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Organisation Study on IREL Chavara 1 
DC School of Management and Technology | Trivandrum 
Summer Internship Program On Organization Study of 
INDIAN RARE EARTHS LIMITED, CHAVARA 
AKHIL P U (Reg. no. 13460007) 
MBA 2013-15 
KERALA UNIVERSITY 
Under the Guidance of
Organisation Study on IREL Chavara 2 
DC School of Management and Technology | Trivandrum 
Certificate (of the Institution) 
This is to certify that the report entitled “An organisation study on Indian Rare Earth Ltd” submitted here is a bonafide record of the work done by 
AKHIL P U, under the guidance and this work has not been submitted by them for the award of any other degree, diploma or title of recognition earlier. 
DC School of Management and Technology (sd) 
Date:……………………….. 
(Seal)
Organisation Study on IREL Chavara 3 
DC School of Management and Technology | Trivandrum 
Certificate ( of the Organisation) 
This is to certify that AKHIL P U,2nd semester MBA student of DC School of Management and Technology has done a project work on “organisation study” in our organization under the supervision of Mr Chandrasekhar, Sr. Manager safety and Environment Department during the period from 21 April 2014 to He has successfully completed the work. 
(Seal) 
(sd) 
Place and Date
Organisation Study on IREL Chavara 4 
DC School of Management and Technology | Trivandrum 
DECLARATION 
We, AKHIL P U 2nd semester MBA student of DC School of Management and Technology, do hereby declare that this organization study titled “An Organization Study onINDIAN RARE EARTHS LIMITED, CHAVARA”under the guidance of Mr. RAJENDRANis the result of original work during the organization study time. We have not submitted the same for the award of any degree, diploma. All the data both primary and secondary are true to the best of my knowledge 
. 
AKHIL P U 
Place: Kollam 
Date:
Organisation Study on IREL Chavara 5 
DC School of Management and Technology | Trivandrum 
ACKNOWLEDGEMENT 
First of all we wish to express my deep gratitude and thanks to God who helped us in completing the organisation study successfully. 
We shall remain grateful to Dr. P.S Mohana Kumar for his amble guidance and encouragement for completing the organization study. We are also extremely grateful to faculty member for their valuable suggestions and 2advice regarding this work. 
We are more obliged to Dr. VeeranKuttyDirector, Dc School of Management and Technology for given helpful suggestions and valuable guidance 
It is our pleasure to express a deep sense of grateful to Mr jayapalan(Deputy generalmanager),Mr Chandrasekhar, Sr. Manager( safety and Environment & QMSDepartment ),Mr SatyabhusanSamantaSr.Manager(Finance) without their untiring efforts and tremendous background information this work would not have materialized. We express our sincere thanks to all the staff of IREL, Chavara for their co-operation during my study in the company. 
Last but not least we thank to all the staff members of the DC School of Management and Technology for the encouragement rendered for the completion of the research work and also we extend our gratitude to all staff and workers in IREL, Chavara for their support in our organization study.
Organisation Study on IREL Chavara 6 
DC School of Management and Technology | Trivandrum 
LIST OF CONTENTS 
Subject 
Page Number 
Chapter 1 
Introduction 
9-12 
Chapter 2 
Industry profile 
13-19 
Chapter 3 
Company Profile 
20-24 
Chapter 4 
Product Profile 
25-27 
Chapter 5 
Customer profile 
28-30 
Chapter 6 
Functional areas of IREL 
31-75 
Chapter 7 
Swot Analysis 
76-78 
Chapter 8 
Porter’s Five Force Analysis 
79-81 
Chapter 9 
PEST Analysis 
82-84 
Chapter 10 
Findings, Recommendations, Conclusion 
85-87
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DC School of Management and Technology | Trivandrum 
LIST OF TABLES & CHARTS 
Table No 
Subject 
Page no. 
2.1 
World production reserves 
16 
2.2 
Resources of Monazite in India 
17 
2.3 
Potential RE markets 
19 
4.1 
Product profile 
26 
4.2 
Uses of the product 
27 
6.1 
Manpower strength 
34 
6.2 
Contract workers 
34 
6.3 
Pay scale for Workers and officers 
37 
6.4 
Production capacity of chavara plant 
48 
Balance sheet 
89 
Statement of profit and loss account 
90
Organisation Study on IREL Chavara 8 
DC School of Management and Technology | Trivandrum 
LIST OF FIGURES 
Fig no. 
subject 
Page no 
1.1 
Corporate structure 
11 
6.1 
Department structure -HRM 
32 
6.2 
Department structure -Mining 
45 
6.3 
Department structure -Production 
46 
6.4 
Production process 
50 
6.5 
Department structure –Quality control 
52 
6.6 
Department structure –Stores and Despatch 
54 
6.7 
Department structure –Internal Audit 
57 
6.8 
Department structure –R&D 
58 
6.9 
Department structure –Project& maintenance 
59 
6.10 
Department structure –Finance 
64 
6.11 
Department structure –Medical 
67 
6.12 
Department structure –Security 
69 
6.13 
Department structure –Safety& Environment 
70 
6.14 
Department structure -Civil 
75
Organisation Study on IREL Chavara 9 
DC School of Management and Technology | Trivandrum 
CHAPTER 1 
INTRODUCTION
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DC School of Management and Technology | Trivandrum 
INTRODUTION 
Each and every organisation has its own importance in the economic wealth of the nation. Different organisation meets different needs of people by offering different products and services. Due to globalisation the world has changed into a global village. In this fast and changing business scenario, it is imperative for every entrepreneur to have a vivid understanding of the functional application of the new age business. As a part of the academic curriculum each student has to undertake an organisational study to get practical exposure. This study is conducted at Indian Rare Earths Limited, Chavara. 
