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CHAPTER 1 General Information

Background of the company:


In 1962 the company started as a subsidiary of a US based company known as Rohm Haas ltd. In 1982 the subsidiary got separated from Rohm Haas ltd. And Mr. K K Modi started it as a division Modipon Ltd. In 2007 it started as a division of Indofil Organics Industries ltd. In 2010 it was renamed as Indofil Industries ltd. It is a part of K K Modi Group Modi enterprise An industrial corporation with diverse business. Modi enterprise has a group asset value of Rs. 28000 crores.

Fig 1

INDOFIL INDUSTRIES COMPANY It belongs to the renowned K. K. MODI GROUP OF COMPANIES. The Management of INDOFIL constitutes a BOARD OF DIRECTORS, with great experience and wisdom. EXCELLENCE as a Foundation and WINNING as a Passion is what describes our Group Chairman, MR. K. K. MODI, who continuously steers his group companies to reinvent and redefine themselves! INDOFIL INDUSTRIES LIMITED, established more than four decades ago, headquartered in Mumbai, a research-led and fully integrated Chemical Company has EMERGED as a successful and vibrant enterprise, riding high on a simple philosophy of retaining loyalty and enlarging the fold of satisfied customers. Head office: Andheri, Mumbai CEO: Mr. R K Malhotra, Head of Marketing Chairman- Mr. K K Modi HOD HR- Dr. Avinash Deolekar, Senior Vice President Finance Head: Mr. Sunil Patel, Sr. Vice President

Indofil Industries Business division:


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Indofil Industries Limited is uniquely placed both in Agricultural Chemicals (ABD) as well as Specialty & Performance Chemicals (S&PC) Business. As a part of K. K. Modi group, Indofil has a well-equipped manufacturing infrastructure, a result oriented Research & Development team, and an excellent domestic and international distribution network. Known around the world as "The Mancozeb People", Indofil has its export presence in more than 50 countries as suppliers of Mancozeb formulations. In India, Indofil is successful in strategic marketing of Insecticides including IGR's, Fungicides (Mancozeb, Tricyclazole, and Zineb etc), Bactericides, Herbicides, Acaricides, Surfactants, and Plant Growth Regulators (PGR). Indofil is driven by "Crop Care Concept" in agriculture business. The focus is to create partnerships for Research & Development, manufacturing & marketing for many more active pesticides & combinations. Specialty and Performance business works with the philosophy to be a solution provider by innovative products for various industries viz. Leather, Textile, Paints, Plastics and Construction Chemicals. The Company's long and successful past also provides customers with the assurance that Indofil will continue to be a valued partner long into the future. Fig 2

Agricultural chemicals:

Fig 3

Speciality & Performance Chemicals

Fig 4

International business: It is spread across the globe in Australia, Africa, New Zealand, India, France, Germany, Paris, etc. Indofil Industries ltd. Is a market leader in: Fungicides- fruits/ vegetables Fungicides- Paddy/ Peanuts Herbicides- Onions Acaricids- Tea/ Vegetables Insecticides- IGRs
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Surfactants

Its Manufacturing units are placed in Thane, Pune, Vapi and Dahej. Its regional offices are placed in Punjab, Uttar Pradesh, Bihar, West Bengal, Maharashtra, Andhra Pradesh, Karnataka and Tamil Nadu. MOMENTS OF PRIDE: Received many awards like:

Asia star World star India star PFFCA state Best company from an emerging region- Agrow Awards Nov 2010, London

Growth trend In 2005- 2006 322 mt In 2006- 2007 233 mt In 2007- 2008 466 mt In 2008- 2009 597 mt In 2009- 2010 740 mt In 2014- 2015 4000 mt

INDOFIL Industries ltd. Dahej:

Company profile:

Bhoomi Pujan: 19th April 08 Construction started: August 08 Plant Completion: June 09 1st Export: August 09

Strength of team Dahej:


They are working on: Productivity improvement Time cycle Reduction Cost Reduction Efficiency Utilization Quality conscious Committed employees
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Believe in TEAM

Milestones since inception:


Project completed and commissioned in a record time of 1 year. Highest daily production 67 metric tonnes on 14th Dec. 10 81 metric tonnes on 25th Jan. 11

Growth trend- Dahej Plant


In 2009 2010- 78.98 mt In 2014- 2015- 4000 mt

Investment in Plant and Machinery:


The initial investment in plant and Machinery in the year 2009 was Rs. 150 crores

Future expansion plans:


To set up a new plant in collaboration with a Chinese company within few years. To set up a speciality chemical plant in Dahej

Present manpower status:


Employee strength: Permanent: 114 Contract labour: 130 Total: 244 (approx)

Organisational Structure:

Fig 5

Types of Communication channels:


FORMAL (written) E-mails Magazines Circulars Notices

INFORMAL (mostly verbal) Intercoms Mobile phones Open forum

Vertical and Horizontal communication applied. Unlike Govt. Communication there is direct & cross functional communication. It believes in Breaking Chain of command.

