A

SUMMER TRAINING REPORT

Subject Code: 536322(36)

On

“OPERATION MANAGEMENT IN TOPWORTH”

Submitted for partial fulfillment of requirement for the award of degree

Of

Master of Business Administration

Of

CHHATTISGARH SWAMI VIVEKANAND TECHNICAL

UNIVERSITY BHILAI (C.G.)

Session 2010-12

Supervised By External Guide Supervised By Internal Guide

Mr. KAMLESH KUMAR PAWAR Prof. N.H. DESPANDE

MANAGER (HR & ADMIN.) (FACULTY OF MANAGEMENT)

Submitted By

AMITESH KUMAR MAURYA

ROLL NO. - 5053609013

Enrollment No.- AE:-6597

MBA III Semester (Section – ‘D’)

DEPARTMENT OF MANAGEMENT

DISHA INSTITUTE OF MANAGEMENT AND TECHNOLOGY

(Disha Education Society)

Satya Vihar, Vidhansabha-Chandrakhuri Marg, Mandir Hasaud, Raipur (C.G.) 492007

DECLARATION

I the undersigned hereby solemnly declare that the report of the summer Training work entitled

“OPERATION MANAGEMENT IN TOPWORTH” is based my own work carried out during

the course of my study under the supervision of external guide Mr. KAMLESH KUMAR

PAWAR MANAGER (HR & ADMIN.) and internal guide Prof. N.H. DESPANDE (FACULTY

OF MANAGEMENT).

I assert that the statement made and conclusions drawn are an an outcome of the project work. I

further declare that to the best of my knowledge and belief that the project report does not contain

any part of any work which has been submitted for the award of degree of Master of Business

Administration of Chhattisgarh Swami Vivekanand Technical University, bhilai (C.G.).

AMITESH KUMAR MAURYA

ROLL NO. - 5053609013

Enrollment No.- AE:-6597

MBA III Semester (Section ‘D’)

CERTIFICATE BY INTERNAL GUIDE

This to certify that the report of the project submitted is the outcome of the project work entitled

“OPERATION MANAGEMENT ON TOPWORTH” carried out by AMITESH KUMAR

MAURYA bearing Roll No. 5053609013 carried by under my guidance and supervision for the

award of Degree in Master of Business Administration of Chhattisgarh Swami Vivekanand

Technical University, Bhilai (C.G), India.

(1) To the best of the my knowledge the report

(2) Embodies the work of the candidate himself,

(3) Has duly been completed, fulfils the requirement of the ordinance relating to the MBA

degree of the university

(4) Is up to the desired standard for the purpose of which is submitted.

Prof. N.H. DESPANDE

FACULTY OF MANAGEMENT

DIMAT, RAIPUR (C.G.)

CERTIFICATE BY THE EXAMINERS

This is to certify that the project entitled

(“OPERATION MANAGEMENT IN TOPWORTH”)

Submitted by:-

Rajesh Kumar Patel Enrollment no :- AG 8018 Has been examined by the undersigned as a part

of the examination for the award of Master of Business Administration degree of Chhattisgarh

Swami Vivekanand Technical University, Bhilai (C.G.).

__________________ _________________

Name & Signature of Name & Signature of

Internal Examiner External Examiner

Date: - Date:-

ACKNOWLEDGEMENT

I AMITESH KUMAR MAURYA, feel great pleasure to thank and acknowledge the help and

inspiration provided by my summer training report guide Prof. N.H. DESHPANDE Faculty of

Management, Dimat, Raipur and heartiest thank to Mr. Ramashankar for help and provide best

knowledge about industries. I am thankful to her for providing us a great opportunity for the

training report.

He has contributed in a substantial way during all stages of the preparation of this report. His

guidance at every stage of the report enabled me to successfully complete this project; otherwise it

would not have been possible without her constant encouragement and motivation.

For making significant contribution directly or indirectly in the project, I extend my hearty gratitude

towards my friends who helped me when ever called for. Finally, I thank all the respondents and

other people for providing their valuable opinion and helping me in successful completion of the

project.

_______________________

Signature

Name:-AMITESH KUMAR

MAURYA

Enrollment no:-AE 6597

MBA III Semester

Section – ‘D’

Preface

The project report on the topic “OPERATION MANAGEMENT IN TOPWORTH “

This project report has prepared for the organization Topworth Steel Power Private LTD.

In which the problems in production processes have been identified to which some

recommendations has been given on the basis of analysis.

The purpose behind this research is to get an exposure of corporate world as well as working

culture by getting associated with research .If this report proves to be fruitful to anybody/any

organization by any means, I will consider my work worthwhile.

This research helps in understanding practical applicability, which is a part from theoretical

concept.

Finally the findings, records & suggest

Chapter – I

Introduction

CHAPTER 1 INTRODUCTION

About topic

Operations management is understood as the process whereby resources or inputs

are converted into more useful products (outputs).

A steel and power industry basically converts raw material (iron ore and

coal/charcoal/dolomite) in useful products. Top worth company uses iron ore and

coal/charcoal as a raw material and converts it into different products like Sponge

Iron, Billets ,Coil Service Center ,Aluminum Foil, I-Beam Structural Steel , TMT/TOR

Steel.

