waheguru

PREFACE

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PREFACE
Management is that function of an enterprise which concerns itself with the direction and control of the various activities to attain business objective. It is the science and art of preparing organizing and directing human efforts to control the force and utilize the materials of nature for the benefit of human beings. This project report titled ORGANISATIONAL STUDY OF ACC Ltd. In JAMUL is an attempt to present the organizational details including its departments, organization structure, etc. In more than one sense it summarizes the result of nearly five weeks of the Study. The work has been compiled to present the relevant facts and opinion on the subject in proper prospective and in an objective spirit. The fact and ideas has been gathered from different sources. Lastly, the researcher owns the entire responsibility of the facts & analysis as also the error, if any. Because there always remain a chance of human error and bias cannot be avoided. Despite this great care has been taken while preparing this report.

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INTRODUCTION

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2.1 INTRODUCTION
ACC (ACC Limited) is Indias foremost manufacturer of cement and concrete. ACC's operations are spread throughout the country with 16 modern cement factories, more than 40 Ready mix concrete plants, 21 sales offices, and several zonal offices. It has a workforce of about 9,000 persons and a countrywide distribution network of over 9,000 dealers. Since inception in 1936, the company has been a trendsetter and important benchmark for the cement industry in many areas of cement and concrete technology. ACC has a unique track record of innovative research, product development and specialized consultancy services. The company's various manufacturing units are backed by a central technology support services centre - the only one of its kind in the Indian cement industry. ACC has rich experience in mining, being the largest user of limestone. As the largest cement producer in India, it is one of the biggest customers of the domestic coal industry, of Indian Railways, and a considerable user of the countrys road transport network services for inward and outward movement of materials and products. Among the first companies in India to include commitment to environmental protection as one of its corporate objectives, the company installed sophisticated pollution control equipment as far back as 1966, long before pollution control laws came into existence. Today each of its cement plants has state-of-the art pollution control equipment and devices. ACC plants, mines and townships visibly demonstrate successful endeavours in quarry rehabilitation, water management techniques and greening activities. The company actively promotes the use of alternative fuels and raw materials and offers total solutions for waste management including testing, suggestions for reuse, recycling and co-processing. ACC has taken purposeful steps in knowledge building. We run two institutes that offer professional technical courses for engineering graduates and diploma holders
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which are relevant to manufacturing sectors such as cement. The main beneficiaries are youth from remote and backward areas of the country. ACC has made significant contributions to the nation building process by way of quality products, services and sharing expertise. Its commitment to sustainable development, its high ethical standards in business dealings and its on-going efforts in community welfare programmers have won it acclaim as a responsible corporate citizen. ACCs brand name is synonymous with cement and enjoys a high level of equity in the Indian market. It is the only cement company that figures in the list of Consumer Super Brands of India.

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Situation: ACC structure is said to have the Largest Network in India with 15 Cement Factories 11 Marketing Offices 21 Area Offices 160 Warehouses 9,000 Dealers The Head office is located at Cement House, Church gate (Mumbai) while 7 Refractory locations, 15 Factory Locations and 11 RMOs spread across the country totaling to 2000 users approximately. ACCs Infrastructure consists of a hybrid WAN network to reach each of the 32 locations. Ajudicious mix of VSAT and VPN links ensure adequate connectivity between each of our locations. Local connectivity to servers at each of these locations are served by switch based LANs. Fiber has been used at each of the manufacturing locations.

2.1 HISTORTY AND PROFILE OF ACC

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ACC has been an interesting story - one that inspired a book. ACC was formed in 1936 when ten existing cement companies came together under one umbrella in a historic merger - the country's first notable merger at a time when the term mergers and acquisitions was not even coined. The history of ACC spans a wide canvas beginning with the lonely struggle of its pioneer F E Dinshaw and other Indian entrepreneurs like him who founded the Indian cement industry. Their efforts to face competition for survival in a small but aggressive market mingled with the stirring of a country's nationalist pride that touched all walks of life - including trade, commerce and business. The first success came in a move towards cooperation in the country's young cement industry and culminated in the historic merger of ten companies to form a cement giant. These companies belonged to four prominent business groups - Tatas, Khataus, Killick Nixon and F E Dinshaw groups. ACC was formally established on August 1, 1936. Sadly, F E Dinshaw, the man recognized as the founder of ACC, died in January 1936; just months before his dream could be realized.

F. E. Dinshaw the founder of ACC ACC stands out as the most unique and successful merger in Indian business history, in which the distinct identities of the constituent companies were melded into a new cohesive organization - one that has survived and retained its position of leadership in industry. In a sense, the formation of ACC represents a quest for the synergy of good business practices, values and shared objectives. The use of the plural in ACC's original name, The Associated Cement Companies Limited, itself indicated the company's

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origins from a merger. Many years later, some stockbrokers in the country's leading stock exchanges continued to refer to this company simply as 'The Merger'. ACC stands out as the most unique and successful merger in Indian business history, in which the distinct identities of the constituent companies were melded into a new cohesive organization- one that has survived and retained its position of leadership in industry . In a sense, the formation of ACC represents a quest for the synergy of good business practices , values and shared objectives . The use of the plural in Accs full name . The Associated cement companies Limited , itself indicates the companys origins for a merger . Many years later , some stockbrokers in the countrys leading stock exchanges still refer to this company simply as The Merger. The ACC Board comprises of 13 persons . These include executive , nonexecutive, and nominee directors. This group is responsible for determining the objectives and broad policies of the company-consistent with the primary objective of enhancing long-term shareholder value. The Board meets once a month. Two other small groups of directors comprising shareholders/investors grievance committee and audit committee of the Board of Directors also meet once a month on matters pertaining to the finance and share disciplines . During the last decade, there has been a streamlining of the senior management structure that is more responsive to the needs of the companys prime business. A managing committee comprising, in the addition to the Managing Director and the two executive directors , the presidents representing multifarious disciplines, finance, production, marketing research and consultancy, engineering and human resource-meets once a week. Besides these bodies, there are senior executives and other regional managers-based at the companys corporate office and other regional managers - based at the companys corporate office and its marketing offices and manufacturing units who contribute to the development and operation of the various functions. While these groups form the core management team thats frames and guides corporate policy, who comprise experts in various disciplines assisted by a dedicated work force of skilled persons. Quite a number of them have logged many
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years of service with the organization .They come from all parts of the country and belong to a variety of ethnic, cultural and religious backgrounds. Because of such a cosmopolitan make-up to, ACC can rightly be said to embrace within its fold, a family that forms a mini-India

