You are on page 1of 73

PREFACE

It is said that practice makes a man perfect. Professional study is incomplete without
its practical knowledge. In the field of business, theory provides the fundamental stone
for the guidance of practice but practice examines the element of truth lying in the
theory therefore stand coordination between theories and practice is very essential to
make B.Com.CA degree perfect.
Each & every activity is started for the accomplishment of goals & for this purpose
management is required. As being student of B.Com.CA, a management stream, we
have to go in different types of analysis for practical knowledge & practical training.
A project is a systematic and scientific study of financial problem with application of
financial skill and concepts. Every company has to recognize its strength and
weakness, opportunities and threat in field of finance to stay in the cut throat
competition.
I was assigned a study of a project on A STUDY ON JOB SATISFACTION AT
MALABAR CEMENTS LIMITED
.
Secondary is to share the practical knowledge and real experience in world of
finance .The details mention in this report is based on real situation and research.
I hope the report will be special interest to the finance students who are on look for
such real life situation beyond their class room study.

ACKNOWLEDGEMENT

I take this opportunity to sincerely thanks to Mr. MANIKANDAN.C.NAIR for


being my research guide and for being my research coordinated for their timely
valuable contribution and keen observation in the completion of my research, which
would not have been completed without assistance and help. I would like to utilise this
opportunity to thank our principal Mr TOMY ANTONY, all HODs and other all
faculty members for their timely contribution and co-operation given to me and I
would like to thank all the respondents who contributed their valuable time to answer
my questionnaire, thus helped me to take research to suitable conclusion.

EXECUTIVE SUMMARY

Malabar Cements contributes to the developmental activities of the State by supplying


the basic construction material. Only Malabar Cements can supply its cement, 'factory
fresh', without any deterioration in the original strength either due to moisture or
humidity, within 12 hrs anywhere in Kerala. With a production capacity of 4.2 lakh
tons of cement per annum, the unit at Walayar is the largest. As part of expansion
programme, it has commissioned a 2.0 lakh tons clinker-grinding unit at Cherthala in
Alappuzha district in August 2003. Thus the total installed capacity of MCL is 6.2
lakh tons. MCL is the first public sector company to receive ISO Certification & to
win the National Award for best achievement in Energy Conservation. Till date, MCL
has experienced no loss of production due to labour unrest. In just over 15 years of
commissioning, Malabar Cements has been able to meet about 10% of total cement
consumption in Kerala. With the expansion plans in progress, the figures are sure to
rise further.
The goal is to gather preliminary data and to reach the real nature of the problem and
to suggest new ideas, Descriptive Research is taken up. Here survey was done by
using structured questions.
The source of our data is primary data and secondary data. Primary data was collected
from the respondents, who were interviewed there, for the first hand frequencies was
the basis on which analysis was carried out. While the secondary data regarding
subject was obtained from various magazines, journals, web sites, newspapers, and
books.
For analyzing and interpreting the data we have used various statistical tools like
SPSS 17,Ms Excel 2007 and Ms Word 2007.statistical data collected through
questionnaire.

TABLE OF CONTENTS

Companys Certificate
Students Declaration
Institutes Certificate
Preface
Acknowledgement
Executive Summary

Sr.
No.

Particulars

1.

Introduction

2.

Review of Literature

3.
Industry Profile
&
Company Profile

Data analysis & interpretation

5
6

Page No

Findings
Suggestions
Conclusion
Bibliography
1

Annexure

Chapter 1
Introduction

TITLE
A STUDY ON JOB SATSFACTIO AT MALABAR CEMENTS LIMITED,
WALAYAR

OBJECTIVES OF THE STUDY


The main aim of the study is to analyze and examine level of job satisfaction among
the Malabar Cements employees and to know the problems faced by the employees of
the various categories.
The specific objectives are as follows:

To present a profile of Malabar Cements and organizational structure etc.


To measure Job satisfaction level from different perspectives
To study the impact of job satisfaction on employee morale
To examine satisfaction regarding the salary and other benefits of its
employees.
To suggest suitable measures to improve the overall satisfaction of the
employees in the organization.

SCOPE OF THE STUDUY


In the survey an attempt has been made to analyze the job satisfaction of employees
of Malabar Cements Limited (Walayar, Palakkad,)
The study tries to understand the level of job satisfaction among the employees of
MCL. It further explains the area on which employees are mostly dissatisfied.
Job satisfaction of the employees has been analyzed on the basis of the following job
related factors.

Salary and monetary benefits


Job security
Promotion policy
Working environment
Employee participation in management
Freedom of expressions
Nature of job
Interest taken by superiors
Superiors and sub-ordinate relationship
Medicare
Conveyance

RESERCH METHODOLOGY
Research methodology is ways systematically solve the research problem. It may be
understood as a science of study how research is done scientifically. There is a vast
difference between research methods & methodology. Research methods do constitute
a part of research methodology; it is not only doing research through methods like
how to calculate the mean, median & mode but also understanding logic behind the
methods which are used. Every researcher should design his/her on research
methodology for the problem identified as the same may differ from problem to
problem.

Research Design
Research design is the plan, structure and strategy of investigation conceived so as to
obtain answer to research questions and to control variance.
8

There are three types of research design that researcher can opt for.
1. Exploratory
2. Descriptive
3. Causal
Out of the three available research design the researcher went for the Descriptive
research design which is suitable to answer the research question and give proper
fulfilment of research objectives in this study.
Descriptive research design
In this research study, the researcher has used descriptive research design. Descriptive
study, Who, What, When, Where, How are the questions for researcher to find their
answers during the study. A descriptive study may be simple or complex. This
research study topic is according to the descriptive study. I have needed to find that all
answers of these questions which come in descriptive study.

SAMPLING
The basic idea of sampling is that by selecting some of the sample from the
population, researcher may draw conclusions about the sample study and generalize
for entire population. A population element is the individual participant or object on
which the measurement is taken.
Population Size
All the employees of Malabar Cements Limited (Walayar) are the population for this
research study.

Sample Size:
Sample size is a part of target population, carefully selected to represent the
population. Here in this research study the Sampling size is 50.

Sampling Technique:
After taken it to consider the limitations of this research study the researcher has used
the Non Probabilistic convenience sampling.