IREL Chavara is located 10 km north of Kerala and 85 km from Trivandrum, capital of Kerala and 135 by road from Cochin is perhaps blessed with the best mineral sand deposit of the country. The plant operates on a mining area containing as high as 40% heavy minerals and extending over a length of 22 kms in the belt of Neendakara and Kayamkulam. 
The deposit is quite rich with respect to Ilmenite, Rutile and Zircon and the mineral Ilmenite happens to be of weathered variety analysing 60% Titanium Dioxide (TiO2). The present annual production capacity of Chavara unit engaged in dry as well as wet (dredging / Up gradation) mining and mineral separation stands at 2,00,000 tonsof Ilmenite, 1,14,500tons of Rutile, 11,750 tons of Zircons and 10,000 tons of Sillimanite. In addition to that, the plant has facilities for annual production of ground Zircon called Zirflour and Microzir of the order of 6,000 tones and 300 tonsrespectively. 
IREL Chavara is one of the oldest and leading public sector undertakings under the Department of Atomic Energy (DAE). It is an ISO 14001: 2000; OHSAS 18000 certified company supplies beach sand minerals to the foreign and domestic market. It caters the requirements of developed countries like U.S.A, U.K, Germany, 
Australia, Japan etc. The major mineral products of IREL are Ilmenite, Rutile, Sillimanite and Zirflour.
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DC School of Management and Technology | Trivandrum 
CORPORATE STRUCTURE 
Fig:1.1 
RESEARCH DESIGN 
A research design is a plan of the proposed research work. The research designs simply a specific presentation of the various steps in the process of research. Design means adopting that type or technique which is most suited for the research and study of the problem. It is a plan, structure and strategy of investigation conceived so as to obtain answers to research questions and to control variance. 
OBJECTIVE OF THE STUDY 
The main objective of the study is to familiarize with the organisational functions in the organisation, there are many other minor objectives also. They are the following:- 
 To understand about how an organisation’s system is performing. 
 To know about various departments and their functions in an organisation. 
 To study the managerial activities performed in an organisation. 
 To know how an organisation coordinates its activities. 
 To get a practical exposure as the future manager. 
OSCOM Plant 
Orissa 
Corporate & Registered 
Office at Mumbai 
Rare Earths Division 
Udyogamandal 
Mineral Division 
Manavalakurichi 
Mineral Division 
Chavara
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DC School of Management and Technology | Trivandrum 
SCOPE OF THE STUDY 
The scope of the study is to know about the organisation, its structure, the functions performed by various departments and to know the overall performance of the organisation. The study will help the management students to get a practical exposure. 
METHODOLOGY 
Both primary and secondary data were used for this study. 
1. Primary Data:- 
The primary data can be obtained either through observation or through direct communication with respondents in one form or another or through personal interviews. There are several methods for collecting primary data. They are observation method, interview method, through questionnaire, through schedule etc. Here primary data were obtained from direct interviews made on with managers, officers and workers of the firm. 
2. Secondary Data:- 
Secondary data means data that are already available ie: - they refer to the data which have already been collected by someone else. Here secondary data were collected from company brouchers, manuals and other records 
LIMITATIONS OF THE STUDY 
 The study is limited to my experience and knowledge. 
 Lack of availability of secondary data from published journals and reports. 
 Secrecy of the organisation prevents them from giving some of the details regarding the firm. 
 Employees were busy in their work so they could not give more information. 
 There may be errors due to the bias of the respondents. 
 Time is a major limitation in the course of study.
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DC School of Management and Technology | Trivandrum 
CHAPTER-2 
INDUSTRY PROFILE
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DC School of Management and Technology | Trivandrum 
INDUSTRY PROFILE 
Rare Earth Elements or Rare Earth Metals are a collection of 17 elements namely scandium, yttrium and lanthanides (15 elements in the periodic table with atomic numbers 57 to 71 namely: lanthanum (La), cerium (Ce), praseodymium (Pr), neodymium (Nd), promethium (Pm), samarium (Sm), europium (Eu), gadolinium (Gd), terbium (Tb), dysprosium (Dy), holmium (Ho), erbium (Er), thulium (Tm), ytterbium (Yb) and lutetium (Lu)). Rare earths are not rare in the sense of their abundance, but have earned this descriptive because they are rarely concentrated enough for an easy recovery from their ores. 
In India, monazite is the principal source of rare earths, which is a prescribed substance as per the notification under the Atomic Energy Act, 1962. Indian Rare Earths Limited (IREL) has been the sole producer of Rare Earth compounds in the country. The recovery of Rare Earth Elements (REE) from Monazite has been restricted due to its thorium and uranium content. There is a need for concerted efforts both by GSI and AMD to explore other primary sources of Rare Earth Elements. In the face of competition from China and due to lack of domestic demand for indigenous materials, IREL had stopped its production. 
Given the concerns over China’ s flexing of its muscle on the international stage by restricting Rare Earths exports, a wave of Mining projects are revived worldwide to tap sizeable deposits of Rare Earths. IREL is also planning to restart production of REE. 
