Organizational Study of KMML

Organizational Study of KMML MS Unit
INTRODUCTION
An organization is a social arrangement which pursues collective goals, which controls Its own performances. An organization is a formal group of people with one or more Shared goals. Each and every person in an organization should identify their position and responsibility and work accordingly for the achievement of the ultimate organizational goal. An organization study is mainly aimed to create awareness about the various functions and operations of an organization. The Kerala Minerals and Metals Limited were established by private entrepreneur in 1932 as F .X. Pereira and sons (Travancore) Pvt .Ltd. During 1956 this concern was taken over by state government and place under the control of its Industries Department on 1-4-1972. With the advent of electric lamp, gas mantles lost their demand and monazite seemed to face great recession in the market .This led to the investigation for other valuable minerals in the beach sand and soon other heavy minerals like ilmenite, rutile, zircon, sillimanite etc were discovered in the same raw material monazite sand used by the industry. Geological survey of India established in the presence of huge quantities of the important heavy minerals in a strip of land between the two tidal channels of Neendakara and Kayamkulam, in Kollam and Alapuzha district respectively. The natural history of the heavy mineral sands begins from the crystalline rocks of the Western Ghats and the Nilgiri Hills .These rocks contain minute crystals and grains of heavy minerals. During weathering, these rocks have been decomposed and worn out and carried into the sea. In the course of ages these grains are transported from the original site in the mountains by streams to be ultimately deposited in the sea. Owing to the peculiar nature of the sea currents and wave action the accumulating sand grains have been swept back on the beach. The action of the waves concentrates these sands by washing away the constitutes ,that are light.TheKollam deposits have thus been a rich source of rare earths and other heavy minerals having of uses Industry and Science.
OBJECTIVES OF THE STUDY
Institute of Management in Kerala, Kollam
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The organizational study at KMML is undertaken with certain clear cut objectives which are classified as: To study the KMML M.S unit Products, Organisational culture and function. To understand the various departmental functions that ensures smooth running of the organization.. To interact with managers at different levels and find out their duties and responsibilities.
METHODOLOGY
The study has been conducted using primary and secondary data. These data were collected with the help of questionnaire; interview and observation. Two sources are used for collections of data. Primary data collections are:The primary data are those which are collected for the first time .the primary data were collected from the employees through personal interview .Observation method is also used to collect the primary data.
Secondary data collections are:Secondary data were collected from the organization books, records, and journals etc provide by the company. It can also be obtained through web information.
SCOPE OF THE STUDY
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Organizational Study of KMML MS Unit To understand actual working conditions of all departments. To get in touch with the industrial and organizational environment
LIMITATIONS OF THE STUDY.

Time is a limitation because the company gave only one hour for data collection per day. The unavailability of some confidential data.
CHAPTERIZATION
Chapter 1 deals with the introductory section of the organization study. It contains the objectives, methodology, scope and the limitation of the study Chapter2 deals with the industry profile which includes world, Indian and state scenario. Chapter3 deals with the company profile. It includes history, vision, mission, objectives, product profile, customers and the future plans. Chapter4 deals with the organizational structure of KMML - MINERAL SEPERATION UNIT. Chapter 5 Departmental Analysis Chapter 6 deals with the findings, conclusions and suggestions Chapter7 deals with the findings, conclusions and suggestions
INDUSTRY PROFILE
Institute of Management in Kerala, Kollam Page 3
The Minerals and Metals Industry has been flourishing since ancient times.Fr. William Gregor in the year 1789 discovered Ilmenite in Konwat in England. He found that the Black Sand contains some important Metal but he failed to discover it. In 1875 a Hungarian scientist MARTIN KEINWITCH found the same metal contents in the refine Minerals. The Geological Survey of India found the presence of Monazite in the coastal sands of kerala .Besides the Mineral deposits are also found in Tamilnadu, Orissa because of which they also have well established Mineral Industries. A) GLOBAL SCENARIO Like many companies in the present economic climate companies operating in the metals and mining market are undertaking policies of cost improvement and margin maintenance whilst looking to further develop immature markets(such as China where it is hoped the development of a growing IT industry will increase demand for precious metals and aluminium used in computers).Although turbulent by its very nature the metals and mining industry and the companies within it, should enjoy a moderate compound annual growth rate (CAGR)going forward with forecasts predicting that the market will reach a value of $900 billion by 2007. The metals and mining industry comprises six sub-categories: Aluminium, Gold, Precious Metals, Other Metal Extraction, and Coal mining and Steel. The largest segment of the global metals market is Iron and Steel followed by aluminium.The iron and steel segment comprises of more than half the industry in terms of volume. Regionally Asia-pacific is the largest market for metals and mining followed by Europe. The metals and mining sector find end-use in industries such as automobiles and consumer durables that rely upon this industry for the raw materials with which they created their familiar everyday products, computers in particular require aluminium, steel and precious metals in their production. For these reasons demand for a broad range of different types of product translates into demand for the products produced in this industry-sustaining in even the harshest economic climates.
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Organizational Study of KMML MS Unit The industry is therefore also highly cyclical and has been negatively affected by the global downturn of the past few years .The industry is highly affected by fluctuations in its largest segment, steel(which accounts for over 60%of the market value)which has been strongly affected by the continuing global economic downturn, and in turn has adversely affected the metals and mining market .Chronic overproduction is a problem in several sectors , especially the beleaguered steel manufacturing industry. The overall outlook for the global metals and mining industry remains positive with the recovery in global economic conditions. Developed regions like US and Europe are showing signs of uptake in industrial output and economic revival .Emerging regions like Asia-pacific are fueling demand as industrial output increases to satisfy latent demand. Transportation is one of the most important markets for the aluminium subindustry, and is expected to prove an important driver of future growth .Increasing numbers of automobiles are aluminium intensive , benefiting from the recyclability and lightweight characteristics of the metal. Aluminium is also widely used for packaging, beverage cans, food containers and foil products. In contrast, the steel subindustry is suffering from massive over capacity; consequently, steel prices have declined in recent years. The steel industry has been subjected to numerous trade disputes over the year with the US in particular imposing tariffs up to 30% on imported steel, triggering a tariff war. The global industry has been boosted by the recent recession .Although the general outlook is positive, the competitive landscape differs across the sectors of the precious metals and minerals sub-industry .The gemstone sector is more susceptible to economic change than gold and is characterized by smaller producers. The diamond industry by contrast is highly consolidated, but has come under ethical pressure recently because of alleged links with African warlords. A global increase in mining capacity is currently underway with numerous new projects around the world. The major mineral sand deposits of the world are spread throughout different continents across the glob. The exploration for mineral sand deposits has intensified since the mid 1980s due to increasing use and demand for heavy minerals. The major countries where these deposits are found are Australia, Canada, India, Keniya, Madagascar, Mozambique, South Africa etc.
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B) INDIAN SCENARIO Mining and mineral industry constitute the backbone for industrial expansion in India. The mining sector contributes substantially in the socio-economic prosperity of our country by supplying essential raw materials to the industries and power sector gifted with a wide range of its minerals, India is one of the leading producers and exporters of several minerals in the world. Mining industry in India started its journey long back in 1774, when the East India Company permitted an English company to undertake mining activity in the coal field in Ranging, gold mining in Kolar gold. In India, 80% of mining is in coal and the balance 20% is in various metals and other raw materials such as gold, copper, iron, lead, bauxite, zink and uranium. India with diverse and significant mineral resources is the leading producer of some of the minerals. India is not endowed with all the requisite mineral resources. Of the 89 minerals produced in India 4 are fuel minerals, 11 metallic, 52 non metalic, 22 minor minerals. India is the largest producer of mica blocks and mica splitting; ranks third in the production of coal and lignite, barites and chromate; 4th in iron ore, 6th in bauxite and manganese ore, and 10th in aluminium and 11th in crude steel. Iron-ore, copper-ore, chromate and zinc concentrate percent of non-metallic minerals. The index of mineral production, excluding fuel and atomic minerals,(base year 1993-94=100) for the year 2005-2006 is expected to be 154.23 as compared to 153.48 in 2004-2005.
