Description
Dry cleaning is any cleaning process for clothing and textiles using a chemical solvent other than water. The solvent used is typically tetrachloroethylene (perchloroethylene), which the industry calls "perc" or "PERC". It is used to clean delicate fabrics that cannot withstand the rough and tumble of a washing machine and clothes dryer; it can also eliminate labor-intensive hand washing.
Index
NO. A B C D 1 2 3 4 PARTICULARS Preface Company certificate Acknowledgement Declaration Scope of the project Objectives Executive summary Industry profile 4.1 introduction 4.2 major segments 4.3 customs duty 4.4 excise duty 4.5 leading chemical units 4.6 news in chemical industry 4.7 export market 4.8 swot analysis 4.9 competitive advantage for India Company profile 5.1 site details 5.2 company view photo copies 5.3 history 5.4 mission 5.5 company layout 5.6 vision 5.7 company’s plan 5.8 production process 5.9 raw material storage and handling along with photo 5.10 policies 5.11 achievement certificate 5.12 organizational structure 5.13 departmental study 5.14 employees profile 5.15 green belt area with photo 5.16 photo copies of lab 5.17 swot analysis Learning Findings Conclusion Bibliography PAGE NO. 2 3 4 5 8 9 10 11 13 13 13 15 16 17 19 22
5
23 24 26 27 28 29 29 31 31 33 35 36 37 39 43 45 46 47 47 48 49
6 7 8 9
Lists of tables
NO. PARTICULARS PRODUCTION PERFORMANCEOF CHEMICALS GROUP WISE CAPACITY & PRODUCTION OF MAJOR CHEMICALS GROUP WISE EXPORT & IMPORT OF CHEMICALS ISCPL’S PRODUCTS PAGE NO. 12
1
14
2
14 30
3 4
Scope Company profile:
ORGANIZATION:
INDUSTRIAL SOLVENTS & CHEMICALS PVT.LTD. (AN ISO 9001 – 2000 ACCREDITED COMPANY )
ADDRESS :
FACTORY: PLOT NO – 7906 TO 7909, GIDC, ANKLESHWAR – 393002 TEL : (02646) 239549 (02646) 239553 (02646) 239554 FAX : (02646) 251173
HEAD OFFICE :
101, ATLANTA 209, NARIMAN POINT, MUMBAI – 400 021 TEL : (022) 22841178 (022)22841180 FAX : (022) 22871957
WEB SITE :
WWW.ISCPL.COM
YEAR OF ESTABLISHMENT :
1993
CHIEF FINANCIAL OFFICER :
MR. THOMAS ESSAW
AUDITOR :
J.K.SHAH & CO
BANKERS :
SBI IDBI
Objectives
The objective of this project report is to get knowledge about chemical industry. So, I have taken permission in industrial solvents & chemicals pvt. Ltd.At Ankleshwar, GIDC. So that I can get information about this company and also the Indian chemical industry, chemical products, segmentation of chemical industry in different products, export performance, policies etc. of chemical industry.
Executive summary
The chemical industry is a knowledge driven industry. This project gives the information about Indian chemical industry. SWOT analysis of Indian chemical industry gives the information about the strength, weakness, opportunities, & threats of the industry. Also it gives information about industrial solvents & chemicals pvt. Ltd. This project consists the induction of ISCPL also their mission , vision, policies, achievement, organizational structure. Different departments of the company and their management system , rules and regulation of the company. Which rules and regulation all employees must follow and what type of facilities company provides to its employees. also the methodology used for collecting the information.
Industry profile
Chemical Industry in India
Introduction:
? Chemical industry is one of the oldest industries in India. It not only plays a crucial role in meeting the daily needs of the common man, but also contributes significantly towards industrial and economic growth of the nation. The industry, including petrochemicals, and alcohol-based chemicals, has grown at a pace outperforming the overall growth of the industry. ? The global chemical market is estimated at approximately USD 1.7 trillion. Western Europe is the largest chemical-producing region followed by North America and Asia. ? The Indian Chemical Industry ranks 12th by volume in the world production of chemicals. The industry’s current turnover is about USD 30.8 billion which is 14% of the total manufacturing output of the country. The export of chemicals in the year 2002 was USD 5.875 billion, which forms almost 0.9 % of the world export of chemical products and about 13% of the country’s total export. Substantial proportion of these exports goes to the USA, Europe and other developed nations. Its contribution to the national revenue by way of custom and excise duties is about 20%. India is strong in basic chemicals that go into production of consumer items like paints, dyes, soaps, medicines, toiletries, cosmetics, etc. ? The Indian Chemicals Industry comprises both small and large scale units. The fiscal concessions granted to small sector in mid-eighties led to establishment of large number of units in the Small Scale Industry (SSI) sector. Currently, the Indian Chemical Industry is in the midst of major restructuring and consolidation phase. With the shift in emphasis on product innovation, brand building and environmental friendliness, this industry is increasingly moving towards greater customer-orientation. Even though India enjoys an abundant supply of basic raw materials, it will have to build upon technical services and marketing capabilities to face global competition and increase its share of exports. ? In terms of consumption, the chemical industry is its own largest customer and accounts for approximately 33 per cent of the consumption. In most cases, basic chemicals undergo several processing stages to be converted into downstream chemicals. These in turn are used for industrial applications, agriculture, or directly for consumer markets. Industrial and agricultural uses of chemicals include auxiliary materials such as adhesives, unprocessed plastics, dyes and fertilizers, while uses within the consumer sector include pharmaceuticals, cosmetics, household products, paints, etc. ? India also produces a large number of fine and specialty chemicals, which have very specific uses and are essential for increasing industrial production. These find wide usage as food additives, pigments, polymer additives, anti-
oxidants in the rubber industry, etc. Some of the important manufacturers of specialty chemicals include NOCIL, Bayer (India), ICI (India), Hico Products and Colourchem. ? The Dyestuff sector is one of the important segments of the chemicals industry in India, having forward and backward linkages with a variety of sectors like textiles, leather, paper, plastics, printing ink and foodstuffs. The textile industry accounts for the largest consumption of dyestuffs at nearly 80%. From being importers and distributors in the 1950’s, it has now emerged as a very strong industry and a major foreign exchange earner. India has emerged as a global supplier of dyestuff and dyes intermediates, particularly for reactive, acid, vat and direct dyes. As for a global production of dyes is concerned, India accounts for 6% of the world production. ? Chemical fertilizers and pesticides played an important role in the "Green Revolution" during the 1960s and 1970s. The consumption of pesticides in India is low in comparison to other countries. Indian exports of agrochemicals have shown an impressive growth over the last five years. The key export destination markets are USA, UK, France, Netherlands, Belgium, Spain, South Africa, Bangladesh, Malaysia and Singapore.
? Production performance of some of the important chemicals including pesticides and dyestuffs are given below:
Installed Item Capacity 31.3.2003 20032002-03 04(Estimated) Soda Ash 2042 1632 1673 1840 2004-05(Anticipated) PRODUCTION
Caustic Soda
1953
1520
1552
1707
Liquid Chlorine
1448
970
1012
1113
Calcium Carbide
86.50
49.00
45
50
Phenol
66.5
76.20
72
79
Methanol
385.00
362.10
366
403
Tech. Pesticides
144.95
68.17
68
75
Dyestuffs
52.70
25.90
27
29
(Source: from www.niir.org)
Major Segments:
Chemical Industry is highly heterogeneous with following major sectors :
? ? ? ? ? ? ?
Petrochemicals Inorganic Chemicals Organic Chemicals Fine and specialties Bulk Drugs Agrochemicals Paints and Dyes
Customs Duty:
? ? ? The peak rate of Customs Duty on most Chemicals is 7.5% On basic raw materials like acid grade fluorspar, sulphur, rock phosphate, natural borates is 5 On most building blocks & feedstock the duty is 5% (ethylene, propylene, crude, naptha, benzene, toluene, xylene, ethylbenzene)
Excise Duty :
On almost all chemicals the excise duty is 16%
Group-wise capacity & production of major chemicals in organized sector (Fig. in MT)
Main Groups
Inst. Cap. as on
March 2007 2001-02 3 4342305 374132 1166575 81803 24789 2002-03 4 4792345 403827 1352653 69565 26196
Production
2003-04 5 5070374 440608 1473855 85118 25940 2004-05 6 5271675 508157 1505895 93966 28498 2005-06 7 5474614 543965 1545262 82240 29541 2006-07 8 5268987 602309 1545442 84701 32552
1 I: ALKALI II: NORGANIC III: ORGANIC IV: PESTICIDES V DYES TOTAL MAJOR CHEMICALS (I+II+III+IV+V )
2 7072334 748615 1889448 145391 52591
9908379
5989604
6644586
7095895
7408191
7675622
7533991
GROUP - WISE EXPORT & IMPORT OF CHEMICALS (Figure in crore Rs)
Group TRADE 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07
INORGANIC CHEMICALS *
Export Import
1259 5730
1946 5579
1949 5916
2871 8130
3431 10446
3629 11473
ORGANIC CHEMICALS
Export
7624
10190
12975
16269
21504
25950
Import
8795
10695
14363
18785
22776
27330
DYEING, TANNING AND COLOURING MATTER
Export Import
2436 1138
2943 1344
3112 1617
3111 1878
3750 2245
4562 2720
PESTICIDES
Export
1356
1487
1746
2096
2791
2877
Leading Chemical Units
M/s.United Phosphorous Ltd, Mumbai M/s. P.I.Industries, Jaipur M/s.BASF India, Mumbai M/s.BASF India, Mumbai M/s. Excel India, Mumbai M/s.Atul Ltd., Bulsar M/s. Colour Chem. Ltd., Mumbai M/s. Sudarshan Chemical Industries, Pune M/s.Colourtex, Ahmedabad M/s. Monsantu Chem Ltd., Mumbai M/s. Jubilant Organosys Ltd., New Delhi M/s. Herdilia-Schentady Ltd. Mumbai National Organics Chemicals Ltd., Mumbai DCM Sri Ram Consolidation Ltd., New Delhi M/s. Gujarat Heavy Chemicals Ltd., Ahmedabad. M/s. India Glycols Ltd., New Delhi M/s. Gujarat Alkalies and Chemicals Ltd., Baroda M/s.Rayalseema Chemcials, Hyderabad M/s. Galaxy Organic Ltd., Mumbai M/s. Lubrizol Ltd., Mumbai M/s. ICI Calcutta
News in chemical industry
India Chemical Industry Outlook to be held in Mumbai
February 15th, 2008 - 5:09 pm New York, Feb 15 (ANI/Business Wire India): Chemical Week and the Indian Chemical Council have teamed up to create the first India Chemical Industry Outlook in Mumbai on April 15. The two-day event is the only chemical conference in India that addresses the full spectrum of issues impacting the country’s chemical sector at this important moment of expansion. The chemical industry in India is poised for rapid development in the coming years. India’s consuming middle class and the population’s disposable income are expanding, potentially driving growth of demand at exponential rates; the government has set in place special economic and investment zones for the chemical sector; and several of the country’s chemical and oil majors have announced aggressive investment plans. The India Chemical Industry Outlook, to be held in Mumbai, will take a look at key segments of the Indian chemical industry and explore the growth opportunities and challenges in each segment. India’s climate for mergers and acquisitions will also be examined. Mukesh Ambani, Chairman and Managing Director of Reliance Industries Limited, said, “The Indian market for petrochemicals will increase four times in the next ten years. It will witness a sustained double-digit growth rate. This growth would be faster than that of China.” Peter Huntsman, President and CEO of Huntsman Corporation, said: “India and Russia are the next two economies after China. Our business in India is growing at double-digit rates. Unless you have a foundation in India today, you will be too late.” “Chemical Week is leveraging its long experience in India and expertise in presenting events across Asia and around the globe to bring you an impressive roster of speakers and topics at this important event,” said Lyn Tattum, Chemical Week Publisher and Group Vice President. Topics to be explored include: – Government investment zones – Expansion plans of domestic companies – The challenges of bureaucracy, labor laws, and logistics – Opportunities in various chemical industry segments. (ANI)
Export market
FACTS OF INDIAN CHEMICAL INDUSTRY
? ? ? ? ? ? ?
