ACKNOWLEDGEMENT

I AM STUDENT OF PGDMIB 2010-12 BATCH IN IILM-CMS GREATER NOIDA. AFTER FINISHING OUR FIRST YEAR OF FOUR TRIMESTERSITS MANDETORY FOR ALL THE STUDENTS TO UNDERGO A SUMMER TRAINING PROGRAMME IN INDUSTRY.

WE EXPRESS OUR SENSE OF GRATITUDE TOWARDS OUR LEARNED PROFESSORS FOR GIVING US KNOWLEDGE REALTING TO PRICIPLES OF MANAGEMENT WORLD WHICH MAKES US CAPABLE OF APPLYING IT IN REAL WORLD PRACTICAL SITUATIONS.

I SPECIALLY ACKNOWLEDGE MR.R.P TRIPATI, SENIOR V.P OF AMBUJA CEMENTS DARLAGHAT, FOR GIVING US THE WONDERFUL OPPURTUNITY TO WORK WITH AMBUJA CEMENTS.AND TO MR.KAMAL VIRENDAR SINGH SR.MANGER & MY MENTOR FOR SUMMER TRAINING, WHO HELPED AND GUIDED ME. AND MR. ANKUR AGGARWAL SIR, DGM OF MINES DEPARTMENT, WHO GUIDED ME THROUGH OUT MY TRAINING PERIOD WITH HIS KNOWLEDGE AS WELL AS VALUBLE SUGGESTIONS

AND FINALLY IM VERY MUCH THANKFULL TO MY MENTOR AND FACULTY GUIDE “MRS. MONIKA JAIN”, WHO GUIDED ME ALL THE TIME AND BY ALL THE MEANS, WITH HER VALUBLE SUGGESTIONS AND GUIDANCE REGARDING THE CORPORATE WORLD AND WORK CULTURE, AND IN PRACTICAL IMPLEMENTATION OF PRINCIPLES OF MANAGEMENT AND ADMINISTRATION IN INDUSTRY.

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CONTENTS

SL NO. TOPIC PAGE NO.1 LETTER OF TRANSMITTAL 42 EXECUTIVE SUMMARY 53 INDUSTRY HISTRY & PROFILE 64 INDIAN CEMENT INDUSTRY 65 CONTRIBUTION OF CEMENT INDUSTRY TO

THE WHOLE WORLD8

6 HOW TO MAKE CEMENT 97 LITERATURE REVIEW 135 COMPANY PROFILE 176 ADWARDS 187 OTHER ACHIEVEMENTS 208 IMPACT OF TECHNOLOGY & OTHER

INNOVATIONS21

9 MAJOR ACHIEVEMENTS OF AMBUJA CEMENTS 2210 SWOT ANNALYSIS 2411 ORGATIONAL STRUCTURE 2512 PRESS RELEASE 2913 ABOUT KASHLOG MINES 3114 REVIEW ON MINING PLAN 3215 OBJECTIVES 3416 RESEARCH METHOLOGY 3517 SOME EQUIPMENTS USED IN MINING 3718 SOME INFORMATION 4019 FINDINGS 4120 SUGGESSIONS 46

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21 SAFETY PRECAUTIONS 4723 CONCLUSION 4924 BIBILOGRAPHY 51

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LETTER OF TRANSMITTAL

From,Subharaj ChakrabortyPGDMIB/10-12/35IILM CMS ,Greater NoidaGreater Noida.

Date: 4/06/2011

To,Mr. Kamal Verinder SinghSr. Manager Technical Department.Ambuja Cements LTD.Darlaghat.

Dear Sir,

Enclosed is a copy of “Mines Assessment Report”. This report is the summary of the findings from the mining site of Ambuja Cements ltd. Visited on past few weeks.

The main purpose of the report is to bring the analysis result of the mining operations of the Kashlog mines of Ambuja Cements ltd, Darlaghat, Himachal Pradesh.The report covers the detail scope of work, approach and methodology, work plan, suggestions etc for the working process of the Kashlog Mines.

The report also outline of the recommendations for the possible countermeasure to avoid the problems happening in the future.

Please free to contact me if you have any questions and/or comments regarding the interpretation of this report.

Thank you for your time to look at the report and hope you will find any thing that may be useful to you.

Sincerely,Subharaj Chakraborty.

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EXECUTIVE SUMMARY

This project report is prepared as the partial fulfillment of two year degree programme of PGDM curriculum of IILM CMS, Greater Noida. This Research project is a compulsory part of the academics. This research is done in the Fifth semester of the PGDM IB program.In this research, I have attempted the research about the mining process and how it can be more improved. The mining department is the key department of the cement factory. The overall purpose of this research is to identify the problems and suggest any improvements for it. I have taken Kashlog Mines of Ambuja Cements ltd., Darlaghat for this research. The whole research is based on the data collected in the field and information gathered from the employees at different designations.