LIMITATIONS OF THE STUDY


This research study only considers the area of Malabar Cements in
Walayar, Palakkad
The sample size is not representing the whole population due to limited
time period and cost related aspects.
Some of answers were because the employee thought that they would be
put into trouble.
Lack of knowledge of employees about certain aspects was also a
constraint.

10

DATA COLLECTION
In the preparation of this report, the researcher collects data from different sources.
The sources of data as follows:
Primary data:
This data is gathered from first hand information sources by the researcher, this data
collection from employees, managers, clerks etc., by administrating the questionnaire
having face to face interaction with employees.
Secondary data:
This will give the theoretical basis required for the report presentation which can be
available from various sources such as company website, HR reviews, magazines, and
office files, inter office manual and internet.

DATA PROCESSING AND ANALYSING


Data, which is gathered by administering questionnaires, was processed in simple
manner to determine the level of job satisfaction among employees. Every response
was assigned some score based on this overall satisfaction level was determined.
Data collected is carefully tabulated and analyzed by using satisfaction methods and
also various graphs are used.

11

Data Collection
In order to do the work properly, an insight about the product, about the organization,
about the employees was necessary. For this purpose an extensive study was initially
done about the job Satisfaction
After the initial study, the survey was started in order to get the questionnaire filled by
them.
On the basis of the information collected in the interviews from the respondents and
filled in questionnaire from them, certain findings were made on that basis and some
recommendations too were given to the organization so as to improve the level of
satisfaction of their customers. These findings and recommendations would go a long
way of satisfaction and service in order to maintain its existing employees as well as
to add 1-1 new employee to its existing data base. They also point the aspect in which
the organization is lacking and need to improvise upon as well as the aspect, which are
its plus point and which can really help in future.

Tools for analysis


Researcher has identified suitable statistical and analytical software after
gathering of data. Researcher has used software to analysis data i.e.
Microsoft EXCEL and other suitable statistical tool also used for data analysis
purpose.

PROBLEM STATEMENT
The implications of technology and various services provided by company for their
employee. The innovations and development takes place in the company sector does
really affect the way of works. The statement of problem is an effort to identify the
impact of technology on production and the employee preference towards it. This
study has been done under the Malabar Cements Limited- Walayar, Palakkad.
12

Chapter-2
Review of literature

BrikendAziri:
Management Research and Practice 12/2011;
13

Employees job Satisfaction represents one of the most complex areas facing todays
managers when it comes to managing their employees. Many studies have
demonstrated an unusually large impact on the job satisfaction on the motivation of
workers, while the level of motivation has an impact on productivity, and hence also
on performance of business organizations. Unfortunately, in our region, job
satisfaction has not still received the proper attention from neither scholars nor
managers of various business organizations.
Allen and Meyer, 1996; Karrasch, 2003:

Organization commitment can be defined as affiliation of employees to the


organization and involvement in it. In general there are three dimensions of
commitment which are continuance commitment, affective commitment and
normative commitment.
Judge, Timothy A.; Thoresen, Carl J.; Bono, Joyce E.; Patton, Gregory
K.Psychological Bulletin, Vol 127(3), May 2001,
Database: Psyc articles
[Journal Article]:
A qualitative and quantitative review of the relationship between job satisfaction and
job performance is provided. The qualitative review is organized around 7 models that
characterize past research on the relationship between job satisfaction and job
performance. Although some models have received more support than have others,
research has not provided conclusive confirmation or discontinuation of any model,
partly because of a lack of assimilation and integration in the literature.

14

Srivastava (2004)
The Impact of Labour Welfare on Employees Attitudes and Job Satisfaction, a
comparative study was conducted on workers in the private and public sectors of
Kanpur city. The researcher attempted to assess the quality of labour welfare
activities; measure the degree of job satisfaction of workers provided.
HalilZaimSelimZaim
Fatih University, TURKEY
Job satisfaction is considered to be a critical success factor for organizations. The
concept of job satisfaction has gained a special concern from both academicians and
practitioners. This study aims to provide a framework for job satisfaction and
determine the critical factors of job satisfaction and to measure their effect on overall
evaluation of job satisfaction in small and medium sized enterprises (SME) based on
the data collected from Turkey. Data analysis revealed that there is a positive
relationship between the each factor of job satisfaction which are named satisfaction
from pay and benefits (P&B), satisfaction from peers (P), satisfaction from
management (M), satisfaction from working environment (WE), satisfaction from
superior (S) and overall employee loyalty in SMEs.

15

Chapter 3
Industry & Company
Profile

16

The Global Cement Industry


Cement is a basic ingredient for the construction industry. Cement is made out of
limestone, shell, clay mined out of a quarry close to the plant. The raw material is
crushed, and then heated at temperature in excess of 1000-C in rotating kiln to become
clinker. Clinker is then mixed with gypsum and ground to a fine powder to produce
final grade of cement. The technology is a continuous process and is highly energy
intensive.
Cost of cement is 29% energy, 27% raw materials, 32% labour and 12%depreciation.
The weight/to price ratio make transportation cost very high. The competitive radius
of a typical cement plant for most common types of cement extends no more than 300
kilometres. However, cement can be shipped economically by sea and inland
waterway over great distances, extending greatly the competitive radius of cement
plants with access to waterborne shipping lanes. Thus, the location of a cement plant
and the cost to transport the cement it produces through its distribution terminals bear
significantly on the plants competitive position and the prices it may charge. The
minimum efficient size for a cement plant is around 1 million ton a year.
As a consequence of a relatively low minimum efficient plant and transportation costs
cement production is highly fragmented. It is estimated that there are around 1500
integrated cement production plants in the world. Although the industry has seen the
emergence of strong global players such a Lafarge or CEMEX, the share of the four
largest firms account only for 23% of the overall demand.
Cement is distributed in bags or is delivered to construction sites through ready mix
Lorries.
The major segments of the industries are:
Aggregates: quarries and crushing minerals to be mixed with cement to make
concrete
Cement production
Ready Mix: distribution of ready to use concrete
17

Cement Consumption and GDP/Cap

2012

2010

2008

Country

GDP

Cement GDP

Cement GDP

Cement

Brazil

11340

353

10678

314

8623

271

China

6091

1581

4433

1322

3414

1036

India

1489

191

1419

131

1042

148

Japan

46720

400

43118

370

37972

446

Russia

14037

402

10710

355

11700

430

Saudi Arabia

31800

1700

19118

1522

19714

1625

Singapore

51709

1035

42784

820

36972

940

South Korea

22590

911

30000

950

27600

1114

Spain

28624

438

29863

453

34977

936

Switzerland

78925

560

70370

637

68555

601

UAE

49800

990

34049

1757

46310

4365

UK

39093

206

36703

205

43480

203

USA

51749

232

48358

220

48407

305

Qatar

3023

71510

4252

84628

4710

Finland

10390
0
45721

302

43846

336

51186

360

Norway

99558

343

86156

340

65190

401

Vietnam

1755

560

1134

605

1165

417

Global average
(Est.)

