A Report 0n The Ion Study at

Travancore Cements Ltd.
LIST OF TABLES & CHARTS

TABLE OR CHART Page NO
Study plan 5
Organization structure 17
Profit & Loss A/c 21
Balance Sheet 22
Structure of the production department 25
Production process 33
Structure of the personnel department 35
List of Apprentices 45
Allowances to employees 46
Employees’ strength of TCL 47
Structure of finance department 48
Structure of the marketing department 55
Pricing of the product 57
Structure of the purchase department 61
1 Organisation study 2008

CHAPTER-1
INTRODUCTION

GENERAL INTRODUCTION
When earth itself was undergoing intense geologic changes, natural cement
was being created. It was this natural cement that humans first put to use. Eventually,
they discovered how to make cement from other materials. Cement is a finely grounded
powder which when mixed with water sets to a hard material. Cement has been most
exclusively used as a building material for past several years and remains so even today.
It is exclusively used in constructing roads, buildings, bridges, dams, canals and in
number of other places. New users are being found all the time, as now we have cement
concrete railway sleepers, electric poles, tenting and even manhole covers. No
replacement exists for the cement in foreseeable future and it is bound to retain its
prominence in the field of construction.
The ancient Romans developed cement and concrete similar to the kinds used
today. They manufactured cement by mixing slaked lime (lime with water) with a
volcanic ash called Pozzuolana. People lost the art of making cement after the fall of
Roman Empire in AD 400’s. In 1759, John Sneaton , a British Engineer found how to
make hydraulic cements by using blue lime with clay content and Pozzuolana from Italy.
I. C. Johnson produced Portland cement in 1845. Portland cement contains about 60%
lime, silica and 5% alumina. Iron oxide and Gypsum make up the rest of the materials.
In the plant the materials go through a chemical process that consists of three basic steps
namely crushing, grinding, burning and finish grinding.
Cement was developed by Joseph Asp Din of England. He manufactured
commercially the improved quality of Portland cement in a country market kiln in the
year 1848. The present day high quality cement is unique versatile building material, a
product of technological development. Cement produced on 21st October 1854 was
patented as Portland cement.
Industrial era in Kerala and its beginning from the time of Sir C.P Ramaswamy
Iyer, Diwan of Travancore State during the pre-independence period. He knew that the
cement is one of the basis industrial needs for the speedy industrialization of the state
and felt it is very essential for the state to have atleast a cement factory. But lime stone

deposits of the required quality were not available to start a cement plant factory in
travancore. However, lime shells available in the backwaters offered in alternative
ofcourse a better source for calcium raw material. Sir C.P Ramaswamy Iyer induced the
promoters of TCL for pulling up cement plant based on the lime shell reserve. Thus the
first cement plant starts its operation on 7.12.1946 in Kerala.
SCOPE OF THE STUDY
The study is about the major functioning of Travancore Cements Ltd. Nattakom, The
study is mainly based on the details collected from each department. Each and every
activities of the company is studied very carefully with the data available. This study is very
beneficial to the future managers as they are put into the real life situations. A study on all the
departments can help to improve the process and there by an over all improvements in the
company’s performance can be made.
OBJECTIVE OF STUDY
The objectives of the study are:
 To get familiar with the organization.
 Getting practical experience regarding the organisational function.
 To learn about the policies and functions of the organisation
 To understand the culture in the organisation and its effect on employees.
 To get industrial exposure and experience.
 To understand the marketing and production methods To acquire knowledge

about the managerial aspect of the firm.
REASON FOR SELECTING THE COMPANY

The following are the main reasons why I selected TCL for my
organizational study:
 TCL is one of the oldest manufacturing industries in Kerala.
 TCL have sufficient number of departments and also the one that is engaged
in active performance in the industry.
 TCL is an organization working with a big work force.

 TCL is one of the famous organization in Kerala involved in the

manufacturing activities.
STUDY PLAN
15-05-2008 General study

16-05-2008 General study
19-05-2008 Visited running plant
20-05-2008 Observed the working of dredger& unloading of lime shell
21-05-2008 Visited production department
22-05-2008 Visited production department
23-05-2008 Visited personnel department
26-05-2008 Visited personnel department
27-05-2008 Visited finance department
28-05-2008 Visited finance department
29-05-2008 Visited marketing department
30-05-2008 Visited marketing department
02-06-2008 Visited purchase department
03-06-2008 Visited purchase department
04-06-2008 Visited packing house, time office, security department
06-06-2008 Visited maintaince department, work shop etc
09-06-2008 Visited lab, transportation department etc
10-06-2008 Preparation of report
11-06-2008 Preparation of report
12-06-2008 Submission of report
13-06-2008 Applied for certificate
DATA PROCESS
METHODOLOGY OF THE STUDY

Research methodology is a way to scientific and systematic research for pertinent

information on a specific topic and solves the research problem.
METHODS OF DATA COLLECTION
The data collected constitutes both primary and secondary data.
PRIMARY DATA
Primary data are those which are a fresh and for the first time and thus happen to be
original in character. Primary data were collected by direct interview with the authorities and
staffs and by observation and participation.
SECONDARY DATA
Secondary data are those which have already been collected by someone else and
which have been passed through the statistical process. Secondary data were collected
from various records kept in departments, company profiles, magazines and websites.
LIMITATION
The following are the limitations which I found during my organization study:
 Some of the data were treated confidential and hence it was difficult to get the
same.
 Most of the datas’were collected through interviews and so the information is
subjected to be biased.
 A detailed interview schedule couldn’t be administered to get primary data.

CHAPTER 2
INDUSTRY PROFILE
CEMENT INDUSTRIES IN INDIA

The cement industry comprises of 125 large cement plants with an installed
capacity of 148.28 million tonnes and more than 300 mini cement plants with an
estimated capacity of 11.10 million tonnes per annum.

The Cement Corporation of India, which is a Central Public Sector Undertaking,

has 10 units. There are 10 large cement plants owned by various State Governments. The
total installed capacity in the country as a whole is 159.38 million tonnes. Actual cement
production in 2002-03 was 116.35 million tonnes as against a production of 106.90
million tonnes in 2001-02, registering a growth rate of 8.84%. Major players in cement
production are Ambuja cement, Aditya Cement, J K Cement and L & T cement.
Apart from meeting the entire domestic demand, the industry is also exporting
cement and clinker. The export of cement during 2001-02 and 2003-04 was 5.14 million
tonnes and 6.92 million tonnes respectively. Export during April-May, 2003 was 1.35
million tonnes. Major exporters were Gujarat Ambuja Cements Ltd. and L&T Ltd.
The Planning Commission for the formulation of X Five Year Plan constituted a
'Working Group on Cement Industry' for the development of cement industry. The
Working Group has identified following thrust areas for improving demand for cement;
i. Further push to housing development programmes;

ii. Promotion of concrete Highways and roads; and
iii. Use of ready-mix concrete in large infrastructure projects.
Further, in order to improve global competitiveness of the Indian Cement

Industry, the Department of Industrial Policy & Promotion commissioned a study on the
global competitiveness of the Indian Industry through an organization of international
repute, viz.
For India, the world's second largest producer of cement, the recent boom
in infrastructure and the housing market has only boosted its cement industry. Add to
that an increasing global demand and a flurry of activity in infrastructure projects –
highways roads, bridges, ports and houses – has sparked off a spate of mergers and
acquisitions in the sector. Furthermore, the country’s finance minister, P. Chidambaram,
has stated that India would double spending on infrastructure over the next five years to
sustain its record economic growth and modernize its infrastructure.
Cement companies are fast developing plants to provide for a rapidly

expanding economy. The cement industry is therefore poised to add 111 million tonne
(mt) of annual capacity by the end of 2009-10 (FY10), riding on the back of

approximately 141 outstanding cement projects. According to a report by the ICRA

Industry Monitor, the installed capacity is expected to increase to 186 mt per annum
(mtpa) by FY08-end, and 219 mtpa by end of FY09, and further up to 241 mtpa by
FY10-end. As a result, India’s cement industry will record an annual growth at 10 per
cent in the coming years with higher domestic demand resulting in increased capacity
utilisation.
DOMESTIC PLAYERS
While the Cement Corporation of India, a Central public sector
undertaking, comprises 10 units; the various State governments own 10 large cement
plants. Among the leading domestic players in terms of cement manufacturing are:
Ambuja Cement, Aditya Birla Group (which owns UltraTech Cement), ACC Ltd.,
Binani Cement, India Cements and J K Cement. They are not only the foremost
producers of cement but also enjoy a high level of equity in the market.
GLOBAL PLAYERS
Rapid urbanisation and the booming infrastructure have lead to an
increase in construction and development across India, attracting even the global
players. The recent years have witnessed a surge of foreign direct investment in the
cement sector. International players like France's Lafarge, Holcim from Switzerland,
Italy's Italcementi and Germany's Heidelberg Cements hold more than a quarter pie of
the total capacity.
• Holcim, one of the world's leading suppliers of cement, has 24 plants in the
country and enjoys a market share of about 23-25 per cent. It will further invest
about US$ 2.49 billion in the next five years to set up plants and raise capacity
by 25 mt in the country. Holcim has a global sale worth about US$ 20 billion,
where India contributes US$ 2–2.5 billion.
• Italcementi Group, the fifth largest producer of cement in the world acquired full
stake in the K.K. Birla promoted Zuari Industries' cement, to strengthen its
presence in India lining up US$ 300 million investment to increase the capacity
of Zuari Industries from 1.7 mtpa to about 6-7 mtpa. Moreover, it plans to invest

US$ 174 million over the next two years in various greenfield and acquisition
projects.
• The French cement major, Lafarge, acquired the cement plants of Raymond and
Tisco with an installed capacity of 6 mtpa. It plans to double its capacity to 12 mt
over the next five years by adopting the greenfield expansion route.
• Heidelberg Cement has entered into an equal joint-venture agreement with S P
Lohia Group controlled Indo-Rama Cement. It aims at a 50 per cent controlling
stake in Indo-Rama's grinding plant of 0.75 mtpa at Raigad in Maharashtra.
Heidelberg is also taking over Mysore Cement of S K Birla group at a
consideration of US$ 93 million.
DECLINING ROLE OF PUBLIC SECTOR
Historically, cement has been one of the most important areas of

operations for the Indian private sector. Unlike much of heavy industry and utilities,
cement was not deemed to be the exclusive preserve of the State sector in the post-
independence development strategy. Cement was also the industry of choice of many
corporates diversifying away from the troubled traditional areas of jute and textiles.
Over the years, the share of the public sector in cement production
has declined. While the private sector (large companies) accounts for around 95% of the
total installed capacity, the share of public sector companies has declined from a level of
11% in financial year 1996 to around 4.4% in financial year 2006. The share in
production of the public sector companies is even lower at 1.2% in financial year 2006
as compared to 6.5% in financial year 1996.
Among cement public sector undertakings (PSUs), Cement

Corporation of India (CCI), a central PSU, is the leading player. It has 10 cement plants
with a total installed capacity of 3.85 mtpa at end financial year 20 06. Other PSU
companies manufacturing cement include State entities such as UP State Cement
Corporation (3 units with total capacity of 2.16 mtpa); and Tamil Nadu Cement (2 plants
with a total capacity of 0.9 mtpa). Given the extent of losses being incurred by most of
these plants, restructuring and revival through privatization appears imminent.
Accordingly, the Yerraguntla unit in Andhra Pradesh, which belonged to CCI, was taken

over by India Cements in FY1998. The three units of UP State Cement Corporation have
been closed since early 1998. These units were taken over by Jaypee Group in financial
year 2006.

