QMM Report Tata Steel

8/8/2019 QMM Report Tata Steel

1/33

ASIA-PACIFIC INSTITUTE OF

MANAGEMENT3, Institutional Area, Jasola, New Delhi 110025

A

Project Report

On

Tata Steel- Tube Division

Submitted To: Submitted By:Prof. Subrata Goswami Priyanka Ghosh

(2K91/M/35 )

Puja Bhalotia(2K91/M/36)

Sushant Sagar(2K91/M/56)

Sayantan Kar(2K91/M/46)

Souvik Sen(2K91/M/53)

Sumitra Nandan Srivastava(2K91/M/54)

PGDM (Marketing) 2009-11


2/33

A Timeless VisionThe nation which gains control of iron soon acquires the control of gold. --

These were the words that inspired a young Jamsedtji Nusserwanji Tata envisages

a bold new dream for India.

TATA GROUP

Jamsedji persuaded Charles Perin - world renowned metallurgist and geologist - to come to India

and work on a steel project. Charles Perin and his team discovered 3 billion tons of ore at Sakchi

and Jamsedji Tatas dream of thirty years was cast into reality. Tata Steel came into being in

1907. On 16th February 1912, the first ingot of steel was rolled out of the Sakchi plant.

The Tata Iron and Steel Company was Indias first and the largest steel company in the private

sector. Today, Tata Steel ranks among the worlds top steel companies and has emerged as one

of the lowest cost producers of steel in the world.

Jamsedji Tata ranks among the greatest visionaries of industrial enterprise of all time. He was

gifted with an open mind to absorb new ideas and a strong determination to make them happen.

He was interested in everything he saw and was always looking for ways to put his knowledge to

use, not just for himself but for India. He laid the foundations of Indian industry, contributed to


3/33

its consolidation, and became a key figure in Indias industrial renaissance. Tata Steel is a solid

manifestation of the iron grit, courage and determination of its founder, Jamsedji Tata.

ABOUT THE PIONEERS

There is a difference between making money for oneself and creating wealth for others. TATA

STEEL is a story of a business house that has created wealth for nation. This is a story of

struggle, anxiety, adventure and achievement. This is the story of pioneers of TATA STEEL.

THE FOUNDER-

Jamsetji Nusserwanji Tata (1839-1904)

Jamsetji Nusserwanji Tata ranks among the greatest visionaries of Industrial

enterprises of all time.

Gifted with the most extraordinary imagination and prescience, he laid the

foundations of Indian industry, contributed to its consolidation, and became

a key figure in Indias industrial renaissance.

Born on 3rd March, 1839 into a family descended from Parsi priests in

Navsari, a centre for age-old Parsi culture, he was educated at Elphinstone College, Bombay.

Initiated early into the techniques of trade by his father, he traveled wide, gained a scientific

outlook, and set up at first, textile business in India, introducing new machinery that vastly

improved the production of cotton yarn in the country. He however realized that Indias real

freedom depended upon her self-sufficiency in scientific knowledge, power and steel, and thus

devoted the major part of his life, and his fortune to three great enterprises The Indian Instituteof Science at Bangalore, the hydro-electric schemes, and the Iron & Steel Works at Jamshedpur.

Wealth to him was not the end but a means to an end, the

increased prosperity of India. His attitude to labour was


4/33

remarkably ahead of his times, constantly reinforcing the norm that the success of industry

depended upon sound and straightforward business principles, the interests of the shareholders,

the health and welfare of the employees. As early as 1892, he established the J N Tata

endowment for higher education abroad of outstanding Indian students.

Sir Dorabji Tata (1859-1933)

J N Tata had exhorted to his sons to pursue and develop his lifes work; his

elder son, Dora Tate carried out the bequest with scrupulous zeal, and

distinction.

Thus, even though it was Jamsedji Tata who had envisioned the mammoth

projects, it was in fact Dorab Tata who actually brought the ventures to

existence and fruition. He was the first Chairman of the gigantic Tata

enterprises.

He had a deep interest in people. The great labour strike in 1920 in Jamshedpur ended in a day

due to his intervention. It demonstrated India could have no better employer of labour than Sir

Dorab.

A great sportsman (riding, tennis, football, cricket), he was President of the Indian Olympic

Association which he served keenly with liberal funds, and total commitment. He was the

Founder of the Parsi Gymkhana of Bombay, and a founder member of the Willingdon Sports

Club.

His charities were numerous and munificent. The Dorab Tata Charitable Trust that he executed,

covering property and crores of rupees is used today for innumerable charitable causes and

institutions.

Bharat Ratna Jehangir Ratanji Dadabhai Tata (1904-1993)


5/33

JRD Tata has been one of the greatest builders and personalities of modern India in the twentieth

century.