Keeping this in view and increasing demand of these metals for high tech applications, Ministry of Mines has stressed the need to incentivize exploration & process R&D for creating indigenous production capacities. To achieve this, a high level Steering Committee has been constituted to look into the current availability of Rare Earths and to suggest short, medium and long term strategies for exploration, production and processing, to ensure long term availability of the raw material
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DC School of Management and Technology | Trivandrum 
WORLD SCEANARIO OF RARE EARTH ELEMENTS (REEs) 
There is large amount of reserves of rare earths minerals in the world. China holds the leading position among producers of the rare earths elements or lanthanide elements. 
Rare earths are also produced in India, Russia, Kazakhstan, Kyrgyzstan, Thailand, Malaysia, Russian Federation, Brazil, Canada, Vietnam, South Africa, Indonesia, Sri Lanka, Mongolia, North Korea, Saudi Arabia, Turkey, Norway, Greece, Nigeria, Kenya, Tanzania, Burundi, Madagascar, Mozambique and Egypt. 
Most recently, it was discovered that Afghanistan may have large deposits of rare earth metals, estimated to be worth US$89 billion. The rare earth deposits are on the south bank of the Helmand River in southern Afghanistan. 
Given the concerns over China’ s flexing of its muscle on the international stage by restricting Rare Earth exports, a wave of Mining projects are reviewed worldwide to tap sizable deposits of Rare Earth. LynaCorporation’s new mining operation in Australia and Molycorop’s plan to restart Mothballed Mountain Pass Mines is a step in this direction. It has also encouraged further exploration and spurring more recycling of Rare Earths.
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DC School of Management and Technology | Trivandrum 
The World production and reserves of Rare Earth Elements are given in table. 
Table:2.1Rare Earth Elements – World Production and Reserves (2009) 
INDIAN SCENARIO 
In India, monazite is the principal source of rare earths and thorium. The mineral monazite is a prescribed substance as per the notification under the Atomic Energy Act, 1962. AMD has been carrying out its resource evaluation for over five decades. It occurs in association with other heavy minerals, such as ilmenite, rutile, zircon, etc. in concentrations of 0.4 - 4.3% of total heavies in the beach and inland placer deposits of the country. The resource estimates of monazite in the beach and inland placer deposits have been enhanced from 7.90 million tonnes in 2002 to 10.21 million tonnes in 2005. 
Country 
Mine Production 
(tonnes) 
% of production 
Reserves (million 
tonnes) 
% of Total reserve 
United States 
0 (no rare earth mining) 
0 
13.0 
13 
China 
120000 
97 
>36.0 
36 
Russia (and 
other CIS 
countries) 
small 
<1 
19.0 
19 
Australia 
small 
0 
5.4 
5 
India 
2700 
2 
3.1 
3 
Brazil 
650 
<1 
small 
Malaysia 
380 
- 
small 
Other 
270 
- 
22.0 
22 
Total 
124000 
>99.0
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DC School of Management and Technology | Trivandrum 
The state wise resources are given below: 
All India 
10.21 
Andhra Pradesh 
3.73 
Bihar 
0.22 
Kerala 
1.37 
Orissa 
1.82 
Tamil Nadu 
1.85 
West Bengal 
1.22 
Table:2.2Resources of Monazite (In million tonnes) 
Exploration & Development 
Apart from Monazite sands, India has to look for rare earths from the primarysource rocks. In India, concentration of REE in hard rock has been recorded in association with carbonatites, syenites, albitites, granites, pegmatite, apatite and phosphorites and carbonaceous schists. Geological Survey of India has carried out preliminary search for REE in carbonatite in Koraput and Kalahandi districts of Orissa. Pegmatite and the granite terrain have been covered in Bhilwara, Ajmer and Udaipur districts of Rajasthan. Carbonatites of Tamilnadu, West Bengal, Meghalaya and Assam were also sampled. So far, Bastnaesite has been reported in association with Carbonatite from Puruliadistt,West Bengal and Monazite has been reported from Carbonatite occurrence of Sung Valley (Meghalaya),Sevattur (Tamilnadu) and Samchampi (Assam).In addition GSI has to examine all the data generated from the proterozoic and younger granites andIron oxide-copper-gold (IOCG) type deposits and also their supergene/ lateriteprofiles. Proper evaluation of existing data and data generated from National Geochemical Mapping Programme can also help in locating suitable target areas for further search of REE. Field investigations carried out by AMD for rare metal
Organisation Study on IREL Chavara 18 
DC School of Management and Technology | Trivandrum 
pegmatites in the last few years has led to the discovery of significant raremetal pegmatites at Pandikimal, Jangapara, Bhurpidungri etc. in Jharsugudadistrict of Orissa and Kawargaon, Bodenar, Metapal, Challanpara etc. in Bastar district of Chhattisgarh apart from the known and established pegmatite fieldsof Bihar , Rajasthan and Karnataka. These pegmatites were assessed and evaluated for their economic exploitability and considerable tonnage wasproved with significant ROM grade. Some of them viz., Pandikimal, Jangaparain Jharsuguda andBodenar in Bastar district are under recovery for Columbite-Tantalite. Beryl i s also recovered as a by-product. Columbite-Tantalite from Jharsuguda area, Orissa is niobium rich whereas those of Bastar region, Chhattisgarh are tantalum rich. In Southern India, a survey by AMD has resulted in locating new pegmatitic occurrences in Holenarispur and Nagmangala Schist Belts of Karnataka. Similarly in Central India Bastar-Koraputpegmatitic belt (BKPB) and pegmatites around Limboi in Sabarkantha Dist., Gujaratis rare metal bearing. Marllagalla pegmatite in Nagamangla Schist Belts forms the single largest Nb- Ta deposit containing economic grades of Ta2O5, which has produced substantial tonnage of Columbite-Tantalite and Spodumene(lithium bearing mineral).Apart from pegmatites, the granitic occurrences of Nb-Ta minerals near Kanigiri, Prakasamdistrict, Andhra Pradesh was also located and evaluated. The carbonatite bodies of Tamilnadu and Meghalaya were reassessed for their pyrochlorecontent. Samchampi Alkali Complex in Mikir Hills of Assam is another potential area for Nb-Ta minerals. The Niobium deposit at the SamchampiCarbonatite Complex, Assam, and India extends over a considerable stretch. High content of Nb, La, Y and Zr have also been reported for the first time in rhyolitic dykes associated with Deccan basalt from Alechhills, Gujarat. The anomalous content in these rocks is due to the presence of xenotime, ilmenorutile and monazite. The non pegmatitic resources for rare metals are low and have problems of beneficiation which are being studied by AMD. 
