Absentism Report by Vivek Mahajan

7/26/2019 Absentism Report by Vivek Mahajan

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A

Project Report

On

Absenteeism among Workers of Ambuja Cement Limited at Mines

Submitted To Himachal Pradesh University Summer Hill Shimla

In The Partial Fulfilment of the Requirement of Award

Of

e!ree of "#achelor of #usiness Administration$ %##A&

Session 2013-2014

Submitted By: - Submitted To:-

'ive( )aha*an Assistant Prof+ An*u #hattna!ar

##A,-thSem+ e.t+of ##A/ 0ovt+ P+0+1+#ilas.ur

Roll 2o+ 3-45 Himachal Pradesh

1


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Tabe o! "ontents1#

$Absenteeism Amon% &or'ers O! Ambuja "ement (imited)#######################1

1#Ac'no*ed%ement############################################################################################3

2#"erti!icate#########################################################################################################4

3#Pre!ace##############################################################################################################+

Section- A

1#,ntroduction To ,ndian "ement ,ndustry######################################################

a) Raw material and

keyinput............................................................................10

b) Overview of Ambuja cement

Limited............................................................12

c) Board of director of

A!L...............................................................................1"2#,ntroduction o! Absenteeism#########################################################################30

a) !aue of

Abenteeim.................................................................................

.#1

b) $ype of

Abenteeim.................................................................................

...##

3#Researc. /et.odoo%y##################################################################################3+

a) %ata

ource.........................................................................................

.........#&

b) Reearc' Approac'( Reearc' intrument(

am...........................................#

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Section- B

1#ata Anaysis And ,nterpretation################################################################3

2#"oncusion######################################################################################################0

uestionnaire########################################################################################################

Bibio%rap.y##########################################################################################################

Ac'no*ed%ement

I would not have achieved success in my .ro*ect without the hel. of various

.eo.le+ I would li(e to than( all those who su..orted me and !uided me all the

way for com.letion of my .ro*ect+

I e6tend a wholehearted than( to /r#S#S#Sod.i /r# ayanandS.armawithout whom my trainin! would not have been com.lete +I would

li(e to than(s my .ro*ect !uide Pro!# Anju B.attna%arfor !uidin! me in

the com.letion of my .ro*ect re.ort+ I would also li(e to than( all the em.loyees

of Personnel e.artment for hel.in! me for successfully com.letin! on the *ob

trainin!+

I e6tend my .rofound !ratitude to the staff of )ana!ement e.t+ Of the 0ovt+

Post 0raduate 1olle!e #ilas.ur %HP& for their co,o.eration in .rovidin! the

required information for the com.letion of .ro*ect+

7ast but not least/ !reat than(s to my .arents without whom nothin! was

.ossible and also than(s to res.ondents who rendered their .recious time and

hel.ed me in fillin! the questionnaire/ which made my .ro*ect more a..ealin!

and attractive+

#


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5,567 /A8A9A

"


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"erti!icateThis is to be certified that .ro*ect entitled 8Absenteeism Amon% 6mpoyees o!

t.e Ambuja "ement (td at /ines)is a bonafied record wor( done by the

5i;e' /a.ajan durin! on the *ob trainin! submitted to the H+P+U shimla in

.artial fulfillment of the award of the de!ree of the #+#+A and that the .ro*ect

wor( has not been .reviously formed the basis of the award of any de!ree+ The

.ro*ect wor( re.resents inde.endent and ori!inal wor( on the .art of candidate

under my !uidance+

Si!+ of the candidate 2ame 9 Si!+ of the 0uide

Si!+ 1oordinator of #+#+A+

ate:

Place:

*


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Pre!ace)ana!ement ideas without any action mean nothin!+ That is why .ractical e6.erience is vital

for any mana!ement student+ Theoretical studies in the classroom are not sufficient to

understand the functionin! climate and real .roblems comin! in the way of mana!ement of

)en/ )aterial/ )achine and )oney+So .ractical e6.osures are indis.ensable to such courses+

Thus .ractical e6.eriences are as a su..lement to the classroom studies+It offers an e6.osure

to real .ractical of mana!ement studies in various or!anisations+

This .ro*ect re.ort deals with 8Absenteeism amon! ;or(ers of Ambu*a at )ines

.eo.le+ The research was limited to wor(ers of mines of Ambu*a+ I have contacted the

wor(ers throu!h .ersonal interviews with the hel. of questionnaires+

The main ob*ective of research study was to find out the rate of absenteeism+ In the last

.hase of the research .ro*ect findin!s/ su!!estion and conclusion has been drawn+

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Section- A

,ntroduction

To

,ndian "ement

,ndustry


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,ntroduction to ,ndian "ement ,ndustry

1ement is fine mi6ture of calcium silicates and aluminates which sets to form a

unit mass when treated with water+ ?ose.h As.din of @n!land first .atented the

manufacture of a very im.roved ty.e of cementatious material for buildin!

construction in BC4 and named it 8Portland 1ement< because of its

resemblance to the famous roc( available in the .lace called Portland in

@n!land+For the constructional .ur.ose the meanin! of term cement/ is

restricted to the bondin! material used with stones/ sand bric( buildin!/ bloc(setc+

India is today second lar!est .roducer of cement %first bein! 1hina& in the world

with an installed ca.acity close to 55 million tonnes .er year+ D5E is

consumed domestically and 5E is e6.orted+ emand is !rowin! at a rate more

than >E .er annum+ )ore than D>E of .roduction comes from lar!e cement

.lants+There are a total of > lar!e and more than 5> small cement

manufacturin! units in the country+

The forms of cement .roduced:

Ordinary Portand "ement,It Is a 1ontrolled #lend Of 1alcium Silicate/

Aluminates and Ferrate+

Portand Sa% "ement,It Is a )i6uture of Portland cements 1lin(er and Sla!

in ;idely 'aryin! Pro.ortions+

)a*or .layers in Indian 1ement Sector are:

Heidelber!

7afar!e

Italcementi

Holcim

Ambu*a 1ement 7imited

A11

Ultratech 1ement

Indian 1ements 1entury 1ements

+


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?ay.ee 0rou.