He assumed Chairmanship of Tata Sons Limited at the young age of 34; but his charismatic,

disciplined and forward-looking leadership over the next 50 years and more, led the Tata Group

to new heights of achievement, expansion and modernization. Under his stewardship, the number

of Tata ventures grew from 13 to around 80, encompassing steel, power generation, engineering,

hotels, consultancy services, information technology, art and culture, consumer goods, industrial

products, etc. He was the pioneer of civil aviation in India. In 1932, he introduced air transport in

the country--the enterprise later became Air India.

He implicitly followed the principles of business ethics of the great visionary Jamsedji Tata, his

ideal. He also personally crusaded for issues that he felt were imperative for Indias

development--family planning, womens education, spread of literacy. The 100% successful

family welfare schemes at Tata Steel and the various educational programs for all, directly

emanate from JRD Tatas insight.

Numerous national and international honours were bestowed on JRD Tata. These included

Knight Commanders Cross of the Order of Merit of the Federal Republic of Germany, Bessemer

Medal of the Institute of Metals, London, and the United Nations Population Award.

Government of India conferred the highest civilian award of the land, Bharat Ratna to JRD Tata

in 1992.

For all his colossal achievements, JRD Tata was a modest, sensitive man, forever espousing the

cause of his employees. His natural love for people endeared him to all... across the entire

spectrum of society.

RATAN TATA (1993 Till now)

Ratan N. Tata serves as Chairman of the board, Member of

Group Corporate Centre and Member of Group Executive


6/33

Board of Tata Group. Mr. Tata was appointed Director-in-charge of National Radio &

Electronics Company Ltd. Indias industrial renaissance. Tata Steel is a solid manifestation of

the iron grit, courage and determination of its founder, Jamsedji Tata (NELCO) in 1971. He

serves as Chairman Emeritus for Nelco Ltd. Tata Motors Ltd. , Tata Chemicals Ltd. , Tata Power

Company Ltd. ,Tata Iron & Steel Co. Ltd. and Tata Tea Ltd. Mr. Tata joined Tata Group in 1962.

As a Chairman of Tata Industries Ltd. since 1981, he was responsible for transforming the

company into a Group strategy think-tank and a promoter of new ventures in high technology

businesses. In 1991, Mr. Tata was appointed Chairman of Tata Sons Ltd. the holding company of

the Tata Entities and currently holds the Chairmanships of major Tata companies. During the

tenure, the groups revenues have grown over ten-fold to annualized group revenues of $62.5

billion. Mr. Tata is on the Central Board of the Reserve Bank of India, a member of the Prime

Minister Council on Trade and Industry beside a member of various global councils. He is also

the Chairman of two of the largest private sector promoted philanthropic trust in India.

The Government of India honored Mr. Tata with its second highest civilian award, the Padma

Vibhushan, in 2008. Earlier, in 2000, he had been awarded the Padma Bhushan. He has also been

conferred an honorary doctorate in business administration by the Ohio State University, an

honorary doctorate in technology by the Asian Institute of Technology, Bangkok, an honorarydoctorate in Science by the University of Warwick, and honorary fellowship by the London

School of Economics. Mr. Tata has been on the company Board since over 19 years including 13

years in an executive capacity and is actively involved with product development and other

business strategies pursued by the company. One of his achievements include designing and

developing an indigenous Indian car-Indica which decides creating a record of sorts, is one the

leading products in its category in the car market.

Steel Industry

Sector structure/Market size


7/33

The steel industry in India has been moving from strength to strength and according to the

Annual Report 2009-10 by the Ministry of Steel, India has emerged as the fifth largest producer

of steel in the world and is likely to become the second largest producer of crude steel by 2015-

16.

Recently, Steel Minister, Mr Virbhadra Singh said that India will become the world's second-

largest steel producer by 2012, more than doubling its capacity to 124 million tons (MT) as part

of the push being given to assist overall infrastructure development.

Production

Steel production rose 4.2 per cent to reach 60 MT in 2009-2010, according to the Ministry of

Steel.

The National Steel Policy 2005 had projected an annual steel consumption growth of 7 per cent

based on GDP growth rate of 7-7.5 per cent and production of 110 MT of crude steel by 2019-

2020. Nonetheless, with the current rate of ongoing greenfield and brownfield projects, the

Ministry of Steel has projected that these growth trends are likely to be exceeded and it is

envisaged that in the next five years demand will grow at higher annual average growth rate of

over 10 per cent as compared to around 7 per cent growth achieved between 1991-92 and 2005-

06.

Moreover, according to the ministry, the crude steel production capacity in the country by 2011-

12 will be nearly 124 MT.

According to the Ministry of Steel, 222 memorandum of understanding (MoUs) have been

signed with various states for planned capacity of around 276 MT. Major investment plans are in

Orissa, Jharkhand, Chattisgarh, West Bengal, Karnataka, Gujarat and Maharashtra.