13% of the total export 13% of the total industrial output & 7% of the GDP 10 % - 12 % growth per annum 2% of global chemical industry Indian pharmaceutical industry ranks 4th in volume & 13th in term of value in the world. India – a strong player in the generic pharmaceutical market India – 2nd largest producer of agrochemicals in Asia
INDIAN PETROCHEMICALS
? ? ? Domestic market size – US$700 million Fastest growing sector at 15% Reliance – key player in this market
Chemical industry in India: interesting facts
INORGANIC CHEMICAL ? Market size – US$260 million ? Growth rate – 9% ? 4.5% of global market ? Mainly used in detergent, glass, soap, fertilizer and alkalis
PHARMACEUTICALS ? ? ? ? ? India ranks 4th In terms of volume & 13th in terms of value. Domestic market size – US$450 million Indian market is 1.6% of the global market Domestic market growth rate – 8 to 9% Strong player in generic market--several of the world’s leading drug companies are based in Indian.
AGRO CHEMICALS AND FERTILISERS ? ? ? Domestic market size – US$88 million Domestic market growth rate – 10% annually 2.5% of the global market.
?
India is largest manufacture of basic pesticide chemicals among South Asia & Africa, next only to Japan.
SPECIALITY & FINE CHEMICALS ? ? ? Market size – US$860 million Major used in textile, leather, paper, detergent, rubber ?Paints, polyester, oil & gas. Growth rate – 10-12%.
DYES & PAINTS ? ? ? ? ? Market size – US$110 million. Growth rate – 12% Indian market is 6% of the global market Major used in Paints, inks, textiles, polymers. Highly fragmented market 25 large & medium players holding 50% of the market. Remaining 50% is with another small 2000 un-organized players
Swot analysis
The Task Force carried out a "SWOT" analysis of the Industry. This analysis comprised evaluation of individual Sub-sectors also. The summary observations of the Task Force based on this analysis are given below
Strengths:
? ? ? ? ? ? ? ?
A diversified manufacturing base having a capacity to produce quality chemicals from World class plants. Competitive Core Industries essential for the development of chemical industries Capability to produce World class end products Large domestic market Major raw material component sources within the country Good R&D base and quality human resources
Specific to Dyes and Dyestuff Industry
Strong base for producing various categories of dyes for different end use applications (Acid, Direct disperse, Azoic, Reactive and VAT dyes etc.) Globally competitive Dyestuff industry catering to nearly 95% of the domestic demand of Dyes.
Specific to Agrochemicals Industry
?
Key producers have direct access via distribution to the market
Weakness:
? ? Cost of Power: Very high cost of power, unreliability of supply and frequent
interruption. Transmission and distribution losses are very high
Cost of Finance:
Chemical Industry is highly capital intensive, cost of finance in India is very high; interest rates are 14% - 15% p.a. as compared to 2% to 6% prevailing in developed countries. Infrastructure:India ranked 55th in infrastructure development in the global competitiveness report 1999. Infrastructure facilities are not of world class. Transport and communications are complex resulting in delays and slow movement of goods. In-adequate port facilities result in high demurrage costs. For example turn around time for Vessels is an average of eight days in India as against one or two days in Singapore Scale of production: Due to earlier policy of import substitution and industrial licensing, Chemical plants in India were built to cater to the domestic requirements. The per-capita consumption in India is less as compared to other countries and hence plant sizes are not comparable to World scale operations. Major Competitors abroad enjoy economies of scale advantage. Technology: In the days of sheltered economy, up-gradation of technology was not critical. Bulk of the Pharmaceutical Industry has grown by concentrating on processes modification rather than basic research. Investment in R&D with a view to generating intellectual property is absent. A change of mind set is needed to invest in R&D to be able to sell value added product and compete in developed countries Cost Disadvantages: Industrialization was spread throughout the country to redress regional imbalances as also for the development of backward areas. However, this has created locational disadvantages, such as extra transport cost for raw materials as well as finished products. Cost of raw materials and catalysts in India is also high as compared to international levels. Multiplicity of Taxes: Indian exporters at present are placed at a considerable disadvantage vis-a-vis their foreign competitors on account of multiple levies (various taxes and duties like sales tax, turnover tax, , service tax, electricity duty and cross subsidies, etc.). Value Added Tax (VAT) must replace multiple taxes to create a level playing field.
?
?
?
?
?
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Labour Laws: Labour & Industrial relation laws at present do not allow flexibility in deployment of Labour. This discourages modernization and investment in technological changes and eventually leads to industrial sickness thus adversely affecting workers as well.
Specific to Dyes and Dyestuff Industry
?
Traditionally Indian manufacturers have been in the commodity dyes business. No efforts for new product development or new application of technology were made (low value addition and value realization The industry, on account of its small size, finds it tough to compete in high margin products with global players, who can offer personalized buyer support on account of their diversified product base and investment in application development
?
Specific to Agrochemicals Industry
?
Likely restrictions on use of Organo Phosphorus Esters on specific crops / indications in certain developed countries may adversely affect the demand for this sector thereby lowering capacity utilization.
Opportunities:
?
A decade of economic reforms has tested the resilience of the Indian Chemical Industry. Individual enterprises have realized their weaknesses and are gearing up to face the new challenges. Success stories in dyes and Agrochemicals have boosted the confidence to take on global competition squarely In certain categories of chemicals, we do have advantage for exports (Dyes, Pharma, and Agrochemicals). By creating strategic alliances with countries like Russia and CIS countries. With the know how available in the country, there is a tremendous potential to grow and increase exports in dyestuff and Agrochemical market India has the capacity for major value addition being close to Middle East. This is a cheap and abundant source for Petrochemicals feedstock
?
?
Specific to Dyes and Dyestuff Industry
?
Stringent environmental laws in the Western countries have led to discontinuance of production of certain dyes for textiles and leather. Climatic conditions in India are favourable for the manufacture of such products and export of the same in an eco-compatible manner Policy of American and European Companies to outsource the lower value products from Non-Traditional Suppliers (NTS) countries like us has increased demand for dyestuffs. This can be exploited aggressively Demand for Disperse dyes and Vat dyes is expected to grow in future
?
?
Specific to Agrochemicals Industry
? ?
Huge potential in Indian Market exists as the per capita agrochemicals consumption in India is much lower than the World average. International companies could use India as production base for domestic market and outsourcing, provided proper IPR regime is in place.
?
It is also possible to employ resources to focus on investment in basic research and development programmes to discover new molecules, safer formulations and processes Potential for use of Biotechnology in the manufacture of agrochemicals can lead to tapping the growing global market for Bio-pesticides.
?
Threats:
As per the WTO agreements, peak customs duty has been brought down. Quantitative restrictions for imports have been removed already. Most of the chemicals are now in the Open General List (OGL) of imports. As a result imports of chemicals, intermediates and end products are freely allowed in the country. Even at these reduced levels of import duty tariff levels in India for most chemicals are significantly higher than other countries manufacturing the chemicals. There would certainly be pressure on the Government to reduce these tariffs levels. In case these levels are reduced competition in the Indian Chemical Industry would become more intense. The users would buy their requirements from the most competitive source. Unless the Indian industry acquires competitiveness, it may face extinction
Specific to Organic Chemical Industry
?
Most of the manufacturers in the unorganized sector need to be better informed about the pollution control measures that could put a halt to their production activity at any time China, a major competitive threat, is investing heavily in infrastructure (they are adopting the cost-effective German model). It would not only overtake India in current export territories but could also invade Indian market with cheaper imports
?
Specific to Dyes and Dyestuff Industry
? ?
Stiff competition from China, Korea and Taiwan Recession in end use industries e.g. The Textile industry (which is the major market for dyestuff industry) is facing a big crisis which has affected the dyestuff industry
Specific to Agrochemicals Industry
?
Large capacity for Organo Phosphorous compound are being set up in China; with economies of scale pushing domestic prices downwards
Competitive Advantage for India :
As a result of the SWOT analysis in the previous paragraph, the taskforce felt that the competitive advantage for Indian chemical industry lies in the following areas. These advantages would have to be urgently exploited to become globally competitive
?