Key successes for the beach sand mineral industry are:- 
 Increase the Ilmenite capacity to reach economic scale of production. 
 Value addition project in minerals and rare earths compound.
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DC School of Management and Technology | Trivandrum 
 Initiate action to develop new mining areas. 
 Forward integrate through stake in world leader in pigment Industry likeTinfoss, DuPont or selling up a pigments plant. 
 Explore other mining options in neighbouring countries. 
Potential RE Markets 
Table:2.3 
End Use 
RE required 
Present Status 
Expected (2030) 
Magnets for wind turbines 
Nd , Pr, Dy, Tb (high strength magnets have 30 % RE) 
12,000 MW of wind ~ capacity 
~ 50,000 MW 
EV, Hybrid vehicles (batteries, motor, catalytic converter) 
La (15 kg per car) 
Nd (1 kg per car), Dy, Tb, Ce 
Negligible EV 
Perhaps up to 1 million vehicles 
LED 
Y, Eu, Tb 
Negligible LED 
Being promoted by 
government, could 
reach ~ 1 million bulbs 
Al, Steel, Mg industry, grain refinement 
Ce, La , mischmetal 
Huge growth 
rate 
Screens brighteners 
(cell phone, 
computers, TV screen) 
Eu 
mostly imported 
Huge growing market 
Other magnets 
Pr, Sm, Gd 
mostly imported 
Computer hard 
disks, microphones
Organisation Study on IREL Chavara 20 
DC School of Management and Technology | Trivandrum 
CHAPTER 3 
COMPANY PROFILE
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COMPANY PROFILE 
On August 18, 1950 Indian Rare Earths Limited (IREL) was incorporated as a private limited company jointly owned by the govt. of India and Govt. of Travancore, Cochin with the primary intention of taking up commercial scale processing of monazite sand at its first unit namely Rare Earths Division (RED) Aluva and Kerala for the recovery of thorium. 
After becoming a full-fledged central govt. undertaking in 1963 under the administrative control of Department of Atomic Energy (DAE), IREL took over a number of private companies engaged in mining and separation of beach sand minerals in southern part of the country and established two more divisions one at Chavara, Kerala and other at Manavalakurichi(MK), Tamilnadu. 
After a gap of 20 years IREL commissioned its largest division called Orissa Sand Complex (OSCOM) at Chatrapur, Orissa. Today IREL operates these four units with corporate office in Mumbai and produces/ sells six heavy minerals namely Ilmenite, Rutile, Zircon, Monazite, Sillimanite and Garnet as well as various value added products IREL is making profit for the last 6 years with its sales turnover reaching a peak exceeding Rs: 2600 million in 2000-01, with export component of above Rs: 1000 million. 
Chavara plant is engaged in the processing of beach deposits available on the coastal belt of Neendakara- Kayamkulam 
HISTORY OF THE ORGANISATION 
IREL’s history should not be narrated without mentioning the name of the Germen chemist Mr. Herr Schomberg who has realised that the shining yellowish brown
Organisation Study on IREL Chavara 22 
DC School of Management and Technology | Trivandrum 
particles sticking to coir, a coconut fiber shipped from India (1909) contained Monazite. 
This sparkled the discovery of vast deposit of monazite a rich source of rare earths a group of elements with a wide variety of uses in industry and science. A few plants were operating at Chavara and Manavalakurichi for the separation of monazite. 
1948:- The govt. of India setup atomic energy commission under the chairmanship of Dr: HomiBhabha. The export of Monazite was stopped and the possibility of setting up a facility to process the beach sand mineral for the production of Rare Earths was examined. 
1950:- IREL was incorporated at Bombay 
1951:- IREL become the full-fledged govt. undertaking under the Department of Atomic Energy and commissioned construction of its rare earths plants at Udyogamandal in Kerala. 
1952:- Rare earth plant was dedicated to the nation on Dec 24 by the Jawaharlal Nehru. 
1955:- Opening Thorium factory of Bombay. 