According to the Annual Report 2009-10 by the Ministry of Steel, domestic crude steel

production grew at a compounded annual growth rate of 8.6 per cent during 2004-05 and 2008-

09.


8/33

Consumption

India's steel consumption rose 8 per cent in the year ended March 2010, over the same period a

year ago on account of improved demand from sectors like automobile, infrastructure and

housing. The countrys steel consumption increased to 56.3 MT in the 12 months to March 2010

from 52.3 MT in the previous year, as per the Ministry of Steel.

Export

About 50% of the steel produced in India is exported. India's export of steel during April -

December 2008 was 64.4 MT as against 9.7 MT in December 2007. In February 2009, steel

export increased by 17% to 12.6 MT from 10.8 MT in the same month last year. More than 50%

of steel from India is exported to China. The Government's decision to reduce export duty on

iron ore lumps from 15% to 5% has given a major boost to the export of steel.

Strengths

There are many strong points of the industry that makes it one of the leading names in the global

steel industry. The rate of labor wage in India is among one of the lowest in the world thereby

making large scale production feasible. The boom witnessed in the automobile industry has

ensured that the demand for steel is increasing gradually and will continue to do so in the near

future. There is huge manpower in India which is another reason why steel production in India is

high and the industry is doing pretty well both nationally and internationally.

Hurdles

Power shortage hampers the production of steel Use of outdated process for production Lags

behind in the production of stainless steel Deficiency of raw materials required by the industry

Labor productivity is low. It is 144 tons per worker per year against 600 tons in Western Europe

as per estimates Inadequate shipment capacity and transport structure


9/33

Investments

A host of steel companies have lined up major investment proposals. Furthermore, with an

expanding consumer market, the Indian steel industry is likely to receive huge domestic and

foreign investments.

The domestic steel sector has attracted a staggering investment of about US$ 238 billion,

according to the Minister of State for Steel, Mr A. Sai Prathap.

This consists of nearly 222 MoUs signed between the investors and various state governments

mostly in the states of Orissa, Jharkhand, Chhattisgarh and West Bengal.

SAIL is planning to set up a 12-million tonne plant in Jharkhand.

In December, Indias largest engineering conglomerate Larsen & Toubro (L&T) and

state-owned Nuclear Power Corporation of India Limited (NPCIL) formed a US$ 373.2

million joint venture for specialised steel and forging products.

Stainless steel manufacturer and exporter, Varun Industries, is setting up a US$ 171.8

million stainless steel-cum-alloy steel plant at Rohat, Jodhpur.

Tata Steel has entered into a joint venture with Japans Nippon Steel for production and

sales of automotive cold-rolled flat products at Jamshedpur. The JV is expected to invest

US$ 400 million to set up an automobile venture in India.

Steel major, JSW Steel has earmarked a capex of US$ 1.6 billion for 2010-11 and plans

to increase capacity of its Bellary plant in Karnataka from 7 MT to 10 MT by end of

2010-11.

Government Initiative


10/33

As per the Press Information Bureau, during 2009, the government took a number of fiscal and

administrative steps to contain steel prices. Central value added tax (CENVAT) on steel items

was reduced from 14 per cent to 10 per cent with effect from February 2009.

Moreover, in the Union Budget 2010-11, the government has allocated US$ 37.4 billion to the

infrastructure sector and has increased the allocation for road transport by 13 per cent to US$ 4.3

billion which will further promote the steel industry.

Steel Tubes Industry

Growing oil and gas demand across the world and the zeal with which oil companies are

investing on adding pipeline infrastructure promise higher revenues for Indian steel pipes

makers. A huge pent-up demand for pipes has cropped up over the last few months. For therefining industry, pipes are the most economical way to transport oil and gas.

Pipe of all types and sizes is critical in building, construction, chemical, energy, and other

industrial applications. The pipe industry is expected to experience considerable change and

varying growth rates in these uncertain economic times. The global export market of the steel

pipes is stated to be close to $27 billion a year with the US, Western Europe, Australia, and

Japan being the biggest importers. India is one of the major exporting nations including

Indonesia, Malaysia and Thailand.

Steel pipe industry in India consists of firms mainly engaged in manufacturing seamless or

welded steel pipes or tubes or ferrous metal pipe or tube fittings. The five primary steel

producers in India are, namely Steel Authority of India (SAIL), Tata Iron and Steel, Jindal

Vijaynagar Steel (JVSL), Essar Steel and Ispat Industries. Major industry bodies like the Corsma,

the All-India Cycle Manufacturers' Association (AICMA), the Federation of Industries of India,

which represent the tubes and pipes makers and a large number of white goods makers, have

joined hands to sort out the matters concerning the future of steel pipe industry.