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Organizational Study of KMML MS Unit C) STATE SCENARIO Gods Own Country is best owed with along coastal belt .Kerala State is endowed with a number of deposits of minerals such as Heavy Mineral Clay ,Fire Clay, Tile and Brick Clay Sand ,Silica (Ilmenite,Rutile,Zircon,Monazite,Sillimanite), Gold, Iron Ore, Bauxite,Graphite,China Sand,Lignite,Limestone,Limeshell,Granite,Gemstones,Magnesite,Steatiteetc.However, mining activities on large scale are confined mainly to a few minerals Heavy Minerals ,China Clay and to a lesser extent Limestone ,Silica Sand and Granite. In fact, Heavy Minerals and China clay contribute more than 90% of the total value of mineral production in the state. The State owns mineral deposits like china clay,limestone,limeshell,silica sand,bauxite,graphite,iron ore etc.The major mineral based industries like Kerala Minerals and Metals Ltd., Chavara,Indian Rare Earth Ltd.,Chavara, Malabar Cements, Walayar,Travancore cements Ltd.,Kottayam,Kundara Ceramics,Kollam.,English Indian Clays Ltd ,Thiruvananthapuram.,Excel Glass Industry , Alappuzha, Kerala Clays and Ceramics Products Ltd,Palayangadi, Kannur are some of the mineral based industries working in the state since several years. The resources of beautiful ornamental granites in the state are being exported to different countries.
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COMPANY PROFILE
HISTORY The Kerala minerals and metals limited, a fully owned Kerala government Enterprises in the worlds fully integrated titanium dioxide plant since its inception, and KMML has made an indelible mark in the field of mining, mineral processing and manufacturing. Kerala is blessed with an extensive deposit of heavy mineral sand. The worlds richest deposit of heavy minerals and containing limonite, rutile, leucoxene, zircon, silimanite and monazite lies in the coastal belt of Kerala between Neendakara and Alleppy. This heavy mineral deposit is rightly called the Black gold mine of gods own country. In the year 1909 Mr. Herm Shoemburg a German sponsored London cosmopolitan syndicate discovered the presence of the monazite in the threpolke beach sands. Monazite was in great demand those days due to its wide use in mantle for gas lights. In the beach sands of chavara coast. Mr. Shoemburg established minerals as separation unit at chavara in 1910.But during the First World War the German agencies started mining and separation of rare earth mineral chavara.The first shipment of limonite left chavara coast in 1922 by 1932, four companies had been working this field. One among them M|S F.X.Pereira and sons , exported was taken over by the state government in the name of Kerala Minerals And Metals Limited bright prospects of the titanium mineral industry with further value addition led to the establishment of the titanium dioxide pigment unit in 1986. Now the company has three units, i.e. o The Mineral Separation Plant (MS Plant) which separates Ilmenite, Rutile, Zircon, Siliminite, Zirflor, Leucoxene etc. o Titanium Pigment Plant (TP Unit) produces Rutile grade Titanium Dioxide through chloride route process. o Titanium Sponge Plant (TSP) produces Titanium Sponge (Raw material for Titanium metal) through Krolls process.
COMPANY LOCATION
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Organizational Study of KMML MS Unit The plant is situated 85 km north of the capital city. It is situated Kovilthottam in Chavara.The factory is situated very near to the N.H [N.H 47] and to the sea coast. VISION STATEMENT KMML to be a world class producer of mineral sand based value added products. MISSION STATEMENT To become the modal agency for promoting and establishing mineral based industries in the state to ensure value addition and effective controlled exploitation of the mineral serves. To become the leader in controlling Green House Gas Emissions so as to promote the concept of green earth. To create more awareness about corporate social responsibilities for chemical industries in the state. To develop adequate supply base for the services and utility for development of the mineral based industries in the state.
COMPANY OBJECTIVES To exploit the mineral wealth abundantly available in the belt. To carry on business of mining minerals and metals of any natural processing ,producing, cleaning, refining using and cleaning in Ilmenite, Rutile and zircon.
CERTIFICATION ISO 9001,14001 and OHSAS 18001
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Organizational Study of KMML MS Unit ISO 9001, OHSAS 18001 awarded for the superior manufacturing practices up held at KMML. GOALS AND OBJECTIVES To become nationally and globally competitive player in beach sand minerals. To improve productivity, capacity utilization and cost effectiveness. To maximize shareholders value. To evolve and implement eco-friendly policies, programmes and project within the AERB regulations. To develop the human resources of the company by optimizing their number, capabilities and quality of life. To strive for optimum value addition through obtaining technology for improving international market share and for growth in the domestic market. To undertake, by it or through independent expert agencies, investigation into new products as well as beach sand erosion and related phenomena of companys operation. QUALITY POLICY Company delights their customers with world class products and services at competitive prices. The company is maintaining a quality manual, which provides adequate description of the quality management system to be followed. The company work for continual improvement in the area of Delivery, Inventory Control, Cost reduction, New Product Development, Communication, Safe and Clean Workplace, Human Resources Development through implementation of ISO 9001-2000 Quality Policy Management System.
QUALITY OBJECTIVES Caring for requirement of society.
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Organizational Study of KMML MS Unit Compliance with Documented Quality System. Customers driven continuous improvement. Encouraging innovation and technology. Training and empowering work force.
MANAGEMENT The Managing Director Heads of the Organization .He is responsible for the effective performance of the company and also the Board of Directors on the other policy decisions regarding the company is taken by MD. There are mainly nine departments:Finance Maintenance (E) Maintenance (M) Marketing Mining Personnel Production Quality control Stores
The MS Unit is where the separation of Ilmenite, Rutile, Leucoxene, Monazite, and Silliminite etc from the beach sand takes place, through the various stages in the
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Organizational Study of KMML MS Unit Wet Concentration Plant, Dryer Plant, Dry Mill, and Rutile & Zircon Recovery Plants. The MS Unit employs Gravitational, Magnetic, and High tension electrostatic techniques for separation of minerals from the sand. KMML always maintains high standards of perfection, achieving technical excellence in every phase of production. Catering to strict guidelines, KMML offers a wide range of products for quality conscious customers. Our products go into the manufacture of a variety of products used in everyday life. Dress materials, facial creams, tablets, newsprints, wood paints, emulsions, enamels, plastics, tooth paste, rubber products, cosmetics, and printing ink All contain titanium dioxide. Believe it; you need our products to brighten your life.
PRODUCT PROFILE
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Organizational Study of KMML MS Unit Table No.1 Composition%(typical) Tio2 Fe2O3 FeO T\Fe SiO2 Cr2O3 Al2O3 ZrO2 V2O5 MgO MnO P2O5 Na2O K2O CaO LOl at 90dc Specific Gravity Source: Secondary data Ilmenite Rutile Leucoxene Zircon Silliminite Monazite 59.88 26.98 8.4 25.34 0.83 0.04 1.16 Traces 0.2 0.79 0.4 0.19 Nil Nil Nil 0.98 4.20 94.04 3.36 Nil Nil 0.58 Nil 0.65 0.64 0.36 Nil 0.05 0.028 Nil Nil Nil 0.22 4.25 79.65 7.5 0.47 5.60 4.18 0.06 3.31 0.65 0.28 1.1 Traces 0.35 Traces Nil Nil 2.38 3.50 0.30 0.86 Nil Nil 30.33 Nil 2.51 64.81 Nil Nil Nil 0.46 0.03 0.02 Nil 0.3 4.69 0.12 1.0 Nil Nil 36.58 Nil 61.62 0.18 Nil Nil Nil Nil Nil Nil Nil 0.47 3.27 5.14 28.21 RE2O357.5% ThO27.96% Acid Insoluble 5.05%
MINERALS AND MINERAL PRODUCTS OF MS UNIT AND THEIR APPLICATIONS The important products separated from the KMML MS unit are as follows:-
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Organizational Study of KMML MS Unit Ilmenite Table No.2 Leucoxene Monazite Rutile Sillimanite Zircon
1. Ilmenite This is highly magnetic and electrically conduction. This mineral is in black colour and contains 58% TiO2.Used for the manufacturer of synthetic lutile, Titanium chloride, Titanium dioxide, Titanium metal alloys, and Welding Electrodes.
Uses
Ilmenite is the primary ore of titanium. It is also used in the manufacture of titanium dioxide for paint pigments. Titanium is used to manufacture a wide variety of metal parts where light weight and very high strength are needed. Examples include: aircraft parts, artificial joints for humans and sporting equipment such as bicycle frames. Titanium is also used in a number of high-performance alloys.
