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Presentation onPRODUCTION & OPERATIONSMANAGEMENT Presented By:   Group A1
• The fertilizer in India consists of three major  players: The Government owned Public Sector  undertakings, Cooperative ...
IFFCO is the largest producer of fertilisers inthe country.A total of 24.49 lakh MT imported urea and14.71 lakh MT importe...
Five units of IFFCO they are:- Kalol Kandla Phulpur Aonla Paradeep
Mission of IFFCO is to establish IndianFarmers to prosper through supply ofreliable, timely, high quality agriculturalinpu...
Attaining an annual turnover of Rs.15000 croreby 2010 which increased to Rs.21195 crore by2011.Backward integration to mee...
The raw materials used in IFFCO are:-AmmoniaPhosphoric acidUreaPotassium chloride
To promote the economic interest of itsmembers by conducting its affairs inprofessional, democratic and autonomousmanner t...
To provide technical consultancy and otherservices to members societies and otheragencies.To subscribe shares of co-operat...
CHAIRMAN                MANAGING DIRECTOR                BOARD OF DIRECTORPRODUCTION   FINANCE                        MARK...
There were 6 streams in IFFCO kandla plant they  are named as A,B,C,D,E,F.  They produce three product in IFFCO Kandla pla...
IFFCO Kandla have the capacity of 9.10 lakh MTP2O5 per annum equivalent to 24.20 lakh MT of bulkfertilizer.They import the...
FUEL OIL:- There are total of three verticalcylindrical fuel oil storage tanks with unloadingand pumping facilities. The 2...
STEAM GENERATION PLANT:- Steam isgenerated at a pressure of 10.5 kg/sq.cm gaugeand is in saturated condition. Three boiler...
WATER:- Water is supplied by Gujarat watersupply and sewerage board(GWSSB) THROUGHA 12” MS pipeline and is stored in three...
LIQUID CARGO JETTY:-IFFCO hasconstructed its capative liquidcargo jetty at kandla port forberthing of ships carrying theim...
CONCENTRATED SULPHURIC ACIDUNLOADING, STORAGE & HANDLINGFACILITIES:- The tank has been constructed along withdiking facili...
PhosphorusAmmonia             Acid                                                Belt                                    ...
A quantity of items that are processed together. Inthe process phosphoric acid, urea, potash andammonia are processed toge...
A method in which production of the itembegins in advance of customers needs. Thefertilizers are made ready before they re...
The operations are repeated daily in the plant.The process are done in a standardized form.The labours process the fertili...
In IFFCO Reward System is plannedand followed. Employees are givenrewards on several activitiesorganized in the organizati...
The ISO 14000:2004 standards requiredocumentation of a firm’s environmental program.According to the International Organiz...
Documentation standards that requireparticipating companies to keep track of theirraw materials use and their generation,t...
Internal and external                      customers        Inputs•Workers                                     Outputs•Man...
Less customer contact and customization                                              ProcessLess process divergence and mo...
A back office process has low customercontact and the work is standardized and routine.In IFFCO plant the process of the  ...
Less customization and higher volume                            Process                                                   ...
Ammonia, urea, phosphoric acid, potassiumchloride are the primary material that continuesits flow till the end and the sam...
Automation is a system, process or piece ofequipment that is self-acting and self-regulating.In operations managers favor ...
A systematic management approach that focuseson actively managing those constraints thatimpede a firm’s progress toward it...
As their raw material come from ship so theyhave to keep raw material inventory but forfinal product they do not keep any ...
In IFFCO kandla their whole supply chain ishanded over by HEAD OFFICE here in IFFCOkandla they just take the raw material ...
Location is helpful to reduce the transaction  cost.  There are some dominant factor in  manufacturing they are as follows...
LOAD DISTANCE METHOD:- Here we can say  that IFFCO kandla used load distance method  because this model is used to evaluat...
They do not use any PLANNING STRATEGYbecause of safety there workers do there workin shifts and go home and if any one wan...
ROTATING SCHEDULES:- They use this conceptso that they change their shifts.RESOURCE PLANNING:- In IFFCO KANDLA theydo not ...
Production and Operations Management at IFFCO Kandla
Production and Operations Management at IFFCO Kandla
Production and Operations Management at IFFCO Kandla
Production and Operations Management at IFFCO Kandla
Production and Operations Management at IFFCO Kandla
Production and Operations Management at IFFCO Kandla
Production and Operations Management at IFFCO Kandla
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Production and Operations Management at IFFCO Kandla

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Production and Operations Management at IFFCO Kandla

  1. 1. Presentation onPRODUCTION & OPERATIONSMANAGEMENT Presented By: Group A1
  2. 2. • The fertilizer in India consists of three major players: The Government owned Public Sector undertakings, Cooperative Societies like IFFCO, KRIBHCO and units from Private sector.• The fertilizer industry has organized itself through Fertilizer Association India (FAI) to coordinate with the Government of India to achieve the macro- economic objectives related to agricultural sector and to provide other services.