)adras 1ements

alima 1ements

The cement industry has continued its !rowth tra*ectory over the .ast seven

years+ omestic cement demand !rowth has sur.assed the economic !rowth

rate of country for the last cou.le of years+ Over the .ast five years %FG,>,>3&/

cement demand has !rown at a 1A0R %1om.ound Annual 0rowth Rate& of

B+3E hi!her than the 1A0R of su..ly of 4+B4E+ emand for cement in the

country is e6.ected to continue its buoyant ride on the bac( of robust economic

!rowth and infrastructure develo.ement in the country+

emand for cement is lin(ed to the economic activity in the country+ The

cement demand in emer!in! economies is much hi!her than the develo.ed

countries where the demend has reached a .lateau+In India demand for cement

wlli affected by s.endin! on infrastructure+

ey drivers for cement demand are real estate sector infrastructure .ro*ects and

industrial e6.ansion .ro*ects+Amon! this real estate sector is (ey driver and

accounted almost 55E cement demand in FG>3+ Infrastructure .ro*ects have

accounted for C>E of the demand and industrial e6.ansion .ro*ects have

accounted for 5E of the total demand+ Other sectors has accounted for >E of

the total cement demand in the country+ The consum.tion .attern of cement has

been shown !ra.hically+

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urin! the .eriod FG >,>3 ca.acity additions in the country %>+- mn tonnes&

were at a slower rate as com.ared to demand !rowth leadin! to hi!her avera!e

ca.acity utilisation rates from B+E in FG > to D+BE in FG >3+This e6erted

.ressure on avera!e .rices have increased from Rs+ 5- .er ba! in FG > to

Rs+C- .er ba! in FG >3+In ecember C>>3/ .rices stood at Rs+ C45,Rs+ C5> .er

ba!+

1ement is a bul(y commodity and can not be easily trans.orted over the lon!

distances ma(in! it a re!ional mar(et .lace+ @ach re!ion has its own demand

and su..ly dynamics+

Over the .ast five years cost of cement has !rown at a 1A0R of B+4E+ To

reduce the cost of .roduction/ the industry is increasin! its focus on ca.tive

.ower !eneration+

)ar(et share of to. five .layers in the industry has increased from 4CE in FG>C to 5-E in FG >3+ In FG >3 the Holcim 0rou. maintained its leadershi.

.osition with mar(et share of CC+-E followed by Aditya 'i(ram #irla 0rou. at

a D+4E mar(et share+ @stimates domestic cement demand to !row at a 1A0R

of a..ro6imately >E for the ne6t five years+ As new ca.acities come in/ we

may witness softenin! in .rices in some re!ions+

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Ra* /ateria and 7ey ,nputs

7imestone .resents the ma*or raw material in.ut for the .roduction ofcement+Hi!h quality limestone is accessible almost all over the country+For the

.roduction of OP1%Ordinary Portland 1ement&/ clay and !y.sum serves as

additives while the .roduction of PP1%Portland Po==olana 1ement& and PS1

requires additives that can be ta(en from industrial wastes such as fly ash and

blast fufnance sla! res.ectively+2either of these in.uts currently .laces any

constraint in terms of availability or quality on the .roduction of cement+Fly ash

can be recovered as a waste .roduct from electricity !eneration while sla!

residues from the blast furnance of steel .lants+

(imestone

It is the basic raw material required for the cement .roduction .rocess+ About

+5 tonnes of limestone is used in the manufacturin! of tonne of cement+

1ement !rade limestone is located only in certain areas in the country leadin! to

estabilishment of cement .lants in clusters+ 7imestone is available in lar!e

quantities in Ra*asthan/ )adhya Pradesh/ 0u*rat/ Andhra Pradesh/ arnat(a/

Tamil 2adu and some .arts of #ihar+This has created a no+ of .oc(ets of

cement .roduction called as clusters+

The Himachal unit of Ambu*a 1 ement 7td+ satisfies its limestone requirement

from the reserves of limestone of ca.tive mines/ which is located at ashlo! at

a distance of near about C>(ms+ From the site of the .lant+It is estimated that

this reserve will last for 5> years+ The limestone is mined by the .rocess of

surface minin!+

The com.any has also acquired the nearby )an!oo #loc( for minin! of

limestone to utilise the incresed .roduction of the .lant+

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"oa

1oal is a wild card for cement industry+ 1oal is used as fuel in cement

manufacturin! .rocess and also used in ca.tive .ower !eneration+

Around C5 tonnes of coal is used to ma(e >> tonnes of cement+ 1oal forms

about C>E of the total o.eratin! cost+ The industry uses about 5E of the coal

.roduced in the country+ Until recently/ .rivate ownershi. of coalmines was not

.ermitted in India and all .urchases had to ma(e from !overnment,owned

coalmines+

1oal is abundantly available in @astern )adhya Pradesh/ Orissa/ #ihar/ 2orth

Andhra Pradesh and @astern )aharastra+ The coal fields are inefficient resultin!

in delays in coal availability+ Since the quality of coal is .oor %hi!h ash content&

and inconsistent/ this leads to .roblems of quality control for cement .lants+

Pet 1o(e %waste .roduct of .etroleum Industry& is !radually ma(in! its s.ace

amon! the fuels used by some of cement .lants mainly in 0u*arat and

Ra*asthan+

A17 unit at Himachal .rocures coal from #ihar %@astern 1oal Fields&+

Transportation

1ement is hi!hly frei!ht intensive in nature+ @very tonne of cement

manufactured involves the trans.ortation of +- tonnes of limestone/ >+C5 tonnes

of coal/ >+>5 tonnes of !y.sum and one tonne of the finished .roduct+ Frei!ht

accounts for about C>E of the total cost+

Po*er

1ement industry on an avera!e requires 5 units of .ower to .roduce one

tonne of cement+Owin! to erratic .ower su..ly/ most of cement .lants have

installed ca.tivevieselJThermal Power !eneration ca.acity+

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O;er;ie* o! Ambuja "ement (imited

