intrnship report1

8/8/2019 intrnship report1

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Preface

This report is not an academic requirement but also gives students a practical vision ofoperations of company. It provided me an opportunity to perceive what is the difference

between theoretical studies and activities.

By the grace of God, I applied all the learning, which was taught to me by my honourable

teachers ,and the books which I read. Some concepts and applicable at DG CementFactory while the others are not. Nevertheless, it gives me a greater practical knowledge

about operations of cement industry. Maximum efforts have been given to make this

report easier to understand for its readers.

I hope that the reader will find this report useful and practicable.


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Executive Summary

DG Khan Cement Factory is one of the computerized cement factories in Pakistan. Itproduces the cement by adopting dry process.

Production Process

These are three raw materials of Cement:

Lime Stone

Shale and

Gypsum

Limestone and shale is taken from quarry with the help of 7-Km long conveyor belt. The

both raw material and mixed in raw mill, heated in kiln upto 1600 OC ground in cementmill along with gypsum almost 5%. The final product cement is prepared.

Location:

The company is located at Sattai Khofli, which is about 40 Km from city of Dera Ghazi

Khan.

Capacity:

The company has two plants

1.Existing

2.Expansion

Both the plants capacity is 2200 ton and 3300 ton clinker per day respectively.

Quality Control


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The company believes on quality assurance not on quantity inspection. So they have gotISO 9002 certification. Following tests are performed at different stages of production

process.

1.Raw Materials

Test on these material are performed

2.Raw Mill

Following Tests are applied

a.Hydraulic Modulus

b.Silica Modulus

c.Limestone Factor

3.Kiln

Same tests are performed as in raw mill.

4.Clinker

Tests are performed to see the quality of clinker.

5.Cement

Following physical tests are performed:

Expansion

Fineness


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Strength

6.Loading

Tests are performed after loading.

Aggregate Planning

Aggregate planning is done to cope with demand by using both demand and capacity

alternatives.

Purchasing

Purchasing of items is the duty of purchase department. Need is recognized when the

indentor raises the demand notice. The purchase department identifies and selects thesupplier and order is placed. Placed order is checked by store department and indentor to

accept the order.

Inventory Control

The store is responsible to manage and control the inventory of inputs. The inventory of

outputs (cement) kept in silos. The received order is inspected by store department. And

accepted material is stored in the store.

Distribution

The company has four sales offices in the following cities:

Multan

Lahore

Karachi

D. G. Khan

These sales offices accumulate demand of their respective regions and send the orders to

the head office Lahore.

Introduction

State Cement Corporation of Pakistan (S. C. C. P) was established in 1984 managed by

the Federal Government. In the beginning, existing plant was purchased from U.B. E.industries of Japan. It had installed capacity of2700-ton clinker daily and started its

production in April 1986.


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The main purpose for the establishment of plant was to fulfil the demand of Northern

Marketing zone. In 1977 the annual demand for cement in Pakistan was about at 3.7

million tons while the production was about 3.1 m. To fulfill 0.6 million gap, a new plantwas required. After a detailed investigation, they selected a place D. G. Khan City where

large high quality material reserves were available at least or 100 years. The location is

ideal because it is near to market as well as prior to raw material.

The govt. privatized the SCCOP, first purchased by Segol Group of Industries and NishatGroup of Industries combinely. In 1992, the company purchased by Nishat Group ofIndustries solely.After privatization it name changed from SCCOP to D. G. Khan

Cement Factory. Before the establishment of expansion plant (new plant) in 1997.

The cement was brought to this and either from Maple Leaf Cement Factory Mianwaliand Zeal Pak Hyderabad and ACC Rohi. The new plant is the relief for Bhawalpur,

Lodhran, Khanewal Muzafargurh, Bhawalnagar, Vehari. It was purchased from F. L.

Smith of Denmark. Its design capacity of4000 ton clinker per day.

Types of Cement

The company has following types of cement:

1.Ordinary Portland Cement

2.Sulphate Resistance Cement

3.Black Cement

4.Heat Resistance Cement

5.White Cement

6.Slag Cement

7.Quick Setting Cement

8.Under Water Setting Cement

9.Acid Resistant Cement

Mission Statement

The mission statement of D. G. Khan Cement Company is:

D. G. Khan Cement Company committed to produce and supply high quality

conforming the local and international standards adopting modern technique satisfying

the customer requirements the most competitive prices.

Production Process


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D. G. Khan Cement factory adopt true dry production process for the manufacturing of

cement. This process consists of following steps.

Drilling

Drilling is done in the quarry with the help of drilling machine. They create a space forthe powder explosive.