Present Product mix:

Fig 6

Competitive Scenario:
Regional and National competition(Agro business) UPL

Sabero Organics

Overall Organisational culture

Employees are associated with the company for many years Employees are committed to their work and their company. Employees believe in team work.

Indofil is an organization where the atmosphere is professional and the culture is warm, informal and open. The company believes in an open door policy, freedom to experiment and a free exchange of thoughts. To encourage this, there are various forums of communication, such as the staff meets for junior level management grades. The basic idea is to have a broad platform for an open dialogue. An in-house journal called Indofil Hilites is circulated amongst all employees quarterly. The company gives significant importance to the development of employees through training and allocates substantial budgets every year. Employees are put through technical training and skill development training related to the specific jobs which they are expected to do. Also there exists a systematic way of identifying specific training needs of the employees during the Performance Appraisal.

Strategies for Future growth and development and Benchmarking


Diversification To develop in house production of the raw material To set up new businesses To cover the European market.

Here the strategic group is known as Growth office. Growth office consists of different personalities who have mastered in their fields, like Finance, Marketing, Human Resource, Production, etc.

Vision statement
Global leader in growth with customer success The VISION of INDOFIL is equally simple - to focus on specific opportunities, drive growth and enhance value for esteemed customers. It has a highly skilled and successful sales team that believes in learning and working with the customers as PARTNERS - thus developing the products and services around core issues, to meet their future needs. Employing 705 people, INDOFIL has a sales turnover of Rs. 782 crores, as on 31st March, 2010.
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INDOFIL has a very strong domestic base and a well recognized international presence. Both businesses, Agricultural Chemicals and Specialty & Performance Chemicals, are poised for much faster growth by partnering/joint ventures for manufacturing, marketing and research and development activities with prospective companies across the world. INDOFIL which is a very strong Company is professionally managed by its CHIEF EXECUTIVE OFFICER & PRESIDENT, MR. R. K. MALHOTRA, a Post Graduate in Agriculture with 35 years "hands-on" experience and is an active and advisory member of various related Technical and Trade Associations. The Company believes in Complete Team working, Team winning strategies and innovation in its products, services and business processes with an unending urge to excel.

Mission statement

Fig 7

Values:
Customer success: Believing that success lies in the success of existing potential customers. On this foundation, doing all possible to understand, fulfil and exceed the customers stated and unstated needs, thus enabling them to succeed on a continual basis. Knowledge: Continually upgrading skills and knowledge about technology, markets, products, customers, regulations and business process. Encourage new ideas and their implementation across the company for commercial benefit. Prosperity: Winning, doing better than others through exploiting new opportunities and enhancing the interests of every employee, share holder and stake holder. To be recognised and perceived amongst the leaders in the segment of operation. Teamwork: Employees and channel partners thinking and working together across functions, business and geographies, leveraging the available resources to achieve common goals. Velocity: Responding to internal and external customers with a sense of urgency by consistent, focussed and accelerated growth of the organisation with timely and optimal utilization of all resources.

CHAPTER 2 Production department

Departmental Structure

Fig 8

ACTIVITIES OF PROCDUCTION DEPARTMENT


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The activities of production department are as follows:-

To ensure safe, continuous operation of plants. To implement and train down the line personnel on quality system. For continuous improvement in operations of plant and utilities conservation. To coordinate with maintenance departments for smooth running of the plant.
To ensure good housekeeping in the plant.

Minimization of waste and maximizing productivity

Types of product and their specifications

Specifications 80% W.P. (powder) Active ingredient(AI) Max. 81.5%

MANCOZEB 85% Technical Max. 85.5% Min. 70% Same Same Manfil 75% WG Granules 75.5% Min 68% Same 30 sec Flow able liquid 35.5% Min 90% Same NA

Suspensibility Min. 72% pH Time to dissolve in water(WOT) Moisture content(MC) Wet Sieve Test(WST) 6.8 7.5 60 sec

Less than 1% More than 99%

Same Same

Max. 2.5%

NA NA

Fig 9

Raw materials used:


Carbon disulphide (CS2) Ethylene Diamine (EDA) Caustic soda (NaOH) Manganese sulphate (MnSO4) Zinc sulphate (ZnSO4) Sodium lignosulphate (SLS)
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Hexamethylene tetramine (HMT)

Production process

Production of D-14 First chilled water is poured into the reactor Then CS2 and EDA are added into the reactor. EDA is added in two lots- 1st lot is added with Caustic soda. And 2nd lot is added with CS2 Caustic Soda is added in 3 lots- 2 lots solo and 3rd lot with CS2 And then excess CS2 is removed through distillation process. Thus D-14 is prepared Production of M-22 Initially there is water present in another reactor. In this reactor the D-14 is poured with MnSO4. MnSO4 is added in 2 lots- 1st lot is the heated lot added solo, 2nd lot is added along with D14. And then the reaction takes place. ZnSO4 is then added to the reaction so that it is not reversed. This is how M-22 is prepared.