2. Leucoxene
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Organizational Study of KMML MS Unit Leucoxene is a fine, granular alteration product of titanium minerals consisting mainly of rutile. Leucoxene is formed through extensive weathering of ilmenite and displays higher titanium dioxide (TiO2) content. Although it is not a recognized mineral species, the name has been applied to products with a Ti02 titanium content ranging from 70% to 93%, but increasingly is limited to material having a typical TiO2 content of 90-91%.Leucoxene is either sold for use in welding electrodes which is a relatively small market or as one of several feedstocks for titanium pigment plants. In the welding applications, the product is used as a fluxing agent in the welding electrodes which are used extensively in shipbuilding and civil engineering. China has been a strong market for leucoxene for this purpose driven by its booming construction industry. It is used as an opacifier in house and car paints, sunscreens, plastics, paper, and textiles. 3. Monazite It is known as the "rare earth" elements and it is a rich source of the radioactive element thorium. Rare earth elements are used in high performance magnets, as pigment in ceramics, in robot motors, x-ray screens, fibre optics, energy efficient lanthanum lamps and co lour television tubes. Thorium is radioactive and is used in incandescent gas mantles and in fuel for nuclear reactors. 4. Rutile Rutile is a major mineral source of the element titanium. Rutile is typically about 60% titanium and 40% oxygen. It can have some iron present, sometimes up to 10%. Rutile is one of the most common titanium minerals, occurring in gneiss, mica, schist, granite, limestone and dolomite. It is also associated with quartz, hematite and feldspar. As a secondary mineral, it is common in beach sand deposits, along with the other titanium mineral, ilmenite.
Major uses of this lightweight, high strength, non-corrosive metal are aerospace, automobiles, sports, and medicine. Still, its main use is in paint as a paint pigment. It replaced lead as the most common paint pigment used in the manufacture of paint.
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Organizational Study of KMML MS Unit Other uses include a coating for tiles, and it is used to treat the air, both to preserve fruits and vegetables and to remove pollution. 5. Sillimanite Sillimanite is one of three Alumino-Silicate Polymorphs, the other two being Andalusite and Kyanite. A common variety of Sillimanite is known as Fibrolite, so named because the Mineral appears like a bunch of fibers twisted together when viewed under thin section or even by the naked eye. Both the fibrous and traditional forms of Sillimanite are common in Metamorphosed Sedimentary Rocks. Widely use all over the world for manufacture of Refractory Bricks, Iron Foundries, Spark Plugs, Glass, Chemicals. 1. Zircon The mineral zircon forms when zirconium, silicon and oxygen bond into a crystal matrix. Zircon crystals also trap small amounts of hafnium, uranium and thorium and serve as the principal source for hafnium metal. Zircon crystals can take almost any color and are often used as semiprecious gems. Ground into fine sands, zircon also has industrial uses in the manufacture of ceramics, glass, metals and chemicals. The mineral also proves invaluable to geologists who assign ages to scientific samples.
USES; Jewelry
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Organizational Study of KMML MS Unit The famed cubic zirconium is a manufactured zircon. The natural mineral can also be cut, polished and set as a gemstone. According to the Zircon Minerals Council, roughly 12 percent of mined zircon becomes jewelry, although some of the crystals have to be heated to destroy the trace radioactive elements they contain. Ceramics Most zircon gets ground by processors into sands of varying grain size. Ceramics manufacturers make the most overall use of zircon, employing the finest zircon sands to give their products high strength and high resistance to heat. Zircon ceramics often serve as protective coatings on metals. Refractories Refractoriness are heat-resistant materials that constitute the linings for high-temperature furnaces and reactors and other processing units. Many of the linings of smelters, chemical vats and heat containment units in power plants employ zircon sands as an essential component. Industrial Abrasives Coarser zircon sands see use as polishing agents at metal foundries and glass works. Zircon sands also serve as the ammunition for some sandblasting machines used to strip paint and mold from buildings.
Glass Screens As with ceramic glazes, adding zircon to glass makes it semi-opaque. Glass mixed with zircon sands often gets used for television screens.
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Organizational Study of KMML MS Unit Welding Some welding rods carry a zircon coating. The mineral protects applied solder from being displaced by subsequent heating.
ORGANISATIONAL STRUCTURE
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Organizational Study of KMML MS Unit A business organization has to perform a number of activities in order to run itself. Like any other public sector undertaking KMML MS unit has separate departments and separate executive heads for each departments. Departments are based on the functional basis. The functional form of departmentation means grouping activities into departments of Production, Marketing, Human Resource Development and Finance. Each department specializes in its own area of operation. The Managing Director is the top official in the management of KMML .KMML MS unit has a separate department head for each department. . The various departments in the KMML MS unit are: Personnel & Administration Commercial Finance Fire & Safety Maintenance(Electrical) Maintenance(Mechanical) Mining Quality control Production Project Stores
ORGANISATIONAL CHART OF KMML
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Chart No.1
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DUTIES, POWER AND RESPONSIBILITIES

MANAGING DIRECTOR
Administrative power: General management of the business of the company subject to the policy and principles, approved by the board of the company. To appoint personnel in the sanctioned posts in conformity with the recruitment rules of the company.MD is the appellate authority of the employees below the level of Deputy Managers and disciplinary authority in the level of Dy.Managers as per the Standing order of the company. The MD shall have the charge and custody of all properties belonging to the company. The MD shall have the power to make all arrangements on behalf of the company as may be necessary to the attainment of the objectives of the company. MD is occupier as per Factories Act. Financial Power: The Managing Director has full powers of operate bank accounts in the name of the company. Also MD has the power to execute any documents on behalf of the company and with the concurrence of the Board of Directors.MD can delegate the above powers to other officers with the approval of the Board.
Responsibility:
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The Managing Director is the owner, Employer and occupier under the various Acts applicable to Factories and of M.S unit under the various Acts applicable to Mines and he is nominated as owner of the mine owned by the company under Mined Act1952. He is responsible for the compliance of the proper implementation of all statutes applicable to Factories Act and Mines Act. GENERAL MANAGER
Administrative power: Deals with corporate and unit levels personnel functions including formation and implementation of policies, actual handling of the situation arising in the company .Responsible for handling manpower recruitment, industrial relation production, maintenance, welfare and administrative functions. Working as unit head, in charge of administrative functions of MS units. Disciplinary authority below the level of Deputy Managers, Unit head of P&A, Commerce, Finance. Financial Power: To approve the petty contracts as per the procedure. Power to operate the bank accounts of the company as per the sub delegation of power given by MD. Responsibility: Responsible to act in accordance with statutes in force. To frame rules and regulations of the company in terms of policy and approval of MD/ Board of Directors.
ASSISTANT GENERAL MANAGER
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Organizational Study of KMML MS Unit Administrative power: Overall control of the administration and technical functions of the Mineral Separation Unit. Agent of the Mineral Separation Unit or KMML. Financial Power: To approve the purchase and contracts as per the purchase procedure and works contract procedure of the company. Power to operate the bank accounts of the company as per the sub delegation of power given by MD. Responsibility: In charge of production and day to day operation of the Mineral Separation Unit .To review the progress of work in various departments and to co-ordinate the works. Responsible as agent of the Mine under various Acts. MANAGER (PRODUCTION & MAINTENANCE)
Administrative Power: Administrative control of all employees working under him ,Reporting of maintenance activities and constraints, Review and annual maintenance plan, technical recommendation of products and spare ,ensuring regular overseeing general house keeping & compliance of safety rules Financial Power: Nil
Responsibility:
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Organizational Study of KMML MS Unit Responsible for the smooth and effective running of the section under their control. MANAGER (FINANCE)
Administrative Power: Co-ordinate the functions in the Finance department preparation and maintenance of all finance records, Sales Tax records etc .Conducting cost audit, maintain companys Bank Account. Financial Power: To exercise financial powers on behalf of the company in terms of the company and orders, circulars issued from time to time. Power to operate the bank accounts of the company as per the sub delegation. Responsibility: Preparation, Custody, Maintanence and Supervision of all books of accounts, monthly and annual tax, bank reconciliation statement, and profit and loss accounts, Balance sheet etc.of the company. Physical verification of cash , to acknowledging receipt of money and payment of bills, to watch expenditure with in the budget provisions, to draw and disburse salary,T.A and other claims of employees. To comply with all taxation laws in force from time to time.