Ambu*a 1ement 7imited was set u. in late B>s+ It was set u. in DB-+ In the

earlier the com.any was (nown as 0u*rat Ambu*a 1ement 7imitrd+#ut in C>>3

this was chan!ed from 0A17 %0u*arat Ambu*a 1ement 7td+& to A17+This

conversion was effective from 5thA.ril C>>3+ The cement industry .resented an

o..urtunity of steady !rowth and ethical com.etition to .romoters+ In the last

decade the com.any has !rown tenfold+

Today Ambu*a is third lar!est cement com.any in India with an annual .lant

ca.acity of 3 million tonnes includin! Ambu*a 1ement @astern 7td+ and

revenue of Rs+ CDB crores+

Ambu*a believes that its valuable assets are not cement .lants+ They are the

.eo.le who run the .lants+ This unique vision is enca.sulated in the com.any$s

home,!rown .hiloso.hy of !ivin! .eo.le in authority to set their own tar!ets

and the freedom to achieve their !oals+It is called $, can)#

This sim.le vision has created an environment where there are no limits to

e6cellence/ no limits to efficiency and has .roved to be .owerful en!ine of

!rowth for the com.any+ As a result/ Ambu*a is the most .rofitable cement

com.any in India and one the lowest cost .roducer of cement in the world+


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Brandin% a "ommodity:

1ement is a commodity/ sold lar!ely on .rice+ Ambu*a 1ement was the first

com.any to create a brand out of cement and command a .remium+ The tric( of

course was to .rovide a consistency hi!h quality of cement/ bac(ed by e6cellentservice+ Ambu*a 1ement is the to. brand in ;estern/ 2orthern/ 1entral and

@astern India+

6=ports:

Ambu*a 1ement e6.orts almost 3E of its .roduction in a very com.etitive

international environment+ For the last ten years/ the Ambu*a 1ement 7imited

remains India$s hi!hest e6.orter of cement+

This has been .ossible for two reasons:

One/ the quality of cement best matches in world+

Two/ the dedicated bul( cement trans.ortation ca.ability of 0u*rat .lant+

T.e 6n;ironment:

From the outset/ Ambu*a has believed that a cement .lant can not flourish at the

cost of environment+ That$s why it adheres to the most ri!orous international

environmental norms+

,nte%ration *it. 8ocim:The Holcim 0rou. holds 43E shares in Ambu*a +

The inte!ration .ro!ram with Holcim is .ro!ressin! well+ It is im.lementin!

various .ro!rammes across the com.any/ which includes buildin! robust

business systems and .rocesses/ throu!h the im.lementation of SAP %System

A..lication Product&+ SAP is a .ro*ect 81onnect India Plus< which aims at

connectin! all the .lants/ business .laces across India online+ It is e6.ected to

!o live by Au!ust C>>B+


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76> P6OP(6 O< A/B?9A@ BOAR O(ms+ by

road and about (ms by belt conveyor+

)ines are of two ty.es: o.en cast or under!round+ The ty.e of minin! de.ends

u. on the factors such as de.th of location of ore/ the waste burden to be

handled and the value of de.osit+ In the case of limestone/ o.en cast minin!

form is usually .refered+

/inin% /et.od Sta%es:

rillin! and #lastin!

1rushin!

Trans.ortation of 1rushed )aterial

/inin% Procedure:

The limestone is mined from o.en cast quarry by conventional drillin! and

blastin! method+ For blastin! e6.losives amonium nitrateNfuel oil and A2FO in

slurry form are used+ The blasted material is e6cavated by hydraulic e6cavaters

and loaded in to haula!e dum.ers+ The material is hauled from quarry to crusher

for si=e reduction+

Occasionally/ hydraulic ri..er also ri.s the limestone+ )arl is du! out by

ri..in! as it is very soft and loose+ Ambu*a 1ement 7imited is also usin!

surface miners for limestone .roduction from mines+ ;ith this/ drillin!/blastin!/ loadin! and crushin! is totally avoided+

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"rus.in%:

"rus.er

Pur.ose: 1rusher is required in the cement .lant to reduce the si=e of bouldersafter the minin! .rocess+ The limestone mined is dum.ed in to crusher ho..er+

The material is conveyed from the ho..er to the crusher by means of .ush

feeder+1rusher used in this .lant are .rimary im.act crusher and secondary

roller crusher+

&or'in%

The .rimary im.act crusher contains one heavy rotor hori=ontally mounted

inside a ri!id frame which lines throu!hout with re.laceable linear .lates+ Thematerial is fed in to the crusher via feed rollers or enters directly on the to. of

the rotor+ ;hen the fed material enters the crusher/ it is initially struc( by

hammer and then .ro*ected a!ainst the brea(er .lates at the o..osite side of

feed o.enin! and in this way the material !ets crushed due to im.act+

The secondary roller crusher contains two rollers rotatin! in o..osite direction+

The material is fed between these two rollers and !ets crushed+

The limestone after bein! crushed is then trans.orted from ashlo! mines to.lant by over land belt conveyor+

Bet "on;eyor:

#elt conveyor is a ty.e of conveyor in which limestone is trans.orted from one

.lace to another+ The belt conveyor .lays a very im.ortant role in a cement .lant

and we can say that belt conveyor as wor(in! hand of cement .lant from

blastin! of limestone to .ac(in! of cement+ The total belt conveyors in Suli

.lant are CC+

O;er (and Bet "on;eyor O(B"

The material after bein! crushed !oes to #1, conveyor from where it is fed to

#1,4 conveyor %O7#1&/ which is at hi!h distance over the land+ It is about

(ms+ 7on! conveyor belt/ runnin! throu!h three hills+

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Stac'in% and Recaimin%:

Stac'er

The .ur.ose of stac(er is to ma(e .iles of limestone on one side of yard

conveyor+ The incomin! material from the yard conveyor is conveyed via

tri..er on to the #oom #elt and dischar!es it on to the Stoc( Pile Area+ Stac(in!

system starts with #oom in lower most inclination travellin! full len!th of .ile+

At .ile end sto..in! for a few seconds it !et reversed with #oom raised by a

small .redetermined ste. and a!ain travellin! full len!th of .ile+

Recaimer

The .ur.ose of reclaimer is to cut .iles across the surface to !et homo!enised

material+

The material is unloaded from the .ile by the action of ra(in! down by

Reclaimer+ The reclaimer cuts stac( .ile in a slice from .arallel to face of .ile

and shifts material %limestone& to belt with the hel. of scra.er+ The scra.er is

desi!ned for homo!enisin! and reclaimin! of bul( material stored onlon!itudinal .iles on either side of machine+