10281

536

9307

447

9211

420

18

The cement industry in India


India's potential in infrastructure is huge. The country is expected to become the
world's third largest construction market by 2025, adding 11.5 million homes a year to
become a US$ 1 trillion a year market, according to a study by Global Construction
Perspectives and Oxford Economics.
Notwithstanding its current position as one of the leaders in cement production,
Indias riches in the sector remain somewhat untapped. Lafarge's India business has
been very successful and the country is among the top 10 markets globally for
Lafarge. But going forward, we should rank higher because of the potential of the
Indian market, says Mr. Martin Krieger, CEO of the Indian branch of the worlds
largest cement manufacturer, Lafarge.

Market Size
India is among the best cement markets in Asia; according to Switzerland-based
cement major Holcim. The company operates in India through group companies ACC
and Ambuja Cements.
The Indian cement sector is expected to witness positive growth in coming years, with
demand set to increase at a CAGR of more than 8 per cent during 201314 to 2015
16, according to the latest RNCOS report titled, Indian Cement Industry Outlook
2016. The report further observed, after analysing the regional trend of cement
consumption, that the Southern region is creating maximum demand, which is
expected to increase in future.

19

Major cement demand drivers


Housing sector accounts for 64 per cent of the total cement demand in India.

Domestic cement consumption


The domestic cement consumption is expected to increase at a CAGR of 10.2
per cent during FY11-17 and reach 398 million tonnes.

20

PESTL ANALYSIS
Political
Political the price of cement is primarily controlled by the coal rates, power tariffs,
railway tariffs, freight, royalty and cess on limestone. Interestingly, government
controls all of these prices. Government is also one of the biggest consumers of the
cement in the country. Most state governments, in order to attract investments in their
respective states, offer fiscal incentives in the form of sales tax exemptions/deferrals.
States like Haryana offer a freeze on power tariff for5 years, while Gujarat offers
exemption from electric duty. (India Info line Ltd nod.)

Economic
currently, the industry is on the boom, with a lot of government infrastructure and
housing projects under construction. In spite of seeing a fall during 2008-09, the
export segment of the industry is expected to grow again on account of various
infrastructure projects that are being taken up all over the world and numerous
outstanding cement plants coming up in near future in the country.

Social
usually, the cement industry in India consists of both the organized sector and the
unorganized sector. Organized sector comprises of the well-known cement
manufacturing companies while the main players of the unorganized sector are the
regional and local cement-producing units in various states across the state. Indian
consumers prefer buying branded cement like ULTRATECH, JAYPEE CEMENT,
LAFARGE CEMENT etc. It has been seen in the past, as well, that mini cement plants
with low brand value and image are not able to survive against the cement giants.
With a population of more than 100 billion people, it is expected that cement industry
will create another 25 lakh jobs in the next 4-5 years.

21

TECHNOLOGY
From mining to production the entire process depends on technology. The
Government of India plans to study and possibly acquire new technologies from the
cement industry of Japan. The government is discussing technology transfer in the
field of energy conservation and environment protection to help improve efficiency of
the Indian cement industry. Cement. industry has made tremendous strides in
technological up-gradation and assimilation of latest technology. At present 93% of
the total capacity in the industry is based on modern and environment-friendly dry
process technology.

Current Trends
Indian Cement- Limestone scenario
The Indian Cement Industry exemplifies this to a nicety. The Cement Industry the
world over is tightly correlated to the GDP (the factor in India is estimated to be about
0.88). Though the roots of the cement industry in India go back to 80 years, the
beginning of Industrialization in India provided the right opportunity for the cement
industry to make its presence felt. Absence of serious competition, the presence of
railway sidings and abundance of limestone seemed to be the only criteria for setting
up cement plants. Though limestone occurs under all ages in India, crystalline
limestone of Archaean age were mostly targeted and plants set up.
And then, the inevitable happened. The now old cement plants based on Archaean
limestone not only found their technology obsolete but also found their limestone
resources fast depleting. The companies were forced to find alternate resources, which
by then had become scarce or find new ways to increase recovery from their existing
deposits. To their dismay, they discovered that the markets - so lenient earlier were
unwilling to bear costs accruing due to the companies' outdated procedures and
processes, 20
demanded higher standards of quality. After decontrol of cement prices new cement
plants sprang up on sedimentary limestone deposits other than Archaean. Which are of
22

simpler nature since the entire run- of- mine could be consumed, the cost of extraction
for these plants was appreciably lower whereas the older set-ups had to manage with
progressively lower recovery ratios. Companies are now forced to work deposits once
considered unviable and/or unworkable with selective mining. Earlier threshold values
are no longer applicable for the older plants and only technology seems to offer the
panacea for survival.

Emerging trends
High degree of mechanization and capacity to handle large volumes has lowered the
run-of- mine costs. Detailed geological explorations and technological advances made
in geo statistics and interpretations, now make it possible for a clearer understanding
of structures and working of limestone, balancing the economics, deploying large
earthmoving equipment handle large volumes of overburden and exploit residual
threshold deposits.

Major players in cement industry


The Indian cement industry is largely dominated by a few companies. The top 20
cement companies account for almost 70% of the total cement production of the
country. During April-September 2009, the Indian cement companies produced 11 MT
cement, whereas the total cement product in the country in FY09 was 231 MT. It is
further expected to reach 236.16 MT in FY11 and 262.61 MT in FY12.