COMPANY SECRETARY
Administrative Power: Entrusted with functions of company secretary such as monitoring of corporate plan. Financial Power:
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Organizational Study of KMML MS Unit Nil Responsibility: Responsible for all statutory functions under the Indian Companys Act and Rules. MEDICAL SUPDT
Administrative Power: General administration of dispensary, maintaining health reports, scrutinizing medical bills submitted by employees, conducting periodical medical check- up of employees. Financial Power: Nil Responsibility: Responsible to discharge functions under Factories Act and Mines Act as applicable.
MANAGER(MARKETING)
Administrative Power: Controlling all administrative work related to publicity for products, marketing research, market development. Arranges customers meet correspondence with customers, Renewal of stockiest ship etc. Financial Power:
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Organizational Study of KMML MS Unit Nil Responsibility: Responsible for the effective functioning of the department and to get more market share for our products at possible minimum cost.
ASST. MANAGER (MINES) Administrative Power: All powers of Mines Manager as per the Mines Act.
Financial Power: Nil Responsibility: Responsible as manager of Chavara Ilmenite Mines of KMML under various Acts. ACCOUNTS OFFICER Administrative Power: Co-ordinate the functions in the finance departments preparation and maintenance of all cost records, Sales Tax records etc. Conducting cost audit, maintain companys bank accounts related to the company. Financial Power:
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Organizational Study of KMML MS Unit To exercise financial power of behalf of the company in terms of rules of the company and orders, circulars issued from time to time .Power to operate bank accounts of the company as per the sub delegation. Responsibility: Maintenance and supervision of all book account, monthly and annual tax, profit and loss account, Balance Sheet etc of the company. Responsible for the physical verification of cash, to watch the expenditure with in the budget provision, to acknowledging receipt of money and payment of bills, to draw and disburse salary, TA and other claims of employees. To comply with all taxation laws in force from time to time. LEGAL OFFICER Administrative Power: Take necessary steps to comply with statutory requirements under ID Act and other relevant statutes, follow up cases and postings before various courts, and obtain necessary legal opinion.
Financial Power: Nil Responsibility: Responsible to attend all legal matters of the company. SECURITY OFFICER
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Organizational Study of KMML MS Unit Administrative Power: General administration of security personnel of the company, ensure security of companys property and its personnel, liaison with local police. Financial Power: Nil Responsibility: In charge of controlling entry or exit of men and material, in charge of operation of vehicles for official purposes. FIRE OFFICER
Administrative Power: Maintaining the Fire protection systems in perfect condition, guarding the fire crew, and inspecting training to all employees and control workmen to operate fire fighting appliances. Financial Power: Nil Responsibility: Identify potential fire hazards in the factory and responsible for the timely action at emergency situation. SAFETY OFFICER
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Organizational Study of KMML MS Unit Administrative Power: Plant inspection ,Accident investigation, Arranging safety committee meetings, Forwarding of safety inspections/ investigations report. Financial Power: Nil Responsibility: Issuing/ clearing of safety work permit and responsible for the safety of all people working in the specified areas.
ALL OFFICERS BELOW THE LEVEL OF MANAGERS NOT MENTIONED ABOVE
Administrative Power: To Co-ordinate the functions of their concerned sections and to supervise the work entrusted with the company. Financial Power: Nil Responsibility: Responsible to work under the instructions and supervision of their immediate supervisor and in terms of rules, regulations, office orders and circulars. ALL EMPLOYEES, WORKERS INCLUDING CASUAL WORKERS
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Organizational Study of KMML MS Unit Administrative Power: Nil Financial Power: Nil Responsibility: Responsible to work under the instructions and supervision of their immediate supervisor and in terms of rules, regulations, office orders and circulars.
MINING DEPARTMENT
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Organizational Study of KMML MS Unit KMML is engaged in the mining of deposit of heavy minerals sand found in coastal area between Neendakara to Kayamkulam extends over a length of 22 Km with an average width of 200 M. For the purpose grating mining lease the entire area is divided into 8 blocks and mining lease is granted for IREL and KMML for alternative blocks.KMML is holding the mining lease for block II IV VI VIII.The total area available in all these block together is 169 hectors and the reserve of raw sand 14.5 Million Tones.
ORGANIZATIONAL CHART OF MINING DEPARTMENT Asst.General Manager
Asst.Mines Manager
Mines Foreman
Mate (Mines)
Workers
Chart No.2
MINING DEPARTMENT
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Organizational Study of KMML MS Unit Mining is the extraction of valuable minerals or other geological materials from the earth. The term also includes the removal of soil. Materials recovered by mining include base metals, precious metal, Ilmenite, Monazite, utile. Any material that cannot be grown through agricultural processes, or created artificially in factories, is usually mined. Mining in a wider sense comprises extraction of any non renewable resource.
Mining process include Mineral recovery plant Concentrate upgrading plant Dry mill For mining purpose KMML use two plants named Mineral Recovery Plants, MRPI, MRPII.The collection of raw sands is also conducted by sea washing. From 1990 the company started a facility of mining by using sanction cutter in floating dredger .Beach washing are collected and concentrated in CUP .It is dried in a furnished bred drier.
PERSONNEL AND ADMINISTRATIVE DEPARTMENT
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Organizational Study of KMML MS Unit Personnel department will be directly responsible for the personnel functions of the company to result in timely action for maintaining smooth industrial relations leading to employee morale and productivity .This department is responsible for the administration of human resources in the most effective manner and provides opportunity for maximum individual development .
ORGANIZATIONAL CHART OF PERSONNEL AND ADMINISTRATIVE DEPARTMENT Asst.General Manager
Manager (P&A)
Personnel Officer Community Development Officer
Time Keeper Medical Assistant Junior .Typist
Peon
Peon
First Aider
Chart No.3
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PERSONNEL AND ADMINISTRATIVE DEPARTMENT Personnel department will be directly responsible for the personnel functions of the company to result in timely action for maintaining smooth industrial relations leading to employee morale and productivity .This department plays a prominent role in the day to day affairs of the company. Assistant General Manager is the supreme authority in the department. Administrative Officer is in charge of time keeping section and a medical officer is in charge of medical section. This department is one of the most important assets of every organization. Personnel department is concerned with peoples dimension in the organization. Manager (P&A) is the head of the department .Regular training and refreshment courses are part of the company life. The courses which include quality consciousness and safety awareness contribute to personality development is to ensure the availability of skilled workers. THE FUNCTIONS OF P&A DEPARTMENT The major functions of personnel department are as follows: Recruitment & Selection Training & Development Promotion & Transfer Retirement & Superannuation General Administration Public Relations Labor Welfare Activities Disciplinary Proceeding
RECRUITMENT & SELECTION
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Organizational Study of KMML MS Unit The company adopts different methods of recruitment of the staffs. For this company give advertisement in Malayalam and English newspapers publishing from kerala and other states of South India. Procedure for recruitment If there is a vacancy in the workman category, it is notified to the concerned employment exchange. In case of officer category, selection is made through Kerala Public Service Commission(KPSC) For requirement of managerial and professional posts ,the applications are received with respect to the advertisements made in the newspaper and the details furnisher by the technical committee are also considered. A committee set up by the board of directors with not less than 3 members and at least one of being government representative makes recruitment to the vacancies. SOURCES OF RECRUITMENT The sources of recruitment of KMML MS unit are: Kerala Public Service Commission Technical Employment Exchange Advertisement in Newspaper
CLASSIFICATIOS OF POSTS
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Organizational Study of KMML MS Unit Table No.3
CLASSIFICATION Senior Managerial(Executive) Cadre
LEVEL E1 E2 E3 E4 E5
DESIGNATION Chief General Manager General Manager Joint General Manager Dy.General Manager Asst. General Manager Manager Dy. Manager Process Engineer & Equivalents
