Tat Chemical Ltd

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APROJECT REPORT

INTATA CHEMICALS LIMITED, MITHAPUR

FROM 24TH APRIL to 9TH JUNE

Prepared byMs. TANVI. J. FALDU .,

MBA SEM II,ROLL NO : 10

ACADEMIC YEAR : 2007-08

PROJECT GUIDE :Mrs. NIHARIKA BAJEJA

SUBMITTEDTO

T. N. RAO. COLLEGE OF MANAGEMENT STUDIES ,SAURASHTRA UNIVERSITY, RAJKOT


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S T U D E N T D E C L A R A T I O N

I the undersigned student Hirapara Shailesh .B of K.K. Parekh

Institute of Management Studies Amreli M.B.A. II Semester,

hereby declare that, the project on TATA CHEMICALS LTD. is my

own work.

In the partial fulfillment of Master Degree of Business

Administration, I had undergone project work at TATA CHEMICALS

LTD. under the guidance of Miss Ripal Madhani K. K. Parekh Institute

of Management Studies Amreli and submitted to Miss Ripal Madhani.

This project work is my original work and has not been submitted to any

where earlier.

Date:- Thanking You,

Place: - Amreli Yours Faithfully


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(Hirapara shailesh)

PREFACE

This project is prepared for when I take industrial visit at TATA

CHEMICAL LTD. MITHAPUR

It is a very well known proverb that The practice makes a man

perfect. As per this proverb we can say that one can only become perfect

by practicing. He or she need to have enough knowledge of practical

implementation in the current scenario of the theoretical knowledge.

As a student of management I have studied many theories in classroom but

after taking Industrial visit, I have experienced and understood it in it fullest

sense which plays a vital role in business field.

Hence, this report is been designed with the objective to gain practical

exposure and to know the motivational analysis of organizational climate.

During the industrial visit I met various functionaries of organization and

interacted with them. I sincerely thank them all whose cooperation and


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guidance enriched my knowledge and this report was made possible

SOUND BECOME MUSIC IF A TRAINED PEOPLE USE IT

ACKNOWLEDGEMENT

Experience is the best guide. I was lucky enough to have take visit

for one day at Excel Crop Care Ltd. It provided me the best opportunity

to learn things first hand. It enables me to apply the theoretical knowledge

and experience the results..

It is very necessar y to have a guide when you are a fresher in the

corporate world because that helps us in finding our way our goals easily.

I would like to express my sincere thanks to all the TATA

CHEMICALS LTD. without their support, this project would not have

been a success.

I would also like to acknowledge and appreciate the guidance given to

me by Miss Ripal Madhani Faculty Members of K.K.Parekh Institute of

management Studies.


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INDEX

INTRODUCTION

COMPANY PROFILE

HISTORY OF THE COMPANY (In Brief)

PRODUCT PROFILE

NATURE AND SCOPE OF PRODUCATION ANDOPERATION MANAGEMENT

MANUFACTURING PROCESS

PRODUCTION CAPACITY AND MANAGEMENT

PRODUCATION PLANNING

LAYOUT OF THE COMPANY


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INVENTORY MANAGEMENT

QUALITY MANAGEMENT

CONCLUSION

COMPANY PROFILE


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Mithapur 361 345

Okhamandal, Gujarat

Tel: (02892) 665 991 / 665 992

Fax: (02892) 223 471

History of TATA chemicals Ltd

The TATA chemicals mithapur , The company that care is one of

its kinds in the world and the companys fertilizer division in babrala is

among the best industrial units in India thats a long way to come from

modest beginnings and it is testimony to the vision and ability of the

pioneers who get tata chemical up and running.

Tata chemical was born in 1939, the year world war-2 the two

consignments were sunk of sea and ordered from Sweden, a natural

country, but the war almost claimed that too. The early years of Tata

chemical were disastrous an international. Expert told to J.R.D. Tata the


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owner of the industry. You are in the wrong place doing the wrong job

the Formula that helped Tata chem. Turn the corner of the production was

Well-guarded sere of about six companies in the world, but Tata chemical,

cracked the Code, it then began negotiating with a German firm to raise its

production capacity From 80 to 200 tones of soda ash per day when a 31

year old chemical engineer called Darbari Seth, fresh from a stint in

America, told managing board that India did not Need foreign help we can

do it, He said, and what is more, we said, and what is more we should

aim not at 200 tones but 400 tones of the 10 members on the board, Only

one person agreed with him J.R.D.