Before selling, you have to produce. It means that the first task of any business is to

manufacture or assemble goods and services. It's the manufacturing process.

This crucial task relies on the Operation Department and notably on the

manufacturing process, which is currently the most expansive component of any

business.

Manufacturing process is often connected to industry but we shall use this term in a

broader meaning for describing any productive process either in an industry or either

in a service.

MANUFACTURING PROCESS

Once the goods or the services have been described, you must define how you will

produce it: It is the manufacturing process.

Regarding marketing and sales, there are some classical channels and we can aim

to describe them entirely. Regarding manufacturing process, there are thousands of

different processes according to the good and the service you product. It's quite

impossible to describe them. However, you can follow some basics.

What is a manufacturing process?

What is a manufacturing process? It is the description of all the technical operations

you have to realize for producing one unit of the good. I will give two examples: a

good and a service

A good Manufacturing Process

Let's suppose that your business idea is to produce plate steels from sponge iron or

salvaged materials. To produce plate steel you have to realize the following

operations:

Operation 1-Raw materials: Collect and store the raw materials: Scrap or sponge

iron: Where do you get it, at what price, how do you store it, what quality is usually

needed, how many people do you put on this task: Salary, outsourcing,

qualifications, safety regulations an so on?

Operation 2- Melting: Sponge iron is melt in an electric arc furnace: What is the

cost of the furnace, where do you implement it, What is the cost of the energy, how

many people on this work station, how many quantities can you manage in one hour

and how many quantities do you get by the end?

Operation 3-Refining: The melting metal is refined . It means that you separate the

chemical elements in order to get the specific steel you need. How do you operate

this separation, qualifications wanted, Do you need a chemist for controlling the

process?

Operation 4-Casting: The liquid steel is cast in products such as billets: A new list

of questions.

Operation 5-Rolling: The billets are heated at 1200c and then rolled in order to get

the plates: A new list of question.

That is what we call a manufacturing process and you have to master it.

As you can see the manufacturing process is a very technical matter and you should

need to have specific knowledge or to partner with a good engineer.

Chapter – II

Company profile

CHAPTER 2 COMPANY PROFILE

Company profile:

About:

Top worth Group of Companies is the Corporate house managed by young and visionary

entrepreneur Mr. Abhay Lodha duly supported by strong team of board of directors,

business advisors and senior team of professionals.

The Group has emerged as a strong player in the Steel trading in the Western Region

supported operations in Chhattisgarh and Maharashtra.

Top worth facilitates decision making process of its Group companies on matters related

to business strategy

The Group has its registered offices at Nariman Point, Mumbai and Corporate offices at

Worli, Mumbai. The Group is established in 1999 by Mr. Abhay N Lodha, Chairman of

the company, who possesses experience of more than a decade in the area of Iron and

steel.

Top worth Steels Pvt. Ltd; was incorporated in year 2004. It operates from DURG ,

Chhattisgarh.

Shri Veerangana Steels Limited was acquired in year 2006, It operates from Nagpur,

Maharashtra.

Satyarth Steel and Power Pvt. Ltd; was acquired in year 2007. It operates from

Raipur.    

Crest Steel and Power Pvt. Ltd; was acquired  in year 2007, It operates from Durg,

Chhattisgarh.

Top worth Cement incorporated in year 2008 and it operates from Durg, Chhattisgarh.

The Group started with main focus on Steel and Steel related business and achieved a

milestone in the recently ended fiscal 07-08, when the group turnover exceeded the mark

of USD 500 Million.

Recently the Group has ventured in the field of Aluminum & Power.

The Group is professionally managed by highly experienced professional and has a Net

worth of USD 80 Million.

Over 600 highly qualified and experienced professionals’ team is supporting the

Company's vision of being one of the major players in Iron and Steel, Energy, Aluminum.

The Company has entered into alliances with strategic business associates by offering

them minority equity.

Vision and Mission:

Our Vision

To create a Business Organization by Optimizing the resources and continuous

improvement Enabling wealth to all the stake holders and be one of the leading group in

India while having identifiable global presence.

Our Mission

To be among the major player of metal, power and aviation industry.

To delight each and every customer of the value chain by providing competitive cost

and high quality products and services.

To have a presence globally.

Group Strength

Strong continued growth and increased net worth.

Successful strategies of building businesses

Risk and return compatibility.

Best of Breed Technical & Functional Expertise

Growth on the Value Chain

Special Purpose Company / Collaborative Models

Ability to network globally

Hands on experience in steel sectors & Indian Geography

Ability to conceptualize and develop business.

All Plants are located in backward C category region of Chattisgarh  state .All plants

are located near to coal bearing region of Raigarh and Korba.

The company is engaged in manufacturing of sponge iron Billet and rolling of steel

while it also generates power for Captive consumption.

A knowledge base of more than 600 highly qualified, experience professionals

In house expertise and commitment for world proven management initiatives Six Sigma,

TPM and PMS Diversified investment strategy for acquisition and operations

Marketing Offices

The marketing offices are at Mumbai, Ahmadabad, Delhi, Nagpur, Raipur, Kolkata,

Chandigarh, Chennai, Hyderabad, Bangalore, Una-HP, and Dubai.