The building & construction industries along with the oil & gas sector are the major

marketplaces for pipe. With the construction market booming and further development of new

markets for steel pipes ranging from commercial framing to water pipes, the future of steel

tubing industry certainly looks bright. Significant consolidation and rationalization of excess

capacity has occurred in some segments, while cost containment and improved process and


11/33

quality control measures have led to productivity gains and quality improvements across the

entire pipe industry.

The five major steel producers in India are as follows:

Steel Authority of India (SAIL),

Tata Iron and Steel,

Jindal Vijaynagar Steel (JVSL),

Essar Steel and Ispat Industries.

INTRODUCTION OF THE COMPANY


12/33

TUBES

Tata Steel Tubes business unit is the largest domestic manufacturer of steel tubes. It promotes

three lines of businesses: Standard tubes, Precision tubes and Closed structural.

Name of the Company : The Iron and Steel Company Limited(Tube Division)

Name of the Business : Manufacturing

HISTORY OF TATA TUBES

A new dimension in steel tube technology opened up in India in the early 50s with the

establishment of the Indian Tube Company Ltd.(ITC), a joint venture between Tata Steel and

Stewarts & Lioyds UK(now a part of British Steel). After the disinvestments by British Steel,

ITC merged with Tata Steel to form the Tubes Division in 1985, which today is the leading

welded steel Tube Company in India with a manufacturing capacity of 2,50,000 tones.

The works situated in Jamshedpur have the following Plants:


13/33

High Frequency Induction Wield (HFIW) Tube Mill for black & galvanized tubes and

rectangular and square hollows.

High Frequency Induction Wield (HFIW) Tube Mill for Precision Tubes.

Currently TATA STEEL (Tube Division) occupies the no.1 position in the Indian Tubes Industry

and is the only company with a National Network.

Tubes Division has well established IT infrastructure, which includes an ERP system covering 30

sales points. Marketing HQ & works through WAN, Lotus Notes Mailing system & other office

automation applications covering marketing and sales network. A web enabled complaint

management system is also being implemented.

Important Milestones:

1953 Formation of erstwhile Indian Tubes Company Limited by Tata Steel, Stewarts and

Lloyds.

1955 Commissioning of F.M.(Frentz Moon)-1, For large size tubes.

1957 C.R.(Cold Rolling) & E.R.W.(Electrical Resistance Welding ) plant started.

1959 Seamless plant goes out in stream.


14/33

1966 F.M.- 11 added.

1975 E.R.W. Modernization.

1981 British Steel decision to disinvest outside U.K, share offered to TISCO.

1983 TISCO, ITC arrangement for conversion of strips into tubes.

1985 Amalgamation of Tata Steel and Indian Tubes. It becomes Tubes Division TISCO.

1990 High frequency Induction Weld Mill (HFIW)added

1993 F.M.1obseleted in April.

1994 2ND PTM (PRESICION TUUBE MILL) added.

1998 Seamless plant obsoleted in January.

CERTIFICATES


15/33

- Tubes division has been awarded the ISO 9002 certificate since October 1994 as

recognition of our excellent quality systems.

- The American Petroleum Institute has given Tubes Division, a certificate of authority to

use the API monogram for Welded line pipes. TATA STEEL is an established player in

this sector and has been supplying seamless tubes in casings, tubings and line pipes to

the oil industry since 1970. In this regard, it is pertinent to mention that the company is

well acquainted with stringent and specific requirements of this segment and has

performed extraordinary well in catering to the needs of their customers.

- The division is recognized by central Boiler board as Well known Tube and Pipe

Maker and granted self certification status for boiler tubes.

- Lloyds Register has approved Tubes division as a manufacturer in accordance with the

accordance with the requirements of Lloyds register for:-Welded pipes and tubes in

carbon, carbon- manganese and alloy steel.

COMPETITORS


16/33

ATLAS STEEL TUBE INDUSTRIES:

It was established in 1987 as the captive unit of Atlas cycle industries Ltd. SONEPAT pioneer of

bicycle manufacturing in India. The tube rolling capacity has been enhanced to 38000 M.T by an

installation of second tube mill in 1994. Precision steel tube from 12mm outer diameter are

produced in thickness range from 0.70mm to 3.65 mm from automobile, bicycle, furmiture &

general engineering industries confirming to national and international quality standards. A team

of highly qualified and experienced engineers mining, controlling and handling the operations

consistently. Continuous improvement and innovation is an unending Endeavour at atlas. Atlas is

able to supply the tubes within the shortest lead time. Atlas has its high speed slitting line,

modern tool room with C.N.C turning centre, tube recutting finishing facilities

TUBE INVESTEMENT OF INDIA LTD:

Tube investment of India known as the flagship company ofRS 8500 cr MURUGAPPA Group.

It manufactures precision steel tubes and strips, car doorframes, automotive and industrial chains

and bicycle. The company has 13 manufacturing / assembly units spread across the country.