CHAPTER 3
COMPANY PROFILE
COMPANY PROFILE

The Travancore Cements Ltd is the only manufacture in the world producing
white cement from natural lime shells. The company was incorporated in 9th October
1946. The master brain behind the establishment of the plant was that of late Sir.C.P
Ramaswamy Iyer, the then dewan of Travancore,who had reali zed the vital role of
cement in the industrial development of Kerala. The company was promoted by M/s
Essel Limited, Bombay and the Technology tie up was made with M/s F.L.Smidth &
Co., Denmark.
The Travancore Cements Ltd is the only manufacturer, perhaps in the whole
World, producing white cement from a raw material other than conventional lime stone.
The raw material for cement is lime shell, which is dredged out from Vembanad Lake;
one of the back waters of Kerala. Lime shell is one of the purest sources of calcium
carbonate available for the cement manufacturer. As it contains magnesium oxide in
traces only the white cement out of lime shell is highly durable and superior in quality,
quick setting and stronger than white cement made from limestone.
In 1988 the company has set up its cement plant at Kakkanadu, near Cochin
with an installed capacity of 120 tones per annum on a single shift. As the production
was far below figure due to insufficient raw material supply, the plant was forced to
close down. The employees of this plant were absorbed by the parent company itself.
LOCATION
Travancore cements Ltd is situated on the banks of Kodoor River and on the
side of state highway M.C Road 4km away from the Kottayam town in kerala, the
southern most state in India. The location of the plant is in such a way that is accessible
by both land and water. The beautiful locality in which the company is situated extends
over an area of 60 acres. The location facilitates the need of transportation of raw
material and finished goods.
PROMOTERS

The company was originally started under private management of M/s Essel Pvt.
Ltd. In 1975 government of Kerala took over the management of the company. The
director of the managing agency of the company at the time of its commencement was
Mr. T.S. Narayanaswamy. The factory was installed under the supervision of Mr. S.
Rudlinger. Now the government of Kerala is holding 51.33% of the equity share capital.
The pyramid group of the company is holding another 25% of the shares and the
remaining shares are held by General Public.
BRANCHE S AND OFFICE S

The company has its registered office and factory at Nattakam, Kottayam, and
Kerala. It has a regional office at Trivandrum apart from this it also has depots at
Bangalore, Coimbatore and Vijay Wada.
PRODUCTS
The products produced in TCL are:
 White cement
 Super Shelcem (Cement Paint)
 Wa l l P u t t y
WHITE CEMENT
Vembanad White Portland cement is manufactured from the nature’s gift of rare
rawmaterials which are Crystal Gypsum are the raw materials. Technology used F.L.
Smith & Company, Denmark, conforms I S 8042 E 1976 specification.
Outstanding Qualities Of Vembanad Brand White Cement

• Lowest magnesia content and hence the most durable White cement.
• Brillant whiteness.
• High strength
• Super soundness
• Excellent properties

• Ideal for manufacture of Cement Paints,Mosaic Tiles.
SUPER SHELCEM (CEMENT PAINT)

Super Shelcem is a technologically unique formulation with the most durable
“Vembanad” White cement. It contains a high percentage of light fast pigments, which
help colour retention.It contains more White cement than any other Cement Paint in the
country. SuperShelcem does not rub, flake or peel off and can be washed. Is un affected
by normal climate conditions and protects the wall against fungi growth. Ideal for
coating on concrete, asbestos, cement sheets, fibreboards or any Cement surface.
Depending on the surface coverage of 7 to 10 Sq.m./kg for two coats is achievable. It is
more easy to apply and hence save time and labour and is quick drying.
Properties
i . WATER PROOFING
Super Shelcem offers excellent protection for the walls against monsoon and fungus
growth.
ii . CAPACITY
Any previous deep shade made on the surface can be effectively hidden with a single
coat of super shelcem. The second coat completely overs the dark patches and stains on
the wall.
iii . COVERAGE
Super Shelcem covers greater area than any other cement paint. 1 kg. Covers 100 sq.
ft. for a single coat or 65 sq. ft. for two coats.
iv. ADHESION
Super shelcem can be applied on a wide variety of surface like cement plaster,
concrete, bricks works, stone and lime plastered surface.
WALL PUTTY

It is a recently launched product. The base of wall putty is time tested Vemband
brand White cement. The object of the Company is to offer Putty of the highest quality,
giving the smoothest finish, highest coverage and durability. It has more coverage than
any other dry wall putty in the market. Due to low MgO content of Vemband white
cement , the durability of Vemband wall putty is more.
OBJECTIVE OF THE COMPANY

The main objectives of the tcl are the following
 To produce white cement paints using natural resources
 To provide employment opportunities
 To earn maximum profit
 To provide training to apprentice
 To make the company as the market leader.
QUALITY POLICY OF THE ORGANISATION

We at TCL are committed to continual improvement of the system enhancing
customer satisfaction by providing consistent quality products through the
implementation of Quality Management System.
VISION OF TCL
In the fast paced global development as the barriers are withering away. India
need proper external synergy creations from the manufacturing sector for which TCL,
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 (4 M’s)
MISSION OF TCL
Having a unique role in the Heavy industry sector of the country, TCL is
committed for catering the society towards the specific need expected by producing
quality product at a customer friendly price while keeping subsatianed growth of the
organization and total growth of the society.

ORGNISATION STRUCTURE
Board of DIrectors
Managing Director
GM(O)
GM(CS&F)
CM(M&W)
CM(M&E) SrM(MM) CM(P&A) CM(F&A)
Jrm
SrM SrM cash
(LIO) (Mktg
) Med
Officer
AM
JCM JCM DM cash
R&D (Engg) (MM)
Pharmacist
CTK
DM DM DM
JRM DM (Serv) Per Prd
R&D (Mait) JrM Fin
Security
JRM Officer
QC Jrm Jrm Jrm Jrm
Jrm IR
Engg Prd CP Kiln MH
Foremen SUPR
Elec
JrEX Jrm
JR Per Chief Stores
MM Foremen Burner supdt
Asst
chemist
Jrm Trans
(Mktg) supdt Jr
Exe
Supdt Civil
Sales Supvr

DIRECTORS
The responsibilities of the directors are:

 Deciding the policies of the company
 The preparation of annual accounts, the applicable accounting standards have
been followed
 Accounting policies were applied consistently and the judgments and estimates
made, are reasonable and prudent so as to give a true and fair view of the affairs
of the company
 Proper and sufficient care for the maintenance of adequate accounting records in
accordance with the provisions of the Act for safeguarding the assets of the
Company and for preventing and detecting fraud and other irregularities have
been taken
 The annual accounts have been prepared on a going concern basis.
MANAGING DIRECTOR
The main responsibility of Managing Director is to implement the policies
decided by the Board of Directors .
GM(O)
All departments except financial department is under the control of General
Manager Operations. He is responsible to arrange all requirements of the the
departments under him.
GM (CS&F)
GM(CS&F) has got overall control of finance . He is also the Company
Seceretyand he is responsible for conduct of annual general body meeting

DIFFERENT PHASES OF DEVELOPMENT
 Started production of Grey Cement in August 1949.

 Started production White Cement in 1959
 Grey Cement production stopped in 1976.
 Diversified into Cement production in 1977.
 Celebrated Silver Jubilee in 1972.
 Became a Government Company in April 1989.
 Celebrated Golden Jubilee in 1997.
 Dry Cement Primer 'Shelprime' production started in January 2000.
 Acrylic Emulsion Paint for exterior & Interior. Sheltex launched in April 2000
 Started production of 'Vembanad' 43 grade OPC in September 2000.
 ISO 9002 certification received for the Company during December 2000
 Due to the lack of market demand Sheltex & Shelprime were stopped production
in 2000.
 2 0 0 8 F e b u r a r y T C L s t a r t e d p r o d u c t i o n o f Ve m b a n a d w a l l
putty

FINANCIAL PERFORMANCE OF THE COMPANY
The financial performance of the company is unsound as the company is

running at a loss for past 8 years. The main reason for this is the rise in the price of
furnace oil which is used as thermal energy in the production process. As some changes
has made in the production process the company expect that it will earn a marginal
profit this year.
The turnover of the Company for the year 2006-2007 was Rs.2374.09 lakhs
as against turnover of Rs.1667.78 lakhs in the previous year, registering continues an
increase of Rs.7065.31 lakhs over the previous year. The income from the other sources
for the year 2006-2007 was Rs.42.27 lakhs as against Rs 25.12 lakhs for the previous
year. Income from other sources has gone up Rs.17.15 lakhs. As a result of substantial
inctease in turnover as also income from other sources the loss for the year 2006-2007
has come down to Rs.84.27 lakhs from loss of Rs.390.01 lakhs in the previous year. The
main reason for incurring loss during 2006-2007 despite substantial increase in turn over
was increased cost of furnace oil. The average cost of furnace oil has gone up by around
Rs.900/-per KL from an average cost of Rs.15386.11 in 2005-2006 to Rs.16284.19 for
2006-2007.The Company continues to exercise strict control on expenditure.
The company has received Rs.100 lakhs from Government of Kerala on