1965:- Opening mineral division at Kollam in Kerala state with manufacturing facilities at Chavara in Kerala and Manavalakurichi in Tamilnadu and a giant mineral sand separation and synthetic Rutile plant at Chatrapur in Orissa. 
VISION OF IREL 
1. To be a leading supplier of beach sand minerals from Asia by supplying 10% of the world demand for beach sand minerals over the next 7-10 years. It would be achieving by maximum utilisation of existing capacities, new capacity addition, capturing major portion of the incremental growth in the global TiO2 feedstock demand and by developing competitive value added Rutile, Zircon, Sillimanite and Garnet products that make handsome contribution to revenue and profits.
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DC School of Management and Technology | Trivandrum 
2. To become the preferred rare earths products supplier (Producer and/ or Marketer) for domestic customers to ensure long term sentences and profitability of rare earths business and to achieve adequate efficiency in monazite processing as long as it is necessary / worthwhile. 
MISSION OF IREL 
1. To harness beach sands in an environmentally and socially responsible manner for efficiently producing minerals and their traditional and innovative value added products of world class quality that are used to make increasingly superior/ novel products required by customers. 
2. To play a dominant role in developing domestic rare earths market by producing and/ or marketing the quality value added products to realise maximum potential or rare earths in a range of applications. 
3. To build a professional, creative and committed workforce and nurture an environment that fosters learning, sharing and development. 
OBJECTIVES OF IREL 
 To become nationally and globally competitive player in beach sand minerals. 
 To improve productivity, capacity utilization and cost effectiveness. 
 To maximise shareholders value. 
 To strive for optimum value addition through obtaining technology for improving international market share and growth in domestic market. 
 To undertake by itself or through independent expert agencies , investigation into new products as well as beach sand erosion and related phenomena of company’s operation. 
 To evolve and implement eco-friendly policies, programmes and projects within the AERD regulation.
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DC School of Management and Technology | Trivandrum 
 To develop the human resources of the company by optimising their number, capabilities and quality of life 
 To strengthen R&D for achieving the above mentioned objectives 
QUALITY POLICY 
IREL is committed to provide products of consistent quality to their satisfaction of the customers through Quality Management Systems (QMS) implementation. 
TECHNICAL EXCELLENCE 
IREL uses state of art technology in mining and mineral processing. The rich experience and professional expertise of people who are one among the best in the industry and strict compliances to quality standards has enabled IREL to remain as the leading supplier of heavy minerals to the nation and abroad. IREL is always been driven by innovation and sound manufacturing practices, be it in product, technology or process.
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DC School of Management and Technology | Trivandrum 
CHAPTER 4 
PRODUCT PROFILE
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PRODUCT PROFILE 
Product means to the goods and services combination the company offers to the target market. 
Product 
Specification 
Specific Gravity 
Density 
Packaging 
Ilmenite 
TiO2 - 58% 
4.45- 4.54 
2600- 2630 
In bulk HLP bags with Polithine liner 
Rutile Q Grade 
TiO2 - 95% 
4.18-4.24 
2630-2650 
In bulk 50kg HLP bags with Polithine liner 
Zircon Special Grade 
ZrO2 - 58% 
4.60-4.70 
2900-3000 
In bulk 50kg HLP bags with Politine liner 
Sillimanite Q Grade 
Al2O3 
3.20-3.25 
1950-2050 
50kg jute bags 
Zirflour 
ZrO2- 64% 
- 
1800-1850 
50kg laminated HLP bags with Polithine liner 
Microzir 
ZrO2- 63.5% 
- 
- 
Liner 20kg laminated Polithine bags 
Table:4.1
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DC School of Management and Technology | Trivandrum 
Products 
Uses 
Ilmenite 
Manufacturing of TiO2 pigment synthetic Rutile and Titanium slag 
Rutile 
Fluxes for welding electrodes 
Zircon sand 
Ceramics, Refractories and foundries. 
Zircon Flour 
Ceramics and foundries. 
Microzir 
Pacifier in Ceramics 
Sillimanite 
Refractories 
Garnet 
Abrasive for sand blasting, water jet cutting and glass polishing. 
Monazite 
Raw material for production of Rare earth Component 
Composite RE Chloride 
Catalyst, Paint driers, basic raw material for Misc. metal which used as lighter frint& mantles. 