Manufacturing/Mining Operations

Chhattisgarh, Himachal Pradesh, Jharkhand, Maharashtra, Orissa Gujarat.

Group Companies

Manufacturing/Mining/HR Service Center Operations:

Top worth Steels Pvt. Ltd.- Durg, Chhattisgarh

Shri Virangana  Steels Ltd.- Nagpur

Crest Steel & Power Pvt. Ltd.- Durg, Chhattisgarh

Satyarth Steel and Power Pvt. Ltd.- Raipur.

Tribos Steels Pvt. Ltd. – Taloja, Navi Mumbai  

Decoiling unit

Top worth Aluminum Pvt. Ltd.

Iron Ore crushing unit in Barbil- Orissa, 90 MT/Hr.

Top worth Energy Pvt. Ltd.

Top worth cement, Durg, Chhattisgarh.

Projects under Progress

Expansion of Top worth Steel Pvt. Ltd.-Durg, Chhattisgarh

600 MW Power Plant at Chhattisgarh

Expansion of Shri Virangana  Steels Ltd.- Nagpur

Expansion of Crest Steel & Power Pvt. Ltd.- Durg, Chhattisgarh

Top worth Pipes and tubes Pvt. Ltd.

Expansion of Top worth Aluminum Pvt. Ltd.

SMS and Rolling Mill- Una, Himachal

Chapter – III

Research Methodology

CHAPTER 3 RESEARCH METHODOLOGY

Research Objective:

To check the operation and production process in Top worth Steel Plant.

To identify the techniques which is used in production process?

To identify how minimizing cost of production.

o To identify or ensuring that goods and services produced conform to preset Quality specification.

o To identify Minimizing cost of producing goods or rendering a service

Research plan:

Research Design: Descriptive

Research Method Used Observation

RESEARCH DESIGN:

Descriptive Research is the research method used because descriptive studies embrace a

large proportion of industrial research. The purpose is to provide an accurate snapshot of

some aspect of the industrial environment. Descriptive research is more rigid than

exploratory research and seeks to describe process of production, determine the operation

of the company or predict future estimation of a production. As opposed to exploratory

research, descriptive research should define questions, people surveyed, and the method

of analysis prior to beginning data collection. In other words, who, what, where, when,

why, and how aspects of the research should be defined.

Descriptive Research Design:

In this research I have conducted Descriptive Research to study the factors influencing

the production processes of Top worth company in Durg, Rasmada. Descriptive research

includes surveys and fact-finding enquiries of different kinds. The major purpose of

descriptive research is description of the state of affairs as it exists at present. The method

of research utilized in descriptive research is survey methods of all kinds, including

comparative and co-relational methods.

PLANT LAYOUT:

DRI : Direct reduction of ironLR : Lube RefineryCPP : Captive Power PlantINPUT : Coal/iron ore/dolomiteDRKC : Direct rotary kiln cross sectionSIMS : Sponge Iron Management & SupplyQM : Quality managementF&G : Fire and GasSA : Storage AreaI-BEAM : Storage and Supply

DRI LR

CPP

DRKC SIMS

F & G I-Beam SA

QM Coal/iron ore/dolomite

STORAGE AREA OVERVIEW

STORAGE AREA OVERVIEW

Need for plant layout in top worth

o When a new plant is set up to manufacture newly designed products.

o When a new product line is introduced in the factory.

o When additional space is required to meet increased demand for products.

o When frequent accident occur in the factory.

o When the existing facilities are to be rearrangement due to change in methods or

production.

o When the existing factory is shifted to a new area.

o When the cost reduction program is launched.

Advantages of plant layout in top worth

Sponge iron

SOLVENT Iron ore

o Better work conditions for workmen.

o Minimization in material handling.

o Minimization in damage and spoilage materials.

o Minimization in congestion of materials, machinery and workmen.

o Flexibility in changing production conditions.

Disadvantages of plant lay out in the company

Since the same workers are involved in more operations. Skilled and versatile workers

are required. The necessary combination of skills may be difficult to find and high

pay level may be necessary.

Movement of people and material to and from the place may be expensive.

Equipment utilization is low because the equipment may be left at a location where it

will be needed again in a few days rather than moved to another location where it

would be productive.

PROCESS LAYOUT:

PROCESSES IN TOP WORTH:

There are many different units in steel manufacturing, for carrying out different processes

like distillation, fast met process, corex process etc. Depending on the products produced by the

manufacturing process top worth lay out layout in a such way that

a) There be very short distance between reactors or units of plant that has to be followed

according to requirement.

b) Less piping and cooling, heating expenses.

c) Pumps, valves and other materials required between successive processes should be

limited and controllable in number.

d) Waiting time for the next process should be minimum.

e) Very little manual labor is required and automation and instrumentation can be done

effectively.

f) Planning and scheduling of specific product can be done accurately and storage and

distribution should be properly maintained.

Advantages of process layout in top worth

A high degree of variety of products can be manufactured.

Flexibility and adaptability to change is high.

Machine breakdown do not cause of stoppage.

It is easier to instill job satisfaction to workers.

Coordination and supervision is simpler.

Disadvantages of process layout in top worth

Higher flow time of the product due to zigzag flow through the system.

