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APROJECT REPORT
INTATA CHEMICALS LIMITED, MITHAPUR
FROM 24TH APRIL to 9TH JUNE
Prepared byMs. TANVI. J. FALDU .,
MBA SEM II,ROLL NO : 10
ACADEMIC YEAR : 2007-08
PROJECT GUIDE :Mrs. NIHARIKA BAJEJA
SUBMITTEDTO
T. N. RAO. COLLEGE OF MANAGEMENT STUDIES ,SAURASHTRA UNIVERSITY, RAJKOT
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S T U D E N T D E C L A R A T I O N
I the undersigned student Hirapara Shailesh .B of K.K. Parekh
Institute of Management Studies Amreli M.B.A. II Semester,
hereby declare that, the project on TATA CHEMICALS LTD. is my
own work.
In the partial fulfillment of Master Degree of Business
Administration, I had undergone project work at TATA CHEMICALS
LTD. under the guidance of Miss Ripal Madhani K. K. Parekh Institute
of Management Studies Amreli and submitted to Miss Ripal Madhani.
This project work is my original work and has not been submitted to any
where earlier.
Date:- Thanking You,
Place: - Amreli Yours Faithfully
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(Hirapara shailesh)
PREFACE
This project is prepared for when I take industrial visit at TATA
CHEMICAL LTD. MITHAPUR
It is a very well known proverb that The practice makes a man
perfect. As per this proverb we can say that one can only become perfect
by practicing. He or she need to have enough knowledge of practical
implementation in the current scenario of the theoretical knowledge.
As a student of management I have studied many theories in classroom but
after taking Industrial visit, I have experienced and understood it in it fullest
sense which plays a vital role in business field.
Hence, this report is been designed with the objective to gain practical
exposure and to know the motivational analysis of organizational climate.
During the industrial visit I met various functionaries of organization and
interacted with them. I sincerely thank them all whose cooperation and
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guidance enriched my knowledge and this report was made possible
SOUND BECOME MUSIC IF A TRAINED PEOPLE USE IT
ACKNOWLEDGEMENT
Experience is the best guide. I was lucky enough to have take visit
for one day at Excel Crop Care Ltd. It provided me the best opportunity
to learn things first hand. It enables me to apply the theoretical knowledge
and experience the results..
It is very necessar y to have a guide when you are a fresher in the
corporate world because that helps us in finding our way our goals easily.
I would like to express my sincere thanks to all the TATA
CHEMICALS LTD. without their support, this project would not have
been a success.
I would also like to acknowledge and appreciate the guidance given to
me by Miss Ripal Madhani Faculty Members of K.K.Parekh Institute of
management Studies.
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INDEX
INTRODUCTION
COMPANY PROFILE
HISTORY OF THE COMPANY (In Brief)
PRODUCT PROFILE
NATURE AND SCOPE OF PRODUCATION ANDOPERATION MANAGEMENT
MANUFACTURING PROCESS
PRODUCTION CAPACITY AND MANAGEMENT
PRODUCATION PLANNING
LAYOUT OF THE COMPANY
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INVENTORY MANAGEMENT
QUALITY MANAGEMENT
CONCLUSION
COMPANY PROFILE
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Mithapur 361 345
Okhamandal, Gujarat
Tel: (02892) 665 991 / 665 992
Fax: (02892) 223 471
History of TATA chemicals Ltd
The TATA chemicals mithapur , The company that care is one of
its kinds in the world and the companys fertilizer division in babrala is
among the best industrial units in India thats a long way to come from
modest beginnings and it is testimony to the vision and ability of the
pioneers who get tata chemical up and running.
Tata chemical was born in 1939, the year world war-2 the two
consignments were sunk of sea and ordered from Sweden, a natural
country, but the war almost claimed that too. The early years of Tata
chemical were disastrous an international. Expert told to J.R.D. Tata the
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owner of the industry. You are in the wrong place doing the wrong job
the Formula that helped Tata chem. Turn the corner of the production was
Well-guarded sere of about six companies in the world, but Tata chemical,
cracked the Code, it then began negotiating with a German firm to raise its
production capacity From 80 to 200 tones of soda ash per day when a 31
year old chemical engineer called Darbari Seth, fresh from a stint in
America, told managing board that India did not Need foreign help we can
do it, He said, and what is more, we said, and what is more we should
aim not at 200 tones but 400 tones of the 10 members on the board, Only
one person agreed with him J.R.D.