08-02-2008. The total financial assistance received from Government so far from 2005
onwards is Rs.487 lakhs.
As the Company has incurred loss, Directors have decided to pass over
dividend for the year 2006-2002.
The Profit & Loss A/c and balance sheet for the year 2007 is given below:

PROFIT &LOSS A/C FOR THE YEAR ENDED 31 MARCH 2007
Particulars 31-03-2007 31-03-2006

RS Rs
I. INCOME
Sales 27,51,87,770 19,29,96,446
Less Excise Duty 3,77,78,668 2,62,18,570
Net sales 23,74,09,102 16,67,77,876
Other Sources 42,26,600 25,12,402
24,16,35,702 16,92,90,278
II. EXPENDITURE
Raw Materials Consumed 2,23,55,632 2,24,29,952
(Increase)/Decrease in Stock (1,37,55,958) 1,51,57,541
Manufacturing and Other Expenditure 24,03,35,229 17,16,70,537
Depreciation 11,28,360 12,88,010
25,00,63,263 21,05,46,040
III. PROFIT/(LOSS) FOR THE YEAR

BEFORE TAXATION
Provision for taxation (84,27,561) (4,12,55,762)
Profit/ (Loss) after taxation
Add: Excess provision written back (84,27,561) (4,12,55,762)
Doubtful Advance 5,38,003
Doubtful Debts 17,790
Deferred Tax Liability
(84,27,561) 16,98,756
Profit /(Loss) for the year (8,70,16,247) (3,90,01,213)
Add: Profit /(Loss) carried forward (4,80,15,034)
(9,54,44,808) (8,70,16,247)
Balance in General Reserve Adjusted 6,98,29,629
Balance Profit/(Loss) forwarded to (2,56,14,179 (8,70,16,247)
Balance sheet )

BALANCE SHEET AS AT 31 MARCH 2007
Particulars 31-03 -2007 31-03-2008

I. SOURCES OF FUNDS
1.SHAREHOLDERS’ FUND:
a)Capital 50,000 50,000
b)Reserves and Surplus 67,04,359 7,65,33,988
2.LOAN FUNDS:
a)Secured Loans
b) Unsecured Loans 1,26,00,000 1,26,00,000
3.GRANT:From Govt of Kerala 2,50,00,000
TOTAL 4,93,04,359 9,41,33,988
II. APPLICATION OF FUNDS
1.FIXED ASSETS
a)Gross Block 8,37,79,272 8,32,79,009
b)Less: Depreciation 7,27,02,909 7,15,74,549
c)Net Block 1,10,76,363 1,17,04,460
2.INVESTMENTS
500 B class shares of Rs100/- each in 50,000 50,000
Employees’ Co-operative Bank Ltd
3.CURRENT ASSETS,LOANS
&ADVANCES 6,12,43,539 4,98,13,455
a)Inventories 32,96,251 32,82,132
b)Sundry Debtors 3,18,66,118 89,41,045
c)Cash & Bank balances 1,56,33,697 2,06,35,902
d)Loans & Advances 11,20,39,605 8,26,72,534
LESS:CURRENT LIABILITIES AND 8,66,56,241 7,55,69,266

PROVISIONS 1,29,40,900 1,18,61,340
a)Liabilities 9,95,97,141 8,74,30606
b)Provisions (47,58,072)
1,24,42,464
NET CURRENT ASSETS

4.MISCELLANEOUS EXPENDITURE:
Preliminary Expenses for: 66,353 66,353
1) Modernisation Project 20,000 20,000
2) Small Hydro Projects 35,000 35,000
3) Ready Mix Concrete Project 121353
2,56,14,179 8,70,16,247
5.PROFIT & LOSS ACCOUNT
TOTAL 4,93,04,359 9,41,33,988

FUTURE PLANS
The company has planned some diversification schemes which will be
implemented in the near future, which include proposal to insist setting up of Enamel
paints and textured coating under cooperative societies. There are proposals to start a
pocking unit, the venturing project for manufacturing Calcium nitrate and Dicalcium
phosphate, shifting of present technology to dry process technology, reinitialize the
production of Grey cement and the proposal to export white cement to Srilanka, Gulf,
South Africa and Mauritius. The company is at present having a bright future ahead.

CHAPTER 4
DEPARTMENTAL DETAILS

PRODUCTION DEPARTMENT
STRUCTURE OF THE PRODUCTION DEPARTMENT
GENERAL MANAGER
(O)
CHIEF MANAGER
DEPUTY MANAGER
JUNIOR MANAGER
CHARGE HANDS BURNERS
SENIOR MACHINE
OPERATOR
FOREMEN
FUNCTIONS OF PRODUCTION DEPARTMENT

• To produce high quality products
• To make optimum utilisation of minimum resources
• To maintain the consistency in purity
• Ensure production without any interruption

WHITE PORTLAND CEMENT

The machineries and equipment required for the manufacturing process is
listed in the order of operations.
1. DREDGING AND STORAGE OF LIME SHELLS
a) Dredger
b) Diluting pump
c) Gravel pump
d) Receiving tank
e) Rotary filter
f) Conveyors
g) Storage tanks (Silos)
2. PROCESSING OF LIME SHELL WHITE SAND AND WHITE CLAY
a) Water pump
b) Wash mill
c) Clay pump
d) Ball mill
e) Elevators
f) Lifting service
g) Slurry pump
h) Slurry silo
3. PROCESSING OF CLINKER
a) Rotary Kiln
b) High pressure screw pump
c) Hammer crusher
d) Shaking and bucket elevators
e) Clinker silos
4. PROCESSING OF CEMENT
a) Cement mills
b) Belt and screw conveyors
c) Cyclone separators
d) Dust collectors
e) Air compressors
f) Cement silos
g) Packing machines

RAW MATERIALS
Vembanad white cement is manufactured from nature’s gift of rare raw
materials which are unique in consistent purity. The company is using high quality raw
materials and net process in order to maintain quality of its products. The main raw
materials are lime shell, white sand, white clay and crystal gyps.
a) LIME SHELL
The main raw material lime shell is procured from under water deposits of
Vembanad Lake. Chemical analysis of lime shell reveals that almost 99% accounts for
calcium carbonate (CaCO3). While the presences of usual impurities like iron and
magnesium compounds are negligible in significance. Vembanad white cement has the
distinctive feature of being the only cement that is manufactured from lime shell.
b) WHITE CLAY
White clay or crude china clay is obtained from southern parts of Kerala,
particularly from Trivandrum District. These white clay deposits are known for their
purity and high ceramic properties. The milky white clay, which is in paste form, that go
in to manufacturing process of Vembanad white cement, is almost 85% pure Hydrated
Aluminium Silicate.
c) WHITE SAND
Earlier white sand was being bought from Chertala in Kerala . But now
since white sand is not available at Chertala it is bought from British India Clay
Company Trivandrum.
d) GYPSUM
Helps to restore the setting action of cement and enhances the initial
setting time of cement. It is bought from Tuicorn, Tamilnadu.
PRODUCTION PROCESS OF VEMBANAD WHITE

CEMENT
The basic cement making process of collecting raw materials, grinding them to
affine stage, blending them to a uniform composition and heating them to the paint of
sufficient fusion when the cement compounds are formed. Portland cement is the
product obtained by cooling and grinding the clinker those formed with gypsum to a fine
powder.

The production process can be mainly divides into three stages

1. Slurry preparation
2. Clinker making
3. Clinker grinding
The different processes under these main stages are:

1. Dredging
2. Unloading station
3. Wash mill
4. Shell sand grinding (Ball mill)
5. Slurry making (Raw mill)
6. Slurry section
7. Clinker making (Rotary Kiln)
8. Clinker grinding (Cement mill)
9. Packing and Dispatching
1.DREDGING
The main raw material for the production of the Vembanad white cement is
lime shell, which is an under water deposit in the Vembanad Lake. It is dredged and
brought to the company by means of power bargers. The company has two dredgers, one
hydraulic dredger and one mechanical dredger. The capacity of two dredgers may be
about 30 Tonnes per hour. The dredger can cut the lime shell around 40 feet maximum
depth. The dredger works on two powerful engines, a dredger pamper engine and an
auxiliary engine.
DREDGER OPERATION
The dredger is placed anywhere in the lake using spuds, one at a lowered
position while the other spud is at the raised position. The cutter is about 10 metres
length. It can cut the shell to a maximum of 30 feet from the water level. For cutting, the
cutter is placed downwards by using a winch when spud 1 is centered which is loosened
and the cutter moves to clock wise direction. Similarly, when the spud 2 is entered the
winch 2 is 100 send cutter moves in anti clockwise direction and cut the shell and after
primary washing, the shell is transferred into the barge.

ll. UNLOADING STATION

The shell brought by the barger from the lake is unloaded here. Shell in the
barger is diluted with about 60% water by means of a diluting pump for easiness of
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
waste materials are washed out during its rotation. Cleaned shell is either passed to the
belt conveyors through hoppers or stored outside. There are two rubber conveyors
(conveyor 1short and straight conveyor, conveyor 2 long and inclined) for conveying the
shell to the ball mill hopper or to the crane gantry.
III. WASH MILL

Before actually using for the process, the clay is mixed with water. This work is
done in a clay wash mill. Clay is put into the mill and about 65% water is also added
during the grinding. During the hammering action of the weights provided in the wash
mill, clay is made to watery and is pumped to a storage tank known as Silo. From Silo it
is taken for the processes when required.
IV. SHELL-SAND GRINDING (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% 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 the
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 balls. The materials coming out of the ball mill is diverted to a hammer
screen by means of a slurry elevator. Fine material comes out of the hammer screen and
is fed to the raw mill. The course materials return to the ball mill for further grinding.

