INTERNSHIP REPORT “AN ORGANISATION STUDY”
AT
ROURKELA STEEL PLANT
Submitted to Bangalore University in partial fulfillment of the requirement for the award of
MASTER OF BUSINESS ADMINISTRATION
SUBMITTED BY
HIMANSU SEKHAR M (REG. NO. 101GCMA043)
UNDER THE GUIDANCE OF
INTERNAL GUIDE: EXTERNAL GUIDE:
Mrs. ANITA D SILVA Mr. SUDHANSU S M
Prof., RVIM Asst. Manager
RASHTREEYA SIKSHANA SAMITHI TRUST R.V.INSTITUTE OF MANAGEMENT
DECLARATION
I, HIMANSU SEKHAR MOHAPATRA hereby declare that the
internship project report titled “An Organization Study at
ROUKELA STEEL PLANT, Rourkela” submitted in partial
fulfillment of the requirements for the award of the degree of
Master of Business Administration (M.B.A) is my original work
under the guidance and supervision of Mrs. ANITA D SILVA, Prof.
RVIM and Mr. SUDHANSU S MOHAPATRA, Assistant Manager,
ROURKELA STEEL PLANT, Rourkela.
This internship project report has not been submitted to any other
institution / university for the award of any degree or diploma or
any other similar titles.
DATE: HIMANSU SEKAHR MOHAPATRA
REG. No 101GCMA043
CERTIFICATE
This is to certify that Mr. HIMANSU SEKHAR MOHAPATRA bearing
Register Number 101GCMA043, student of III semester MBA
programme, has undertaken an internship study on the topic “An
ORGANIZATION STUDY at RORKELA STEEL PLANT, Rourkela”
under the guidance of Mrs. ANITA D SILVA, Prof. R.V.I.M. The report
is being submitted in partial fulfillment of requirements for the award of
the degree of Master of Business Administration.
This internship report has not been submitted to any other institution
for the award of any degree or diploma of any other universities.
Dr. R.K.GOPAL Dr.T.V. RAJU
Professor & H.O.D
Director
GUIDANCE CERTIFICATE
This is to certify that Mr. Himansu Sekhar Mohapatra bearing
University Regd.no.101GCMA043 has successfully completed the project
work entitled “An Organisation Study at Rourkela Steel Plant” in our
organization for the partial fulfillment of degree of MBA program in
R.V. Institute of Management, Bangalore under Bangalore University,
Karnataka.
No part of this work has been submitted anywhere for award, for
any degree or otherwise to the best of my knowledge.
Signature of the Guide
Mr.S.S.Mohapatra
Assistant manager
Personnel (PIS)
GUIDE CERTIFICATE
This is to certify that Mr. HIMANSU SEKHAR MOHAPATRA bearing
REG NO. 101GCMA043 student of III semester MBA programme has
undertaken an internship on the topic “An ORGANIZATION STUDY
at ROURKELA STEEL PLANT, Rourkela” under my guidance and
supervision. The report is being submitted in partial fulfillment of the
requirements for the award of the degree of Master of Business
Administration.
This internship project has not been submitted to any other institution
for the award of any degree or diploma for any other universities.
DATE:
Mrs. ANITA D SILVA
ACKNOWLEDGEMENT
The successful completion of any task would be incomplete without mentioning the people who made it possible and whose constant guidance secured as success.
I express my deep gratitude to our Director Dr.T.V.RAJU, R.V. Institute of Management, Bangalore, for his support in the successful completion of the project and Dr.R.K.Gopal, HOD, MBA programme, for giving an opportunity to complete this study successfully.
It is with humble sense and gratitude with heartfelt appreciation to my beloved Internal guide Mrs. ANITA D SILVA . whose estimable aid, keen surveillance, support, continued inspiration, valuable guidance and meticulous supervision throughout project and to bring this project to a successful completion.
I express my immense gratitude to the External Guide Mr. SUDHANSU MOHAPATRTA, Asst. Manager (PL), R & PIS of the company for providing me continuous support, advice and encouragement to go about completing my project successfully.
I owe my sincere gratitude to all the members and heads of various departments in ROURKELA STEEL PLANT. I extend my sincere thanks especially to all the members of Rourkela Steel Plant & especially HRD department who have made my stay in RSP most fruitful and a learning experience.
I also thank members of non teaching staff of RVIM for their continuous support during my internship training. I am grateful to my parents, friends and well wishers who have encouraged and supported me throughout my internship programme at ROURKELA STEEL PLANT, ROURKELA.
PLACE:
BANGALORECHAPTERS
INDEX
PAGE
NO
CHAPTER 1 INDUSTRIAL PROFILE
1-10
INTRODUCTION
DEMAND OF THE STEEL INDUSTRY
GLOBAL SCENARIO
MAJOR PLAYERS
STEEL AUTHORITY OF INDIA LTD (SAIL)
SAIL’SS CORPORATE PLAN- 2012
MANAGEMENT OF SAIL
SAIL INTO THE FUTURECHAPTER 2 COMPANY PROFILE
11 – 34
ROURKELA STEEL PLANT
LOCATION
SPECIAL FEATURES OF RSP
VISION, MISSION, AND QUALITY POLICIES
PRODUCT PROFILE
PRODUCT MIX OF RSP
PRODUCT AND ITS APPLICATION
COMPETITORS
ORGANIZATION STRUCTURE
PRODUCTION PROCESS MODELCHAPTER 3 FUNCTIONAL DEPARTMENTS
35 – 65
CHAPTER 4 SWOT ANALYSIS
66 – 68
CHAPTER 5 FINDINGS & SUGGESTIONS & CONCLUSION
69 – 72
BIBILOGRAPHY
73 - 74
CHAPATER 1
INDUSTRY PROFILE
•
INTRODUCTION
•
DEMAND OF THE STEEL INDUSTRY
•
GLOBAL SCENARIO
•
MAJOR PLAYERS
•
STEEL AUTORITY OF INDIA LTD. (SAIL)
•
SAIL’S CORPORATE PLAN- 2012
•
MANAGEMENT OF SAIL
INDUSTRY PROFILE
INTRODUCTION:
Steel Authority of India Limited (SAIL) only the name is sufficient gives a brief idea about the company. As we know Mr. Jameshdji Tata sowed the seeds of modern steel industry in 1907 when Tata Iron & Steel Company Ltd (TISCO) was established. In the year 1939 the production of steel started in another private steel company called the Indian Iron and Steel Company, now a subsidiary of the SAIL. After the independence SAIL became a major player of steel and iron and a major supplier to all the fields. After Globalization SAIL having big opportunity to expand their sales globally and became one of the major suppliers of steel and iron. As we know that what ever is made that must be for some purpose and that must be sold but the process may be different from one another.