One of the largest resources of scientific and technical manpower in the world
? ? ?
Large Domestic Market for various sectors of chemicals A developed financial market comprising regulated stock exchanges, all types of money instruments and capable of transacting business at a very fast speed Largest English Speaking population in the World and rapid growth in Information Technology can provide competitive access to the rich European and American market
Company profile
INDUSTRIAL SOLVENTS &CHEMICALS PVT. LTD.
PIOT NO. 7906-7909, GIDC INDUSTRIAL ESTATE, ANKLESHWAR . DIST-BHARUCH-393002 GUJARAT
( AN ISO 9001-2000 ACCREDITED COMPANY )
SITE DETAILS :
LOCATION :AS ABOVE PLOT AREA : 47,440 SQ.METER GREEN BELT AREA : 9,000 SQ.METER BARODACITY
IMPORTANT PLACES AROUND ANKLESHWAR ARE: BHARUCHCITY SURATCITY
THE NEAREST LARGE CITY :IS SURAT , WHICH IS ABOUT 62 KM AWAY THE PROJECT SITE. ANKLESHWARCITY :IS 4 KM AWAY FROM THE PROJECTSITE WITHIN 10 KM INFLUENCE ZONE : NO DEFENSE INSTALLATION NO NATIONAL PARK NO ECOLOGICALLY SENSITIVE AREA
Company view
HISTORY OF ISCPL
? ISCPL is a company incorporated under the company act 1956 having its registered and head office situated at 101, Atlanta, 209 Nariman point, Mumbai -400 021 on Mumbai.
It was the year 1960, the company had started the manufacturing activities at Thane in Maharashtra by putting up its first plant for the manufacture of Ether solvents I.P/B.P. during the sub sequent years, the company has added other products in the range of manufacture and put up the plants for the manufacture of Ether Anaesthetic I.P/B.P , Dimethyl sulphate, Dimethyl aniline,Ethyl benzyl aniline etc. it is a matter of pride to recall that the manufacturing unit at Thane had received excellent industrial safety performance awards, consecutively for 3 years (1995 to 1997) from Thane manufacturers association. The said certificate was jointly signed by the chairman of Thane manufacturers association and the joint Director, Directorate of industrial safety and health,Thane. The products manufactured as well as the raw materials used by the company are Hazardous and inflammable over the years, thane has become very much congested. Consequently it was becoming more & more difficult for the company to continue the manufacturing activities of these Hazardous products in this congested city of Thane. Further, though there was a growing demand for the products, there was no scope for any expansion for the reasons stated above. In the circumstances, as a prudent step , the mgmt had decided to start a second manufacturing unit at Ankleshwar in Gujarat . thus, a plant was put up for Dimethyl sulphate in the year 1994 , followed by other plants for the manufacture of N.N.Dimethyl aniline , Ethyl benzyl aniline , Diethyl sulphate, Ether solvents, I.P/B.P, during the subsequent years . ISCPL have developed most of the products by their own R & D department and some of the products from reputed consultants.
Mission
The chemical industry today is going through a consolidation phase. In the coming years, India will be a major player in the world chemical intermediates market.
Industrial solvents & chemicals Pvt. Ltd. Believes that its strengths are in manufacturing. Intermediates & handling Hazardous chemical and in the future will continue to do the same. Its strategy is to be a world class and world capacity manufacturer of specialty chemicals, it will continue to make value added products over the years and provide the chemical industry basic chemicals & intermediates at competitive rates. Chemicals are an indispensable part of our human life. Having successfully completed a decades in the field of manufacture of Hazardous chemicals, it has provided its with a lot of Enthusiasm. Its success has given it the courage to continue to grow and meet the existing and the exciting challenges of the new millennium.
Company layout
STROAGE TANK
BOILLER HOUSE
D M S P L A N T
EBA PLANT
ADMIN OFFICE
D S P L A N T
SULPHARE PLANT
E T P P L A N T
S T O R E ETHER PLANT
P O W E R H O U S E
G A R D E N
GARDEN
OCCUPATIONAL HEALTHCENTER SECURITY OFFICE
G A R D E N
S U L P H A R E YARD
GATE
vision
Today industrial solvents & chemicals Pvt. Ltd. Is one of the largest manufactures of a range of intermediates which has application in the pharmaceuticals , dyestuffs, agro chemicals and other related industries . today the plant of ISCPL is per the international standards having large capacities and state of the art manufacturing facilities and quality control equipment to ensure production as per international standards . As on today, ISCPL exports almost 40% of its production to reputed international companies in U.K., SPAIN, FRANCE, GERMANY, USA, JAPAN, TAIWAN, KOREA AND BRAZIL. Exports are done based on customer’s requirements. In UN approved drums or ISO tanks which are leased from international companies to carry Hazardous cargo.
Company’s Plan
In order to meet the growing export and domestic market demand of chemicals and having sufficient space for additional manufacturing facility for chemicals in existing plant , ISCPL propose to expand manufacturing activities by increasing production capacity of chemicals to 46027 mt/month from the existing capacity of 16392 mt/month. For this proposal company has received permission from government.
Water requirement
The entire water requirement is met from GIDC water supply.
Company’s products
SERIAL PRODUCTS PRODUCTION
NO.
1 2 3 4 5 6 7 8 9 DIMETHYL SULPHATE (DMS) N.N.DIMETHYL ANILINE (DMA) DIETHYL SULPHATE (DES) N-ETHYL ANILINE (NEA) ETHYL BENZYL ANILINE(EBA) DIETHYL ANILINE(DEA) ETHER SOLVENT (ES) ETHER ANAESTHCTIC (EA) MONO ETHYL METATOLUIDINE & DIETYL META TOLUIDINE(MEMT&DEMT) ABSOLUTE ALCOHOL MONOMETHYL META TOLUIDINE & DIMETHYL META TOLUIDINE (MMMT& DMMT) METHYL BENZYL ANILINE (MBA) MONO ETHYL ORTHO TOLUIDINE (MEOT) ETHYL CHLORIDE SPENT SULPHURIC ACID 65% N-METHYL ANILINE(NMA) DIMETHYL PARA TOLUDINE(DMPT) CHLORO SULPHONIC ACID (CSA) SULPHUR TRIOXIDE (SO3)
CAPACITY ( MT/MONTH )
3,000 600 500 100 60 100 500 15 25
10 11
100 10
12 13 14 15 16 17 18 19
10 10 2 800 30 30 1500 9000
? All this products are used in production of colours, dye industries, basic chemical, fertilizer industries, pharmaceuticals (drugs) in other company.
PRODUCTION PROCESS
```````` RAW MATERIAL RECEIPT
QUALITY CONTROL ANALYSIS
UNLOADING
PROCESS
FINISH PRODUCT
STORE
SALES
Raw material storage and handling
? The major raw materials are received in road tankers, Hdpe drums as well as some of the chemicals in gunny bags. ? Some storage tanks of hazardous flammable substances are located with in premises in separate storage area. E.g. solvent farm area. (Separate hazardous flammable storage facility available as per the explosive act) ? Solvents like methanol & ethyl alcohol are stored in under ground ms tanks as per the statutory requirement with all the precautionary measures. ? Large area is covered by well-designed warehouse, which is containing store office, raw material store, finished product store etc.
Hazardous waste management
? All the solid and hazardous waste generated from plants will be stored and disposed as per GPCB & CPCB rules/guide lines.
Raw material storage area
policies
Quality policy
? ISCPL the manufacturers of chemicals & drugs are committed to comply and continually improve the quality mgmt system so as to supply products meeting quality standards to meet or enhance customer satisfaction. ? This shall be achieved by strict monitoring of quality systems, straight process controls, application of statistical quality controls, team work and involvement of all personnel with utmost concern for safety and conducive environment.
Environmental policy
? ISCPL is in business of manufacture of quality chemicals under stringent process controls. ? It is committed to meet or exceed the regulatory requirements related to environment. ? It shall endeavor in the following areas ; ? Prevention of pollution ? Promote recycling & recovery of materials ? Resource conservation ? Enhancing awareness about importance of environmental protection amongst employees, vendors, customers & surrounding public. ? Minimize the environment aspects & impact of its products, process of service. ? It shall commit resources conservation for maintenance & promotion of environment & prevention of pollution at its site.
Health & safety policy
? The mgmt believes that the safety of employees ranks in high importance with production, product quality & costs while the maintenance of safe working condition & operating procedures in their plant can result in significant savings, they believe that human values are of greater importance to employer, employees and surrounding community. ? Mgmt recognizes the need for maximum safety and responsibility by providing the safe conditions for their employees to avoid accidents. The main object of their safety policy is to avoid accidents & to maintain neat, clean, safe, healthy & attractive working conditions and to train & motivate their people for safe work practices & to comply with statutory safety provisions. Lastly, no job is so important and no order is so urgent that they can not take time to perform their work safety. ? It shall be the policy of ISCPL to prevent injuries to employees and control damage to property by conducting all operations safety. Safety
starts from the planning stage and continues through design, purchase, storage, fabrication, construction, installation, operation & maintenance. It is an integral part of each and every job and operation. ? All practical steps shall be taken to maintain safe and healthy work / working environment by building in safety and healthy conditions. Safety and loss prevention are the direst responsibility of all levels of mgmt / supervision & are important measures of managerial / supervisory performance. This responsibility has been accepted by every one who conducts the affairs of ISCPL no matter in what capacity he may function.
Achievement certificate
This certificate was awarded from BUREAU VERITAS PVT. LTD. For management system of the ISCPL was as per the requirement of standard ISO 9001:2000.
Organizational structure
DIRECTORS
DIRECTOR PURCHASE/ MARKETING/ ACCOUNT DEPT.
