An Organizational Study At Kirloskar Ferrous |__Company Secretary _ Registered Office CS Panicker ~ 13 Laxmanrao Kirloskar Road, Khadki, 411003, Maharashtra URL hitp://kirloskarapps sarc Auditors PG Bhagwat Listing BSE , NSE BSE Code 500245 NSE Symbol L KIRLOSFERR BSE Group B Index Constituent of BSE SmallCap Face Value (Unit Rs. INR) 5.00 ISIN INES84B01025 Registrar Details Link Intime India Pvt Ltd - Pune, Akshay Complex, Block No. 202, 2nd Floor, Off. - Dhole Patil Road, _Near Ganesh Temple, Pune - 411001, Maharashtra _| 2.2 AREA/ LOCATION OF KIRLOSKAR FERROUS INDUSTRIES LIMITED (KFIL): > Kirloskar Ferrous Limited Co. was incorporated on 10" September 1991 as a Public Limited. Kirloskar Oil Engines Ltd. and Shivaji Works Ltd promote the company. The main objective of the company is to manufacture Pig Iron and ferrous casting. The company commenced production in 1994 and up an additional blast furnace in 1995. > Kirloskar Ferrous Industries Limited is located at Bevinahalli of Koppal district. Spread over 200 acres of spacious land with lush greenery around. Kirloskar Ferrous Industry Limited has 2 mini blast furnaces each of 250 M’ working volume, technology and design of TATA-KORF limited in technical collaboration with Korf technology Brazil for extracting pure iron ore. REGIONAL INSTITUTE OF CO-OPERATIVE MGMT, BANGALOREMORLOSKAR FERROUS INDUSTRIES LIMITED An Organizational Study At Kirloskar Ferrous = » Each furnace producing 1, 20,000 tones of Pig Iron metal/ year. The plant manufactures foundry grade Pig Iron suitable for automobile castings. > Raw materials are produced from Sandur and Donimalai sector near Hospet, abundance of rich iron deposits are available in these areas. Fluxes such as limestone, dolomite, quartzite and manganese are available in the nearby surrounding area. Both iron ore and fluxes are easily accessible by road. Coke is imported from China or Japan which is unloaded at GAO / Chennai / Mumbai port and brought to the work site by rail or road. Coke is biggest raw material to the company and it accounts for almost 80% of raw material costs. Kirloskar Ferrous Industries Limited is the first pig iron manufacturer in India with QS 9000 certification. >» Company located on the banks of the Tungabhadra reservoir at Hospet near to the rich iron ore belt of the Hospet- Bellary range, with the Kirloskar philosophy of adopting cutting -edge technology from around the world adapting it to Indian conditions, is today committed to delivering casting of international quality in order to ensure the highest levels of customer satisfaction. NATURE OF BUSINESS CARRIED: 1. Casting and Ploughs REGIONAL INSTITUTE OF CO-OPERATIVE MGMT, BANGALORE QAn Organizational Study At Kirloskar Ferrous JaRLOSKAR FERROUS INOUSTRIES LIMITED 2. Compressors pumps, electric Power 3. Machine tools 4. Engines and components, diesel engines 5. Hotels 6. Advertising 7. Financial Services TIME LINE OF KFIL: 1994 Year of inception 1994 Commercial production of Pig Iron from Mini Blast Furnace | 1995 Commercial production from Mini Blast Furnace 1! 1995 ISO 9002 certification 2001 QS 9000 certification 2002 1SO 14000 certification REGIONAL INSTITUTE OF CO-OPERATIVE MGMT, BANGALORE GOJIRLOSKAR FERROUS INDUSTRIES LIAAITED An Organizational Study At Kirloskar Ferrous —— PRODUCTION PROCESS OF PIG IRON PIG IRON PLANT (PIP) Pig iron is produced using raw materials such as iron ore, coke, and fluxes such as limestone, dolomite, quantize, and manganese are pre-requisite quantity of iron ore, coke. Fluxes are then feeded into the furnace by means of the electronic weighing system. Consisting of load cell, batching controller and programmable logic controllers. Pig Iron is produced through MBF's. RAW