Vision, Mission, Objectives and Values of ACC ltd:-

MISSION:
Leadership:-Maintain our relationship of the Indian current industry throughout the continuous modernization and expansion of our manufacturing facilities and activities, and through threstablishment of a wide and efficient marketing network.

Profitability:-Achieve a fair and reasonable return on capital by promoting productivity throughout the company. Growth:-Ensure a steady growth of business by strengthening our position in the cement industry. Quality;-Maintain high quality of our products and services and ensure their supply their supply at fair prices. Equity:-Promote and maintain fair industrial relations and an environment for the effective involvement welfare, and development of staff at all levels. Pioneering:-Promote research and development efforts in their areas of product development and energy and fuel conservation and to innovate and optimize productivity. Responsibility:- Fulfill our obligation to society, specifically in areas of integrated rural development and in safeguarding the environment and natural ecological balance.

VISION
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Objectives and Goals The company wants to capitalize on the synergies seeing the big picture. The
company would visualize a budding with aim and vitality for occupying a vantage position in the best cement company across the globe.

Values
Our values are fundamental to our success. They are the foundation of company, define who we are and set us apart from the competition. They underlie our vision of the future, our business strategies and our decisions ,actions and behaviors. We live by them. They endure.

2..2 INDUSTRY PROFILE

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A.C.C. Cement Factory is Indias one of the leading manufacturer of cement. It

has a huge network spread all over the country. Among the many places in India where the units of Cement Factory of A.C.C. have been set up, the recently established Indian state of Chhattisgarh is one. It is situated at a place called Jamul in the district of Durg, which is an important district in the state of Chhattisgarh .It is important part of CHHATTISGARH INDUSTRIAL AREAS. The name of the Cement Factory in Jamul is known as Jamul Cement Works. The total production capacity of the A.C.C. Cement Factory in Durg District is 1.58 Metric Tons in each year. It is the first plant established in the country with the sole aim of utilizing blast furnace slag, a waste product generated in the manufacturing process of steel of Bhilai steel Plant. It can boast as a first plant of its kind to produce 100% PSC right from its inception.

Energy Consumption The company had always strived for minimizing the energy consumption through continuous efforts to improve operating / process parameters, modernization / up gradation of plant etc. The downward trend in the electrical energy consumption is the effect of energy conservation measures undertaken in the previous years wherever possible.

Energy Conservation Commitment, Policy and Set up With a view to conserve natural energy resources and also to minimize the production cost, the factory has the special drive to reduce energy consumption at all sections of the plant. The plant has well-defined & organized energy management activities coordinated by a Energy Conservation Cell.

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Each department collects, maintains and compiles the production and energy consumption data from various sources, analyses them and takes corrective actions wherever required. Apart from daily performance review, monthly performance review is also done through different forums such as energy review meeting, management review meeting etc. The daily production report, monthly energy utilization report and status of energy saving jobs are sent to companys operations division for comparison at all Works basis. The area requiring improvements / assistance are pointed out to individual works. Annual energy review meeting of Industrial / process Engrs. is conducted as a part of information and experience sharing process for need base improvement. For monitoring and controlling the energy consumption of the plant, energy management committee has been formed, which meets once in a month to discuss the progress of on-going projects, steps / help required for expediting them and consider new proposals.

2.3 PRODUCT PROFILE

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ACC manufactures the following types of cement, in addition to which, it provides Bulk Cement and Ready Mix Concrete. Ordinary Portland Cements 43 Grade Cement (OPC 43 Grade) ACC Cement is the most commonly used cement in all constructions including plain and reinforced cement concrete, brick and stone masonry, floors and plastering. It is also used in the finishing of all types of buildings, bridges, culverts, roads, water retaining structures, etc. What is more, it surpasses BIS Specifications (IS 8112-1989 for 43 grade OPC) on compressive strength levels. ACC Cement is marketed in specially designed 50 kg bags. 53 Grade Cement This is an Ordinary Portland Cement which surpasses the requirements of IS: 12269-53 Grade. It is produced from high quality clinker ground with high purity gypsum. ACC 53 Grade OPC provides high strength and durability to structures because of its optimum particle size distribution, superior crystalline structure and balanced phase composition. It is available in specially designed 50-kg bags.