At the .ile base the material is sei=ed by the blades on the endless scra.er chain

and is conveyed to belt conveyor %#1,3& that runs lon!itudinally alon! the .ile+

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Ra* /ateria Crindin%:

The reclaimed limestone from #1,3 is then conveyed to raw limestone ho..er

and the additives %shale/ red ochre 9iron orew& are conveyed to raw material

ho..ers throu!h #1,B 9 #1,D+ The desired amount of limestone and additives

are fed to common belt conveyor #1,> throu!h ;ei!h Feeders and then in to

raw mill throu!h #1,+

Ra* /i

The raw mill !rinds the mi6ture of limestone/ shale/ red ochre and iron ores to

.roduce a raw meal mi6ture suitable for calcination by the PreheaterJ iln+

A chute directs the raw material from the tri.le !ate to a circular !rindin! table+

The centrifu!al force from the revolvin! table moves the material outward and

under the !rindin! rollers+ The coarse material is re*ected and sent bac( a!ain to

mill for re!rindin!+

The fine material from the mill is carried throu!h the cyclones where most of it

dro.s out+ This material is conveyed by a series of air slides to buc(et elevator+

The buc(et elevator conveys the material in to #lendin! Silo+The remainin! fine

dust is carried throu!h the #a! House ust 1ollector by a series of chain

conveyors and the buc(et elevators to sur!e silo+

Cass Ba% 8ouse

The !lass ba! house contains a lar!e no+ of ba!s which are made u. of s.ecial

fiber (nown as !lass fiber+ The heavy raw material !ets sun( in the ba! at the

bottom and the fine .articles in the form of !as are ta(en out to main stoc( by afan %#a! House Fan& where they let out by a chimney+ The raw material is

collected and then conveyed to blendin! silo by means of chain conveyors and

buc(et elevator+

2"


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Ra* /ea Stora%e Bendin%:

Bendin% Sio

Purpose: #lendin! of raw meal+

&or'in%: The !round raw meal is conveyed by buc(et elevators to a stron!

vessel called #lendin! Silo+ The blendin! silo is CC meter in diameter and D

meter in hei!ht+ The blendin! silo is li(e an inverted cone in its structure and

form+ The stora!e ca.acity of blendin! silo is 45>> tonnes+

In the blendin! silo further mi6in! and homo!enisation of raw feed ta(es .lace+The stored raw mill material is blended and e6tracted simultaneously+ The

bottom of blendin! silo consists of a central cone/ .eri.heral area of which is

divided in to > .ortions/ which are fitted with air slides inclined towards cone

havin! > dischar!e o.enin!s fitted with control flow !ates+ O.eration is

controlled in such a way that any two o..osite !ates are o.en to!ether in .airs+

2*


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Pre.eatin% and Burnin%:

Pre.eatin%

The .reheatin! section is subdivided in to two .arts called .re,calcinin! strin!

and (iln strin!+

Preheatin! is done by .re,heater and burnin! is carried out in acalciner heater

consists of - sta!e cyclone .reheatin!+ The hot !ases comin! from iln are

.ushed u.wards usin! iln Strin! fan9 1alcinatin! Strin! fan+ The hot !ases!oin! u. heat the raw material comin! down+ The material se.aration from air

is done in - sta!es throu!h cyclones which force the material to !o downward

and hot !ases to move u./ hence heat e6chan!e ta(es .lace+ The whole .rocess

ta(in! .lace in both of the strin!s is called 1alcination+ 1alcination .rocess is

ta(in! .lace in .reheater and only >E of calcination .rocess ta(es .lace in the

iln section+

Burnin%

The burnin! .rocess ta(es .lace in the rotary (iln in which the material comin!

from blendin! silo is converted in to fluid by heatin! u. to tem.erature of 4>>,

->> de!rees+ It is desi!ned to .roduce 4->> metric tonnes of clin(er .er day+

Automatic s.ray lubrication system is also .rovided for (iln !irth !ear+ A multi

channel/ hi!h efficiency burner is .rovided for (iln+ The burner offered is

suitable to o.erate with coal havin! calorific value of B>> ( calJ (!+ The burner

is desi!ned for a ca.acity of B+4 million ( calJ hr+

2&


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"in'er "ooin%D Brea'in% and Stora%e:

The hot material from (iln is fed on to the .lates of cooler havin! holes+ It has a

reci.rocatin! movement which is used for material flow from one .late to

another+ #elow the .lates there are chambers havin! fans and air at hi!h

.ressure is blown throu!h holes+ ue to this the clin(er is cooled to 5> de!ree

centi!rades+ The cooled clin(er is fed to 1lin(er #rea(er that crushes the bi!

.ieces in to .redetermined si=e+ The cooler e6haust !ases are vented out to

atmos.here throu!h an electrostatic .reci.itator+

The cooler used in the coolin! .rocess are 0rate 1oolers+

The 0rate 1ooler is divided in to three sections:

1ontinuous Im.act System %1IS&

1ontrolled Flow 0rate %1F0&

1onventional 1ooler %11&

The material %clin(er& after bein! cooled is stored in clin(er stoc( .ile or also

called clin(er yard+ The most of the clin(er/ say about 3>,B>E is trans.orted to

Ro.ar !rindin! unit of Ambu*a and rest C>,>E of clin(er is used in the

arla!hat .lant for cement manufacturin!+

"ement /i and "ement Stora%e:

