A PROJECT REPORT ON DOMESTIC SUPPLY CHAIN MANAGEMENT & MARKETING CHANNEL FROM TCIL WORKS TO CUSTOMER (DESPATCH SECTION) AT

Submitted in partial fulfillment of the requirement of MMM programme:

By:

RANBIR KUMAR SINHA

Indira Institute of Management, Pune SESSION:

2011-2012

Acknowledgement
A fruitful work is incomplete without paying a word of thanks to all the people who are directly or indirectly involved in its completion. The successful completion of this project work incorporates the combination of numerous people. At the outset , I take the opportunity to convey my sincere gratitude to Tinplate Company of India LTD. for giving me an opportunity of learning & contribution through this project. I would first of all like to express my gratitude to my project guide Mr. Prashant Maurya ( Dy. Mgr. COMD) for assigning me such a worthwhile topic in Tinplate Company of India LTD. In spite of his busy schedule he always found time to guide me through the project. I am also grateful to him for reposing confidence in my abilities for working me on this project.

I would also like to thank, Mr. D.K.Singh (D.M, Sc), Mr. Somen Mitra (Asst. Mgr, COMD), Mr. N.K.Singh (Asst. Mgr, COMD),Mr. Rajesh (Dy. Officer, COMD), Mr. Ashish Chakraborty ( Dy. Officer, COMD) , Mr. Niraj Thakur (Asst. Mgr Commercial Service), Mr. Ajay, Mr. Mr. Sanjay Sinha, , Mr. R.Singh (Asst. officer COMD) and other members of the department for providing valuable guidelines and insightful suggestion . Without their guidance and support, my project work would not have been a success.

I express a deep sense of guide to Prof Ajay Warade, who had given his valuable time to help me during my project tenure & improve my knowledge & awareness towards the topic.

I would like to thank all those employees of Tinplate Company & the respondent who gave me their valuable & relevant information required for the project. Last but not the least, I give my sincere gratitude & thanks to my parents whose blessings and support have helped me to complete this project.

(Ranbir Kumar Sinha) MMM, Roll No. - 37

Declaration
I hereby declare that the project entitled DOMESTIC SUPPLY CHAIN MANAGEMENT & MARKETING CHANNEL FROM TCIL WORKS TO CUSTOMER is submitted in partial fulfillment of my MBA 2005-2007 was carried out with sincere intention of benefiting the organization. The project duration was from 27 MAY 2011 to 27 JULY 2011

To the best of my knowledge it is an original piece of work done by us and it has neither been submitted to any other organization nor published at anywhere before.

Name: Date: 24.July.2011 Place: TCIL (Jamshedpur)

Signature

EXECUTIVE SUMMARY
Every manufacturing company follow the supply chain management. An organizations cost can be reduced and the profit can be increased if it is able to properly maintain its supply chain management. This project is a sincere effort to study and analyze the supply chain management of TCIL. It involves analysis of the various information system and the various process till their activity levels. The internship is a bridge between the institute and the organization. This made me understand how theoretical knowledge can be applied to practical field. The experience that I have gathered the data of past two month that have certainly provided the orientation, which will help me in shouldering any responsibility in future.

INDEX

SR. NO. 1 2 3 4 5 6 7

TITLE Introduction to study Company Profile Objectives of the study Review of Literature Research Methodology Competitors details COMD Planning for domestic sales and dispatch

PAGE NO.

8 9 10

Data Analysis & Interpretations Observation & Findings Conclusion & Suggestions

 Bibliography  Questionnaire

2011
Chapter 1
THE TINPLATE COMPANY OF INDIA LIMITED CHAPTER - 1

INTRODUCTION TO STUDY

 REASONS & OBJECTIVES OF TOPIC SELECTION  SCOPE OF STUDY  PROBLEMS & LIMITATIONS OF STUDY

Chapter 1 INTRODUCTION OF STUDY

The Tinplate Company of India Limited is the largest manufacturer of Tinplates in India and the largest seller of Tinplates with having 40% of Market Share. Its demand is for processed food, both for indigenous consumption and exports. Tinplate is the ideal packaging material for processed food. It offers prime grade Tinplate in various categories. The Products are:

Product
    Oil Can (OC) Non Oil Can (NOC) Open Top Sanitary Can (OTSC) Tin Free Steel (TFS) Double Reduced (DR)

Market
Vanaspati Dairy Food, Processed Food Processed Food Crown Cork

  

Baby Food

Cold Rolled Coils Printed and lacquered sheets

In course studies I have read about supply chain management so when I joined Tinplate company of India Limited for summer training at that time I decided to study the various plan, type & about the company and measure the performance of some of them comparative 8

manner so that I can get an idea hoe the supply chain have become major contributor in manufacturing sector. Topic: Domestic supply chain management

Reason & objective of topic selection:

 To know how the overall process of supply chain management is done in manufacturing sector.  To study how the planning is done from orders taking till the dispatch.

Scope of study:
As the major focus in this project was to get an insight of the supply chain management, it involved through study of various material of supply chain and the process is using in the companies. It involved study of planning, order taking, order processing, dispatching and the comparison of the past year sales data in order to deduce certain conclusion and suggesting improvements wherever needed. This report also studies raw material, work-in-process inventory, and finished goods.

Limitations of study:  
The time constraint was the major problem while conducting the research or in data collection process. Use of secondary data creates confusion for data redundancy.

PROBLEM OF STUDY: 
The data of order taking and the planning which is done accordingly is confusing to understand.