V. SLURRY MAKING (RAW MILL)

The raw mill is a hollow cylindrical shell, the inside of which is lined with flint
blocks. The steel linings are avoided to reduce the contamination of slurry by iron. The
grinding media used id Flint pebbles. The mill is rotated by a motor at a constant speed
while passing through the mill, the fine materials are discharged from the ball mill and
the clay pumped from the clay silo are finally grounded and comes out as a party
material known as slurry which then flows to the slurry pit.
VI. SLURRY SECTION

Slurry discharged from the raw mill is stored in Silos by means of pumps. The
chemical composition of the 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 the compressed air and is stirred well. The slurry is
taken from this basin for burning in the kiln.
VII. CLINKER MAKING (ROTARY KILN)

Kiln is a cylindrical steel shell with refractory bricks lining, mounted at an angle
of 60 to base on roller supports, so that it can be rotated. The Kiln is having a length of
about 285 feet. Its diameter varies from 250 to300cm. In the Kiln there are three zones
called the drying zone, the calcinating zone and the burning zone. Fuel used in the Kiln
is burned to 1000c by an electric heater for better atomization. Air is sucked through the
coolers provided around the Kiln by the fan, which drives the Flue gas through the
chimney. There is a damper provided at the chimney for efficient operation and it
controls the air inlet to the Kiln. The collected slurry is injected at the upper end of the
Kiln. Hot gases or flames are forced through the lower end of the Kiln. The portion of
the Kiln nearer to the upper end is known as the drying zone and at this zone; the water
of he slurry is evaporated. The temperature of this zone is about 2200C. In the central
part of the Kiln, where the temperature is around 7500C-9000C, the slurry undergoes
decomposition to form quick lime and carbon dioxide and the latter escapes out. The
materials form small lumps known as nodules. (Calcinating zone)
In the lower part of the Kiln the temperature is between 1400 0Cto 15000C. Lime
and clay undergoes chemical interaction and fuses, yielding calcium aluminates and
silicates which then fuses together to form small hard dark greenish blue balls which are
known as clinkers. The size of the clinker varies from 3mm to 20mm and they are very

hot when they come out of the burning zone of the Kiln. Then, Diesel is applied through
a nozzle to remove impurities on clinker and to give colours to it. Cracking takes place
here.
Fe2O4 Fe2O3
To prevent reverse reaction quenching is done. Oxygen released during the

cracking process reacts with hydrogen and becomes steam. There is a provision to cool
down hot clinkers. The clinkers are passed through the coolers connected to the Kilns
periphery. The air entering through the cooler exchange the heat and thus the clinker gets
cooled and at the sane time air gets preheated. Cooled clinkers are having a temperature
of 950C and are collected in containers of suitable size.
CHEMISTRY OF THE PROCESS

In the upper part of the kiln, where the temperature is around 4000C, most of the
slurry gets evaporated (Drying zone)
In the central part of the kiln, where the temperature is around 10000C, slurry
undergoes decomposition to form quick lime and carbon dioxide and the latter escapes
out.
CaCO3 CaO+CO2
In the lower part of the kiln the temperature is between 15000C to 17000C. Here
lime any clay nodules undergo chemical interaction or fusion, yielding calcium
aluminates and silicates (clinkering zone).
2CaO+SiO2 Ca2SiO4 Dicalcium silicate

3CaO+SiO2 Ca3SiOS5 Tricalcium Silicate
3CaO+Al2O3 Ca3Al+2O6 Tricalcium aluminate
4CaO+Al2O3+Fe2O3 Ca3Al+2O6 Tricalcium aluminate
4Ca0+Al2O3+Fe2O3 Ca4Al2Fe2O10 Tricalcium Aluminoferrite
VIII. CLINKER GRINDING (CEMENT MILL)

The clinker as obtained from rotary kiln is carried by conveyors into the cement
mill. There are three cement mills A,B, C with clinker grinding capacity of 60 Tonnes
,50 Tonnes, 50 Tonnes respectively.. The mills B and C are identical in nature. During

grinding, small quantity of about3% to4% Gypsum is added. The Gypsum controls the
initial setting time of cement. If Gypsum is not added, the cement would sit as water is
added. The Gypsum acts as retarder and it delays the setting action of cement. It thus
permits cement to be mixed with aggregates and to be placed in position. The cement
coming out of the mill is conveyed to the claufies by means of bucket elevator. In the
separator, coarse particles are separated and they flow to the mill while fine particles
flow to the Flaxo pump, which is operated by compressed air. Using Flaxo pump cement
is transferred to the cement Silo located at the packing house.
I. PACKING AND DISPATCHING

The white cement stored in Silos is packed in paper bags in the packing house.
Compressed air is used for the free flow of the cement from the Silo and hopper located
above the packing machine. When the bag is filled with 50Kg material discharges from
the spout is automatically transferred to truck through a fixed point belt conveyor and a
movable belt conveyor. The filled bags fall down from the spout to the wire net
conveyor and are transferred to truck through a fixed point belt conveyor and a movable
belt conveyor.
CEMENT PAINT DEPARTMENT

Paint is a surface coating which decorates and protects the surface on which it
is applied. Paint is a mixture of four elements they are:
1. Solvents
2. Binders
3. Pigments
4. Additives
The total paint market is broadly categorized into four segments.
1. Architectural finish or decorative paints
2. Industrial finish-general industrial sector automobile sector
3. Heavy duty coatings
4. Marine paints
Decorative paints are the largest market segment and constitute around 75% of
the market share. Super Shelcem is self curing cement paint manufactured by the TCL.
It is an inmate mixture of white Portland cement, water proofing compounds as oxide
extender, non fading oxide pigments hardening agent and fungicide. Super Shelcem

unlike other cement paints does not require water curing after first and second coats.
Unlike other paints, metal primer is not required when using this paint. Only initial
willing of the surface is necessary. This makes Super Shelcem ideal for exteriors of
multi storied buildings and sky scrappers. For interiors too super Shelcem id ideal. It
carries ISI marks and is available in a wide range of colours -43 shades to be precise.
PRODUCTION PROCESS
Lime shell Clay
Dredging Clay unloading
Barger Wash mill
Rotary filter Clay silo
Sand silo Clay pit
Raw mill
Slurry pit
Slurry silo
Correction pit
Slurry basin
Slurry feeder
Rotary kiln
Hammer crusher
Clinker silo
Cement
Gypsum Cement Mill Fluxo pump Silo
White Cement

PRODUCTION AND DESPATCH
The shell production, clinker production, and cement production and cement
despatch during the past three years were as follows:
2006-2007 2005-2006 2004-2005

Item Mts Mts Mts
Shell 26750 12945 28670
Clinker 22528 11808 22901
White cement 21474 15134 23965
White cement dispatch 21425 15393 23821
RESPONSIBILITY OF KEY PERSONS

GENERAL MANAGER OPERATIONS
• Has overall control on production department

• Has to report to MD
• Verification of stock of raw materials
• Make arrangements for repairs & maintence by the respective department
CHIEF MANAGER
• Maintain necessary stock of raw material

• Purchase machinery equipment & grinding media which may become necessary.
Jr. MANAGER
JR. Manager has to assist chief manager
FUTURE PLAN OF PRODUCTION DEPARTMENT
To change the production technology from WET process to DRY process.

PERSONNEL DEPARTMENT
STRUCTURE OF THE PERSONNEL DEPARTMENT
GENERAL MANAGER(O)
CHIEF MANAGER
(Mktg&Per.)
DEPUTY MANAGER
Jr.MANAGER(IR)
Jr. MANAGER
Per. In Charge
OFFICE ASSISTANTS
TYPIST
PEON

FUNCTIONS OF PERSONNEL DEPARTMENT
• To maintain good relationship between the employees

• To look into the welfare of the employees
• To maintain leave register
• Attendance making
• Overtime confirmation
It is the department that is connected to other departments in TCL. This
department is headed by Joint General Manager. Under him Joint Chief Manager
followed by Junior Executive and Office Assistants. This department does the
recruitment and selection of the personnel. Another important function of the personnel
department is to look into the welfare of its employees. Time office comes under this
department. The function of the time office is to maintain leave register, attendance
making, over time confirmation etc. The above data is forwarded to the accounts
department for accounting the wages of the employees.
The employees of the company are classified into Three categories. They are:
1. Officers.
2. Staff.
3. Workers.
1. OFFICERS
The Officers of TCLl are further classified into five. They are:
i) General Manager grade.
ii) Manager grade.
iii) Special grade.
iv) Class one grade.
v) Class two grade.
2. STAFF

People working in the office, security and senior employee in the plant comes
under the staff category. The grade of staffs varies from 1 to 7. 1 being the lowest grade
ahend 7 being the highest grade.
3. WORKERS
Workers in TCL are classified into
i) Permanent.
ii) Probation.
iii) Temporary.
iv) Casual.
v) Apprentice.
The grades of workers vary from i) to v). i) being the lowest grade and v) being
the highest grade.
TIMING
The office time is from 9:00am to 5:00pm on all working days from Monday to Friday.
On Saturdays Office time is till 1:00pm and the factory is working on shift basis.
1) 3 continuous shifts of 5 hours each.

2) 2 special shifts of 8 hours each.
3) Special shifts for special work of 8 hours.
4) A general shift of 8 hours.
There are 3 shifts in the factory.
1st shift: 12 midnight to 8.00 pm.
2nd shift: 8.00 am to 4.00 pm
3rd shift: 4.00 pm to 12 midnight
MANPOWER PLANNING
Manpower planning is a key economic resource of an organisation. Manpower
planning isw a kind of checking weather the people at the right place for things for
which they are economically useful. It enables the management to adopt suitable
strategies for each situation.

Improper manpower planning results in delays in executing new projects and

expansion programmes. Manpower planning includes a series of activities consisting of
the following:
1. Forecasting
2. Anticipating manpower requirements
3. Manpower audit
4. Planning
Proper manpower planning is done at TCL to ensure the right number and
proper utility of manpower
INDUSTRIAL RELATIONS
TCL maintains a good working relation between management and employees.
The work opportunities for the company personnel are developed and maintained in the
best interest of the company and its employees.
WORK CULTURE
Culture of a society or organisation comprises the core values, norms, beliefs
and attributes that affect the behaviour of people. An organisation is a replica of a
society. The culture of an organisation depends upon various policies and practices such
as how work is organised and how people relate to each other within the organisation
and outside it. TCL is maintaining a good and harmonious relationship between
employees and customers.
RECRUITMENT AND SELECTION

WORKERS
The workers are selected through PSC test and physical test. 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.

OFFICE STAFF
Recruitment of office staff is done through direct application and through

employment exchange. Selection is mainly based on written test and interview. But it is
also done accordig to the discretion of management. Selected persons will have to
undergo training, which is usually six months.
MANAGERIAL LEVEL
Recruitment for managerial level is done through direct application and through
employment exchange. Selection is mainly based on written test and interview. Selected
persons will have to undergo training for more than one year.
TRADE UNION
The recognised trade unions in the company are :
1. The Travancore Cement Workers Union AITUC

2. The Kerala Cement Labourers Union CITU
3. The Kottayam Cement Employees Union INTUC
4. The Kottayam Cement Employees Congress
WORKING CONDITIONS
Proper working conditions are maintained in the company. Facilities like
bathrooms, toilets are provided at all the plants and offices. Rest rooms and seating
facilities are provided.
MEDICAL REIMBURSEMENT
One month salary (Basic + D.A.) for officers and half month salary (Basic +
D.A.) for staff workers who are out from ESI scheme.
COMPANY SCHOLARSHIP
Company is providing scholarship to children of all the employees in the
company.