Larger number of machine set-ups.

Low machine utilization.

More material handling.

Production Planning and Scheduling

The main objective of this work is to discuss planning and scheduling applications for

manufacturing operations in top worth.

Major Steps Involved In Planning:

STEP 1: Nonlinear planning model for production is developed. The model represents a

general manufacturing topology and allows the implementation of nonlinear process models

as well as blending relations.

STEP 2: Optimization model is developed considering the market limitations for each steel

derivative usually supplied by the . The optimization model defines all operating points, thus

increasing the production of more valuable products, while satisfying all specification

constraints.

Major Steps Involved In Scheduling:

STEP 1: To overcome scheduling problems in steel manufacturing process mixed integer

optimization models are formulated that rely on both continuous and discrete time

representations. This model takes care of the problem of steel production inventory

management that involves the optimal operation of iron ore/sponge iron unloading from

trucks, transfer to storage and the charging schedule for each distillation unit.

STEP 2: Development and solution of optimization models for short-term scheduling of a set

of operations that includes: product receiving from processing units, storage and inventory

management in intermediate tanks, blending in order to attend steel / sponge iron

specifications and demands, and transport sequencing in conveyor belt, road lines(through

transportation).

Materials management in top worth

Top worth has emerged a front-runner, in providing excellent services to the customers, and

also delivering state - of - art - products.

Various products of top worth are as under:

Sponge Iron : Sponge iron is one such product being manufactured and

marketed at Topworth, Rasmada. They produce and market all the

three grades of sponge iron viz., fe/100, 60/70 & 30/40. The quality

control measures are observed very stringently, and the sponge iron

is tested as per the requirement of the business. Topworth has

made a foray into newer products such as carbonized and

polymerized sponge iron.

Fuels: Topworth uses variety of fuels. Some of them are listed

below.

o Petrol

o High Speed Diesel

o Furnace Oil

o Light Diesel Oil

o Low Sulphur Heavy Stock

Steel – : The steels offered are in following categories:

o Billets

o Coil Service Center

o Aluminum Foil

o I-Beam

o Structural Steel

o TMT/TOR Steel

Sponge iron: Sponge iron is very important product produced by

top worth. Top worth has large customer base and large distribution

network. Sponge iron is sold at very subsidized rate that is loss for

the company. But it recovers that loss by selling at very high

margin.

Electricity: top worth also produces electricity and sir plus

electricity sold to Chhattisgarh State Electricity Board.

Chapter – iv

Enterprise Resources Planning

CHAPTER-4 Enterprise Resource Planning at Top worth

To strengthen business management and improve customer services, TOP WORTH

implemented an advanced Enterprise Resource Planning (ERP) system.

The ERP system was implemented at more than 43 locations across India from 2003 to 2005,

and is used by over 200 employees. Top worth is continuously looking at innovative ways of

enhancing customer satisfaction by leveraging technology.

The real time, on-line availability of information from across all the geographically spread

locations of the corporation on a centralized system, has enabled top worth to improve

efficiencies in the Ares of tracking and monitoring customer receivables, credit management,

inventory management and provide enhanced service to customers and other stake holders.

Upgrading to an integrated business management platform gave top worth an enterprise-wide

view of its finance, manufacturing human resources, and sales and distribution processes.

Online access to information ensured managers could keep track of procurement, inventory,

production schedules, and customer orders.

The company also standardized business practices, ensuring process consistency across

multiple locations. A document archival system is an integral part of the ERP system,

allowing top worth to store invoices, purchase orders, checks, and other material. This

ensures the company can locate critical documents quickly and efficiently.

Boosting Service to Customers and Vendors

In keeping with Top worth’s aim of enhancing customer satisfaction, the company designed

portals that draw on information gathered by its ERP system to provide clients with dispatch

details, account statements, and a history of sales transactions completed over the past three

years. Customers log in to the portal using a secure user ID and password. Separate portals

for aviation, direct sales, sponge iron/steel, and retail customers were established.

Top worth also developed an electronic payment system to promote smoother and faster

payments to its vendors, contractors, transporters, and other service providers. The system is

integrated with the company’s banking institution, enabling payment information to be

seamlessly transmitted between the two organizations and ensuring timely payment to

suppliers.

Streamlining Distribution Workflows

Top worth realized another efficiency improvement when it streamlined its distribution

processes and implemented new notification alerts. For example, the company’s dealers and

distributors now receive e-mails and text messages via their cell phones informing them of

impending shipments. This information is sent to dealers and distributors immediately

following the generation of an invoice, enabling them to keep track of their orders.

Training Encourages Greater User Acceptance

A change management program was established to facilitate a smooth transition to the new

system for employees. Comprehensive training was provided to staff during the

implementation, followed by refresher courses post-deployment.

Competency development programs for specific user groups such as regional managers,

finance staff, heads of terminal/process/power plants, sales officers, project engineers, HR

officers and clerical staff are also conducted regularly.

Top worth organizes virtual training sessions from time to time to allow staff in remote

locations to learn about new system features. This reduces travel time and cost for

participants and enables quick dissemination of new information to users.

Chapter – v

Quality management

CHAPTER -5 Quality Management

Quality refers to the sum of the attributes of properties that describe a product.