Thorium Nitrate 
Gas Mantles 
TABLE:4.2
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CHAPTER 5 
CUSTOMER PROFILE
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CUSTOMER PROFILE 
Prime customers of the major products of the company are the following:- 
A. ILLMENITE:- 
1 KOCHIN MINERALS AND RUTILE LTD. KOCHI. 
2 DCW LTD. TUTICORN. 
3 TRAVANCORE TITANIUM PRODUCTS LTD. 
4 KILBURN CHEMICALS LTD. TUTICORN. 
5 KOLMAK CHEMICALS LTD. KOLKOTA. 
B. RUTILE:- 
1 ESAB INDIA LTD, CHENNAI/ KHARDAH. 
2 ADOR WELDING LTD., MUMBAI/CHENNAI. 
3 D & H SECHERON ELECTRONICS (I) LTD., INDORE 
4 MARUTHI WELD LTD., GURGAON. 
5 ROYAL ARC ELECTRODES PVT. LTD.VASAI, THANNE DIST. 
C. ZIRCON:- 
1. THIRUPATHI MICROTECH (P) LTD., UDAIPUR. 
2. RUBY CERAMICS PVT LTD., PUNE. 
3. ASTRON CERA, SALAL DIST, SABARKANTHA. 
4. JOHNSON MATTHAEY CERAMICS INDIA LTD, HOSUR, TN 
5. FOUR FIELD, PUNE. 
D. ZIRFLOUR:- 
1. FOSECO INDIA LTD., PUNE. 
2. VIDEOCON NARMADA GLASS, BHARUCH. 
3. H & R JOHNSON (I) LTD., MUMBAI. 
4. NAHAR COLOUR & COATING LTD., UDAIPUR 
5. BHANU CERGLAZE P.LTD.
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E. SILLIMANITE:- 
1. MAITHAN CERAMICS PVT. LTD., CHIRKUNDA, JHARKHAND 
2. MANISHRI REFRACTORIES, CUTTACK. 
3. ASSOCIATED CERAMICS, CHIRKUNDA, JHARKHAND. 
4. TATA REFRACTORIES, BELPAHAR, ORISSA. 
5. ASSOCIATED CEMENT COMPANIES LTD., NAGPUR/KATNI. 
F. RARE EARTHS CHLORIDE:- 
1. CIBA SPECIALITY CHEMICALS, UDYOG NAGAR, GUJRAT. 
2. DHIRAJ INTERMEDIARIES P LTD., VAPI, GUJRAT. 
3. RAVESHIA PIGMENTS LTD., VAPI, GUJRAT. 
4. ANUPAM COLOURS, VAPI, GUJRAT. 
5. BERGER PAINTS INDIA LTD., VAPI, GUJRAT. 
G. THORIUM NITATE:- 
1. FARGO MANTLE PRODUCTS LTD., MUMBAI. 
2. MAKANI PRODUCTS LTD., MUMBAI. 
3. B.K SHAW INDUSTRIES (P) LTD., KOLKATA. 
4. A.D.C MANTLE MANUFACTURING CO., MUMBAI. 
5. ELITE INDUSTRIES, MUMBAI.
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CHAPTER 6 
FUNCTIONAL AREAS
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DEPARTMENTS 
I. HUMAN RESOURCE DEPARTMENT:- 
IREL Chavara takes place it’s highly motivated and trained human resource that has maximised its performance and their by its growth and profit. Morale of the employees remains facilitating smooth working of the company. Skill requirement related to different disciplines are identified and training programs and workshops are efficiency of the human resource. 
Fig:6.1 
HR department lead by HOD & Section Head to assist him. The Security Department and Time Office are working under the HOD of HR Department.Executives & Personnels are working under section head of HRM.People are the most important resources of an organization. 
The main functions of HR Department are:- 
1. Administration 
2. Industrial Relations 
3. Training and Employee Welfare 
4. Time Management 
1. ADMINISTRATION 
The administrative functions of HR department include 
a) Manpower planning 
b) Recruitment policy 
HOD(HRM) 
SECTION HEAD(HRM) 
HRM Executives 
HRM Personnel
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c) Performance appraisal 
d) Salary and wages administration 
e) Industrial discipline 
f) Maintaining service book and personnel file 
g) Maintaining reservation register 
a) Manpower Planning:- 
Manpower Planning is important for any type of organisation. It is the process which determines how an organisation should move from its current manpower position to its desired manpower position. For this purpose, the HR department at IRE collects feedback from all department inorder to identify their manpower requirements of various departments and then the HR department crosscheck whether there is any overstaffing in any of the departments. If these departments have excess of staff, they are transferred to those departments where there is a shortage. 
The company considers the number of employees presently as significantly high. There is a problem that sometime the VRS can lead to scarcity to workers for particular job. At IREL using the process of multitasking the employees are made fit to work in other function also. By the VRS scheme more than 100 employees have been sent out within span of 3 years.
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Manpower of the company 
There are 386 employees in the company. Total executives are 102 and workmen are 284.The number of contract workers are 632. 
Details showed as below. 
Manpower strength 
MALE 
FEMALE 
TOTAL 
EXECUTIVES 
86 
16 
102 
WORKMEN 
260 
24 
284 
TOTAL 
346 
40 
386 
Table:6.1 
CONTRACT WORKERS 
LOADING 
35 
CIVIL 
42 
MINING 
120 
BAGGING 
110 
CANTEEN 
12 
TOTAL 
319 
Table:6.2 
b) Recruitment policy:- 
Recruitment in Chavara Plant is done through local employment exchange for find out prospective workers. The office staffs and managers are recruited by the Head Office through tests and Interviews. 
Recruitment Criteria 
For the recruitment of candidates, the candidates should be above 18 years of age.
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The following steps are taken before the recruitment of employees. They are govt. guidelines, the recruitment only through employment exchange, notification in internet and advertisement in newspaper should be needed. Application will be scrutinised with the help of a selection committee and eligible candidates are called for an interview. 
Selection:- 
The steps followed in the selection process are; 
1. Inviting and receiving applications 
2. Scrutinizing the applications 
3. Selection Test: - The selection tests of employees are 
a) Aptitude Test 
b) Personality Test 
c) Achievement Test 
d) Trade Test 
Appointment will be based on certain criteria’s like they are medically tested after that induction training should be given. After training for a period of one year or more they will be put as permanent employees. 
c) Performance Appraisal:- 
Appraisal is the evaluation of work quality or merit. In the case of IRE performance appraisal is a systematic evaluation of employees by supervisors or other familiar with their performance. 