Middle Level Executive
E6 E7 E8
Junior Level Executive
E9
Asst. Process Engineer & Equivalents
Operator Grade A & Equivalents W1 W2 W3 W4 W5 Operator Grade B & Equivalents Operator Grade C& Equivalents Junior Grade Operator & Equivalents Workers in the scale of pay Rs.5510-9920
SELECTION
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KMML MS UNIT employs various tools and techniques for the recruitment of new workers. One tool is by employing application form to the recruiter for getting their detailed biodata and then calling the eligible candidate for interview for technical post, company conduct practical and written exams. For the post of staff category the company first conducted written exams and based on performance, the eligible candidates are selected for the interview .The final selection will be made based on the performance in the written exam and the interview .For securing selection the employees has to pass through medical exam. Moreover, the selections are subjected to communal reservation policy of the Government. TRAINING AND DEVELOPMENT This aspect is given top priority by the P&A department .The training and development activities are taken by personnel department for making their employees at par with the new technology and to increase their productivity .The training requirements of the employees are designed under the guidelines of the ISO.As per the ISO norms the annual training schedule is prepared on the basis of the individual training needs identified by the Head of the department in specific formats collected from all department heads on or before march 15 every year. If any departmental head feels that there is an urgent need for training ,the matter is forwarded to the administrative officer who makes arrangements for training program .He accepts the training proposal by taking into account of the factors such as: Workers current position New skill that have to be imparted Qualification required Motivation or Communication required
PERFORMANCE APPRAISAL SYSTEM
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When an employee is transferred in promotion from a post during the course separate performance report must be prepared for period prior to such promotion or transfer .The performance appraisal forms in respect of employees in various sections are being separately sent by Human Resource Development Department to respective head of the department for getting the report completed and forward the same to the Personnel Manager with remarks of assessing the reviewing officers. PROMOTION Promotion is the movement of an employee from a lower position to another position with a better pay and responsibility. Every organization chances of promotion came up occasionally. Employees will consider for promotion only if they have qualification and experience in the respect field. Grade II worker in the MS unit who completes 8 years of continues service will be automatically promoted to Grade I. Promotion post will be notified with the plant and the officer of the unit, giving educational qualifications and experience. The application received will be screened by the Personnel Department .Every employee promoted to a higher post will be on probation in that post for a period of one year. Four factors are considered for promoting an employee: Seniority Test/ Interview Attendance Performance
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TRANSFER There is only interdepartmental transfer in the company. RETIREMENT AND SUPERANNUATION KMML MS UNIT being a Kerala Government undertaking company, the retirement or superannuation is fixed at the age of 58. WAGES Wages is carried out by the government wages and safety revision will be made in every 5 years. SALARY STRUCTURE The Pay structure , Dearness Allowance, other allowance and other fringe benefits to the employees in the category of workmen are regulated through long term settlements arrived at the company and the unions representing majority of the workmen, from time to time .The workers are given specified amount as basic wages per the agreement .The agreement is valid for 4 years. REMUNERATION At present a time wage system is adopted. Workers are paid at hourly, daily and monthly wages. Permanent workmen who have completed 8 years of service are allowed higher grade.
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Organizational Study of KMML MS Unit PAY SCALE OF EMPLOYEES IN THE CATEGORY OF WORKMEN Table No.4 Master Scale:CATEGORY GradeII ,unskilled workers
EXISTING SCALE 5510-140-6770-160-8210-180-9290-210-9920
Grade I ,unskilled workers
6350-140-6770-160-8210-180-9290-210-11600-24012560
Senior Grade, skilled workmen
6770-160-8210-180-9290-210-11600-240-13760-28016280
Junior Level, skilled workmen
8210-180-9290-210-11600-240-13760-280-16560320-17520
Grade C,skilled workmen
8570-180-9290-210-11600-240-13760-280-16560320-17840-360-18200
Grade B, skilled workmen
9500-210-11600-240-13760-280-16560-320-17840360-18920
Grade A, skilled workmen
9920-210-11600-240-13760-280-16560-320-17840360-19280-400-20480
5510-140-6770-180-13760-280-9290-210-11600-240-13760-280-16560-32017840-360-19280-400-20480
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Organizational Study of KMML MS Unit PAY SCALE OF EMPLOYEES IN THE CATEGORY OF OFFICERS Table No.5 CATEGORY Asst.Plant/Process Engineer & equivalents EXISTING SCALE 13260-340-13600-380-15500-450-18200-500-21200-55023950
Plant/Process Engineer & Equivalents
14360-380-15500-450-18200-500-21200-550-24500-60026900
Dy.Manager & Equivalents
16850-450-18200-500-21200-550-24500-600-28100-70033700-800-34500
Manager & Equivalents
23400-550-24500-600-28100-700-33700-800-36900
Asst.General Manager
25700-600-28100-700-33700-800-38500-900-39400
Dy.General Manager
27500-600-28100-700-33700-800-38500-900-41200
Joint General Manager General Manager
28800-700-33700-800-38500-900-41200-1000-43200 32300-700-33700-800-38500-900-41200-1000-44200
Chief General Manager
33700-800-38500-900-41200-1000-45200
Master Scale:-
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Organizational Study of KMML MS Unit 13260-340-13600-380-15500-450-18200-500-21200-550-24500-600-28100-70033700-800-38500-900-41200-1000-45200. TRADE UNIONS Sec 2(h) of trade union act 1926, defines the term trade union as any combination whether temporary or permanent formed primarily for the purpose of regulating the relationship between workmen and employers, between workmen and workmen , or between employers and employers or for imposing restrictive conditions on the conduct of any trade or business and includes any federation of 2 or more trade union. In KMML MS unit there are mainly two trade union have been recognized through referendum. They are: INTUC CITU
COMMITTEES Canteen Managing Committee Welfare Fund Trust Recreation Club
WORKMEN CLASSIFICATION Permanent Employees Employees engaged on contract Basis Temporary or Seasonal Workers Casual Labor Apprentice
HOURS OF WORK SHIFT
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As per the mines act 1952 working hours are fixed 8 hours per day .There are mainly 4 major shift ABC and a General shift Shift A B C General TYPE OF LEAVE Annual Leave Casual Leave Sick Leave Leave without wage Special leave for blood donation 26 day/annum Time 6.00 am to 2.00 pm 2.00 pm to 10.00 pm 10.00 pm to 6.00 am 9.00 am to 5.00 pm
- 14 day/annum - 16 days with full pay
WELFARE ACTIVITIES Bonus:-Employees who are drawing more than Rs. 3500/- per month are eligible for bonus; almost all the employees working here are eligible for bonus irrespective of permanent or casual worker. Provident fund:-Introduced in 1956 and administered by a trust. Here both the employer and the employee have to continue 12% each of the basic pay, where eight and one third percent is transferred to pension fund. Gratuity:- Minimum amount payable as gratuity is Rs.3500 employees having continuous service of the year are eligible for gratuity. Employees State Insurance:-All the employees working in the company come under Employee State Insurance Scheme. LABOUR WELFARE ACTIVITIES
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The allowances provided by the company for its employees are as follows: Conveyance Allowances Shift Allowance House Rent Allowance Education Allowance Stitching Allowance Milk Allowance Washing Allowance
BENEFITS Retirement Benefit Death Relief Fund Medical Facility Transportation Facility Financial Aid to prolonged Treatment Subsidized Canteen Facility
RECORDING OF THE ATTENDANCE The electronic punching system is adopted in KMML MS unit .Every employee had punch the card on entering the work.
HR DEVELOPMENT PROGRAMMES Transaction analysis Page 44
Organizational Study of KMML MS Unit Communication skill Leadership skill Personality skill Technical training programme Computer training Safety training Stress control and mind development
TIME KEEPING AND TIME BOOKING A separate wing is concerned with time keeping and time booking in the company. With the help of the punch card this section keeps an attendance register .Main function of this section are attendance recording of lease wage ,absence, late coming, early going, ,lost hours,overtime,shift allowance, wages due to work holidays etc. SOCIAL WELFARE Drinking water supply for the surrounding village through a 25 km pipeline network. Conducting Medical camp, Hygiene Health programs for the public in association with charitable organization. Offering financial assistance to local schools, clubs for the purchase of books, furniture, sports goods etc. Supporting rural electrification.