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Blended Cements Fly-ash based Portland Pozzolana Cement This is a special blended cement, produced by inter-grinding higher strength Ordinary Portland Cement clinker with high quality processed fly ash - based on norms set by the company's R&D division. This unique, value-added product has hydraulic binding properties not found in ordinary cements. It is available in specially designed 50-kg bags. What is special about ACC Fly-ash based PPC? ACC Fly-ash based PPC is made by intergrading high strength clinker with specially processed flash. This imparts a greater degree of fineness to ACC Fly-ash based PPC cement, improved workability properties while mixing, and makes concrete more corrosion resistant and impermeable. All of this makes for better long-term strength and improved corrosion resistance and therefore, greater life for your constructions. ACC Fly-ash based PPC is an eco-friendly cement What are the advantages of using ACC Fly-ash based PPC ? In concrete made from ordinary cements, moisture reacts with calcium hydroxide in concrete to form calcium bicarbonate, which leaches out of the concrete, leaving pores that reduce its strength. ACC Fly-ash based PPC has ingredients which react with calcium hydroxide to form CSH gel, to provide additional strength, which actually makes the concrete grow in strength over the years. It also produces less heat of hydration and offers greater resistance to the attack of aggressive waters than normal Portland cement. Can ACC Fly-ash based PPC be used for all jobs in construction? ACC Fly-ash based PPC easily replaces OPC and provides additional advantages for practically all types of construction applications - commercial, residential, bungalows, complexes, foundation, columns, beams, slabs and RCC jobs. It is especially
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recommended for mass concreting work, and where soil conditions and the prevailing environment take heavy toll of constructions made with ordinary cements. How does ACC Fly-ash based PPC stand up to corrosive environments? Due to its inherent characteristics, ACC Fly-ash based PPC makes very corrosion resistant concrete that is superior to concrete made with OPC. It is more impermeable to oxygen, CO2, chlorides, etc. Leaching of alkalis is reduced and the alkaline environment around steel is maintained. Portland Slag Cement This is a slag-based blended cement that imparts strength and durability to all structures. It is manufactured by blending and inter-grinding OPC clinker and granulated slag in suitable proportions as per our norms of consistent quality. PSC has many superior performance characteristics which give it certain extra advantages when compared to Ordinary Portland Cement It is available in specially designed 50-kg bags. What is special about ACC PSC? \ Compared to OPC, ACC PSC imparts some important additional advantages

Reduction in free lime leaching. Ultimate higher strength. Improved workability, reduced bleeding as well as segregation and corrosion. Denser, less permeable concrete, and mortar. Better resistance to sulphates, chlorides, and CO2 and alkali-aggregates reaction.

Less heat, reduced plasticity and drying shrinkage. Increased static modulus of elasticity.
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Increased serviceability with less deflection of members and micro cracks and reduced cost of construction and maintenance.

All these factors make for a strong, durable, and longer lasting construction. ACC PSC benefits the structure, protects the environment by reducing CO2 emissions and helps conserve energy. Which is why it is often referred to as an eco-friendly cement. The Federation International de la Precontrainte (FIP) Guide to Good Practice for "concrete constructions in hot weather," states that if concrete is likely to be exposed to an environment of sulphate-bearing water or soil, it is preferable to use a proven type of blended cement containing ground granulated blasts furnace slag. Concrete made with ACC PSC has a higher density than concrete made with OPC, and hence it improves the durability of concrete structures. It can, therefore, be used for all purposes where OPC or PPC is used.

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ORGANIZATIONAL STRUCTURE

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ORGANIZATIONAL STRUCTURE
The Structure of the organization represents the hierarchy of the organization. It represents the reporting System of the organization. Thus organizational structure is the pattern of relations among various components or parts of the organization. This prescribes the relationships among various activities and positions. From the structure of the organization we can have a clear picture of the responsibilities of the various personnel working in the organization. Hence organizational structure is the basic framework within the managers decision-making behavior takes place. An organization can be structured in many different ways, depending on their objectives. The structure of an organization will determine the modes in which it operates and performs. Organizational structure allows the expressed allocation of responsibilities for different functions and processes to different entities such as the branch, department .workgroup and individual. The framework, typically hierarchical, within which an organization arranges its lines of authority and communications, and allocates rights and duties. Organizational structure determines the manner and extent to which roles, power, and responsibilities are delegated, controlled, and coordinated, and how information flows between levels of management.

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ORGANISATION STRUCTURE Director Plant

Procurement Department

Human Resource Department

Marketing Department

Finance Department

Head Plant Operation

Mechanical Department Department `

Mining Department

Captive Power Plant Production Department Safety & Health Department

Environmental Protection & Quality Department

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DETAILS OF THE DEPARTMENTS

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PROCUREMENT DEPARTMENT

ACC has a countrywide spread of 14 modern cement plants. This large network of manufacturing units consumes a wide spectrum of inputs about 60,000 different items ranging from Coal, Gypsum, Slag, Packaging material (bags), Refractoriness, Steel, Grinding Media, Electrodes, Cables, Bearings, Conveyor Belts, Spares of various mechanical, electrical and instrumentation equipment, Mining Equipment and their spares and explosives. ACC has a vendor base of more than 6000 suppliers spread across the country. A team of professionals at Corporate, Regions and Plant Level manages the procurement function. The function is organized so as to derive maximum value for the company through economies of scale from central pooling and procurement of some inputs at the corporate level while meeting individual operational requirements at plant level. The Procurement function comprises a Central procurement team at the corporate office for the requirement of major inputs for the operations of cement plants.

Code of conduct ACC treats its vendors as business associates. All vendors are treated with respect and dignity. Our vendor base includes reputed manufacturers and trusted brand names, usually the leading 3-4 vendors of their particular industry segment who are technically and financially sound and have the intrinsic capacity to supply material of desired quality and on time. ACC prefers vendors who demonstrate good corporate citizenship and promote sustainable development. Adequate care is taken to ensure transparency in procurement processes. Our procurement policy has a clearly defined code of practice for procurement conduct and encourages fair and open competition in markets.

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HUMAN RESOURCE DEPARTMENT

ACC has a large workforce of about 9,000 people, comprising experts in various disciplines assisted by a dedicated workforce of skilled persons. ACC employees, referred to as the ACC Parivar, come from all parts of the country and belonging to a variety of ethnic, cultural and religious backgrounds. ACC employees display a strong sense of loyalty to the Company and their special stellar qualities as value-adding human capital are well known in the industry. ACC has clearly stated guidelines concerning recruitment, termination, career advancement, performance appraisal, professional and employee ethics and code of conduct. The Companys personnel policies and processes enshrine equal opportunities to all and non-discrimination with regard to gender, caste, creed, ideology or other opinion, whether social, political or religious. Also ensured is a due process for employee consultation and participation in organizational development and policy

formulation.