WORKS DIRECTOR
SENIOR PRODUCTION MANAGER
ELECTRICAL INSTRUMENT/Q UALITY CONTROL/ ADMI. / STORE
PLANT MANAGER
PLANT INCHARGE
SHIFT INCHARGE/ SUPERVISOR
PLANT OPERATOR
Departmental study
Head persons in each department
DESIGNATION MARKETING MANAGER DIRECTOR FINANCE PRODUCTION MANAGER LABORATORY INCHARGE ADMIN. STORES DESPATCH PURCHASE
NAME OF PERSON C.A.JONSAN THOMAS ESSAW ARVIND PATEL B.J.PANDIT M.J.PATEL M.C.RANA ULPESH R. SHAH VAIBHAV S. PATIL
Introduction of the departments :
(A) PLANTS :
THE COMPANY CONSISTS OF THE FOLLOWING PLANTS: 1} DIMETHYI SULPHATE (DMS) 2} DIMETHYI ANILINE (DMA) 3} ETHYL BENZYL ANILINE / DIETHYL ANILINE (EBA/DEA) 4} ETHER SOLVENT / ETHER ANAESTHETIC 5} DIETHYL SULPHATE (DES) 6} SULPHURIC ACID
(B) MECHANICAL:
Maintenance of all plants and machinery and other erection works are carried out by this department. (C) PERSONNEL & ADMINISTRATION: Interviews, recruitments, attendance recorde, salary payments, leave records etc are handled by p & a dept. also the general administration comes under this department. All the statutory and other records related to the above are maintained by this department.
(D) STORES:
The stores department consists of raw material, packing materials, laboratory chemicals and the engineering items. As regards raw materials, based on the monthly production planning, purchase department arranges procurement. However, with regard to packing materials, laboratory chemicals and engineering items, indents are placed by the stores based on which the purchases are arranged. All the necessary records with regard to the receipt, issue and the balance are maintained by the stores department. Material is issued against requisition slips.
(E) DESPATCH:
The dispatch department consists of local sales as well as export dispatch schedules are sent from the sales / export departments based on which dispatches are made. Since the end products are excisable, the relevant central excise records along with other records connected with the production and dispatches are maintained by this department.
(F) PURCHASE:
Based on the monthly production plan, the purchase department plans the purchase for the month in respect of raw materials & important packing materials. As regards the laboratory chemicals and engineering items, the purchase is made based on the indents received from the stores department. Delivery schedules are coordinate with the production programmes.
(G) MARKETING (LOCAL & EXPORT) :
Marketing department consists of local sales as well as export .based on the purchase order received, as per the requirements, despatch schedules are sent to factory along with relevant instructions based on which the dispatch department at factory arranges the dispatches. All the necessary details such as name of the party, basic price, mode of dispatch, payment terms etc. are incorporated in the dispatch schedule sent by the marketing department.
Every morning company conducts meeting of each department head personnel.
Employee profile
Rules / regulations / facilities
? Interviews / recruitments :
Interviews for the various positions are conducted at factory, appointment orders are issued to each and every employee & the service conditions are governed as per the terms & conditions, mentioned in the appointment order. ? Joining reports : Each employee has to submit joining report and the necessary format is available with personnel and administration departments. ? Attendance : Each & every employee is provided with a punching card & the entry and exit are recorded by punching the security gate. Based on the above, the salary & overtime are prepared for the month. Necessary muster roll is maintained as per the statutory requirements. ? Salary /O.T.payment : Employees are paid their salary /o.t. on or before 7th of every month ? Identity cards : Employees are provided with identity cards giving the particulars such as name of the company, name of the employee, designation, dept. etc. all the employees are required to carry the same with them. ? Provident fund : All the employees are covered under employees provident fund scheme 1952 and the same is applicable from the date of joining. The eligibility, rate of deduction etc. will be strictly as per the provisions of the act. ? Employees state insurance scheme : The employees are covered under employee’s state insurance act.1948.
Today ISCPL is in very competitive world and to with stand the global competition, it has to run the company with optimum efficiency. Various rules/ regulations/ guidelines are framed by the company from time to time for the smooth operation. All the employees are advised to follow and observe all such rules and regulations framed so as to enable the company to achieve maximum effiency. ? Dress code :
The company provided two pairs of uniform per annum to all the employees and they required wearing the same while on duty. ? Safety requirements : The objective of the company is to achieve safe working conditions and healthy environment. Therefore, it is mandatory for all the employees to wear safety shoes, helmets, and goggles etc. which are provided by the company. ? Promotion/ termination/ resignation : The company believes in giving encouragement to the existing employees and therefore promotions are given to the existing employees depending on the merits/ performance. The appointment order contains guidelines with regard to resignations and terminations. ? Timings : The factory is working in all the three shifts, as all the plants are continuous process plants. The details of shifts and the timings are given below: Shift: time A 7.00 hrs to 15.00 hrs B 15.00 hrs to 23.00 hrs C 23.00 hrs to 7.00 hrs D 9.00 hrs to 17.30 hrs All the employees working in plants up to the level of production. Officer are working in shifts (a,b,&c). As regards the office staff including the stores, plant engineers and managers are working in general shifts. At the beginning of every month, shifts schedule is prepared and employees are required to work in shifts as per the schedule. ? Siren : The factory has installed a siren to announce the beginning and end of shifts as per the details given below: 7.00 hrs – starting A shift & end C shift 9.00 hrs - starting G shift 13.00 hrs – lunch break of general shift 13.30 hrs – end of lunch break 15.00 hrs – end of A shift and start of B shift 17.30 hrs – end of G shift 23.00 hrs – starting C shift & end of B shift In case of emergency also, siren is used to inform the employees and in such case, the siren will be sounded continuously for 2 minutes. All the employees are required to come at the assembly points in such situation.
? Department wise training checklist : Employees working in different department are given periodical training and necessary check lists of the training are maintained. ? Training records on induction training : Induction training is given to each and every employee on their joining the service and records of the same are maintained separately. ? Mock drill : Even if you have the best safety policy/ system, accidents may happen and therefore we should be prepared for such eventualities. To prepare all the employees for facing such situations, mock drills are conducted regularly to get the necessary training .records of such drills conducted are maintained. Mock drills also make assessment of preparedness of the employees to face and act during emergency situations.
? Safety measures provided : ? The personnel protective equipment like hand gloves, gumboot, goggles, helmet, clothing, self breathing apparatus, etc. are provided to those handling hazardous chemicals as per requirement. All motors & electrical connections are of flameproof. All electrical installations are provides with double earthings. Flameproof equipments & fittings are provided for handling of inflammable chemicals & solvents. All storage tanks, pipelines & joints carrying solvents generating static charges are provided with double earthing. Road tankers & unloading lines are provided with double earthing. Process, equipments & plant involving fire hazards are designed as per prescribed guidelines. Flameproof pumps & motors are provided for solvent transfer. Sufficient access for firefighting is existing in the plant. Banning of mobile in the plant.
? ? ? ? ? ? ?
? Medical facility : ? ? ? ? ? Per employment medical check up Medical check up of all employees done regularly as per statutory requirement. First aid box is available with necessary medicines for each department. All the employees are covered under ESI & other medical insurances scheme Vehicle/ van facility available in case of emergency
? ? ?
Full fledged occupational health center provided Services of part time qualified medical officer available at any time Nearest hospital is MODIHOSPITAL and its phone no. is (02646)222220 /224550
? Social welfare activities : ? ? ? ? ? ? Public liability policy under PLI acts for factory surroundings. Public liability policy under PLI acts for the transportation of products. Distribution of food packets, water pouch during Surat floods. Distribution of food packets , water pouch during national calamities in surrounding areas Workmen welfare activity such as books, cloth & other financial aids to the family Tree guards for plantation the trees in the estate and nearby areas.
Green belt
? ? Company also gives special thrust for plantation & developing the greenery. ISCPL has developed green belt within factory premises. Total land area available at the existing site is 47,440 sq.meter; out of this area about 4,000 sq.meter area is covered as greenbelt and other forms of greenery.
? ? ?
There are 510 nos. of fully grown trees & other ornamental plants with in factory premises Company is planning to grow more trees in existing greenbelt area and also proposing additional 5,000 sq.meter area for greenbelt So that after proposed expansion approximately 9,000 sq.meter area shall be greenbelt.
Green belt area
Photo copies of lab
Research methodology and swot analysis
Research methodology used for data collection is primary data collection method & interview method for collection of data.
SWOT ANALYSIS
Strength:
? ? ? ? ? ? ? Many years experience in this industry Dedicated and responsive staff Monopoly in production Quick support from staff Good infrastructure facility Large domestic market Good R & D base and quality human resources
Weakness:
? ?
Need of large investment in plant ISCPL is a chemical manufacturer so employees turn over ratio is high so some times company can not get enough manpower for proper production
Opportunities:
? If company will receive permission from government for expansion of business than company’s production will increase and company will capture more market share
Threats:
? ? ?
Due to the diversification of various players in chemical this segment has become highly competitive Speedy changes in technology All plant’s manager are masters in production planning . if other company will offer high salary to them and if they will leave the company than company’s monopoly will reduce
Learning
? ? ? ?
I got practical knowledge about working in the chemical company. I also came to know regarding the environment of organization. I have understood the system of working of the organization. I also got the opportunity to work with the higher-level people
Findings
Company has monopoly in production of all products. so management has not given permission to me for enter in production plant and also does not give information about inventory management, name of the machinery used in production process.
Some Slogans of the company
? ? ? ? ? ? ISC BELIVES IN SAFEY SAFETY HAS NO HOLIDAY PRODUCTION MUST BUT SAFETY FIRST SAFETY IS A WAY OF LIFE SAVE (YOUR LIFE, YOUR FAMILY, YOUR INDUSTRIES ) SAFETY – THE MEASURES OF SUCCESS.
Conclusion
So, according to the above all data of report I conclude that company’s management system is very best and also company takes many steps for awareness of its employees and also for society. Company is very strict for safety, its slogans indicates its strictness about safety. Company provides many facilities to its employees it is very good. Also company follows the all rules and regulations of government. Company has to takes more steps for reduce the employees turnover ratio. so company can keep its monopoly. ISCPL follows the all rules and regulation of government so govt. should gives permission to ISCPL for expansion of business so company can increase its production and increase the export market of India.