This M-22 has great moisture content, so to remove excess moisture M-22 is passed through Larox Pressure Filter, where its total solid content is adjusted to around 50% and moisture content is brought down to 52%- 54%. Preparation of Slurry The slurry is prepared by adding water and then stirring it well in the Reconstitution tank. Preparation of powder Now this slurry is poured in Spray Drier where small droplets are formed of it with the help of atomiser. Then Hot air (temp- 310 degree Celsius) is blown in the Spray drier which removes the excess moisture and reduces from 52% to 10%- 12%. This is how the powder is prepared. Finished Product:

This powder is sent to a storage tank SILO from where is sent to Rotary Vacuum Drier (RVD). Here the air and moisture is removed with the help of heating and then vacuuming. The moisture content here is reduced from 12% to less than 1%. Thus the finished product is prepared and sent to cooler for cooling and then further sent for packaging.

Production Layout: (approximate)


EDA + CS2 + Water+ NaOH = D 14

Precipitator: MnSO4 + D14 + Water = M22 Larox Pressure filter = M22 Moisture

Rotary Vacuum Drier: Powderair - Vacuum

Spray Drier: Slurry Moisture

Homogenizer (preparation of Slurry)

Cooler Blender (for packaging)

Fig 10

TYPES OF PRODUCTS AND THEIR USES


In this plant only 1 product is manufactured. But it is produced in different varieties. The main use of Mancozeb is to be used as Fungicide. It is used all over the world to prevent fruits & vegetables from fungus attack. This product is not used directly. A solution is prepared according to the need by mixing it with water in a certain proportion and sprayed all over the fields.

COORDINATION BETWEEN PRODUCTION DEPT &.....


Logistics and Purchase: Here first the planning department plans the budgeted sales of the year. They inform the purchase department about the raw materials required to meet the budgeted sales and the Production department about the budgeted production to be done in order to meet the sales. The purchase department consults with the inbound logistics department to get the status of the present raw material and identify the gap between the required and available. The Production department co-ordinates with the logistics department for production process Production and dispatch: During the production period the samples are sent to the QA department for verification and testing. The final products samples are also sent for testing. After the approval by the QA department, only then the finished goods are sent to outbound logistics for further packaging according to the consignment. Now the consignment is sent to Sales department for further dispatch procedure. Production and Engineering Production department perform day wise production planning. Here Engineering department comes into picture as it has to provide daily preventive maintenance schedule so as to maintain a smooth working of production process. And in case if some breakdown takes
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place, the production department issues a work permit (via SAP) to the engineering department (shift wise) which performs the required action and fix the problem. Usually Daily review Meetings are conducted to report and discuss the problems, breakdowns per day and to come up with the solution. And these daily Review meetings are further reviewed in Weekly Review Meetings and these meetings are further revised in Monthly meetings, based on which the budget is planned.

Material handling equipments:


Forklift trucks The plant is designed in such a way so that it can use gravity as an equipment to move materials from one stage to another. The plant is basically designed on gravity.

DCS- Digital Control System


DCS system is used in controlling all the activities of the production process through computerized software. All the vessels and reactors are controlled through this system. There are 4 operators handling this system. The pressure, the heat, the material entry, its exit, etc are controlled by this system. All the similar activities are grouped together in order to simplify the process.

CHAPTER 3 Human Resource department

Department Structure and all activities:

Fig 11

The activities of Personnel /HR department are as follows:-

Ensure management of recruitment of personnel at the manufacturing unit. Ensure administration of the performance management system at the manufacturing facility.
Ensure compliance with all statutory and regulatory requirements relative to the

manufacturing facility. Identify training need and implement. Efficient administration of welfare, hospitality, communication, estate etc. Liaison with government authority, external agencies / Institutions & local authority. Implementation of multi skill for shop floor personnel. Proactive approach of handling land losers employments issue.
Impart training to officers and above. 2

Functions of time office:


The main purpose of time office is to keep record of absent and presence of employee. Office timings: - 9.00 Hrs. to 17.30 Hrs. Weekly off Day: - Sunday Attendance system: - Computerized Windows Based Punching system. Shift timings: Morning Shift Afternoon Shift Night Shift 6:00hrs to 14:00hrs

14:00hrs to 22:00hrs. 22:00hrs to 6:00hrs

LEAVES
Privilege leave Casual leave Sick leave Maternity leave 30 days p.a. 8 days per annum 7 days p.a. N/A

PERSONAL DETAILS OF EMPLOYEES:


1. 2. 3. 4. 5. 6. 7. C.V. (Curriculum Vitae). Employment form (Education and experience). Offer letter copy. Appointment letter copy. Conformation letter copy. All education certificates. Other Certificates (like Certificate of residential proof for loan applications). 8. Warning letters for misconduct. 9. Xerox copy of Form no. 2 ( declaration/ Nomination form)