FUNTIONS OF HR DEPARTMENT
Recruitment

Recruitment in ACC is a very fair and transparent process with adequate opportunities to look for suitable candidates internally as well as from outside. Applicants are generally invited on the basis of specific advertisements in newspapers and websites. A Committee of officers called the Central Recruitment Committee handles the entire recruitment process comprising screening of applications, preliminary short-listing, interviews and final selection. Every attempt is made to make the selection process as objective as possible by incorporating tests of competence. In some cases,
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outside consultants are retained. All decisions of the recruitment committee are recorded in respect of each candidate. Candidates are informed of their short-listing and selection immediately after the interview or at the earliest thereafter.

Performance management

The Companys performance management system is in itself a benchmark that provides ample opportunities and motivational incentives to employees so as to reward and retain good talent within the Company. These incentives include Performance Linked Incentives, Good Work Awards, Letters of Appreciation, Special Increments, Promotions, Nomination to external training programmed in India and abroad, public felicitation and appreciation. Some plants have Best Employee and Employee of the Month Awards and recognition. Competent employees and those who display aptitude are invited to become Trainers themselves and receive Train the Trainer facilitation.

Training & Development

ACC new Performance Management System incorporates a process called Competency Assessment and Training and Developmental Needs wherein appraisers are specifically called upon to identify and assess training needs of employees at specific intervals that do not coincide with Performance Appraisals. This is so that training needs can be assessed objectively. Training is imparted to take care of an individuals career development as well as functional and skill enhancement. Competency and Development training inputs include Skill and general performance enhancement, communication skills and Career development. Functional training needs are identified and conducted by functional departments while Corporate HR organizes competency and developmental inputs.
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Employee welfare & perquisites Employee welfare receives prime attention at ACC. We have several schemes for general welfare of employees and their families. These cover education, healthcare, retirement benefits, loans and financial assistance and recreation facilities.

ACC townships have excellent schools that are often the best in the district. Education at these schools is subsidized for employees wards. We offer attractive scholarship allowances for children studying at places away from their parents, merit scholarships for outstanding children and financial assistance for employees children to pursue higher professional education.

Liberal medical benefits are made available to employees and their family members by way of reimbursements towards normal medical treatment, domiciliary treatments and special sanctions for serious illness. Each of our townships has wellequipped health care centres with qualified medical staff and facilities, ambulance, referrals and tie-ups with reputed hospitals for specialized treatment. In addition, there are regular health checkups, camps and programmed.

Employees are eligible to apply for loans and financial assistance for various purposes such as purchase of assets, residential premises as well as a scheme that provides for supply of cement at subsidized rates to those building their own houses.

At our cement plants and factories, employees are provided furnished and unfurnished accommodation based on their entitlements. At many locations, the employees are
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given free electricity, free water supply and free bus facility for nearby places and schools. These houses are well-maintained and periodically upgraded.

Employee Satisfaction

In addition to periodic internal Employee Satisfaction Surveys, we participate in Employee Satisfaction and Work Places Surveys conducted by reputed external agencies and organizations like Hewitt Associates Grow Talent. And from time to time, ACC has also retained reputed firms like Mercer and Boston Consulting Group to study our internal work environment and employee policies and suggest areas of improvement. We share below salient points of the latest survey of employees:

People are treated fairly regardless of religion and gender

ACC is a safe place to work

Management is competent in running business

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Employees feel good about what we do for society

Proud to tell others I work here

Management thinks positively

The overall findings show significant job satisfaction at all levels as also deep respect for the company, its performance management system and its overall business performance.

FINANCE DEPARTMENT

Finance is defined as The life and blood of any organization. It can also be defined as Anticipation of financial resources, Acquiring of financial resources, and Apportionment of financial resources to profitable channels.
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Main functions of finance department Determining the financial needs of an organization Choosing of sources of funds Financial analysis and interpretation Cost-volume-profit analysis Capital budgeting Working capital management Profit planning and control Dividend policy of the company

Functions of finance department:ACCOUNT SECTION:The account section deals with all the general accounting, employee payroll and matter related to taxation etc. The departments activities are coordinated by Assistant manager fianc that report to manager finance. COST SECTION:The cost section does Accounting relating to preparation of monthly cost data and Bill providing Assistant manager cost coordinates the departmental activities and reports to manager finance. Finance Overview Internal Audit and Risk Key Objectives

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 Evaluation of the overall control environment to provide assurance to management on the existing controls Risk based reviews to ensure compliance/ identity gaps in the critical areas of review

Investment Operations Key Objectives Settlement and custodian of investment with effective cash management NAV calculation and publication Ensuring every investment is within the regulatory framework Tracking and analysis investment performance

Accounts Key Objectives Financial reporting as per regulatory and management requirement Timely and accurate processing of expenses

Planning, Business Analysis and Commercial Key Objectives Planning and business analysis Development of strategic and operational plans Tracking and analyzing business performance

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 Cost analytics ensuring initiatives

values delivery across organizational

Sales compensation acquisition payout operations

Legal and compliance Key Objectives Secretarial functions Compliance Group insurance policy documentations Legal functions Drafting and vetting of documents Attending to legal cases

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MARKETING DEPARTMENT
ACC Indias first name in cement.