In petrochemical industry quality is generally expressed in terms of specific product

characteristics such as color, specific gravity, viscosity etc.

Top worth has latest quality control technology that is mandatory for improvement of

refinery throughput, quality and yield.

Its quality control department has been successful in carrying out improvement in iron ore

viscosity, API gravity, and reduction /removal of sulfur, increase distillation yield and

overcome other operational problems from time to time using upgraded technologies in

manufacturing.

Quality Control & Maintenance

Quality control is achieved in Top worth by following ways:

1) All material supplies are ensured from approved suppliers and manufactures only.

2) All items procured are inspected /tested.

3) Sampling of the products is done thrice a day and analysis at each stage is carried out.

Strict quality control is ensured.

4) Stage wise inspection and certification of jobs by inspectors.

5) In Top worth highly experienced and highly skilled craftsmen handle jobs.

Prequalified and highly skilled Engineers inspect quality departments. Even refinery

workers, welders etc are tested and certified for job.

Maintenance plays a crucial role in the production process in the steel plants. A plant may be

regarded as successful when it operates without interruptions, which can however be

achieved only when its facilities are in perfect working order at all times. The strategic

importance of maintenance increases with increasing sophistication. The overall objective is

to maximize production output at minimum total cost.

Asset Integrity Management (AIM)

This type of program involves world-class standards of inspection and maintenance of

production facilities and pipelines to ensure the uninterrupted, reliable and efficient

operation. This program, which utilizes advanced technologies and methodologies, is vital to

minimize the risks and vulnerabilities of large scale petroleum operations, protect the safety

of the workforce and neighboring population, and to maximize energy security for India.

HPCL will be adopting it in near future.

FULLY AUTOMATION

Top worth has adopted a strategy of complex process so as to decrease the idle times of

plants and machineries. It is highly automated. Controlling of process is done from control

rooms of top worth.

Top worth have 5 electronic carousel of automatic type which fills cylinders automatically

basis. Filling of kiln are interlocked in the system.

Import and Storage facilities:

Top worth has steel/sponge iron storage facility of 650 tons of steel and import terminals.

Storage facilities of three types:

1) Above grounds bullets of capacity 50 MT TO 150 MT each.

2) Spheres of capacity 600 MT TO 1400 MT each.

3) Mounded storage of capacity 200 MT to 1000 MT each.

Quality Assurance

Manufacturing process is based on iron ore and coal with all impurities as input. Step by step

it tries to reduce impurities by changing it to less harmful component or remove after

converting to separable component. Processes like desulfurization, hydrogenation, hydro

cracking etc. are used to achieve this.

1) Viscosity

Viscosity reduction is achieved by removing impurities that contributes to higher viscosity,

which includes polycyclic aromatics.

Reduction of viscosity is carried out using some chemical processing which enables more

rapid and uniform feedstock management, improved heat transfer, faster mixing and shorter

residence time ensuring consistent quality.

2) API Gravity

API gravity is the most frequently used measure to estimate the quality of a sponge iron/steel.

It is one of the parameters focused for determining the price of sponge iron, the thickness of

steel is reduced and elasticity is increased.

3) F ast met process

Fast met is a direct reduction process using rotary hearth furnace (r.h.f.). Various carbon

sources such as coal, coke, breeze or carbon bearing waste can be used as a reluctant.

Reduction process is completed in 6-12 minutes.

Quality control and quality assurance both are very important aspects of quality management

in refineries. It helps reduce production cost and increase productivity. At the same time

quality is the main weapon in competition. top worth has high customer loyalty due to its

high quality products.

CONTROL ROOM OF HPCL, MAHUL

Chapter – vi

Work Measurement

CHAPTER - 6 Work Measurement

Work measurement is a process of establishing a time that a given task would take

when performed by a qualified and worker working at a defined level of performance.

WORK MEASUREMENT:

Work measurement is the process of establishing the time that a given task would take when

performed by a qualified worker working at a defined level of performance.

A qualified worker is one who has acquired the skill, knowledge and other attributes to carry out

the work in hand to satisfactory standards of quantity, quality and safety

Work measurement also refers to the process of estimating the amount of worker time required

to produce one unit of output.

goal of work measurement is to develop labor standards that can be used for planning and

controlling operations.

LABOR STANDARDS:

A labor standard is the number of worker-minutes required to complete an element, operation, or

product under ordinary operating conditions.

Labor standards are used in:

Cost estimation

Pricing of products and services

Incentive pay systems

Capacity planning

Production scheduling

RECRUITMENTS AND PROMOTIONS:

Upon successful completion of training, OT is absorbed at the entry level in the Management

Cadre in Salary Grade.

After absorption, the officer is on probation for next 6 months. On successful completion of

probationary period, the officer is conformed as the employee of the enterprise.

Officers

Most of the times recruitment is done at entry level only. However, Topworth at times recruits

Officers at senior levels, through open advertisements, to meet some specific requirements, like

Exploration & Production, R&D etc. for which expertise may not be available internally.

IT Officers and Accounts Officers are also directly recruited through open advertisement in S/G

‘A’.

Campus Recruitment:

Top worth also visits Engineering & Management Institutes for campus recruitment of

Engineers – From engineering collage, NITs, etc.