MATERIALS >» Coke > Iron ore > Lime stones, Dolomite > Aurtoz Raw material brought-venders site-testing the quality-sent ferrous through convert belts-Raw material put into the silvo-step by step ie, Coke, Iron ore plasles (Lime stones) quarter-heat-1300c when Iron ore melts than it is typically for every two hours-help of drilling machine when it is drilled the method Iron ore comes out of the ferrous and then in load to barrel- both help of it is into the moulds and then sent for cooling purpose when it is paused and cooled then it is ready for marketing. REGIONAL INSTITUTE OF CO-OPERATIVE MGMT, BANGALORE |faRLOSKAR FERROUS INDUSTRIES LIRAITED An Organizational Study At Kirloskar Ferrous DEMAND & AVAILABILITY OF PIG IRON (UNITS) Years Demand Availability 2000-01 | 2400 | 3224 2001-02 | 2900 | 3469 | 2002-03 | a 3733 2003-04 2900 , 4016 2004-05 | 3100 | 4322 2005-06 | 3300 - 4650 2006-07 | 3600 4900 l 2007-08 SOS 3a00.2~=~=©~|~C~C*«<‘C:*«S THO a 2008-09 | 4100 | 5233 2009-10 i ‘4400 5474 REGIONAL INSTITUTE OF CO-OPERATIVE MGMT, BANGALORE QFORLOSKAR FERROUS INOUSTRIES LINMITED An Organizational Study At Kirloskar Ferrous —— FOUNDRY PLANT: 1. MANUFACTURING PROCESS OF FOUNDRY CASTING: In the first process they prepare fiber castings and then the same fiber mould which is prepared according to 86 the design of customer and then according to same to fiber mould sand mould and prepared and then they are dipped into the water for to make moulds strong. Then they are placed in box. Then boxes are and arranged in male and female and attached together and sent further their coal is put on their boxes and processed to get a shape and this process in continued. Further the moulds are sent to press pour to those boxes with iron. This press pour is contained of hot iron liquid after pouring into moulds they are sent for cooling at degree of 300c. After cooling sand is removed and sent for finishing. Press pour contained hot liquid Iron, which is brought from Frances, which has a capacity of 30 tons each, totally they are two foundries having capacity of each furnace of 250mt and producing about 400 tons per day. The Iron liquid is bought to casting from first furnaces are shutdown the iron is brought from second furnace and then steel is added to chat melted Iron. REGIONAL INSTITUTE OF CO-OPERATIVE MGMT, BANGALORE iORLOSKAR FERROUS INDUSTRIES LIMITED An Organizational Study At Kirloskar Ferrous Foundry business is the core expertise of the group. In KFIL the state of art technology in foundry is adopted to meet the high volume of demands of automotive and farm mechanization sector. This also meets the requirements like reduced wall thickness, low machining allowance, above all receptive dimensional accuracies. They supply castings in the domestic market companies like KOEL, TATA Engineering Locomotive Co., Punjab Tractor Ltd., Mahindra and Mahindra, Simpson, Maruti Udyog Ltd. 2. THE LIST OF INDUSTRIAL PRODUCTS: The following table represents the basis of products differentiation & the list of industries where these products are used. Different Chemical composition is the reason for production of different kinds of products, Mainly products are differentiated on REGIONAL INSTITUTE OF CO-OPERATIVE MGMT, BANGALORE |IRLOSKAR FERROUS An Organizational Study At Kirloskar Ferrous ew 1.Sesa Goa “1. Ashok Iron Works Private. Ltd. 2.Kudharemukha Iron & Ore | 2.DGP Foundry 3.Kalyani | 3.Nelcast /4J8w | | 5.Usha Ispat | 5.7 INFRASTRUCTURAL FACILITY PIG IRON PLANT Mini Blast Furnace (MBF): > Mini Blast Furnaces: 250 cubic meters - 2 nos. > Capacity of liquid metal production : 240,000 tons per year. > Pig Casting Machine: 2 nos. >» Capacity : 76 MT per hour. v o 3 @ 8 a aS a hd 5 2 = a. rf 2 & fg a = = a