ACC cement is India's foremost manufacturer of cement and concrete. ACC's operations are spread throughout the country with 16 modern cement factories, more than 40 Ready mix concrete plants, 20 sales offices, and several zonal offices. It has a workforce of about 10,000 persons and a countrywide distribution. ACC's brand name is synonymous with cement. Its marketing, sales and distribution processes are industry standards. The brand building approach to marketing cement which was first adopted by ACC has proved to be exceptionally successful in respect of blended cements in terms of providing more effective communication with customers and has been emulated by other companies in the industry. Marketing strategies of ACC ltd:1. Segmentation:- The company has segmented the market geographically ,it sells

its product all over the India with major northern region.
2. Pricing strategies:- Before deciding the price of the cement company has

considered following points:

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Officers expenses Tax and interest Competitors pricing and offering

3. Marketing strategies for competitors:- Company always keep an eye over its

competitors activities and offering like different promotional scheme ,product price etc. It also proper action according to competitors strategy.
4. Distribution strategies:-The company is distributing cement by following ways:-

Direct to consumer Depot

1. Wholesaler 2. Retailers

Director general of sales & disposal

1. Tender sales 2. Government Department

Non trading sales

1. Wagon land

Institutional sales

Method of developing dealer:Company conduct market survey also to motivate sub dealer and advertise programmer, The company takes profile of the dealer and gives dealership only those in a particular area where there is not having already existing dealer.

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Objectives of Marketing Strategies:

To increase sales in high realization . To develop stockiest network consisting of retailer or final outlet which directly sell. Marketing distribution network more efficient and cost effective.

Marketing Department includes:

1. Marketing In charge 2. Marketing intelligence officers 3. Customer service In charge 4. Logistic In charge 5. Administrative support

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Research and Development

ACC is the only cement producer in India with its own in-house research and development facility. This unit, recognized by the Department of Scientific & Industrial Research (DSIR) in the Ministry of Science and Technology, is engaged in research and development activities related to cement and concrete areas. The R & D programmes addresses a spectrum of activities that cover technical services for quality and technology up-gradation and development of products and processes in the companys core business. Given the inherent variability in the mineral resources used in cement manufacture, considerable attention has been devoted to continuously optimizing process conditions including raw materials proportioning to ensure the highest quality. ACC has a unique track record of innovative research and specialized technological services. Some special products born out of this own in-house research, include a range of unique products of immense value to the concrete and construction sectors such as High Performance Concretes, Ancones a non-explosive demolition agent and ACC Marg a novel technology for flexible pavements suitable for resurfacing and strengthening roads and hig

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HEAD PLANT OPERATION

Head plant operations department includes overall maintenance and operation related to plant .It includes different functions which are given below:-

1. ENVIRONMENTAL PROTECTION & QUALITY DEPARTMENT

Jamul Cement Works, a part of ACC, in tune with the change of times had gone in for Quality System s Certification ISO 9002 and Environment Management Certification ISO 14001. Every employee is made to aware of companys quality and environment policy. To enable the employees to know the companys vision, values and mission statement, the same are exhibited / displayed at prominent places in the plant and colony. Jamul Cement works has committed itself to Total Productive Maintenance (TPM), Bench Marking and Re Engineering to achieve organizational excellence. Many hierarchical layers of Management are eliminated for constituting Small Group Activities, Quality Circle Groups, kaizen etc., which are, to a large extent self managing and capable of taking initiatives.

Total Productive Maintenance (TPM) has been adopted and implemented at Jamul Cement Works in great Zeal and enthusiasm. Under TPM, main emphasis has been given to enhance several systems like Maintenance Management system, Production Management system, Total participation through Small Group Activities, Quality Circle, Suggestion Box Scheme, Save Energy Reduce Waste Action Committee (SERWAC)etc. as tools for over all improvement of the organization.

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Through Small Group Activities (SGA), innovations for new creations are generated and implemented for achieving excellence. SGA comprises of employees from different departments and thus giving impetus to Cross Functional Team Participation.

In Quality Circles (QC), workers are encouraged to generate ideas, discuss and finalize their own action plan. All management staff meet every fortnight in the brainstorming management development forum to discuss the new and recent development / technological changes in cement manufacturing and other related areas.

SUGGESTION BOX SCHEME Jamul Cement Works follow the principle that Ideas However Small And Whatever the Source Has Its Value. Based on this idea we have a Suggestion Box Scheme open to all employees. Suggestions selected and implemented are given awards at gate meetings.

Energy Conservation Achievements As discussed earlier, Jamul Cement Works had made continuous efforts for energy conservation with utmost priority, which is clearly shown in the energy utilization pattern. The various concepts explained above which are in vogue at our works have contributed immensely to the productivity of the company which is reflected in the parameters achieved during the year 2001-2002. The various factors contributed to the above savings are installation of energy efficient equipment / system, optimization of process operating parameters, plugging of leakages etc.

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Energy Conservation Plans and Targets As a continuous improvement process, being the companys Quality Policy, Jamul Cement Works puts its effort to reduce the energy consumption on continuous basis. The targets for energy consumption are set yearly. The targets are set after considering the following aspects. 1) Comparison with International & Indian norms 2) Best achieved in the past years 3) Comparison with performance with sister works. 4) Present condition of the equipment. 5) Conformance to Corporate targets. These targets are set Kwh per tonne of cement produced. The power consumption per tonne of cement is monitored every day. A daily productivity report is prepared which includes the power consumption of each major equipment. If the power consumption exceeds the fixed norms, necessary actions are taken. The reporting job is assigned to the process Egg. Dept., who puts up this in the daily communication meeting for finding out the reasons leading to this condition and the steps to be taken to rectify this.

Basis for the fixation of the energy targets : 1) Review of past performance of individual sections. 2) Detect unfavorable trends and find out method to arrest the same within the limit. 3) Discussion with departmental heads, local & corporate management regarding fixation and achievement of energy targets. 4) Conversion of targets to monetary value for effective control. 5) Energy of each section. 6) Providing some amount of capital budget for energy saving schemes.

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Environment and Safety Apart from business ethics, Jamul Cement Works had shown immense concern for society and community development. It has a commitment to preserve & safeguard environment. The creation of environmental department is an ample example of its commitment and has also taken up conservation and protection of environment in following areas: Ambient Air Quality Management Water Quality Management Noise Control Management Solid Waste Management.