2011
THE TINPLATE COMPANY OF INDIA LIMITED CHAPTER - 2

CHAPTER -2
COMPANY PROFILE

10

Company profile
TCIL is today the largest indigenous producer of tin coated and tin free steel sheets in India, enjoying 35-40% market share and undoubtedly the industry leader for 85 years. The company exports about 20-25% of its production directly to end-users (can-makers) and its products are well accepted in the markets of SE Asia, Middle East and some developed countries in Europe. Headquartered in Kolkata, the Companys Works is located at Jamshedpur, Jharkhand. There are presently 12 offices in India and a distribution network with 17 stocking points. TCIL Works, situated at Golmuri, Jamshedpur has presently two dual processing line for ETP/TFS and Cold Rolling Mill (CRM).The company has commenced CRM-2 set-up as a backward integration in feeding the second tinning line with TMBP coils. The Company is in the business of manufacturing and supplying reliable, cost-effective, value-added tin mill products. It manufactures various grades of electrolytic tinplates, tin-free steel sheets and Full Hard Cold Rolled Sheets (FHCR) used for metal packaging. In pursuit of its downstream agenda, the company has been bonding with food processors and fillers by way of world class printing and lacquering facilities at the "Solution Centre".

Company History
The company was incorporated in 1920 and the site chosen was Golmuri, Jamshedpur. The first steel plate of Tinplate gauge was rolled on 18th Dec 1922 at the Hot Dip Plant (HDP) producing Hot Dip Tinplate, from tin bars supplied by Tata Steel and this continued till 1979 albeit with capacity enhancements. For 50 years, TCIL thus almost single-handedly built up the Indian Tinplate Industry. To keep pace with technological developments, TCIL was the first to Set up a combination line capable of producing both Electrolytic Tinplate (ETP) and Tin Free Steel (TFS). This plant, the first of its kind in India, was commissioned in 1978 and commenced production in January 1979. In 1982, Tata Steel bought the shareholding of Burmah Oil, the then major shareholder and took over the management of the Company. In 1991-92, TCIL undertook backward integration to setup a Cold Rolling Mill (CRM) for production of TMBP Coils based on Hot Rolled Coil supplies from Tata Steel which was also setting up its Hot Strip Mill (HSM) at the same time. The CRM was thus a strategic fit for TCIL with Tata Steel. The Cold Rolling Mill (CRM) was commissioned in 11

1996-97 but with heavy time and cost over runs , the company started incurring severe losses. A turnaround strategy was developed with the objective of ensuring Revival and Setting Fundamentals Right, and implemented during the financial years of 1997-2001. The basic elements of this strategy were:
y y y

Operational Improvements Financial Restructuring Hot Dip Plant (HDP) phase out and downsizing

Since April 1998, TCIL operates under a conversion arrangement with Tata Steel for its business. Today, TCIL is the only indigenous manufacturer of value-added Tinplate and TFS for processed food, battery, dairy product, beverage and soft drink crown caps in both single reduced and double reduced forms. The establishment of the Solution Centre in December 2005 should provide further impetus to its business purpose of being a cost- effective metal packaging solution provider with focus on innovation and consumer convenience. The solution centre will facilitate the process of building solutions for end-use customers i.e. fillers / food processors, complement the efforts of can fabricators across the country and develop R&D capabilities . TCIL with its continuing for quality, productivity, cost - effectiveness and customer service, looks forward to the future with confidence.

Vision
Be an Industrial leader in value creation, servicing packaging needs and creating greener future.

Mission
Service customer requirements of green packaging by offering reliable, cost-effective & value added tin mill products.
OBJECTIVE

 Reach status of world -class suppliers of tin mill products.  Attain leadership position in providing cost effectiveness packaging solutions for products edibles.  Create and sustain robust customer relationship system.  Establish and institutionalize continuous improvement and learning process to benefit all stakeholders.

12

Company Products and Services

Product Range - Electrolytic Tinplate (ETP) Line Single Reduced Tinplates Open Top Sanitary Cans (Otsc) Tin Free Steel Double Reduced Tinplate Sheets

Cold Rolling Mill (CRM) Products

Hr Pickled Coils
Full Hard Coils

Temper Rolled/ Double Reduced (Dr) Coil

Premium Packaging for Quality Food

Proven solutions in packaging paints

Printed and lacquered tinplate

13

Organization Structure - Management & Board

Board Committees 1. Audit Committees Remuneration Committees 2. Shareholders 3. Grievances Committees

Board of Directors (3 Directors from Promoters, 3 Independent Directors, 1 Nominee Director, 1 Non-Executive Director, 1 Executive Director [MD]

Chief (Works)S.venkatraman

National Head (Marketing & Sales)Ashwini Sharma

Chief (Tinplate Project) Hemant Gupta

Chief Finance Officer (C.Joseph)

Dir. Medical Service (Dr. C.D. Singh)

Div. Mgr(E&E)ETP/CRM Sanjay Malhotra, Sr. Mgr(E&E)R.K.Topno, Sr. Mgr(Cranes)H.C Tiwary

Head (Intl. Trade) Abesh Chattopadhyaya

Chief (Project)S.K Rao, Chirf(Spl ProCRM)K.K Mahajan

Company Sec. S.Kar

Chief (Medical) Dr. P.D Gokhale

Div. Mgr. (Logistics) S.G Rebello

Chief Div Mgr(Quality Assurance) Ranjit Sinha

Chief Div Mgr(Project) P.K Bandopadhyaya

Chief Div Mgr(Finance & A/C) M.K jha

Chief Paediatrician & Superintendent Dr. Sanjoy Sarkar

Div. Mgr.(Elec. Services) s.c sinha

Chief Div Mgr(Comml Services) Harjit Singh

Div Mgr (CRM-2 Contracts) D.A Sinha

Chief Div Mgr. (Finance) Mubarak Hussain

Sr. Mgr. (Coating Lines) Prabhat Sinha

Sr. Mgr.(Stores standardization, Sources Development) Sambhu Shekhar

Div Mgr. Project (Mech) Somenath Bose, Div. Mgr (Proj) D.S Chauhan

Chief Internal Auditor B.P singh

Sr. Mgr (MM)CRM Chanchal Kumar, Sr. Mgr(MM)ETP K.K.Cakraborty

Div. Mgr.(Supply Chain) D.K Singh

Sr. Mgr. (Instrumentation) S.K Rai

Div. Mgr.(Insp) A.K Prasad, Sr. Mgr.(Cust. Supp) Joginder Lal, Sr. Mgr.(QA)ETL B.P Sinha, Dy. Mgr. (R&D) & CRM (Q.A) Joydeep Chatterjee