Mithapur, the city of salt, is the mother Indias heavy chemical

industry, in the late 1920, kapil ram vakil, a chemical engineer established

the okhamandal salt works later he setup A soda ash plant of the site

company also has a slogan for the Tata salt Hum Des ka Namak Khate hai,

Hum des Ka Namak Banate hai.

After the survey of the western coast, kapil ram vakil, a chemical

engineer, decide on a point seven miles from okha, the western most tip of

India where the Arabian Sea Meets the Rann of Kutch but he could not bear


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the financial burden of running the plant for long. And approached the Tata

then the maharaja of Baroda sayaji roa in whose territory mithapur fall, also

where to the Tata suggesting that they might like to assist with national

project.

The company is growing to its destination fifty years back, mithapur was a

desolate Place providing little to the material tribe that inhabited its

neighborhood with the induction of industry these sturdy people have found

a means of livelihood in December 1963, when prices of heavy chemical

were decontrolled the company Reduced its prices much to the annoyance

of its competitors mithapur expanded its Capacity to 1000 tones of soda ash

per day and today produce 2400 tones later when There was a surplus of

soda ash in the market 2000 more customer registered with the Company it

also generates 1000 (tones per day) of vacuum evaporated salt and 33 other

product.

Tata chemical spread its writing in 1994 with commissioner of its

fertilizer division at Babrala in utter Pradesh. Today it has an installed

capacity of 2250 tpd of urea and 1350 tpd of a ammonia. The company


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arranged for suitable treated seawater to replace fresh water in plant

operation and it put in place a thoughtful recycling.

Arrangement and other innovative methods of solving on water the

company has established seawater plant named equalization plant

consumption was reduced from 22 lakh gallons per day.

TCLS slogan is leadership with trust which is not merely a slogan

but the Originality of the company our heritage of returning on society

about evokes that is trust among customer, employee, share holder and

community.

The organization which embarks upon quality management system,

certificate (such as ISO 9000 or demanding prize) Formulation and

dissemination of quality policy is required first step for certification TATA

was certified by ISO 9000 in 1996. As ISO 9000 is certified like that safety

department is certified by OSHAS 18001occupation safety and health

assessment services. In the technological world to stay in Competition to

implement ERP package of oracle and after words means in 1999 they are

working on Sap at present the turnover of soda ash is more than 2000 tones


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TEAM OF TATA CHEMICALS

Chairman Ratan N. Tata

Vice-chairman R. Gopalkrishnan

Managing director Homi R. Khusrokhan

Directors Nusli Wadia

Dr. D. V. Kapur

P. R. Menon

Dr. T. Mukherjee

Dr.Vijay L. Kelkar

Nasier Munjee

Dr. Yoginder K. Alagh


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PRODUCTS

CHEMICALS

One of India's leading manufacturers of inorganic chemicals, TCL's

products and production processes are benchmarked with the best of global

touchstones and meet the most rigorous international specifications

The company's state-of-the-art manufacturing systems are backed by a

highly efficient and committed marketing team. The chemicals strategic

business unit (SBU) of Tata Chemicals, oversees both forward and

backward integration across a wide spectrum of products and business

segments


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The Chemicals SBU comprises

Soda ash

This multipurpose chemical is used in a variety of industries, most

prominently in the manufacture of glass, where it reduces the melting

temperature of the sand used in glass formation and helps in the

'workability', or shaping, of glass articles.

Soda ash is also a major ingredient in the making of soaps and

detergents. Here it is employed as a builder, or filler, to give a smoother

surface in formulations of soaps, detergents and other cleaning compounds.

This resourceful alkali, the least expensive of soluble alkalis, is widely used

in the production of other chemicals. Soda ash is used in mineral processing


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in mining, pulp and paper manufacture, the making of sodium compounds,

water treatment, metal refining, textile processing, cleaning preparations,

petroleum and metallurgical refining, iron and steel, aluminum, and drugs.

Cement

Cement is a major success story for TCL, and a fine example of how the

company's philosophy of 'avoid, reduce and recycle' operates.