Blasting

The powder explosive is blasted under a controlled process to get different smallsegments of limestone. The large segments are also converted into small segments whichis called crushing process.two hammer crushers are installed on quarry site having

capacity of800ton/hr and 300 ton/hr.

Transportation


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The small fragments are loaded on the 7-Km long 3 belts conveyor system running over

rough terrain. This conveyor takes the new material from quarry to the factory site. The

limestone and shale to stored in the open space.

Grinding

After storage, the stored limestone and shale are fed to the raw mill with the help of twohoppers according to predetermined mixed proportion. The roughly crushed material

passed through 3 rollers. The mixture is dehydrated, sized, and fine particulars are

separated.

The cyclone extracts different gasses, which are emitted in this process. The collectedseparated mixture is called raw meal. It is stored in a silo of15000 ton. During the

process water is also used with the purpose:

To lower the gas volume

To control the variation

To maintain the temperature

Clinker

The raw meal is fed into kiln shell. The kiln shell has following particulars.

Length of shell 45 m

Diameter 3.5 to 6.5 m

Slope 1.5o

In this kiln shell following reactions take place.

CaCo3 CaO + O2 (Calcium Oxide)

CaCo + SI O2 CaoSio2 (Calcium Silicate)

CaOSio2 + CaO 2 CaoSio2 (Dicalcium Silicate)

2CaoSio2 + CaO 3CaoSio2 (Tricalcium Silicate)

CaO + Al2 O2 CaO Al2 O3

CaO Al2 O3 + CaO 2 CaO Al2 O3

2 CaO Al2 O3 + CaO 3 CaO Al2 O3


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3 CaO Al2 O3 + CaO + Fe2 O3 C4AF*

(Tetra Calcium Aluminum Fersite)

The kiln shell can be divided into four portions.

Firstly, the incoming raw meal is heated with the help of preheated air which comes fromthe cooler at the terminal end of the kiln. Heat is provided by the combustion of the

furnace oil. The raw meal is moved on the sloped shell which have four zones of

temperature.

1.Calcination zone 1200 OC

2.Transition zone 1250 OC

3.Sintering zone 1300 OC

4.Burning zone 1400 - 1500 OC

After the position of burning zone the mixture is cooled down with the help of air fans of

graze cooler. The heated is omitted which reduce the temperature of mixture. This heatedair is used to raise the temperature of raw meal entering into the kiln. The finished

product is called clinker, which is stored in an open yard having capacity of 30000 tons.


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Grinding

Now the clinker enters into Cement Mill. In this mill clinker is ground with gypsum.

Almost 5% of gypsum is added. The main purpose of addition of gypsum is to increase

the setting time.

The final product cement is prepared. It is stored in the silo having capacity of 10,000 toneach.

Packing

In the packing unit, there are 4 rotary packers and each packer has 8 nozzles. The wholepacking process is automatic. Cement bags are loaded on the trucks and heavy trollers

automatically. Each cement bag has 50 Kg weight. Sometimes heavy users ask for bulk

quantity of cement without packing. It is loaded into the truck.

Computerized production process flow is attached at the end of the report.

Quality Control

Quality a Competitive Priority

There are four competitive priorities

1.cost

2.time

3.flexibility

4.quality

The product like cement cost priority is not best because of legal consideration and suffer

heavy losses. Time can be used as competitive priority. On time delivery is most

important but the sometimes demand is very high the company is unable to provided ontime delivery. The flexibility is less because cement is standardized product. The only

one competitive priority is the main base which offer the competition. This is achieving

the high quality. As it was mentioned in the mission statement of the organization.Provide the high quality cement at competitive prices. Because the prices of cement arefixed so quality is the only competitive weapon through which a company can compete

the market. Keeping this in its view, D. G. Cement Factory applied for ISO 9000

certificate.

ISO 9002


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D. G. Khan cement factory is providing high quality cement for its beginning. After the

establishment of expansion department. The company No. 1 in the cement industry

Pakistan.

To cope with the environment they apply for ISO 9002 certificate. The company hired

Shakeel and Company Lahore as consultant to get ISO 9002 certificate. A committee isformed under the control of GM of the company Mr. Dr. Asif Bashir to be certified as

ISO 9002.

The company get the ISO 9002, certificate in the long run. The main aim to get the

certificate is to provide the customers the quality cement and competitive prices.

After getting the ISO 9002 certificate. The company reduce its inefficiencies in

management as well as in production. It reduce in rework cost because of clear cutresponsibilities are awarded to employees. It also increase the reliability of employee

upon the D. G. Cement.