Mgr. (Oprn)CRM Sivesh Kr. Singh, Dy. Mgr(o)CRM Rajesh Roshasn

Organizational Ch Structure (1 st Apr

14

Process HR Coil indenting Pickling

Key Requirements

Out put measures

Control Limits

Coil chemistry thickness and width Complete removal of iron scales from H.R Coils and edge trimming cost: Fuel rate Acid Consumption Rate -Gauge tolerance as per TDC and proper shape -Emulsion consumption -Power rate -Roll consumption rate

Coils of required specification Scale free, bright silvery finish and good trimming Kg Coal / MT Kg/MT Output gauge as per TDC, defectfree surface -Ltr / MT -KWH / MT -Kg/MT

No deviation on size, thickness and chemistry 0% under pickling <5% of the length over pickled. 40 Kg/MT 15 Kg/MT Tolerance on set gauge as per TDC -0.70 Ltr / MT -135 KWH / MT -1.35 Kg / MT

In process Measures

Coil chemistry, thickness and width % acid concentration % iron concentration Acid bath temperature Emulsion: -Oilconcentration (%) & Temp. -Iron concentration (%) -Roll roughness & dia. Alkali concentration and temperature dryer temperature. Current density Base stacking rules. Base temperature gas temperature, cycle time.

Annealing

Removal of emulsion-oil & mill dirt from steel Degreasing surface Cost: Alkali consumption Fuel rate Achieving desired hardness of steel as per customers TDC through various Annealing cycles Cost: Fuel Rate Power Rate To obtain desired temper, shape & strip roughness as per TDC Cost: Roll consumption Work Roll Back-up Roll To trim coil as per the TDC Material Yield

6-Hi Mill

Oil and dirt free surface Kg / MT Kg-Coal / MT a) Hardness as per TDC b) Free from Annealed defects Kg Coal / MT KWH / MT a) Temper b) Shape Kg / MT Kg / MT

Oil < 20 mg /sq. mtr. At the strip surface 2.4 Kg / MT 42 Kg / MT

Temper Range

T52 T55 T57 T61 14.25 42KWH / MT

50-54 53-56 55-59 58-62

Temper Mill

T52 to T61 Cross bow 15 Max, Long bow 50mm Max, Diff. Long bow 10mm Max 0.0845 0.0387 Width setting: +1 / 0 of the nominal width or as specified in TDC Edge waviness<1mm

a) Emulsio n Concentration & temp. for DR rolling b) Roll roughness, roll dia, roll crown.
Diameter of cutters, horizontal and vertical overlap of cutters.

CPL

Measurement of trimmed width. Edge waviness & edge burr % yield

ETP/TFS PLANT

Electrolytic tinning / TFS of Tin Mill Black Plate coils as per TDC

Tin Coating gm/m 2 Hardness (Temper Grade) Shape / Dimensional Tolerances Oil Coating Passivation Film Chromium Coating

Coating as specified in TDC, Cut length-0/2mm shape tolerance or as per TDC, Bowness15mm Max Edge waviness 3mm Max Out of squareness 0.15% max.

a) Concen tration Stannous free acid ENSA b) Temp. of bath c) Current density
TFS Plating: Concentration, Chromic acid, Sulphate Temp. Current Density

15

Branches & Locations

REGIONAL/SALES OFFICES
KOLKATA 4, Bankshall street, Kolkata-700001 BANGALORE Unitf-8, Naveen Apartments, 10 palace road, 13. main,vasantnagar, Bangalore-560052 DELHI Flat no. 3, scindia house, 3rd floor, janpath, New delhi-110001 CHENNAI 823, jeevanandan Road, k.k.nagar Chennai- 600078 MUMBAI A-4 Daffodil, 1st floor, Hiranandani gardens A.S.Road, Powai, Mumbai -400076 1) North zone: Rajpura, Chandigarh, Delhi, Jaipur, Hissar, Ghaziabad 2) South zone: quilion, Hyderabad 3) East zone: Bhubaneswar, Kolkata 4) West zone: Bhopal, Silvasa, Mumbai, Baroda. Apart from these stockyards TCIL sells its own material to direct customer also.

Turnover

The TINPLATE co. of India Limited having 40% of share with turnover around 850 900 carore per annum.

16

Manpower Details
Employees are categorized as Executives (E-level), Supervisors (O-level), Workers (U-level) and Trainees. An equal opportunity employer, TCIL periodically inducts fresh talent at all levels. TCIL engages contract Labour for some non-core areas like packaging, canteen services, cleaning etc.
Male Female Total As on 31st Mar 11 Avg. Jsr. Age Works Jsr. Non Works Outside Professional Graduate No Jsr. n Gra dua te/I TI 60 258 83 5 15 17 00 92 22 02 00 282 213 220 102 618 56 670 153 884

Executives (E) Supervisors (O) Workers/Staff (U) Trainees Total

320 264 838 247 1669

26 27 56 08 117

346 291 894 255 1786

42 47 47 38 44

176 188 673 217 1254

110 88 204 38 440

17

2011
Chapter 3
THE TINPLATE COMPANY OF INDIA LIMITED CHAPTER - 3

OBJECTIVES OF THE STUDY

18

OBJECTIVES OF THE STUDY

   To study about the dispatch taking the data of past years. To study and analyze the problems faced while delivering the product to final customer. To study and analyze about the transporters and problems faced by them.

