Industrial Visit Project (BBA): Bhushan steel limited

1. BHUSHAN STEELS LTD.
INTRODUCTION
Bhushan Steel Limited, is an ISO 9002,QS 9000 certified and a company of
Rs. 2868 crores ($650 million approx.).
The Khopoli plant, commissioned in 2004 has been playing a remarkable
role not only in the growth of exports, but in the production of a much wider
variety of value added steel like Colour Coated Sheets, High Tensile Steel
Strappings, Hardened and Tempered Strips and Precision Tubes. In addition to
these, the Khopoli plant has recently launched the Galume value added steel
(Aluminium & Zinc Coated Sheet) for the first time in the country.
Operating with the most advanced technology, expressed through a large fleet of
latest equipment, machinery and systems, the Khopoli plant has given a
tremendous boost of 425000 MT per annum to BSL's total production capacity
Including 240000 MT of galvanised steel, which are further forward integrated
into Colour Coated Sheet, Galume and other value added products.
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2. BHUSHAN STEELS LTD.
As a strategic move to optimise the usage of resources and services, as well
as to streamline the functioning of all systems and process within the
organisation, BSL has recently implemented SAP (the global leader in Enterprise
Resource Planning Systems). After all, with sales touching Rs. 3070 crores and
installed capacity in the one million tonnes per annum range, BSL is now India's
3rd largest Secondary Steel Producer after SAIL and TISCO. BSL has the
distinction of being the only producer In India of the widest width CR Sheet,
besides being a preferred supplier of automotive grade steel sheets for inner and
outer panels to all leading 4-wheeler and 2-wheeler manufacturers in the
country.

3. BHUSHAN STEELS LTD.
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ABOUT COMPANY
Company has many suppliers. But mainly the raw material is supplied
from JINDAL STEELS, and RUSSIA. Bhushan Steels are the 3rd
largest
producer in ASIA. The company has given a tremendous boost of 425000 MT per
annum to BSL's total production capacity including 240000 MT of galvanised
steel, which are further forward integrated into Colour Coated Sheet, Galume
and other value added products. Most of the machineries of the company has
been imported from Austria and Cut To Let machine is imported from
Germany.
Bhushan Steels Ltd. is an ISO 9002-2000 company and also possess the
certification of BVQI. This year the turnover of the company was 3070 crores
and the profit earn was 220 crores. The company is the single largest supplier to
almost all automobile and white goods manufacturers of the nation.

4. BHUSHAN STEELS LTD.
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Putting a spotlight upon the brilliant track record of the company would reveal
several attributes that are global in their scope, which have translated in a
sustainable phase of unprecedented growth for BSL the more important ones out
of these attributes include:
Performance at a
Glance
(Rs. In Crores)
Year 200120022003200420052006 2007
Gross Sales 1058 1139 1263 1745 2868 3070 4202
Exports 70 115 300 389 1051 1006 1527
PBDIT 177 183 202 277 410 408 659
Net Profit 46 46 61 96 153 154 313
Cash Accruals 105 108 133 203 317 312 580
Net Worth 481 528 573 664 805 960 1338
Gross Block 940 989 1302 1529 2044 3091 4586
EPS (Rs.) 14 14 15 22 38 38 75
Interest
Coverage Ratio
2.70 2.71 3.04 4.18 5.08 4.92 8.50
NETPROFIT AND TURNOVER

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OBJECTIVE OF VISITING BHUSHAN STEELS LTD.
We have a subject in our course industrial exposure, so that we can have a
insight look of how an company actually works. We visited this company so that
we can have a practical knowledge of how an company functions.
Our main Objectives for visiting the Company were :
● to gather the information about how the steel is processed;
● how does the process takes place;
● what are the costs involved in processing one coil of steel;
● how many workers are engaged in the manufacturing process;
● in how many shifts workers work.