Growth:
In the era of planned economy, iron and steel, a core and basic sector, received the full attention of the government. It became a key sector for public investment for the First Five Year Plan itself. The year 1953 saw the first agreement being signed with Germans to establish a 1 million tone plant at Rourkela in Orissa. Two more agreement for setting up steel plants at Bhilai with erstwhile USSR’s assistance and another at Durgapur with the help of U.K. was signed in1956. Successive capacity augmentations at Bhilai, Durgapur and Rourkela saw their capacity increase to 2.5, 1.6 & 1.8 million tones per annum respectively by the end of the 60’s
A new plant at Bokaro with a capacity of 2.5 million tones per annum went into production in 1973-74. The year 1978 witnessed a major restructuring of these steel making public sector units giving birth to the public sector giant, SAIL, having a “Navaratna” status
today, with an aggregate capacity of over 10 million tones. The first shore-based public sector integrated plant, viz.The Rashtriya Ispat Nigam Limited of 3 million tones per annum capacity went into production in August, 1992. During First two decade of planned economic
development, i.e. 1950-60 and 1960-70, the average annual growth rate of steel production exceeded 8 percent. During 1970-80, this growth rate in steel production came down to 5.7% per annum and gathered up marginally to 6.4% per annum during 1980-90.
Until the 1990’s the iron and steel sector was by and large the exclusive preserve of only public sector, the sole exception being TISCO. The new economic policy, substantial private investments flowed in with the consequent changes heralding a new beginning for the interplay of free market enterprise in this vital sector.
Changes:
A glance at the pre-and post 1991 era reveals some interesting and significant structural changes. At the consumer or demand end market for steel has been transformed from a seller to a buyer market. Control and regulation have been replaced by competition. Administered price have been replaced by supply and demand determined market prices. In the post liberalization era, the structure of steel industry is significantly and vastly different with the advent of major steel producers in the private sector which have come up with the world class technology and capacities.
There has been clear shift towards the selection of the product mix. During the pre-1991era, the private sector was mainly confined to the production of long products. The only producer of hot-rolled flat products was SAIL in the public sector. Now there are 5 additional
major producers of flat products of steel in the private sector was mainly confined to the
production of long products. The only producer of hot rolled flat product was SAIL in the public sector. Now there are 5 additional major producers of flat products of steel in the private sector.
Presently, India can boast of new technology like Corex, Thin Slab Casting and Compact Strip Mill Technology, DC Electric Arc Furnaces. Twin Shells AC EAFs etc. in the steel
industry. The industry has now to focus on customer satisfaction and outstanding quality of steel products in a competitive environment. Steel producers in the public and private sector have taken upon themselves with determination and commitment to overcome the new and arduous challenge to come up to thee Government’s expectations as also the people of our country in the most difficult and trying period for the last couple of years.
Impact:
The response of the private sector in particular has been quite encouraging in the post liberalization era. Many all India financial institutions also came forward to support these
initiatives and had sanctioned financial assistance to 19 steel projects involving an investment of about Rs. 30,000 crore covering an additional capacity of 13 million tones per annum during the post liberalization era. Today, India is the tenth largest steel producers in the world. The industry represents over Rs.90,000 crore of capital and directly provides employment to over 0.5 million people.
Production:
The production of finished steel increased from 14.333 million tones in 1991-92 to 23.82 million tones in 1998-99. The private sector’s contribution in the availability of finished steel has constantly been increasing. From 51.4% in 1991-92 it increased to over 68% in 1998-99. This trend is likely to continue.
Export:
Although India started steel production as early as in 1911, steel exports began only in 1964. Exports in the first five years were mainly due to demand downturn in the domestic iron
and steel market. Once domestic demand revived, exports declined India once again started exporting steel only on 1975, touching a figure of 1 million tonne of pig iron and 1.4 million tones of steel export in 1976-77. Therefore exports again fell rapidly to meet the challenges arising from increased domestic demand.
There has been a substantial growth in export of steel during the post liberation period. It increased from 0.9 million tones valued at Rs.700 crore in 1992-93 to 3.4 million tones valued at Rs.2580 crore in 1997-98, even overtaking sectors like electronic goods and man-made fabrics. There has been a qualities change in the export of steel items. Earlier, export consisted mainly of plates, bars and rods and structural, whereas now semis, hot-rolled coils, cold rolled coils and galvanized sheets are also being exported.
India’s Present per capita consumption of crude steel is only 24 kg. which is very low compared to the developed and developing countries- 422 kg. in USA, 417 kg. in Germany 109 kg, in Russia and 87 kg in China. Our consumption is less than one fifth of the world average (121 kg).
Ministry Initiatives:
The Government has been making all out efforts to help the domestic steel industry to overcome the problems faced by them. To boost the demand and assumption of steel, an
Institution for Steel Development & Growth (INSDAG) was set up involving leading steel producers in the country. The Development Commissioner for Iron & Steel had launched a
National campaign for increasing the demand for steel in non traditional sectors, particularly in construction, rural and agro based industrial sectors. Other areas include reduction in power and railways tariffs, reduction in input costs, strengthening of antidumping mechanism, setting up a steel exporter’s forum and an empowered committee for research and development.
DEMAND OF THE STEEL INDUSTRY:
• Global steel demand is rising on the back of accelerated infrastructure activity in China, CIS and India, housing boom in USA, and white goods resurgence in Europe. During the recent recessionary phase the industry has consolidated in terms of ownership as well as mothballing of inefficient capacities. Steel prices continue firming up.
• For the first time in last 20 years, there is demand growth all over the world for steel.
• In US, the demand is led by the booming housing industry. Additionally the auto industry is showing signs of recovery as auto sales hit their strongest levels for the year in July even as US postedba2.4% GDP growth.
• In Europe, there is demand from a buoyant housing and white goods industry according to industry sources.
• In India, China and other Asian countries the demand is led by emphatic investment activities in infrastructure.
• Russia and other CIS nations are also witnessing strong internal demand.
• Iraq re construction work is expected to fuel further demand for steel over the next three years.
• China is consuming steel like never before for its infrastructure with investment such as Three Gorges project on Yangtze as well as part of its build up to the Beijing Olympics in 2008 and the Songhai Expo in 2010.
The demand supply gap is expected to increase this will drive steel prices northwards, even as the global steel industry is not prepared for this demand onslaught.
GLOBAL SCENARIO:
The Asian countries have their respective dominance in the production of the steel all over the world. India being one among the fastest growing economies of the world has been considered as one of the potential global steel hub internationally. Over the years, particularly after the adoption of the liberalization policies all over the world, the World steel industry is growing very fast.
Steel Industry is a booming industry in the whole world. The increasing demand for it was mainly generated by the development projects that have been going on along the world,
especially the infrastructural works and real estate projects that has been on the boom around the developing countries. Steel Industry was till recently dominated by the United Sates of America but this scenario is changing with a rapid pace with the Indian steel company on an acquisition spree. In the last one year, the world has seen two big M&A deals to take
place:-The Mittal Steel, listed in Holland, has acquired the world's largest steel company called Arcelor Steel to become the world's largest producer of Steel named Arcelor-Mittal.
Tata Steel of India or TISCO (as listed in BSE) has acquired the world's fifth largest steel company, Corus, with the highest ever stock price.
It has been observed that Steel Industry has grown tremendously in the last one and a half decade with a strong financial condition. The increasing needs of steel by the developing countries for its infrastructural projects have pushed the companies in this industry near their operative capacity.
The most significant growth that can be seen in the Steel Industry has been observed during the period 1960 to 1974 when the consumption of steel around the whole world doubled. Between these years, the rate at which the Steel Industry grew has been recorded to be 5.5 %. This roaring
market saw a phase of deceleration from the year 1975 which continued till 1982. After this period, the continuous fall slowed down and again started its upward movement from the early 1990s.