For S.S.L.C, Plus Two, Degree and Diploma.

Rs. 750/- for first rank.
Rs. 500/- for second rank.
EDUCATIONAL ALLOWANCE
The company provides this facility for the children of permanent employees.
They are getting an amount of Rs. 300 a month.
SPECIAL ADVANCE
For medical treatment [Upto a maximum of Rs. 15000]
For marriage expense [upto a maximum of Rs. 25000]
TWO WHEELER / CYCLE LOAN : To all employees

CAR / COMPUTER LOAN : For officers only
FACTORY DAY COMPLIMENT : Every year
TRAINING AND DEVELOPMENT

There are both internal and external training for workers and employees, and
the HRD centre under the supervision of the personnel deparrtment, it is conducted. Job
rotation is allowed only for officers. Conference talks, workshops etc. are conducted as a
part of training and development.
PROMOTION
Promotion from a lower grade to higher grade will be given in accordance
with efficiency and seniority of the person, subject to the vacancy position.
WELFARE FACILITIES PROVIDED BY THE COMPANY
There were several welfare measures provided by the company. Now TCL is
running under huge loss. So the company is not able to provide the benefits to the
employees as in the earlier years.
They were provided with the following benefits:
1. Uniform

2. Footwear allowance
3. Umbrella
4. Raincoat
5. Washing soap & toilet soap
6. Turkey towel
7. Two wheeler / Cycle loan
8. Car/ computer loan
The benefits provided to the employees even the company is facing loss are:
CANTEEN
A fair price canteen is operating at the premises. The employees are given Rs.
25 per day of attendance as canteen allowance. Rs. 750 is the maximum allowance given
per month.
DEATH BENEFIT
Rs. 5000 will be given to the dependent of the deceased employee to meet the
expenses in connection with funeral.
TRANSPORTATION
Free transportation facility is provided to employees for coming and returning
after duty and for their children and for attending education institutions in and around
Kottayam.
COMPANY’S PRODUCT AT CONCESSIONAL RATE

Super Shelcem paint are sold to employees at fatory gate price.
QUARTER‘S FACILITY
A limited number of employees are provided with quarter’s facility with free
electicity and water. Very nominal rents are charged.
RECREATION FACILITY
Recreation facility for indoor games like shuttle, badminton, carroms etc. are
provided. Reading room facility is also provided with newspaper and periodicals;
television is also provided with cable faility.

WELFARE FUND SUBSCRIPTION

The company has a welfare fund scheme under which an employee has to
contribute Rs. 20 and the company contributes at the rate of Rs. 10 for each member per
month.
TRAINING FACILITY FOR EMPLOYEES’ CHILDREN

Employees’ childre with ITI / diploma / professional degree, are given training
facility at free of cost. (as unpaid apprentice)
SALARY & WAGES

Salary and wages, paid to the employees are determined on the basis of an
agreement between CMI and Trade Union. In TCL, pay revision is done in every 4
years. The salary is fixed for officers & staff according to KSR rules. And the provision
of Cement Manufacturers Association (CMA) determine workers’ wages.
SCALE OF PAY
The Cement Manufacturers Association (CMA) determines the wages and salaries of all
cement factoies in India. Since there is fixed pay structure for every grade of employees,
management can develop a coordinated pay system without having to determine a
separate pay rate for each job in the organisation. All the jobs within a grade have the
same range of pay regardless of points.
HOUSE RENT ALLOWANCE
The employees who are not provided with quarters are given allowances at
10% of their basic pay.
EMPLOYEE PROVIDENT FUND
The company deducts 12 % of basic pay and dearness allowance of the

employee as monthly contribution. The company also contributes an equal amount.
FAMILY PENSION SCHEME

A portion of the provident fund is reserved for the family pension scheme.
This is kept for giving to the employees after their retirement on monthly basis.
ESI
The employees having basic pay below Rs. 7500 are able to get the benefit of
ESI.
GRATUITY
Gratuity is also given to the employees.
And it is calculated as: Gratuity = (BP + DA) * 15/26 * total years of service
LEAVE PATTERN
Prelivage Sick Casual
Staff & manager 30 12 14

Wo r k e r s 16 12 8
PROVISIONS REGARDING HEALTH OF THE

EMPLOYEES
a. Cleanliness is maintained.
b. Wastes and effluents are disposed properly.
c. Proper ventilation and temperature is maintained.
d. Masks are provided for protection against dust.
e. Cold water facilities are provided.
f. Proper lighting is maintained.
PERSONNEL RECORDS
TCL keeps records about each and every employee, from the date of joining till
his separation from the company. It also includes details of salaries or wages,transfers
and other details related to the job.

RESPONSIBILITIES OF KEY PERSONS IN PERSONNEL

DEPARTMENT
GENERAL MANAGER(O)
General Manager(O) has an overall control in Personnel Department.
CHIEF MANAGER(MKTG &PERSONNEL)
Chief Manager (Mktg&personnel) is the signing authority in personnel

department.
DEPUTY MANAGER
Deputy manager is responsible for the preparation &verification of documents

forwared to chief manager
Jr. MANAGER(IR)
Jr. Manager (IR) has the control of human resources section.
Jr. MANAGER (PERSONNEL IN CHARGE)
Jr. Manager (Personnel In Charge) has to prepare letters relating to the Personnel
Department. Jr. M has also the responsibility relating Employees’ Welfare Fund
activities.
FUTURE PLAN OF PERSONNEL DEPARTMENT

Conduct SWOT analysis of each employee and the company and to assign the
responsibility which is suited to each employee
LIST OF APPRENTICES

Type of Apprenticeship
I Graduate Apprentice (Engineering degree)
1. Electrical Engineering
2. Mechanical Engineering
3. Chemical Engineering
II Technical Apprentice (Engineering Diploma)
1. Automobile
2. Mechanical
3. Chemical
4. Civil
5. Electrical
6. Commercial Practice
Trade Apprentice
1. Electrician
2. Fitter
III
3. Welder
4. Turner
5. Mechanic Motor Vehicle
6. Carpenter
7. Forger & Head treater
8. Plumber
9. Mechanic Diesel
ALLOWANCE S TO EMPLOYEE S
GRADE DA% TA HRA EA CA LTA PA

E Nil 30 125 300 515 400 50
D 2½ 30 125 300 515 400 50
C 5 33 125 300 515 400 50

B 5 33 135 300 515 400 50

A 5 36 135 300 515 400 50
I 5 30 125 300 515 400 50
II 5 33 125 300 515 400 50
III 5 33 135 300 515 400 50
IV 5 36 135 300 515 400 50

V 5 36 145 300 515 400 50
VI 5 38 145 300 515 400 50
VII 5 38 150 300 515 400 50
DA—Dearness Allowance
TA — Tr a v e l i n g A l l o w a n c e
HRA—House rent Allowance
E A — E d u c a t i o n A l l o w a n c e ( 11 0 + 1 9 0 = 3 0 0 / m o n t h )
CA—Conveyance Allowance (450 + 100 + 125 = 575/ month)
LTA — L e a v e Tr a v e l A l l o w a n c e ( 2 0 5 + 1 3 5 = 4 0 0 / m o n t h )
PA — P e r i o d i c a l A l l o w a n c e
EMPLOYEES’ STRENGTH OF TCL AS ON

01.01.2008
SLNO NAME OF S TA F F O P E R AT I V E S
D E PA RT M E N T
1 Dredeger 10 71
2 Wa t e r t r a n s p o r t 3 22
3 Running plant 15 47
4 Packing house 6 13
5 Wo r k s h o p 15 64

6 Office 47
7 Marketing & sales 19
8 Lab 3 11
9 General stores 3 5
10 Ti m e o f f i c e 6
11 Civil Engg 1
12 Electrical Engg 8 15
13 General transport 15 4
14 Wa t c h & w a r d 17
15 Camp & sanitation 3 6
16 Cement paint units 9 11
17 Medcial Aid 1
18 Material handling 3 26
T O TA L 167 312
To t a l s t a f f 167
To t a l o p e r a t i v e s 312
Officers 26
G R A N D T O TA L 505
FINANCE DEPARTMENT
S T R U C T U R E O F T H E F I N A N C E D E PA RT M E N T

GENERAL
MANAGER(F)
CHIEF MANAGER
ASSISTANT MANAGER
Jr.MANAGER
ASSISTANT
SUPERIENDENT
OFFICE ASSISTANT
FUNCTIONS OF FINANCE DEPARTMENT

 Financial forecasting and planning
 Acquisition of funds
 Investment of funds
 Maintaining proper liquidity

 Assigning the Chief Accounts officer and others

 Accounting of all receipts and payments, cash at bank, sales etc.
 Preparation of annual accounts and other periodical report and statements
 Checking of wages and salaries
 Regular payments of statutory dues like Provident Fund, Sales tax etc.
 Furnishing necessary records relating to finance cash to Managing Director or
Chief Accounts Officer.
Financial Management is that specialised functions of general

management which is related to the procurement of finance and its effective
initialisation for the achievement of common goal of the organisation. It deals with each
and every aspect of financial activity in the business. It includes planning and control of
financial resources. It is also concerned with finding out various sources for raising
capital for the firm. The source must be suitable and economical for the needs of the
business. The most appropriate use of such funds also form a part of Financial
Management.
Finance is indispensable to facilitate efficient and effective operation
of business enterprise. In this context, effective financial management holds key to
success in todays highly competitive world, modern financial managers are assigned five
roles:
1. Planning of funds
2. Raising of funds
3. Allocation of funds
4. Allocation of earnings
5. Control of funds
The finance department consists of Chief Manager, Junior manager and
Office Assistants. The accounts of Tcl are controlled through the budget presented and
passed by the Annual General Meeting of the TCL. There are mainly three sectors of
finance department of TCL. They are
1. Accounts Section
2. Finance Section
3. Cash Section