19

2011
THE TINPLATE COMPANY OF INDIA LIMITED CHAPTER - 4

CHAPTER-4

REVIEW OF LITERATURE
y WEBSITES y BOOKS

20

1. Title: Supply Chain Management Author: William C. Copacino I studied about the problems addressed by the supply chain management and the business process integration. Supply chain management must address the following problems:
y

y y

Distribution Network Configuration: number, location and network missions of suppliers, production facilities, distribution centers, warehouses, cross-docks and customers. Distribution Strategy: questions of operating control (centralized, decentralized or shared); delivery scheme, e.g., direct shipment, pool point shipping, cross docking, DSD (direct store delivery), closed loop shipping; mode of transportation, e.g., motor carrier , including truckload, LTL, parcel; railroad; intermodal transport, including TOFC (trailer on flatcar) and COFC (container on flatcar); ocean freight; airfreight; replenishment strategy (e.g., pull, push or hybrid); and transportation control (e.g., owner-operated, private carrier, common carrier, contract carrier, or 3PL). Trade-Offs in Logistical Activities: The above activities must be well coordinated in order to achieve the lowest total logistics cost. Trade-offs may increase the total cost if only one of the activities is optimized. For example, full truckload (FTL) rates are more economical on a cost per pallet basis than less than truckload (LTL) shipments. If, however, a full truckload of a product is ordered to reduce transportation costs, there will be an increase in inventory holding costs which may increase total logistics costs. It is therefore imperative to take a systems approach when planning logistical activities. This trade-offs are key to developing the most efficient and effective Logistics and SCM strategy. Information: Integration of processes through the supply chain to share valuable information, including demand signals, forecasts, inventory, transportation, potential collaboration, etc. Inventory Management: Quantity and location of inventory, including raw materials, work-in-progress (WIP) and finished goods. Cash-Flow: Arranging the payment terms and methodologies for exchanging funds across entities within the supply chain.

Supply chain execution means managing and coordinating the movement of materials, information and funds across the supply chain. The flow is bi-directional. Successful SCM requires a change from managing individual functions to integrating activities into key supply chain processes. An example scenario: the purchasing department places orders as requirements become known. The marketing department, responding to customer demand, communicates with several distributors and retailers as it attempts to determine ways to satisfy this demand. Information shared between supply chain partners can only be fully leveraged through process integration. Supply chain business process integration involves collaborative work between buyers and suppliers, joint product development, common systems and shared information. Operating an integrated supply chain requires a continuous information flow. However, in many companies, management has reached the conclusion that optimizing the product flows cannot

21

be accomplished without implementing a process approach to the business. The key supply chain processes are:
y y y y y y y y

Customer relationship management Customer service management Demand management style Order fulfillment Manufacturing flow management Supplier relationship management Product development and commercialization Returns management

Much has been written about demand management. Best-in-Class companies have similar characteristics, which include the following: a) Internal and external collaboration b) Lead time reduction initiatives c) Tighter feedback from customer and market demand d) Customer level forecasting One could suggest other key critical supply business processes which combine these processes stated by Lambert such as: a. b. c. d. e. f. g. h. Customer service management Procurement Product development and commercialization Manufacturing flow management/support Physical distribution Outsourcing/partnerships Performance measurement Warehousing management

2. Title: Research Methodology

Author: C.K Kothari Publisher: New Age International Year of Publication: 2004 The concepts have been found from Research Methodology by C.K Kothari. Research is define as The process which includes defining an redefining problems formulating hypothesis or suggested solutions, Collecting, Organizing, and Evaluating data, making deduction reaching conclusions and at last carefully testing the conclusion determine whether they fit the formulating hypothesis Research Design: A research design is arranging of conditions for collection and analysis of data in a manner that aims to combine relevance to the research purpose with economy in procedure. Objective of research: To gain familiarity with phenomenon or to achieve new insights in to it. To determine the frequency with which something occupiers or with which associated with something else. To test hypothesis of a casual relationship between variable. Significance of research: All progress is born of inquiry. Research has special significance in solving various operational and planning problems of business and industry are responsible for business.

22

Websites:
y

www.soople.com as on 5th July 2011

Supply chain management (SCM) is the management of a network of interconnected businesses involved in the ultimate provision of product and service packages required by end customers. Supply chain management spans all movement and storage of raw materials, work-in-process inventory, and finished goods from point of origin to point of consumption (supply chain).

Functions of supply chain management:

Supply chain management is a cross-function approach including managing the movement of raw materials into an organization, certain aspects of the internal processing of materials into finished goods, and the movement of finished goods out of the organization and toward the end-consumer. As organizations strive to focus on core competencies and becoming more flexible, they reduce their ownership of raw materials sources and distribution channels. These functions are increasingly being outsourced to other entities that can perform the activities better or more cost effectively. The effect is to increase the number of organizations involved in satisfying customer demand, while reducing management control of daily logistics operations. Less control and more supply chain partners led to the creation of supply chain management concepts. The purpose of supply chain management is to improve trust and collaboration among supply chain partners, thus improving inventory visibility and the velocity of inventory movement. Several models have been proposed for understanding the activities required to manage material movements across organizational and functional boundaries. SCOR is a supply chain management model promoted by the Supply Chain Council. Another model is the SCM Model proposed by the Global Supply Chain Forum (GSCF). Supply chain activities can be grouped into strategic, tactical, and operational levels. The CSCMP has adopted The American Productivity & Quality Center (APQC) Process Classification Framework a highlevel, industry-neutral enterprise process model that allows organizations to see their business processes from a cross-industry viewpoint.

Theories of supply chain management

Currently there is a gap in the literature available on supply chain management studies: there is no theoretical support for explaining the existence and the boundaries of supply chain management. A few authors such as Halldorsson, et al. (2003), Ketchen and Hult (2006) and Lavassani, et al. (2009) have tried to provide theoretical foundations for different areas related to supply chain by employing organizational theories. These theories include:
y y y y y y y

Resource-Based View (RBV) Transaction Cost Analysis (TCA) Knowledge-Based View (KBV) Strategic Choice Theory (SCT) Agency Theory (AT) Institutional theory (InT) Systems Theory (ST) 23

y y y y y y y y y y y

Network Perspective (NP) Materials Logistics Management (MLM) Just-in-Time (JIT) Material Requirements Planning (MRP) Theory of Constraints (TOC) Total Quality Management (TQM) Agile Manufacturing Time Based Competition (TBC) Quick Response Manufacturing (QRM) Customer Relationship Management (CRM) Requirements Chain Management (RCM)

www.tatatinplate.com as on 24th June 2011

I have collected information about vision, mission, history, profile of the company from the website of Tinplate.