Marketing office acts as an interface between customer requirements and production team. The

companys are listed on national, Mumbai and Chennai stock exchange within India and GDRs

on the Luxembourg stock exchange. The companys product segments are engineering, metal

formed products and cycles. TI is the market leader in precision tubes with 61% market

share by virtue of its quality and application of engineering capabilities. TI is the market leader

in roll formed car doorframes with 57% market share by virtue of its cost efficiency,

association with key auto majors and rolling forming capabilities. TI is the market leader in

automotive chain with 35% market share by virtue of its cost, quality and delivery and

association with two wheelers majors TI is the leading player in bicycle segment with 30%

market share by virtue of its brand equity, product development capacity and proximity to the

markets.

Bhushan Steel & Strips Limited (BSSL)


17/33

The flagship company of the Bhushan Group was incorporated in 1983. It deals with rolled steel

strips, steel ingots, and the scrap obtained from the manufacturing process.

The products manufactured by the company are cold rolled steel coils/sheets, galvanized

steel coils/ sheets, hardened & tempered steel strips, high tensile steel strapping, precision

tubes (ERW and CEW) having applications in Automotive, Boiler & Heat Exchangers, Air

Heater, Bicycle & Propeller Shafts Shock Absorbers, Textiles industry etc.

The company has entered into a technical collaboration with Sumitomo Metal Industries, Japan

in order to acquire the latest know-how and the quality requirements of all clients in the

engineering, Automobile & White Goods Appliances industry. Be it specialized steel for the

automotive and white goods industry, or steel for highly discerning international clients. BSSL is

in the process of setting up one of the most advanced Hot Rolling Plants of the world in Orissa.

Automobiles & White Goods/ Domestic appliances & General Engineering Industries Its

automobile clientele includes Maruti Udyog, Honda, Telco, Hindustan Motors, GM

Hyundai Motors, Ford Motors, M&M, Richer Tractors, Ashok Leyland, LML, Scooters

India Ltd, Bajaj Auto, Honda Motorcycle, Yamaha Motors and Bajaj Tempo.

Its Home Appliance clientele includes LG Electronics, Whirlpool, Videocon, Daikin Shriram,

National Matsushita, Samsung Electronics Godrej, Voltas, IFB, Fedders Lloyd, Carrier

Refrigeration, Electrolux Group, Hitachi Air conditioners, KF Bearing Cromptom Greaves, BPL

and Philips India. Its Engineering clientele includes BHEL Aistom Limited, L&T, GE Motors,

Jhonson Lift, Kone Elevator, Lucas TVS, NRB Bearing, Harsha Engineers Limited, Bundy India

Limited and Tecumseh.

PRODUCTS & ITS APPLICATIONS


18/33

I. Standard Tubes: Standard tubes are extensively used in:

PLUMBING IRRIGATION COLD STORAGE: The cold storage industry constitutes a very important market

segment for TATA PIPES. Pipes are the lifelines of cold storage unit.

TATA PIPES is the market leader in this segment.

It was found necessary that we consolidate our leadership position through a marketing strategy

that shall strengthen brand loyalty, both in the short term and the long term.

II. Precision Tubes: Precision tubes are extensively used in:


19/33

Automobile, power & industrial boilers, Transformers, super heaters, Economizers, heat exchangers, Bicycles, automobiles Railway electrification, Furniture applications,

A team of highly qualified engineers in the research and development wing keeps pace with

improved techniques and latest developments in tube technology pertaining to this field.

ERW Precision tubes offer many advantages, such as Close tolerances in diameter.

III. Closed Structural: Closed Structural tubes are extensively

used in:

Agricultural implement frames, amusement park & play ground equipment. Automobile chassis, bridges, bus stands. Conveyor gantries, cranes Drilling rigs, exhibition stalls Furniture, partition frames, flood light masts Guard rails, staircase, industrial lifting equipment Industrial sheds, large span portal frames. Pallets, footbridge, sign supporting structures Space frames, sport galleries, transmission line towers, trolley, trucks & bus body

members and lots of other application.

Tata tube steel introduced hollow pipe in 2005 under the brand name of Tata Structura

A combination of lightness, strength, firmness & flexibility gives Tata Structura

circular, rectangular and square steel hollow section


20/33

All airports under modernization have used Tata Structura extensively and

Commonwealth games Stadiums in Delhi have also used these sections.

It is being widely used in office buildings, shopping malls, bridges, highways, bus bodies

and automobile chassis

PRODUCT PROFILE OF TATA TUBES

The Tata Steel Tubes Division manufactures Tubes in accordance with the Lioyds Register and

according to Central Boiler Board; we are a well known pipe maker under regulation 4C (2) of

the IBR Act 1950. Few tube makers in India enjoy this self-certification status. The division has

also been accredited with the ISO 9002 Certification for confirming to high quality standards.