PRODUCTION DEPARTMENT
Institute of Management in Kerala, Kollam Page 45
Production department performs the function of converting the inputs into finished products.KMML is engaged in the process of mining of raw sand and separation of individual items. So the production process of KMML starts from the collection of raw sand to the classification into individual item likes Ilmenite, Rutile, Zircon, Silmanite,Zirflor,and Microzir. ORGANIZATIONAL CHART OF PRODUCTION DEPARTMENT Asst. General Manager
Manager (P&M)
Deputy Manager (P)
Asst.Plant Engineer
Charge man
Technician
Junior .Technician
Workers
Chart No.4
PRODUCTION DEPARTMENT Institute of Management in Kerala, Kollam Page 46
The Production Department processes and tracks all of the drawings for any given project once they are released from the design department .We have the ability to know when and where a specific drawing is during the fabrication and manufacturing phases through drawing management as well as a production schedule. .The annual production capacity as follows:Ilmenite Rutile Zircon Sillimanite Zirflor _ _ _ _ _ 1, 50000 tones 55000 tones 12000 tones 7000 tones 5000 tones
PROCESS The production process starts with the collection of beach sands from various places. For collecting this beach sand uses the following two methods:Sea Washing There is heavy mineral deposit over a length of 22.5 Km .They are found over a coastal belt having an average width of 800 meters. The sea waves deposit the mineral sand on the beach line and it is collected by using bulldozers .Then it is send to the mineral separation plant.
Dredging
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KMML uses Mineral Recovery Plant for dredging. For improving the quality and increasing the production a 14 crore MRP was set up with the technical collaboration of an Australian company. The MRP consist of a floating dredging plant which could be moved from one place to another. The plant is placed in an area having a water depth of 9 meters .The sand along with water is sucked into the main unit. Then the mixture is send to a storage tank called Trommel and from their it is sending for separation. The MRP can dredge about 40 to 60 tones per shift. The raw sand having an average of 40% heavy mineral is fed to the floating plant and updates it to 85% mineral content. The tailing of MRP is used for backfill. The concentrate from MRP is fed to the Concentrate Upgrading Plant [CUP] and upgraded to 93 % .The raw sand collected through sea washing is also concentrated in the CUP. The Concentrate from CUP is sent to HUP and from their to mineral separation plant for separating minerals. Mineral separation plant The heavies from the HUP are fed to the mineral separation plant and separated into individual minerals. The process involved in the mineral separation is conductivity separation, magnetic separation, and gravity separation and froth floatation. Conductivity separation It is done using high tension electrostatic separation and two fractions namely conductivity and non conductivity are separated out.
Magnetic separation
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Organizational Study of KMML MS Unit The conductivity fraction containing of Ilmenite and Rutile is then subjected to electromagnetic separation .There are two types of magnetic separators are used. .They are: Low intensity magnetic separator for Ilmenite and High intensity magnetic separator for non magnetic fraction Gravity separation It is mainly used to separate out heavy and light fraction of minerals .There are 3 types of gravity separation. Spiral gravity separation In this the light fractions are thrown out aside and the heavies with high density are collected down. Wet table gravity separation It is a moving table of water that separates out the light and heavy fractions. Flotex separation This is a column type of gravity separator. The input is fed from the top and water with high pressure and force is pumped from the other end thus the low density fractions are separated aside and the heavier are collected down. Floatation method This uses some chemicals for this purpose such as sodium silicate and oleic acid, which is used for the separation of Sillimanite. PRODUCTION PROCESS
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Organizational Study of KMML MS Unit Beach sand Mineral separation unit
Ilmenite 60% TiO2
Rutile 95% TiO2
Leucoxene 70-75% TiO2
Zircon 65% ZrO2
Sillimanate 65%Al2O3
Monazite 57%Reo 8% Tho2
TiO2 pigment unit
Ilmenite Beneficiation Plant

Synthetic Rutile 92% TiO2
Spent Acid
Acid Regeneration Plant
Hcl acid 18%
Iron oxide Brick making plant
Chlorination plant
Titanium tetrachloride Oxidation plant Raw TiO2 pigment Finished pigment plant
Sales Ticl4 Oxygen Nitrogen KEMOX -RC800 KEMOX -RC800PG KEMOX -RC802 KEMOX -RC813 KEMOX -RC822 KEMOX -RC808
Building bricks Air separation plant
Rutile Tio2 pigment grade
Chart No.5
FINANCE DEPARTMENT
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Organizational Study of KMML MS Unit Finance refers to money, cash or hands available for the operation of business. Finance may be defined as the requirement of funds wanted .It is the life blood of business activities The business pulsates with life only through finance. Financial management will include planning, organizing, direction and controlling.
ORGANIZATIONAL CHART OF FINANCE DEPARTMENT Asst. General Manager
Manager (Accounts)
Accounts Officer
Asst. Accounts Officer
Accountant
Typist
Peon
Chart No.6
FINANCE DEPARTMENT
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Organizational Study of KMML MS Unit Finance is the study of funds management. The general areas of finance are business finance, personal finance (private finance), and public finance. Finance includes saving money and often includes lending money. The field of finance deals with the concepts of time, money, risk and how they are interrelated. It also deals with how money is spent and budgeted. . The main function of this department is to collect all the receipts and make all the payments and also to record all the transactions and prepare the final accounts. The major functions of these departments are as follows: Maintain the accounts as per the provisions of the sec 20 G of the company act 1956. Provide depreciation at the rate prescribed in schedule 14 of the companys act 1956, on straight line method. To account excise duty on goods manufactured when it dispatched To ascertain the accrued gratuity, liability of the company on the date of balance sheet. To value finished goods at cost or market price which ever is lower. Stock of raw materials, spares and chemicals are valued at weighted average method. Treat the claims against the company which are not admitted as contingent liability.
AUDITING
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Organizational Study of KMML MS Unit Auditors are appointed by the government for a period of one year. There exist an external audit and internal audit. Internal Audit: - These are part of the organization .There is an internal auditing sector .They is in charge of periodical audit. External Audit: Statutory Audit Account Generals Audit Inspection Audit Sales Tax Audit Income Tax Audit Cost Audit
FUNCTIONS Purchase are recorded and analyzed Salary section and Pay division Sales and Revenue accounting Cash and Bank transactions Major banks of the company Costing Calculation of Depreciation
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COMMERCIAL DEPARTMENT Any product moves in the market depends upon the marketing efforts undertaken by the company. It is said that a good marketer can even sell the worst product available in the market; where as a bad marketer can make a good product which does not move in the market. Keeping this fact in mind, KMML has incorporated a good marketing department, with highly talented professionals.
ORGANIZATIONAL CHART OF COMMERCIAL DEPARTMEN Asst. General Manager
Commercial Officer
Asst. Commercial Officer
Assistant
Junior.Assistant
Peon Chart No.7
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Organizational Study of KMML MS Unit COMMERCIAL DEPARTMENT Commercial Officer is the supreme authority as far as commercial department is concerned. The commercial department is concerned with sales and purchase. The commercial Officer is responsible for the entire activities and decision making FUNCTIONS The main objective of the commercial department is to promote, distribute, sell and service the products of the organization. The activities of commercial department include Sales Management, Sales Analysis, Market Research and Intelligence, Advertising, New Product Development, product Pricing and Customer Service.
MARKETING MIX OF KMML M.S UNIT The Product: The major products that are marketed from the company is Rutile and Ilmenite.The products is mainly used Welding and Electrode industries. Price: Price is the only element in the Marketing Mix that provides revenue for the company.Fixing the price is the number one problem faced by the Marketing Executives.