s % 8 8 8 3 a Power Generation: > Turbine Generators: 2 nos. > Capacity :7 MW REGIONAL INSTITUTE OF CO-OPERATIVE MGMT, BANGALORE |sORLOSKAR FERROUS INOUSTRIES LINAITED An Organizational Study At Kirloskar Ferrous > Diesel Power Plant with capacity :19 MW FOUNDRY PLANT Melting: >» ABB Make Holding / Melting Furnaces : 3 crucibles & 2 controls > Capacity: 30 tons holding capacity, each. > ABB make Press Pour Furnace with 7 tons holding capacity Mould Shop: » George Fischer makes high pressure moulding machine and auto mould handling system. » Type of moulding machine : Air Impact Plus » Speed : 70 moulds per hour > Box Size: 1250 X 900 X 400 / 400 mm. » Core setting mechanisms: 2 nos. » Sand Plant with capacity of 110 tons per hour with mold ability controller. Core Shop: Cold Box Core Shooters: REGIONAL INSTITUTE OF CO-OPERATIVE MGMT, BANGALORE |SOMLOSKAR FERROUS INOUSTRIES LIRMITED An Organizational Study At Kirloskar Ferrous > Core Shooter capacity : 40 liters >» Number of core shooters: 20 nos. Shell Core Shooters: > Capacity : 40 liters, 20 liters and 15 liters >» Number of core shooters: 10 nos. Casting cleaning: > George Fischer designed Special Purpose Shot Blast machine > Hanger type shot blast machine Quality: > ARL Spectrometer » Chemical laboratory > Sand laboratory > Brinnel Hardness Tester > Universal testing machine > Casting sectioning machine >» Microscope with photo & CCTV attachment REGIONAL INSTITUTE OF CO-OPERATIVE MGMT, BANGALORE GQIRLOSKAR FERROUS INOUSTRIES LIRAITED An Organizational Study At Kirloskar Ferrous WORK FLOW MODEL PIG IRON The raw material required for manufacturing Pig iron are iron ore, lime stone, manganese, coke and dolomite. There are 2. MBF functioning in KFIL for manufacturing by adopting following procedures: PROCESS Iron with ferrous is reduced in he presence of metallurgical coke in a blast furnace into which they are charged along with fluxes in aprés determined production manner the carbon monoxide gas that raises up HT column or the change reduced that Iron oxide. The molten Iron is periodically tapped and cast in moulds placed ona large diameter turntable - the blast furnace process used for producing pig REGIONAL INSTITUTE OF CO-OPERATIVE MGMT, BANGALORE QJORLOSKAR FERROUS INDUSTRIES LIMITED An Organizational Study At Kirloskar Ferrous iron in a process which is used world over the only difference in this case the small size of the blast furnaces in comparison with those seen in integrated steel plants. The mini blast furnaces process is already in use in several countries especially Brazil and China. There is viable in spite of its small size because of several capitals and operating cost. MOULDING First the pattern is prepared for moulds according to the requirements of the customers. High squeeze presence high density molding machine short squeeze for the box size. The health of the molding high quality dimension stability of the green sand moulds will be achieved to give dimensional close control of the casting molding machine. CASTING Casting is the final produce produced by KFIL, for producing casting the hot molten metal is poured in to the mould through runners of moulds and the hot metal occupies the shape of the mould and it is allowed to solidity. After solidification the caste item is reversed from the molding box and necessary operations like grinding and other process are carried out to set required dimensions according to the requirements. REGIONAL INSTITUTE OF CO-OPERATIVE MGMT, BANGALORE |sORLOSKAR FERROUS (INOUSTRIES LIMITED An Organizational Study At Kirloskar Ferrous ~ 3. Other raw material MATERIALS | SUPPLIERS 1.Grade sand Mangalore minerals 2.iron ore VS. Lad & sons National minerals development -Rajalaxmi