Apart from holding IS/ISO 9002 quality system certification, Jamul Cement Works has acquired ISO 14001 system certification for Environment Management. In addition to this, Jamul Cement Works always keeps its glory by achieving awards like

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AWARDS AND ACCOLADES WON

Golden peacock Commendation Award for Environment Management for the year 1997; Various Safety and Environmental Awards from Mines Safety and DGMS; Various in house organizational awards in TPM, Safety and housekeeping.

M/S DIN & GRAY who carried out the study in 1997 evaluated the performance level of our works as 72.63 % on overall environmental aspects. To have clean and hygienic environment various steps have been taken up such as installation of high capacity and state of art Electrostatic Precipitators and dust collectors. Large-scale plantation has also been done.

Jamul Cement Works is highly safety conscious and has the safety policy for both management staff ass well as employees. To implement safety at all stages, the unit is having a team headed by safety officer. The safety patrollers of the safety department monitors the problem areas, provide solutions to overcome the problems. To improve safety awareness, every month safety meeting is being held at the main gate, which is followed by a nukkad drama on safety. In addition to this, training on safety, fire fighting and first-aid is also given to the employees. safe working conditions / practices. competitions are also conducted Committed to Environment Protection ACC is among the first Indian companies to include commitment to environmental protection as one of its corporate objectives. Long before pollution control norms and regulatory laws came into existence, ACC inducted the use of sophisticated high efficiency pollution control equipment for cement kilns, raw mills, coal mills, power
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Safe protecting

equipments are given to all the employees. Displays are provided to give emphasis on To improve the safety awareness, slogan / essay

plants and coolers. That was in 1966. Today each ACC factory has high efficiency stateof-the art pollution control equipment and devices. Each of our manufacturing units has a separate Environment Section manned by a qualified environmental engineer and supporting staff. ACC is the industry leader in the urgent race to reduce CO2 emissions. Our performance is seen by independent sources to be best in class. We have established systems and procedures to manage improvements in the control of greenhouse gas and atmospheric emissions. Energy Efficiency Energy is a prime concern. We have made significant strides in attaining energy efficiency through our captive power plants and the pursuit of building our capacities in clean renewable energy sources such as wind energy farms Greening the Environment Each of our cement plants has its own success story of tree plantation, greening activities, horticulture, flower and fruit cultivation and water conservation. Tree plantation and green belt development programmers have been extended to cover areas in the vicinity of our plants for the benefit of the local community. A forestation programmed in used mines have helped transform the barren and dry ambience into lush greenery. Tree plantation is a regular and committed activity at ACC. Each One, Plant One is a message that inspires our employees. Water Conservation With an avowed policy to maintain Zero Water Discharge, we continuously seek better ways to manage our water resources efficiently. The water used in plants for industrial cooling is recycled through cooling towers, water ponds and tanks. Our cement plants have converted old abandoned mines into huge reservoirs by collecting rainwater from catchments around mines. As a result, we have several outstanding examples of achievements in water harvesting and in the creation of reservoirs in

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abandoned mines and quarries. Some of our plants have become near self-reliant in respect of their water requirements for industrial and domestic consumption. Transforming and Managing Wastes ACC has achieved spectacular results in the utilization of two hazardous and pollutant industrial wastes - namely slag from steel plants and fly-ash from thermal power stations - to make blended cements that offer unique advantages to concrete. We were first in the use of waste sludge from the fertilizer industry to make cement. ACC is now actively engaged in the promotion of alternate fuels and raw materials and in coprocessing waste materials through effective use of cement kilns. Co-processing is the act of adapting an existing industrial process in a single combined operation whereby waste materials generated in other industrial processes may be put to gainful use as alternative fuel or raw materials in cement kilns, dryers and captive power plants. These materials include agro-wastes like rice-husk and other wastes such as plastics, biogases, lubricants, paints, used tyres, municipal and domestic solid wastes. ACC takes pride in extending its waste management services to a wide range of industries in the country that generate hazardous and non-hazardous wastes.

2. MECHANICAL DEPARTMENT
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Directs and supervises the activities of Mechanical Division to Basic Function : provide timely and efficient maintenance of mechanical components of assigned plant equipment and machinery. Includes formulating and recommending policies and procedures that relate directly to assigned Division. Receives from Section Engineers, reviews and submits to Manager, Engineering Department, mechanical engineering studies designed to improve productivity and efficiency and reduce operating costs. Coordinates with other Departments/ Divisions for material requirements and performance of maintenance jobs. Duties Performed : a) Directs, coordinates and supervises the activities of personnel assigned to Mechanical Division. Performs supervisory functions and exercises authority at the Division Head level as established by Management. b) Develops, reviews and recommends policies and procedures related to Mechanical Division, such as methods of work assignments and usage of spare parts, materials and equipment, to ensure the proper and effective functioning of the Division. Includes the proper administration of approved policies and procedures and ensuring their adherence within the Division. c) Ensures the formulation of, reviews and recommends to Manager, maintenance Engineering plans and Department, methods implementation covering of preventive

maintenance of mechanical components of assigned equipment and machinery. Includes ensuring the efficient repair, inspection and utilization of manpower and materials, cost and budget

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controls, etc. d) Receives and reviews comprehensive and periodic reports on the performance of the assigned Sections, identifies problem areas and directs Section Engineers on means and methods of improving their respective Sections' productivity and efficiency. Submits to Manager, Engineering Department, periodic reports outlining the Division's performance and plans. e) Designs and establishes systems for the Division to prepare exception reports for personnel and for equipment and machinery assigned for maintenance so that nonstandard performance and failures are identified and corrective actions and measures are taken whenever necessary. f) Directs the development of, reviews and recommends

implementation of feasible proposals based on mechanical engineering studies associated with planning, installing and maintaining of new or modified existing cement plant machinery and equipment for improving efficiency and reducing costs. Regular contacts with personnel up to Department Head level for performing and coordinating work of assigned division with proponent organization. Work Contacts : Occasional contact with machinery suppliers and maintenance contractors.