23

LIST OF FAMOUS COMPANIES IN INDIA


Following are the list of Famous cement companies in India:
1. ACC Limited
2. Ambuja Cements Limited
3. UltraTech Cement Limited
4. India Cement Limited
5. Shree Cement Limited
6. Rain Cement Limited
7. Prism Cement Limited
8. Malabar Cement Limited
9. Birla Cement Limited
10. JK Cement Limited
11. Chettinad Cement Limited
12. Dalmia Cement Limited
13. Sagar Cements Limited
14. Madras Cements Limited
15. Bheema Cements Limited

24

Company Profile

25

INTRODUCTION OF MALABAR CEMENTS LIMITED

Malabar Cements Ltd., a fully owned Govt. of Kerala Undertaking, is synonymous


with superior quality cements, vouched by customers spread across the state of Kerala.
The Company was incorporated in April 1978 and commenced production in April
1984 at its Walayar plant. At Malabar Cements, product improvement is not just a
one-time strategy for boosting sales, rather a quest of excellence. Perfecting the
product quality is everybody's concern here. Our distinction begins with scientifically
selecting the best raw materials for clinker. Stringent quality control is exercised right
from pre-blending raw materials, clinkerisation, clinker grinding, and finally to
cement packing.
Malabar Cements contributes to the developmental activities of the State by supplying
the basic construction material. Only Malabar Cements can supply its cement, 'factory
fresh', without any deterioration in the original strength either due to moisture or
humidity, within 12 hrs anywhere in Kerala. With a production capacity of 4.2 lakh
tons of cement per annum ,the unit at Walayar is the largest. As part of expansion
programme, it has commissioned a 2.0 lakh tons clinker-grinding unit at Cherthala in
Alappuzha district in August 2003. Thus the total installed capacity of MCL is 6.2
lakh tons. MCL is the first public sector company to receive ISO Certification & to
win the National Award for best achievement in Energy Conservation. Till date, MCL
has experienced no loss of production due to labour unrest. In just over 15 years of
commissioning, Malabar Cements has been able to meet about 10% of total cement
consumption in Kerala. With the expansion plans in progress, the figures are sure to
rise further.

26

HISTORY OF MALABAR CEMENTS LIMITED

Cement is a necessary constituent of infrastructure development and a key raw


material for the construction industry. As late as the 70s, the State of Kerala was
virtually starving for cement. The state lacked a Portland cement factory in either
private or government Sector. In 1961-62, the Geological Survey of India located a
limestone deposit in the Pandarethu valley of the Walayar region on the northern side
of the Palakkad gap. Located in dense forest area, the hilly terrain was required heavy
investment to mine. The State Govt. ventured to put up a Cement factory in the region.

The feasibility study conducted revealed that the construction of a 1200 tpd dry
process cement plant using the Pandarethu limestone is feasible. KSIDC obtained an
Industrial License for the manufacture of cement in November 1976 and decided to go
ahead with the project and formed Malabar Cements Limited to set up, own and
operate the proposed cement plant. The plant was successfully commissioned in 1984
and the commercial cement production started on 1984.

Now, The Company is all equipped to set precedence among public sector units in the
state. The launch of two Superior quality products under the brand name Malabar
Super and Malabar Classic, in the year 1994-95 gave a boost to the market
presence. Various modifications carried out since 1995 have improved production and
productivity of Malabar Cements. A 2.5 MW multi-fuel power plant was
commissioned in June 1998 to complement 25% of the total power requirement for
the Walayar plant operations. As part of expansion, the company has commissioned a
600 tpd Grinding Unit at Cherthala in August 2003. The modernization of Cement
Mill, completed in December 2004, helped to increase the cement production.

27

The company has upgraded the plant with state-of-the-art technology; Belt bucket
elevators, Kiln automation, modification of cement mill internals etc, are few to
mention. The 0.42 million tones capacity is less than 10% of the cement consumption
in Kerala and expansion will allow the company to harness the markets beyond its
core segment.

28

MISSION & VISION OF MALABAR CEMENTS LIMITED

VISION
To help in building a better habitable Kerala by providing best solutions in the field of
constructions.

MISSION
To provide quality products & services to the public through effective intervention in
the market.

29

OBJECTIVES OF MALABAR CEMENTS


Manufacture and sell best quality cement at affordable price to general public of
the state and to be an important part in the socio-economic development of the
state

Quality Policy
Every employee of Malabar Cements Limited commits to comply with all
requirements to continually improve the effectiveness of the Quality
Management System and strives

30

BORD OF DIRECTORS

Sri P.H.Kurian IAS, Principal Secretary to


Govt. of Kerala
Industries & IT, Govt. of Kerala, Secretariat,

Chairman & Director

Thiruvananthapuram Ph:0471-2518977,2329024
K. Padmakumar,

Managing Director

Malabar Cements Ltd, Walayar,


Palakkad. Ph 0471- 3921244
Mob: 98950 55535

Director

Sri. Venugopal K Nair IPS (Rtd)


P1, Waterford Appartment
PT Karuppan Road, Thevara,
Kochi-682013, Mob:9447500010

Director

Sri J.Vijayamohanan
Addl Secretary, FInance Department
Govt of Kerala, Secretariat, TVM-01
Mob:9447736268

Director

Sri. T.K Mohanachandran


General Manager, District Industries Centre,
Vellakinar, Alappuzha, Kerala Mob:9495054320

Director

Adv. S.Adbul Rasheed


Koyikkal House,Krishnapuram PO,
Alappuzha-690533
Mob: 9847042096

31

Director
Sri. C.V.Balachandran
Aswathy, Main Road, P.O Chalissery,
Palakkad-679636
Mob: 9447065627
Director
Adv.Jose Tom
Pulikkunnel House, Edamattom PO,
Pala, Kottayam, 686578
Mob:9447466145
Director

Sri.K.K.Nazer
K.K.House
Changuvetti, Kottakkal P.O
Malappuram-676503
Mob: 9447143820