1. ACCOUNTS SECTION
The most important task done by accounts section is the recording of
day to day accounts. Routine accounting functions like sales tax payment, receipts and
payment of cash, cheques etc. come under the preview of the accounts section.The
employee payroll function is also undertaken by the accounts section of the finance
department. It is the duty of this department to prepare Trial Balance, Profit & Loss A/c
and Balance Sheet and send it to the top level authorities for audit and for other decision
making purpose.
2. FINANCE SECTION
Finance section is mainly concerned with the maintenance of
accounts. The various financial statements are kept in the computer as well as in the
manual form.
3. CASH SECTION
The cash section is concerned with the disbursement of cash.
DUTIES OF FINANCE DEPARTMENT

i. Overall financial control
ii. Monitory decision amking in consultation with Managing director
iii. Finalization of accounts
iv. Budget preparation
v. Control overall matters relating finance in the organisation
The accounts and finance departments have to ensure that the salaries due to
the employees are paid in time. The department is also concerned with the preparation of
budget and budgetory controlof the concern. The department has to ensure that all the
entries are properly posted in the books of accounts.
The main accounts that are kept by the accounts department:

i. Cash book
ii. General ledger

SCOPE OF FINANCIAL MANAGEMENT

It can be summarised as follows:
a) ESTIMATING FINANCIAL REQUIREMENTS

The first task of a Finance Manager is to estimate short term and long term financial
requirements of his business. For this purpose, he will prepare a financial plan for the
present as well as for the future.The amount required for purchasing fixed assets as well
as needs of funds for working capital have to be ascertained. The estimations should be
based on sound financial principles so that neither there are inadequate nor excess funds
with the concern. The inadequacy of funds will adversely affect the day to day working
of the concern whereas excess funds may tempt the management to indulge in
extravagant spending for speculative activities.
b) DECIDING CAPITAL STRUCTURE

Capital Structure refers to the kind and proportion of different securities for
raising of funds. After deciding about the quantum of funds required, it should be
decided which type of securities should be raised. It may be to arise finance through
long term debts Even here if gestation period is longer, the share capital may be most
suitable. Long term funds should be employed to finance working capital. Entirely
depending upon over drafts and cash credits for meeting working capital needs may not
be suitable. A decision about various sources of fund should be linked to the cost of
raising funds. If cost of raising funds is very high, then such sources may not be useful
for long. A decision about the kind of securities to be employed and then proportion in
which these should be used is an important decision which influence the short term and
long term financial planning of the enterprise.
c) SELECTING A SOURCE OF FINANCE

After preparing a capital structure, an appropriate source fo finance is selected. Various
souces from which finance may be raised include share capital, debentures, financial
institutions, commercial banks, public deposits etc. If finances are needed for shorter
period, then banks, public deposits and financial institutions may be appropriate, on the
other hand, if long term finances are required, then share capital and debentures may be
useful. If the concern doesn’t want to tie down assets as securities, then public deposits
may be the suitable source. If the management doesn’t want to dilute ownership, the

debentures should be issued in prefernce to shares. The need, purpose, object and cost
involved, may be the factors influencing the selection of a suitable source of financing.
d) SELECTING A PATTERN OF INVESTMENT

When funds have been purchased, then decision about investment pattern is to be taken.
The selection of an investment pattern is related to use of funds. The funds with have to
be spent first on fixed assets and then an appropriate portion will be retained for working
capital. While selecting a plant & machinery, even different categories of them may be
available. . the decision making techniques such as capital budgeting, opportunity cost
analysis etc. may be applied in making decision about capital expenditures.While
spending on various assets, the principles of safety, profitability and liquidity should not
be ignored. A balance should be struck even in these principles. One may not like to
invest on a project, which may be risky, even though there may be more profits.
e) PROPER CASH MANAGEMENT

Cash management is aso an important task of finance manager. He has to assess various
needs of the company at different times. He has to make arrangements for cash. Cash
may be required a) to purchase raw material b) to make payment to creditors c) to meet
wage bills d) to meet day to day expenses.
The usual source of cash may be a) cash sales b) collection of debts c) short term
arrangement with banks etc. The cash management should be such that neither there is a
shortage of it nor it is idle. Any shortage of cash will damage the creditworthiness of the
enterprise. The idle cash with the business will mean that it is not properly used. Cash
flow statement is regularly prepared so that one is able to find out various sources and
applications. All these information will help in efficient management of cash.
ACCOUNTING POLICIES
The accounts of TCL are prepared in accordance with the accounting policies accepted
in India and in line with the relevant laws as well as the guidelines 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.

i SYSTEM OF ACCOUNTING
The company adopts the accrual basis in the preparation of accounts.
ii 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 (written down value) in terms of sec. 350 of Companies Act, 1956 at the
rates prescribed under schedule XIV of the said Act.
iii INVENTORIES
Raw materials, stores and spares and work in progress are valued at cost. Finished
goods have been valued at cost or market price whichever is less and doesn’t include
excise duty, except in case of stock at depots.
iv SALES
Sales are inclusive of excise duty and sales tax. Sales include the value of white
cement transferred for the manufacturing of cement paint.
v RETIREMENT BENEFITS
Gratuity, leave encashment, provident fund are the benefits provided in the company.
CAPITAL STRUCTURE
No long term loan was availed by the company and hence the debt equity ratio is nil.
RESERVES AND SURPLUS

The company is operating on the previous years’ surplus amount.
RESPONSIBILITIES OF KEY PERSONS IN FINANCE

DEPARTMENT

GENERAL MANAGER(F)
General manager(F) has control on overall financial matters. He has to control
expenditure. GM has to arrange the sources of finance and its proper distribution.
General Manager is the displinary authority of all the staff working under him.
CHIEF MANAGER
Chief Manager controls day to day affairs in connection with finance and
accounts. CM has to distribute the duties among the staff under him.
ASSISTANT MANAGER
Assistant Manager has to assist Chief Manager. Assistant Manager has to control
daily receipts and payments. AM has to attend all the papers submitted to him by the
subordinates who are directed to report.
Jr. MANAGER
Jr. Manager has to prepare all statements like budget, balance sheet, profit &
loss A/c, cost data. Jr. M has to attend all the papers submitted to him by the
subordinates who are directed to report.
FUTURE PLAN OF FINANCE DEPARTMENT

This department is planning to have full computerization.
MARKETING DEPARTMENT

STRUCTURE OF MARKETING DEPARTMENT
GENERAL
MANAGER(O)
CHIEF
MANAGER(MNP)
SENIOR
MANAGER(Mkt)
Jr.MANAGER Jr.MANAGER
(Sales) (Mktg &Sales)
REPRESENTATIVES
FUNCTIONS OF MARKETING DEPARTMENT

• To identify the needs and wants of the consumers
• To meet the demand of the consumers
• Developing new better product
• Successful distribution of the products
• Improving the quality of products or services

INTRODUCTION
Marketing as a field of study has become almost as broad as business itself. In
the early days marketing concepts was considered important for consumer products but
recently the trends have changed. Today marketing is an important part of any industry.
Marketing is defined as the process of identifying the needs and wants of

consumer and producing goods and services to satisfy their needs and wants.
MARKETING DISTRIBUTION CHANNELS

Company Depots Stockists Dealers Customers
NUMBER OF STOCKISTS
There are 40 stokist to supply the products in credit .
MARKETING ACTIVITIES
TCL has a well established marketing department. There is an efficient
salesforce which is under the Marketing Manager. The whole system comes under the
General Manager. TCL has got 14 sales representatives throughout Kerala.
PRODUCTS
The company is producing four products. Two products were launched in the year
2000 and has got good marketing share.
1. Vembanad White Cement

2. Super Shelcem Cement Paint
3. Vembanad wall putty
The first two products are established and they have good demand in the market.
Vembanad White Cement has 40% market share and Super Shelcem Cement Paint has
30% market share in Kerala market. Vembanad White Cement has also market in Tamil
Nadu. Sales representatives go around the state for collecting the order other than the
networks. TCL supply its products to various government agencies like PWD, FACT,
public sector companies etc. at special rates.

PRICING OF THE PRODUCT

Item Qty(kg) Price
Vembanad White cement (Kerala) 50 866.75
Vembanad White cement (Outside Kerala) 50 797.00
Vembanad White cement 5 118.50
Vembanad White cement 1 24.10
Super shelcem cement paint 1 34.40
Vembanad wall putty 5 180
Vembanad wall putty 20 619
REASONS FOR HIGH PRICE

The production process of TCL is very old and it is known as WET process and
is very expensive. This is the only company which is using this old process. The other
companies are using DRY process. This is comparatively less expensive. So the other
companies can reduce price. Another reason is the raw materials particularly lime shell
and white clay is scarce. So these products are priced very high.
ANALYSIS OF ENVIRONMENT
Marketing environment is constantly presenting new threats and opportunities
and successful companies continuously monitor and adapt to that environment. TCL is
facing various threats like increased energy cost, pollution, changing role of
Government etc.
RESEARCH & DEVELOPMENT

The company for improving the quality of product takes up much research. The
company doesn’t need many strategies to study in the market as its product is of great
demand and the company has a good percentage of market shares.
It is the responsibility of the marketing to conduct various programmers to
improve the user’s awareness about the company’s product.
 To conduct study classes for workers and users
 To organize exhibitions
 To conduct educational tour

MARKETING RESEARCH
TCL is not conducting any marketing research. Using project students,
company gets feedback from the customers. Thus necessary steps are taken to cure the
complaints.
SEGMENTING, TARGETING & POSITIONING

TCL identified the segments for the white cements as cement paint
manufacturing, Tile manufacturing, Manufacturers of Terrazzo flooring, Mosaic Tiles,
Primer coat, PWD for road making, pointing brick works.
The target customers of Vembanad White Cement are tile manufacturers. The
main customers Scorpio tiles Manufacturers, Melathil Tile manufacturers, Ultra tile
manufacturers. Even though the tile manufacturers are the target customers, Vembanad
white cement is consumed mostly by TCL itself for the production of cement paint.
Positioning the act of designing the company’s offering and image to occupy a
distinctive place in the mind of the target market, is done by Vembanad White Cement as
a quality product.
MARKETING CHANNELS AND PRACTICES

WHITE CEMENT
TCL has got six sales representatives throughout Kerala. TCL is having sales
officers and godowns at Bangalore, Coimbatotre, Calcutta and Delhi. Transport is
through trucks and railway wagons to distant places. Regional office is situated at
Trivandrum.
MARKET SHARE
Today out of the total production of white cement in India, the market share of
TCL is 40% in Kerala .
SUPER SHELCEM PAINT