minerals | ~ Guru Rajendra minerals 3.Low grade iron ore lumps -Rajapur minerals | Bellary mining corporation | 4.Low grade sponge iron -Hospet Ispat Ltd, [5 Merallurgical coke | “Adhi global pvt Ltd, IMR metallurgical 6.Lime Stone | Sharada cements Vaadhiraj minerals 7.Dolomite -Vaadhiraj minerals ‘8 Scrap bundie “Mysore enterprises MATERIALS WITH SUPPLIERS: REGIONAL INSTITUTE OF CO-OPERATIVE MGMT, BANGALORE ||An Organizational Study At Kirloskar Ferrous - ware User Me M Stock, - Y Requirement Maa Repodt Y — Stock | | Tem Maer — Plan } ’ Procurement Plan Indent Creation — 3.4 PRODUCTION DEPARTMENT REGIONAL INSTITUTE OF CO-OPERATIVE MGMT, BANGALOREsam.osKan reRnnous INDUSTRIES LIMITED An Organizational Study At Kirloskar Ferrous PRODUCTION: As history has it, the Kirloskar dream started taking shape on 32 acres of barren land strewn with cacti and infested with cobras. Driven by the faith in human ability, Laxmanrao Kirloskar banded together 25 workers and their families and went to transforming the barren expanse into his dream village. Since then a century had passed and there has been no looking back. Those 32 acres has expanded into 350,000 m. sq of developed land with state of art facilities. PRODUCTION FUNCTION: Equipment processes personnel are qualified to perform the required operation’s respective department reports qualified records objectives evidence of conformance to specified requirements. PRODUCT IDENTIFICATION TRACEABILITY: 1, Purpose: To provide guidelines for establishment procedure fire identifying the product by suitable mean’s respect during stages of production to delivery. 2, Quality system: To provide guidelines to establish. Document & maintaining a quality a means to ensure that REGIONAL INSTITUTE OF CO-OPERATIVE MGMT, BANGALORE |JORLOSKAR FERROUS (NOUSTRIES LnAITEO An Organizational Study At Kirloskar Ferrous product conformance to requirements. To outline structure of documentation in quality systems. Trade line document, the quality planning is done to meet the requirements of product. 3. Method: Incoming raw materials shall be identified by location marked for supplier wise storage other materials are identified by any of the following means tag location for storage point marks pencils marks name plates boards sticker. » Quality assurance manual (QAM): The top ties document prepared primarily conveying the organization commitment to quality & maximizing customer satisfaction » Common procedure manual (CPM): This is second ties document issues to all department heads for common procedure. + Divisional procedure manual. (DPM): This is also second ties document prepared by divisional heads dealing how a job is done with responsibility specified department procedure of HRM & TRG are prepared by respective department heads. REGIONAL INSTITUTE OF CO-OPERATIVE MGMT, BANGALORE QAn Organizational Study At Kirloskar Ferrous JaRLOSKAR FERROUS INDUSTRIES LIMITED 4. Work instruction: This is third ties document primary to operate with specify work details there are generally iss ued by document or sectional heads & when required they translated in vernacular language (Kannada) Forms/ formats Standards check seats supporting documents etc these are primarily designed by departments taking into consideration the procedures/ work instruction details. MANUFACTURING PROCESS: 1. Charging the blast furnace: After processing, the ore is blended with other ore and goes to the blast furnace. A blast tower- shaped of steel, and lined with refractory or heat - resistant bricks. The furnace is a structure, made mixture of raw material, or charge, enters at the top of the blast furnace. At the bottom of the furnace, every hot air is blown, or blasted, in through nozzles