Bibliography
Websites:
? ? ? ? www.niir.org www.indianchemicalportal.com www.energymanagertraining.com www.cacci.org
doc_638888752.docx
Dry cleaning is any cleaning process for clothing and textiles using a chemical solvent other than water. The solvent used is typically tetrachloroethylene (perchloroethylene), which the industry calls "perc" or "PERC". It is used to clean delicate fabrics that cannot withstand the rough and tumble of a washing machine and clothes dryer; it can also eliminate labor-intensive hand washing.
Index
NO. A B C D 1 2 3 4 PARTICULARS Preface Company certificate Acknowledgement Declaration Scope of the project Objectives Executive summary Industry profile 4.1 introduction 4.2 major segments 4.3 customs duty 4.4 excise duty 4.5 leading chemical units 4.6 news in chemical industry 4.7 export market 4.8 swot analysis 4.9 competitive advantage for India Company profile 5.1 site details 5.2 company view photo copies 5.3 history 5.4 mission 5.5 company layout 5.6 vision 5.7 company’s plan 5.8 production process 5.9 raw material storage and handling along with photo 5.10 policies 5.11 achievement certificate 5.12 organizational structure 5.13 departmental study 5.14 employees profile 5.15 green belt area with photo 5.16 photo copies of lab 5.17 swot analysis Learning Findings Conclusion Bibliography PAGE NO. 2 3 4 5 8 9 10 11 13 13 13 15 16 17 19 22
5
23 24 26 27 28 29 29 31 31 33 35 36 37 39 43 45 46 47 47 48 49
6 7 8 9
Lists of tables
NO. PARTICULARS PRODUCTION PERFORMANCEOF CHEMICALS GROUP WISE CAPACITY & PRODUCTION OF MAJOR CHEMICALS GROUP WISE EXPORT & IMPORT OF CHEMICALS ISCPL’S PRODUCTS PAGE NO. 12
1
14
2
14 30
3 4
Scope Company profile:
ORGANIZATION:
INDUSTRIAL SOLVENTS & CHEMICALS PVT.LTD. (AN ISO 9001 – 2000 ACCREDITED COMPANY )
ADDRESS :
FACTORY: PLOT NO – 7906 TO 7909, GIDC, ANKLESHWAR – 393002 TEL : (02646) 239549 (02646) 239553 (02646) 239554 FAX : (02646) 251173
HEAD OFFICE :
101, ATLANTA 209, NARIMAN POINT, MUMBAI – 400 021 TEL : (022) 22841178 (022)22841180 FAX : (022) 22871957
WEB SITE :
WWW.ISCPL.COM
YEAR OF ESTABLISHMENT :
1993
CHIEF FINANCIAL OFFICER :
MR. THOMAS ESSAW
AUDITOR :
J.K.SHAH & CO
BANKERS :
SBI IDBI
Objectives
The objective of this project report is to get knowledge about chemical industry. So, I have taken permission in industrial solvents & chemicals pvt. Ltd.At Ankleshwar, GIDC. So that I can get information about this company and also the Indian chemical industry, chemical products, segmentation of chemical industry in different products, export performance, policies etc. of chemical industry.
Executive summary
The chemical industry is a knowledge driven industry. This project gives the information about Indian chemical industry. SWOT analysis of Indian chemical industry gives the information about the strength, weakness, opportunities, & threats of the industry. Also it gives information about industrial solvents & chemicals pvt. Ltd. This project consists the induction of ISCPL also their mission , vision, policies, achievement, organizational structure. Different departments of the company and their management system , rules and regulation of the company. Which rules and regulation all employees must follow and what type of facilities company provides to its employees. also the methodology used for collecting the information.
Industry profile
Chemical Industry in India
Introduction:
? Chemical industry is one of the oldest industries in India. It not only plays a crucial role in meeting the daily needs of the common man, but also contributes significantly towards industrial and economic growth of the nation. The industry, including petrochemicals, and alcohol-based chemicals, has grown at a pace outperforming the overall growth of the industry. ? The global chemical market is estimated at approximately USD 1.7 trillion. Western Europe is the largest chemical-producing region followed by North America and Asia. ? The Indian Chemical Industry ranks 12th by volume in the world production of chemicals. The industry’s current turnover is about USD 30.8 billion which is 14% of the total manufacturing output of the country. The export of chemicals in the year 2002 was USD 5.875 billion, which forms almost 0.9 % of the world export of chemical products and about 13% of the country’s total export. Substantial proportion of these exports goes to the USA, Europe and other developed nations. Its contribution to the national revenue by way of custom and excise duties is about 20%. India is strong in basic chemicals that go into production of consumer items like paints, dyes, soaps, medicines, toiletries, cosmetics, etc. ? The Indian Chemicals Industry comprises both small and large scale units. The fiscal concessions granted to small sector in mid-eighties led to establishment of large number of units in the Small Scale Industry (SSI) sector. Currently, the Indian Chemical Industry is in the midst of major restructuring and consolidation phase. With the shift in emphasis on product innovation, brand building and environmental friendliness, this industry is increasingly moving towards greater customer-orientation. Even though India enjoys an abundant supply of basic raw materials, it will have to build upon technical services and marketing capabilities to face global competition and increase its share of exports. ? In terms of consumption, the chemical industry is its own largest customer and accounts for approximately 33 per cent of the consumption. In most cases, basic chemicals undergo several processing stages to be converted into downstream chemicals. These in turn are used for industrial applications, agriculture, or directly for consumer markets. Industrial and agricultural uses of chemicals include auxiliary materials such as adhesives, unprocessed plastics, dyes and fertilizers, while uses within the consumer sector include pharmaceuticals, cosmetics, household products, paints, etc. ? India also produces a large number of fine and specialty chemicals, which have very specific uses and are essential for increasing industrial production. These find wide usage as food additives, pigments, polymer additives, anti-
oxidants in the rubber industry, etc. Some of the important manufacturers of specialty chemicals include NOCIL, Bayer (India), ICI (India), Hico Products and Colourchem. ? The Dyestuff sector is one of the important segments of the chemicals industry in India, having forward and backward linkages with a variety of sectors like textiles, leather, paper, plastics, printing ink and foodstuffs. The textile industry accounts for the largest consumption of dyestuffs at nearly 80%. From being importers and distributors in the 1950’s, it has now emerged as a very strong industry and a major foreign exchange earner. India has emerged as a global supplier of dyestuff and dyes intermediates, particularly for reactive, acid, vat and direct dyes. As for a global production of dyes is concerned, India accounts for 6% of the world production. ? Chemical fertilizers and pesticides played an important role in the "Green Revolution" during the 1960s and 1970s. The consumption of pesticides in India is low in comparison to other countries. Indian exports of agrochemicals have shown an impressive growth over the last five years. The key export destination markets are USA, UK, France, Netherlands, Belgium, Spain, South Africa, Bangladesh, Malaysia and Singapore.
? Production performance of some of the important chemicals including pesticides and dyestuffs are given below:
Installed Item Capacity 31.3.2003 20032002-03 04(Estimated) Soda Ash 2042 1632 1673 1840 2004-05(Anticipated) PRODUCTION
Caustic Soda
1953
1520
1552
1707
Liquid Chlorine
1448
970
1012
1113
Calcium Carbide
86.50
49.00
45
50
Phenol
66.5
76.20
72
79
Methanol
385.00
362.10
366
403
Tech. Pesticides
144.95
68.17
68
75
Dyestuffs
52.70
25.90
27
29
(Source: from www.niir.org)
Major Segments:
Chemical Industry is highly heterogeneous with following major sectors :
? ? ? ? ? ? ?
Petrochemicals Inorganic Chemicals Organic Chemicals Fine and specialties Bulk Drugs Agrochemicals Paints and Dyes
Customs Duty:
? ? ? The peak rate of Customs Duty on most Chemicals is 7.5% On basic raw materials like acid grade fluorspar, sulphur, rock phosphate, natural borates is 5 On most building blocks & feedstock the duty is 5% (ethylene, propylene, crude, naptha, benzene, toluene, xylene, ethylbenzene)
Excise Duty :
On almost all chemicals the excise duty is 16%
Group-wise capacity & production of major chemicals in organized sector (Fig. in MT)
Main Groups
Inst. Cap. as on
March 2007 2001-02 3 4342305 374132 1166575 81803 24789 2002-03 4 4792345 403827 1352653 69565 26196
Production
2003-04 5 5070374 440608 1473855 85118 25940 2004-05 6 5271675 508157 1505895 93966 28498 2005-06 7 5474614 543965 1545262 82240 29541 2006-07 8 5268987 602309 1545442 84701 32552
1 I: ALKALI II: NORGANIC III: ORGANIC IV: PESTICIDES V DYES TOTAL MAJOR CHEMICALS (I+II+III+IV+V )
2 7072334 748615 1889448 145391 52591
9908379
5989604
6644586
7095895
7408191
7675622
7533991
GROUP - WISE EXPORT & IMPORT OF CHEMICALS (Figure in crore Rs)
Group TRADE 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07
INORGANIC CHEMICALS *
Export Import
1259 5730
1946 5579
1949 5916
2871 8130
3431 10446
3629 11473
ORGANIC CHEMICALS
Export
7624
10190
12975
16269
21504
25950
Import
8795
10695
14363
18785
22776
27330
DYEING, TANNING AND COLOURING MATTER
Export Import
2436 1138
2943 1344
3112 1617
3111 1878
3750 2245
4562 2720
PESTICIDES
Export
1356
1487
1746
2096
2791
2877
Leading Chemical Units
M/s.United Phosphorous Ltd, Mumbai M/s. P.I.Industries, Jaipur M/s.BASF India, Mumbai M/s.BASF India, Mumbai M/s. Excel India, Mumbai M/s.Atul Ltd., Bulsar M/s. Colour Chem. Ltd., Mumbai M/s. Sudarshan Chemical Industries, Pune M/s.Colourtex, Ahmedabad M/s. Monsantu Chem Ltd., Mumbai M/s. Jubilant Organosys Ltd., New Delhi M/s. Herdilia-Schentady Ltd. Mumbai National Organics Chemicals Ltd., Mumbai DCM Sri Ram Consolidation Ltd., New Delhi M/s. Gujarat Heavy Chemicals Ltd., Ahmedabad. M/s. India Glycols Ltd., New Delhi M/s. Gujarat Alkalies and Chemicals Ltd., Baroda M/s.Rayalseema Chemcials, Hyderabad M/s. Galaxy Organic Ltd., Mumbai M/s. Lubrizol Ltd., Mumbai M/s. ICI Calcutta
News in chemical industry
India Chemical Industry Outlook to be held in Mumbai
February 15th, 2008 - 5:09 pm New York, Feb 15 (ANI/Business Wire India): Chemical Week and the Indian Chemical Council have teamed up to create the first India Chemical Industry Outlook in Mumbai on April 15. The two-day event is the only chemical conference in India that addresses the full spectrum of issues impacting the country’s chemical sector at this important moment of expansion. The chemical industry in India is poised for rapid development in the coming years. India’s consuming middle class and the population’s disposable income are expanding, potentially driving growth of demand at exponential rates; the government has set in place special economic and investment zones for the chemical sector; and several of the country’s chemical and oil majors have announced aggressive investment plans. The India Chemical Industry Outlook, to be held in Mumbai, will take a look at key segments of the Indian chemical industry and explore the growth opportunities and challenges in each segment. India’s climate for mergers and acquisitions will also be examined. Mukesh Ambani, Chairman and Managing Director of Reliance Industries Limited, said, “The Indian market for petrochemicals will increase four times in the next ten years. It will witness a sustained double-digit growth rate. This growth would be faster than that of China.” Peter Huntsman, President and CEO of Huntsman Corporation, said: “India and Russia are the next two economies after China. Our business in India is growing at double-digit rates. Unless you have a foundation in India today, you will be too late.” “Chemical Week is leveraging its long experience in India and expertise in presenting events across Asia and around the globe to bring you an impressive roster of speakers and topics at this important event,” said Lyn Tattum, Chemical Week Publisher and Group Vice President. Topics to be explored include: – Government investment zones – Expansion plans of domestic companies – The challenges of bureaucracy, labor laws, and logistics – Opportunities in various chemical industry segments. (ANI)
Export market
FACTS OF INDIAN CHEMICAL INDUSTRY
? ? ? ? ? ? ?
