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A PROJECT REPORT
ON
A STUDY ABOUT HUMAN RESOUCE
MANAGEMENT AND MATERIALS
MANAGEMENT AT ULTRA TECHCEMENTS (Arrakonam Plant)
BY
MASTER OF BUSINESS ADMINISTRATION
SCHOOL OF MANAGEMENT
SRM UNIVERSITY
ACKNOWLEDGEMENT
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I would like to express my deep gratitude to all those who, directly or indirectly made
this project possible.
I have got considerable help and support in making this project report a reality from
many people.
I
Thank you
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INTRODUCTION
The Aditya Birla Group is an Indianmultinationalconglomerate corporation
headquartered inMumbai, Maharashtra,India.[4]
It operates in 33 countries with
more than 133,000 employees worldwide. The group has diversified business
interests and is dominant player in all the sectors in which it operates such as
viscose staple fiber, metals, cement, viscose filament yarn, branded apparel,
carbon black, chemicals, fertilizers, insulators, financial services, telecom, BPO
and IT services.
The Aditya Birla group is a US$ 40 billion conglomerate which gets 60 %
of its revenues from outside India. The Aditya Birla Group has been adjudged
the best employer in India and among the top 20 in Asia by the Hewitt-
Economic Times and Wall Street Journal Study 2007. The origins of the group
lie in the conglomerate once held by one of India's foremost industrialists
Mr.Ghanshyam Das Birla.
Aditya Birla is organized into various subsidiaries that operate across different
sectors. Among these areviscose staple fiber,non-ferrous metals,cement,
viscose filament yarn, branded apparel, carbon black,chemicals,Retail (under
the 'More' brand supermarkets),fertilizers,chemicals,insulators,financial
services,telecom,BPO andIT services. The Group consists of five main
companies, which operate in various industry sectors through subsidiaries, joint
ventures, etc. These areHindalco,Grasim,Aditya Birla Nuvo,Idea
cellular andUltraTech Cement.
http://en.wikipedia.org/wiki/Multinational_corporationhttp://en.wikipedia.org/wiki/Conglomerate_(company)http://en.wikipedia.org/wiki/Mumbai,_Maharashtrahttp://en.wikipedia.org/wiki/Aditya_Birla_Group#cite_note-3http://en.wikipedia.org/wiki/Aditya_Birla_Group#cite_note-3http://en.wikipedia.org/wiki/Aditya_Birla_Group#cite_note-3http://en.wikipedia.org/wiki/Ghanshyam_Das_Birlahttp://en.wikipedia.org/wiki/Viscosehttp://en.wikipedia.org/wiki/Non-ferroushttp://en.wikipedia.org/wiki/Cementhttp://en.wikipedia.org/wiki/Chemicalshttp://en.wikipedia.org/wiki/Retailhttp://en.wikipedia.org/wiki/Fertilizershttp://en.wikipedia.org/wiki/Chemicalshttp://en.wikipedia.org/wiki/Insulatorshttp://en.wikipedia.org/wiki/Financial_serviceshttp://en.wikipedia.org/wiki/Financial_serviceshttp://en.wikipedia.org/wiki/Telecommunicationhttp://en.wikipedia.org/wiki/Business_process_outsourcinghttp://en.wikipedia.org/wiki/Information_technologyhttp://en.wikipedia.org/wiki/Hindalcohttp://en.wikipedia.org/wiki/Grasimhttp://en.wikipedia.org/wiki/Idea_cellularhttp://en.wikipedia.org/wiki/Idea_cellularhttp://en.wikipedia.org/wiki/UltraTech_Cementhttp://en.wikipedia.org/wiki/UltraTech_Cementhttp://en.wikipedia.org/wiki/Idea_cellularhttp://en.wikipedia.org/wiki/Idea_cellularhttp://en.wikipedia.org/wiki/Grasimhttp://en.wikipedia.org/wiki/Hindalcohttp://en.wikipedia.org/wiki/Information_technologyhttp://en.wikipedia.org/wiki/Business_process_outsourcinghttp://en.wikipedia.org/wiki/Telecommunicationhttp://en.wikipedia.org/wiki/Financial_serviceshttp://en.wikipedia.org/wiki/Financial_serviceshttp://en.wikipedia.org/wiki/Insulatorshttp://en.wikipedia.org/wiki/Chemicalshttp://en.wikipedia.org/wiki/Fertilizershttp://en.wikipedia.org/wiki/Retailhttp://en.wikipedia.org/wiki/Chemicalshttp://en.wikipedia.org/wiki/Cementhttp://en.wikipedia.org/wiki/Non-ferroushttp://en.wikipedia.org/wiki/Viscosehttp://en.wikipedia.org/wiki/Ghanshyam_Das_Birlahttp://en.wikipedia.org/wiki/Aditya_Birla_Group#cite_note-3http://en.wikipedia.org/wiki/Mumbai,_Maharashtrahttp://en.wikipedia.org/wiki/Conglomerate_(company)http://en.wikipedia.org/wiki/Multinational_corporation -
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TH E AD IT YA B IR LA GR OU P
VISION:
To be a premium global conglomerate with a clear focus on each business.