Mithapur, the city of salt, is the mother Indias heavy chemical
industry, in the late 1920, kapil ram vakil, a chemical engineer established
the okhamandal salt works later he setup A soda ash plant of the site
company also has a slogan for the Tata salt Hum Des ka Namak Khate hai,
Hum des Ka Namak Banate hai.
After the survey of the western coast, kapil ram vakil, a chemical
engineer, decide on a point seven miles from okha, the western most tip of
India where the Arabian Sea Meets the Rann of Kutch but he could not bear
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the financial burden of running the plant for long. And approached the Tata
then the maharaja of Baroda sayaji roa in whose territory mithapur fall, also
where to the Tata suggesting that they might like to assist with national
project.
The company is growing to its destination fifty years back, mithapur was a
desolate Place providing little to the material tribe that inhabited its
neighborhood with the induction of industry these sturdy people have found
a means of livelihood in December 1963, when prices of heavy chemical
were decontrolled the company Reduced its prices much to the annoyance
of its competitors mithapur expanded its Capacity to 1000 tones of soda ash
per day and today produce 2400 tones later when There was a surplus of
soda ash in the market 2000 more customer registered with the Company it
also generates 1000 (tones per day) of vacuum evaporated salt and 33 other
product.
Tata chemical spread its writing in 1994 with commissioner of its
fertilizer division at Babrala in utter Pradesh. Today it has an installed
capacity of 2250 tpd of urea and 1350 tpd of a ammonia. The company
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arranged for suitable treated seawater to replace fresh water in plant
operation and it put in place a thoughtful recycling.
Arrangement and other innovative methods of solving on water the
company has established seawater plant named equalization plant
consumption was reduced from 22 lakh gallons per day.
TCLS slogan is leadership with trust which is not merely a slogan
but the Originality of the company our heritage of returning on society
about evokes that is trust among customer, employee, share holder and
community.
The organization which embarks upon quality management system,
certificate (such as ISO 9000 or demanding prize) Formulation and
dissemination of quality policy is required first step for certification TATA
was certified by ISO 9000 in 1996. As ISO 9000 is certified like that safety
department is certified by OSHAS 18001occupation safety and health
assessment services. In the technological world to stay in Competition to
implement ERP package of oracle and after words means in 1999 they are
working on Sap at present the turnover of soda ash is more than 2000 tones
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TEAM OF TATA CHEMICALS
Chairman Ratan N. Tata
Vice-chairman R. Gopalkrishnan
Managing director Homi R. Khusrokhan
Directors Nusli Wadia
Dr. D. V. Kapur
P. R. Menon
Dr. T. Mukherjee
Dr.Vijay L. Kelkar
Nasier Munjee
Dr. Yoginder K. Alagh
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PRODUCTS
CHEMICALS
One of India's leading manufacturers of inorganic chemicals, TCL's
products and production processes are benchmarked with the best of global
touchstones and meet the most rigorous international specifications
The company's state-of-the-art manufacturing systems are backed by a
highly efficient and committed marketing team. The chemicals strategic
business unit (SBU) of Tata Chemicals, oversees both forward and
backward integration across a wide spectrum of products and business
segments
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The Chemicals SBU comprises
Soda ash
This multipurpose chemical is used in a variety of industries, most
prominently in the manufacture of glass, where it reduces the melting
temperature of the sand used in glass formation and helps in the
'workability', or shaping, of glass articles.
Soda ash is also a major ingredient in the making of soaps and
detergents. Here it is employed as a builder, or filler, to give a smoother
surface in formulations of soaps, detergents and other cleaning compounds.
This resourceful alkali, the least expensive of soluble alkalis, is widely used
in the production of other chemicals. Soda ash is used in mineral processing
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in mining, pulp and paper manufacture, the making of sodium compounds,
water treatment, metal refining, textile processing, cleaning preparations,
petroleum and metallurgical refining, iron and steel, aluminum, and drugs.