24

2011
Chapter - 5
THE TINPLATE COMPANY OF INDIA LIMITED CHAPTER - 5

Methodology of study

y y y y y

Research Objective Research Approach Data source Research Process Sampling technique and sampling size

25

CHAPTER 5 METHODOLOGY OF STUDY Meaning of Research:

Research is essentially a systematic enquiry seeking facts through objective variable method in order to discover the relationship among them and to deduce from them broad principles and laws. It is really a method of critical thinking it comprises defining and redefining problems, formulating hypothesis or suggested solutions, collecting, organizing an evaluating data, making deduction and making conclusions and at last, carefully testing the conclusion to determine whether they fit the formulated hypothesis. Thus, the term research experimentation or examination has as its aims the revision of accepted conclusions, in the light of newly discovered facts.

Definition:
The Process which includes defining and redefining Problems, formulating hypothesis or suggested solution: collecting, organizing data: making deduction and reaching conclusions and at last carefully testing the conclusions to determine whether they fit the formulating hypothesis -Clifford Woody

Meaning of Survey:
Survey is process of finding facts and figure related to the problem to provide best solution to the identified problem in this process researcher use the questionnaire as a instrument of data collection and while collecting the data he personally observe, find and feel something which he wish to include in his data analysis.

Difference between Research and Survey:

Research is the process of finding solution on the basis of problem on the basis of certain hypothesis in which the researcher use various instrument to draw a conclusion and given solution. Survey is the personal efforts taken by researcher to collect the relevant information. But the difference in research and survey is research will be done on the basis of collection which is fully depend on the basis of researchers own views.

Research Objective
  To study about the dispatch taking the data of past years. To study and analyze the problems faced while delivering the product to final customer.

26

To study and analyze about the transporters and problems faced by them.

Research Approach
Main thrust has been given to quantitative analysis of historical data. Data so analyzed has been expressed and summarized both numerically and graphically. It helped in arriving at conclusion of the project and formulating some suggestion for the same.

Methods of data collection In this project all the collected data is collected from
primary and secondary sources and used for data analysis Primary data: Primary data mean data which is collected by the researcher by using various techniques and implementing strategies with the help of instrument like questionnaire. Sources of primary Data: y Interview y Survey y Expert opinion y Tele-calling y Employee y Questionnaire I have collected primary data on the basis of questionnaire, survey and by way of Telecalling. The questionnaire is to be designed so as to systematically guide the respondent through the desire path. Format of questionnaire use in research was structured non disguised questionnaire to collect the primary data. Secondary data: The data which is collected by the other researcher or data which is available for final use to draw conclusion called secondary data. The secondary data has very much importance while identifying the problem. Sources of Secondary data: y Internet websites: soople.com,google.com, tatatinplate.com y Books y Company data base y Magazines Secondary data is collected from various websites, company database and books. The secondary data has very much importance while identifying the problem. It gives final result to the end use

27

Research process:
DOMESTIC SUPPLY CHAIN MANAGEMENT: This section involves the customer order processing, supply chain of domestic, Dispatch and the overall time taken to deliver till final customer or stockyard.

Sampling technique and sample size

In order to select the mutual fund companies and insurance companies, non-random judgment sampling and convenience sampling methods have been used. For the performance of sale (past 2 months values) company official website and other sources is used. Sample size Considering the constraints the sample size of 5 transporters and past year records have taken.

28

2011
Collection of Data Sources of data Secondary Primary

Prospectus

Internet

Books

Data Base

Questionnaire

Interview

Discussion

Employees

Survey

Observation

Expert Opinion

Tele Calling

Data Analysis & Interpretations

Observation and Findings

Conclusions and Suggestions

29

Chapter - 6
THE TINPLATE COMPANY OF INDIA LIMITED CHAPTER - 6

Competitors Details of Tinplate Company of India Limited

Competitive Environment

Global scenario : Though worldwide tinplate installed capacity is over 20 million MT,
currently annual production is about 14 million MT (Europe / N America: 7; E Europe / S America: 2.1; Africa / SE Asia: 2.5; China / Japan: 2.3). Rapid light weighting (estimated at about 35% in last 20 years ) and substitutes pressure has led to apparent stagnation in tinplate production in the developed countries. This impact on structure / profitability has resulted in consolidation / capacity rationalization in dev eloped economies (eg. Arcelor France and Corus Britain) as a result of which tinplate continues to enjoy strong contribution margins with increasingly consolidated suppliers.

However in developing economies, particularly in SE Asia & China, the annual consumption growth rate is about 8%. 33% of world production is traded internationally, almost half of which is traded in Indias freight advantage zone (i.e. approx 1.5 million MT). TCIL (backed by Tata Steel) is the only virtually integrated s teel plant between Turkey & Taiwan hence, technical and logistics advantage.

Domestic competition : TCIL (capacity 90000 MT) & SAILs Rourkela plant (capacity
150,000 MT) are the only indigenous producers. While TCIL has achieved over 140% capacity utilization through world class practices and continuous improvements, SAIL continues to operate at barely 20 -25% capacity levels. Therefore despite availability of sufficient indigenous capacity, a high proportion of imports are required to meet the domes tic demand (further aggravated due to an inept and weak regulatory mechanism).

30

2011
THE TINPLATE COMPANY OF INDIA LIMITED CHAPTER - 7

C
COMD Pl i

-7

for Domesti sales and Dispatch

Customer

Sales

Order Placement

Sales Admin Shipment Production Planning

Plant Production

RM Procurement

Thi i the overall cycle from taki the order from the customer till the delivery of the fi ished good to the customer. Initially the customer gives the order of its good then accordingly planning is done. In planning it is seen that whether the companycan make the product according to the requirement of the customer if it can be done then they take the order and then proceed to make the product. When the order is placed then the communication is done with Kolkata office. After the planning everything isdone then the order for raw material order is given then the production of the good starts after the finished

31

product is made then it gets dispatch according to the domestic or export and then finally it gets deliver to the customer.