MISSION:
To deliver superior value to our customers, shareholders, employees and
society at large.
VALUES:
Integrity
Commitment
Passion
Seamlessness
Speed
ABG is a 24 billion dollars corporation; the Aditya Birla Group is anchored by an
extraordinary force of 100,000 employees, belonging to 25 different nationalities. The
diversity of location, language and culture blends seamlessly into a common work ethos,
which hinges on fostering excellence, recognizing and rewarding
entrepreneurship.
ABG believes in empowerment, delegation and calculated risk taking. ABGs
ongoing endeavor is to create an organizational ambience where talent can bloom. To
do so, ABG strives to make the workplace a source of creativity, innovation and one
that makes work meaningful.
ABG ensures that all the Groups polices, forward looking initiatives and
goals are fully communicated to all employees and that they understand and relate to
these. ABGs commitment to their people is reflected in the sense of belonging and
pride every employee feels towards the Group and the passion and commitment they
bring to their work.
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The Aditya Birla Group is Indiasfirst truly multinational corporation. Global in
vision, rooted in Indian values, the group is driven by a performance ethic pegged on
value creation for its multiple stakeholders. Over 50 per cent of its revenues flow from
its operations across the world. The Aditya Birla Groups products and services offer
distinctive customer solutions wor ldwide . The Group has operations in 20
countries - India, Thailand, Laos, Indonesia, Philippines, Egypt, China, Canada,
Australia, USA, UK, Germany, Hungary, Brazil, Italy, France, Luxembourg,
Switzerland, Malaysia and Korea.
In India, the Group has been adjudged The Best Employer in I ndia and
among the top 20 in Asiaby the Hewitt-Economic Times and Wall Street Journal
Study 2007. This has been announced recently.
G LOBAL LY T HE A DIT YA BI RL A G ROUP IS :
A metals powerhouse, among the worlds most cost-efficient aluminum and
copper producers. Hindalco, (Plant: Howrah) from its fold, is a Fortune 500
Company. It is also the largest aluminum rolling company and one of the 3 biggestproducers of primary aluminum in Asia, with the largest single location copper
smelter.
No. 1 in viscose staple fiber
The 3rd largest producer of insulators
The 4th largest producer of carbon black
The 11th largest cement producer globally and the 2nd largest in India
With some more units which are under construction now, ABG will becomethe largest cement producer in India by 2013.
Among the worlds top 15 BPO (Business Process Outsourcing) companies
and among Indiastop 3
Among the best energy efficient fertilizers plants.
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I N I NDI A:
A premier branded garments playerGrasim Suitings
The 2nd largest player in viscose filament yarn
The 2nd largest in the Chlor-alkali sector
Among the top 5 mobile telephone companies
A leading player in Life Insurance and Asset Management
Birla Sun Life.
Rock solid in fundamentals, the Aditya Birla Group nurtures a culture where success
does not come in the way of the need to keep learning afresh, to keep experimenting.
BEYOND BUSI NESS:
A value based, caring corporate citizen, the Aditya Birla Group inherently
believes in the trusteeship concept of management. Part of the Groups profits is
ploughed back into meaningful welfare driven initiatives that make a qualitative
difference to the lives of marginalized people. These activities are carried out under
the aegis of the Aditya Birla Centre for Community Initiatives and Rural
Development, which is spearheaded by Mrs. Rajashree Birla.
Working in 3700 villages.
Reaching out to 7 million people annually through the Aditya Birla Centre forCommunity Initiatives and Rural Development, lead by Mrs. Rajashree Birla.
Focus areas are: health care, education sustainable livelihood, infrastructure
and promoting social causes.
Run 45 Schools and 18 Hospitals.