Steel Industry is becoming more and more competitive with every passing day. During the period 1960s to late 1980s, the steel market used to be dominated by OECD (Organization for Economic Cooperation and Development) countries. But with the fast emergence of developing countries like China, India and South Korea in this sector has led to slipping market share of OECD countries. The balance of trade line is also tilting towards these countries.
The following table gives a clear picture upon the major crude steel producers in the world as of the year 2004.
Country Crude Steel Production (mtpa) China 272.5 Japan 112.7 United State 98.9 Russia 65.6 South Korea 47.5 F.R.Germany 46.4 Ukraine 38.7 Brazil 32.9
India 32.6 Italy 28.4
In the year 2004, the global steel production has made a record level by crossing the 1000 million tones. Among the top producers in the steel production, China ranked 1 in the world. Production of steel in the 25 European Union countries was at 16.3 mmt in January 2005. Production in Italy increased by 11.5 per cent in comparison to the same month in 2004. Italy produced 2.5 mmt of crude steel in January 2005. Austria produced 646,000 metric tones. In Russia it increased by 4.0 per cent to reach at 5.5 mmt in January. In case of the North America region particularly in it was 1.5 mmt of crude steel in January 2005, up by 8.0 per cent compared to the same month in 2004. Production in the United States was 8.3 mmt. Brazil had produced 2.6 mmt of crude steel in January 2005. In South America region it was 3.7 mmt for January 2005. According to rating made by the “World Steel Dynamics", Indian HR Products are categorized in the Tier II category quality of products. Both EU and Japan have ranked the top. USA and South Korea comes as like India.
MAJOR PLAYERS IN THE STEEL SECTOR:
• Steel Authority of India Ltd.
• Tata Iron and steel Company
• Jindal Steel and power Ltd.
• Jindal Iron and Steel Ltd.
• Jindal Vijayanagr Steel Ltd. Jindal Stainless Ltd.
• Ispat Industries Ltd.
• Kalyani Steel Ltd.
• Lloyds Steel Ltd.
• Nippon dendro Ispat Ltd. Essar Steel Ltd.
STEEL AUTHORITY OF INDIA LIMITED (SAIL):
SAIL is among India's largest steel producing companies and tops among them. It is one of the companies which have been accorded the “Maharatna” status for greater autonomy in its management. With a production capacity of 13.9 million tonnes it is one of the top twenty steel producing companies in the world. It is a fully integrated iron and steel maker, producing both basic and special steels for domestic construction, engineering, power, railway, automotive and defense industries and for sale in export markets. The company has the distinction of being India’s second largest producer of iron ore and of having the country’s second largest mines network. This gives SAIL a competitive edge in terms of captive availability of iron ore, limestone, and dolomite which are inputs for steel making.
It was initially established as Hindustan steel limited in the year 1954. The company initially as Hindustan Steel Limited was established to control the plant at Rourkela but later it took up the managing of other plants at Bhilai and Durgapur. SAIL was incorporated as a holding company in the year 1973 with an authorized capital of Rs. 2000 crore, was made responsible for
managing five integrated steel plants at Bhilai, Bokaro, Durgapur, Rourkela and Burnpur, the Alloy Steel Plant and the Salem Steel Plant to oversee iron and steel production. In 1978 SAIL was restructured as an operating company. Since its inception, SAIL has been influential in establishing a sound infrastructure for the industrial development of the country. It also has immensely contributed to the development of technical and managerial expertise. It also has played an important role in secondary and tertiary growth of the country by providing for the consumer industry.
SAIL’s wide range of steel products is much in demand in domestic as well as in the international market. This responsibility is carried out by SAIL’s own central marketing
organization (CMO) and the international trade division. CMO consists of a wide network of 38 branch offices and 47 stockyards located at major cities and towns across India.
With technical expertise and know-how in steel making gained over four decades, SAIL
Consultancy Division (SAILCON) at New Delhi provides services to clients worldwide. Sail has a well equipped research and development centre for iron and Steels (RDCIS) at Ranchi which helps to develop new technology for production of quality steel. SAIL also has its own in-house Centre for Engineering and Technology (CET), Management Trainee Institute (MTI) and SAIL Safety Organization (SSO), a Corporate Unit set up in 1988 at Ranchi, monitors and guides the safety Promotional, fire and Occupational Health Services activities undertaken at different steel Plants/Units/Mines/Stockyards. To accomplish the above mentioned functions, SSO formulates and prepares appropriate safety policies, procedures, systems, action plans, guidelines etc. and follows up for their implementation and thereby helps in providing accident free work
environment.
HISTORY OF SAIL: The Precursor
SAIL traces its origin to the formative years of an emerging nation - India. After independence the builders of modern India worked with a vision - to lay the infrastructure for rapid
industrialization of the country. The steel sector was to propel the economic growth. Hindustan Steel Private Limited was set up on January 19, 1954. The President of India held the shares of the company on behalf of the people of India.
Expanding Horizon (1959-1973)
Hindustan Steel (HSL) was initially designed to manage only one plant that was coming up at Rourkela. For Bhilai and Durgapur Steel Plants, the preliminary work was done by the Iron and
Steel Ministry. From April 1957, the supervision and control of these two steel plants were also transferred to Hindustan Steel. The registered office was originally in New Delhi. It moved to Calcutta in July 1956 and ultimately to Ranchi in December 1959.
A new steel company, Bokaro Steel Limited, was incorporated in January 1964 to construct and operate the steel plant at Bokaro. The 1 MT phases of Bhilai and Rourkela Steel Plants were completed by the end of December 1961. The 1 MT phase of Durgapur Steel Plant was
completed in January 1962 after commissioning of the Wheel and Axle plant. The crude steel production of HSL went up from .158 MT (1959-60) to 1.6 MT. The second phase of Bhilai Steel Plant was completed in September 1967 after commissioning of the Wire Rod Mill. The last unit of the 1.8 MT phase of Rourkela - the Tandem Mill - was commissioned in February 1968, and the 1.6 MT stage of Durgapur Steel Plant was completed in August 1969 after
commissioning of the Furnace in SMS. Thus, with the completion of the 2.5 MT stage at Bhilai, 1.8 MT at Rourkela and 1.6 MT at Durgapur, the total crude steel production capacity of HSL was raised to 3.7 MT in 1968-69 and subsequently to 4MT in 1972-73.
Holding Company
The Ministry of Steel and Mines drafted a policy statement to evolve a new model for managing industry. The policy statement was presented to the Parliament on December 2, 1972. On this basis the concept of creating a holding company to manage inputs and outputs under one umbrella was mooted. This led to the formation of Steel Authority of India Ltd. The company, incorporated on January 24, 1973 with an authorized capital of Rs. 2000 crores, was made responsible for managing five integrated steel plants at Bhilai, Bokaro, Durgapur, Rourkela and Burnpur, the Alloy Steel Plant and the Salem Steel Plant. In 1978 SAIL was restructured as an operating company.
Since its inception, SAIL has been instrumental in laying a sound infrastructure for the industrial development of the country. Besides, it has immensely contributed to the development of
technical and managerial expertise. It has triggered the secondary and tertiary waves of economic growth by continuously providing the inputs for the consuming industry.
SAIL Today
SAIL today is one of the largest industrial entities in India. Its strength has been the diversified range of quality steel products catering to the domestic, as well as the export markets and a large pool of technical and professional expertise. Today, the accent in SAIL is continuously adapt to the competitive business environment and excel as a business organization, both within and outside India.
