Dessler, Human Resource Management, 12
th
Edition, Pearson Education India
3) R. Panneerselvam, Production and Operations Management, 2
nd
Edition, , 2005
4) I.M.Pandey, Financial Management 10
th
edition, Vikas Publishing House Pvt Ltd, 2010
5)Kothari.C.R-(2004)- Research Methodology methods & techniques
New age international publishers, New Delhi.

Journals and Magazine
Various reports kept in its departments like Annual reports, financial statements.

Websites
www.travancorecements.com
www.travcement.com