HUMAN RESOURCE PLANNING:


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The organisation follows the common human resource planning process. 1) 2) 3) 4) 5) 6) Analysing the present situation of manpower. Forecasting demand of manpower in future Determining the supply of manpower. Comparing the demand and supply of the manpower Action plans Monitoring and Audit

Recruitment and selection


In Indofil, recruitment is done when any department is in a need of manpower. So departmental head has to fill man requisition form, in which detail regarding job title when required, description of duties, specific experience required and education & special training required are mentioned. This form is then signed by departmental head then it is sent to HR department head and then sent to GM. Then the personnel dept. through its sources i.e. internal/external fulfils the requirement of the dept. Firstly, the personnel dept. tries its internal source i.e. within the company if any employee is suitable for that vacancy the he is appointed or the personnel dept. refers the computer data bank or through internal reference. If the internal source cannot fulfil the requirement then through external source the requirement of the dept. is fulfilled. The external sources of Indofil are approved placement consultants or newspapers. The Recruitment Vacancies are classified as follows:

A 1 B C 2 3 B B C A 4 B A 5 B C General Manager Chief Manager Sr. Manager Manager Deputy/ Assistant Manager Sr. Executive, Shift Manager Officer and Executive Process Engineering Field, Electrical Sr. Vice President, Vice President and Director

Fig 12

Sources of recruitment:

Internal sources: Employee

retention References of internal employees External sources Employment exchanges Advertisement in News papers, Journals, etc. External references

SELECTION PROCESS:
In selection procedure, interviewer assists the interviewee on the basis of general intelligence, ability to express self verbally, enthusiasm, relevant experience and qualification and then overall rating is decided. Now shunting of all the applications for the vacancy is done as per the requirement and convenience of the company. This sorting process is done under the supervision of the HR mgr. After the sorting process the selected candidates are called in the organisation for the interviews.

Interview 1st Interview- Interviewer- HR Manager 2nd Interview- Interviewer- HR Manager and Heads of Department 3rd Interview- Interviewer- General Manager, HR Manager, and HODs
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After the 3rd interview, the candidate is finalized by the general manger. Then GM informs the head office and sends the offer letter to get it signed. Mean while the medical check up of the candidate is done Then the offer letter and the appointment letter are handed over to the selected candidate.

Performance Appraisal system for different levels:


Performance appraisal is the system used to evaluate the performance of employees, and to provide some rewards & incentives on their performance. Performance Appraisal focused primarily on helping the individual to develop his/her present role capability for that role. There is same PA system for every employee and trainee in the Organisation. At the beginning of the financial year, the employee decides his goals and objectives towards the organisation. This is known as the key result area. Key result area has certain Key Performance Indicators which are the small tasks or jobs performed in order to achieve the objectives or goals. At the end of every quarter HODs have a meeting and they measure and compare the actual KRA of an employee with the performance of an employee. At the yearend an annual report of the KRA is prepared and PA is conducted on that. Any gap or deviation or fulfilment of the objective is communicated to the employee and corrective measures are taken.

Training and development activities including Feedback process:


Training is a steady process but it can be healthy exercise means making one effective and perfect in his work assigned to him and to perform better in future. There are various training programme carried out in Indofil Industries ltd. for better performance of an employee, following are the types of training programme carried out

Behavioural training

Functional training Safety and health training Fire fighting training, Induction training On job training ,
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Class room training, Technical training, Process related training System training

These training needs of an employee is identified by the yearly performance appraisal form, also with the help of their training needs identification form which is being periodically send to department head and accordingly the employee are being trained. Any newcomer in the organisation in the organisation is given the required training on the basis of his job and an overall awareness required.

New joiner

Induction training

Awareness

Fig 13

FEEDBACK PROCESS OF TRAINING PROGRAMME


After the training programme is over, management tries to know the effective of the training programme. For this Training Programme Attendance, Feedback and course effectiveness form is filled up to know that is there any change in his working attitude and quality of work.

AVERAGE TRAINING MAN-DAYS


It is the policy of the company that each and every employee must get at least 2 Man-Days training in a year.

ROLE PLAYED BY DIFFERENT PARTIES IN TRAINING PROCESS


In training employee the main party involves are Company, Manager and Employee. This could be better understood as follows

COMPANY Provide structure, materials, resources and guidance to learn and develop 1

ROLES IN TRAINING PROCESS

MANAGER:Provides personal coaching, counselling and feedback encourages initiative

EMPLOYEE = DRIVER Task responsibility and initiative, seeks for opportunities for self learning a feedback from the manager and colleagues.

Fig 14

PROMOTION AND TRANSFER POLICY

PROMOTION A promotion may be defined as an upward advancement of an employee in an organization to another job, which commands better pay/wage, better status/ prestige & higher opportunities/ challenges & authority, better working condition & facilities at a higher rate. Rating factors: Promotion is based on an employees performance and need. The other factor that is taken into consideration is whether the employee is capable of handling a higher level job or not. TRANSFER Transfer can be defined as change or shift in the work place with same status, responsibility & authority, etc. It is based on needs of the organization, also on the bases of organization requirement and written down policy of the organization.