1) Straight ranking method:- 
Under this method men as a whole are compares from other men and ranked on the basis of overall performance. 
2) Grading method:- 
Under this method certain categories of work such as excellent, very good, average, poor, very poor are established and defined actual performance of each employee then compared with the grade definitions and ranked to evaluate the performance of the employees. Last grade employees that are 8th& 9th grade, their work performance have been observed by supervisors. But in the case of executives MBO’s are observed their
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performance and efficiency. 
In IRE performance appraisal is done on a yearly basis to assess the performance of the employees. The appraisal is done by three persons. 
1. Reporting Officer. 
2. Reviewing Officer. 
3. Evaluating Officer. 
Firstly the employees themselves do an appraisal and this is given to the reporting officer and the person who has done the Key Appraisal together identifies the Key Result Areas and weightage is allotted to each one of them. This is usually done at the beginning of the year. The reporting officer checks whether the result areas set where met by the appraisal or if there any deviation from it. And this is to be sent to reviewing officer and then evaluating officer. Various other factors such as the appraiser’s managerial skills like job knowledge, interpersonal skills are also included and guided and that is allotted in the appraisal and there promotion is based solely seniority. 
Promotion: 
In IREL promotion is given seniority based or based on experience. Promotion is a transfer of an employee to a job that pay more money or that enjoys some preferred status. Sometimes the company is considering the length of the service, education, training courses completed, previous work history etc. Sometimes the company is also considered ability, hard work, co-operation, honesty etc. 
Condition for getting Promotion:- 
1. Average leave should not exist more than 15 days. 
2. Any disciplinary actions should not be taken during the service of periods. 
3. Should not apply for job in any other organisation. 
d) Salary and Wages Administration:- 
Wages in the widest sense means any economic compensation paid by the employer under some contract to his workers for the service rendered by them. 
Acts Followed: 
1. Workmen Compensation Act 1923 Sec 2(m).
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2. Payment of Wages Act 1936 Sec 2 (VI) 
3. Payment of Wages Act 1948 
PAY SCALE 
The monthly remuneration received by each of the employees including system of compensation. 
FOR WORKMEN 
Scale of Pay:- 
Grade 
Scale of Pay 
W - I 
Rs: 8340-23470 
W - II 
Rs: 8440-23750 
W - III 
Rs: 8550-24060 
W - VI 
Rs: 8670-24400 
W - V 
Rs: 8800-24770 
W - VI 
Rs: 8940-25160 
W - VII 
Rs: 9090-25580 
W - VIII 
Rs: 9250-26030 
W - XI 
Rs: 9420-28968 
Table:6.3 
FOR OFFICERS 
code 
Designation 
Pay Scale 
E-0 
Deputy Officer 
12600-32500 
E-1 
Officer 
16400-40500 
E-2 
Senior Officer 
20600-46500 
E-3 
Deputy Manager 
24900-50500 
E-4 
Manager 
29100-54500 
E-5 
Senior Manager 
32900-58000 
E-6 
Deputy General Manager 
36600-62000 
E-7 
General Manager 
43200-66000 
E-8 
Chief General Manager 
51300-73000
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e) Industrial Discipline:- 
Disciplinary actions are taken in the HR department. Procedure for disciplinary actions is on receiving a complaint about a particular employee, explanation is asked. Employee will give an explanation before 15 days. If the explanation is not satisfactory he will be given a charge sheet and will also conduct a domestic enquiry. For this purpose an enquiry officer is placed. After conducting the enquiry the report should be sent to the disciplinary committee and if necessary certain punishment may also give. 
2. INDUSTRIAL RELATION 
Most of the disputes will be settled by the company and trade unions. If it is not cleared, they can approach to the government. The Trade Unions active in IRE are:- 
1. United Trade Union Congress (UTUC) 
2. Indian National Trade Union Congress (INTUC) 
3. All India Trade Union Congress (AITUC) 
4. Travancore Mineral Workers Union (UTUC (B)) 
5. Indian Employees Rare Earth Federation (CITU) 
6. Indian Rare Earth Mazdoor (BMS) 
These are the recognised unions. There are some criteria for recognizing a union; the union will have 15% of employees as their members. Also some participative forum is present; they are plants committee, safety committee and House building committee. These committees will have the equal participation. 
3. TRAINING & EMPLOYEE WELFARE 
Training and Development:- 
“Training is the act of increasing the knowledge and skills of an employee for during a particular job”. Indian Rare Earth Ltd adopted various techniques of training for increasing the mass productivity. The training program is restructured regularly in IRE. The objective of training and development in IRE
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1. Increase the efficiency 
2. Increase the moral of the people 
3. Reduce the absenteeism 
Procedure for Training 
1. Identifying the training needs. 
The company identifies the training needs through 3 ways: - 
a. Organisation Analysis 
b. Task Analysis 
c. Man Analysis 
2 Executives themselves will discuss the training needs 
3 Charting out the training plan for a period 
4 Based on feedback individual training is given 
Training Methods 
IRE has mainly four types of training methods. 
1. In-house Training 
2. External Training 
3. Vocational raining 
4. First Aid Training 
The training method can be grouped on the basis of level of personnel in the organisation. 
1. In-house Training: - Otherwise known as on the job training. In this method expert from outside come to the organisation and give training. 