called tuye’res. The coke REGIONAL INSTITUTE OF CO-OPERATIVE MGMT, BANGALORE/ORLOSKAR FERROUS INOUSTRIES LNAITED An Organizational Study At Kirloskar Ferrous = burns in the presence of the hot air. The oxygen in the air reacts with the carbon in the coke to from carbon monoxide. Cc + oO; _ 2cO (Coke) (Hot Air) (Carbon monoxide) 2. Separating the iron from the slag: The melted iron sinks to the bottom of the furnace. The limestone combines with the rock and other impurities in the ore to form a slag which is lighter than the iron and floats on top. As the volume of the charge is reduced, more is continually added at the top of the furnace. The iron and slag are drawn off separately from the furnace. The melted iron might go to a further alloying process, or might be cast into ingots called pigs. The slag is carried away for disposal. 3. Treating the gases: The hot gases produced in the chemical reaction are drawn off at the top and routed to a gas cleaning plant where they are cleaned, or scrubbed, and sent back into the furnace; the remaining carbon monoxide, in particular, is useful to the chemical reactions going on with in the furnace. A blast furnace normally runs day night for several years. Eventually the brick REGIONAL INSTITUTE OF CO-OPERATIVE MGMT, BANGALORE GBioscan remus An Organizational Study At Kirloskar Ferrous "ue? lining to crumble and the furnace is then shut down for maintenance. 7.3m | 14.9.em Pig Iron, Pig Iron: Grades REGIONAL INSTITUTE OF CO-OPERATIVE MGMT, BANGALORE |URLOSKAR FERROUS INDUSTRIES UNITED An Organizational Study At Kirloskar Ferrous The specifications of the various grades of Pig Iron produced at KFIL are as follows: PIG IRON Carbon (%) Silicon (%) | Manganese — Sulphur (%) Phosphorous GRADES (%) (%) Foundry 3.80-4.20 200-250 0.50-0.90 0.06Max 0.09Max Grade 3.80-4.20 1.80-1.99 0.50-0.90 0.06Max 0.09Max 3.80-4.20 1.51-1.79 —_0.50-0.90 0.06Max 0.09Max Basic Grade 3.80-4.20 = <1.00 0.40-0.80 0.08Max 0.09Max 3.80-4.20 1.00-1.25 0.40-0.80 0.08Max 0.09Max 3.80-4.20 1.26-1.50 0.40-0.80 0.80Max 0.09Max S.G.Grade 3.80-4.20 150-210 0.30Max 0.03Max 0.08Max FOUNDRY: Grade Specifications of the various grades of Foundry produced at KFIL are as follows India British Japanese German USA Iso REGIONAL INSTITUTE OF CO-OPERATIVE MGMT, BANGALORE |An Organizational Study At Kirloskar Ferrous Standard IS Standard Standard Standard Standard Standard 210-78 BS: 1452-98 JIS: G-5501-89 DIN: 1691-85 ASTM 48-83 ISO: 185-88 FG200 180 FC 200 GG-20 30A 200 FG220 220 FC 250 GG-25 35A 250 FG2I 260 GG 6 + 300 ova er ras et Fea 300 | Fig-|-Bragips Flow diagtae fou g ion ang} 300faR.OSKAR FERROUS INDUSTRIES LIMITED An Organizational Study At Kirloskar Ferrous » The Organization should take suggestions from workers and that have to be implemented seriously > By adopting more and more technological methods in production it can enter easily to global market > The organization should adopt various cost cutting measures by % Reduction in wastage 2. Reduction in maintenance. CONCLUSION The 5 weeks in plant training in KFIL has given a detailed knowledge of the management of an organization and a clear picture of work flow of the complex organization. KFIL is a pig iron plant which is used as a basic raw material for the production of the steel. This study has given a information of how really a big organization works by facing so many hurdles. As it is a pig iron plant it totally covered by the risks & company is successfully overcoming the problems. The culture in KFIL is very cordial and the atmosphere of the workforce is also very good which contributed to the study a lot. BIBILIOGRAPHY Company annual reports KFIL Journals REGIONAL INSTITUTE OF CO-OPERATIVE MGMT, BANGALORE GQ