Independence of Operation :

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Reports to Manager, Engineering Department

Works according to specialized professional and administrative standards. Completed work is subject to review of Manager, Engineering Department. Supervises: 3 Section Engineers plus approximately 140 subordinates. Moderate physical exertion while supervising and inspecting maintenance work. Work Environment : Normally AC environment but occasionally exposed to prevailing weather conditions while inspecting maintenance work.

Supervisory Responsibility : Physical Effort :

3. MINING DEPARTMENT

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All the cement plants of the company are equipped with advanced technological facilities which make them completely environment friendly. The plants use some of the sophisticated pollution control devices in various parts such as raw mills, power plants, cement kilns, coolers and other equipments. In addition, the mining technologies that have been implemented in the cement plants of ACC Ltd are also based on environment safeguard norms.

In its endeavor towards greenery, the company has also started various types of a forestation, horticulture and tree planting programs near its cement plants. It not only reduces pollution but also helps conserve the mineral resources. The vacant spaces in the mines and the cement plans are being utilized for the purpose of planting of trees. In some of the ACC Ltd. Cement Plants in places like Chaibasa, Kymore, Jamul and Gagal, greenery has been added to around 40% of the total area which is around 10% more than the normal norms that has been set. The management of these plants has given stress on the green belt development programs.

The ACC Ltd. Cement Plants consist of high quality Zero Water Discharge facilities which help in proper water management. The water that is used in the plant for the process of industrial cooling is recycled by the use of tanks, water ponds and cooling towers. Through this process, the company has successful in water harvesting.

4. PRODUCTION DEPARTMENT

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The high quality cement that is manufactured and exported by ACC Ltd is produced in the ACC Ltd. Cement Plants. ACC Ltd is one of the front runners in the cement industry in India and produces some of the best quality cement in the country.

Nature of Work in the Cement Plant The process of cement production is varied and requires several levels. The ACC Jamul plant is engaged in the Semi-Dry process The following is a detailed outline of the production process as well as the number of workers involved in each process. The delegation consulted the unions Chhattisgarh Cement Karmachari Sangh (CCKS) and Pragatisheel Cement Shramik Sangh (PCSS), which represents the contract workers and provided figures of around 1000 contract workers.

1. Limestone extraction/mining at the quarries is done from two mines located at a distance of 2 and 22 kilometers away from the plant respectively. From here, the limestone is transported on a daily basis through dumpers to the plant. 40 contract workers deployed in this operation with about 15 permanent workers. 2. Next, it comes to the crusher department of the plant where it is reduced to smaller size (1 inch, quarter of an inch etc.) There are about 10 permanent and 20 contract workers in this operation. workers are employed. Jamul plant has 8 cement mills, In addition to the permanent workers there are about 150 contract workers employed in this stage. 3. Thereafter, this is stored in Silos and the packing department takes over. The work in \the packing department is totally outsourced with about 122 contract workers 4 BWI / ICEM mission report 16 June 2011involved in packing and loading in the wagons. There are about 8 packing units .

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4. This raw meal then comes to the Kilns (Jamul Plant has 3 units of the same). In addition to the 30-35 permanent workers, 60-70 contract workers are employed in this stage. 5. From the kilns, it goes to the Cement Mill. About 60-65 permanent Jamul plant each requiring about 10-20 workers (based on the demand to dispatch cement). 6. In addition, about 50 contract workers are involved in Electrical department along with 30 permanent workers, 30 contract workers in slag warming, 12 each in Housekeeping and Maintenance work, 150 contract workers in Civil department along with 3 permanent workers, 50 contract workers in Power Plant long with 30-35 permanent workers, 25 contract workers in the Coal mill along with 10 permanent workers and 50 contract workers along with the same number of permanent workers in the Plant Workshop.

The management states that contract workers only provide support structure to the permanent workers who are involved in key operations and supervisory roles. The PCSS states that permanent workers are involved as supervisors and in highly skilled jobs such as fitters and machine technicians and all the other daily work is done by the contract workers.

The cement plant operates throughout the year without any stoppages with the exception of maintenance work or plants. possible mechanical breakdowns of any of the During rainy season, the production is continuous; however, the overall

production may slow down due to demand decreases at this time period.

5.SAFETY AND HEATH DEPARTMENT

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Occupational Health & Safety (OHS) is a vital part of ACCs journey towards Sustainable development. Safety Audits are being carried out in ACC since 1995 by National Safety Council based on the 5 Star Auditing System of British Safety Council. There is a continuous effort to measure and improve Safety Management Systems to avoid accidents. We have an Apex OH & S Committee headed by the Managing Director. This committee oversees implementation of our OH & S policy Each of our plants and manufacturing units have Professional Doctors and medical facilities for continuous monitoring and observation of workplace hygiene and occupational health. The following are some OH & S initiatives at our plants:

OH & S brochures, signage, posters and mailers used extensively Monthly Safety Gate Meetings held at all our plants. Safety Audit and TPM Audits carried out annually Safety Professionals meets twice a year to discuss and share knowledge on Safety Safety Observation Tours (SOT) conducted weekly by all line managers Behavioral Safety Training programmers for workers at all plants Incident investigations for all incidents including near misses (with potential for

Statistics and implementation of safety measures at each unit.

injuries). The findings and recommendation are shared across the company

OUR OH & S VISION NO HARM ANYWHERE TO ANYONE ASSOCIATED WITH ACC

NO HARM means:
No fatalities No disabling Injuries No Lost Time Injuries No Medical treatment Injuries No First Aid Injuries No Occupational Illness

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ANYONE means:
Employees Contractors personnel on site Ready-mix drivers on job Third party contractors on site Visitors to ACC site

OUR OH & S POLICY We manage our activities in a responsible manner to avoid causing any harm to the health and safety of our employees, contract personnel and visitors. We apply OH&S standards and guidelines; provide the necessary resources, training and education and measure performance for continuous improvement. FIVE CARDINAL RULES FOR SAFETY 1. Do not override or interfere with any safety provision nor allow anyone else to override or interfere with them. 2. Personal Protection Equipment (PPE) rules, applicable to a given task, must be adhered to at all times. 3. Isolation and Lock Out procedures must always be followed. 4. No person may work if under the influence of alcohol or drugs. 5. All the injuries and incidents must be reported.