This is the planning of domestic sales. PRE SALES: When the order is taken the inquiry is done whether the product can be made if yes then the quotation is given and then the order for the product is given which is call purchase order. ORDER PROCESSING: In order processing they plan for the raw material. Then the order conformation is given and then discuss with the sales admin which is Kolkata office. PRODUCTION: When the raw material is got then the production starts. In CRM the productions is done then go to the ETP and then if the order is for solution center then it goes to there for printing then when the product is made then either it gets transferred direct stockyard. SHIPPING & SALES: Here when the product is made so while delivery when the payment is received then the billing is done then the product gets dispatch. This is the final process.

32

N. ZONE
DESTINATI

S.ZONE DA 8 6 6 9 4
DESTINATI

E.ZONE DA 7 6 5 8
DESTINATI

W. ZONE DA 2 3
DESTINATI

DA 5 6 7

DAYS

DAYS

DAYS

DAYS

BARODA DELHI GHAZIAB AD JAMMU KANPUR

BANGLU RU CHENNAI HYDERA BAD

MANGALO RE

HALDIA KOLKAT A

NAGPUR INDORE JAIPUR

KANP R
(Coil

8 7 7

RAJPURA SONEPAT

33

These are the stockyards and the destination transit days. There are four zonesand in each different zone different stockyards are there. The zones are North zone, South zone, East zone and West zone.

Here the planning of the shipping is shown. The area sales departments which are marketing departments there they take the order and according to the order discuss with the sales administration which is in Kolkata and then the planning is done with the COMD department and when the whole planning is done then the production starts and after doing the production then they communicate with the transporters then they dispatch the finished product.

34

2011
Chapter-8
THE TINPLATE COMPANY OF INDIA LIMITED CHAPTER - 8

DATA ANALYSIS AND INTERPRETATIONS

35

INTRODUCTION
Supply chain management is the art of managing the flow of material and products from source to user. The system includes the total flow of material from the acquisition of raw material to delivery of finished product to ultimate users. As such, it includes the activities of sourcing and purchasing, conversion including capacity planning, technology solution, operations management, production scheduling, and material planning, distribution planning and management industry warehouse operations, inventory management and inbound and outbound transportation, and the linkage with the customer service, sales, promotion, and marketing activities.

36

Secondary Data Analysis uantitati e Analysis of Performance:

MONTH WISE DISPATCH STATUS FOR THE YEAR 2010-2011

1) Data analysis of dispatch data

Stock Yard Direct Sol. Ctr (D) Total Apr 7706 2875 1260 11841 May 8403 4740 1274 14417 June 5685 6571 1054 13310 July 10163 4926 842 15931 Aug 10172 5200 1022 16394 Sept 9716 7277 1032 18025 Oct 10300 3270 1455 15025 Nov 11050 4021 1227 Dec 9031 6259 1448 Jan Feb 13553 9848 2675 1811 5230 1707 Mar 8645 7038 1506 Total 114272 60082 15638 189992

16298 16738

18039 16785 17189

14000 12000
10000 8000

6000
4000 2000

0
Stock Yard Direct Sol. Ctr (D)

apr may june july aug sept oct nov dec jan feb mar

INTERPRETATION: According to above figure, in the month of Jan dispatch is in maximum ton of finished material but in the month of June dispatch is minimum. As per the direct dispatch figure in the month of September maximum dispatch is done and after three month dispatch was lesser in Jan and in the year 2010 11 maximum dispatch done in month of Jan and minimum dispatch done in the month of July.

37

Stocks jsr ETP Sol. Center Total

Apr 5533 100 5633

May 6318 100 6418

June 6923 505 7428

July 8164 362 8526

Aug 4405 483 4888

Sept 2923 319 3242

Oct 3330 406 3736

Nov

Dec

Jan 2989 399 3388

Feb

Mar

3596 2559 540 519 4136 3078

2439 1960 393 393 2832 2353

9000 8000 7000

Apr May June

July Aug

6000 5000

Sept

4000 3000 2000 1000

0

Oct Nov
Dec Jan Feb

ETP

Sol. Center

Total

Mar

INTERPRETATION: All the collected data shows in the month of July in 2010-11
was peak month in stock jsr, Diff between maximum & minimum dispatched is 6204 . In ETP maximum dispatch done in month of Jan but minimum was March and Sol. Center dispatched average in all months in 2010-11

38

MONTH WISE DISPATCH STATUS FOR THE YEAR 2009-2010

Destination Apr Stock Yard 6184 Direct 5734 Sol. Ctr (D) 1135 Total 13053
12000
10000 8000 6000

May Jun July 7395 6204 7450 5938 4540 3812 1031 811 706 14364 11555 11968

Aug 6660 5379 849 12888

Sept Oct Nov Dec Jan 5947 8949 7416 5536 9760 6220 3794 3296 7167 3369 1182 973 1087 848 1492 13349 13716 11799 13551 14621

Feb 8090 6239 1738 16067

Total Mar 7355 86946 10101 65589 2193 14045 19649 166580
Apr

Jun

Jul

Aug Sept

4000 2000
0

Oct Nov
Dec Jan

Stock Yard

Direct

Sol. Ctr (D)

Feb

INTERPRETATION: It is been observed that in the year 2009-10 there was more dispatch through stockyard. There was consistently increase but only in the month of September and December there was a downfall. In direct dispatch there was increase and decrease of the dispatch but in the month of March the growth was hig h. Same was noticed in the dispatch through solution center there is increase and decrease in the dispatch.