6. BHUSHAN STEELS LTD.
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7. BHUSHAN STEELS LTD.
WHY AT KHOPOLI?
The plant was set up at Khopoli because of several reasons. The reasons are as
follows:
1. Proximity to Alibarg and Candla ports. This helps them to export
there goods easily.
2. Proximity to Mumbai.
3. The company whose capacity is to produce 425000 MT per annum
cannot be set-up in the city. Thus it is well set away from the
residential area but not too far from the market.
4. The Khopoli plant is 6kms away from NALCO.
5. Proximity to river water.
6. Proximity to railway.
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8. BHUSHAN STEELS LTD.
PRODUCT RANGE
1. COLD ROLLED PRODUCTS
 Cold Rolled Coil
 Cold Rolled Sheet
 Cold Rolled Closed Annealed Coil
 Cold Rolled Closed Annealed Sheet
2. GALVANIZED PRODUCTS
 Galvanized Sheet
 Galvanized Coil
 Galvanized Corrugated
 Galvanized Profile Sheet
3. GALUME PRODUCTS
 Galume Plain Sheet/Coil
 Galume Profit Sheet
 Galume Corrugated Sheet
 Bare Galume Tile Profit Sheet
4. COLOUR COATED / PRE PAINTED PRODUCTS
 Pre Painted Galvanized Plain Sheet / Coil
 Pre Painted Galvanized Corrugated Sheet
 Pre Painted Galvanized Profile Sheet
 Pre Painted Galvanized Profile Panels
 Pre Painted Galvanized Cable Tray
 Pre Painted Galume Plain Sheet / Coil
 Pre Painted Galume Corrugated Sheet
 Pre Painted Galume Profile Sheet
 Pre Painted Galume Tile Profile Sheet

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5. PRECISION TUBES
 Electric resistant Welded Precision Tubes Round / Ovel / Rectangle
/ Square / Boiler / Air heater
 Cold Drawn Welded Precision Tubes Round
6. HARDENED AND TEMPERED STRIP
 Hardened and Tempered Sheet / Coil
7. HIGH TENSILE STEEL STRIPPING
 High Tensile Steel Stripping
 Metal Seal

10. BHUSHAN STEELS LTD.
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11. BHUSHAN STEELS LTD.
PROCESS FLOW CHART
TUBE MILLING

CLEANING PROCESS

BOTT JOINT PROCESS

ACCUMULATION PROCESS

FORMATION PROCESS

SIZING PROCESS

CUT TO LENGTH PROCESS

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PROCESS IN DETAIL
The raw material which has been purchased from Jindal, Russia, and such
other suppliers is stored in the warehouse. These raw materials are in the form of
steel coils. Then as per the requirement or order given by the customer this raw
material is taken for Tube Milling Process, were the sheet is folded to make a
pipe.
After the folding process of the sheet, these pipes are sent for Cleaning
Process. In this process pipes are cleaned from inside. This process will help to
remove all the useless particles on the pipe.
Then the cleaned product has to under go the Bott Joint Process. Here the
folded pipe is joined with the help of welding. That is both the sides of the sheet
which were brought together in folding process are joined. The finishing is done
so accurately that the joint can not be identified.
Now Accumulation Process takes place. Here the pipe is kept I hold position
till the other pipe is get welded. Due to this type of process no machine is kept
ideal. Thus helps in optimum utilization of machineries.
From butt joint process and sizing process pipe becomes very hot. So it is
allowed to go from the Formation Process. In the formation process the hot pipe
has to under go the showering of the lubricant. The lubricant is nothing but the
mixture of DM + lubricant oil. DM is water without minerals. This type of
lubricant helps the pipe to make it cool.
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13. BHUSHAN STEELS LTD.
After the pipe is joined the thickness and the diameter of the pipe is
maintained in Sizing Process. Here the pipe of required diameter and of required
thickness is prepared according to the demand of various customers. This sizing
process changes as per the demand of the customer. Every customer has different
requirements thus the management has to change the settings of there
machineries regularly as per the customers.
After the formation process pipes have to be cut in a particular length.
Thus this work is done using Cut To Length Process. Here the pipe is being cut in
equal length according to the requirement of there customer. As sizing process
this process also requires to change the setting of the machineries as per the
demand of the customers. Thus management has to be very careful.
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14. BHUSHAN STEELS LTD.
OBSERVATION IN THE COMPANY
All the process mentioned above are managed from the control room. Thus the
processes in the company were much of automation. PPC is used.
CONCLUSION
The company has pre-set objectives and tries to achieve them. In a very short
span of time it has achieved a high quality standard. One more interesting fact is
that the company is very time bound and strictly follows time table. The
company expects its employees to achieve the pre-defined targets. Company also
provides training to its employee and is concerned with their upliftment. If the
company continues to grow at the same rate it will have a very bright future in
the field of steels.

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