SAIL’S SEVEN DIMENSIONS OF CUSTOMER SATISFACTION: • Consistent Quality
• Committed delivery
• Customized product mix
• Competitive price
• Contemporary product
• Complaint settlement
• Culture of customer service
CORE VALUES OF SAIL: • Customer satisfaction
• Concern towards people
• Commitment to excellence
• Work culture
MAJOR UNITS:
Sail has integrated steel plants i.e. from extraction of ore to production of steel is done in same plant. The five integrated steel plants of sail are:-
• Bhilai Steel plant.
• Bokaro steel plant
• Durgapur steel plant
• Burnpur steel plant
SPECIAL UNITS:
• Alloy Steels Plants (ASP), Durgapur, West Bengal
• Salem Steel Plant (SSP), Tamil Nadu
• Visvesvaraya Iron and Steel Limited (VISL), at Bhadravathi, Karnataka
CENTRAL UNITS:
• Centre for Engineering and Technology
• Research and development centre for iron and steel
• Management Training Institute
• SAIL safety organization
• Raw materials division
• Central Marketing Organization
• SAIL consultancy organization
JOINT VENTURES:
• NTPC SAIL Power Company Pvt. Ltd (NSPCL)
A 50:50 joint venture between Steel Authority of India Ltd. (SAIL) and National Thermal Power Corporation Ltd. (NTPC Ltd.); manages the captive power plants of Rourkela and Bhilai Steel Plant
• Bokaro Power Supply Company Pvt. Limited (BPSCL)
This 50:50 joint venture between SAIL and the Damodar Valley Corporation formed in January 2002 is managing the steam generation in Bokaro Steel Plant.
A 50:50 joint venture between SAIL and Tata Steel formed in 2001. This company promotes e-commerce activities in steel and related areas. Newly added services include e-Assets sales, Events & Conferences, Coal Sales & Logistics, and Publications etc.
• Bhilai JP Cement Ltd
SAIL has incorporated a joint venture company with M/s Jaiprakash Associates Ltd to set up a 2.2 MT slag based cement plant at Bhilai. The company shall commence cement production at Bhilai by March'2010,
• Bokaro JP Cement Ltd
SAIL has incorporated another joint venture company with M/s Jaiprakash Associates Ltd to set up a 2.1 MT cement plant at Bokaro utilizing slag from BSL. The project implementation is under progress.
• SAIL&MOIL Ferro Alloys (Pvt.) Limited
SAIL has incorporated a joint venture company with M/s Manganese Ore (India) Ltd on 50:50 basis to produce ferro-manganese and silico-manganese required for production of steel.
• S&T Mining Company Pvt. Ltd
SAIL has incorporated a joint venture company with TATA Steel for joint acquisition & development of coal blocks/mines. New indigenous opportunities for coking coal development are being explored by the Joint Venture Company for securing coking coal supplies.
• International Coal Ventures Private Limited
Towards achieving the target of making steel PSUs self reliant a joint venture company comprising of five central PSU companies i.e. SAIL, Rashtriya Ispat Nigam Limited (RINL), Coal India Limited (CIL), NTPC Limited and National Mineral Development Corporation (NMDC) has been incorporated. The company is scouting for coal properties in Australia, Mozambique and other target countries.
SAIL’S CORPORATE PLAN 2012:
Sail announced its corporate plan in the year 2004 and set itself on a growth track making steady progress in launching several projects. The company has initially aimed at increasing its annual hot metal production capacity from 13 million tonnes to 20 million tonnes. But following the inclusion of IISCO in Feb. 2006 and firming up of growth plan for Sail’s specialty steel plants, it has been revised to 22.5 million tonnes
The growth plant forces the company’s finished steel production of mild steel from its five integrated plants being raised to a level of 17.5 million tonnes per annum. The broad product
portfolio of SAIL will consist of 30% market share in flat and 26% in long by 2011-12.Besides capacity enhancement, the growth plan addresses the need of the sail plants and other units toward eliminating tech gaps, interlinking product profile with the growth segments and focusing on customer centric business processes. The key technological up gradations undertaken during growth period that are expected to achieve:
>State-of-the-art process control automation
>State-of-the-art online testing and quality control facilities.
>Gradual implementation of Enterprise Resource planning (ERP) across its plants.
MANAGEMENT OF THE SAIL:
Steel Authority of India Limited is managed by an efficient and experienced board of directors aided by the chairman.
Chairman of SAIL : Shri Chandra Shekhar Verma
Director (Personnel) : Shri B B Singh
Director (Commercial) : Shri S.S. Ahmed Director (Technical) : Shri V.K. Gulhati MD of Rourkela Steel Plant : Shri S.N Singh
MD of Bokaro Steel Plant, Bokaro : Shri S.S. Mohanty
MD of Bokaro Steel Plant : Shri Virendra Kumar Shrivastav
SAIL - INTO THE FUTURE
:
Modernization & Expansion:
SAIL, is in the process of modernizing and expanding its production units, raw material resources and other facilities to maintain its dominant position in the Indian steel market. The objective is to achieve a production capacity of 26.2 MTPA of Hot Metal from the base level production of 14.6 MTPA (2006-07 – Actual).
A new unit coming up at ISP
Orders for all major packages of ISP & SSP and part packages of BSL, BSP, RSP & DSP Expansion have been placed and these packages are in various stages of implementation
Objective of Expansion Plan
100% production of steel through Basic Oxygen Furnace (BOF) route 100% processing of steel through continuous casting
Value addition by reduction of semi-finished steel Auxiliary fuel injection system in all the Blast Furnaces State-of-art process control computerization / automation State-of-art online testing and quality control
Energy saving schemes Secondary refining
Adherence to environment norms
Production Target:
The production target of hot metal, crude steel and saleable steel after Expansion is indicated below:
(Million tonne per annum)
Item Base Case (2006-07) Actual After Expansion Hot Metal 14.6 26.2 (23.5) Crude Steel 13.5 24.6 (21.4) Saleable Steel 12.6 23.1 (20.2)
Figures in bracket indicate capacity after implementation of ongoing phase of modernization and expansion to be completed by 2012-2013.
Capital Expenditure:
Amount spent on Expansion Plan and other Capital Schemes of SAIL (incl. subsidiary) during last 3 years are as follows:
Year Total
2007-08 2181
2008-09 5233
2009-10 10606
PRODUCT MIX OF SAIL:
PRODUCT WISE
Semis Blooms, Billets & Slabs
Long Products Structurals, Crane Rails, Bars, Rods & Rebars, Wire Rods
Flat Products HR Coils, Sheets & Skelp, Plates, CR Coils & Sheets,
GC Sheets\ GP Sheets and Coils, Tinplates, Electrical Steel
Tubular Products Pipes
Railway Products Rails, Wheels, Axles, Wheel Sets PLANT WISE
Bhilai Steel Plant Blooms, Billets & Slabs Beams, Channels, Angles, Crane Rails Plates, Rails, Pig Iron, Chemicals & Fertilizers
Bokaro Steel Plant HR Coils & Sheets, Plates, CR Coils & Sheets, GP Sheets & Coils/ GC Sheets, Pig Iron, Chemicals & Fertilizers
Durgapur Steel Plant Blooms, Billets & Slabs, Joists, Channels, Angles, Bars, Rods & Rebars, Skelp, Wheels, Axles, Wheel Sets, Pig Iron, Chemicals & Fertilizers
Rourkela Steel Plant Plates, CR Coils & Sheets, GP Sheets/ GC Sheets, Tinplates,
Electrical Steel, Pipes, Pig Iron, Chemicals & Fertilizers
CHAPTER 2
COMPANY PROFILE
•ROURKELA STEEL PLANT (RSP)
•
LOCATION
•
SPECIAL FEATURES OF RSP
•
VISION, MISSION AND QUALITY POLICIES
•
PRODUCT PROFILE
•
PRODUCT MIX OF RSP
•
PRODUCT AND ITS APPLICATION
•
COMPETITORS
•
ORGANISATIONAL STRUCTURE
ORGANISATION PROFILE:
ROURKELA STEEL PLANT:
INTRODUCTION & INCEPTION:
Rourkela Steel Plant (RSP) is one of the most important units of the Steel Authority of India Ltd (SAIL). Rourkela Steel Plant (RSP), the first integrated steel plant in the public sector in India, was set up with German collaboration with an installed capacity of 1 million tonnes.