WELFARE ACTIVITIES

Welfare can be defined as the measure implemented by the company, the working conditions of the employees. Welfare activities are a kind of return, which is given to employees in return to their work. Following are the some welfare facilities provided by Indofil industries ltd....

Transportation Uniform for employee Canteen and guest house LTA Medical aid Sports day Water cooler and toilet Special gathering Picnics Movie shows Competitions for school kids

WAGES AND SALARY STRUCTURE


Wage and salary are different at different level, which is as follows

Components of salary:Basic Salary HRA Medical LTA Bonus Conveyance Fig15 40% of total CTC 40% Rs. 1250 10% 20% Rs. 800

INDUSTRIAL RELATION
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In Indofil, management is more concerned about the development of their employees. And employees, in return, are concerned about the development of the organization by providing quality work and proper coordination with management and their ultimate superior. In Indofil, there is no Trade union; this shows that there is warm and friendly relationship with employee-employer and employee-management. Every employee is free to express their views and problems with the management. In Indofil, there is no single warning letter being issued, no court cases going on. Management provides counselling for all employees to improve their work quality. Management also discusses the problems freely and friendly.

ACTIVITIES CARRIED OUT TOWARDS ORGANISATIONs DEVELOPMENT


Indofil carries out activity like Training of employee and suggestion form from employee for improving their work environment and ultimately the organization. Indofil has the strategy of 5 S which is a Japanese system of maintaining cleanliness in the organization.

ADMINISTRATIVE ACTIVITIES
Administration department has the following activities to perform... Communication with all dept. Transportation facilities Medical service Welfare activities House keeping Canteen facilities Tickets, coupon and accommodations

TRANSPORTATION

Administration department look after the transportation of all the employees in the organization, all the shift employees are being picked up from different stoppage.

SECURITY

The main function of security is to look after the Men, Machine and Materials. It has to protect these all over. In Indofil there are 3 officers, 1 Executive and 17 Contractual Guards (including both the shifts).

COMPUTER SOFTWARE USED

Record regarding time office is done in Windows based punching system. Record of employees is made in excel only. For pay roll of employees SAP software is used.

CHAPTER 4 Accounts department

Departmental structure

Fig 16

Activities:

The following is the main activities of Accounts dept.


Indofil Dahej plant reporting Monthly, Quarterly and Annually.

Compiling companys yearly budget.


To monitor monthly cash flow.

Managing day to day funds requirements. To manage the accounts of the company To manage the taxation policy

BUDGETING
A budget is a co-coordinated financial estimation of the income and expenditure of an organization related to a specified. Budget says Are plans of action quantified in money terms for some future period in time.

BUDGET MANUAL:

Budget manual is prepared by taking following points in to consideration. Pricing and duty structure. Sales volume forecasting. Raw material cost. Utility cost. Fixed cost. Interest cost. Capital cost. Previous years expenses statements.

BUDGET PERIOD
Budgets are prepared annually from 1st April to 31st March

ANNUAL BUDGET
The company prepares 2 types of annual budget: Expenses budget- Production budget Cash Mgmt Budget.

LONG TERM AND SHORT TERM FINANCE

LONG TERM The long term requirement of Indofil Dahej is fulfilled by the Head office in Mumbai.

SHORT TERM Short term requirement of Indofil, Dahej is fulfilled from Head office through HDFC bank.

ACCOUNTING METHOD / SYSTEM


SAP system is used in Indofil for maintaining all the transactions.
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COSTING OF THE MAIN PRODUCT Costing of the product is based on following factors Product cost includes the Input landed cost of raw material. Variable utility cost The following are the variable utility cost. Electricity and power Fuel Water Various other expenses. FIXED COST The following are the Fixed Cost Salary and wages Employee welfare Insurance Depreciation/interest

RESPONSIBILITY ACCOUNTING Department heads are considered as responsibility centre. Plants are considered as the profit centres.

CASH MANAGEMENT
Management of cash includes monitoring cash inflows and outflows of cash. Cash Inflows: Cash Inflows of Indofil are through: Receipt from debtors

Cash Outflows:
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Cash Outflows of Indofil are through: Payment to creditors

CREDIT MANAGEMENT
CREDIT POLICY Indofil allows credit to its debtors for 60 to 180 days.

CONTROL OF RECEIVABLES Receivables are controlled by preparing Aging schedule and Days sales outstanding. Collection activities are carried out from Head office at Mumbai.