There are various sections of mines department like:➢ Drill Section.➢ Blast Section.➢ Movement from extraction area to crusher.➢ Crusher (control)

There are three shifts :• from 6:00 am to 2:00 pm• from 2:00 pm to 10:00 pm• from 10:00 pm to 6:00 am

There are about 40 employees working in the mines department per shift.The amount of lime stone extracted from the site is about 21000-22000 metric tons.There are a primary crusher and a secondary crusher. The main crusher can crush 700 metric ton per shift.

The OLBC (Over Land Belt Conveyer) is about 3.2 km which transport the crushed limestone from the mines to the plant for further processing to cement.

The main problem about the production process at the mines is the cycle time of the various equipments. The dumpers's spoting time is more than 15 min at average due to the lack of the number PCI Excavators.The problem can be prevented in the future by increasing the number of PCI excavators or by reducing the use of the number of dumpers as per use per shift.As per the safety precautions is taken into account due to the open cast mining in the time of blasting the workers should be provided with safety glasses due to the danger of eye damage due to the tiny rock particles.

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INDUSTRY HISTORY AND PROFILE

CONTRIBUTION OF CEMENT INDUSTRY TO THE WHOLE ECONOMY

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Industry history and profile

Man is very ambitious being from the very beginning he has always liked to innovate & make the things more possible & more comfortable. Firstly he used to stay in hots made up of straws & mod, then of bricks & later of cement. But then also he didn’t stopped from there he keep on going more better good, than letter & best out of it.Cement has been amongst the major industries in India there is now at throat competitionin this stream too. For diverting more people, different types & varieties of cement areavailable.Cement is considered to be the basic building material today in construction industry. In 1757 AD, chemical engineer JOHNS SMEATON discovered that by mixing of lime and clay, the resulting product process the property of hydraulicity. This was the discovery of cement. In 1807 AD French chemist Vicart followed Smeaton’s observation to its natural and logical conclusion in making a cement by burning together finally pulverized chalk and clay, after having mixed them into paste.In India, manufacturing of cement was first started in Madras in 1904 first three companies were started in 19912-1913.when the plans started there were 21 factories with an annual capacity of 328 million tones.The real impetus was provided when partial decontrol was announced in 1982. through this policy all existing cement industry units were required to give up 66.67% of their installed capacity as levy at controlled price. The most important objective of decontrol was to eliminate black-marketing and bring down the price in the free market.it was in follow through that the industry was fully controlled in 1989. in the last decade of 90s cement capacity increased by more than twice. The industry was de-licensed in 1991, which augmented its production in the very first year.

INDIAN CEMENT INDUSTRY

India is today world’s second largest cement producing country after china. Spread across the length and breath of the country, there are about 60 cement companies with 134major plants and an installed capacity of about 147 million tones. Besides, there are 60 surviving tiny and mini cement plant with a capacity of 6.3 million tones.

In India, the per capita cement consumption is abysmally low at 99 kgs as against a world average of 255 kgs and asian average of 200 kgs. These figures indicate good potential for growth of the industry. In essence, cement is a simple business. Unlike other industries it does not suffer rapid technological obsolescence or shifting consumer trends. Therefore, it constantly attracts new investments. Which results in surplus capacity. This means only the very efficient players can prosper.

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Contribution of cement industry to the whole economy

The Indian cement industry plays a key role in the national economy,generating substantial revenue for the state and central govt. It is the third highest contribution in terms of excise duty of over Rs. 3,500 crores a year. Sales to state Govt. Royalties ,octroi And the other cesses add another 1500 crore the industry employ a work force of over of 1.5 lakh persons and supports a further complement of 12 lakh people engaged indirectly.

The industry crossed 127 million tones of cement dispatched, recording an impressinve 8.5 % growth over the previous year. similarly Indian economy as a whole grew by 7%, over and above the 8.5% growth that was achieved in 2003-04. this is the beginning of a new economy of growth for the Indian economy the growth momentum is getting into a virtous cycle. Wherein high growth attracts large capital inflows,which in turn fuels further growth. Government has pledged to continue with reforms ininfrastructure and invest in rural development and boost the housing sector as well.

As the infrastructure development is the best measure of country’s Development Indian Government is going now for many infrastructural project which proves that Cement industry is booming now a days.

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HOW TO MAKE CEMENT

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HOW TO MAKE CEMENT

Since ages, humans have been using a binding material to make brick walls and firm structures to dwell in. Limestone was the earliest binder and the quest to obtain desirable characteristics, derived the cement, the ultimate binding material. It is a substance which not only sets fast but, also hardens as time passes. It also has most noteworthy quality of binding almost any material. The word 'cement' has a Roman descent. They described the structures made from crushed rock binded with burnt lime, by the term 'opus caementicium'. But, the procedure of making the modern day cement involves using some state of art techniques. But, how to make cement blocks? Let us try to find some of these answers.

The Process of Making Cement

As said earlier, the procedure of making cement is a complex one and is done using some latest technology. Here are the various chemical and thermal processes which are important to know how to make cement from scratch:

Raw Material MiningLimestone, sand and clay are three main raw materials required to make cement. They contain the four essential mineral elements required in making cement - calcium, silicon, aluminum and iron. Limestone and clay is mined from quarries by drilling or setting off explosions in to the rock. Large sized limestone rocks and boulders are fragmented in to smaller pieces and transported to the cement making plant using either huge dump trucks or high capacity conveyor belts.