Cement
Cement is a major success story for TCL, and a fine example of how the
company's philosophy of 'avoid, reduce and recycle' operates.
The cement plant at Mithapur was set up solely to consume the solid
waste generated during the manufacture of soda ash. The plant has an
installed capacity of 1,500 tonnes per day and it manufactures three
varieties of cement: Ordinary Portland Cement (grades 43 and 53) and
Pozzolana Portland Cement (under the Shudh Cement brand name).
Caustic soda
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Due to its adoption of energy-efficient, membrane-cell technology
and the captive availability of salt and of power, TCL has been able to
deliver low-cost caustic soda to the market.
As a versatile alkali, caustic soda is used in a variety of industries, the
major ones being rayon, cellophane, soap, pulp and paper. Apart from
caustic soda, TCL also produces hydrochloric acid and liquid chlorine.
Bromine
TCL manufactures several variants of bromine and bromine-based
compounds, such as liquid bromine technical, potassium bromide PQ,
sodium bromide PQ, methyl bromide, ethyl bromide and hydrobromic acid.
FOOD ADDITIVES
Tata Chemicals' food additives strategic business unit has two of the
company's premium product groups under its wing: branded salt and
sodium bicarbonate. Widening the product range and increasing market
share is the two-pronged thrust in this sphere
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Salt
TCL makes 3,50,000 tonnes of vacuum-evaporated iodised salt
annually at its Mithapur complex, the largest and most integrated chemicals
facility in India. The company manufactures four varieties of salt: iodised
salt, crystalline salt, vacuum salt and pure salt.
Tata Salt, the outstanding offering in TCL's food-additives basket, is
a household name with top-of-the-mind brand recall and a 41-per cent share
of the Indian branded iodised salt market, way ahead of the nearest
competitor. It has consistently proved its mettle by being rated in the top 10
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most trusted brands in the survey conducted by The Economic Times ,
India's largest financial newspaper. Tata Salt was named the 'No.1 Food
Brand' in 2003.
Crystalline salt
Samunder Crystal Salt is a refined, iodised, clean, white crystal salt.
It offers customers a purer and cleaner alternative to the loose, unbranded
crystalline salt widely available in Indian markets.
Sodium bicarbonate
TCL's sodium bicarbonate plant has a capacity of 50,000 tonnes per
annum. The company produces three varieties of sodium bicarbonate -
sodium bicarbonate technical, sodium bicarbonate refined and sodium
bicarbonate granular - all of which meet stringent quality standards.
The company markets its sodium bicarbonate products in India, the Middle
East, Africa and Bangladesh.
Cooking soda
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Tata Chemicals has launched a branded cooking soda sold in small,
single-use sachets under the brand name Tata Samunder Cooking Soda.
Cooking soda is an ingredient already familiar to Indian consumers but so
far, it has only been available in an unbranded form and is purchased either
loose or in unmarked plastic pouches. Tata Samunder refined food grade
soda bicarbonate (NaHCO 3 ) is pure and unadulterated, and a value-for-
money alternative to the unbranded products available in the market.
Manufacturing Process Of Soda Ash
Lime burning
Lime hydration
Ammonia distillation
Ammonia absorption
Carbonation
Gas compression
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Manufacturing Process Of Cement
Filtration
Packing and storage
Minning
Crushing and pre blending
Reclaimer
Hoppers
Raw mill
Blending silo
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Production planning & control
Production Planning and control are 2 important aspect of production.
Production planning is prerequisite of production control. Production control
cannot be imaged without production planning.
Production planning is the function of management to look ahead,
anticipate difficulties and take steps to remove obstacles before they are
Coal mill
Cement mill
Cement silos
Packing plant
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materialized. Where n unit is constantly evaluated and compare with the
standards set in advance.
At TCL Production planning is jointly done with dispatch department
on the basic of order and dispatch for the next month provider by dispatch
department production department plans production and its operations. And
on the basic of production planning, department and strict control on the
production activity and continuously evaluated the performance through tar
as it is totally computerized plant.
PRODUCTION PLANNING INVOLVES FOLLOWING STEPS
Development and introduction of new product
Modification of existing lines
Changing needs and preference
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Discontinuous of margined unprofitable or obsolete product
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Plant layout
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