TAXES
The company receives financial incentives as it comes under Special Economic Zone (SEZ). Almost all the finished goods are exported therefore there is no sales tax applicable. A special tax known as MAT (Minimum Alternate Tax) is applicable from this year that is FY 2011-2012, which is based on income. Some of the incentive facilities offered to SEZ units is: Duty free import/domestic procurement of goods for development, operation and maintenance of SEZ units 100% Income Tax exemption on export income for SEZ units under Section 10AA of the Income Tax Act for first 5 years, 50% for next 5 years thereafter and 50% of the ploughed back export profit for next 5 years. External Commercial Borrowing by SEZ units up to US $ 12500 billion in a year without any maturity restriction through recognized banking channels. Exemption from Central Sales Tax. Exemption from Service Tax.

Exemption from State sales tax and other levies are as extended by the respective State Governments.

FINANCIAL MIS
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Monthly cost sheet


Monthly P&L A/C

Monthly budget Preparation of Balance sheet Profitability report


Fixed / variable cost report

CHAPTER 5 Quality Assurance

Departmental structure:
1

Fig 17

Activities:
To establish and maintain product list results of QA Indofil comparable with

customers standards.
Adherence to calibration of instruments/ equipments and analysis of standard

samples.
Customer complaints - Export and Domestic customers

Impart training to officer and above.


To undertake 3 types of QUALITY analysis:

Input (raw materials/ packaging materials) In process

Finished goods. To undertake plant audit periodically- weekly, fortnightly; to see if Standard Operating Procedure is working right or not. To execute export activities as per procedures defined.

Types of instruments used:

1. Gas chromatograph 2. High performance liquid chromatograph 3. Particle size analyzer 4. U V visible spectrophotometer 5. pH meter 6. Karl Fischer apparatus 7. Viscometer 8. Melting point apparatus 9. Centrifugal machine 10. Hot air oven 11. Water bath 12. Moisture analyser

Method of Calibration
Calibration is done through outside agencies as well as in house. Depending upon the use of instruments, the frequency is decided. Quality Assurance is responsible for looking after and fulfilling the standard quality norms as lay down, it undertakes quality checks daily. It checks on the quality of product randomly selecting one of each type from every batch dispatched only after the product is marked with Q.A., passed that it is allowed. If quality is meeting as per requirements and as per specification then only finished goods are dispatched to customers. There is quality check at every stage of production so as to detect fault, if any, and to take corrective measures.

Parameters tested in the lab


Product Stage/sample Parameter Frequenc y % AI 1 batch/ fortnightly 1 batch/ fortnightly 1 batch/ fortnightly Each batch 1 batch/ fortnightly Each batch 1 sample/ batch Max 3 samples for WDG None Specifications

Mancozeb D-14

70% minimum 0.1% maximum 2 to 2+

% Na2S

Colour

pH

8.6 to 8.8

ETU

0.1% maximum 0.8% to 1%

M22 precipitant

Excess of MnSO4 % AI

50% 55%

%Total Solids

50% - 58%

% Purity

Minimum 95%

pH M-45 % Total Solid %AI % Purity Viscosity by ford cup method Spray Drier % M/C by IR % AI

None 1 sample/ batch None None None

6.8 to 7.2 Min 52%

46% - 49% Min 82% 24 sec maximum

None

10% to 12%

Once in a day Daily after 4 hrs interval Daily after 2 hrs interval

77 to 80 %

pH

6 to 7.2

WST

45 minutes

Fig18

Stage Final sampling

Parameter WOT WST pH

Frequency Each batch Each batch Each batch

Specification Maximum 60 sec Minimum 99% 6 to 7.1 for tech. 6.8 to 7.5 for 80% WP

Dry sieve test

One batch per day

No hard lump more than 3mm, easily soaked in water, residue not more than 250 mg Not more than 10 -12 black particles -

Wet screen test

Each batch

M/C by moisture Each batch


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analyser

Fig 19

Product

Stage/sample

Parameter % total solid

WDG ( wetable Homonizer slurry dispersible granules)

%AI 1st milled slurry % total solid Sediment 2nd milled slurry Total solid Particle size Viscosity Final sample %AI % suspensibility WOT per sec % attribution resist Appearance pH Blooming Clouding % % M.C. by IR Persistent foam ETU(ethelyne thio urea)% Mn content% Wet sieve test % Retention test Fig 20
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Quality plan& Sampling for key raw materials: Criteria for approval: Based on suppliers COA
1. CS2

2. EDA 3. MnSO4 sol. 4. ZnSO4 sol. 5. Sodium lingo sulphate(SLS) 6. Hexamine ( also based on solubility) MnSO4 monohydrate powder- appearance, pH, organic impurity, purity, COA, Caustics soda lye- appearance, assay Quality plan & Sampling plan for packaging materials: Parameters: For Multiwall laminated yellow paper bag (25 kg) imported Visual inspection for colour printing Measurement of dimension Weight of 2 bags For Multiwall laminated yellow, white, green, red paper bag (25 kg & 10 kg) Indian Visual inspection for colour printing Measurement of dimension Weight of 2 bags As per suppliers COA