2


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Purpose:1ement mill is used for the .ur.ose of !rindin! of clin(er and other

additives for ma(in! cement+

The .ro.er amount of clin(er %obtained from clin(er yard&/ fly ash from fly ash

silo and !y.sum are fed in to their res.ective wei!h feeders throu!h res.ective

ho..ers+ Then throuhh belt conveyor #1B/ the whole mi6ture is fed in to

cement mill also called ball mill+1ement mill is a hori=ontal mill/ which

contains a no+ of steel balls of different diameter as !rindin! media/ so called

ball mill+ The cement mill consists of two com.artments in first com.artment

!rindin! steel balls are of ->,3> mm of diameter ran!e and in second

com.artment they are of C5,> mm in dia+ ;hen clin(er/ fly ash and !y.sumcome in contact with so many steel balls fallin! u. and down/ they !et crushed

in to fine and coarse .articles and mi6ed homo!eneously with each other to

form cement+

The coarse .articles are recirculated by O,Se.a fan+ The coarse .articles !et

collected in furnance while fine .articles are stored in silos conveyed by buc(et

elevators+ Silo in which cement is stored is called 1ement Stoc( Silo+ There are

four cement silos each havin! a stora!e ca.acity of 3>>> tonnes and each is

used to store 5>>> tonnes of cement+

A micro.hone sensor estimates the amount of cement .rocessed in cement mill

at a .articular instant by sensin! the sound .roduced by rotatin! cement mill+

Inductive .ro6imity switches sense the RP) of cement mill+e,dustin! of !ases

.roduced durin! the .rocess is achieved by electrostatic .reci.itators and ba!

filters+

"ement Pac'in% and ispatc.:

2+


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1ement stored in the cement silos is then e6tracted and is fed to electronic

Rotary Pac(ers by .neumatic !ravity conveyor and buc(et elevator+ The rotary

.ac(ers are three in number/ one with twelve no==les and two with si6 no==les

each+

Rotary Pac'ers

The rotary .ac(ers are used for .ac(in! cement in to cement ba!s+

Automated .ac(in! of cement ba!s involves followin! ste.s :,

S*itc.in% on o! a Pac'er: -Pac(er automatically selects the no==le whose no+

is .rovided at the in.ut+

Pacin% o! 6mpty Ba%s:-The ba!s are .laced manually by the wor(er and heactivates a lever+This in turn !ives a si!nal to a solenoid valve that o.erates the

cylinder .neumatically which holds the ba!+

Tarrin%: - ;hen em.ty ba! .laced by the wor(er is detected/ the total wei!ht is

ad*usted to =ero by controller+

"oarse


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+ To (now whether wor(ers remain absent from their wor( or not+

C+ To find out the reasons of absenteeism+

+ To find out that at which shift the ma6imum no+ of wor(er remain absent+

4+ To study the effects of absenteeism on the wor(ers+

5+ To study the effects of absenteeism on or!anisation+

-+ To (now the e6.ectations of wor(ers from the or!anisation+

,ntroduction to AbsenteeismAbsenteeism is said to be there when an em.loyee fails to come to his

scheduled wor(+ It is a bi! .roblem and a challen!e to the wor(in!or!anisations+@6cessive absenteeism involves a considerable loss to the

#0


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enter.rises as the wor( schedules are u.set and delayed/ and mana!ement has to

!ive overtime wa!es to wor(ers to meet the delivery dates+ The rates of

overtime wa!es are usually double than the normal rates of wa!es and as the

mana!ement has to .ay overtime wa!es to their wor(ers which becomes

financial burden to the wor(in! or!anisations with the .assa!e of time+Therefore it becomes necessary for the wor(in! or!anisations to find out the

reasons of absenteeism to deal with the .roblem in a better way+

;or(ers may remain absent from their re!ular wor( due to hard nature of *obs/

monotony in the wor( and due to their .ersonal reasons+ This leads to the

absenteeism+It is a normal and natural tendency amon! the factory wor(ers+

Absenteeism means absence of wor(ers from the re!ular wor( without/ .rior

.ermission/ information/ notice or sanction+ It is unauthorised leave and it istotally different from re!ulal leave or holiday+ In brief/ absenteeism means

absence which is wilful and can be avoided+ Unauthorised absence from the

re!ular wor( is absenteeism+ However/ absence on account of stri(es/ loc(,out

etc+ does not constitute absenteeism+

The rate of absenteeism is e6.ressed as the .ercenta!e of mandays lost throu!h

absence to the total no+ of mandays scheduled in a !iven .eriod+

The no+ of mandays scheduled to wor( is calculated by multi.lyin! the avera!e

number of wor(ers by the number of wor(in! days durin! the !iven .eriod+

Absenteeism is a universal .roblem in industry+ It becomes a .roblem when it

e6ceeds the >E as it disturbs the normal .roduction schedules and creates

many .roblem for the or!anisation+ 0enerally few .ercenta!e of wor(ers

account for a lar!e .ercenta!e of absenteeism+ O.erative em.loyees remain

absent frequently than the su.ervisors and mana!ers and any other em.loyee of

the or!anisation+

"auses o! Absenteeism

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Absenteeism is one of the indicators to monitor and evaluate various labour

welfare .ro!rammes and labour .olicies+ In order to identify the various causes

and e6tent of absenteeism/ .ro.er record should be (e.t in every de.artment for

various causes of absenteeism by such divisions as a!e/ se6/ days of wee( and

classes of *ob+ #ut it should always be in mind that it is not .ossible for anyresearcher to enlist the e6act causes and their .ercenta!e+ The .erson who is

evaluatin! the .ersonnel .ro!ramme should classify the data relatin! to

absenteeism and must try to analyse the various causes of absenteeism+ The root

causes of absenteeism are as follows:

ature o! &or': Ifthe wor( is tou!h and monotonous in nature/ the wor(ers

!et tired both .hysically as well as mentally+ The e6cessive load of wor( ma(es

the wor(ers to remain absent from their wor( and they start remainin! absentwithout !ivin! information to the em.loyer+

&or'in% "onditions: The .oor and unsafe wor(in! conditions adversly affect

the health of the em.loyee+ He !et tired of wor( environment and start

remainin! absent from the wor(+

Super;ision: The .oor su.ervision and less chec( on em.loyee ma(e him tofeel that if he remains absent and there is no chec( on him/ then he start to

revise the thin!s a!ain and a!ain and this leads to affect the or!anisation with

the .assa!e of time+

Poor "ontro:Poor .roduction and material control can result in absenteeism+

Unless the flow of wor( between de.artments is balanced and continuous/

wor(er may stay away from their *obs because they loose their interest in wor(

and also loose the feelin! of im.ortance of bein! de.endable+

Absence o! Re%uar (ea;e Arran%ement:@very wor(er requires atleast 5 to

C> leave in a year for his .ersonal wor(+ The em.loyer should .rovide for such

leave to all wor(ers+ However/ in many factories/ wor(ers are not !iven leave as

and when required+ 2aturally/ wor(ers remain absent without any intimation to

the em.loyer+ Thus/ absence of re!ular leave arran!ement leads to labour

absenteesm+

#2


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Accidents: Industrial accidents and occu.ational diseases brin! about