Transcending the conventional barriers of business to send out a message that
WeCare.
12
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P LAN T P RO FILE
U LT R AT ECH C EM ENT LI MI T ED
I NTRODUCTI ON:
UltraTech Cement Limited was formed effective July 2004, with the demerger
of Cement Division from Larsen & Toubro Limited, and was taken over by the Aditya
Birla Group and got merged into Aditya Vikram .Birla Group of Industries.
UltraTech Cement Limited is a technology driven company with leading edge
capabilities in fields related to infrastructure and basic industries. In terms of main
stream criteria viz., sales, profit, assets and market capitalization, UltraTech Cement
Limited ranks among top ten in India's private sector. The company is also ranked
high by less tangible yardsticks such as intellectual capital and brand-worth.
UltraTech Cement Limited & its subsidiaries, has manufacturing facilities at
10 locations in India and 3 Terminals including one at Srilanka. Almost all the
factories have secured ISO-9001, 14001, 18001 (OHSAS) and other certificates of thehighest ord er. UltraTech Cement Limiteds d i s t r ibut ion and services
out -reach underlines its strong customer orientation. The network extends to
virtually every district in the country. A concern for the environment is an integral
part of the company's vision. UltraTech Cement Limited is committed to growth in
consonance with the ecology and the needs of the communities it serves.
UltraTech Cement Limited is India's largest cement producer, with a
manufacturing capacity of over 17 million tons per year. UltraTech Cement Limited
manufactures and markets.
Ordinary Portland cement43 grades / 53 grades
Portland Blast Furnace Slag Cement
Portland Pozzolana Cement
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U L TRAT ECH CEMENT PL ANTS ARE L OCATED AT:
1. Awarpur cement works. Awarpur, Maharashtra
2. Hirmi cement works. Hirmi , Madhya Pradesh
3. Gujarat cement works. Kovaya, Gujarat
4. Andhra Pradesh cements works. Tadpatri, Andhra Pradesh
U L TRAT ECH CEMENT GRI NDI NG UNI TS AREL OCATED AT:
1. Jarsuguda Orissa
2. Arakkonam Tamilnadu
3. Durgapur West Bengal
U L TRAT ECH CEMENT LI MI TED S UBSI DI ARI ES:
Cement Plants:
Narmada Cement Company Limited Gujarat
Grinding Units:
Magdalla Gujarat
Ratnagiri Maharashtra
U L TRAT ECH CEMENT T ERMI NAL S ARE L OCATED
AT:
1. Navi Mumbai Mumbai
2. Mangalore Terminal Karnataka
3. UltraTech-Ceylinco Srilanka
1
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HUMAN RESOURCE MANAGEMENT
H UM AN R ES OU RC E SY ST E M IN U LT RA T EC H
C EM E NT LIM ITE D:
Human Resource policy is managed at corporate level and unit levels. Major
policy and strategies in certain areas are formulated at Corporate HR. APCW
formulates the local level strategies and policies in line with the Corporate HR. HR
SET at UltraTech, APCW, implements both local level and corporate level HR
polices and strategies. Unit Head, Operations Head, Functional Heads and Unit
Personnel Manager are involved in formulating APCW polices and strategies.
The Corporate HR regularly conducts HR conclaves in order to bring about
greater cohesion of OD level HR polices, so as to align these systems with individual
units requirements and also keeping in view overall business goals. Units head and
HR heads attend these meets.
MAN POWER:Based on requirement of individual departments, Head of that department is
asked to give information to man power planning department regarding the number of
persons required. The departmental heads assess their requirements based on the
available departmental job description to ensure role clarity and to avoid role
ambiguity. The Central Personnel Dept. carries out the recruitment process.
The total employees in APCW are 444 covering all departments as on
26.06.2007, out of which 225 are in Officers and Supervisor Cadre, 44 are Monthly
rated employees and 175 are Daily rated employees. There are nearly 500 contract
labors working every day on casual basis.
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P EOPL E MANAGEMENT AT U L TRAT ECH
CEMENT LI MI TED:
"Employee Delight is the key to Customer Delight" is the conviction of
UltraTech Cement Limited.
UltraTech Cement Limited's residential management development center
offers employees the opportunities for Knowledge enhancement and learning through
self-study and introspection. The faculty is drawn from India's premier management
institutes. UltraTech Cement Limited has also found a place for itself as the only
"Asian member of benchmarking forum for American Society for Training &
Development (ASTD). Self-learning facility comprising of programs on CD-ROMS
enables employees to work at their own place.