39

MONTH TO YEAR DISPATCH SINCE 2003-04 to 2010-11

2008 - 09 11756 15126 15197 15275 15309 14089 14304 15357 11617 16133 19193 21263 184619 2009 - 10 17264 19043 15514 15206 16432 18719 17332 17717 21356 20819 21807 26717 227926 2010 - 11 18210 21014 20885 22134 22710 21117 16450 19901 20196 20583 19107 20412 242719

Apr May Jun Jul Aug Sep Oc Nov Dec Jan Fe Mar Total

40

Chart itl
30000 25000
20000 15000

10000 5000 0
    

ay

J l

2008 - 09

INTERPRETATION: In data analysis from the year 2008-09 to 2010-11 it is been

observed that there is consistently increase in the dispatch and in the year 2009-10 there was maximum increase in dispatch.

Se

ct

Dec

Ja

Fe

ar

2009 - 10

2010 - 11

41

Domestic

2008 - 09 137776

2009 - 10 2010 - 11 167192 198081

Tonne
250000

2010 - 11, 198081

200000 2009 - 10, 167192 150000

2008 - 09, 137776

100000

50000

2008 - 09

2009 - 10

2010 - 11

INTERPRETATION :
every year.

It is been observed that there is continuously increase in

42

TRANSPORTERS DETAILS Sl. Name Address Phone/E-Mail No. 1. Kabra 12/1, New 9431131948 Transport Kalimati kabratransport@sify.com Road, Sakchi 0657 - 2434476, 2429125 2. Om 2nd Floor, Enterprises Matri Bhawan, Email:opparikh@sify.com New Kalimati Road, Sakchi 305, 0657 - 2341218, Mobile3. OTS Limited
Akashdeep Plaza, P.O. Golmuri, Jamshedpur 831 003. 14/406, New Kalimati Road Sakchi Jamshedpur Canara Bank Campus 2nd floor, New Kalimati Road Sakchi Jamshedpur 09331049333 E-mail : otsjamshedpur@sify.com

Contact Person
Mr. Pradip Kabra

Mr. Sunil Prakash Parikh, 9431133725 Mr. S.K.Bansal

4.

Utility Transport

0657- 32427251 09334637269 E-mail : utilitytransport@yahoo.com 09334219424 E-mail : jsr@westcong.com

Mr. Daljit Singh

5.

Western Carriers

Mr. V.Bothra

Q.1 which is the places you provide transportation service? Sr. No. Transporter Name Places Base Jamshedpur, ludhiyana, Haldia, Paradeep, 1. Kabra Transport Visakhapatnam, Barbil, Dhanbad, Kharagpur etc. All over India. 2. Om Enterprises All over India. 3. OTS Limited All over India. 4. Utility Transport

43

5.

Western Carriers

All over India.

Interpretation: As per the data all the transporters except kabra transport all the other transporters they supply all over India. Q.2 Name of the companys you provide service? Sr. Transporter Name Companies Name No. Usha Martin, Tinplate, Tube Company etc. 1. Kabra Transport Any Company. 2. Om Enterprises Tata Steel, Tata Motors, Tinplate, Sail, Jindal, Lafarge 3. OTS Limited etc. Tinplate etc. 4. Utility Transport Tata Steel, Tata Motors, Tinplate, Usha Martin etc. 5. Western Carriers Interpretation:
The Transporters they mostly provide service to the Usha martin Tinplate, Tata steel and Tata motors.

Q.3 Average Monthly supply of these companys (in Ton) Transporter Tinplate Tata Tata Tata Name/Company Steel TDS Refrestic Name 5000 Kabra

Tata Over Motors(Engine) All 15000 6500 2750 6000 8000

Transport Om Enterprises OTS Limited Utility Transport Western Carriers

6000 750 6000 2000 6000

500 2000 4000

1000

44

100%
90% 80%

70%
v er All t rs E g i e )
  #  "

60% 50% 40%

30% 20% 10%

Tata

Tata Re restic

Tata TDS Tata Steel

&%

Ti

l ate

0%
     

Interpretation:

It is been noticed that the kabra transport supply is more comparatively from other transporters but the Om enterprise and utility transport the supply is more for TINPLATE company.

Q.4 How companies communicate you for Truck placement Transporter Tinplate Tata Steel Usha Name/Company Martin Name Mail, Kabra Previous Transport Order Companies Om Tender, Enterprises Mail OTS Limited Phone, Mail Mail, Utility Previous Transport Order Mail Website(VTC) Phone Western

program? Tata Refrestic

Phone

Carriers

Interpretation: The communication is mostly done through phone and mail. Q5. How you plan for truck placement? Ans. They get intimation before 24 hour from the placement time. So they provide and send the truck accordingly. Q6. Average time for truck placement after getting program.
45

 

Kabra Tra s r t
 

E ter rises

TS Li ite

Utility Tra s rt

Wester a rriers

Tata Motors(Engine)

Mail

Ans. The mostly average time within for truck placement after getting program is 12 to 24 hours in same day.

Q7. Average time on truck reaching to the destination. Transporter In company transit Before company Name/Transit Time time transit time Always Kabra Transport Always Om Enterprises Always OTS Limited Utility Transport Always Western Carriers Always

After company transit time Some times in other case Some times in other case Some times in other case Some times in other case Some times in other case

Interpretation: Generally it is reached on time or before time but in some cases like
accidents or truck break down then it gets delayed.

Q.8 What is the average time taken for vehicle in and out movement? Transporter Name/Vehicle in & out timing 0 12 Hour 12 - 24 Hour 24 48 Hour

Kabra Transport Om Enterprises OTS Limited Utility Transport Western 7.5 Carriers

36 36 36 24

46

40

35
30

25
24 48 Hour 20 12 - 24 Hour

15
10

0 12 Hour

5
0
'

Kabra Transport

Om OTS Limited Enterprises

tility Transport

Western Carriers

Interpretation: The vehicle in and out movement is 48 hours maximum.