13% of the total export 13% of the total industrial output & 7% of the GDP 10 % - 12 % growth per annum 2% of global chemical industry Indian pharmaceutical industry ranks 4th in volume & 13th in term of value in the world. India – a strong player in the generic pharmaceutical market India – 2nd largest producer of agrochemicals in Asia
INDIAN PETROCHEMICALS
? ? ? Domestic market size – US$700 million Fastest growing sector at 15% Reliance – key player in this market
Chemical industry in India: interesting facts
INORGANIC CHEMICAL ? Market size – US$260 million ? Growth rate – 9% ? 4.5% of global market ? Mainly used in detergent, glass, soap, fertilizer and alkalis
PHARMACEUTICALS ? ? ? ? ? India ranks 4th In terms of volume & 13th in terms of value. Domestic market size – US$450 million Indian market is 1.6% of the global market Domestic market growth rate – 8 to 9% Strong player in generic market--several of the world’s leading drug companies are based in Indian.
AGRO CHEMICALS AND FERTILISERS ? ? ? Domestic market size – US$88 million Domestic market growth rate – 10% annually 2.5% of the global market.
?
India is largest manufacture of basic pesticide chemicals among South Asia & Africa, next only to Japan.
SPECIALITY & FINE CHEMICALS ? ? ? Market size – US$860 million Major used in textile, leather, paper, detergent, rubber ?Paints, polyester, oil & gas. Growth rate – 10-12%.
DYES & PAINTS ? ? ? ? ? Market size – US$110 million. Growth rate – 12% Indian market is 6% of the global market Major used in Paints, inks, textiles, polymers. Highly fragmented market 25 large & medium players holding 50% of the market. Remaining 50% is with another small 2000 un-organized players
Swot analysis
The Task Force carried out a "SWOT" analysis of the Industry. This analysis comprised evaluation of individual Sub-sectors also. The summary observations of the Task Force based on this analysis are given below
Strengths:
? ? ? ? ? ? ? ?
A diversified manufacturing base having a capacity to produce quality chemicals from World class plants. Competitive Core Industries essential for the development of chemical industries Capability to produce World class end products Large domestic market Major raw material component sources within the country Good R&D base and quality human resources
Specific to Dyes and Dyestuff Industry
Strong base for producing various categories of dyes for different end use applications (Acid, Direct disperse, Azoic, Reactive and VAT dyes etc.) Globally competitive Dyestuff industry catering to nearly 95% of the domestic demand of Dyes.
Specific to Agrochemicals Industry
?
Key producers have direct access via distribution to the market
Weakness:
? ? Cost of Power: Very high cost of power, unreliability of supply and frequent
interruption. Transmission and distribution losses are very high
Cost of Finance:
Chemical Industry is highly capital intensive, cost of finance in India is very high; interest rates are 14% - 15% p.a. as compared to 2% to 6% prevailing in developed countries. Infrastructure:India ranked 55th in infrastructure development in the global competitiveness report 1999. Infrastructure facilities are not of world class. Transport and communications are complex resulting in delays and slow movement of goods. In-adequate port facilities result in high demurrage costs. For example turn around time for Vessels is an average of eight days in India as against one or two days in Singapore Scale of production: Due to earlier policy of import substitution and industrial licensing, Chemical plants in India were built to cater to the domestic requirements. The per-capita consumption in India is less as compared to other countries and hence plant sizes are not comparable to World scale operations. Major Competitors abroad enjoy economies of scale advantage. Technology: In the days of sheltered economy, up-gradation of technology was not critical. Bulk of the Pharmaceutical Industry has grown by concentrating on processes modification rather than basic research. Investment in R&D with a view to generating intellectual property is absent. A change of mind set is needed to invest in R&D to be able to sell value added product and compete in developed countries Cost Disadvantages: Industrialization was spread throughout the country to redress regional imbalances as also for the development of backward areas. However, this has created locational disadvantages, such as extra transport cost for raw materials as well as finished products. Cost of raw materials and catalysts in India is also high as compared to international levels. Multiplicity of Taxes: Indian exporters at present are placed at a considerable disadvantage vis-a-vis their foreign competitors on account of multiple levies (various taxes and duties like sales tax, turnover tax, , service tax, electricity duty and cross subsidies, etc.). Value Added Tax (VAT) must replace multiple taxes to create a level playing field.
?
?
?
?
?
?
Labour Laws: Labour & Industrial relation laws at present do not allow flexibility in deployment of Labour. This discourages modernization and investment in technological changes and eventually leads to industrial sickness thus adversely affecting workers as well.
Specific to Dyes and Dyestuff Industry
?
Traditionally Indian manufacturers have been in the commodity dyes business. No efforts for new product development or new application of technology were made (low value addition and value realization The industry, on account of its small size, finds it tough to compete in high margin products with global players, who can offer personalized buyer support on account of their diversified product base and investment in application development
?
Specific to Agrochemicals Industry
?
Likely restrictions on use of Organo Phosphorus Esters on specific crops / indications in certain developed countries may adversely affect the demand for this sector thereby lowering capacity utilization.
Opportunities:
?
A decade of economic reforms has tested the resilience of the Indian Chemical Industry. Individual enterprises have realized their weaknesses and are gearing up to face the new challenges. Success stories in dyes and Agrochemicals have boosted the confidence to take on global competition squarely In certain categories of chemicals, we do have advantage for exports (Dyes, Pharma, and Agrochemicals). By creating strategic alliances with countries like Russia and CIS countries. With the know how available in the country, there is a tremendous potential to grow and increase exports in dyestuff and Agrochemical market India has the capacity for major value addition being close to Middle East. This is a cheap and abundant source for Petrochemicals feedstock
?
?
Specific to Dyes and Dyestuff Industry
?
Stringent environmental laws in the Western countries have led to discontinuance of production of certain dyes for textiles and leather. Climatic conditions in India are favourable for the manufacture of such products and export of the same in an eco-compatible manner Policy of American and European Companies to outsource the lower value products from Non-Traditional Suppliers (NTS) countries like us has increased demand for dyestuffs. This can be exploited aggressively Demand for Disperse dyes and Vat dyes is expected to grow in future
?
?
Specific to Agrochemicals Industry
? ?
Huge potential in Indian Market exists as the per capita agrochemicals consumption in India is much lower than the World average. International companies could use India as production base for domestic market and outsourcing, provided proper IPR regime is in place.
?
It is also possible to employ resources to focus on investment in basic research and development programmes to discover new molecules, safer formulations and processes Potential for use of Biotechnology in the manufacture of agrochemicals can lead to tapping the growing global market for Bio-pesticides.
?
Threats:
As per the WTO agreements, peak customs duty has been brought down. Quantitative restrictions for imports have been removed already. Most of the chemicals are now in the Open General List (OGL) of imports. As a result imports of chemicals, intermediates and end products are freely allowed in the country. Even at these reduced levels of import duty tariff levels in India for most chemicals are significantly higher than other countries manufacturing the chemicals. There would certainly be pressure on the Government to reduce these tariffs levels. In case these levels are reduced competition in the Indian Chemical Industry would become more intense. The users would buy their requirements from the most competitive source. Unless the Indian industry acquires competitiveness, it may face extinction
Specific to Organic Chemical Industry
?
Most of the manufacturers in the unorganized sector need to be better informed about the pollution control measures that could put a halt to their production activity at any time China, a major competitive threat, is investing heavily in infrastructure (they are adopting the cost-effective German model). It would not only overtake India in current export territories but could also invade Indian market with cheaper imports
?
Specific to Dyes and Dyestuff Industry
? ?
Stiff competition from China, Korea and Taiwan Recession in end use industries e.g. The Textile industry (which is the major market for dyestuff industry) is facing a big crisis which has affected the dyestuff industry
Specific to Agrochemicals Industry
?
Large capacity for Organo Phosphorous compound are being set up in China; with economies of scale pushing domestic prices downwards
Competitive Advantage for India :
As a result of the SWOT analysis in the previous paragraph, the taskforce felt that the competitive advantage for Indian chemical industry lies in the following areas. These advantages would have to be urgently exploited to become globally competitive
?