Size Range of 2ERW Mill

ERW Range from 12.70 mm to 50.80 mm OD with thickness range of 0.60 mm to 5.50

mm

Size Range of 3HFIW Mill

ERW Range from 12.70 mm to 76.20 mm OD with thickness range of 0.60 mm to 6.00

mm

Size Range of 4ERW Mill

ERW Range from 31.75 mm to 114.30 mm OD with thickness range of 1.50 mm to

6.00 mm


21/33

PRODUCT SPECIFICATION

Steel Tube Technology opened up in India in the early 1950s with the establishment of the IndianTube Company Ltd. (ITC), a joint venture between Tata Steel and Stewarts & Lloyds UK (now a

part of British Steel).

After the disinvestments by British Steel, ITC merged with Tata Steel to form the Tubes Division

in 1985, which today is the leading Welded Steel Tube Company in India with a manufacturing

capacity of 200,000 tones.

STANDARD TUBES

Indian Standards: IS 1239 Part-1, IS 1161

British Standards: BS 1387

American Specifications: ASTM A 53

PRECISION TUBES

Indian Standards: IS: 1914, IS: 1978, IS: 2039, IS: 3074, IS: 3601, IS: 7138, IS: 8036, IS:

1161, IS: 4923

British Standards: BS: 980, BS: 1717, BS: 1775, BS: 3059, BS: 6323

American Specifications: ASTMA 178, ASTM A 214

Japanese Standards: JIS: G 3445


22/33

COMMERCIAL TUBE MILL

Reliable, long lasting and customized Precision welded tubes from Tata Steel meet national and

international standard.

Standard/Commercial tubes are manufactured from hot rolled steel, the finest quality steel from

Tata Steels state of art HSM plant. Used extensively in power and industrial boilers,

transformers, super heaters, economizers, heat exchangers, automobiles and other engineering

applications, precision welded tubes are manufactured with customary TATA commitment to

quality. The manufacturing process is governed by comprehensive quality plan. Constant quality

check is carried out during the manufacturing process, both in the two and three inch mill, with

size ranges from 12.70mm OD to 76.2mm OD, with thickness ranging from 0.91mm to 4.06mm.

The manufacturing process involves forming of hot rolled steel strips in to a tabular shape, the

edges being weld under pressure using induction heating.

The HR strip coil stock is then leveled and cut, before the ends are welded together in the flash

welder. After edge slitting, the strip is progressively bent into tabular form. Forming takes place

at an ambient temperature, with a close control on dimensions and surface finish is maintained.

Welding and sizing follow this. The continuous tube is then straightened and cut to the requiredlength.

In order to identify defects both in parent material as well as the welded zone, non destructive

testing is done both online and off line this process is particularly useful for ensuring the quality

of boiler tubes. The state of the art 2inch mill has an automatic high speed cut off machine. The

tubes are finally sent to the normalizing furnace. Normalizing removes metallurgical differences

between the weld zone and the body of the tube and the effect of cold working caused in the

forming process. This restores the grain structure and there by stress relieves the tubes. It is also

necessary for achieving the desired level of mechanical properties, such as hardness, yield and

tensile strength. Normalization is done for all boiler and cold drawn tubes. It may be done for

other tubes also if specified. Precision welded tubes are reverse engineered to meet exact

customer requirements. New products are developed to meet changing customer needs.


23/33


24/33

mill. The strip edges are then trimmed to ensure cleanest possible surface for welding. The mill

proper consists of series of forming rolls which bend the strip progressively into tubular form by

centre forming with abutting edges.

The process of tube making in the 3 inch Commercial tube mill, through quite similar to that of

the old mill, incorporates the latest technology. The superior edge forming technique employed

here has made it possible o roll tubes with thickness/diameter ratio ranging from 1.6to10%.it has

a state-of-the-art automatic weld-temperature controller, which ensures complete consistency in

the weld quality irrespective of any minor variations in the mill speed, strip thickness etc. its

automatic high speed cut-off machine is designed to cut tubes of at speeds of 100 meters/minute.


25/33

Q Factor at Tata Steel

Tata Steel lays a great emphasis on quality and all the tubes manufactured undergo various

quality assurance tests, to ensure customer delight. The manufacturing process is governed by a

comprehensive quality plan. Each and every plant in the tubes SBU today has been certified toISO: 9001:2000.

The quality of the product is controlled during the manufacturing process. It starts with slitting

the strip edges, continues with speed, temperature control during the high frequency induction

welding and is followed by non destructive eddy current testing directly after welding. In-house

testing laboratory is equipped to carry out various tests as per the specific requirements.

Tata tubes are manufactured in ISO certified manufacturing facilities. The SBU also has well-documented Customer Complaint Handling procedures for settling complaints as required by

ISO: 9001:2000.

The Precision Tubes mill has been TS 16949 certified, besides being recognized as self certified

Boiler Tube Manufacturer by the Central Boiler Board.