MAJOR CUSTOMERS IN INDIA
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Accurate Welding Products in Utter Pradesh Amritsar Industries in Gujarat Anand Engineering Industries in Mharashtra R.K ARC Industries Pvt Ltd near Thane in Maharashtra Dado Zircon in Rajasthan Four Field near Pune in Maharashtra Honavar Electrodes in Mumbai Donthi Electrodes Ltd in Mysore MAJOR CUSTOMERS IN KERALA AUTO CAST Ltd in Cherthala Modern Electrodes,Thiruvalla Lakshmi Electrodes Kodakara
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Organizational Study of KMML MS Unit MAINTANENCE DEPARTMENT (ELECTRICAL) The maintenance department of KMML MS unit can be grouped into Electrical, Mechanical section. The Assistant General Manager is the top of the authority. This department is under the control of Plant Engineer (Electrical).It is the function of the department to ensure the flow of electricity through out the company ORGANIZATIONAL CHART OF MAINTANENCE DEPARTMENT (ELECTRICAL)
Manager (P&M)
Plant Engineer (E)
Asst. Plant Manager
Charge man
Junior. Technician
Workers Chart No.8
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MAINTANENCE DEPARTMENT (ELECTRICAL) This department specializing in electrical wiring of buildings, stationary machines and related equipment in an organization. It may be employed in the installation of new electrical components or the maintenance and repair of existing electrical infrastructure .The maintenance department of KMML MS unit can be grouped into Electrical, Mechanical section. The Assistant General Manager is the top of the authority. This department is under the control of Plant Engineer (Electrical).It is the function of the department to ensure the flow of electricity through out the company. OBJECTIVES Carry out maintenance work in plant Types of maintenance Take preventive measures to avoid breakdown of Electronic equipment Electrical maintenance
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MAINTANENCE DEPARTMENT (MECHANICAL) The maintenance department of KMML MS unit can be grouped into Electrical, Mechanical section. The Assistant General Manager is the top of the authority. This department is under the control of Plant Engineer (Mechanical). Function of the department is to ensure the easy working of machines .The Company is doing periodical shutdown to carry out necessary maintenance and servicing of the plant ORGANIZATIONAL CHART OF MAINTANENCE DEPARTMENT (MECHANICAL)
Manager (P&M)
Asst.Plant Engineer
Charge man
Workers
Chart No.9
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MAINTANENCE DEPARTMENT (MECHANICAL) New mechanical maintenance strategies such as TPM and preventive maintenance are placing new demands on mechanics, technicians, and other mechanical systems specialists to upgrade their skills as quickly and efficiently as possible in order to maintain job security and enhance their chances for career advancement. The maintenance department of KMML MS unit can be grouped into Electrical, Mechanical section. The Assistant General Manager is the top of the authority. This department is under the control of Plant Engineer (Mechanical). Function of the department is to ensure the easy working of machines .The Company is doing periodical shutdown to carry out necessary maintenance and servicing of the plant
OBJECTIVES Carry out maintenance work in plant Types of maintenance Take preventive measures to avoid breakdown of machines Vehicle maintenance Central mechanical repair shop maintenance
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QUALITY CONTROL DEPARTMENT Quality control emphasizes testing of products to uncover defects, and reporting management who make the decision to allow or deny the release, whereas quality assurance attempts to improve and stabilize production, and associated processes, to avoid, issues that led to the defects in the first place. ORGANIZATIONAL CHART OFQUALITY CONTROL DEPARTMENT Asst. General Manager
Scientific Officer (QC)
Asst. Scientific Officer (QC)
Chemist
Asst.Chemist
Shift Analyst
Workers
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Organizational Study of KMML MS Unit Chart No.10 QUALITY CONTROL DEPARTMENT Quality control is a process by which entities review the quality of all factors involved in production. Quality control emphasizes testing of products to uncover defects, and reporting to management who make the decision to allow or deny the release, whereas quality assurance attempts to improve and stabilize production, and associated processes, to avoid, or at least minimize, issues that led to the defects in the first place. For contract work, particularly work awarded by government agencies, quality control issues are among the top reasons for not renewing a contract. FUNCTIONS Raw materials collected Intermediate products Final products Quality evaluation of waste Table No.6 MINERALS Ilmenite PRODUCT STANDARDS 58.0% min
Rutile
92.0% min
Zircon Sillimanite
0.25% max 58.0% min
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STORES DEPARTMENT The store department plays an important role in the proper functioning of a company. A store manager is the person ultimately responsible for the day-to-day operations (or Management) of a retail store. ORGANIZATIONAL CHART OF STORES DEPARTMENT Asst.General Manager
Asst.Plant Engineer (stores)
Charge man
Junior Charge man
Workers
Chart No.11
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STORES DEPARTMENT The store department plays an important role in the proper functioning of a company. Store Section deals with: Receiving the material Inspection of material Storage and Presentation Proper classification and codification of material Material handling Issue and dispatch Stock records Store accounting Stock taking
STORAGE FUNCTIONS Various documents are prepared by the stock section for the proper functioning of the department the documents maintained are as follows:1. Stores inwards book:- On receiving any material to the store, it is entered in a document called stores inward book (SIB). 2. Inspection of goods: - On receiving any material and preparation of SIB inspection request is send to the concerned technical office for technical evaluation and reports are prepared on this basis.
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3. Store received note: - After the preparation of SIB and inspection of goods or materials, Stores Received Note (SRN) is prepared. This is the document showing that the, material received is accepted and payment can be made for it. The SRN is sent to the Finance-department for payment. Four copies of SRN are maintained in KMML .Usually the company gets a credit facility for 45 days. 4. Materials issued note:- Any material is issued from the store only after receiving a material requisition or Material Issue Note (MIN) .MIN contains all the details regarding the material as well as the indenter. 5. Stock transfer note: - For transfer of materials between store or contractors, for transfer of material between store and section prepared , it contains details such as material code, cost center, material description ,unit and quality. It should be mentioned that from which section and to which section is the transfer-taking place. 6. Material return note: - Sometimes material issued from the stores may be returned. In case Material Return Note (MRN) is prepared. It contains details such as the name of the department from which the material is returned, value, quality, code, unit, balance and reason for return. BINCARD BINCARD is a document attached to bin and it contains the quantities details of material received, issued and closing balance. In addition to this, it indicates information regarding different stock levels like minimum level, maximum level, recorder level etc coded number and name of materials.
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SWOT ANALYSIS
A critical activity in the strategy formulation process is the evaluation of the fit between the companys resource strengths and weakness and the external opportunities and threats. In achieving this, companys strengths, weakness, opportunities and threats should be understood using what is commonly known as the SWOT analysis. Identifying a companys Resource Strength A companys strength is the availability of a particular resource with the firm to leverage it to performing certain activities better than its competition .It could arise from any of the following factors:a) Physical asset, like ownership of building, plant and machinery, financial resources, strategic location of the plant and distribution of networks. b) Human asses, like good quality intellectual capital and a pool of talented and qualified R&D scientists. Identifying a companys Resources Weakness A companys weakness is the non- availability of a particular resource with the firm, or the inability of the firm to leverage that resource in performing certain activities better than its competition. It could arise from any of the following factors:a) Lack of physical, human, organizational or intangible assets that are critical to the firms survival and success in that particular industry. b) Lack of a strategic direction for the company to understand and fulfill the needs of the specific customer segment.
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Identifying a companys Market Opportunities A companies market opportunities are those industry following factors:a) Emergence of new customer segment in the market /opening up of new markets for the company. b) Changes in the customer habits and preference and their buying behaviors. Identifying the companys Environmental Threats A companys environmental threats are those factors in the company environment that the firm is not equipped to handle .The environmental threats could arise out of the following changes:a) Changes in the technological, regulatory, social or economic environment of the industry that have an impact on the product- market scope of the firm ,increase costs and decrease productivity. b) Entry of new competitors in the market with new business models , better technology and superior services. The SWOT analysis presents an excellent opportunity of a company to evaluate and regulate its resource strengths with the market position. An analysis of the companys opportunities and threats not only indicating the attractiveness of the companys situation ,but also drives the strategic action by capitalizing on the opportunity of the firm can and intend to capture and defending the companys impact of threats imposed by the external environment. opportunities that the
company is equipped to capture .The market opportunity could arise out of the
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SWOT ANALYSIS OF KMML M.S UNIT S-STRENGTHS KMML M .S Unit is the only company where the separation of minerals like Ilmenite, Rutile, Leucoxene, Monazite, and Silliminite Strong relation between the Management and the different levels of employees is the back bone for the success of the company. Raw material is found in nearby areas. Price leadership. Constant up gradation technology Monopolistic nature of business. The Proximity of infrastructure facilities such as seaport, Railway station and International Airport is one of the greatest strength of the company. W- WEAKNESSES The inability of management to control effectively the resistance raised by the local people in some radical issues. Trade union dominated firm. Inability to root out the pollution & related issues. External/ Political / Governmental interference in companys day-to-day affairs. Often works undertaken by the company are put off in the middle way..
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O-OPPORTUNITIES Steady growth of clients/ users industry such as Paints, Welding products, Electrodes etc. Faster growth rate of market in Asian countries where separation facility is limited. Kerala state being made better known to the out side world with the expansion of tourism and infrastructure technology sector. Technical collaboration with ISRO World wide deposit of Ilmenite is depleting day by day due to over exploitation, where as in India only 10% of the total Ilmenite deposit is utilized. T-THREATS Mining policy of central and state government can allow small time entrants to the sector. Unavailability of minerals The cost of production will be higher due to the price of raw materials like Petroleum coke, burning oil.LPG will grow higher in future Trade unions resistance to change will cause a barrier to bring about necessary changes in future.