absenteeism de.endin! u. on the nature of .rocess and machinary used+

Accidents ma(e the wor(ers inca.ale of wor( for some days+ They also create

,mental .roblems+

(ac' o! ,nterest: 7ac( of interest and lac( of feelin! of res.onsibility and

worth,whileness are also fundamental causes of absenteeism+ Attitude of mind

caused by environmental and sociolo!ical factors may condition some to

develo.e a feelin! of irres.onsibility about !oin! to wor(+

,rre%uar Transport


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6ntrepreneurs: @ntre.reneurs are those absentees who consider their *ob to be

too small for themselves+They en!a!e themselves in several economic and

social activities+ The motive behind such activities in monetary status and

.owers/ sense of achievement and social reco!nition+

Status See'ers: For status see(ers/ the discri.ancy between the ascribed andachieved status is the .rimary cause of deviant wor( behaviour+ ;or(/ *ob and

money no doubt im.ortant to them but only to e6tent to which these hel. them

to achieve their !oal+

6picureans: @.icureans are disclined to underta(e activities which call forinitiative/ res.onsibility/ disci.line and .hysical discomfort+ They strive to

or!anise their activities and social roles in a manner which brin!s them

unavoidable trouble+ ;or( is frustratin! e6.erience for them and they see( to

avoid it to the ma6imum .ossible e6tent+


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7abour absenteeism is harmful to both the em.loyers and the wor(ers as

follows:

+ 2ormal wor(,flow in the factory is disturbed+

C+ Overall .roduction in the factory !oes down+

+ ifficulty is faced in e6ecutin! the order !oes down+

4+ 1asual wor(ers may have to be em.loyed to meet .roduction schedules+Such

wor(ers are not trained .ro.erly and this can lead to accidents if they do not

(now about the wor(+

5+ Overtime allowance bill increases considerably because of hi!h absenteeism

and com.any has to face it as a financial burden+

-+ Absenteeism creates .ressures of e6tra wor( on the collea!ues of the

absentees+

3+ ;or(ers lose wa!es for the unauthorised absence from their wor(+

B+ Habitual absentees may be removed from the service which can lead them to

!reat hardshi.+

D+ ;or(,culture of the or!anisation !et affected as the other wor(ers mayremain absent by loo(in! to the absentees+

#*


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Researc. /et.odoo%y

Research means a search for (nowled!e or !ains some new (nowled!e while

methodolo!y refers to the theoretical analysis of methods a..ro.riate to a field

of study or to the body of methods and .rinci.les .articular to a branch of

(nowled!e+ A Research )ethodolo!y has a a..lied framewor( for collectin!

the data in an effective manner+ Research methodolo!y means 8definin! a

.roblem/ definin! the research ob*ectives/ develo.in! the research .lan/

collectin! the information/ analysin! the information and .resentation of

findin!s


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1# ata Source:

The researcher can !et two ty.es of data:

a& Primary ata

b& Secondary ata

Primary ata

Primary data is a data which does not e6ist earlier and is bein! collected by

the researcher first time for s.ecific ob*ectives+ It is also called a fresh data+

In other words/ direct collection of data from the source of information/

technolo!y includin! .ersonal interviews/ tele.honic interviews and with the

hel. of questionnaire+

Secondary ata

Any data which has been collected earlier by someone else for some s.ecific

.ur.oses is called secondary data+ Indirect collection of data from sources

containin! .ast information such as brouchers/ annual .ublication/ boo(s etc+

constitute the secondary data+

Secondary data sources are as follows:

Te6t #oo(s

Internet Sites

2ews.a.ers and ?ournals

#rouchers

Annual 0ade!ts

2# Researc. Approac.:

#


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Survey is best suited for descri.tive and analytical ty.e of research+Survey

are underta(en to learn about .eo.le$s (nowled!e/ beliefs/ .references/

attitude and satisfaction+ Therefore/ I have conducted this survey fordescri.tive and analytical research .rocess+

3# Researc. ,nstrument:

uestionnaire: Luestionnaire is a ty.e of statistical survey handed out in

the .a.er form usually to a s.ecific demo!ra.hic to !ather information inorder to .rovide better services or facilities+ A document that contains a set

of questions that has been formulated as a means of collectin! information

and surveyin! o.inion etc+ on a s.ecified sub*ect/ to.ic or theme etc+ A

questionnaire was constructed by me for the survey on s.ecified to.ic that

was on absenteeism+

4# Sampin% Pan:

Sam.le is a !rou. of few ob*ects or thin!s which re.resents the .o.ulation

or universe from where it has been ta(en+ The sam.lin! .lan calls for

followin!s:

Sampe ?nit-who is to be surveyed

The tar!et .o.ulation must be defined that has to be sam.led+ It is necessary

so as to develo.e a sam.le frame so that everyone in the tar!et .o.ulationhas an equal chance of bein! sam.led+ I have com.leted my survey in

Ambu*a 1ement 7imited/ arla!hat+

Sampe SiEe- how many .eo.le to be surveyed

0enerally/ lar!e sam.le si=e !ives more reliable results than the small si=ed

sam.les+ The selection consisted of -> wor(ers of mines of Ambu*a+ The

selection of wor(ers was done on the basis of Sim.le Random Sam.lin!+

#+


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Sim.le random sam.lin! is the technique in which every item in the universe

and .o.ulation has an equal chance of bein! selected in the

sam.le+Researcher has no role to .lay or he cannot influence the selection

.rocess+

"oectin% t.e ,n!ormation

After this I have collected the information from the res.ondents with the

hel. of Luestionnaire+

Anaysis o! ata

The ne6t ste. is to e6tract the .ertinent findin!s from the collected data+ The

data collected has been analysed by means of !ra.hs/ charts usin! sim.le

avera!es in order to ma(e research more accurate+

Presentations o!