Quality Management System

It may not make sense to many in the steel industry to invest in various quality control drives

during such a tough time, but for Tata Steel, pursuing such goals has been a passion and the very

essence of its existence. The company has recently won the Deming Application Prize for its

excellence in total quality management (TQM), the only steel company in the world outside

Japan to bag the award.

The steel major, which in earlier years had been saving around Rs 200-300 crore annually,

would, aided by Deming this year (2008-09), target to save around Rs 600 crore.

This is not because of the effect of market prices or impact of raw material costs going up or

down, it is purely internalfrom improvements in the work processes the company has brought

about.


26/33

The steel majors commitment to the best practices can be gauged by Tata Steel. In every walk of

life, whether it is in running a business, in sports or education, if you take care of the processes,

the results will take care of themselves

Tata Steel, which expects to emerge strongly from the ongoing global recession, has already put

in place a revised plan for the second half of 2008-09 (Oct onwards). The plan includes

techniques/benefits learnt in Deming and the target has been set in crores.

Various items, right from the raw material side to marketing & sales, several daily management

items which could be done better while bringing about cost reduction, cost-cutting contributions

from its Aspire projects (problem solving, Six Sigma application, etc), efforts from supply

chain management by following inventory replenishment models (while ensuring that whatever

the customer was wanting was readily available to him) have been listed.

Deming is a very robust and a very involving process in which one cannot escape the

enlightenment at the end of it. It is only the application of the steps involved in Deming and the

consequent effects that emerged gives one the real insight into its working.

Each key performance indicator (KPI) is being tracked by the company, like zinc consumption,

coal rate, coke rate, etc, including whether any delays were taking place or not.

Tata Steel Tube Division is a three sigma company. It follows three sigma concepts. Tata tubes

are manufactured in ISO certified manufacturing facilities.

Quality Process

Tata Tube Division has a robust quality process. It starts from the beginning of the process. Each

tube undergoes a extensive quality process so that there is no chance of defect. Quality process

starts at the suppliers end. Companys quality experts go to suppliers end and check the raw

material to decide whether the material is of the best quality. After that it starts with slitting the

strip edges. The quality of product is controlled during the manufacturing process. During each


27/33

process quality check is done to make sure that product is of the best quality. Product is

completely quality checked before dispatching.

Company Do basically two type of testing on product. First one is Online Destructive Testing

and the second one is Offline Non-destructive Testing. In first one product goes through a

destructive testing. In this Tube becomes spoiled. It happens to reduce the defects. It is done

when production is in continuation. That is why it is called online testing. This test is done to

determine whether the pipe has holes.

Second type of testing is Offline Non-destructive Testing. This testing is done when the lot is

manufactured. Non destructive testing is done with a certain objectives.

Some non-destructive testing are-

Hydraulic Testing is done for irrigation purpose. It is done to check whether pipe can handle the

pressure of water.

Thrust Testing is done for automobile purpose. It is done for handling the jerks.

Eddy Current Testing In this testing current is flown through the pipe and it is checked whether

pipe is crack or defected somewhere.

Temperature is controlled during the high frequency induction.

Apart from all these testing Company also does some specified testing according to customers

requirements. Thus company can satisfy the different customer by catering them different quality

checked products. In-house testing laboratory is equipped to carry out various tests as per

specific requirements.

After completing all testing company does the final product sampling. From every lot pipes are

selected randomly and stored in laboratory for two years. It facilitates company to tackle future

risks related to quality.

Quality policy

Company considers the research part very important. Company spends sufficient amount of

money on research. Tube division does not have its own R&D department but research carries on

at Tata Steel R&D center. There is special Tube section to focus on the pipes.

Company follows BIS standard to cater the domestic market. It produces the pipes according to

Indian standard. There are different standards for different variants of the products.


28/33

Company follows different standards for catering the other markets. Company is focusing in

producing the different products according to different weather and physical conditions.

Company also maintains quality by adopting the latest technology. It reduces the defects and

improves the productivity. Currently company is using the machinery from Italy and Taiwan.

Company focuses on minimizing the scrap so that quality can be improved. Scrap is reused by

the company. So company has adopted good waste management system.

Competition is growing day by day so company always seeks for best technology available

across the world. Company procures that technology that can improve the quality and reduce the

wastage. The technology gives competitive edge to the company in this competitive corporate

world.

Role of Quality in Marketing

When any company goes for marketing of its product or services, quality of the product plays a

very important role. Same is the case with Tata steel, tube and pipes division.

Brand Name TATA: The brand is the household symbol of trust and

commitment. When the sales force of the company go for selling of the product half of

the work is already done as they say the brand name Tata. It is because of its good quality

and very good quality nothing else.