CrushingThese medium sized rocks now go through the first process in the plant. Here, they are first put in to heavy crushers which break down the rocks in marble sized pieces (approx 1½ inch in size).

PrehomogenizationThis is a very important process of proportionally mixing the different raw materials. The limestone pieces are added to a blender where they are mixed with other raw materials in the exact required proportion.

Raw Material MillingA vertical steel mill is made use of in this process which further grinds the blended material using the pressure exerted by three conical rollers. The rolling of these three rollers on the turning milling table crushes the blend in fine powder. Sometimes, horizontal crushing mills are also used in this process.

CalcinationThis is the must know core process if you want to learn how to make cement. In the process of calcination, the crushed and blended raw material goes into a huge, extremely hot, rotating kiln to undergo a process called sintering. In this phase, the raw blend turns in to sort of partially molten state. The raw materials reach about 2700° F (1480°C) inside the furnace. This state facilitates some chemical and physical processes in the raw material. The resultant coming out of the furnace is small,

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dark gray, red-hot nodules called clinker, which are 1-2 inches in diameter.

Cement MillingThese clinkers are cooled and grounded into a fine gray powder. To extend the cement's setting time, small amount of gypsum is added during this process as this powder makes its way through the mill's two chambers. This is now the finished product and is called Portland cement or simply cement.

PackagingCement is stored in dry storage silos, from where it is extracted and packed in sacks on demand. It can be shipped by rail, road or ships, but extreme care is taken to maintain dryness.

Cement is one of the most important commodity today and its production and consumption is constantly on the rise. China is the largest manufacturer of cement in the world and accounts for about 45% of the world's cement. India and the US are distant 2nd and 3rd respectively with 6.5% and 4.5% of world's cement production respectively.

Cement manufacturing also has its environmental effects. The cement industry is responsible for emitting about 5% of the global CO2 emissions. Nearly 900 kg of CO2 is emitted for every 1000 kg of cement produced. The burning of fossil fuels produce other polluting gases as well.

The above mentioned article enlists the most vital steps in making cement, which can be called a purely industrial process. After learning how to make cement, we can conclusively say 'don't try this at home'.

An example of how cement can be made

1.) Limestone is taken from a quarry. It is the major ingredient needed for making cement. Smaller quantities of sand and clay are also needed. Limestone, sand and clay contain the four essential elements required to make cement. The four essential elements are calcium, silicon, aluminum and iron.

2.) Boulder-size limestone rocks are transported from the quarry to the cement plant and fed into a crusher which crushes the boulders into marble-size pieces.

3.) The limestone pieces then go through a blender where they are added to the other raw materials in the right proportion.

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4.) The raw materials are ground to a powder. This is sometimes done with rollers that crush the materials against a rotating platform.

5.) Everything then goes into a huge, extremely hot, rotating furnace to undergo a process called "sintering". Sintering means: to cause to become a coherent mass by heating without melting. In other words, the raw materials become sort of partially molten. The raw materials reach about 2700° F (1480°C) inside the furnace. This causes chemical and physical changes to the raw materials and they come out of the furnace as large, glassy, red-hot cinders called "clinker".

6.) The clinker is cooled and ground into a fine gray powder. A small amount of gypsum is also added during the final grinding. It is now the finished product - Portland cement.

The cement is then stored in silos (large holding tanks) where it awaits distribution. The cement is usually shipped in bulk in purpose-made trucks, by rail or even by barge or ship. Some is bagged for those who want small quantities

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LITERATURE REVIEW

As the initial step to start the project I have implemented some basic techniques to understand the process of mining, first I have first studied how the different activities that takes place in a mine and after reading and getting an idea from the internet, I started implementing the techniques of Project Management, Job design and work measurement as we have studied in our college text book 'Operations & Supply Management' by Richard B. Chase & others. The project structure is of Pure Project and various models implemented are critical path method (CPM), Time-Cost Models, etc.

Cement Industry literature:The most pioneering book was written in two volumes by poddar in 1962 and 1966 respectively. The author has made very sincere attempt to enumerate all the historical facts relating to various aspects of the industry. The general problems in historical perspectives have been studied by various institutions like, Eastern Economist, Cement Manufacturer's Association, Association of Trade and Indusrty, Tariff Commission, Commerce Research Bureau, State Bank of India, Tata consultancy Services and Economic Times.

In Ghost's article (1962) an attempt has been made perhaps for the first time to examine the relationship between employment, earning and productivity of labour in the Industry.

In 1964, the Indian Association of Trade and Industry published a book, which analysis the financial trends and productivity in the private sector of the industry during 1937-1964. Its financial analysis is based on the annual report of 19 companies comprising (32 factories) 90% of the entire production.

An important article, published in 1967 by Sawhney measures productivity trends in the cement industry. The period of his study covers 1950 to 1961. Devising the methodology framework he has attempted to show how productivity gains have been shared by different factors of production.