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Section-B

ata Anaysis

And

,nterpretation

"0


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L++ o you ever remain absent from your wor(

Particulars Res.onse Percenta!e %E&

Ges C C>

2o 4B B>

Total -> >>

,nterpretation:Accordin! to the survey it is clear that most of the wor(ers

%B>E& do not remain absent from their wor(+ Only few .ercent of the wor(ers

%C>E& remain absent but this .ercenta!e is above the normal+

"1


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L+C+ ;hy do you remain absent from your wor(


ue to @mer!ency > -+--

ue to Illness 4> --+--

ue to Gour ;ill B +4

ue to overwor( C +4

Total -> >>

,nterpretation:

Accordin! to the survey it is clear that most of the wor(ers remain absent due to

illness %--+--E& followed by emer!ency %-+--E&+ There are only few wor(erswho remain absent by their will %+4E& and by overwor( %+4E&+

"2


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L++ ;hen do you remain absent from your wor(


At mornin! Shift%Bam,C.m& 4 C+4

At evenin! Shift%C.m,B.m& - >

At ni!ht Shift%B.m,-am& 4> --+--

Total -> >>

,nterpretation: Accordin! to the survey it is clear that most of the wor(ers

remain absent at the ni!ht shift %--+--E& followed by evenin! shift %>E& and

then by mornin! shift %C+4E&+

"#


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L+4+ How many days you remain absent in a month


day C- 4+4

C days C> +

days 5 B+

Others D 5

Total -> >>

,nterpretation:

Accordin! to the survey we find that ma6imum no+ of wor(ers remain absent

for one day %4+4E& in a month+ After that ma6imum no+ !oes to the wor(ers

who remain absent for two days %+E& in a month+ Only few no+ of wor(ers

remain absent for three %B+E& or more days %5E&+

""


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L+5+ ;hat are the Penalties for Absenteeism


Salary deduction C5 4+-3

@6tra ;or(JAssi!nment 5 C5

2o salary for absent

.eriod

5 C5

Remove from *ob for few

days

5 B+4

Total -> >>

,nterpretation:

Accordin! to the survey It is 1lear That Salary eduction %4+-3E& is hi!hly

.enalty and after this e6tra wor( %C5E& and no salary is %C5E& and removal of

*ob is %B+4E& it is the lowest res.onse in the .enalties for absenteeism+

"*


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L+-+ Is there lac( of better wor(in! conditions


Ges C5 4+-3

2o 5 5B+

Total -> >>

,nterpretation:

Accordin! to the survey it is clear that the ma*ority of wor(ers say that there are

better wor(in! conditions %5B+E&/ while remainin! wor(ers say that there is

lac( of better wor(in! conditions %4+-3E&+

"&


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L+3+ what is the salary .ayment system in the or!anisation


Fi6ed salary > 5>

Salary as .er the wor(in!

days

C> >

Salary as .er the

.roductivity

> C>

Total -> >>

,nterpretation:

Accordin! to the survey it is found that .ayment system is define in followin!

ways+ In this there are fi6ed salary is %5>E& and as .er wor(in! days %>E& and

as .er .roductivity %C>E& is the salary .ayment system in the or!anisation+

"


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L+B+ Are you overburdened with wor(


Ges B

2o 4D BC

Total -> >>

,nterpretation:

Accordin! to the survey we find that the most of the wor(ers are not

overburdened %BCE& with wor(+Only a few .ercent of the wor(ers are

overburdened %BE&+

L+D+ Are you not .rovided better wa!es and salaries

"+


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Ges CB 4-+--

2o C 5+4Total -> >>

,nterpretation:

Accordin! to the survey it is clear that near about %4-+--E&of the wor(ers say

that they are not .rovided better wa!es and salaries while %5+4E& of the

wor(ers says that they are !iven better wa!es and salaries+

",


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L+>+;hat do you thin( about leaves and holiday$s .olicy .rovided in this

com.any


0ood > 5>Satisfactory B >

2ot satisfactory C C>

Total -> >>

,nterpretation:

Accordin! to the survey it is clear that 5>E .eo.le feel that there are !ood+>E

feel that there are satisfactory and C>E feel that there are not satisfactory leaves

And holidays are .rovided in the or!anisation+

*0


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L++ Is there lac( of effective su.ervision


Ges C> +4

2o 4> --+--

Total -> >>

,nterpretation:

Accordin! to the survey it is clear that ma6imum no+ of wor(ers say that there is

effective su.ervision %--+--E&+ Only few wor(ers feel that there is lac( ofeffective su.ervision %+4E&+

*1


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L+C+ oes absenteeism affects your daily wor( routine


Ges 45 35

2o 5 C5

Total -> >>

,nterpretation:

Accordin! to the Survey it is clear that ma6imum no+ of wor(er feel that

absenteeism affects their wor( %35E& while some wor(ers say that absenteeism

has no effect on their wor( %C5E&+

L++ In what way absenteeism affects your wor(

*2


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0et Overburdened 5 5B+44

7a!!ed #ehind Others C> +0et Stressed 5 B+

Total -> >>

,nterpretation:

Accordin! to the survey it is clear that ma6imum no+ of wor(ers !et

overburdened %5B+44E& if they remain absent while some wor(ers la!!ed

behind %+E& others in the wor( and some wor(ers !et stressed %B+E&+

L+4 oes absenteeism affect or!anisational efficiency

*#


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Ges 4C 3>

2o B >Total -> >>

,nterpretation:

Accordin! to the survey it is clear that the ma*ority of wor(ers are in the favour

of .oint of view that absenteeism has effect on or!anisational efficiency %3>E&while remainin! others thin(s that absenteeism has no effect %>E& on

or!anisation+

L+5+ In what way absenteeism affects or!anisational efficiency

*"


55/66


Productivity 0et Reduced C 5

1ost of ProductionIncreases C C>

7abour Turn,Over Increases - >

;or(in! 1ulture 0et

Affected

> 3

Total -> >>

,nterpretation:

Accordin! to the survey it is clear that ma6imum no+ of wor(ers say that the

.roductivity !ets reduced %5E& if they remain absent+ After that the ma6imum

no+ of wor(ers says cost of .roduction increases%C>E&/ followed by the wor(ers

who say that wor(in! culture !et affected%3E& followed by the wor(er who

say that the labour turn over increases%>E&+

**


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L+-+ ;hat do you e6.ect from or!anisation