The best quality assurance: Tata assure their customer that they are getting the best

quality. This company is accredited with different ISO certificate related to not only

quality but as well as health and safety of their employees & environment in which we

live.

Long Term Relationship: Any long term relationship can be built on the basis of trust

and understanding. Tatas believe in that. They built trust in their customers by providing

good quality product. Understanding is developed through continuous customer feedback

system.


29/33

Customer feedback: This is a customer centric organization. They manufacture the

product according to customer need and specification. That can be understood while be in

a continuous touch with the customer. They make house of the quality to better fulfill

their customer requirement and so to delight them.

Rich Product Mix: Tatas has a very wide range of product category. They are very

innovative and they always add some new and innovative product in their line. Since they

are making the product according to customers requirement so it helps in widening their

product rang. Due to the Rich product mix they are able to cater ever changing demand of

Indian market.

Product delivery on companys risk: Company takes the entire risk till the product

is delivered to customers end. If any mishaps happens during transportation, company

will bear all loss and compensate that loss to the customer. This is a very good quality in

terms of selling strategy of company which gives it competitive advantages and helps to

gain customer trust.

Warranty and Guarantee as per the product: They manufacture a verity of pipe

products which use in different sectors. Like Plumbing, irrigation, cold storage, HVAC,

bicycles, steel furniture, transformers, automobiles etc. So they provide warranty and

guarantee of the product according to product requirement.

Distribution: Retail plays a major role in distributing the Tata Pipes Products to its

consumer.


30/33

Tata Steel- Tube Division has adopted a well formed retail infrastructure. Company sends

the product to its well established warehouses at different places in the country. It has a

vast presence across the country. Whenever warehouses demand for the goods company

fulfills the requirement. After that Local dealers contact to the warehouses and place their

orders. Thus local dealers can purchase the pipes according to their requirements and

capacity. This system also reduces the inventory at dealers end and further it reduces the

stock keeping risk and cost.

Clientele

Tatas have a very big client base. They export in forty-two countries. Here is some of the

name given.

Hero Honda

TVS

Yamaha

Tata Motors

Exports in 42 countries

Australia, U.K., Oman, Singapore, South Africa, etc


31/33

Tata has been providing the best quality products over the years. That is the reason it has a rich

clientele which includes big corporate houses like Hero Honda, TVS and Tata Motors itself. Tata

Pipe is exported in different countries as well. There are many countries across the world where

product is exported. Tata supplies the product according to the weather and other conditions.

Thus Tata has a strong client base in domestic and foreign markets as well.

Complaint Handling

Complaint handling is one of the major tasks done by Tata tubes. Tata tubes not only ensure best

quality service and products but also accept the complaints if any fault arises due to there

negligence. The fault may be technical i.e. it may occur during the production process or the fault

may be due to the miss handling in case of packaging or delivery. Every fault is taken in concern

and a proper complaint handling process is implemented to overcome loop holes. The complain

handling is a well documented procedure to settle the complaints and providing solution to it.

The procedure of complaint handling is approved by ISO 9001: 2000.

The procedure adopted to settle the complaints is properly synchronized and implemented after

ample research done to improvise the process. The process so selected is the best process among

the various alternative. The process is such that, as the complaint is launched by the customer, a

report is prepared containing detailed description to be handled. The company appoints a

surveyor who makes a note of the complaints launched; chronologically arrange the complaints

as per his priority to be handled. The first listed complaint in his list is settled in a particular

procedure. The procedure implemented by the surveyor is: he visits the customers place make a

descriptive check of the product, identify the complaints and the fault, assure the customer that

the complained has been taken into consideration and a quick solution will be given, prepare a

report on the significance of the complain, submit the report to the company and lastly the

company pays compensation if the fault is found. The tool of negotiation is used during

settlement of the complaint.


32/33

The complaint handling process

FUTURE PLANS

One million ton production by 2012 currently producing five lakh ton- Tata tubes is

targeting for producing one million ton which in 2012 at present the company is

producing 5 lakh there is a continues growth in p-production and the growth is more than

expectation and this proves that Tata tubes will soon reach to its targets. The target will

ascertain in 2012.

No. 1 in precision tubes by 2012 currently at second position- Curetting Tata tubes is

number 1 in commercial tube but it is missing its first position in precision tubes. The

next future plan of Tata tubes is to rank first in precision tube also, Tata tubes will soon

achieve first position in precision tubes

Looking up to achieve 4 sigma level currently at 3 sigma level- Tata tubes is currently

working in $sigma level very soon it will be start working on 3sigma level. This is next

future plan of Tata Tubes.


33/33

Focusing on global market on the basis of more improved quality and diverse products-

Tata tubes has its business in international market also curenting its catering companies

are in places such as Australia, South Africa, Thailand and other countries. They are

making product according to geographical requirement of the state. This is the next future

plan of Tata tubes.

Documents

QMM Report Tata Steel