Ramanathan paper in 1970 is very significant contribution to this field. Later he presented a comprehensive study in 1973 which deals with many aspects of the industry, along with productivity and capital-intensity in the industry during the period 1950-64, by taking the help of data published by CMI and ASI. He has disproved the general impression that labour productivity indices move downward.

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AMBUJA CEMENTS LTD. COMPANY PROFILE

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COMPANY PROFILE

Ambuja Cements was set up in 1986. In the last decade the company has grown tenfold. The total cement capacity of the company is 18.5 million tonnes. Its plants are some of the most efficient in the world. With environment protection measures that are on par with the finest in the developed world.

Ambuja Cements Limited, formerly known as Gujarat Ambuja Limited is a major Cement producing company in India. The Group's principal activity is to manufacture and market cement and clinker for both domestic and export markets.

The Company also operates a hotel through its subsidiary GGL Hotel and Resort Company. It has shown innovation in utilizing measures like sea transport, captive power plants, and imported coal and availing of govt. sops and subsidies to constantly check the costs.

The company's most distinctive attribute, however, is its approach to the business. Ambuja follows a unique homegrown philosophy of giving people the authority to set their own targets, and the freedom to achieve their goals. This simple vision has created an environment where there are no limits to excellence, no limits to efficiency. And has proved to be a powerful engine of growth for the company.

As a result, Ambuja is the most profitable cement company in India, and one of the lowest cost producers of cement in the world.Its focus:-

Best quality cement Good packaging Logistic management - strong distribution network Customer service

Capacity built up from 0.7 Mn tonnes in 1986 to 18.0 Mn tonnes as of today at CAGR of 18%

Organic growth and growth through acquisitions

2001 - Private equity investors (American International Group & Government of Singapore) invested in ACIL

2005 - ACIL restructured as a joint venture with Holcim

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2006 - Founder promoters sold part of their holding in ACL in favour of Holcim

ACL is a Holcim Group company since May 2006Capacity built up from 0.7 mn. Tonnes in 1986 to 16.0 mn. Tonnes today.

Sea transportation of bulk cement from Gujarat to 3 terminal ports at Surat, Mumbai & Sri Lanka.

A captive port at Muldwarka (Gujarat) for inward / outward movement of goods.

MISSION:

Delighted customers, Inspired employees, Empowered partners, Energized society

VISION:

To be India’s most admired company

OBJECTIVE OF COMPANY:

The management of Gujarat Ambuja decided some objectives to become topper in

the market. And the objectives are:

• Better quality then other company.

• Fair returns to share holders.

• A higher productivity to cover maximum market.

• Maximum customer satisfaction.

• Clean & healthy Environment for employee’s growth.

• Try to lower pollution to fulfillment of social responsibilities

Customers, Suppliers and Stakeholders:The Company is committed to create value for each of its stakeholders. The

Directors and Employees shall treat the Company’s customers, suppliers and

stakeholders with respect and dignity. There should not be any coercive

measures used while dealing with any of the stakeholders.

THE FOLLOWING MAP SHOWS THE COMPANY'S UNIT CHAINS:

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ADWARDS:2003-2004

• Business World & FICCI ‘Corporate Social

Responsibility’ (CSR) award for recognising the impact of business on environment and society: second runner-up

• Asian Institute of Management CSR award

for ‘poverty alleviation’

2005-2006• 'Asian CSR Award'

(Environment Excellence) 2005 for corporate sustainable development at GAC (India) Works

• Centre for Science and Environment Green rating

Project award to GACL (second rank)

• 'Best Environment Management Practices

Award' for the Ropar unit from the State Pollution Control Board

• Capexil 'Certificate of Export Recognition' to GACL

(Mumbai) in recognition of outstanding export performance

• Awards won by the Maratha Limestone Mine of Maratha

Cement Works (a unit of Ambuja Cements Ltd) Upparwahi

• 'Directorate of Mines Safety Award 2006', as part of the

Metalliferous Mines Safety Week

2004-2005• Ernst & Young

‘Entrepreneur of the Year’ (Manufacturing)

• Asian Institute of Management Award for

‘Environmental Excellence’• Greentech 'Environment

Excellence Award' in the Gold category by Greentech Foundation to GACL, Bhatinda

• 'Enviroment Week awards' for plantation, air,

noise and water pollution control and community development

• 'Safety Week awards' for safer mining

2007• In Mines Environment &

Mineral Conservation Week–Indian Bureau of Mines

• 'Corporate Excellence Award 2007' awarded to

ACL by the Indian Institute of Materials Management, Chandigarh

• Dun & Bradstreet 'American Express Corporate Award

2007' to ACL• 'National Award for

Environmental Excellence' in Opencast Mining from NCBM (2nd place – to Ambuja’s Sugala Limestone Mine)

2008• 'Certificate of Merit' by

Rajasthan State Productivity Council, Jaipur

• 'Gobar Times Green Schools Programme

Awards' by Centre for Science and Environment (CSE) For the Year 2008 : Ambuja Public School : Rabriyawas

2009• BCT Panvel received re-

certification on ISO 9001-2008, ISO 14001-2004 & OHSAS18001-2007

• Ambujanagar has won 'Best Environmental Excellence in

Plant Operation' – National award by NCBM 2009'Certificate of Appreciation' for Accident Free million man hour our worked - Gujarat Safety Council – Baroda 2009

OTHER ACHIEVEMENTS:(BUSINESS)

First plant set up in record time:When Ambuja set up its first plant in 1986, the accepted time period for installing a plant was 3 years.