  3. 3. IFFCO is the largest producer of fertilisers inthe country.A total of 24.49 lakh MT imported urea and14.71 lakh MT imported DAP were handled bymarketing division from various ports directly.Fertilisers marketed through 39877cooperative societies and 158 farmers servicecenters.Only fertiliser institution in the country toproduce 85.83 lakh MT of fertilisers and125.88 lakh MT of sales during 2010-11. Thisis highest sales in India as well as the wholeworld by a single fertiliser major.
  4. 4. Five units of IFFCO they are:- Kalol Kandla Phulpur Aonla Paradeep
  5. 5. Mission of IFFCO is to establish IndianFarmers to prosper through supply ofreliable, timely, high quality agriculturalinputs and services in an environmentallysustainable manner and undertake othercavities to improve their welfare.
  6. 6. Attaining an annual turnover of Rs.15000 croreby 2010 which increased to Rs.21195 crore by2011.Backward integration to meet feedstockrequirement such as Phosphoric Acid etc.Generation of powerExploration of HydrocarbonsValue addition to Agro-products and marketingIT enabled services and financial services
  7. 7. The raw materials used in IFFCO are:-AmmoniaPhosphoric acidUreaPotassium chloride
  8. 8. To promote the economic interest of itsmembers by conducting its affairs inprofessional, democratic and autonomousmanner through self-help and mutual co-operation for undertaking.To maintain transport units of its own or incollaboration with any other organization inIndia or abroad for movement of goods by landand sea.
  9. 9. To provide technical consultancy and otherservices to members societies and otheragencies.To subscribe shares of co-operative and otherinstitution.To act as an warehousing agency under thewarehousing act and construct its own godownsor higher godowns for the storage of fertilizerand other goods.
  10. 10. CHAIRMAN MANAGING DIRECTOR BOARD OF DIRECTORPRODUCTION FINANCE MARKETING H.R MANAGER MANAGER MANAGER MANAGERSUPERVISOR ACCOUNTANT FACTORY SUPERVISOR MANAGER WORKER CLERK WORKER
  11. 11. There were 6 streams in IFFCO kandla plant they are named as A,B,C,D,E,F. They produce three product in IFFCO Kandla plant they are:- NPK1 NPK2 DAP These products should have their standard ratio like: NPK1 have (10:26:26) NPK2 have (12:32:16) DAP have (18:46:00)
  12. 12. IFFCO Kandla have the capacity of 9.10 lakh MTP2O5 per annum equivalent to 24.20 lakh MT of bulkfertilizer.They import there main raw material urea from outside countries because of some legal obligations.
  13. 13. FUEL OIL:- There are total of three verticalcylindrical fuel oil storage tanks with unloadingand pumping facilities. The 250kl storage tank islocated at kandla phase-II plant. Two day tanksare provided at the boilers for storage of fuel oilused for steam generation.PLANT AND INSTRUMENT AIR:- There are total offour air compressors catering to both plant airand instrument air requirements.
  14. 14. STEAM GENERATION PLANT:- Steam isgenerated at a pressure of 10.5 kg/sq.cm gaugeand is in saturated condition. Three boilers areavailable of type three pass, smoke tubepackage boilers.POWER:- Electricity is purchased from Gujaratelectricity board(GEB) through a double circuit66 KV line from GEB Anjar. In addition to thisfacility, they have one emergency power DG setof 800 KVA capacity.
  15. 15. WATER:- Water is supplied by Gujarat watersupply and sewerage board(GWSSB) THROUGHA 12” MS pipeline and is stored in three tanksout of which two are MS tanks of 5000 KLcapacity. Another 1 tank is kept spare for firefighting purposes.PRODUCT STORAGE AND BAGGING:- Twocovered storage silos for product storage areavailable, one for kandla phase-I plant and theother for kandla phase-II plant. Each of thesesilos has a storage capacity of 30000 MT.
  16. 16. LIQUID CARGO JETTY:-IFFCO hasconstructed its capative liquidcargo jetty at kandla port forberthing of ships carrying theimported raw materialsphosphoric acid and ammonia.It has a capacity of unloadingtwo million metric tonnes per annum of liquid cargo.
  17. 17. CONCENTRATED SULPHURIC ACIDUNLOADING, STORAGE & HANDLINGFACILITIES:- The tank has been constructed along withdiking facility. An 8 inch unloading line facilityfrom jetty to the main storage tank has beenprovided.