Subsequently, its capacity was enhanced to 1.9 million tonnes. It presently has achieved a capacity of 2.27 million tonnes of hot metal and 2.13 million tonnes of crude steel. RSP surpassed the two-million tonnes mark in hot metal production for the fourth consecutive year and in crude steel production for the third consecutive year.
It went into operation in the year 1959 and was the first integrated steel plant established by the Government of India. RSP was the first plant in India to incorporate LD technology of steel making. It is also the first steel plant in SAIL and the only one presently where 100% of slabs are produced through the cost-effective and quality-centric continuous casting route. The initial thrust for establishment of the plant was provided by the appointment of a team to survey the possibility for setting up a steel plant by the Govt of India in 1948. The plant was started in the year in 1956 with the technical and financial assistance of Messers Fried Krupps Essen and Messres Demang A.G. Duisburg, the leading steel makers from Federal republic of Germany. It was designed to produce flat product. The plant recently has been modernised with state of art facilities and most of the old units have been revamped and which has lead to the substantial improvement of the quality of products, reduction in cost and also ensuring cleaner environment. Developed infrastructures of support systems like captive power plants, brick manufacturing units, railway transport system etc facilitate the smooth operation of the plant. Other services
like electrical shops, air conditioning which is maintained by centralized services has brought about a great change in the quality of products. In- house R&D projects undertaken with RDCIS
(Research and Development centre for Iron and Steel), Ranchi lead to the enhanced productivity and efficiency while conserving energy. Quality control is ensured through state- of- the art computerization. Through computerization control in all production units, there is continuous data analysis, monitoring, network coverage, data management and document handling. Total quality management has been implemented since 1992 and awareness on total quality and to employee involvement in quality involvement projects through interactive participation also undertaken.
GEOGRAPHICAL LOCATION:
Rourkela Steel Plant is located in the north western tip of Orissa and at the heart of a rich mineral belt. Being situated on the Howrah-Mumbai mainline, Rourkela is very well connected with most of the important cities of India. The nearby airports are Ranchi (173 km),
Bhubaneswar (378 km) and Kolkata (413KM). Rourkela also has an Airstrip maintained by Rourkela Steel Plant.
One of the largest steel plants of the Steel Authority of India Limited is situated here. It is surrounded by a range of hills and encircled by rivers. It is situated in an area with the richest deposit of mineral wealth in Orissa. It came into prominence in 1955, with the establishment of the Rourkela Steel Plant. The city's name is derived from the famous 'Ruhr' iron & steel belt of Germany, with whose collaboration the Rourkela Steel Plant was setup. The plant which is one of the major contributors to render Rourkela a place in the national diary.
SPECIAL FEATURES OF ROURKELA STEEL PLANT:
• 1st public sector integrated plant to be set up in the country.
• It is the only Plant producing large diameters ERW/SW Pipes confirming to most rigid standards of API.
• It is the first steel Plant in India to adopt external desulphurization of hot metal by calcium carbide injection process.
• It is the only steel Plant in SAIL producing Cold Rolled Oriented (CRNO) Steel sheets for use in the electrical industries with installed capacity of 73000 Ton/yr
• Rourkela is the first in vacuum degassing metallurgy. This system has been adopted primarily for production of silicon steel for the cold rolled non-oriented sheets. This system consists of vacuum arc refining and vacuum oxygen refining units and degassing facility.
• It is the first integrated Steel Plant of SAIL which adopted the cost effective and quality centered continuous casting route to process 100% of steel produced.
• All the major production departments and some service departments and some service departments certified to ISO 9001:2000 QMS.
• Silicon Steel Mill, Environmental Engineering Department and Sinter Plant-II certified to ISO 14001:2004 EMS.
• It has got an electrical sheet mill capable of producing both dynamo and transformer grade electric sheet.
• It has a special plate plant where special alloy steel plates are shaped to different shapes as per requirement in the defense sector.
• RSP has the distinction of being the unique steel plant in India with an integrated Fertilizer Complex.
• It has two captive power plants (CPP) with a generation capacity of around 120 mw.
GUIDING PRINCIPLES OF RSP:
VISION:
“To achieve market leadership and prosper in business through satisfaction of customer needs by continual improvement in quality. Cost of delivery of products and services.”
MISSION:
“The future of our steel plant lies in our own hands. It is our individual and collective
responsibility to rebuild our plant into a profitable, harmonious and vibrant organization. We will do whatever things are necessary which are good for our plant. We shall never do anything that hurts our plant’.
QUALITY POLICY:
“We have to create and sustain a peaceful work environment where every employee can
PRODUCT PROFILE:
As far as RSP’s products are concerned, there are two types of products of
RSP-• Primary Products • Secondary products PRODUCT RANGE OF RSP: Primary Products: I. Pet 1. Pipes a. ERW Pipes b. Spiral Wield pipes
2. Electrical Steel Sheets
a. Cold Rolled Non Oriented Steel Sheets (CRNO) b. Cold Rolled Grain Oriented Steel sheets(CRGO) c. HRD Sheets
3. Electrolytic Tin Plates
a. Plates
b. Hot Rolled Coils c. Hot Rolled Sheets d. Prime Slab
e. Cold Rolled Sheets f. Galvanized Plane Sheets g. Pipe Plant Return (PPR) Coils
Secondary Products:
I. Iron and Steel
a. Cast iron skull scrap b. Cast iron U/R ingot steel
c. MS turning and Burning O.S scrap d. Tundish Steel skull
e. Steel skull trimming scrap f. Iron and steel BF fines scrap g. BF dumps iron
h. Used/rejected CI bottom plates scrap i. Used/rejected CI mould scrap
j. Cast iron scrap
II. Re-Rollable Scrap
a. Steel plates cutting scrap b. Steel plates shearing scrap c. Steel crop ends scrap
d. Concast steel short length slab e. Comcast steel slab crop end.