MBAs – Premier Management Institutions 

Chartered Accountants – Institute of Chartered Accountants.

All Officers are entitled to other applicable benefits: 

         Contributory Provident Fund

         Contributory Medical Insurance Scheme

         Group Savings Linked Insurance Scheme

         Group Personal Accident Insurance Scheme

         Gratuity and are members of the top worth Employees Superannuation Benefit Fund

Scheme

DA, HRA, Conveyance etc. Benefits like Furniture Loan, Vehicle Loan, Housing Loan,

Medical, Home Lease etc. are also available to Officers satisfying minimum service criteria.

Learning & Development and Career Progression

Systematic & continuous quality Training and Job rotation is provided to all Employees to gain

wider exposure which facilitates overall development of the Officer.

Top worth believes in pro-active Human Resource Development and nurtures the internal talent

of the organization by practicing the following, to name a few:  Reward and Recognition

Scheme, providing challenging work environment Balanced Score Card based performance

appraisal system along with Competency Development Programme, Profit sharing and

Performance Linked Incentive Scheme

At Top worth the work measurement practice followed is “Standard Operating Procedure”

(SOP) and Job Definition (JD). The process is standardized based on time and motion studies.

Chapter – vii

Environmental Management

CHAPTER - 7 Environmental Management

Impact on land

Impact on water regime

Impact on atmosphere

Noise &vibrations

Impact on ecological environment

Acid mine drainage:

From various places, e.g. o/c mines, dumps, etc. may enhance heavy metal pollution in

surface water bodies.

Acid mine water is produced to oxidation of pyrites minerals found in coal, ore bodies &

overburden. If mines are located in permeable formations acid mine water percolates into

aquifers and perched water eats away metals .Due to low pH, heavy metals becomes soluble

in water making it toxic and unusable for domestic and industrial purposes. It is an unique

pollutant as acid generation and discharge continues to occur even after ceasing of mining

operation.

Toxic pollution:

Mining & Allied activities contribute heavy metals to the aquatic system which are found to

be toxic in trace amounts and have tendency to bio accumulate.

It is reported that mine workers suffer with serious diseases like siderosis, silicosis, etc. due

to inhalation of ore dust in Mn &Fe ore mining regions. The fall out of particles of dust may

also damage the soil, vegetation water &aesthetics of surroundings.

Gases &smoke: Arises from

Refuse and stock piles— in case of coal mines contaminate the air by emitting

smoke & foul gases due to spontaneous heating.

Diesel equipment– produce toxic gases like NOx, SO2 ,CO & unburned

hydrocarbons.

Mine fires – contributes heat, SPM, hydrocarbons, SO2, CO2, CO, etc to the atmosphere

Coal seams, carbonaceous shale & paddy fields—

Contributes methane (CH4) .

Burning of coal & rock masses having sulphur & pyrites may contributes SO2.

Impact on ecological environment

• Loss of all vegetation – from the land designated for opencast mining, dumping of

soils &overburden, construction, etc.

• Deforestation— removal of forests for clearing the land for mining.

• Disturbances in the living of wild animals – due to deforestation, noise, vibrations,

air and water pollution, blocking of corridors, etc.

Effluents and Solid Waste Analysis in Topworth:-

On regular basis analytical studies of effluents and soil samples where sediments from the

treated effluents are dumped is carried out. These are then analyzed for physicochemical

properties, metallic and non-metallic ions.

These parameters are compared with established international standard (FEPA). Effluents

were classified as:

PROCESS WASTE WATER (PWW) : Process waste water (PWW) is water that is intended

to come into contact with hydrocarbons or treated chemicals at the petrochemical plant.

CLARIFIED WATER (CW): Clarified water (CW) is a combination of PWW and sewage.

FINAL DISCHARGE (FD): The final discharge water (FD) is the effluent, which has

undergone both chemical and biological treatment to eliminate or reduce waste contents to

acceptable levels.

Some of the Effluent Treatment Methods Used:

The treatment procedure of the effluents in the company is as shown below:

1) Equalization

2) Sedimentation

3) Flocculation

4) Floatation Dissolved Air Basin

5) Biodegradation

Analysis of Waste Water and Effluent Treatment Methods:

Waste Water Analysis: Determinations of major parameters are carried out according to

standard methods.

1. Determination of Biological Oxygen Demand (BOD),

2. Determination of Dissolved Oxygen (DO),

3. Determination of Chemical Oxygen Demand (COD),

4. The determination of Total Dissolved Solid (TDS),

5. Total suspended solid (TSS),

6. Total Hydrocarbon (THC),

7. pH determination

8. H) Level of Cl-, (PO4) 3-, (SO4) 2- and NO3

9. I) Determination of the heavy metals including nickel (Ni), lead (Pb), zinc (Zn), iron

(Fe), copper (Cu), cobalt (Co) and cadmium

Analysis of Sediments: Sediment samples are air-dried by thinly spreading on a clean

laboratory bench surface at room temperature, and brought to a relatively homogenous state

by thoroughly mixing, and sieving with 2 mm mesh before being treated. In the case of fresh

samples, large stones and roots were picked out before mixing and weighing.