Ambuja, did it in less than 2 years. And with a significantly lower capital expenditure.

In 1993 the company went a step further and bettered its own record. Ambuja's second plant was installed in a mere 13 months- the quickest time for setting up a one million tonne cement plant.

A whole new way of transporting cement:

In the early 90s, almost all cement in India travelled by rail or road. And in bags. A mode that involves deterioration of both, the quality and volume of cement.

In 1993, Ambuja Cement set up a complete system of transporting bulk cement via the sea route.Making it the first company in India to introduce bulk cement movement by sea. Others followed and today, about 10% cement travels by this new route.

The facility comprises: A dedicated port at the Gujarat plants, capable of berthing 40,000 DWT vessels, three bagging terminals at Mumbai, Surat and Sri Lanka, and seven special bulk cement vessels.

This capability has enabled us to supply fresh cement to many coastal markets – domestic and international.

Branding a commodity:Cement is a commodity, sold largely on price. Ambuja Cement was the first company to create a brand out of cement and command a premium.

It was also the first to introduce a special cell, providing technical services to consumers and masons. Today, this has become the norm in cement marketing.

The trick of course was to provide a consistently high quality of cement, backed by excellent service. This was reinforced by a strong dealer network.

The result is that customers are ready to pay 2-3% premium for Ambuja Cement for the value they receive. Ambuja Cement is the top brand in Western, Northern, Central and Eastern India.

Exports:Ambuja Cement exports almost 17% of its production in a very competitive international environment. For the last ten years, Ambuja Cement remains India’s highest exporter of cement.

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This has been possible for two reasons –

One, the quality of cement matches the best in the world.

Two, the dedicated bulk cement transportation capability at our plant.

The Environment

From the outset, Ambuja has believed that a cement plant cannot flourish at the cost ofthe environment. That’s why it adheres to the most rigorous international environmentalnorms.

The pollution levels at all its cement plants are even lower than the rigorous Swissstandards of 100 mg/NM 3.

At the Gujarat plants, surface miners have been employed to scrape the surface of themines. Thus ensuring that all the mining is totally blast free. There is no noise or airpollution.

Similarly at the Himachal Pradesh plant, Ambuja has employed techniques that havemade mining absolutely safe and pollution free.

Not surprisingly then, the company has consistently won awards for its pollution freeplants. Awards as prestigious as the National Award for Outstanding Pollution Controland The Eco-Gold Star of Tata Energy Research Institute (TERI).

Corporate Social Responsibility

In 1991, the company set up Ambuja Cement Foundation to trigger all-rounddevelopment of the people around its cement plants. The Foundation decided totraverse the difficult but more productive path of helping the people to help themselves.With great dedication and commitment, the foundation energized the local people toparticipate and own their development process. It became a facilitator and catalyst,rather than a one-time fund provider. It developed easily replicable and sustainablemodules for water management, sustainable agriculture and healthcare.All this effort in discharging its social responsibility has earned the company recognitionacross Asia.

MilestonesBuilding of a cement plant in record 13 months.

2.8 kilometer conveyor belt running through three hills was constructed in just 9 months.Introduced a completely new system of transporting cement in India – the bulk cementtransportation by sea.Introduced complete blast free limestone mining by using the surface miner in limestone

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mining for the first time in India.Created water reservoirs in used up mines and raised the water table in arid areas.

Our plants have achieved the lowest pollution levels – comparable with the moststrongest Swiss standards.

Impact of technology And other InnovationTo being echo friendly "AMBUJA CEMENT LTD" installed pollution control equipments, by M/s. ABB & M/s. Thermex. The plant achieved 148% productivity with lowest consumption of raw material & electricity after innovation of plant.

• Computerized process control system● Zero error electronic equipments

SAP IMPLEMENTATION:

The company is implementing a project - Connect India Plus”, which aims at connecting all the plants, business places across India online, under a standardized business template to run on SAP software.

The implementation of “Project CONNECT” India Plus started in June, 2007& is expected to go live in August, 2008. After the Go Live, all operations, locations and transactions will become fully integrated in a manner that is in line with the updated data and information.

The new system will greatly enhance the company’s capability to capture and process a comprehensive range of data to be used for decision making and day-to-day operations, while automating some processes which were not part of the IT legacy system.

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Ambuja Cements

Ambuja Cements Limited was earlier known as Gujarat Ambuja Cements Limited (GACL). Thecompany was set up in 1986. In this short span Ambuja Cements has achieved massive growthand presently, the total cement capacity of the company is 16 million tonnes. The company hasthree subsidiaries, viz, Ambuja Cement Rajasthan Limited (ACRL), Ambuja Cement EasternLimited (ACEL) and Ambuja Cement India Limited (ACIL). Ambuja also has a strategic investment in ACC through its subsidiary (ACIL).