Modern equipped laboratory establishment

Quality to check according to plan at each stage.

Cement x-ray Spectrometer is used to check the quality of the product at different stage.It takes 5 minutes to assess the ingredients of the product. There are six tests for the

quality assurance at different stages of the production process.

Raw Material

Raw material of cement can be categorized in three types:

Limestone

Shale

Gypsum

Lime Stone

The sampling point of limestone after blasting the rocks. The fragments of the rocks aretaken and check its chemical composition. Several benches have been opened and

abandoned if found to be lantern* low grade limestone. The main components oflimestone is calcium oxide (CaO). The following equation shows the %age of CaO

Heat

CaCO3 CaO + CO3


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100% 56% 44%

The production department accept only those limestone having at least 52% of CaO.

Shale or Clay

Th second component of cement is shale. Shale can be found near the quarry. They take

different samples of shale at different points to find out which shale has high quality.They utilize these shale first and then any other next.

Gypsum

Gypsum is another component of cement. It is 5% of the whole cement. It is mostly takenfrom outside supplier. Its quality is checked at the entering gate. If it is according to

contsuit* then it is selected otherwise rejected to suppliers.

Raw Mill

When the mixture reach in raw mill, three sophisticated chemical tests are performed.

They take different samples having different composition of two raw material (limestone& shale). Usually six samples of following composition is taken.

Sample No. Limestone %age %age of Shale

1. 77% 23%

2. 78% 22%


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3. 79% 21%

Hydraulic Modulus (HM)

In hydraulic modulus the above taken samples are taken and put the %age values of

composition of different compound in the following formula.

HM = = 2.1-/+ 0.2

CaO

Si2O + Al2O3 + Fe2O3

The standard values is 2.1 and + 0.2 variation is allowed. The above formula tell us by

changing the composition CaO we can get the exact result.

Silica Modulus

The test is also performed similarly to the above by taking different ingredients. The

formula is given below

SM =

SiO2

Al2 O3 + Fe2O3

The SiO2 is the main component of shale. By changing the composition we can get the

standard result.

Ume* Saturation Factor (LSF)

This test is applied to find out the amount of CaO in the mixture. We can calculate the

LSF factor by the following formula

LSF = = 90 + 3

CaO

28Si2O + 1.2Al2O3 + 0.65FerO3

90% of lime in mixture is a standard value while + 3 stands for variation.

Kiln

When the raw meal is fed to the kiln, it is also checked chemically by taking different

samples. Some test of hydraulic modulus, silica modulus and lime saturation factor isapplied to raw meal as well. The main purpose of the raw meal test is to find out the

temperature required to heating purpose of raw meal.


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Clinker

When the raw meal passes through kiln shell and take a form of clinker. A sample is

taken manually at this moment and then it is analyzed chemically with the help of cement

x-ray spectrometer. Clinker is a hasd* granular material. They grand into powder formand analyze. If the result is not according to standard they dispose it otherwise mixed in

high quality clinker.

Cement

When the 5% gypsum is added to ground clinker, the final product is cement. They takethe sample of cement to find out the right %age of gypsum in cement. As well as the

fineness of cement.

Following tests are performed for quality assurance of cement:

1.Expansion

2.Setting Time

3.Fineness

4.Strength

Expansion

The expansion test check that upto what extent the cement is expanded after addition ofwater. It is a complex test. According to world standard the expansion of cement should


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not be more that 10-mm. The company mostly test shows the expansion of 0.5 to 5.5 mm.

Which is obviously excellent.

Setting Time

The setting time shows the time taken by cement to become solid.

There are two types of setting time.

Initial Setting Time

Initial setting time is the time when we can penetrate the specific middle exact half

position of the cement block.

Final Setting Time

It is the time when we cant penetrate the specific needle into cement block.

We can compare initial and final setting time of D. G. Cement with the world standards.

Setting time DG Cement World Standard

Initial Setting Time 150 minutes at least 45 minutes

Final Setting Time 200 minutes at least 10 hours

Fineness Test / Blaine Test

Blaine test measures the small size of the particles in specific weights. The world

standard for the fineness test is that the should not be less than 2250 cm2/gm while in D GCement it is 2800 Cm2/gm.

Strength Test

The strength test check the strength of cement after passing different number of days.

The world standard and their standard are given below:

Strength Unit Company Std. World Standard

3 days PSI 3800-4400 2200

7 days PSI 4800-5400 340028 days PSI 6000-7000 5000

Loading


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Existing Plant 2700 tons

Expansion Plant 4000 tons.