.9 How you track the truck once it is left from Jamshedpur? Ans. To track the truck it is traced through E-Trance card, Drivers Phone, GPS Device etc. Q.10 How you manage if truck gets break down? (Truck get stuck in transit) Ans. Transporter Name Minor Break down Major Break Down Solved by driver Transhipment Kabra Transport Solved by driver Transhipment Om Enterprises Solved by driver Transhipment OTS Limited Solved by driver Transhipment Utility Transport Solved by driver Transhipment Western Carriers

Interpretation: It depends on the breakdown. If the breakdown is minor then the driver
himself repairs it and if it causes the major breakdown then they take the permission from the Tinplate Company to replace the truck and once the permission is taken then they replacethe truck and the penalty is given by transporter to the company for the loss of time or for any other loss.

.11 What is your annual turnover? Transporters Name

Kabra Transport Om Enterprises OTS Limited Utility Transport Western Carriers

Annual Turn Over (in crore) Confidential Confidential 90 Confidential 15

47

Annual Turn
100 90
80

er (in rore)

70 60
50
0 ( 1 ( ((

40

u al Tur

v er (i cr re)

30 20
10

0
E ter rises
) ( ( 3 2 1 21

Interpretation: All the other company turnover details are kept confidential. The
turnover of the OTS ltd. Is more than the western carriers. Q.12 Any suggestion for COMD to minimize Truck placement time Transporters Name Suggestions In & out taken time should reduce. Right information at right time. Reduce taken time in company. Perfect communications. Max. Vehicle order should give in package system.

Kabra Transport Om Enterprises OTS Limited Utility Transport Western Carriers

Q.13 Any suggestion to improve supply chain in TCIL? Transporters Name Suggestions Time factor. If they improve their own service than we improve our own service. Meeting should be done properly. Long term contract should be done, Dispatch should be planned.

Kabra Transport Om Enterprises OTS Limited Utility Transport Western Carriers

Q.14 Any suggestion from your side?

0) (

Kabra Tra s r t
0) (

TS Li ite

Utility Tra s r t

Wester a rriers

48

Transporters Name

Kabra Transport Om Enterprises OTS Limited Utility Transport Western Carriers

Suggestions Advance planning. Intimation should be give after production. Weekly advance program for loading & destination.

49

2011
THE TINPLATE COMPANY OF INDIA LIMITED CHAPTER - 9

Chapter-9

OBSERVATIONS & FINDINGS

50

Observations & Findings

On the basis of Data Analysis & Interpretation of Dispatch data of TINPLATE Co. of India limited
y y y y y y y y y y y y

There is lot of scope of improvement in Supply Chain of TINPLATE Company. Product quality of TINPLATE Company is best in whole country than all the domestic competitors. According to all previous data we got more dispatches done by stock yard then direct and lastly solution centre. Some of Transporters are not satisfied with companies loading process, They are having some of problem like deviation from loading plan. Transporters have lack of information for dispatches and next stock yard. In domestic Supply transit time is more than expected time. According to all previous data The TINPLATE Co. doubling its capacity to 3,80,000 MTPA. 78% (*)TCIL customers are satisfied according to the customer satisfaction survey. TCIL is the largest seller and manufacturer of tinplates. Complaint Mgmt is also less - 0.2(*) consistently improving and better than benchmark levels*. Total revenue growth is less than previous year, it is around 1129 (Rs Crs)*. Quality of order lead time, customers complaint resolution, and product promotion activity are the areas of improvement for TCIL. Value of quality 1.9(*). Its more than previous six years quality value.

(* - Refer Application for TATA Business Excellence Model, 2011)

51

52

2011
Chapter-10
THE TINPLATE COMPANY OF INDIA LIMITED CHAPTER - 10

SUGGESTIONS AND RECOMMODETIONS

53

SUGGESTIONS AND RECOMMODETIONS

On the basis of findings and conclusions here are some suggestions for TCIL which the company should follow to have a good, effective and efficient supply chain of Tinplates. And this will be in favor of the company as well as its channel members. The suggestions for improvement in various sectors:

y y

TCIL should make pre plan for every next week dispatches. Every meeting of management & transporter should done properly & timely in every week.

Company should communicate properly with transporter for dispatch the finished good, It will solve the problem of both.

y y y y y y

If solution centers order will increase, TCIL can grow up more than expected. Truck in & Out time should be less. Company should improve the service it will help to company n transporters also. Transit time should something lesser than present transit time. First order should move first or dispatch first. Every quarterly one meeting should arrange between Transporters, Management & Head of the Company.

54

55

2011
Chapter-11
THE TINPLATE COMPANY OF INDIA LIMITED CHAPTER - 11

QUESTIONARIE

56

ANNEXURE
QUESTIONARIE

Transporter Name: ADD:

INTERVIEW PERSON NAME: DESIGNATION:

57

1. Which are the places you provide transportation service?  2. Name of the companys you provide service?  .. 3. Average Monthly supply of these companys (in MT) Company Name/Yard IN MT IN %

TOTAL 4. How companies communicate you for Truck placement program? Company Name/Yard Mode of communication

TOTAL 5. How you plan for truck placement? .. 6. Average time for truck placement after getting program. Yard Name Day 1 Day 2 Day 3 Day 4

7. Average time on truck reaching to the destination. Yard Name Average Time

TOTAL

58

2011
8. What is the average time taken for vehicle in and out movement? Vehicle IN Time Vehicle OUT Time Average time

9. How you track the truck once it is left from Jamshedpur? . 10. How you manage if truck gets break down? (Truck got stuck in transit) .. 11. What is your annual turnover? 2008-09 Transporter Name 09-10 10-11 11-12 Expected

12. Any suggestion for COMD to minimize Truck placement time 13. Any suggestion to improve supply chain in TCIL? 14. Any suggestion from your side?

59

2011
THE TINPLATE COMPANY OF INDIA LIMITED CHAPTER - 12

Chapter-12
BIBLOGRAPHY

60

Sr. No.

Title

Author

Publisher

Year of Publication

Edition

1.

www.soople.com

2.

www.google.com

3.

www.tatatinplate.com

4.

TCIL Intranet

5.

Supply chain management

William C. Copacino

61