Moisture determination of duplicate samples of the sediment was carried out for dry weight

correction. The sediment samples are then prepared (extraction method) for the various

physicochemical determinations.

Various physicochemical properties are determined by various analytical methods.

Safety and Hazards Management:

Causes of Accidents in Topworth : industrial accidents are often the result of unexpected

interaction between automated process equipment and operators. Equipment failures or

operator errors can lead to sudden and unexpected changes in the plant operation. If these

disruptions to normal process operation exceed the capabilities of the operators or the

capacity of the safety systems, a severe accident can occur, potentially producing a

devastating fire, explosion, or toxic release.

Safety Department: Special team of experts is present in Top worth to investigate loss in

such accidents, including material failures, fires, and explosions. These investigations range

from high-loss disasters to small incidents.

In the drive to improve safety and reliability, chemical process facilities tend to rely heavily

on automation using sophisticated instrumentation, computers, and programmable logic

controllers to run their plants. Honeywell does all the instrumentation work for Top worth,

Rasmada.

In an effort to improve energy efficiency and reduce pollution, various pieces of equipment

are interconnected in ways that complicate their operation.

Safety department of the refinery performs following functions:

1. Accident and incident investigation 

2. Root-cause analysis (RCA) 

3. Fire and explosion analysis 

4. Fire protection engineering 

5. Fitness-for-service evaluation 

6. Specification, corrosion control, and failure analysis of materials 

7. Evaluation of pressure relief systems, vessels, and piping 

8. Analysis of atmospheric releases, spills, and environmental fate 

9. Groundwater and soil remediation support 

10. Compliance with standards and regulations 

11. Risk and reliability analysis and quantitative risk assessment 

12. Process hazards analysis (PHA) 

13. Hazard and operability analysis (HAZOP) 

14. Failure modes and effects analysis (FMEA) 

15. Review of process safety management (PSM) and risk management program (RMP) 

16. Safety and health training 

17. Environmental impact and baseline assessments 

18. Site security and vulnerability analysis 

19. Site investigation and remediation 

20. Hydrology and groundwater monitoring 

21. Project management, performance, scheduling, and construction delay analysis

Benefits of Having Safety Department includes better understanding of employee’s

exposures to potentially hazardous situations, current knowledge of asset vulnerabilities,

identification of opportunities for cost-effective mitigation measures to reduce potential

losses, and better knowledge of loss exposures from an insurance perspective.

Their experiences provide engineers unique insights in addressing various risk and reliability

issues and assessing environmental and health impacts, to help increase the safety of workers,

processes, and facilities and minimize operational disruptions and property loss.

Chapter – viii

Value Engineering

CHAPTER-8 Value Engineering

Value engineering at Top worth is carried out in the following steps:

Feasibility Phase

During the initial phase, current constraints such as product quality, current market demand,

existing refinery capacity and existing condition are established. Typically, this type of

investigation includes physical on site examination of equipment as well as a review of

inspection and other records. A process simulation will be performed to obtain a model for

use in further design and to establish the operating constraints.

Existing legislation and product standards, locally and internationally, are reviewed to

establish likely future product requirements. Market research based on current economic

conditions and expected future conditions, are used to predict demand. This research is often

done using the expertise of consultants with appropriate local experience.

This phase could take 4 to 6 weeks, depending on the complexity of the system.

Conceptual Phase

The predicted future demand is used to establish various revamp scenarios. Using the

simulation and existing equipment data, the extent of revamp required to reach different

demand cases is determined. Using conceptual estimating techniques, an order-of-magnitude

cost estimate for the different scenarios is obtained. The emphasis for this type of cost

estimate is on establishing the differences between different options.

The cost estimates for different demands are compared with revenue generated and the

information is used to plan a revamp process to meet demand for the required period into the

future.

At this stage, a formal value engineering exercise is carried out to establish where

opportunity exists for increasing value. Typically, a number of alternate designs or options

are generated, the best of which are investigated further. The optimum alternatives are then

incorporated into the design for further engineering. As the design progresses and more detail

and firmer costs become available, it is often useful to perform another value engineering

exercise.

The conceptual phase takes 6 to 8 weeks depending on the required estimating accuracy,

complexity of solutions/options and the number of scenarios to be estimated. Typically at the

end of this phase the following are available:

Process flow diagrams, mass and energy balances

Equipment lists

Preliminary equipment sizing

Order-of-magnitude cost estimates

Economic evaluation

After the concept has been finalized and agreed with the refinery management, the design

proceeds to firm up details. Process conditions are frozen and detailed equipment

specifications are produced. Input from mechanical, piping, control systems, electrical and

civil engineering disciplines is included to complete the design. Experts are used from other

organizations where specialized skills are required. Detailed Piping and Instrumentation

Diagrams are produced showing the requirements of all disciplines. Equipment,

instrumentation and material specifications are sent to suppliers to obtain quotations and

details of required items. Global procurement is used to source material in the most effective

manner, from both cost and schedule considerations.

During this phase, which could last about 3 months, reviews are held with clients, suppliers

and internally to ensure the refinery's requirements are met and that the suppliers understand

their requirements. Suppliers are often selected at this stage, although orders are not yet

placed.