6.CAPTIVE POWER PLANT

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Steam based Captive Power Plants (CPP) play a vital role in improving our cost competitiveness and providing quality power to our plants. In 2009, gross generation of power by our CPPs was 1733 million kwh which was 1 4% higher than the gross generation of 1517 million kwh in 2008. This helped increase the share of power from CPPs in total power consumption for cement production, from64% in 2008 to 70% in 2009. The sale of surplus power from CPP after meeting the requirements of cement plants increased three times, from 32million kWh in 2008 to 113 million kwh in 2009. During the year under review, the company commissioned one 15 MW CPP as a part of Bargarh plant expansion. Additional captive owe regenerating capacity of 50 MW in Wadi, 15 MW in Bargarh and 25 MW in Chanda is scheduled to be commissioned and stabilized in 2010. With this increase captive generation, we grid power to go down further. except dependence on

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SWOT ANALYSIS

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SWOT Analysis

STRENGTHS. 1. It is having a good image and brand loyalty among consumers. 2. Service is good 3. Dhalai karne ke liye people ask for ACC
4.

They have same price prevailing for wholesale at dealers/stockiest retailers end.

WEAKNESS.
1.

The competitors are doing much promotional activity rather than ACC

Limited thats why facing more problems in selling of product in the market.
2.

Lack of awareness program for consumers.

OPPORTUNITY. 1. Rapid growth is taking place in Bihar and Madhya Pradesh.

2.

People are opting for more stable structures and intensive, even government is use of cement is taking place spending heavily on infrastructure projects . Thus, this is the right time to fully tap these markets.

3. As Indian core industry is also growing at rate of nearly 10% per annum,it is having a good future. 4. Foreign direct investment in infrastructure sector going to increase in coming years, which will increase the demand of cement. 5. Roads are undergoing through the transformation process through which the traditional method of road building will be replaced by modern concrete roads.

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THREATS:

Large number of players in cement industry makes it more competition

ACC to carefully price its product and at the same time satisfy its dealers and customers.

Players such as Jaypee Cement, Prism Cement, and Birla Samrat are eating up considerable market share.

Due to Indians exponential growth many new international cement companies are expected in coming years which will bring a tide of change and can start price war.

The emergence of small players in this market may increase the competition and start the malpractices, and heavy discounts to retailers. They can also influence many retailers by giving better profit margin, and other Ben shared.

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FINDINGS, SUGGESTIONS AND CONCLUSION

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FINDINGS

ACC has a unique track record of innovative research, product development and specialized consultancy services. It is an important benchmark for the cement industry in respect of its production, marketing and personnel management processes.

ACC is proud of its many innovations over the years and realizes that innovativeness is an essential characteristic of leadership.

ACC has made significant contributions to the nation building process by way of quality products, services and sharing expertise. Its commitment to sustainable development, its high ethical standards in business dealings and its on-going efforts in community welfare programmers have won it acclaim as a responsible corporate citizen. ACC (HOLCIM) Plant Jamul Town employs a high number of contract workers. Permanent workers and contract workers are treated differently for the same work at the same workplace, e.g. wages and benefits.
There is no evidence that the company guarantees the equal rights of contract

workers and fully respects international labor standards and conventions, e.g. discrimination.

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SUGGESTIONS

ACC ltd must focus on its vision and mission in order to attain its objectives. ACC ltd should focus on expanding its market in order to grab the market

shares. It should also try to maximize the shareholder wealth. ACC ltd should not choose those project which may dilute the brand name just for the sake of gaining market shares.

It should focus on the convert itself from question marks to stars. ACC ltd has a high growth potentials so its try to raise funds timely in order to meet its target.

ACC ltd should not do overpromise as it will deteriorate its goodwill. ACC ltd must focus on its competitors strategy in order to gain a competitive edge.

ACC ltd should try to for diversification to minimize risk factor and to explore new market as well.

The company should concentrate more on the advertisement, as it is not doing much on this. This can be done by ways of various advertisement tools like media (TV, news paper), sponsorships etc.

The company should concentrate on the overall improvement of the agents in the aspect of sales and attracting new customer

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Conclusion

It is concluded that ACC Limited is Indias foremost manufacturer of cement and ready mix concrete with a countrywide network of factories and marketing offices. ACC ltd has undergoing manufacturing operation BIHAAN which aims to

increase productivity by reduce cost.ACC ltd has prepare a social agenda which aims to change old mindset of people towards work.ACC ltd believe this constitutes balancing the Triple Bottom Line - defined as the achievement of three interdependent and mutually reinforcing goals of economic development, social development, and environmental protection. ACC has taken purposeful steps in knowledge building. We run two institutes that offer professional technical courses for engineering graduates and diploma holders which are relevant to manufacturing sectors such as cement. The main beneficiaries are youth from remote and backward areas of the country. ACC LTD JAMUL mission towards their employees: We demand and stand for equal treatment for all contract workers in the same way as for permanently employed in the Cement Industry in India.

BLIOGRAPHY
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Text Books Organizational Behaviour - K Ashwathappa Personnel Management - C B Mamoria

Other References Broachers, pamphlets , postures published by acc limited

Websites www.acchelp.in www.accltd.com www.goggle.com

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