Director

Sri. P.Muhammed Kunji Master


Athinchal, Manikkoth,
Kasargod- 671316
Mob:9847284045

Director

Sri V.K Raju


Advocate, Cherukayalkara Veedu
Murukkumpuzha, TVM 695 302
Mob: 94477 61744

32

HIGHLIGHTS OF MCL

No of Employees

900+

Working Shift

6:00 to 2:00, B- 2:00 to 10:00, Night


Shift 10:00 to 6:00 , General Shift
8:30 to 5:30

Product

Cement

Brand

Malabar Super
Malabar Classic
Malabar Aiswarya

Country

India

Logo

Tagline

Keralathinte Ketturappu

33

Competitors

ACC , UltraTech

AWARDS & ACHIEVMENTS

Kerala State Pollution Control Board Award - 1990-91


Secured first State award for Energy conservation - 1992
VSSC Rolling Trophy for safety measures - 1994 & 1995
NCBM National Award for the Best improvisation
in energy - 1998
Kerala State Energy Conservation Award - 1998
Govt. of Kerala awarded for outstanding
achievement in Pollution abatement - 2007
Introduced ERP system for integrated operation
of all functional areas. - 2007
Kerala Trade Award of Kerala Government - 2010
Kerala State Pollution Control Board Award - 2011
Kerala State Pollution Control Board Award - 2012

CERTIFICATIONS & ACHIEVEMENTS

34

IS/ISO 9002: 1994 certification obtained in November 1996. First PSU to


secure this certification.
Switched over to the revised standard ISO 9001: 2000 in august 2003.
Switched over to Quality Certification ISO : 9001 :2008 in 2010

GROWTH STORRY

Feasibility Study for a cement plant at Walayar. - 1975


Industrial License for the manufacture of Cement - 1976
Date of Incorporation of Malabar Cements - 1978
Commencement of mining activities - 1981
Commissioning of Walayar Plant - 1984
Commencement of clinker production - 1984
Commercial Cement Production started - 1984
43-grade OPC cement Malabar Super launched - 1994
New product: Malabar Classic launched - 1994
Obtained ISO : 9002 certification, first PSU in Kerala
to secure this certification - 1996
Installation of 2.5 MW multi-fuel power gen. set - 1998
35

Introduction of Malabar Aiswarya brand - 2003


Commissioned of 600 tpd cement grinding unit at
Cherthala - 2003
Modernization of Cement Mill to close circuiting - 2005
Introduced ERP system for integrated operation
of all functional areas. - 2007

Switched over to Quality Certification


ISO : 9001 :2008 - 2010

36

Plant & Factory Details


The Geological Survey of India had identified a cement grade limestone deposit in the
Walayar reserve forest way back in 1961-62. The Mineral Exploration Corporation
Limited confirmed its efficacy.
Malabar Cements Ltd., fully by the Government of Kerala, is the only Portland
cement manufacturer in Kerala. The company was incorporated in April 1978 and
commenced commercial production in 1984 with capital outlay of Rs. 680 million and
paid up equity capital of Rs. 260 million. The 1200 TPD plant at Walayar has
continuously registered profit year after year.
The company has upgraded the plant with state-of-the-art technologies through the
years. After the inception and in line with technological developments, company has
carried out lot of modifications in the system for minimizing energy consumption,
Pollution control measures, process modifications etc. Some of the salient features of
the plants are listed below:
Limestone reserve of about 10 million tons.
Modern 110 TPH Closed Circuit Cement Mill.
Strict Quality Control system to ensure quality of the product.
Most modern Instrumentation & Control system for efficient process
engineering.
Modern dry process manufacturing technology with four-stage suspension pre
heater system.

Elaborate pollution control system to meet pollution control standards.

37

Health & Safety


Malabar Cements is always committed to sustain development of health and safety
working environment complying with all statutory requirements. We undertake
various programmes, methods and initiatives towards this by adopting proactive safety
approach rather than reactive ones. The plant uses sophisticated pollution control
devices in various parts such as raw mill, cement kiln, coolers and cement mill. In
addition, the mining technologies that have been implemented are also based on
environment safeguard norms. Periodical inspection and assessment of working
conditions is considered as the key tool for identifying hazards and risk involved in
each activity. We give utmost importance to enhance competency of human resources
by providing adequate awareness, training with the help of an established fully
fledged Training & Development department.
We believe that safety is an integral part of all jobs and that can be achieved only
through active participation and involvement of employees from all levels, from top to
bottom. We promise workers participation in safety management by establishing
Safety Apex Committee and departmental safety sub committees. These committees
oversee the implementation of our OH & S policy. We practice Japanese 5S concept of
housekeeping to achieve excellence in maintaining clean and hygienic working
conditions.
Our keen attention is always to create a green & healthy environment. In its endeavour
towards greenery, the company has initiated various types of forestation, horticulture
and tree planting programs. To comply with the numerous standards and norms
stipulated in various statutes of environment conservation, timely Modernization plans
are prepared and implemented
38

39

LABOUR WELFARE
It can be undoubtedly stated that our company is providing numerous measures both
statutory and non-statutory when compared to neighbouring industries as well as other
Public Sector Undertakings in the State. Here is the gist of welfare measures provided
by the company.
1. CANTEEN
Full-fledged round the clock canteen facilities are provided in plant and mines for
employees on duty. These provide food at subsidised rates.
2. MEDICAL CENTRE AND AMBULANCE
A full-fledged Medical Centre with two bed facility is situated in Township for the
benefit of employees and their dependant family members and the treatment &
medicine are provided free of cost. The services are rendered by two Medical Officers.
Apart from Medical Centre one Ambulance each is provided at the Plant and Mines
for meeting emergency medical assistance of the employees.
3. COMPLIMENTS & GIFTS
Annual gifts are distributed among all employees in appreciation of their efforts in
writing home good profit. During the last two years, 4 gms Gold Coin was issued to
each employee as annual gift while a gold coin of 8 gms was gifted to each of the
employees retiring on superannuation. Employees completing 25 years of regular
services in the company were given 10 gms Gold Coin. Gifts are also given away to
employees annually in connection with Safety Day Celebrations.
4. SCHOOL / FESTIVAL ADVANCE
Interest free recoverable advances are paid to all employees in connection with Onam
festival and School re-opening. In addition to this festival advance is also paid

40

5. WELFARE FUND
A welfare fund constituted by the company lends a helping hand to needy employees
at times of financial crises. The Governing committee consists of Management as well
as elected representatives of the workmen.
Apart from financial assistance for treatment of specified diseases, retirement benefit,
death benefit etc., the fund is also linked with Group Medical Insurance through
which members and their dependents can avail cashless facility/ reimbursement for
inpatient treatment. In the case of death, dependant benefit is also paid by the
employer.
6. MEDICAL REIMBURSEMENT
Medical Reimbursement to the tune of one month salary per year is provided to those
employees who are not covered under the E.S.I. Act.
7. CEMENT AT SUBSIDY RATE
Cement at subsidy rate is provided to employees who have completed 10 years of
regular service, on request. On superannuation, employees are offered a cement
agency subject to the rules and regulations applicable.
8. CONVEYANCE
Conveyance facility on the Walayar Palakkad route is provided for the employees
for their to and fro journey to attend duty. Free conveyance is also provided to school/
college going children of employees from township to Palakkad.
9. COMPASSIONATE EMPLOYMENT SCHEME
this scheme provides employment in the company to the dependant of the employees
die while in service.
10. ACCOMMODATION
Family and bachelor accommodation is provided for the company employees.