f. CI Skull scrap g. URIN/IS
h. Steel skull scrap GR-I i. Side trimming
j. BF drums iron
k. BF fines
l. Steel skull scraps
III. Steel Melting Scrap
a. Steel skull scrap
b. Scrap bales (Bundle scrap from rail lines press) c. MS turning and boring
d. Side trimming e. Scrap slab
IV. Industrial Scrap
a. CR steel cutting scraps b. CR steel coils end scraps c. CR steel cut flat end scrap d. CR steel bas cut scraps e. HR steel- cutting scraps f. Sticker coils
g. Semi Rolled steel plates h. Steel test piece scraps
V. Defectives
• Defective HR Coils (2.0mm)
• Defective HR Coils (2.5mm)
• Defective HR Coils (2.8mm)
• Defective HR Coils (3.15mm)
• Defective HR Coils (above 3.15 & up to 5 mm)
• Defective HR Coils (above 5mm)
• HR U/T Coils from CRM (below 3.15mm)
• HR U/T Coils from CRM (3.15mm & above)
• Defective HR Coils (Pickled) (2.0mm)
• Defective HR Coils (Pickled) (2.3mm)
• Defective HR Coils (Pickled) (2.5mm)
• Defective HR Coils (Pickled) (2.8mm)
• Defective HR Coils (Pickled) (3.15mm)
• Defective HR Coils (Pickled) (above 3.15 & Up to 5mm)
• Defective HR Coils (Pickled)(above 5mm)
• Defective CR Coils (0.4mm) • Defective CR Coils (0.5mm) • Defective CR Coils (0.63mm) • Defective CR Coils (0.8mm) • Defective CR Coils (1.0mm) • Defective CR Coils (1.25mm) • Defective CR Coils (1.6/1.8mm) • Defective CR Coils (2.0mm) • Defective CR Sheets (0.4mm) • Defective CR Sheets (0.5mm) • Defective CR Sheets (0.63mm) • Defective CR Sheets (0.8mm)
• Defective CR Sheets (1.0mm) • Defective CR Sheets (1.25mm) • Defective CR Sheets (1.6/1.8mm) • Defective GP Sheets (0.35mm) • Defective GP Sheets (0.4mm) • Defective GP Sheets (0.5mm) • Defective GP Sheets (0.63mm) • Defective GP Sheets (0.8mm) • Defective GP Sheets (1.0mm) • Defective GP Sheets (1.25mm) • Defective GP Sheets (1.6mm)
• Defective Chequered plates (5-10mm)
• Defective HR plates
• Defective plates (6-20mm)
• Defective plates (above 20mm)
• Defective Under sized plates (length 400-610)
• Defective Electrolytic Tin plates
• Defective CRNO Sheets
VI. Semis
a. MS ingot (Non – Silicon) b.Pig iron
VII. BF Slag
BF granulated slag (NLT)
a. Hard coke
b. Mixed coke Nut coke c. Mixed breezed coke
PRODUCTS OF RSP:
BY NAMES
Minerals
RSP Corporation’s family of minerals, sorted by their names, all with Silica as their major constituent, including Quartz, Feldspar, Silica and Clays.
Refractories
Acidic and basic Refractories, including the most popular and highest exported VINRAM®
Acidic Ramming mass, suitable for Induction furnace lining.
Chemicals
Lime and Sodium based chemicals for the leather, color and other related industries.
BY USER INDUSTRIES
Engineered stone
RS Glassy White Quartz for Engineered Stone Industry of Breton technology, making Quartz countertops, in filler, grits, also crushed mirror.
Silica based minerals, from Clays to Silica, from Quartz to Potassium Feldspar, in all grits, flours, fillers, particle size distribution, for industrial and other ceramic tiles, sanitary ware etc.
Glass
Silica based minerals, from Feldspar to Silica. Highest purity Quartz to lead crystal and high purity glass manufacturers. Very strong in Potassium Feldspar and Quartz.
Induction furnaces
VINRAM Acidic Ramming Mass, with premixed Boric Acid, Silica sand and Bentonite for Ductile and other foundries with induction furnace.
Construction chemicals
Various minerals such as Silica, Quartz and various chemicals like Hydrated Lime etc. to the construction chemical industries, with foreign collaborations and in all specifications.
Oil well drilling
Strong thrust on oil drilling industry with franc sand, Silica, Quartz, Bentonite, Sodium Silicate, exporting to Middle East, as per API (American petroleum institute) specifications.
Foundry Casting
Crystalline silica has a higher melting point than iron, copper and aluminum. This enables castings to be produced by pouring molten metal into moulds made out of silica sand and a binder. Castings form the basis of the engineering and manufacturing industries. Quartz and cristobalite flours are the main components in investment casting (also called precision casting) for the production of specialist products such as jewellery, dental bridges, aviation turbines and golf clubs.
Blasting
Silica is used for sand blasting purposes, as micro blaster, for micro graving, for filter sand, as glass beads for sand blasting, as paint stripping blasting sand.
PRODUCT MIX OF RSP:
PRODUCT-MIX TONNES/ANNUM
Plate Mill Plates 2,99,000
HR Plates 92,500
HR Coils 3,98,000
ERW Pipes 75,000
SW Pipes 55,000
CR Sheets & Coils 4,33,000 Galvanized Sheets (GP& GC) 1,60,000 Electrolytic Tin-Plates 85,000
Total Saleable Steel 16,71,000
PRODUCTS AND ITS
APPLICATIONS:-Products Applications
HR Coils LPG Cylinders, automobile, railway wagon chasis and all types of high strength needs.
Plates Pressure vessels, ship building and engineering structures
Chequered Plates Flooring & staircases in the industrial sectors and railway platforms etc.
CR Sheets & Coils Steel furniture, white goods like refrigerators, washing machines, automobile bodies, railway coach paneling, drums, barrels, deep drawing and extra deep drawing etc.
Galvanized Sheets Roofing, paneling, industrial sheeting, air conditioner ducting and structural
Electrolytic Tin Plates Containers for packaging of various products including edible oils, vegetables and confectionary items
Silicon Steel sheets & Coils Small generators, stators for high efficiency rotating equipment and relays etc.
Spiral Weld pipes High pressure transportation of crude oil, natural gas and slurry transportation, water supply, sewage disposals, grain silos, civil engineering pilings etc.
ERW Pipes High pressure transportation of oil and water, sewage disposal, tube wells etc.
Plates and Sheets
Coils
COMPETITORS OF SAIL:
A) Tata Iron & Steel Company
• Sales turnover Rs.132, 110 crores.
• With an annual crude steel capacity of 31 million tones.
• Product mix changing.
B) RINL
• Sales turnover Rs.9202 crores.
• With an annual crude steel capacity of 3.6 million tones.
C) ISPAT GROUP
• Started in 1976 by setting up a multicrore ISP in Indonesia & going ahead as one of the fastest growing companies in the world.
• Sales turnover Rs.10, 000 crore.
• With the acquisition of Turkish steel company Izmir Demir Celik, its capacity will go up to 15 million tones.
D) Lioyd Steel Industries Ltd. E) Jindal Strips Ltd.
F) Essar Steel Ltd. G) Malvika Steel Ltd. H) Bhusan Steel.
ORGANIZATIONAL STRUCTURE:
The most important asset from which RSP derive its true competitive strength is its committed and talented workforce. The employees of RSP range from unskilled labourers to senior management officials. In RSP the manpower planning is done on yearly basis. The employees of the steel plant range from unskilled Khalasi to supervisor and charges man. The employees at the steel plant are basically divided into two group; those who take part in the production process are known as workers whereas those who provide associate services are the non-workers. These two groups of employees can be each further classified into categories of Executives (EXE) and Non-Executives (N-EXE).