Ambuja Cements is the most profitable cement company in India, and the lowest cost producerof cement in the world. One of the major reasons that Ambuja Cements is the lowest costproducer of cement in the world is its emphasis on efficiency. Power consists over 40% of theproduction cost of cement. The company improved efficiency of its kilns to get more output forless power. Thereafter Ambuja Cements set up a captive power plant at a substantially lowercost than the national grid. The company sourced a cheaper and higher quality coal from SouthAfrica, and a better furnace oil from the Middle East. As a result, today, the company is in a position to sell its excess power to the local state government.Ambuja cement is the first company to introduce the concept of bulk cement movement by seain India. This resulted in speedier transportation and brought many coastal markets within easyreach. Ambuja Cements has a port terminal at Muldwarka, Gujarat. It is an all weather port thathandles ships with 40,000 DWT. The port has a fleet of seven ships with a capacity of 20500DWT to ferry bulk cement to the packaging units. The company has bulk cement terminals atSurat, Panvel, and Galle. The Surat terminal has a storage capacity of 15,000 tonnes andPanvel terminal has a storage capacity of 17,500 tonnes. Both the terminals have bulk cementunloading facility. The port at Galle, 120 km from Colombo, Sri Lanka, handles million tonnes ofcement annually.

Major Achievements of Ambuja Cement• Most profitable cement company in India.• Lowest cost producer of cement in the world.• Its environment protection measures are at par with the best in the world. The pollution levels at all I

ts cement plants are lower than the rigorous Swiss standards of 100 mg/NM3.• The only cement company to be awarded with the National Quality Award.• First cement company to first to receive the ISO 9002 quality certification.• Received ISO 14000 Certification for environmental systems.• India's largest exporter of cement.• Received Best Award for highest exports by CAPEXIL.• First company to introduce the concept of bulk cement movement by sea in India.

Ambuja Cement net profits rise on lower input cost• Holcim Group companies, ACC and Ambuja Cement, have posted a strong performance for

the quarter ended September 30. While ACC showed a 60 per cent growth in net profit, Ambuja Cement’s rose 27 per cent.

• ACC’s turnover rose nine per cent to Rs 2,077 crore (Rs 1,900 crore) in the quarter under review. Cement production was up three per cent to 5.01 million tonnes (mt).

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SWOT ANALYSIS OF AMBUJA CEMENTS LTD.ORGANISATIONAL STRUCTURE

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SWOT ANALYSIS:Strength

• Growth at approx CAGR of 9% in last 5 years• Growing Domestic cement consumption at approx CAGR of 8% in last 3 years• Highly Capital Incentive so difficult for small entrant• Not much restriction by govt.• Market consolidation taking place

Weakness

• High Oil Prices, Cost of Power increase production cost• Supply exceeds Production lead to competition in price• Low Quality as compared to international standard but improving.

Opportunity

• High Mortgage Penetration - Low Interest Rates• Easy loan availability for housing finance• Increased investments in Infrastructure• Increased govt. outlay on BHARAT NIRMAN, GOLDEN QUADRILATERAL, BRTS etc.

Threat

• Further Hike in Oil Prices• Use of plastic engineering in construction• Sub prime market loss may affect

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ORGANISATIONAL STRUCTURE:

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PRESS RELEASE ABOUT AMBUJA CEMENTS LTD.

MEDIA RELEASE BY AMBUJA CEMENTS LTD.

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PRESS RELEASE

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KASHLOG MINEREVIEW OF MINING PLAN

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ABOUT KASHLOG MINE

The Kashlog limestone mine of Ambuja Cement is located near village Kashlog in Arki Tehsil of Solan District in Himachal Pradesh. This mine was awarded Sita Ram Rungta Memorial award for social awareness for the year 1998-1999 by Federation of Indian Mineral Industries (FIMI). The total requirement of Ambuja cement’s Plant in Himachal Praedsh is met from this mine. Crushed limestone from mine to plant is transported by a 3.2 Km long closed overland belt conveyor system in an Eco-friendly manner.

The exploitation of limestone is being carried out by highly mechanized open-cast mining system. The deposit has been opened up at two different locations and this facilitates simultaneous excavation of various grades of limestone. This approach helps in conservation of minerals by proper blending and solves the problem of slope stability by avoiding formation of series of benches at a particular place. The 10m height benches are planned to have a slope of 70° with an ultimate pit slope of 45°.

Drilling is carried out by deploying hydraulic drills for primary blasting purpose. It is resorted to at locations which are difficult to work by Ripping and Dozing techniques. Around 70% of the production requirement is met by drilling and blasting.

As the limestone deposit is Rippable at certain locations, a giant Ripper-Dozer has been deployed to produce limestone from such places. The adoption of Ripping and Dozing technique at mine has considerably reduced dependence on blasting and its associated problems.