41

11. EMPLOYEES CO-OPERATIVE SOCIETY


An Employees Co-operative Society is functioning in Township with ample assistance
from the Company. The Society is providing provisions, stationary items etc. to the
employees on credit, which will be deducted from their salary.
12. EMPLOYEES RECREATION CLUB & LIBRARY
A recreation club is working to boost the creative talents of employees and their
children in the field of arts and sports. A full-fledged Library graded as A by State
Library Council is also functioning in the Township.
13. COMMUNITY HALL
A community hall with a seating capacity of more than 300 is constructed in the
Township. The community hall is used as Indoor Stadium also for games like
Badminton, Table Tennis, and Caroms etc.

42

PRODUCT PROFILE
The Making of Cement
MCL manufactures cement through the most modern dry process method based on
world-renowned German technology. The major raw materials for cement
manufacture are limestone and late rite, which are natural minerals obtained within the
state. These raw materials provide all necessary ingredients of cement like lime, silica,
alumina and iron oxide. The entire manufacturing process is computer controlled from
a central control room and stringent quality control measures are applied at all stages
of production. We are in the process of installing X - Ray Analyzer for better quality
control. The state of the art pollution control measures like bag filters are also being
installed. The process generally involves three stages of production.
1. Raw meal production.

The limestone obtained from captive mines is enriched with higher quality limestone
procured from nearby states as and when required. The raw mix normally contains
95% limestone and 5% late rite. The raw materials are crushed to around 20-25 mm
size and the proportioned raw materials are ground in a ball mill in dry condition to a
very fine powder. The resultant product is called raw meal and is stored in concrete
silos where it is pneumatically homogenized to get a uniform production.
2. Clinker production
Clinker is produced in a rotary kiln, which is a cylindrical steel shell of 65m length
and diameter 4.2m, lined with refractory bricks. The kiln is inclined at 3% and set
rotating at a speed of 2 2.2 rpm. It is provided with a 4-stage multi cyclone preheater system through which the homogenized raw meal is fed to the kiln inlet by
means of belt bucket elevators. The Kiln is fired with pulverized coal and maintained
at a temperature of about 14500C. In the pre-heater and kiln, the raw meal undergoes a
series of physical as well as chemical changes giving rise to the cement minerals. The
resultant product in nodular form obtained from the kiln is called clinker. Clinker is
43

immediately quenched in the clinker cooler to stabilize its properties and stored in the
clinker stockpile
3. Cement production.
Cement is produced by grinding clinker with 3-5% gypsum in a closed circuit ball mill
to required fineness. Gypsum is added to control the setting properties of cement.
Grinding clinker and gypsum produces ordinary Portland cement (OPC). Fly ash /
Slag at required proportion is ground along with clinker and gypsum to produce
Portland pozzolana cement (PPC) / Portland slag cement (PSC). The ground cement is
stored in concrete silos and packed in 50 Kg bags using electronic packing machines.

44

45

MCL Product Range

Malabar Cements uses the state of the art, dry process technology for the
manufacturing of super quality cement and the quality is much above the national
standards. For Various applications, the company has three brands viz, "Malabar
Super", "Malabar Aiswarya" & Malabar Classic"
1. Malabar Super

A fabulous product in every sense: Super in strength, Wonderful in workability,


Incredible in aging, Implausible in durability, and Fantastic in strength gain. An
amazing performer!
Tests carried out by Bureau of Indian Standards have established unshakeable
credentials of Malabar Super. Super strength accelerates setting time and fine finish.
Malabar super is superior in strength to ordinary '43' grade cement. It attains the 28
days' strength required as per IS in just 7 days time. Not only that, the strength
attained in 28 days time is about 50 percent more than the IS specification. The
amazing strength of Malabar Super arises from its unequalled particle fineness, 33
percent more than the IS specification and consistency in composition, made so by
computerized process control system.
Technical Specification
Malabar Super offers better setting characteristics - prolonged initial set and short
final set timings; providing more time for concrete mixing and placing, and less time
for keeping the concrete undisturbed, free from movement and vibration, the property

46

Engineers and mansions relish having, in the cement they work with. Malabar Super is
finer when compared to normal OPC, and has the best Rate of hydrogen and strength
gain.
Benefits
Malabar Super's superior setting properties, quick strength gain, and higher finished
strength, gives at least 10% cement reduction in volume batching. By designing the
mix, reduction in cement requirement can go beyond 30% under good production and
placement practices. Malabar super is therefore economical

2. Malabar Classic

Superior in its class of cements, it offers better setting properties delayed initial set
and early final set offering more working time and reduced observation
time. Structures achieve excellent dimensional stability with the heat resistant
properties of MALABAR CLASSIC. It also reduces heat generation during hydration,
making it a better workable finished product absolutely reliable. The extra fineness
welded into it allows MALABAR CLASSIC better coverage and finish in wall and
roof plastering. This in turn, reduces paint consumption
Technical Specification
We take pride in developing the cement most suited to the south Indian climate ,
through in-house studies and continuous researches in product improvement. Malabar
Classic, with scientifically proportioned sand and coarse aggregates, is the most
cohesive mix possible that surpasses the otherwise inherent drawbacks of concrete
like segregation and bleeding. The fly ash interweaved with Malabar Classic makes it
sulphate resistant-a basic property that cement should posses, for constructions and
structures in seacoasts and in alkaline waters. Malabar Classic is best suited to resist