At the end of this phase a Hazard and Operability study is held to ensure the design is

workable and safe. The cost estimate is updated with an improved accuracy, based on the

additional information.

Detailed Engineering and Construction

Once all the planning and analysis is complete, the engineering departments get into full

swing. Orders are placed for equipment, especially long delivery items. Any items not yet

firmed up are defined and engineering completed. Any changes or updating are extremely

tightly controlled to prevent omissions, schedule threats or escalating costs. The duration of

this phase normally depends on equipment delivery. Careful planning is required to reconcile

delivery times and commissioning and start-up requirements. Material must arrive on site in

time to facilitate construction. Effort is concentrated on expediting and inspection to ensure

that items reach site on time and are correct.

Any delays during engineering can cause an impact on the construction team, who need the

flexibility to respond appropriately. A key consideration during construction phase is the

safety of construction labor and other people in the vicinity of the site. At the end of

construction the site is normally handed back to the owner for commissioning and start-up.

During this final phase, the process of transferring the revamped refinery back to the

operations department is done.

Chapter – ix

Findings/Conclusions

CHAPTER 9 FINDINGS /CONCLUSIONS

Accuracy of Authoritative Written policy is the average influencing factor.

Designing & Quality Planning Exercise consider moderate influencing factor.

Pre-Productions Activity/ Feedback from Trial are below average influencing

factor for respondents.

Satisfy customer through compliance of their needs, by delivering premium

quality products in a cost effective manner on time & every time.

Continuous improvement in process, quality, sales and delivery. All members

of the organization are developed by effective implementation and up

gradation of the Total Quality Management System.

This company believes on continuous improvement in its production and

adding value to the society

The Group has emerged as a strong player in the Steel trading in the

Western Region supported operations in Chhattisgarh and Maharashtra.

Top worth facilitates decision making process of its Group companies on

matters related to business strategy.

HOW ????????

FINDINGS OF THE STUDY

Top worth based on continues production system.

Merits of top worth steel company:

While undergoing an industrial training and completing a project in the company many

Merits were visible to us. Some of them are as follows –

Improved automation

While surveying it was found that the company had laid more stress on automation i.e.

Work is being carried out with automatic machines in place of manpower. Hence the

probability of accident has reduced to a great extent.

Controlled dust

Sponge iron plants are considered the most polluted plants because of large amount of dust

produced in various parts of the plant.

Steps taken here to control the dust-

Electro static participators have been used, which purifies air and settle the dust. I t

works on the principle of electro static precipitations.

Daily ash and dust is removed. It is watered regularly so that dust may not spread to

nearby areas.

Back flow system

An extra ordinary system has been developed by the engineers of the company known as

back flow system .It has reduced the danger of burning and other health hazards to the

workers and engineers.

Reduction in waste

In the purchase ore fines are also present in considerable amount which should be

utilized hence the cost of the company is using the size of even 3mm of ore.

Crushing unit

Another point of view in the favor of the company is that it has installed its own crushing unit

hence the cost of mineral processing such as crushing and grinding is reduced.

LARGE AREA

Various departments such as process steel melting shop, thermal power plant are distantly

spaced; still a large area is available for setting up other project.

Thermal power station

Unlike other sponge iron plants Top Worth Company is self sufficient in the field of power

requirements. I t has installed a power plant of capacity 20 MW. and the surplus power is also

sold.

Point against the company;

There is always some possibility of improvement and Top worth steel company is no

exception. There are some areas in which company may improve.

Improper website

The data provided by the company website is properly figured.

It should contain the detail such as names and e- mail addresses of key persons of the

company.

It should be regularly updated.

Pollution and health problem

All though some steps have been taken to control the dust, but better technology should be

used such as.

Dust separation system

Chemical dust separations system may be provided in coal and iron ore conveyor circuits

to reduce dust during circuit operation. Chemical may also sprayed over the running belt to

entrap the flaying dust generated and suppressed on to the belt itself.

Road vacuum cleaning machine

The road vacuum cleaning machine may be used for cleaning the roads of the company.

the machine sucks the road dust and control air pollution.

RE-circulation of water;

Water should be re circulated in the process and a part of it may be used for road cleaning

washing and gardening.

Chapter – x

Suggestions

CHAPTER X SUGGESTIONS

Authoritative Written policy should be effective that reflects the importance of

legal policies.

Company should make better quality product satisfy the customers as much as

possible.

Company should be maintaining production of power generation area.

Esteem gas linkage in many different areas in plant it may be cause of accident.

Notification of the company is not in proper way or not reached easily to their

worker.

If company visit in collages for recruitment it help to recruit more capable

student as employee.

Challenging work environment is more beneficial for employees.

Provide safety and health training to all employees.

Limitations:

Storage facility of raw materials and finished products is not in proper way.

Some data’s are confidential for the company, so they don’t want to disclose their

details to us.

BIBLIOGRAPHY

Reference:

Citation from Books:

1. Production and operations management :Ashwathappa/ Bhat

2. Operations management : Roberta Russell/Bernard Taylor

3. Productions operations management : Martand Telesang

4. Total Quality Management, S M Sundara Raju, 8th print 2004, 0074624520

Citation from websites:

http//www.topworthgroup.com

http//www.citehr.com

http//hrleader.com

www.books.google.in