One of the largest resources of scientific and technical manpower in the world
? ? ?
Large Domestic Market for various sectors of chemicals A developed financial market comprising regulated stock exchanges, all types of money instruments and capable of transacting business at a very fast speed Largest English Speaking population in the World and rapid growth in Information Technology can provide competitive access to the rich European and American market
Company profile
INDUSTRIAL SOLVENTS &CHEMICALS PVT. LTD.
PIOT NO. 7906-7909, GIDC INDUSTRIAL ESTATE, ANKLESHWAR . DIST-BHARUCH-393002 GUJARAT
( AN ISO 9001-2000 ACCREDITED COMPANY )
SITE DETAILS :
LOCATION :AS ABOVE PLOT AREA : 47,440 SQ.METER GREEN BELT AREA : 9,000 SQ.METER BARODACITY
IMPORTANT PLACES AROUND ANKLESHWAR ARE: BHARUCHCITY SURATCITY
THE NEAREST LARGE CITY :IS SURAT , WHICH IS ABOUT 62 KM AWAY THE PROJECT SITE. ANKLESHWARCITY :IS 4 KM AWAY FROM THE PROJECTSITE WITHIN 10 KM INFLUENCE ZONE : NO DEFENSE INSTALLATION NO NATIONAL PARK NO ECOLOGICALLY SENSITIVE AREA
Company view
HISTORY OF ISCPL
? ISCPL is a company incorporated under the company act 1956 having its registered and head office situated at 101, Atlanta, 209 Nariman point, Mumbai -400 021 on Mumbai.
It was the year 1960, the company had started the manufacturing activities at Thane in Maharashtra by putting up its first plant for the manufacture of Ether solvents I.P/B.P. during the sub sequent years, the company has added other products in the range of manufacture and put up the plants for the manufacture of Ether Anaesthetic I.P/B.P , Dimethyl sulphate, Dimethyl aniline,Ethyl benzyl aniline etc. it is a matter of pride to recall that the manufacturing unit at Thane had received excellent industrial safety performance awards, consecutively for 3 years (1995 to 1997) from Thane manufacturers association. The said certificate was jointly signed by the chairman of Thane manufacturers association and the joint Director, Directorate of industrial safety and health,Thane. The products manufactured as well as the raw materials used by the company are Hazardous and inflammable over the years, thane has become very much congested. Consequently it was becoming more & more difficult for the company to continue the manufacturing activities of these Hazardous products in this congested city of Thane. Further, though there was a growing demand for the products, there was no scope for any expansion for the reasons stated above. In the circumstances, as a prudent step , the mgmt had decided to start a second manufacturing unit at Ankleshwar in Gujarat . thus, a plant was put up for Dimethyl sulphate in the year 1994 , followed by other plants for the manufacture of N.N.Dimethyl aniline , Ethyl benzyl aniline , Diethyl sulphate, Ether solvents, I.P/B.P, during the subsequent years . ISCPL have developed most of the products by their own R & D department and some of the products from reputed consultants.
Mission
The chemical industry today is going through a consolidation phase. In the coming years, India will be a major player in the world chemical intermediates market.
Industrial solvents & chemicals Pvt. Ltd. Believes that its strengths are in manufacturing. Intermediates & handling Hazardous chemical and in the future will continue to do the same. Its strategy is to be a world class and world capacity manufacturer of specialty chemicals, it will continue to make value added products over the years and provide the chemical industry basic chemicals & intermediates at competitive rates. Chemicals are an indispensable part of our human life. Having successfully completed a decades in the field of manufacture of Hazardous chemicals, it has provided its with a lot of Enthusiasm. Its success has given it the courage to continue to grow and meet the existing and the exciting challenges of the new millennium.
Company layout
STROAGE TANK
BOILLER HOUSE
D M S P L A N T
EBA PLANT
ADMIN OFFICE
D S P L A N T
SULPHARE PLANT
E T P P L A N T
S T O R E ETHER PLANT
P O W E R H O U S E
G A R D E N
GARDEN
OCCUPATIONAL HEALTHCENTER SECURITY OFFICE
G A R D E N
S U L P H A R E YARD
GATE
vision
Today industrial solvents & chemicals Pvt. Ltd. Is one of the largest manufactures of a range of intermediates which has application in the pharmaceuticals , dyestuffs, agro chemicals and other related industries . today the plant of ISCPL is per the international standards having large capacities and state of the art manufacturing facilities and quality control equipment to ensure production as per international standards . As on today, ISCPL exports almost 40% of its production to reputed international companies in U.K., SPAIN, FRANCE, GERMANY, USA, JAPAN, TAIWAN, KOREA AND BRAZIL. Exports are done based on customer’s requirements. In UN approved drums or ISO tanks which are leased from international companies to carry Hazardous cargo.
Company’s Plan
In order to meet the growing export and domestic market demand of chemicals and having sufficient space for additional manufacturing facility for chemicals in existing plant , ISCPL propose to expand manufacturing activities by increasing production capacity of chemicals to 46027 mt/month from the existing capacity of 16392 mt/month. For this proposal company has received permission from government.
Water requirement
The entire water requirement is met from GIDC water supply.
Company’s products
SERIAL PRODUCTS PRODUCTION
NO.
1 2 3 4 5 6 7 8 9 DIMETHYL SULPHATE (DMS) N.N.DIMETHYL ANILINE (DMA) DIETHYL SULPHATE (DES) N-ETHYL ANILINE (NEA) ETHYL BENZYL ANILINE(EBA) DIETHYL ANILINE(DEA) ETHER SOLVENT (ES) ETHER ANAESTHCTIC (EA) MONO ETHYL METATOLUIDINE & DIETYL META TOLUIDINE(MEMT&DEMT) ABSOLUTE ALCOHOL MONOMETHYL META TOLUIDINE & DIMETHYL META TOLUIDINE (MMMT& DMMT) METHYL BENZYL ANILINE (MBA) MONO ETHYL ORTHO TOLUIDINE (MEOT) ETHYL CHLORIDE SPENT SULPHURIC ACID 65% N-METHYL ANILINE(NMA) DIMETHYL PARA TOLUDINE(DMPT) CHLORO SULPHONIC ACID (CSA) SULPHUR TRIOXIDE (SO3)
CAPACITY ( MT/MONTH )
3,000 600 500 100 60 100 500 15 25
10 11
100 10
12 13 14 15 16 17 18 19
10 10 2 800 30 30 1500 9000
? All this products are used in production of colours, dye industries, basic chemical, fertilizer industries, pharmaceuticals (drugs) in other company.
PRODUCTION PROCESS
```````` RAW MATERIAL RECEIPT
QUALITY CONTROL ANALYSIS
UNLOADING
PROCESS
FINISH PRODUCT
STORE
SALES
Raw material storage and handling
? The major raw materials are received in road tankers, Hdpe drums as well as some of the chemicals in gunny bags. ? Some storage tanks of hazardous flammable substances are located with in premises in separate storage area. E.g. solvent farm area. (Separate hazardous flammable storage facility available as per the explosive act) ? Solvents like methanol & ethyl alcohol are stored in under ground ms tanks as per the statutory requirement with all the precautionary measures. ? Large area is covered by well-designed warehouse, which is containing store office, raw material store, finished product store etc.
Hazardous waste management
? All the solid and hazardous waste generated from plants will be stored and disposed as per GPCB & CPCB rules/guide lines.
Raw material storage area
policies
Quality policy
? ISCPL the manufacturers of chemicals & drugs are committed to comply and continually improve the quality mgmt system so as to supply products meeting quality standards to meet or enhance customer satisfaction. ? This shall be achieved by strict monitoring of quality systems, straight process controls, application of statistical quality controls, team work and involvement of all personnel with utmost concern for safety and conducive environment.
Environmental policy
? ISCPL is in business of manufacture of quality chemicals under stringent process controls. ? It is committed to meet or exceed the regulatory requirements related to environment. ? It shall endeavor in the following areas ; ? Prevention of pollution ? Promote recycling & recovery of materials ? Resource conservation ? Enhancing awareness about importance of environmental protection amongst employees, vendors, customers & surrounding public. ? Minimize the environment aspects & impact of its products, process of service. ? It shall commit resources conservation for maintenance & promotion of environment & prevention of pollution at its site.
Health & safety policy
? The mgmt believes that the safety of employees ranks in high importance with production, product quality & costs while the maintenance of safe working condition & operating procedures in their plant can result in significant savings, they believe that human values are of greater importance to employer, employees and surrounding community. ? Mgmt recognizes the need for maximum safety and responsibility by providing the safe conditions for their employees to avoid accidents. The main object of their safety policy is to avoid accidents & to maintain neat, clean, safe, healthy & attractive working conditions and to train & motivate their people for safe work practices & to comply with statutory safety provisions. Lastly, no job is so important and no order is so urgent that they can not take time to perform their work safety. ? It shall be the policy of ISCPL to prevent injuries to employees and control damage to property by conducting all operations safety. Safety
starts from the planning stage and continues through design, purchase, storage, fabrication, construction, installation, operation & maintenance. It is an integral part of each and every job and operation. ? All practical steps shall be taken to maintain safe and healthy work / working environment by building in safety and healthy conditions. Safety and loss prevention are the direst responsibility of all levels of mgmt / supervision & are important measures of managerial / supervisory performance. This responsibility has been accepted by every one who conducts the affairs of ISCPL no matter in what capacity he may function.
Achievement certificate
This certificate was awarded from BUREAU VERITAS PVT. LTD. For management system of the ISCPL was as per the requirement of standard ISO 9001:2000.
Organizational structure
DIRECTORS
DIRECTOR PURCHASE/ MARKETING/ ACCOUNT DEPT.