47

alkali aggregate reaction, a defect eventually resulting in excessive cracks and


subsequent un serviceability of structures.
Benefits
The extra fineness welded in to it allows Malabar Classic better coverage and finish in
wall and roof plastering. This in turn reduces the paint consumption. With its superior
strength properties, it is economical to use Malabar Classic.10% cement is normally
guaranteed. Using a design mix gain can go up to 30%
3. Malabar Aiswarya

It brings prosperity in many ways. It increases the life of your structures by


safeguarding against sulphate attack. Aiswarya offers high quality at reduced price.
Aiswarya generates less heat of hydration, reduces the formation of getting cracks.
This product is best studied for constructions in soil and water with excess alkali
metals, sulphates, alumina, iron and acidic waters. To obtain the best quality cement,
only glassy granulated slag is used for product manufacturing. With very low
magnesium oxide content this provides shape stability for concrete structures.
Technical Specification
Malabar Aiswarya brings prosperity in many ways. It increases the life of your
structures by safeguarding against sulphate attack. Aiswarya offers high quality at
affordable price. Aiswarya generates less heat of hydration, and thus reduces the
formation of cracks. This product is best studied for constructions in soil and water
with excess alkali metals, sulphates, alumina, iron and acidic waters. To obtain the
best Quality cement, only glassy granulated slag is used for product Manufacturing.
With very low magnesium oxide content this provides Shape stability for concrete
structures. Aiswarya has excellent strength And strength gaining capacity

48

BORD OF DIRECTORS

49

50

Chapter 4
Data analysis

51

1. Do you think that the superior has to closely monitor the activity of an
employee?
Option

No of respondents

Percentage

Yes

17

34

No

20

40

Dont know

13

26

Table 4.1

45

40

40
34

35
30

26

25
20

20

Yes
No

17

Dont know
13

15
10
5
0

No of respondents

Percentage

Figure 4.1
Analysis: In this table we find and also I think 34%employee is the superior has to
closely monitor activity of an employee. And 40% of employee said .superior not has
closely monitored the activity an employee. And some 26% of employee doesnt
know about these things.
In this above table It can be inferred that the 40%f the Employees of Malabar
Cements said that they are superior not has top closely monitor activity of an
employee .but 34%of employee are superior has to closely monitor activity of an
employee . So last we can find Malabar Cements employee it means 60% not satisfied
with superior has to closely monitor activity of an employee
2. As an employee do you think that lack of satisfaction in jobs leads to.

52

Option

No of respondent

In%

Lower productivity

Lower performance

26

52

Poor output

10

Lack efficiency

10

20

Absenteeism

All the factors are


relevant

10

Table 4.2

60
52
50
Lower productivity

40

Lower performance

30

Poor output

26

Lack efficiency

20

20
10

10
2

Absenteeism

10
2

10

All the factors are relevant

0
No of respondent

In%

Figure4.2
Analysis: 52% of the employee said that lack of job satisfaction in job directly affects
on their performance, 20% said that efficiency will decrease, 10%of the employee said
these all factors are relevant
From above it can be inferred that majority of the employees of Malabar Cements feel
that lack of job satisfaction highly effects on job performance of the employee.
Remaining employees feel that lack of job satisfaction also effects on productivity,
output, and efficiency to some extent.

53

3. How far do you agree with the statement if you are satisfied you can perform

better?
Option

No of respondent

Percentage

Strongly disagree

Somewhat disagree

Neutral

10

Somewhat agree

18

Strongly agree

31

62

Table 4.3

70

62

60
50

Strongly disagree
Somewhat disagree

40
31

Neutral

30

Somewhat agree
18

20
10

Strongly agree

10
4

0
No of respondent

Percentage

Figure 4.3
Analysis: 80% of the employee feels that higher job satisfaction leads to performance
where as 10% of the employee feel that job satisfaction does not have any impact on
the performance. About 10%0f the are unable to say anything
It can be concluded higher the job satisfaction higher the performance of an
employee.

4. Considering working hours and physically environment how satisfied are


with your job?
54

Option

No of respondent

Percentage

Very dissatisfied

18

Somewhat
dissatisfied

Neutral

Somewhat agree

29

58

Strongly agree

12

70
58

60
50

Very dissatisfied
Somewhat dissatisfied

40

Neutral

29

30

Very satisfied

10

Not sure

18

20
9
4

12
4

0
No of respondent

Percentage

Analysis: From the above table it is observed that 70% of the employee feels that the
physical environment and workings hours give more job satisfaction .about 26%feel
that physical environment and working hours do not give job satisfaction
It can be inferred that good physical environment and congenial working hours
coupled with closed supervision of the superior to lead to higher performance
ultimately.
5. As an employee do you feel that you have enough
freedom in your position to take independent action when
required?

55

Option

No of respondent

Percentage

Strongly disagree

Somewhat disagree

18

36

Neutral

18

36

Somewhat agree

09

18

Strongly agree

Table
40

36

36

35
30
Strongly disagree

25

Somewhat disagree
18

20

18

18

Neutral
Somewhat agree

15

Strongly agree

10

0
No of respondent

Percentage

Figure
Analysis: About 40% of employee feels that they do not have
enough freedom to take independent action. 36%are unable to
decide and 24% feels that they have the freedom of taking
independent decision.
It can be inferred that the employee s Malabar Cemntes do not
have sufficient freedom to take independent their action.

56

OPTIONS

In (%)

No. Of Respondents

6.

40

81

16

Somewhat Disagree

Strongly Disagree

Neither agree nor


disagree

Strongly agree
Somewhat Agree

Full co operation received from other department


Table
90

81

80
70
Strongly agree

60
50
40

Somewhat Agree
40

Somewhat Disagree
Strongly Disagree

30

Neither agree nor disagree


16

20
10

8
1

No. Of Respondents

In (%)

Figure
Analysis: The above table reveals that, 81% of the total employees agree that they get
full co-operation from the other dept. About 2% of the total employees do not agree
for the above statement.
In above statement we can be find 81% of the total employee agree that they get full
co operation from the other dept. in this Malabar Cements employees are full co
operation in different department.
7. Job promotion this organization is fair and objective?
57

OPTIONS

In (%)