The following diagram shows the organizational structure of Rourkela Steel Plant: MANAGING DIRECTOR ED (PROJ) ED (FINANCE) ED(MM) ED(MED) ED(WORKS) ED(P&A) DGM (PL) W GM(P&A) DGM (PL)NW AGM AGM AGM UPE UPE UPE AGM WELFARE AGM IR,RULES AGM RECRUITMENT DGM OD
CENTAL FUNCTION OF PERSONNEL DEPARTMENT DGM I/C (PL) W
CHAPTER-3
•
PRODUCTION DEPARTMENT
•
PERSONNEL DEPARTMENT
•
MARKETING DEPARTMENT
•
FINANCIAL DEPARTMENT
•
PUBLIC RELATION DEPARTMENT
•
QUALITIY CONTROL SYSTEM
The organization structure of RSP can be classified under two broad heads. Such
as-• Works
• Non-works
The work area is the process related area, where as the non-works area is the non processed
area.
Works area:
The works area deals with the process of bringing of raw materials to the making of finished goods. The work area directly refers to the all major units which come under production department. The SAIL has its own mines, which procures raw material and produces steel from it. Iron ore, one of the ingredients to produce steel is not purchased from outside. But coal is purchased, generally imported from foreign countries.
Therefore work area constitutes following
departments:-OBBP- Ore Bedding and Blending Plant SP-Sintering Plant
BF-Blast Furnace
SMSI &II-Steel Melting Shops CCM-Continuous Casting Machine HSM-Hot Strip Mill
CRM-Cold Rolling Mill PLATE MILL
PIPE PLANTS
The production flow is depicted below. The first step is to bring raw material from the mines to OBBP, then it comes to sinter and then to blast furnace. After that it reach to SMS I and SMS II
MINES OBB P SP BF SMS I & II CCM HSM CRM SSM PLATE PIP E
and take the form of liquid steel and then becomes solid. Then it comes to CCM, then to HSM and finally gives the final output in the form of plates or pipes
Non-works Area:
Works area deals with the process of raw material to finished goods where as the
non-works area consists of several non process area departments such • PERSONNEL • MARKETING • FINANCE • PURCHASE • STORE • PBLIC RELATION • HOSPITALITY
All these six departments or areas come under the non-works area. Besides these, RSP has two special departments which comes under non-works area as well. They
are:-• HOSPITAL &
• TOWNSHIP
These two facilities do not come under the necessary obligation of RSP rather these are non-statuary obligations. The idea of having medical allowance and House Rent allowance is ruled out. Because of the task of providing rental accommodations to 20000 employees is enormous. And so is the case of providing well equipped hospital.
The total number of employees of Rourkela Steel Plant as on 01.09.2010 is 19220, among whom 2187 are executives and 17033 are non-executives.
PRODUCTION DEPARTMENT
Major production units of
RSP:-1. Ore Bedding and Blending plant 2. Coke oven
3. Sintering plants 4. Blast furnace
5. Steel melting shop (SMS-I & SMS-II) 6. Continuous casting mill (cmc-i) 7. Plate mills
8. Hot strip mills
9. Electrolytic tinning line 10. Galvanizing lines 11. Silicon steel mills 12. Pipe plants
13. Traffic & Raw material 14. Environment Management 15. Computerization
16. HRD centre 17. CPTI
Ore Bedding and Blending Plant RSP’s Ore Bedding & Blending Plant (OBBP) has a base
mix preparation system with on-ground bedding, blending and conveying facilities. Set up under the earlier modernization programme to provide pre-mix feedstock to Sinter Plant-I & -II, the plant has an annual dispatch capacity of 500,000 tonnes of material.
The facilities in OBBP include major installations like wagon unloading (tipplers & track hoppers), iron ore crushing and screening system, raw material storage yard, rod mills and roll
crushers for flux and coke crushing, proportioning bins and elaborate conveying systems.
Coke Oven
RSP has five 4.5-metre-tall coke oven batteries (COBs) that produce coke as the input for blast furnaces. The coke ovens are equipped with wagon tipplers, automatic handling and conveying facilities, coal blending provisions, coke wharf age crushing together with screening and conveying systems.
Sintering Plant
RSP’S two sinter plants feed sinter to the blast furnaces with a combined capacity of 3.07 MT per annum. Sinter Plant-II is operating at more than its rated capacity since the year 2000. This has facilitated the increased usage of sinter in blast furnace burden.
Blast furnaces
The four blast furnaces of RSP, with a combined capacity of 2 MT, produce hot molten metal for steel production.
Steel Melting Shops SMS-I
Apart from a computerized LD process which has enhanced shop capability, the LA Vacuum Metallurgy Technique has been also adopted for secondary refining of steel. This facilitates production of special steels for application in electrical machines, pipe making, tin plate, boilers and auto chassis members. The shop was originally designed to produce ingots for conversion to slabs through the Slabbing Mill route. However, after the discontinuation of the ingot route, SMS-I produces slabs through casting machines.
SMS-II
Provided with the latest steel making, secondary refining (ladle furnace and argon rinsing) facilities and two single-strand slab casters to produce 1,355,000 tonnes of steel slabs annually, the shop is equipped with automation through three levels of computerized control, LD gas
cleaning and recovery, power distribution system, water and utility services.
Plate Mill
RSP’s 3.1 meter wide, 4 high reversing mill is equipped with online thickness measurement facilities. Provision for inspection by customer’s nominees, online ultrasonic testing and checking ensure dispatch of superior quality plates to customers. The Plate Mill also has a walking beam-type furnace with a capacity of 100 tonnes/hour for slab heating. The mill has a production capacity of 299,000 tonnes per annum.
Hot Strip Mill
The facilities of the 1.44 MT per annum mill has:
• Two new walking beam type reheating furnace (225 TPH) • Roughing/sizing stand RoVo with automation
• Automated coil box
• Quick roll change system in Roughing Stand-1 and finishing mills • Coil marking, sampling and conveying systems.
Cold Rolling Mill
Produces about 678,000 tonne of cold rolled sheets per annum, RSP’s Cold Rolling Mill has a modern 5-stand tandem mill and a 4-high 1700-mm reversing mill. The tandem mill is equipped with automatic gauge control, x-ray gauge, data logging and thyristorisation.
Electrolytic Tinning Line
The continuous electrolytic tinning line produces a shining tin-coated surface in a variety of coating thicknesses. The tinplate shearing lines are equipped with sensitive pinhole detectors and an automatic sorting system.
Galvanizing Lines
Two continuous hot-dip galvanizing lines are equipped with jet-coating facilities. There are 2 multi-roller-corrugating machines as well which produce corrugated sheets.
Silicon Steel Mills
This unit produces steel for the electrical industry through various operations carried out in sophisticated, continuous/semi-continuous processing lines and a 4-high reduction mill. Advanced process control and product testing facilities ensure product quality.
Pipe Plants
A highly sophisticated Spiral Welded (SW) Pipe Plant is equipped with submerged arc welding process and produces large diameter pipes. Hydrostatic pressure testing, ultrasonic testing and eddy current testing are some of the features which ensure quality control.
This plant has been recently upgraded to enable it to produce API grade pipes.
Traffic & Raw Material
The Traffic & Raw Material Department deals with procurement and supply of raw materials to various user departments, internal movement of in-process and other material from one unit to another and dispatch of finished products in railway wagons to outside parties or SAIL
warehouses. The department maintains 350 wagons, 40 locomotives and a network of 240 kms rail tracks across the plant.