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RECRUI TMENT & S EL ECTI ON:
Recruitment sources include, advertisements given in newspapers and data
banks, depending upon the manpower requirements as stated by departmental heads,
depending upon the number of applications received, the qualification may be
generalized (in case of very few applications). Then, the persons with required
qualification are interviewed. The interviewing panel comprises of personnel officials
in the department. If the applications are in large number they will be short-listed
according to the norms of the organization.
The wage board employees are assessed on factors like:
Technical Aptitude
English and
Critical Reasoning
All employees are kept under probation for a period of 6 months after joining and
before their services are confirmed on rolls.
The O&S cadre employees will be assessed on factors like:
Management Aptitude
Leadership Behavior
The recruitment of Diploma Engineering Trainees (DET) and Graduate
Engineering Trainees (GET) are done at Central Personnel Department once in a year
through Campus Selections / advertisements in famous newspapers. The recruited
candidates are kept under probation for a period of 2 years and then are absorbed to
suitable c a d r e in the organization. During the probation period the absorbed
candidates are sent to each department to get acquainted with the departmental
activities and then they are sent to the other units of UltraTech Cement Limited for
proper orientation in the respective fields.
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P ERF ORMANCE APPRAI SAL S YSTEM:
UltraTech Cement Limited probably is the first organization in India to
introduce an integrated HRD system in the year 1975 with the introduction of
"Performance Appraisal Feedback & Counseling System".
PA includes sub-systems like:
Potential appraisal
Training & Development
Employee counseling and
Career Planning and Development.
In order to provide avenues of growth, among the Wage Board cadre, Merit
Rating procedure is in place. The performance of the employee evaluated through a
two stage process by immediate superior and Facilitator/Champion of AET/SET.
Further, in order to encourage more career opportunities to wage board employees,
company has a detailed NonSupervisor to Supervisor Scheme in place.
The new initiatives in Performance Appraisal System in APCW are Online
Performance Appraisal linked with POORNATA module. It is implemented by
Groups Corporate Office at Mumbai. It was started in last year. This form of
Performance Appraisal is mainly for Officers and Supervisors only.
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SAFETY AND HEALTH MANAGEMENT
Human Resource is responsible for carrying safety and health of the workers in the
company
UltraTech Cement has marked occupational safety as its core value and the responsibility
towards Safety, Health & Environment (SHE) is driven by the desire to protect people we
work with and the society at large.
We understand that safety starts at the top and if not, remains on paper. Therefore, there are
executive directions on safety from our Business Director. There is also the documented
demand for assurance from the Line function. We value the safety of all stakeholders,
business partners and local communities.
SAFETY PRINCIPLES
All injuriesand illnesscan be prevented.
Each line function is responsible forpreventing miunes while safety function isresponsiblefor facilitating safety systemimprovement.
All unsafe incidents and injuries must be reported, investigated and action completed.
All leaders shall demonstrate care for people by conducting safety Observations and
propagate safety awareness at every opportunities.
All Employees, Contractor's Employees and others entering plant for work shall be trained
to work safely
Safety consideration shall influence all our businessdecisions.
Regular Audit must be conducted and deviations shall be corrected promptly.
Working safely shall be condition of employment.
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MATERIALS MANAGEMENT AT ULTRATECH CEMENTS
Materials management is a separate department at ultratech cements. It deals with the
tangible components of a supply chain. Specifically this covers the acquisition of spare parts,
replacements, quality control of purchasing and ordering such parts, and the standards
involved in ordering, shipping, and warehousing the said parts.
The main goal of materials managements is to consolidate and efficiently handle core
services. It creats truck deliveries and service vehicle routes that reduce conflicts. Costs is
reduced when it comes to solid and hazardous waste removal, storage and recycling.
QUALITY ASSURANCE
Alarge componants of material management is ensuring that parts and materials used in the
supply meet minimum requirements by performing quality assurance. Parts and materials are
tested are tested both before and after the purchase orders are placed during use, to ensure
there are no short or long term issues that would disrupt the supply chain. This aspect of
material management is mostly important. Since failure can slow or even stop production
lines.
The other major component of materials management will be gradual movement towards
compliance. There are standards that are followed in supplt chain management that are
important to supply chain function. Systems reliant on vendor-managed
inventoriesmay begin to acquir e up-to -date compute rized inventories and
begin to explore robustordering systems for outlying vendors to place orders on.