For corrugated fibre board sheet 44 x 44 for export Visual inspection Measurement of dimension As per suppliers COA HMHDPE 120 lt. full open top drums Visual inspection Measurement of dimension As per suppliers COA Weight of 2 drums

LDPE Poly liners for 120 lt. Full open top drums Visual inspection
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Measurement of dimension As per suppliers COA Weight of 2 drums LDPE cover (44x44x12) Visual inspection Measurement of dimension As per suppliers COA Weight of 2 covers

Pine wood heat treated wooden pallets Visual inspection Finishing physical defects like knots, poor nailing, etc Measurement of dimension As per suppliers COA

Liner carton for Manfil vacuum pack (1 kg & 500 gm)


Visual inspection for colour and printing

weight of 2 packs Measurement of dimension As per suppliers COA

For corrugated fibre board boxes for small packing


Dimensions of 2 boxes

As per suppliers COA

CHAPTER 6 LOGISTICS AND DISPATCH Departmental Structure

Fig 21

MAIN ACTIVITIES OF DISPATCH AND LOGISTIC

Following is the main activities of warehouse: To maintain mini/max level of inventory To make procurement plans for imported and local raw material.

Coordinating Raw material inventory with the purchase department To ensure safe operation in ware house.
Adherence of Customs (SEZ) laws. To update and maintain all the documents.

Timely dispatch of material according to marketing department. To maintain proper housekeeping in warehouse. Coordination with other department to ensure smooth functioning. Shifting of FG from plant to warehouse and stacking to the Godrej Racks.

MODE OF DISPATCH Mode of dispatch is based on two types of sales made by the Indofil are as follows:Note: 90 % to 95% of finished goods are exported.

For Domestic sales- Road transportation For Export sales- from Dahej plant to Mumbai Port by Road transport and from there to different countries through ship vessels.

Sources of mode of dispatch


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ROUTING OF INVOICE and DISPATCH PROCEDURE


Documents required: Commercial invoice Shipping bill Certificate of analysis LR copy (lorry Receipt) Gate pass 402 form for border crossing

Details of commercial Bill: Party name L C no. Material description Shipping mark Container no. Seal no. Batch no. Price Exchange Currency

The invoice generates from the Marketing Department at the Head Office. From there it is sent to the Plant and the invoice number is generated here. Along with that other relevant details are also generated at the plant, namely:

Date of dispatch Batch number Shipping mark Consigners name Container number Purchase order number L.C. number Gross weight Net weight , etc

This invoice is then verified by the custom office in order to fill the shipping bill, which is generated there. These documents are then given to the driver of the container along with the Certificate of Analysis and a 402 form. Driver gives these documents to the Main SEZ gate in order to clear the container out of the gate. The officer here checks the documents and makes a record at the gate and let the vehicle pass after verifying them. After getting cleared from the SEZ gate the container moves towards Mumbai Port where it is unloaded at a place known as Buffer until the booked ship vessel arrives. Before loading the container into the ship, all the documents are checked and verified and then the shipping bill is endorsed by the Custom authority and the container is ready to get loaded. Now the ship takes the consigned container to the consigner.

Dispatch
Invoice generates from the Marketting dept. at

Comes to plant

Shipping bill is prepared

Plant generates the invoice no. and other details

Arrange the transportation

Truck reaches to company

1 Truck inspection

Comes to loading point

Empty truck weight

Prepare loading slip

Handover the invoice and other docs. to transporter

He prepare Dispatch document

Gross/Net weight of truck

Gate entry

Fig 22
Truck is out of gate

CHAPTER 7

STORES DEPARTMENT

Types of stores
There are mainly three types of stores and they are Raw material store Engineering stores Finished goods stores

Classification of material
1

Carbon disulphide is classified in to 3 category of material. Ethylene Diamine (EDA) is classified in to 3 category of material. Finished Product (Mancozeb) is classified in to 9 category of material.

INVENTORY MANAGEMENT SYSTEM


Inventory is managed through Automatic Storage Retrieval System (ASRS). It is a fully automatic system which reads the barcode of the finished goods pallet and stores the finished goods according to the space available.

MATERIAL CODING SYSTEM


Since there is only one product manufactured. There is no material coding system applicable in this plant.

Storage medium
The storage mediums used in the company are:

120 lt. capacity drums Bags - 1 kg and 500 g capacity. For vacuum sealing Bags 50 kg, 25 kg, 10 kg

Material handling within the stores


Materials are handled within store through forklifts only.