WORKS DIRECTOR
SENIOR PRODUCTION MANAGER
ELECTRICAL INSTRUMENT/Q UALITY CONTROL/ ADMI. / STORE
PLANT MANAGER
PLANT INCHARGE
SHIFT INCHARGE/ SUPERVISOR
PLANT OPERATOR
Departmental study
Head persons in each department
DESIGNATION MARKETING MANAGER DIRECTOR FINANCE PRODUCTION MANAGER LABORATORY INCHARGE ADMIN. STORES DESPATCH PURCHASE
NAME OF PERSON C.A.JONSAN THOMAS ESSAW ARVIND PATEL B.J.PANDIT M.J.PATEL M.C.RANA ULPESH R. SHAH VAIBHAV S. PATIL
Introduction of the departments :
(A) PLANTS :
THE COMPANY CONSISTS OF THE FOLLOWING PLANTS: 1} DIMETHYI SULPHATE (DMS) 2} DIMETHYI ANILINE (DMA) 3} ETHYL BENZYL ANILINE / DIETHYL ANILINE (EBA/DEA) 4} ETHER SOLVENT / ETHER ANAESTHETIC 5} DIETHYL SULPHATE (DES) 6} SULPHURIC ACID
(B) MECHANICAL:
Maintenance of all plants and machinery and other erection works are carried out by this department. (C) PERSONNEL & ADMINISTRATION: Interviews, recruitments, attendance recorde, salary payments, leave records etc are handled by p & a dept. also the general administration comes under this department. All the statutory and other records related to the above are maintained by this department.
(D) STORES:
The stores department consists of raw material, packing materials, laboratory chemicals and the engineering items. As regards raw materials, based on the monthly production planning, purchase department arranges procurement. However, with regard to packing materials, laboratory chemicals and engineering items, indents are placed by the stores based on which the purchases are arranged. All the necessary records with regard to the receipt, issue and the balance are maintained by the stores department. Material is issued against requisition slips.
(E) DESPATCH:
The dispatch department consists of local sales as well as export dispatch schedules are sent from the sales / export departments based on which dispatches are made. Since the end products are excisable, the relevant central excise records along with other records connected with the production and dispatches are maintained by this department.
(F) PURCHASE:
Based on the monthly production plan, the purchase department plans the purchase for the month in respect of raw materials & important packing materials. As regards the laboratory chemicals and engineering items, the purchase is made based on the indents received from the stores department. Delivery schedules are coordinate with the production programmes.
(G) MARKETING (LOCAL & EXPORT) :
Marketing department consists of local sales as well as export .based on the purchase order received, as per the requirements, despatch schedules are sent to factory along with relevant instructions based on which the dispatch department at factory arranges the dispatches. All the necessary details such as name of the party, basic price, mode of dispatch, payment terms etc. are incorporated in the dispatch schedule sent by the marketing department.
Every morning company conducts meeting of each department head personnel.
Employee profile
Rules / regulations / facilities
? Interviews / recruitments :
Interviews for the various positions are conducted at factory, appointment orders are issued to each and every employee & the service conditions are governed as per the terms & conditions, mentioned in the appointment order. ? Joining reports : Each employee has to submit joining report and the necessary format is available with personnel and administration departments. ? Attendance : Each & every employee is provided with a punching card & the entry and exit are recorded by punching the security gate. Based on the above, the salary & overtime are prepared for the month. Necessary muster roll is maintained as per the statutory requirements. ? Salary /O.T.payment : Employees are paid their salary /o.t. on or before 7th of every month ? Identity cards : Employees are provided with identity cards giving the particulars such as name of the company, name of the employee, designation, dept. etc. all the employees are required to carry the same with them. ? Provident fund : All the employees are covered under employees provident fund scheme 1952 and the same is applicable from the date of joining. The eligibility, rate of deduction etc. will be strictly as per the provisions of the act. ? Employees state insurance scheme : The employees are covered under employee’s state insurance act.1948.
Today ISCPL is in very competitive world and to with stand the global competition, it has to run the company with optimum efficiency. Various rules/ regulations/ guidelines are framed by the company from time to time for the smooth operation. All the employees are advised to follow and observe all such rules and regulations framed so as to enable the company to achieve maximum effiency. ? Dress code :
The company provided two pairs of uniform per annum to all the employees and they required wearing the same while on duty. ? Safety requirements : The objective of the company is to achieve safe working conditions and healthy environment. Therefore, it is mandatory for all the employees to wear safety shoes, helmets, and goggles etc. which are provided by the company. ? Promotion/ termination/ resignation : The company believes in giving encouragement to the existing employees and therefore promotions are given to the existing employees depending on the merits/ performance. The appointment order contains guidelines with regard to resignations and terminations. ? Timings : The factory is working in all the three shifts, as all the plants are continuous process plants. The details of shifts and the timings are given below: Shift: time A 7.00 hrs to 15.00 hrs B 15.00 hrs to 23.00 hrs C 23.00 hrs to 7.00 hrs D 9.00 hrs to 17.30 hrs All the employees working in plants up to the level of production. Officer are working in shifts (a,b,&c). As regards the office staff including the stores, plant engineers and managers are working in general shifts. At the beginning of every month, shifts schedule is prepared and employees are required to work in shifts as per the schedule. ? Siren : The factory has installed a siren to announce the beginning and end of shifts as per the details given below: 7.00 hrs – starting A shift & end C shift 9.00 hrs - starting G shift 13.00 hrs – lunch break of general shift 13.30 hrs – end of lunch break 15.00 hrs – end of A shift and start of B shift 17.30 hrs – end of G shift 23.00 hrs – starting C shift & end of B shift In case of emergency also, siren is used to inform the employees and in such case, the siren will be sounded continuously for 2 minutes. All the employees are required to come at the assembly points in such situation.
? Department wise training checklist : Employees working in different department are given periodical training and necessary check lists of the training are maintained. ? Training records on induction training : Induction training is given to each and every employee on their joining the service and records of the same are maintained separately. ? Mock drill : Even if you have the best safety policy/ system, accidents may happen and therefore we should be prepared for such eventualities. To prepare all the employees for facing such situations, mock drills are conducted regularly to get the necessary training .records of such drills conducted are maintained. Mock drills also make assessment of preparedness of the employees to face and act during emergency situations.
? Safety measures provided : ? The personnel protective equipment like hand gloves, gumboot, goggles, helmet, clothing, self breathing apparatus, etc. are provided to those handling hazardous chemicals as per requirement. All motors & electrical connections are of flameproof. All electrical installations are provides with double earthings. Flameproof equipments & fittings are provided for handling of inflammable chemicals & solvents. All storage tanks, pipelines & joints carrying solvents generating static charges are provided with double earthing. Road tankers & unloading lines are provided with double earthing. Process, equipments & plant involving fire hazards are designed as per prescribed guidelines. Flameproof pumps & motors are provided for solvent transfer. Sufficient access for firefighting is existing in the plant. Banning of mobile in the plant.
? ? ? ? ? ? ?
? Medical facility : ? ? ? ? ? Per employment medical check up Medical check up of all employees done regularly as per statutory requirement. First aid box is available with necessary medicines for each department. All the employees are covered under ESI & other medical insurances scheme Vehicle/ van facility available in case of emergency
? ? ?
Full fledged occupational health center provided Services of part time qualified medical officer available at any time Nearest hospital is MODIHOSPITAL and its phone no. is (02646)222220 /224550
? Social welfare activities : ? ? ? ? ? ? Public liability policy under PLI acts for factory surroundings. Public liability policy under PLI acts for the transportation of products. Distribution of food packets, water pouch during Surat floods. Distribution of food packets , water pouch during national calamities in surrounding areas Workmen welfare activity such as books, cloth & other financial aids to the family Tree guards for plantation the trees in the estate and nearby areas.
Green belt
? ? Company also gives special thrust for plantation & developing the greenery. ISCPL has developed green belt within factory premises. Total land area available at the existing site is 47,440 sq.meter; out of this area about 4,000 sq.meter area is covered as greenbelt and other forms of greenery.
? ? ?
There are 510 nos. of fully grown trees & other ornamental plants with in factory premises Company is planning to grow more trees in existing greenbelt area and also proposing additional 5,000 sq.meter area for greenbelt So that after proposed expansion approximately 9,000 sq.meter area shall be greenbelt.
Green belt area
Photo copies of lab
Research methodology and swot analysis
Research methodology used for data collection is primary data collection method & interview method for collection of data.
SWOT ANALYSIS
Strength:
? ? ? ? ? ? ? Many years experience in this industry Dedicated and responsive staff Monopoly in production Quick support from staff Good infrastructure facility Large domestic market Good R & D base and quality human resources
Weakness:
? ?
Need of large investment in plant ISCPL is a chemical manufacturer so employees turn over ratio is high so some times company can not get enough manpower for proper production
Opportunities:
? If company will receive permission from government for expansion of business than company’s production will increase and company will capture more market share
Threats:
? ? ?
Due to the diversification of various players in chemical this segment has become highly competitive Speedy changes in technology All plant’s manager are masters in production planning . if other company will offer high salary to them and if they will leave the company than company’s monopoly will reduce
Learning
? ? ? ?
I got practical knowledge about working in the chemical company. I also came to know regarding the environment of organization. I have understood the system of working of the organization. I also got the opportunity to work with the higher-level people
Findings
Company has monopoly in production of all products. so management has not given permission to me for enter in production plant and also does not give information about inventory management, name of the machinery used in production process.
Some Slogans of the company
? ? ? ? ? ? ISC BELIVES IN SAFEY SAFETY HAS NO HOLIDAY PRODUCTION MUST BUT SAFETY FIRST SAFETY IS A WAY OF LIFE SAVE (YOUR LIFE, YOUR FAMILY, YOUR INDUSTRIES ) SAFETY – THE MEASURES OF SUCCESS.
Conclusion
So, according to the above all data of report I conclude that company’s management system is very best and also company takes many steps for awareness of its employees and also for society. Company is very strict for safety, its slogans indicates its strictness about safety. Company provides many facilities to its employees it is very good. Also company follows the all rules and regulations of government. Company has to takes more steps for reduce the employees turnover ratio. so company can keep its monopoly. ISCPL follows the all rules and regulation of government so govt. should gives permission to ISCPL for expansion of business so company can increase its production and increase the export market of India.
Bibliography
Websites:
? ? ? ? www.niir.org www.indianchemicalportal.com www.energymanagertraining.com www.cacci.org
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