Inventory management or controlrefers to the management of idle resources which have
future economic value. Alternatively, Inventory may be defined as usable but idle resources
that have economic value.
Inventory control isconcerned with minimizing the total cost of inventory. The three mainfactors in inventory control decision making process are:
The cost ofholdingthe stock (e.g., based on the interest rate).
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The cost of placing an order(e.g., for row material stocks) or the set-up cost ofproduction.
The cost of shortage, i.e., what is lost if the stock is insufficient to meet all demand.
Stock controlis defined as "the activity of checking a shops stock".[1]Many shops now use
stock control systems. The term "stock control system" can be used to include various aspects
of controlling the amount ofstockon the shelves and in the stockroom and how reordering
happens. Typical features of stock control software include:[2]
Ensuring thatproductsare on the shelf in shops in just the right quantity. Recognizing when acustomerhas bought a product. Automatically signaling when more products need to be put on the shelf from the
stockroom.
Automatically reordering stock at the appropriate time from the mainwarehouse. Automatically producing management information reports that could be used both by
local managers and athead office.
STORES
T he t e rm s to res , s to rehous e , wareho use e t c r e fe r to the ph ys ica l pl ace be
it a bui lding or a room etc. where ma terial s of all variet y are kept.
The function of stores is to receive, store and issue materials .stores are normally divided into
various sections such as -
receiving section tool stores general stores raw materials stores finished parts stores etc.
the following are the principal functions of a store;
http://en.wikipedia.org/wiki/Stock_control#cite_note-1http://en.wikipedia.org/wiki/Stock_control#cite_note-1http://en.wikipedia.org/wiki/Stock_control#cite_note-1http://en.wikipedia.org/wiki/Stockhttp://en.wikipedia.org/wiki/Stockhttp://en.wikipedia.org/wiki/Stockhttp://en.wikipedia.org/wiki/Stock_control#cite_note-2http://en.wikipedia.org/wiki/Stock_control#cite_note-2http://en.wikipedia.org/wiki/Stock_control#cite_note-2http://en.wikipedia.org/wiki/Product_(business)http://en.wikipedia.org/wiki/Product_(business)http://en.wikipedia.org/wiki/Product_(business)http://en.wikipedia.org/wiki/Customerhttp://en.wikipedia.org/wiki/Customerhttp://en.wikipedia.org/wiki/Customerhttp://en.wikipedia.org/wiki/Warehousehttp://en.wikipedia.org/wiki/Warehousehttp://en.wikipedia.org/wiki/Warehousehttp://en.wikipedia.org/wiki/Head_officehttp://en.wikipedia.org/wiki/Head_officehttp://en.wikipedia.org/wiki/Head_officehttp://en.wikipedia.org/wiki/Head_officehttp://en.wikipedia.org/wiki/Warehousehttp://en.wikipedia.org/wiki/Customerhttp://en.wikipedia.org/wiki/Product_(business)http://en.wikipedia.org/wiki/Stock_control#cite_note-2http://en.wikipedia.org/wiki/Stockhttp://en.wikipedia.org/wiki/Stock_control#cite_note-1 -
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PRINCIPLE FUNCTIONS OF A STORE.
To receive raw materials, components, tools, spares, supplies,equipments and otheritems and account for them.
To provide adequate, proper and efficient storage and preservation for all the items Physical checking of all incoming materials as per the deliverychallan / invoice and
proper maintenance of daily goods receiptregister or records.
Arrange for inspection of incoming materials. Ensure that goods inward notes (gin) are raised and distributed withoutdelay Issue materials to the consuming departments against authorisedrequisitions and
account for the same. Maintain accurate and uptodate records of material received,issued, rejected,
disposed, and quantity on hand of all the items.
Ensure that all documents relating to receipts and issue are sent tostock control,accounts and other concerned departments.
Undertake stock verification as per approved procedure.
To highlight stock accumulation, discrepancies and abnormalconsumption and initiateappropriate control action, wherever necessary.
To minimise obsolescence, surplus and scrap through proper codification,standardization, preservation and handling.
To ensure good housekeeping so as to minimise the need for materialhandling. To make available a balanced flow of materials so as to economise oncapital tied up
in inventory.
To accept and store scrap and other discarded materials. Depending upon the nature of business (i.e. manufacturing, tradingservices, etc,) one
or more of these functions may gain primacy over the rest.