Environment Management
RSP has provided air pollution control equipment like ESPs, Bag Houses, Dry Fog Dust
Suppression systems & Wet Scrubbers in different units. RSP has also provided dedicated Waste Water Treatment Units in different plant units for treatment of wastewater. The treated
wastewater is recycled back to the process and blow down water is discharged only into drains
for final treatment at Lagoon before discharging into river. RSP has established a full-fledged Environmental Engg. Department way back in 1989, along with Environment Laboratory which is certified with IS/ISO14001. RSP has adopted 4R (Reduce, Reuse, Recover & Recycle) strategy for enhancing the utilization of wastes. With the dedicated efforts of RSP collective the pollutant levels have shown drastic reduction. The pollutant levels monitored during Apr.-June,’10 & for 2009-10 are;
SN. Environmental Indicator Description June,’10Apr – 2009-10 Norm
1. Ambient air quality (Average levels monitored at 6 stations) Units : mg/m3 • PM10 • Suspended Particulate Matter • Sulphur dioxide • Oxides of Nitrogen • Ammonia • Lead 76 – 99 289 – 487 37 – 68 24 – 63 12.8 – 58.6 0.02 – 0.09 90.2 283.8 49.5 32.0 28.2 0.04 100 --80 80 400 1.0
--Environment coming from different
stacks (kg/TCS) 1.09
3.
Quality of finally treated effluent discharged from Lagoon into river Brahmani
• PH • Suspended Solids • Oil & Grease • BOD3 • COD
(All units are in ppm except pH) 7.3 – 7.4 83.5 – 88 2 – 4 13 – 16 44 – 92 7.22 47.8 2.17 8.4 35.8 6 – 8.5 100 10 30 250
4. Solid Waste Utilisation • % 79.1 75.9
--Computerization
Rourkela Steel Plant’s online Production Planning & Control (PPC) system, developed and executed in house, connects various functional departments of RSP into a single network.
Human Resource Development Centre (HRDC)
The Human Resources Development Centre (HRDC) of Rourkela Steel Plant was set up in the late 1950s. It consists of a Management Development Programme wing, auditoriums, well-equipped workshops, skill up gradation shops, lecture halls for apprentices and a well-well-equipped library on a plethora of technical and managerial subjects. The HRDC has received ISO
9001:2000 QMS certification.
Central Power Training Institute (CPTI)
RSP’s Central Power Training Institute (CPTI) is a CEA-certified category-1 institute that meets the statutory training needs of power engineers of SAIL. Certified with ISO 9001:2000 QMS, CPTI conducts training largely for operation and maintenance personnel of SAIL’s captive power plants and Power Distribution Network departments.
PERSONNEL DEPARTMENT:
INTRODUCTION:
The overall growth of the organization depends on the Human Resource Development. It is the foundation for any successful organization. Personnel management is a profession on transaction and in any organization which looks toward to a positive and dynamic management philosophy. Purpose of human resource in RSP is to increased production, productivity,
sophisticated technology and automation that depend on human endeavor.
Personnel department is responsible for following
activities:-1. Takes care of growth, deployment, grievance redressal etc. of employees 2. Manages employees services functions
3. Manages Industrial relation with respect to the plant. 4. Recruits quality manpower.
6. Regulates Contract labour deployment inside the plant.
Personnel department is headed by Executive Director(ED) (Personnel & Administration). Under him is the GM who reports to the ED. GM (P&A) is the head of personnel-works and Personnel-Non-works unit. Under the GM are the DGM’s of the works and non-works areas. In turn AGM comes under the hierarchy. The AGMs of works area manages the unit personnel executives(UPE) of the different personnel units and the AGMs of the Non-works area manages central functions of Personnel department such as the recruitment, welfare and the Contract Labour, Rules , Industrial relation sections.
All the executives of RSP are managed by personnel (OD) and all non-executives are managed by Unit Personnel Executives.
The above organizational structure is prevalent for all plants in SAIL.
The hierarchy is given below in flow diagram
The total number of employees working in Rourkela Steel Plant as on February 2011 is 18,000. The employees are broadly categorized into
• Executives
• Non-Executives
May 2011 June 2011 July 2011
Executives 2282 2308 2297
Non-Executives 16472 16414 16378
Total 18754 18722 18655
HUMAN RESOURCE MANAGEMENT IN RSP:
The Human Resource Management is a integral part of the personnel department as well as the personnel organization. It is classified into three
heads-(i) Personnel Function (ii) Industrial Function (iii) Welfare Function
(i) PERSONNEL FUNCTION:
• Recruitment
• Induction and Placement
• Promotion
• Transfer
• Incentive and reward
(ii) INDUSTRIAL FUNCTIONS
• collective bargaining
• conciliation arbitration and adjudication
• Joint consultation and participation
• Discipline and its maintenance.
(iii) WELFARE FUNCTIONS
• Maintaining working schedule
• Giving leave facilities like, L.T.C., L.L.T.C.
• Scholarship schemes for children of RSP employees
• Medical treatment facilities
• Various types awards
- Nehru Vishist Award - Jawahar Rojgar Award -Creativity Award -Srujani Award etc.
TRAINING AND DEVELOPMENT ACTIVITIES:
The training and development is a vital part of the organization. The training activities carried out by plant itself namely Central Power Training Institute (CPTI) at Rourkela
Types of training :
(i)Technical (ii)Mechanical
(iii)Technical & Mechanical
Objective of training:
(i) De-Criticalise/key/critical skills
(ii) Prepare individuals for higher responsibilities
(iii)Develop ability in employees to run and maintain new units as per standard operating parameters.
HR PLANNING OF RSP:
It is the process by which the guiding members of an organization manages and leads the people who will be responsible for analysis, forecasting, planning and implementing the
strategies necessary to fulfill its mission and reach its vision. Therefore, it is necessary for every organization to make a HR plan.
Similarly, Rourkela steel plant has also its human resource plan. The human resources deployed in RSP are of various cadres i.e. the executive and the non-executive. Again, these two cadres are sub divided into various grades
Non – Executive Selection:
The non-executive includes 11 different grades as given below. 1. S1 2. S2 3. S3 4. S4 5. S5 6. S6 7. S7 8. S8 9. S9
10. S10 11. S11
Note-Here ‘S’ denotes Scale.
S1 is the lowest grade in which employees are to be employed. With the help of the promotions the employees go up the higher level and according to the better performance performed.
Employees may be recruited in different grades directly. They are given below.
• S1 – Lowest level-Earlier KHALASI are recruited in this cadre. They are the minimum qualification required for the workers, (matric holders)
• S3 – Next higher level of recruitment are the Diploma holders with or without graduates (B.Sc ) (Nurse, paramedical, etc.)
• S6- In this grade also recruitment is made. Earlier Diploma engg. were recruited in this grade.
• S10 – The recruitment is made to them who fulfills the eligibility criteria of the engineers and comes under compassionate ground.
Executive selection:
Like the non-executive cadre, in the executive section E1 is the base level. In E1 cadre MTT for engg and MTA (for MBAs).Doctors and other professionals like law graduates
and finance graduates are also recruited. Once recruited in this cadre they can be promoted. The hierarchy is given below.
E1-junior manager
E2-Assistant manager
E3-Deputy manager