No. Of Respondents
26

52

16

32

Somewhat Disagree

10

Strongly Disagree

Neither agree nor disagree

Strongly agree
Somewhat Agree

Table
60
52
50
Strongly agree

40
32
30

Somewhat Agree
Somewhat Disagree

26

Strongly Disagree
20
10
0

16

Neither agree nor disagree


10
5

6
0

No. Of Respondents

0
In (%)

Figure
Analysis: The above tabular column reveals that, employees agree that promotion at
Malabar Cements is fair .It is based on performance and not on Favoritism. About
10% of the employees are quite satisfied with the promotions. 6% of employees are
disagreeing for the promotions.
So from the above table Malabar Cements employee are 52% of employee strongly
agrees to the promotion. So employee agrees that promotion at Malabar Cements is
fair.
8. I am satisfied with Malabar Cement unit as a place to work.
58

OPTIONS

In (%)

No. Of Respondents
43

86

13

Somewhat Disagree

Strongly Disagree

Neither agree nor


disagree

Strongly agree
Somewhat Agree

Table
100
86

90
80
70

Strongly agree

60

Somewhat Agree

50

Somewhat Disagree

43

40

Strongly Disagree

30

Neither agree nor disagree

20
10

13
6

No. Of Respondents

In (%)

Figure
Analysis: At Malabar Cement 86% of employee is satisfied with Malabar Cement
unit as a place to work .And 1%0f employee are dissatisfied with Malabar cement unit
as a place to work
From above all tabular columns it is observed that employees are satisfied for being
the part of the unit of Belgaum works.
59

OPTIONS

No. Of Respondents

In (%)

41

82

14

Somewhat Disagree

Strongly Disagree

Neither agree nor


disagree

Strongly agree
Somewhat Agree

Your opinion taken into account in department

Table

60

9.

Option

No of respondent

percentage

Strong agree

36

73

Somewhat agree

12

23

Strongly disagree

Somewhat disagree

Neither agree nor


disagree

90

82

80
70
Strongly agree

60
50

Somewhat Agree
41

Somewhat Disagree

40

Strongly Disagree

30

Neither agree nor disagree

20
10
0

14
7

No. Of Respondents

In(%)

Figure
Analysis: 82%of employee is strongly agreed for our opinion taken into account
dept .and also 4%of employee disagrees for our opinion taken into account dept.
From the above table it is observed that employees are given opportunity to express
their views and ideas for which even they get appreciation.
10. Training is provided time

61

.....
..

Table
80
70
60
Strong agree

50

Somewhat agree

40

Strongly disagree
Somewhat disagree

30

Neither agree nor disagree

20
10
0
No of respondent

Percentage

Figure

Analysis: The above question was asked to know the agreement level of employees
about the training provided at Malabar Cements. 73%of the employees agree they get
training on time.23% of the employees are quite satisfied for the above statement.
Malabar Cements providing training timely.73%of employee are satisfied for
providing training timely. And also Malabar Cements Company provides training
when training is is need. So employee is satisfied.
11. Are u satisfied wages paid to you?

62

Options

No. Of respondents

Percentage

Yes

18

36

No

32

64
Table

36%
YES

NO

64%

.
Figure

Analysis: 36 percent of the employees are satisfied with the wages paid to them. 64
percent of the employees feel that there should be a hike in wages paid to them.

12. Do you have any incentives wage scheme for efficient work on your
organization?
63

Options

No. Of respondents

Percentage

YES

28

56

NO

22

44
Table

60
50
40
30
20
10
0
YES

NO

Figure

Analysis: 56 percent of the employees feel that there should be an incentive wage
scheme for efficient work in the organization. 44 percent of employees are
dissatisfied.

13. To what extent do you agree with the working condition?

64

Options
Extremely Dissatisfied
very Dissatisfied
Somewhat Dissatisfied
Neutral
Somewhat Satisfied
Extremely Satisfied
Total

No. Of
respondents
0

Percentage

27

54

12

10

20

50

100

Table
27

10
4

6
3

Figure

Analysis: Almost 54% of the employees are Neutral stand with the present
working conditions and environment. 20% of the employees extremely satisfied with
their work condition. And 12% are somewhat satisfied. And others are having some
problems with their present working condition.

14. Is the management helpful & Sympathetic to your problems in work stations?

65

Options

No. Of respondents

Percentage

YES

40

70

NO

10

30

Table

70
60
50
40
30
20
10
0
YES

NO

Figure

Analysis: 70% of the employees feel that the management is sympathetic to some
extent in their problems faced at workstation. 30% others feel that the management is
sympathetic to large extent in their problems faced at the workstations.

15. Are you satisfied with the facilities provided to you?


66

Options

No. Of respondents

Percentage

Yes

30

80

No

20

20

Table

NO; 20%

YES; 80%

Figure

Analysis: Almost 80% employees are satisfied with facilities provided with the
organization.
So Malabar Cements provide good facilities to their employees.

67

16. Does the top management involve employees in the management decision?
Options

No. Of
respondents

Percentage

Yes

12

No

44

88

Table

90
80
70
60
50
40
30
20
10
0
YES

NO

Figure

Analysis: almost 88% employees said that the management does not involve them for
decision making process. Just 12% of employees said management involve them for
making decisions.

68

17. Do you think there is good career prospect in your organization?

Options

No. Of respondents

Percentage

YES

40

80

NO

10

20

Table

80
70
60
50
40
30
20
10
0
YES

NO

Figure

Analysis: almost 80% employees said that they have a good career prospect at
Malabar Cements Limited. Their personal view is it is a Government Organization.

69

18. Are you satisfied with the top management?

Options

No. Of
respondents

Percentage

YES

48

96

NO

Table

YES
NO

Figure

Analysis: 98% employees satisfied with their top management. So Malabar Cements
Limited has a highly skilled & efficient management system.

70

19. Are you satisfied with the working hours at this company?
Options

No. Of
respondents

Percentage

YES

39

78

NO

11

22

Figure

NO

YES

20

40

60

80

100

120

Figure

Analysis: 78% of employees satisfied with the Malabar Cement working hours
Some employees have some family related problems due to the working hours.

71

20. Does the organization provide medical facilities for employee?

Options

No. Of respondents

Percentag
e

YES

50

100

NO

Table

120
100
80
60
40
20
0
YES

NO

Figure

Analysis: this is an awesome achievement in the history of Malabar Cements


Limited. 100% employees are satisfied medical facilities provided by the company

72

73