Shelcem paints are marketed in powder form. The sales representatives take
orders from the dealers and the company supplies it directly to the stockists of that
respective area, who in turn supplies it to the dealer.
MARKET SHARE
Cement paint market is classified into two sectors such as organised and
unorganised sectors. The total market share of organised and unorganised sector is 15%.
In the unorganised sector, Super Shelcem is the market leader.
SALES PROMOTION
TCL has an advertisement budget of Rs. 50 lakhs per annum. Since the amount
is too small, the company is advertising at a low level. Other promotional activities
include, conducting dealers’ meeting once in two years. In addition to these, the
company offers various incentive schemes for its dealers according to their sales
performance.
Due to the very low advertisement budget, company doesn’t engage in any large
scale type of advertisement activities. The company occassionally engages in
advertisement through newspapers, magazines etc.The main modes of advertisement are
display boards, that are positioned where they get maximum attention.They also used
Asianet Cable Vision, wall painting etc.
COMPETITIONS
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 companies new product Sheltex Acrylic Emulsion Paint has only 5%
market share and facing competition from majors like Apex, Excel etc.
CONDITIONS OF SALES

 The sale is at the ex-factory Kottayam. The company is not responsible for any
levies
 Every care is taken in packing and their responsibility ceases once the company
sells it.
 Goods once sold and dispatched will not be taken back.
 All disputes under the invoice will be settled in court having jurisdiction at
Kottayam.
 Buyer man in sure the goods at their own risk account against transmit risk.
RESPONSIBILITIES OF KEY PERSONS IN

MARKETING DEPARTMENT
GENERAL MANAGER(O)
General manager(O) has overall control of marketing of all products. GM
has to suggest proposal of policy decision regarding marketing.
SENIOR MANAGER
Senior manager has the administration work of marketing. SM has to
supervise junior manager and the representatives at field. SM has the responsibility to
look into statutory matters regarding marketing. SM has to initate proposals regarding
advertising, sales promotion, appointment of workers.
FUTURE PLANS OF MARKETING DEPARTMENT

The future plan of this department is to establish the product wall
putty

PURCHASE DEPARTMENT
STRUCTURE OF THE PURCHASE DEPARTMENT
GENERAL MANAGER (O)
CHIEF MANAGER
Jr. MANAGER
Jr. EXECUTIVE MANAGER
OFFICE ASSISTANTS
FUNCTIONS OF PURCHASE DEPARTMENT

 To determine the type of raw materials to purchase
 To purchase good quality raw materials
 To purchase raw materials at low cost
 To formulate purchasing policies
Purchase department is the department which decides the type of raw materials
to purchase. Highly paid officials with specialised knowledge are included in this
department.

ADVANTAGES OF PURCHASE DEPARTMENT IN TCL
1. Because of centralized purchasing of materials, favourable terms like trade

discount or economic in transportation cost can be obtained, because quantity
will be large.
2. The purchase department is staffed with highly paid officials who are experts in
the art of purchasing the material. Specialized knowledge and skill of these
persons can be utilized.
3. All records with regard to purchase department is kept under the supervision of
the purchase officer.
4. This department helps in achieving uniform purchasing policies, practices and
procedures.
5. It avoids duplication of efforts and is helpful in achieving standardized products.
VENDOR SELECTION
The TCL has a main list of suppliers for all items it have to purchase. The
company invites tenders through advertisements in the newspapers.The suppliers give
quotations and after a detailed study of the concerned department, the supplier should be
selected and the order is placing.
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 which evaluates the vendors. The committee consists of officers
from concerning finance and material departments. Vendor who is rated below 50% will
be removed from the lists. Vendors rated between 50% & 75% are advised to improve
their quality.
VENDOR RE-EVALUATION RATING
The suppliers of raw material who are re-evaluated periodically by the

company.

i Vendor supplying all raw materials for white cement and cement paint.
ii Packing material
iii Critical spares and machinery
Vendor rating is done by the composite weighted average calculated by the

following formula:
R = A + B; where A is quality rating
” B is delivery rating
FUNCTIONS OF PURCHASE DEPARTMENT IN TCL

 Placing order
 Inviting quotations
 Correspondents
To perform the functions effectively, the purchasing department has to follow
the following procedure.
a. PURCHASE REQUISITIONS
The purchase officer does not initiate any action for purchasing of materials on
his own record. With the help of purchase requisitions, the purchase officer come to
know the types of materials needed by the organisation. A purchase requisition is a from
used as a formal request for the purchasing department to purchase materials.
b. EXPLORING THE SOURCES OF SUPPLY & SELECTING THE SUPPLIER

A source of supply of materials is to be selected after the receipt of purchase
requisition. In TCL, 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 comparitive statement of purchases. It is a
statement prepared by the purchase department.
c. PURCHASING ORDER
After choosing the supplier, the purchase department prepares the order for the
supply of stores. The order is a written authorisation to the supplier to supply the

particular material or materials. It is the evidence between the buyer and the supplier
having the terms and conditions of the purchasing order.
d. 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 makes the
general purchase only. When goods are received in stores, the consuming department is
informed and the personnels from this department come to stores and inspect the quality,
quantity etc.
e. CHECKING & PASSING BILLS OF EXCHANGES

After checking, the bills are passed. Generally, the payment terms of TCL are
 Against invoice or acceptance of stock a minimum 15 days credit

 In case of monopoly suppliers, they are sent or paid through banks.
CONDITIONS REGARDING RECEIPT OF GOODS
 If the suppliers are within Kerala, a time within 15 days of sending or inviting
quotations
 If the suppliers are outside Kerala, a period within 20 or 30 days
 The company makes a local purchase itself within 2 or 3 days.
PURCHASE LIMITS
In TCL, they followed an authorised purchasing system. The purchase units are
as follows:
1. Below and upto Rs.25000, purchases are maintained by Deputy Manager and
sanctioned by General Manager(O)
2. Rs.25000 – Rs.1000000, purchases are maintained by Chief Manager should
sanctioned by General Manager
3. Rs. 1000000 – Rs.5700000, it should be signed and approved General
Manager(O)
4. Rs.5000000 and above, approved by Managing director

OTHER DEPARTMENTS
STORES DEPARTMENT
Purchase Manager
Store keeper
Assistant store keeper
Helper
Sweeper
FUNCTIONS STORES DEPARTMENT

 To store the raw materials for different departments
 To prepare the purchase order
 To prepare the stores records such as Bin card and Karade - X card
Stores is the department for storing the raw materials. The materials are
collected as per the order made by the department, which is known as purchase order.

LOCATION & LAYOUT
The location of stores department should be carefully planned out and it

should be near to the receiving department, so that transportation cost should be
minimum.The department is a centralized storage system in the company. The raw
materials for different departments are stored in the stores.
ADVANTAGES OF CENTRALIZED STORES IN TCL

1. Better control can be exercised over stores because all stores are housed in one
department.
2. Better layout of stores is possible.
3. Investment in stock is minimised.
4. Economy in cost.
5. Economy in staff and concentration of experts in one department will lead to
development in high technical skills.
6. Less botherisation in inventory checking as all the stores are located in one place.
STORES RECORDS
The Bin card and Karade – X card are the two important stock records that are
kept in TCL for making a record of various stores.
BIN CARD
A bin card makes a record of the receipts and issue of materials and is kept
for each item in the stores. Quantity of materials received are entered in the receipt
column and the quantity of stocks issued are recorded in the issue column of the bin card
and the balance of the quantity of stock is taken after every receipt or issue , so that the
balance can be seen readily at any time. A bin card is usually hanged up or placed in
shelf, rack or bin where the materials have been kept.

KARADE X - CARD
This card is used in TCL by store keeper in addition to the bin card for storing
the list of stock of items. TCL doesn’t maintain a stores ledger now, instead of this all
the details are stored using software in the computer. The existing system is a Foxpro
based system.
PURCHASE ORDER
To make a purchase order for the General Stores department, it requires the
following process:
1. GENERATION OF SPI
The purchase requisition for the General Sotres department is generated through Store
Purchase Indent. It is used for informing the purchase department, where the materials
are stored and what is the price, and a general awareness about how it is previously
dealt. Demanded items, ordered from consumer section and Replenishable items,
ordered from the General Stores departmet itself are the two types of items stored here.
Demanded items which are highly expensive are ordered as per the order of the
consumer. Replenishable items are highly consumable items, so the consumers would
not demand it always, so it is ordered from the General Stores departmet itself.
2. ISSUE OF MRI
Material Received Intimation is used for intimating whether the materials are
received or not and also for certifying the quality of materials.
3. ISSUE OF MRR
Material Received Report is used for recording the details about the received
materials, about its quality and quantity.
4. STOCKING OF MATERIALS
Materials should be properly stacked and it should be kept according to its code
number, shelf number and godown.

5. ACCOUNTING & DELIVERY OF MATERIALS
The payment of the materials can be made in cash or cheque. The materials
should be accounted accordingly. Certain items will be delivered in advance or at the
time of payment or after 15 or 30 days.
MAINTENANCE DEPARTMENT
General Manager
Chief Manager Chief Manager Chief Manager

( P&A) (M&E) (Finance)
Deputy Manager
(Electrical Engineer)
Foreman
Chargehands
Electrician
Electrical section & Mechanical section are the two sections included in the
Maintenance department.