The ripped / blasted and fragmented limestone is raised using 4.5 cubic meter hydraulic excavators and 5.74 cubic meter wheel loader and loaded to 50 tonne capacity Dumpers. The crushed material from crusher to plant is conveyed through 3.2 Km long closed conveyor belt system having adequate carrying capacity. The conveyor passes through 3 tunnels with varying lengths and gradients along three major ridges falling between plant and mine area. Load cells have been installed in tunnel to monitor creep displacement.

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REVIEW OF MINING PLAN

Name of mine: Kashlog Limestone Mine.

Particulars of approval of mining plan:

The mining plan of Kashlog limestone mine was approved by Indian Bureau of Mines, Dehradun (U.P) vide their letter no. 614(2)/76-DDN dated 12.04.03. “Modifications in mining plan were approved vide letter no. 614(2)/MP-A-2/96-MCCM(N) DDN dated 5.3.98.First scheme of mining for the period 1 April 1999 to 31 March 2004 was approved vide letter no. 614(2)/MS-A-69/99-DDN dated 14.10.1999 while second scheme of mining for the period 1 April 2004 to 31 March 2009 was approved vide letter no. 614(2)/MSA-139/2003-DDN dated 21.06.2004.

Date of commencement of mining operations:

The mining operations started in western (Kashlog) Block of Kashlog Limestone Mine (KLM) on 13.05.1994.

Deficiencies existed in the approved mining plan or last two schemes of mining.

Lease Conditions:

The Ambuja Cement has taken lease from the Himachal Government. The lease condition is that, when the whole mining activities will be over, then the compant need to restore the spot as it was before, upto the possible extend.

When the company had taken lease of the land then it had repositioned the residing people in that mining are to other places.

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OBJECTIVES OF THE PROJECTRESEARCH APPROACH FOR THE PROJECT

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OBJECTIVES

The purpose of research is to discover answer to question through the application of scientific procedures. The main aim of research is to find out the truth which is hidden &which has not been discovered yet.However, each research study has its own specific purpose. There are several common objective of research as follow:-

• To understand the operational activities of the mining process.• To calculate the cycle time of the various equipments of the mining process

like dumpers, crushers etc.• To study about the safety precautions in the mining process.• To give a report about the assessment of the mining process to the

management.• To report about the violations of the safety precautions and misconduct done

which may or may not result to production loss.• To give a presentation at end of the project to the management and submit a

good project hard-copy to the company.

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RESEARCH METHODOLOGY

Project Research Type• Descriptive Research

Data Sources –• Primary Data

Research Approach• Survey Method/ Field servey/ data collected from employees.

Data Analysis• Logical analysis

Sampling Procedure• Random Sampling

Geographical Coverage• Kashlog Mines

There are different research methodology has been taken place to complete the project:

➢ First studying about mining activities from the internet.

➢ Second referring the books related to operations & supply management,

to implement the various techniques and models for the project

design and management.

➢ Third consulting with the various employees of different designations to

extract the data for the project and understanding the environment

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of work.

➢ Fourth to go to the field of extraction of limestone and manually gather

the recent cycle-time of various equipments.

➢ Fifth going to the different departments and gather the data at different

points.➢ Sixth I have also done some calculations at certain points.

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SOME OF THE EQUIPMENTS USED IN MINES ARE:

1107-D Vibratory Soil Compactor Dozer-D11

ESCORT CRANE F-15 G710 B Motor Grader

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hmt-4922 Tractor Komatsu PC 1250-10 BACKHOE

Komatsu-HD465-7 - torso REAR DUMP TRUC Kpc1250-7 Excavator

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ROC L8 Drill Machine

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SOME INFORMATION GEATHERED ABOUT THE MINEFINDINGS OR PROBLEMS

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SOME INFORMATION GEATHERED ABOUT THE KASHLOG MINES:

➢ The amount of crushed limestone processed per hour i.e, TPH (Tons per hour) is 1100 tph.

➢ The fuel required for the drillers per hour is 30-40 liters.➢ Fuel required for the dumpers per hour is 35 liters.➢ There is preventive repairs every week of the equipments.➢ The maximum capacity of the dumpers to carry lime stone is 50 tons.➢ The fuel required for the excavators per hour is 80 liters.

FINDINGS/ PROBLEMS

➢ It has been observed that crusher is of under capacity. Crusher should be of 1200 TPH to feed both the plants from single mine. Average crusher TPH in a shift was found to be 944 TPH on an average.

➢ It has been observed that the hopper on a particular shift was only 79% full at maximum time interval instead of 100% or 90% which means the interval of dumpers to dump the raw lime-stones into the hopper is not adequate.Some of the time intervals between the dumpers are as follows:

From first dumper to 2nd : 5 min

From 2nd to 3rd : 2 min

From 3rd to 4th : 2:30 min

From 4th to 5th : 3:45 min

From 5th to 6th : 8:26 min

From 6th to 7th : 4 min

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From 7th to 8th : 9:30 min

From 8th to 9th : 1 min

From 9th to 10th : 13 minTaking the average time between the dumpers, the time interval between in approx 5:30 min which is not enough to fill the hopper and utilize its optimum capacity.