)ore 7eaves C> +

#etter ;or(in! 1ondition 5 C5

@ffective Su.ervision > -+-3

#etter )ana!ement Policies 5 C5

Total -> >>

,nterpretation:

Accordin! to the survey it is clear that the ma6imum no+ of wor(ers e6.ect from

or!anisation better mana!ement .olicies%C5E&/ followed by the wor(ers who

e6.ect better wor(in! conditions%C5E&/ more leaves%+E& and lastly who

e6.ect effective su.ervision%-+-3E&+

*&


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L+3+ o you want to !ive any su!!estion


Ges C -4

2o CB -

Total -> >>

,nterpretation:

Accordin! to the survey it is clear that the ma*ority of the wor(ers want to !ive

su!!estions %-4E&+ Only some wor(ers do not !ive any su!!estion %-E&+


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+ The wor(ers who remain absent from the wor( are the C>E of the total

.o.ulation surveyed+

C+ The most of the wor(ers remains absent at the time of emer!ency

followed by illness+

+ The ma*ority of wor(ers remains absent at the ni!ht shift+

4+ ;or(ers are not overburdened with wor( and there is no lac( of effective

su.ervision+

5+ The wor(ers who remain absent thin( that they are not .rovided bettersalaries and wa!es+

-+ The most of wor(ers thin( that absenteeism affects their wor( as well as

or!anisational efficiency in res.ect that the .roductivity of the

or!anisation is reduced+

3+ The ma6imum no+ of wor(ers wants better mana!ement .olicies in favour

of them+

(imitations

1. The study was restricted to only -> wor(ers of Ambu*a 1ement+ It was

not coverin! the entire unit+

*+


59/66

2# The study was only for -,B wee(s/ which was not sufficient time to deal

with all as.ects+

3# 7ac( of finance+

4# The biasness of wor(ers cannot be chan!ed+

+# Some wor(ers were not interested in !ivin! interview+

# The wor(ers were very busy/ so it was difficult for the wor(ers to fill the

questionnaires+

# The findin! of our survey may differ from actual+

Su%%estions

*,


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+ The .ro.er selection and .ro.er orientation of wor(ers so that their

critical attitude is reduced+

C+ The contract wor(ers/ who are renderin! their service for a lon! time/

must be incurred in to wa!e board+

+ ;or(er should be !iven bonus at the time of festivals+ It increases their

morale and ma(es them to feel ha..y at wor(+

4+ Hi(e in the wa!es and of salaries of wor(ers time to time+

5+ )ana!ement must ma(e .olicies which are favourable for both

mana!ement as well as wor(ers+

-+ Rest rooms must be .rovided to wor(ers+

3+ There is no effective .romotion .olicy for wor(ers+

B+ isci.linary action must be ta(en a!ainst those who frequently remain

absent+

"oncusion

The ma6imum number of wor(er (now that absenteeism affect their

wor( as well as or!anisational efficiency/ but in s.ite of (nowin! all this

they remain absent from their wor(+ The .ercenta!e of wor(ers who

remain absent is hi!h which is not !ood for manufacturin! industry/whose out.ut lar!ely de.ends u. on wor(ers+

&0


61/66

The absenteeism rate above 5E is not considered !ood for industry so

the rate found by the survey is above 5E which is not a !ood si!n for the

industry li(e this+

The case is not li(e that the wor(ers are not .rovided leaves+ They remainabsent from the wor( because they thin( that they are not .rovided

salaries accordin! to their wor(+

The wor(ers e6.ect better .olicies from their mana!ement which are

beneficial to both wor(ers as well as or!anisation+

uestionnaire

ear Res.ondent/

I am a student of ##A -thSem+ of 0ovt+ Post 0raduate 1olle!e #ilas.ur %HP&+ I

am conductin! a survey on absenteeism amon! @m.loyee+ So I need your co,

o.eration which will hel. me to draw a conclusion+ I assure that your

information will be (e.t confidential+

&1


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2ame:

A!e:

e.artment:

)arital Status:

;a!e #oard ;or(erJ 1ontract ;or(er:

+ o you ever remain absent from your wor(

Ges 2o

C+ ;hy do you remain absent from your wor(

ue to @mer!ency ue to illness

ue to your will ue to overwor(

+ ;hen you remain absent from your wor( At mornin! shift %Bam,C.m&

At evenin! shift %C.m,B.m& At ni!ht shift%B.m,-am&

4+ How many days you remain absent in a month

day Cdays days other s.ecify

5+ ;hat are the Penalties for Absenteeism

Salary deductione6tra wor(Jassi!nment

2o salary for absent .eriodremove from *ob new days

&2


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-+ is there lac( of better wor(in! conditions

Ges 2o

3+ ;hat is the salary .ayment system in the or!anisation

Fi6ed salary salary as .er wor(in! days

Salary as .er .roductivity

B+ Are you overburdened with wor(

Ges 2o

D+ Are you not .rovided better wa!es and salaries

Ges 2o

>+ ;hat do you thin( about leaves and holiday .olicy .rovided in this

com.any

0ood satisfactory not satisfactory

+ is there lac( of effective su.ervision

Ges 2o

C+ oes absenteeism affect your daily wor( routine

Ges 2o

+ In what way absenteeism affect your wor(


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0et over burdened 7a!!ed behind others !et stressed

4+ oes absenteeism affect or!anisational efficiency

Ges 2o

5+ In what way absenteeism affect or!anisational efficiency

Productivity !et reduced1ost of .roduction increases

7abour turn,over increases wor(in! culture !et affected

-+ ;hat do you e6.ect from or!ani=ation

)ore leaves #etter wor(in! conditions

@ffective su.ervision #etter mana!ement .olicies

3+ o you want to !ive any su!!estion

Ges 2o

B+ ;hat is your su!!estion

Bibio%rap.y

#oo(s

1hhabra/ T+2+/ 8Human Resource )ana!ement>3/ PP 4--,-D

&"


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0u.ta/ 1+#+/ 8Human Resource )ana!ement>>/ PP 5C,5-

othari/ 1+R+/8Research )ethodolo!y:)ethods9Techniques>3/ PP 5,D

;ebsites

www+ambu*acement+com

www+indianbba+com

&*


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Documents

Absentism Report by Vivek Mahajan