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PEST ANALYSIS
POLITICAL FACTORS The company is subjected to the budget, accounting of audit controls as applicable to government activities. Being a public sector concern political interference has been creating problem. Industrial policy of government of India and growth restricts in the current policy. Liberalization, Industrialization and Globalization has an immense impact of KMML M.S unit. ECONOMIC FACTORS Exposure to global prices is double edged sword. Ilmenite and Rutile finds use in variety of industrial products. The demands increased which paved a growth rate of its production. Industry largely in public domain with skills and technical know how comparable to highest in international states. SOCIAL FACTORS Continuous emphasis is given to the safety of plants & personnel through continuous up gradation of safety equipment and fire fighting facility and rigorous training. Nurturing a performance oriented work culture with a comparative mindset. Increased customer focus & loyalty. In the emerging competitive business environment, KMML M.S unit is further shaping its customer focus and providing customaries products.
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TECHNICAL FACTORS Depend on engineering construction, operation and maintenance and vast knowledge requirements for marketing of the KMML M.S products. New innovation techniques are adopted. Modernization, Capacity enhancement and pollution abatement schemes are to be carried out on an emergency basis.
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PORTERS FIVE FORCE MODEL

The model of the five competitive forces was developed by Michaels. Porter in his book Competitive Strategy: Techniques for Analysis Industries and Competitors in 1980. Since that time it has become an important tool for analyzing an organizations industry structure in strategic process. Porters model is based on the insight that a corporate strategy should meet the opportunities and threats in the organizations external environment. Porter has identified five competitive forces that shape every industry and every market. These forces determined the intensity of competition and hence the probability and attractiveness of an industry .Based on the information driver from the Five Forces Analysis, management can decide how to influence or to exploit particular characteristics of their industry. The Five Competitive Forces: 1. Bargaining power of Suppliers. The term suppliers comprises all sources for inputs that are needed in order to provide goods or services. 2. Bargaining power of customers. The bargaining power of customers determines how much customers can impose pressure on margins and volumes. 3. Threat of new entrants.
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Organizational Study of KMML MS Unit The competition in an industry will be the higher; the easier it is for other companies to enter this industry. In such a situation, new entrants could change major determinants of the market environment at any time.
4. Threat of Substitutes A threat from substitute exists if there are alternative products with lower prices or better performance parameters for the same purposes. They could potentially attract a significant promotion of market volume and hence reduce the potential sales volume for existing firms.
5. Competitive Rivalry between existing players. This force describes the intensity of competition between existing companies in an industry. Higher competitive pressure results in pressure on prices, margins and hence on probability for every single company.
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PORTERS FIVE FORCE MODEL
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PORTERS FIVE FORCE MODEL FOR KMML M.S UNIT
THREAT OF NEW ENTRY * Is not a high barrier as it enjoy monopoly over the separation of Ilmenite and Rutile
BARGAINING POWER OF SUPPLIERS *Is not very high as the main raw material is produced by the industry itself.
COMPETITIVE RIVALRY * Enjoy monopoly in India .Face stiff competition from abroad
BARGAINING POWER OF BUYERS * Is low because of increasing demand of Ilmenite & Rutile in the welding and
THREAT OF SUBSTITUTES * No close substitute for minerals like Ilmenite and Rutile
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1. Bargaining power of suppliers This usually happens when the market is dominated by a few large suppliers rather than fragmented sources of supply, and when there are no substitutes for the particular input. In KMML, the main raw materials for the production are obtained from here itself (from the black sand of Chavara beach). So the dependants over the suppliers are much lesser. Then about the other raw materials, there is large number of suppliers for such inputs. So the company has a better choice option. Therefore, the switching cost from one supplier to other will be less. 2. Bargaining power of customers Bargaining power of customers determines how much customers can impose pressure on margins and volumes. In KMML paint industry contribute large customers of Titanium Dioxide, other largest customers include such industrial as paper, plastic. The main customer companies are Asian paints, Nerolac paints, Shalimar paints etc. As the paint industry buys titanium pigment in very large quantities of production, the company allows some bit price offers for them.
3. Threat of new entrants The competition in industry will be higher, the easier it is for other companies to enter this industry. KMML has a monopolistic nature in titanium dioxide pigment industry in India. The company has some competitors in the world market. The threat of new entrance cannot be avoided. A titanium dioxide pigment is about to start very nearly in Thuthukudi( in India itself). So that it can be a threat for the company.
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4. Threats of Substitutes A threat of substitutes exists if there are alternative products with lowest prices or better parameters for the same purpose. As far as the product of KMML is not so common in nature, the threat of substitutes is not much high. Even if it happens the close customers relationship and the quality and finishing of the product can solve the problem to some extent. 5. Competitive rivalry between existing players Although, the product is unique and the company has a monopolistic nature in Titanium dioxide pigment industry in India, it has many competitors in the world market. The main competitors are DuPont (USA), Ishihara (Japan), Millenium (Germany), Hoiter (USA), Tijin (Netherlands), etc. in India the other plants which produces titanium pigment is there in Trivandrum. But it is mainly used for some other purpose and KMML is the only Rutile grade Titanium pigment plant in Kerala.
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FINDINGS
Experienced highly efficient and competitive manpower. Every employee is considering the company as their own. Monopolistic nature of the company helps to pave the way of success. A cordial relationship between workers and management helps to attain their goals. The minerals that are separated from the company is highly demanded in the electrodes and welding industries. The upcoming of new mining companies of Titanium product will make stiff competition on KMML. The long term solvency position of the company is satisfactory. The inability of the management to control effectively the resistance raised by the local people in some radical issues. The company is highly eco-friendly and posses Corporate Social Responsibility. The welfare activities implemented by the company are very effective The company is effectively using the technological advancement in its operations. Computerization of all department is effective The company has a strong commitment towards the society. The working condition in the organization is remarkably good. The employees were satisfied with the welfare policies which are practice and the scale of pay at present.
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SUGGESTIONS The company should give more emphasis to environmental matters. The facing tough competition from foreign companies so that the quality of the product has to be improved to sustain in the market. The company has to find out more funds from the outside and foreign investment. The company takes necessary steps to solve the trades union issues and make good relation between the employees, employers and management.
If the company can make more cordial relation between the employee, employer and management, then it has far reaching effect on the long run and the company can continue its legacy.
The company can adopt different mode of sales other than the direct sales which is mainly done in KMML M.S unit
Along with the other traditional ways, the company should think about the scope of electronic for its transactions, which is not yet fully functional in KMML M.S unit.
The company should recruit more professional employees as many of highly skilled officials are retiring in the near future.
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Organizational Study of KMML MS Unit The government policies can change any time and so the possibility of entry of private players. So the company should always be careful to maintain its product quality, brand identity and customer relations management.
CONCLUSION If the company visit and study conducted for the preparation of this organization functional report immensely helped to understand the practical significance of the theories taught in the classroom under different courses. It has provided an opportunity to make an insight in to the working of this understanding. The net profit of the company reducer great extent to the last year due to the increase in operating cost and decrease in sales due to tight competition from other nation. The raw economic policies of the government adversely affected the industry. The company should take straight marketing techniques to boost sales. To avoid threats from pollution control board public the company spent heavy amount on non-profitable asset. This also affects the probability of the company. This study on the whole, has revealed that the Kerala Minerals and Metals Limited Mineral Separation unit ,Kollam is growing progressively and that has a bright future.
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BIBLIOGRAPHY
Aswathappa.K (2006) Human Resource Management and Personnel Kamala Go Lakota, R. Srinivasan, Vipin Gupta, Business Policy and Kothari C.R (2006) Research Methodology, new age international (p) Ltd. Sekaran Uma (2003) Research Methods for Business, Fourth Edition, New
Management, New Delhi, Tara Mc Graw Hill. Strategic Management: Concepts and Applications, 2nd Ed, New Delhi.
Delhi: Wiley India (p).Ltd. Reference A Manual of Personnel Policies (2009) Spreading Splendor, Monthly Magazine of KMML (June 2011) Website www.kmml.com,www.wikipedia.org.
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