This the picture of the crusher machine

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➢ Here some sample of the dumpers cycle time is taken in a particular shift and depended upon this some findings have been calculated:

SL no. Transport time to

site

Spotting time in site

Loading time

Transport time to crusher

Spotting time to crusher

Unloading time to crusher

Total Cycle time

1 6:20 min 3 min 1:35 min 8 min 4:30 min 00:21 sec 23:06 min

2 5 min 3:54 min 2:00 min 4:12 min 26:91 sec 00:23 sec 15:16 min

3 3:51 min 2:58 min 2:15 min 4:00 min 1: 46 min 0:30 sec 14 min

4 3:37 min 15 min 2:56 min 4:00 min 00:16 sec 00:34 sec 25:43 min

By looking at the table we can see that the cycle time variation is large due to variation in lead distance. The highest cycle time here is nearly 26 min. After seeing the figures it could be easily pointed out that the variation is likely due to the idling time at crusher and loading point of excavator.

➢ The problem of excessive idling time in the extraction area is more likely due to the excess of dumpers in compare with the PC Excavators. Due to this after completing the cycle up to unloading and return for re-load, more than 2 dumpers have to wait in a line before the previous dumpers is loaded and ready to go. This is mainly due to

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low crusher capacity.

➢ Some times in place of 3 dumpers which are needed for the purpose, 4 dumpers are used and so due to the spotting time excessive amount of fuel is consumed. As we know that a dumper nearly consumes 25-28 liters per hour and in idle time In engine start position it consumes 5% of the total fuel per hour. So, nearly 1.4 liters it is consuming unnecessarily per hour. And considering it in a financial year it is a big loss.

➢ Sometimes it has been observed that the dumpers capacity is 50 tons but some dumpers carry 38 tons, 40 tons, some times 55 tons-58 tons which is over weight, so sometimes dumpers adequate capacity utilization lacks for which some production problem may also arise.

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This is a picture has been taken at the lime stone extraction area.

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In place of one dumper 2 dumpers are waiting for loading.

SUGGESSIONS FOR SULUTIONS OF THE PROBLEMSSAFETY PRECAUTIONS

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SUGGESSIONS

➢ The cycle time of the equipments should be minimized like the dumper by employing certain techniques like minimizing the idle time of the dumpers at the extraction area by limiting the use of more dumpers in place of few needed.

➢ Or by increasing the numbers of PC excavators in the ratio of the dumpers like now there are 3 excavators, there should be 1 more.

➢ When the dumpers are in idle position the engine should be switch off which may result in saving the fuel.

➢ The maximum attention should be given to utilize the optimum capacity of the hopper at the crusher, so that production can be increased.

➢ Optimum utilization of the machines should be done to increase output.

SAFETY PRECUATIONS UNDERTAKEN IN MINING AREA

➢ Only the authorized employees are permitted to handle the explosives.➢ There are demarcations around the blast location like barricades, flag

signs etc.➢ The blast holes are being loaded under the control and supervision of the

designated competent person.➢ The controlled blasting technique is being adopted.➢ Cellular phones are not allowed in the blasting zone.➢ The explosive van's speed should not exceed 25km/hr.➢ Warning signals are given within a radius of 500 meters from the place of

firing.➢ After the blasting a siren is blown as signal if it is all clear and safe.➢ As the blasting is very dangerous for the eye at some distance also, safety

glasses should be provided and used at the blasting site.

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SAFETY PRECUATIONS SUGGESTED

➢ In the mines the Helmet & safety boots should be worn every time specially in the field.

➢ The use of safety glasses should be encouraged

➢ In the night shift there should be adequate light facility.➢ The vehicles speed at the mines area should not exceed 30 km/hr under

any conditions.➢ The distance between the dumpers should be more then 10 meters.

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CONCLUSIONBIBILOGRAPHY

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CONCLUSION

The main conclusion from the research is that there should be optimum utilization of the available resources and when by the use of a certain number of equipment can do the job extra equipment should not be employed. And as per the servery of the mines department it can be said that as per the reputation of Ambuja Cements ltd. is in the market the mines department taking maximum safety precaution is also doing a great job in consideration of the hazard landscape position of Darlaghat. By the time of my assessment I found that the cyclic time of the different equipments of the mining area are not up to the mark due to the deficiency of the PCI excavators in comparison with the dumpers , so the problem can be simplicity by using more PCI excavators or by minimizing the dumpers usages and only use the numbers of dumpers according to the production demand. By optimizing the use of equipments the cost of fuel consumption can be reduced and profit can be increased. In the sense of safety precaution it can be suggested that the use of safety glasses for the protection of the eye in the time of blasting or excavation should be encouraged.

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BIBILOGRAPHY

• Chase Richard B.-“Operations & Supply Management”, Edition 06

Pearson Education India, 2006

• Ashleigh C., Arthur A. S., Fedor Gladkov- “Cement”

Northwestern University Press, 1960

• Gani Mary S. J. “Cement and concrete”,

Taylor & Francis, 1997

• Das Kumar Bar- “Cement industry of India”,

APH Publishing, 1987

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