During peak seasons both the plants are working above their allocated capacity while

during off season it works slow their allocated capacity. It is harmful for the plant to runit above their recommended capacity.

Distribution Requirement Planning

All the dealers are allotted the dealership number. They booked their orders in one of the

sales office. For all orders, dealers have to pay the amount in advance. The sales officeclerk accumulates all these orders and sends to the head office in two ways. Either he

filled customer order form or telephone.

The Head office (Lahore) make the distribution requirement planning. How much amount

of dispatch needed for coming days. Usually dispatch lot size is dependent on two things.

1.Quota imposed in distribution

2.Non-quota distribution

Head office informs the GM for daily dispatch all the dispatch process is done on

automatic machines. 40% of excise duty is paid on each bag. All the transportation cost

paid by dealer.

Although the lead-time is one day but it takes more than one day because of any

disturbance in market and operation.

Aggregate Planning

D. G. Khan Cement Factory has a family of cement types which consists of three cements

ordinary port land cement, black cement and sulphate resistance cement. They make their

aggregate plan keeping in view the demand of cement and capacity of plant. There are

two types of alternatives:

1.Demand alternative (Reactive Alternatives)

2.Capacity alternative (Aggressive Alternatives)

D. G. Khan cement factory apply both the alternatives to aggregate planning. We discuss

these alternatives one by one.


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Demand Alternatives (Reactive Alternatives)

This alternative is apply to cope with demand of the cement. In summer, the demand of

cement is very high. To cope with this demand, they hire extra unskilled and semiskilledlabor. They also offer overtime to highly specialized and skilled person. Mostly unskilled

labor is taken from subcontractors.

The Company allows vacation schedule in winter, the month of Ramazan and rainy days.

The plant is shut for repairing and maintenance work.

The company always keeps the anticipation inventory to meet the unexpected demand

e.g. in the peak season both the silo are filled most of the time to cope with any mishaps

sometimes the bricks of the kiln shell were broken and work was stopped at least 3 days.

During these 3 days anticipated inventory cope with the demand.

The company also gives relaxation to their workers during the peak season. Schedules are

formed to give the employee more rest.

Capacity Alternatives (Aggressive Alternatives)

The company uses these alternatives during the slack. When the demand is less than theircapacity. How to utilize their idle capacity? The answer is to apply the aggressive or

capacity alternatives. Aggressive alternatives allocation that attempt to modify demand

and resource requirement.

In the slack season the demand of ordinary postcard cement is low the company change

the production OPC to sulphate resistance cement and supply into the Karachi.

Another method is also used to enhance the demand by lowering the prices. When the

price of cement will reduce the demand will increase.

Inventory Management

We can divide inventory management broadly in two ways.

1.Inventory Management of Output (Cement)

2.Inventory Management of Inputs

D. G. Cement factory has no inventory in bags. They keep the cement in the 10000 tons

capacity silos.

The main problem of inventory management of inputs. Each and every department is

responsible for its inventory. Each department has to raise the demand notice to the


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purchase department. The store department provides them the required. In the case of

shortage, the purchase refer it to purchase department.

Types of Inventory in Store Department

The store department provides the inventory of inputs to each department. Its mainpurpose is to control and manage the inventory.

The store department categorizes its inventory of two types as:

1.Immediately consumable goods (Fast Moving Goods)

2.Non-consumable goods (Slow Moving Goods)

Immediately Consumable Goods

Immediately consumable goods are those goods which lose their quality and quantitywith the usage of items e.g. explosive, stationary, soap, towel, oil etc.

Non-consumable Goods

Non consumable goods are those goods which do not lose their quantity and quality with

the usage and time. These are everlasting items e.g. spare parts, machinery, either moving

equipment or plant assets.

Functions of Store Department

The store department performs two basic functions:

Management of Inventory

Controlling of Inventory

Management of Inventory

The store department perform follwing functions for management of inventory.

1.the inward card is issued when the truck passes through factory gate.

2.Inspection of quantity of material done on the gate. Inspection note is sent

to the concerning department. The manager or incharge who raise the

order called indentor write the remarks upon it after checking the quality.It is the duty of indentor to write the acceptance and rejection note upon it.

3.All accepted material is stored by store department and write material

receiving report.


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One of copy of material receiving report is sent to following departments.

1.Finance department

2.Store department

3.Purchase department

4.MIS department

5.Supplier

All the received items are written in the records books.

Control of Inventory

The store department controls the inventory both manually and by computer. Twosystems are introduced for physical control of inventory.

