Chapter – 6 Production / Operations Department

(In Case of Manufacturing)

HINDALCO INDUSTRIES

6.1 Raw Materials Used

Our Indian operations are integrated and consist of bauxite mining, alumina refining,
smelting and converting primary metal into value-added products. We have dedicated
sources for critical raw materials such as bauxite, power and coal. We also have
committed supply sources for auxiliary chemicals.

Our finished products include alumina, primary aluminium and steel in the form of
ingots, billets and wire rods, value-added products such as rolled products, extrusions and
foils. Metallurgical alumina is used for our own captive needs.

Our facilities are in regions close to raw material sources, low cost and available labour
and demand markets. This helps in reducing costs and improving profit margins. The
technology upgrade has resulted in higher utilisation rates at our plants and improved
efficiency.
6.2 Turnover

Hindalco Industries Limited, the Aditya Birla Group metals flagship, today announced
consolidated results for the quarter and year ended March 31, 2021. The Company
reported its best quarterly performance with consolidated PAT up 189 % at ₹1,928 crore,
a nearly three-fold increase YoY.

6.3 Plant Location

Plant Name Location

Renukoot Plant P.O. Renukoot -231217
Dist Sonbhadra
Uttar Pradesh.
Tel: (05446) 252077-9
Hirakud power Post Box No.12
Hirakud 768 016
Dist: Sambalpur, Odisha
Tel: (0663) 2481307
Durgmanwadi Mines At Post Radhanagri
Dist: Kolhapur
Maharashtra - 416 212
Tel: (02321) 2020133
Belur sheet 39, Grand Trunk Road
Belurmath 711 202
Dist: Howrah, West Bengal
Tel: (033) 2654 7210/12
6.4 Inventory Policies
6.5 Layouts Used
6.6 Products Produced

The company operates across the value chain – from bauxite mining to alumina refining,
aluminium smelting, rolling and extrusions. It services key industry sectors such as
building & construction, automotives, packaging, electrical, consumer durables,
refractories, and ceramics.

The company produced various products and that are as follows :

1. Flat Rolled Products

2. Aluminium Extrusions
3. Foil & Packaging
4. Copper Cathods & Countinuous Cast Copper Rods
5. DAP Fertilisers
6. Precious Metals

6.7 Machines / Equipment Used

Production facilities at Hindalco include Befesa ingot casting machines (125 KTPA*2),
O.D.T. Sow casting machine (50 KTPA), Properzi wire rod mill (90 KTPA) and wag
staff billet casting machine (55KTPA) to produce premium quality products.
6.8 Process Used

The production process can be categorized into upstream and downstream activities.

The Upstream process involves mining and refining while the downstream process
involves smelting and casting & fabricating.

The Downstream process involves fabricated products consist of rods, sheets, extrusions
and foils.

6.9 Quality Maintenance

Quality lies in continuous improvement and in redesigning systems, processes and

practices to satisfy customer needs and expectations. It extends to manufacturing,
maximizing operational efficiency, capacity utilization and productivity.

The unit is no longer restricted to competing against just Indian Organization. In the
effort t become globally competitive, the unit has chosen Total Quality which is proving
to be an excellent tool in managing the change.

At Hindalco Quality is pursued through 5 pillar of total quality management.

 Customer Orientation
 Continuous Improvement
 Management By Facts
 Process Facts And Improvement
 Involvement Of Everyone (Employees, Customers and Suppliers)
6.10 Specific Operations Policies

The main operations are based in the CPBP, Alumina and special products. These
departments are the core for the manufacturing of Alumina carbon block, carbon paste
and special products. These departments comprise of smaller departments and each of
these 3 major departments has a department head.

The majority of the people are working in Alumina, CPBP and Special products
departments, and the work is carried out in shifts.

6.11 Services Provided

It services key industry sectors such as building & construction, automotives, packaging,
electrical, consumer durables, refractories, and ceramics.