STORAGE PROCEDURE
Receipt procedure: Whenever raw material, chemicals reaches to the company and in stores, stores dept. prepares GRN (Goods Receipt Note). Storage procedure: As an when goods come to store it is inspected, and if found defective, the item is rejected and not stored in store dept. After inspection the goods are sent to the raw material warehouse from where they are loaded to racks/ shelves where the entry is being made through WMS/ SAP. Issue procedure:
1

Goods are issued on FIFO method. Finished Goods storage Procedure Once the finished goods reach the F.G. warehouse after the quality check, they are transported to the ASRS system. The forklift places the 1 pallet at a time on the rack of ASRS, from where the pallets barcode is read by the machine. Then the machine lifts up the pallet from the rack and places it on one of the shelves which is empty automatically. This new FG pallet is recorded in the software used by the ASRS and the entry is made of the new finished goods. The bar code on the pallet contains all the required information such as products specification, its manufacturing date, expiry date, etc. So when the barcode reader reads, it makes the entry. Issue procedure of finished goods: The goods are issued on FIFO basis. When they are required, the operator enters the quantity and the product specification required to the ASRS software and the ASRS machine brings the appropriate pallet on the rack and places on it. From here forklift takes the pallet and takes it to the container or the place from where the goods have to be dispatched.
STOCK VERIFICATION Stock is verified thrice in a month.

CHAPTER 8 ENVIRONMENT SAFETY, HEALTH DEPARTMENT

Departmental structure

Fig 23

Main activities of EHS Towards Environment and Safety


To provide safe environment to all the employees and workers. To prevent accidents in plant. To provide PPE to all the employees and workers and follow the compliance. To provide training to all employees regarding EHS. Investigation and Reporting of all accidents. To properly treat all the waste generated in the plant as per legal compliance
3

Operation of the ETP to meet the Pollution Control Board standards. Proper disposal of hazardous waste. To keep relations with government authorities like Gujarat Pollution Control Board, factory inspectors Maintain Fire Production Systems.

Towards Health of Employees and Workers

To operate the occupation Health Centres Monitoring of hygienic conditions Monitoring of Workplace environment Periodical Medical check up of employees Maintain First Aid box inside the plant.

Resources available for Emergency:


Emergency Response team First aid Team Rescue team Fire Men Fire extinguishers Fire hydrant lines Self containing Breathing Apparatus

Personal Protective Equipments available:


Helmets Shoes Goggles Hand Gloves Dust masks Paper masks Ear Plugs

At times of emergency the company has its own Onsite Emergency Plan which help it solve the problem and to find the route cause as soon as possible The roles and responsibilities are of the Emergency Response team is pre-defined by the company itself.

Onsite Emergency Control Plan


Classification of Emergencies A- Smouldering/ localised fire B- Fire in large area/ toxic release/ heavy spillage/ injuries to personnel requiring hospitalization. C- Major fire- potential to spread/ Explosion/ Bulk leakage/ serious injuries to personnel may require evacuation of works partly or wholly.
1

D- Natural Calamities E- Environmental emergencies

Handler Incident controller Site Controller

Emergency A B, C, D, E

Fig 24

Roles:
Roles Site Main Controller (SMC) Person responsible
Chief of Unit/Operation. Mech. Engr. (During odd hrs.) Shift Production manager Geographical Area InCharge HR Manager and or Security In charge on duty ERT Member Manager / Executive

Reporting location
Emergency Control Room

Incident Controller (IC) Dy. Incident Controller, Liaison Officer. Emergency Response team/ Medical Services Safety In-Charge- Manager Production and Electrical, Utility Safety In-Charge Fire pump Operator

Scene of Incident Scene of Incident At security gate Reach at the scene of incident First aid centre

Sr. HSE Manager / Sr. Executive Utility operator (Cooling tower pump operator)

Scene of incident Fire pump house

Fig 25

CHAPTER 9 ELECTRICAL AND INSTRUMENTS DEPARTMENT

Departmental structure:

Fig 26

Activities of electrical department:


Provides continuous power without interruption. Energy saving Providing and keeping Electrical equipment in good condition for better production. Provide reliable service to other departments for electrical equipments.

The power supply is provided by Torrent Energy. Torrent Energy takes power from DGVCL. There are transformers of 2500 KVA in the plant and 1250 amp. VCB high tension breaker There are 2 DG set of 860 KVA on standby in case of power cut emergency.

Contractor / Technician

Activities of Instruments department:


They are responsible for smooth running operation of plant. Maintenance of all field instrument e.g.: 1. Pressure Transmission 2. Level Transmission 3. Flow Transmission 4. Temperature Transmission 5. Gages Transmission
3

Maintenance of control system, e.g. DCS (Distributed control system) Breakdown Maintenance of all systems instrument. New modification of system /new technology arrive New Project /Expansion work. Preventive maintenance of all instruments. Calibration of all instruments.

CHAPTER 10 MAINTENANCE DEPARTMENT

Departmental structure:

Fig 27
1

Activities:
Responsible for smooth running and operations of plant. Maintenance of all Mechanical equipments like: Reactors Heat Exchanger Rotary Vacuum drier Rotary Cooler Blender Spray drier Blowers, etc Breakdown maintenance of all mechanical equipments Preventive maintenance of all mechanical equipments Preventive maintenance of all mechanical equipments To undertake new projects and expansion work.