  18. 18. PhosphorusAmmonia Acid Belt Screening Pornutraliser (PN) Granulator Hot N Dryer Slurry Production Cooling Process Fume Conveyor Bagging Distribution Wagon
  19. 19. A quantity of items that are processed together. Inthe process phosphoric acid, urea, potash andammonia are processed together.
  20. 20. A method in which production of the itembegins in advance of customers needs. Thefertilizers are made ready before they reach thefarmers and the needs and wants of the farmersare fulfilled.
  21. 21. The operations are repeated daily in the plant.The process are done in a standardized form.The labours process the fertilisers, load them inthe wagon and then they are sent.
  22. 22. In IFFCO Reward System is plannedand followed. Employees are givenrewards on several activitiesorganized in the organization.We observed some of theRewards given to the employeeswhen we reached IFFCO on4th march which wasNational Safety Day.
  23. 23. The ISO 14000:2004 standards requiredocumentation of a firm’s environmental program.According to the International Organization forStandardization, “ the ISO 14000:2004 familyaddresses environmental management byspecifying what the firm does to minimize harmfuleffects on the environment caused by its activities,and to achieve continual improvement of itsenvironmental performance.”
  24. 24. Documentation standards that requireparticipating companies to keep track of theirraw materials use and their generation,treatment and disposal of hazardous wastes.To reduce and control pollution IFFCO releasesonly 1% unwanted gas.In IFFCO they even do not waste water. Thewaste water is reused in some other uses inthe plant premises only so that it don’t harmenvironment.
  25. 25. Internal and external customers Inputs•Workers Outputs•Managers •Goods•Equipment Processes and•Facilities operations•Materials•Land 1 3•Energy 5 2 4 Information on performance
  26. 26. Less customer contact and customization ProcessLess process divergence and more line flows characteristics High interaction Some interaction Low interaction Flexible flows with Front office individualized processes Flexible flows Hybrid office with some dominant paths Line flows, BACK OFFICE routine work performed
  27. 27. A back office process has low customercontact and the work is standardized and routine.In IFFCO plant the process of the fertilizers aredone repeatedly, they have low customer contactand are passed on to their customers who arefarmers after the final process.
  28. 28. Less customization and higher volume Process Low volume Few major High volume characteristics Multiple products products products products Customized process job processLess divergance and more line flows small batch Disconnected process line flows large batch process Connected Line process line Continuous Continuous flow process flows
  29. 29. Ammonia, urea, phosphoric acid, potassiumchloride are the primary material that continuesits flow till the end and the same process isrepeated in the plant.
  30. 30. Automation is a system, process or piece ofequipment that is self-acting and self-regulating.In operations managers favor fixed automationwhen demand volumes are high, productdesigns are stable and product life cycles arelong.Over here labours are there to look after theprocess while the whole process is carried on bythe machine itself.
  31. 31. A systematic management approach that focuseson actively managing those constraints thatimpede a firm’s progress toward its goal.Plant makes use of its resource effectively andtries to attain profit in all prospects.
  32. 32. As their raw material come from ship so theyhave to keep raw material inventory but forfinal product they do not keep any inventorythey make product and send to HO daily directlyfrom their bagging plant. So by this we can saythat they are using centralizedplacement inventory becausethey made and send the productwithin there plant warehousein wagons.
  33. 33. In IFFCO kandla their whole supply chain ishanded over by HEAD OFFICE here in IFFCOkandla they just take the raw material from hoprocess it and then send the final product to HO.So here they do not have any supplier orcustomer relationship system.
  34. 34. Location is helpful to reduce the transaction cost. There are some dominant factor in manufacturing they are as follows:- Favorable labour climate Quality of life Proximity to suppliers and resources Other factors
  35. 35. LOAD DISTANCE METHOD:- Here we can say that IFFCO kandla used load distance method because this model is used to evaluate location based on proximity factors the distance is less in shipment between plant to reduce the load distance score. OPERATIONS PLANNING &SCHEDULING:- Part time workers Subcontractors On role workers {shifts}
  36. 36. They do not use any PLANNING STRATEGYbecause of safety there workers do there workin shifts and go home and if any one wants to doovertime then they have to take priorpermission from HR department.SCHEDULING EMPLOYEES:- They give themshifts to work so they know that at what timethey have to come and do their work.
  37. 37. ROTATING SCHEDULES:- They use this conceptso that they change their shifts.RESOURCE PLANNING:- In IFFCO KANDLA theydo not do any resource planning because herethey only produce and send their product to hoin standard quantity.

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