The cement plant at Mithapur was set up solely to consume the solid

waste generated during the manufacture of soda ash. The plant has an

installed capacity of 1,500 tonnes per day and it manufactures three

varieties of cement: Ordinary Portland Cement (grades 43 and 53) and

Pozzolana Portland Cement (under the Shudh Cement brand name).

Caustic soda
http://www.tatachemicals.com/0_plants/mithapur_plant.htmhttp://www.tatachemicals.com/0_plants/mithapur_plant.htm


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Due to its adoption of energy-efficient, membrane-cell technology

and the captive availability of salt and of power, TCL has been able to

deliver low-cost caustic soda to the market.

As a versatile alkali, caustic soda is used in a variety of industries, the

major ones being rayon, cellophane, soap, pulp and paper. Apart from

caustic soda, TCL also produces hydrochloric acid and liquid chlorine.

Bromine

TCL manufactures several variants of bromine and bromine-based

compounds, such as liquid bromine technical, potassium bromide PQ,

sodium bromide PQ, methyl bromide, ethyl bromide and hydrobromic acid.

FOOD ADDITIVES

Tata Chemicals' food additives strategic business unit has two of the

company's premium product groups under its wing: branded salt and

sodium bicarbonate. Widening the product range and increasing market

share is the two-pronged thrust in this sphere


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Salt

TCL makes 3,50,000 tonnes of vacuum-evaporated iodised salt

annually at its Mithapur complex, the largest and most integrated chemicals

facility in India. The company manufactures four varieties of salt: iodised

salt, crystalline salt, vacuum salt and pure salt.

Tata Salt, the outstanding offering in TCL's food-additives basket, is

a household name with top-of-the-mind brand recall and a 41-per cent share

of the Indian branded iodised salt market, way ahead of the nearest

competitor. It has consistently proved its mettle by being rated in the top 10


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most trusted brands in the survey conducted by The Economic Times ,

India's largest financial newspaper. Tata Salt was named the 'No.1 Food

Brand' in 2003.

Crystalline salt

Samunder Crystal Salt is a refined, iodised, clean, white crystal salt.

It offers customers a purer and cleaner alternative to the loose, unbranded

crystalline salt widely available in Indian markets.

Sodium bicarbonate

TCL's sodium bicarbonate plant has a capacity of 50,000 tonnes per

annum. The company produces three varieties of sodium bicarbonate -

sodium bicarbonate technical, sodium bicarbonate refined and sodium

bicarbonate granular - all of which meet stringent quality standards.

The company markets its sodium bicarbonate products in India, the Middle

East, Africa and Bangladesh.

Cooking soda


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Tata Chemicals has launched a branded cooking soda sold in small,

single-use sachets under the brand name Tata Samunder Cooking Soda.

Cooking soda is an ingredient already familiar to Indian consumers but so

far, it has only been available in an unbranded form and is purchased either

loose or in unmarked plastic pouches. Tata Samunder refined food grade

soda bicarbonate (NaHCO 3 ) is pure and unadulterated, and a value-for-

money alternative to the unbranded products available in the market.

Manufacturing Process Of Soda Ash

Lime burning

Lime hydration

Ammonia distillation

Ammonia absorption

Carbonation

Gas compression


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Manufacturing Process Of Cement

Filtration

Packing and storage

Minning

Crushing and pre blending

Reclaimer

Hoppers

Raw mill

Blending silo


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Production planning & control

Production Planning and control are 2 important aspect of production.

Production planning is prerequisite of production control. Production control

cannot be imaged without production planning.

Production planning is the function of management to look ahead,

anticipate difficulties and take steps to remove obstacles before they are

Coal mill

Cement mill

Cement silos

Packing plant


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materialized. Where n unit is constantly evaluated and compare with the

standards set in advance.

At TCL Production planning is jointly done with dispatch department

on the basic of order and dispatch for the next month provider by dispatch

department production department plans production and its operations. And

on the basic of production planning, department and strict control on the

production activity and continuously evaluated the performance through tar

as it is totally computerized plant.

PRODUCTION PLANNING INVOLVES FOLLOWING STEPS

Development and introduction of new product

Modification of existing lines

Changing needs and preference


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Discontinuous of margined unprofitable or obsolete product


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Plant layout


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Documents

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