FUNCTIONS OF MAINTENANCE DEPARTMENT
 Operation of electrical equipments & machineries

 Maintenance of electrical equipments & machineries
Maintenance of equipments
Annual maintenance Preventive maintenance
Half yearly maintenance
Quarterly maintenance
Monthly maintenance
Fortnightly maintenance
Weekly maintenance
Daily maintenance
Hourly monitoring

PURPOSE
a. To ensure smooth and safe running of the electrical machinery.

b. To provide safe and trouble free operation without risk to health of workers.
SCOPE
It covers all electrical machinery and equipments connected in HT & LT side

of transformers at Nattakom.
ELECTRICAL SECTION
The total number of employees working in the electrical maintenance section

is 24, out of which 12 employees are concerned with the electrical maintenance of the
plant and other 12 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 five tier system of electrical
maintenance is practiced here.
1. 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. If any minor fault will find out, it may be attended by himself. Otherwise it
would be informed to the electrical department.
2. PERIODICAL INSPECTION AND CHECKING

All the electrical equipments and machineries are periodically checked by
Electrical section inorder to ensure the safety of workers and also for the smooth
functioning of the department.
3. BREAKDOWN MAINTENANCE

In case of any breakdown of the machineries in the production department,

information regarding the breakdown is given to the maintenance department, and
subsequently maintenance workers are sent to production department to solve the
machine failure.
4. PREVENTIVE MAINTENANCE
Under this activity, a team of maintenance workers is sent directly to the
production plant to find out whether there is any failure in the machinery or not.
5. SHUT DOWN MAINTENANCE

When the plant is shut down due to the failure, the employees in the production
department sent a letter to the maintenance department to solve the problem.
MECHANICAL SECTION
All mechanical works are undertaken by the mechanical section of the

maintenance department. The company has a workshop under the control of this
department.
There are nine subdivisions for the mechanical section. They are:
 Fitter
 Automobile section
 Diesel mechanic section
 Welder
 Turner
 Blacksmith
 Carpenter
 Khalasis
 Tool section
The total number of workers in the mechanical section is 72 out of which 4 are
chargehands, a foreman and an attender. The rest include the officers and other skilled
workers.

LAB
Junior Manager (Quality control)
Junior Manager ( Lathe)
Junior Executives ( Lathe)
Assistant Chemist
Chief Gauger
Tester
Sample boy
Helpers
FUNCTIONS OF LAB
 To test the quality of raw materials
 To whether the product involves the right proportion of raw materials
 To maintain the quality of the products
Unlike other government organisations, where quality is secondary, at TCL

quality is being given the prime position. The ISO 9002 certification is a proof for

enduring the quality commitment of TCL. TCL has its own laboratory which
continuously striving to maintain the quality of the products. There are three levels of
testing conducted in the laboratory. They are:
a. RAW MATERIAL TESTING

Raw materials are tested for ensuring the quality of products even before
manufacturing.
b. PROCESS TESTING
Process testing is done before the grinding of lime shell, sand and clay.
c. INTERMEDIATE TESTING
In this testing, slurry is tested for finding out whether it contains right
proportion of lime shell, sand and clay. Then slurry is taken to kiln for burning.
TRANSPORTATION DEPARTMENT
Chief Manager (M&E)
Deputy Manager (Stores)
Transport Suprend
Charge hand
Fitter
Barge crew

WATER TRANSPORT DEPARTMENT
FUNCTIONS OF THE DEPARTMENT
 Lime shell dredging

 Transportation of lime shell
Mainly water transportation facilities are used for bringing limeshell from
Vembanadu 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 bargers and the capacity of each barger is 70 tonnes approximately. The
bargers are used for transporting lime shell from Vembanadu lake to the unloading
station.
There are four workers in a dredger, foreman, chargehand and two operators.
The capacity of two dredgers is 3 tonnes per hour. The cutter of dredger is about 10m in
length. There are six workers in a barger. The capacity of a wooden barger is 70 tonnes.
GENERAL TRANSPORT DEPARTMENT

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
shift.
WORKSHOP
Officer
Foreman
Chargehand

FUNCTIONS
 Maintenance of machinery parts
 Repairing of spare parts, pipe line, oil line, vehicles etc.
The company has one workshop under the control of the mechanical
maintenance department. The maintenance and repairing of machinery spare parts, pipe
line, oil line, vehicle etc. are undertaken in the workshop. Fitter, Automobile section,
Diesel mechanic section, Welder, Turner, Blacksmith, Carpenter, Khalasis, Tool section
are the nine different sections in the mechanical maintenance department.
The repairing of machinery spare parts, pipe line, oil line etc. and the
machineries related with plant are undertaken in the workshop. Dredger and barger is
also repaired here in this department. If any fault occurs in the running plant, workers
from this department will be sent there.
There are 80 employees working in different sections of the workshop as
welders, fitters, blaksmith, carpenter etc.
PACKING HOUSE
Packing house in charge
Assistant in charge
Supervisor
Fitter
Packer
Helpers

Here cement is drawn from storage spoils and packed in the paper bags by
automatic machines and dispatche.
DREDGING DEPARTMENT
The main raw material for the production of Vembanadu White Cement is
limeshell an under water deposit in Vembanadu lake, is dredged and brought to the
company by means of power bargers. The company has two dredgers, one hydraulic
dredger named Lokanathan of 5000 gallion capacity and one mechanical dredger,
Rudger of 2000 gallions capacity. The dredger can cut the limeshell around 40 ft.
maximum depth. The dredger works on two powerful engines, a dredger pamper engine
and an auxilliary engine.
TIME OFFICE
Time Office comes under the personnel department. The main function of the
office is to maintain attendance register and calculate the monthly working hours of each
employee. The company follows punch card system for measuring attendance.
CAMP & SANITATION DEPARTMENT

This department is concerned about the cleanliness and neatness maintained at
the premises of the company.
SECURITY DEPARTMENT
The department is mainly concerned with the security and control of the
company. There are 28 employees working in the security department on shift basis.
MEDICAL DEPARTMENT
This department provides medical aid to both permanent and temporary
employees. The medical leave of the employees is recorded and sactioned from this
department.

CHAPTER 5
SWOT ANALYSIS

SWOT ANALYSIS
STRENGTHS
As TCL is a government owned firm, it enjoys privileges granted by the
government. Standard quality products are produced here.TCL is the only white cement
manufacturer in the world to manufacture cement from natural lime shell, and it uses
wet process technology for cement production.Therefore the product maintains high
quality.
 Only company which uses the natural lime shell for manufacturing white
cement
 Standard quality products
 Good training system
 Good organisational climate
 TCL is a government owned firm, it enjoys privileges granted by the
government
 Brand image
WEAKNESS
Very low budget for advertisement, influence from government and political
parties, sales representatives are less, surplus labour, lack of transportation
facility,scarcity of main raw material lime shell etc. can be traced as the weakness of the
company.
 Company is running on loss
 Poor advertisement
 Sales representatives are less
 No credit facility
 Dealers dissatisfied with credit facility

 There is no proper mechanism to handle customer grievances

 Influence from government and political parties
 High price compared to other brands
OPPORTUNITY
The company should opt for psycho graphic segmentation of the market,
where more stress should be given to the quality and fitness of the product. It should
expand the distribution network to those markets where the competitors are less
powerful. It can compete in the national market supported by good advertisement.
 Compete in the national market if there is good advertisement
 Liberalisation demand for cement paint
 Company introduces promotional programmes
THREATS
 High competition
 Liberal policy of other brands
 Promotional programmes of other brands
 Complicated national market
 Good replacement of other brands
 Increasing oil price

CHAPTER 6
OBSERVATION/SUGGESTIONS

OBSERVATIONS/SUGGESTIONS
 Replace the production technology with DRY process where the cost of
production is less.
 The company is working with more employees than required is happened due to
political pressure. Hence the company has to work independent of political
influence.
 Employees has the fear that the Company may be winded up due to loss and are
favoring privatization of the Company to save the Company from winding up
 The Company has to expand its business outside Kerala where there is less
competition.
 The company should advertise its product so that more people may know about
the products
 The company should plan to have market network in rural areas of Kerala
which are not covered under the market network of TCL

Chapter 7
Conclusion

CONCLUSION
TCL Kottayam is one of the pioneers in the white cement industry.

TCL is an ISO 9002 certified company, which was certified by Bureau of Indian
Standards (BIS). This shows company’s consciousness towards high quality production.
But the company is making a recovery from this by the utilisation of better opportunities
and making further diversifications. The company is earning profit by the last three
months as it got a fund of 2 crores as government aid. And the cost of the furnace oil,
which is used for the WET technology is decreased and the company has sufficient raw
materials now.
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. TCL happens to be the
only manufacturer of white cement with limeshell as its main raw material. With the
implementation of a new technology, improving the marketing strategies, and solving
the existing problems, the company is ensured of bright prospects.

BILIOGRAPHY
 Mamoria C. B., Personnel Management, Himalaya publishing.

 Kothari C.R., Research Methodology, New Age Information (P) Limited.
 Dr. Gupta C. B., Human Resource Development, Sultan Chand and sons.
 Kotler Philip, Marketing Management, Pearson Education.
 Dr. Mahasweri S.N., Pandey I..M., Principles of Management Accounting,
 Dr. Prasad L. M., Principles and Practice of Management, Sultan Chand and sons.

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Travancore Cements Ltd.

LIST OF TABLES & CHARTS

Profit & Loss A/c 21

Structure of the production department 25

Structure of the personnel department 35

Employees’ strength of TCL 47

Structure of finance department 48

Structure of the marketing department 55

Pricing of the product 57

Structure of the purchase department 61

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SCOPE OF THE STUDY

 To understand the marketing and production methods To acquire knowledge

REASON FOR SELECTING THE COMPANY

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 TCL is one of the famous organization in Kerala involved in the

15-05-2008 General study

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Research methodology is a way to scientific and systematic research for pertinent

METHODS OF DATA COLLECTION

The data collected constitutes both primary and secondary data.

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CEMENT INDUSTRIES IN INDIA

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The Cement Corporation of India, which is a Central Public Sector Undertaking,

i. Further push to housing development programmes;

Further, in order to improve global competitiveness of the Indian Cement

Cement companies are fast developing plants to provide for a rapidly

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approximately 141 outstanding cement projects. According to a report by the ICRA

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DECLINING ROLE OF PUBLIC SECTOR

Historically, cement has been one of the most important areas of

Among cement public sector undertakings (PSUs), Cement

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BRANCHE S AND OFFICE S

Outstanding Qualities Of Vembanad Brand White Cement

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• Ideal for manufacture of Cement Paints,Mosaic Tiles.

SUPER SHELCEM (CEMENT PAINT)

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OBJECTIVE OF THE COMPANY

QUALITY POLICY OF THE ORGANISATION

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The responsibilities of the directors are:

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DIFFERENT PHASES OF DEVELOPMENT

 Started production of Grey Cement in August 1949.

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FINANCIAL PERFORMANCE OF THE COMPANY

The financial performance of the company is unsound as the company is

The company has received Rs.100 lakhs from Government of Kerala on

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PROFIT &LOSS A/C FOR THE YEAR ENDED 31 MARCH 2007

Particulars 31-03-2007 31-03-2006

III. PROFIT/(LOSS) FOR THE YEAR