Computer Records

The second system for controlling of inventory is computer records. All the transactions

are updated in the computer.

The store department manages and controls 22000 inventory items for all the

departments. In any of stock out (the inventory level down the minimum level) store

department is responsible for the replenishment. He order to the purchasing department

for purchasing of goods.

Matching the tow systems

Both the systems records are matched at the end of accounting period in order to check

the correctness of records.

In any disturbance in the records the physical inspection is also done.

The possible causes for disturbance of balance for an item may be the following.

1.Misplacement of inventory

2.Mistake in records calculating

3.Due to theft

In order to reduce the theft, the department due the physical inspection after every these

months. It also reveals some other problems with the inventory.


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Purchasing

The purchasing of or different items done by the purchase department of the D. G. KhanCement Factory. The purchase department not only purchase for the factory as well as for

the sales offices. Usually the department purchases machinery furnace oil, officeequipment, supplies, paper sacks, explosive etc:

The purchase department acquire the things through the acquisition process.

The Acquisition Process

The acquisition process consist of following steps.

Need Recognition

Need for the acquisition of raw material arises when the production department asks tothe store department of some particular item. The store department is unable to fulfil the

need. So he recommends to the purchase department.

Production

Department

Needs a calculator

Store Department

Calculator is not available

Need to Purchase calculator

Supplier Selection

Purchase

Department


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In the supplier selection stage, Different suppliers are identified. Suppliers are of two

types.

1.Permanent Suppliers

2.Random Supplier

The company has permanent contractor to the different items. Contracts are of long termin nature. So they dont need any frequently selection of random supplier. The company

selected the supplier do to following characteristics.

Past experience

Past performance

Financial strength

Quality of material supplied

Price charges

Nature of relationship with the supplier

One of these factors can change the decision.

Placing the order

The purchase department has authority to buy the items. The purchase is done once the

particulars given by the store department. The following particulars are given in theindent form:

Name of the department

Description of the item needed

Last purchase date

Quality of item

Quantity of item

The order placement is dependent upon the requirement of item. Different purchases

procedure are adopted depending upon

Urgency

Availability

Importance


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There are three types of purchase processes:

Regular Purchase

Spot Purchase

Importance

Regular Purchase

Regular purchase is the purchase of those items which they are required after the certain

period with regularity. It exhibits the follwing characteristics.

Such items are very expensive

Such items are not needed urgently

These are consumable goods.

The order is placed in the newspaper in the form of tender notice. The terms andcondition are mentioned in the tender notice. The supplier get the tender form from the

nearest sales office (mentioned in the newspaper) on submission of fee. In this tender

notice all the description of item is mentioned. The supplier fills the form and submits todepartment with a security fee. The supplier is selected on the basis of low bid of the

supplier. In case, the company accepts the tender notice of supplier who give maximum

discount.

Sometimes the indentor is also considered for the selection of supplier which negotiatewith the supplier in term of quality of item.

After the supplier has been identified and selected the company will issue purchase order

to the supplier.

Spot Purchase

Sometimes, different items are purchased on the spot. These items are urgently needed,having more alternative and payment made in cash e.g. towels, tube lights, stationary,

bullets, bed sheets and spoons, dishes etc. Spot purchase is done through spot purchase

committee which is consists of

Indentor or end user

Purchase department representative

Commercial


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The spot committee visits different suppliers evaluate the items in terms of price, quality

and delivery date. The committee make the payment to the supplier on the spot. One

month is needed for the spot purchase to be completed.

Import

The company imports those items which are not available here or having low quality.

Import is a long and complex process, it takes six months for an import purchase to be

completed mostly earth moving machinery, fire bricks and spare parts are imported.

Track the order

Track the order means routine follow ups of orders to anticipate late deliveries orprobable deviations from requested order quantities. Different modes are used or tracking

the orders e.g. telephone, letter, fax. The company usually tracks the order when some

delay will stop the production.

Receiving the order

When the order is received from the supplier, the indentor checks the quality of the

incoming materials. The indentor writes the remarks about items either it is accepted orrejected. Acceptance or rejection note is issued by the store department. If the materials

are accepted the store department issues material receiving report. One copy of the

material receiving report is issued to each of the following department.

Supplier

Finance Department

MIS Department

Store Department

Purchase Department

The rejection of items is informed to the purchase department and they return to the

supplier. The purchase department also maintain and updates their records of differentsupplier on punctuality, quality, quantity deviations and price. All these information help

for future evaluation of supplier.

When the finance department has received the material receiving report from the storedepartment supplier as paid and entries are passed in their records.

Documents

intrnship report1