2. External Training: - Also known as off job training is given outside the organisation. 
3. Vocational Training: - At least 20% of the employees should be trained every year. 
4. First Aid Training: - 30 people in one batch and give them training.
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Employees Welfare:- 
Two types of employee’s welfare are present in IREL. They are; 
1. Statutory welfare and 
2. Non Statutory Welfare 
Gratuity, Provident Fund, Pension, Canteen, Medical Allowance is included in the statutory welfare. Festival Allowance, LTC, Recreation, Tour Facilities are included in the no statutory welfare. Also the IREL give some kind of allowances. They are; 
Shift Allowance 
For employees working in shifts expect general shifts will get anallowance as follows 
1st Shift (6 am to 2 pm) -Rs: 25/day 
2nd Shift (2 pm to 10 pm) -Rs: 15/day 
3rd Shift (10 pm to 6 am) -Rs: 35/day 
Hard Shift Allowance 
Since the plant handles sand for its production, it creates a dust in the atmosphere. Considering this hardship in work every employees of Chavara plant gets Rs: 135/-month as hardship allowance. 
Uniform Allowance 
Every employee is provided with two pairs of uniform in every year. Rs: 100/ month as washing allowances is granted for all employees. 
Transportation Allowance 
Every employee (except officers) gets Rs: 1200/- per month as conveyance allowance. Officers will get 10% of their basic pay as their Transportation Allowance. 
Canteen 
A round the clock canteen is provided for the employees. Company will charge Rs: 6/day from each employee. The canteen is under the control of company. 
Attendance Bonus 
To increase attendance in the company gives annual bonus of 12 days wages for every employee who have minimum 268 days presents.
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Production Incentives 
Every employee gets an amount of Rs: 525/ year as Production Incentive from the profit. 
Leave facilities available in IRE 
Casual Leave - 
15 days/ year 
Sick Leave 
- 
10/year (workers) 
10 full/20 half (Officers) 
Earned Leave - 
33 days (It can be maximum of 240 days) 
Surrender Leave - 
Each employee can surrender maximum 90 
Days/year or 75% of earned leave. 
Other Benefits 
 750 ml milk/ day 4 
 pears soap/month 
 One Turkey or Towel/year 
 Shoes (1 pair)/ year 
 One Umbrella/year 
 House loan up to 7.5 Lakhs 
 Medical Facilities 
 Educational Allowances to workers children 
 Festival Allowance 
 Group Insurance Scheme 
 Holiday Facility Leave Travel Concession (LTC) 
4. TIME OFFICE 
There is a full-fledged office headed by Deputy administrative officer. It follows a punch card system. Different allowances of employees are given and it is mainly depend on attendance. It is providing according to the report from the time office. The time office is working under the HRM department. The main function of this department is to maintain attendance records, leave and service records etc. The various allowances, attendance
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bonus all these records are maintained by the time office department. Also yearly attendance bonus is given to the employees. 
Attendance of 265 days/ year -12 day’s salary 
Attendance of 262 days/ year -10 day’s salary 
Attendance of 243 days/ year -7 day’s salary 
Structure of the time office as follows; 
Fig:6.1.1 
For recording attendance punching system followed here. The attendance register usually keep in time office. The time office collects attendance from concerned authority also and match with the punching system and avoiding swapping. Time office has three centers for punching in convenience of employees. In mining area, in dredging plant also keep mechanical punching machine. For the purpose of salaries the time office is sending the records to the finance department. If the finance department asks for any clarification they will do it. 
HOD(HRM) 
SECTION HEAD(TIME OFFICE) 
TIME OFFICE(PERSONNEL)
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TRANSFER POLICIES OF IREL, CHAVARA 
Transfer is the movement of an employee from one job to another without involving any substantial change in his duties, responsibilities. The company is following 4 methods. 
1. Production Transfer:- 
When a particular department or job is faced with the pressure of works, its strength may supplement through from other departments. Such transfers are generally made where any department is overstaffed and other is short of manpower. 
2. Replacement Transfer:- 
A replacement transfer is the transfer of a senior employee to replace with a junior employee or new one. 
3. Shift Transfer:- 
When units in shifts,employees are transferred from oneshift to another on similar job. 
4. Department Transfer:- 
Transfer from one department to another within the plant or within the organisation.
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MINING DEPARTMENT 
In IRE the raw materials for production process are collected through mining process. The production process starts with the collection of beach sand from various places. For collecting this beach sand IRE uses the following two methods: Sea Washing and Dredging. 
SEA WASHING 
Raw sand is collected from sites where deposits are occurred due to natural beach washing. Presently IRE owns two sites one at Vellanathuruthu/Ponmana and one at 132 mining area. There is a heavy mineral deposit over a length of 22.5 Km. They are found over or coastal belt having an average width of 800 meters. The sea waves deposits the minerals sand on the beach line and it is collected. Then it is send to the mineral separation plant. 
DREDGING 
The plant DWUP used for the mechanised recovery of minerals from the beach sand. The DWUP consist of a floating dredging plant operating hydraulically and electrically which could be moved from one place to another based on the requirement. The plant is floating in an area having a water depth of 6 meters. The sand along with water in the form of slurry (a mixture of sand and water) is pumped to the heavy Upgradation equipments. The equipment consist of a series of transfer bin rotating screens called Trommer, Spiral Separators, Hydro cyclones, pumps etc all being electrically operated. The DWUP can dredge about 40 to 60 tons per hour. The raw sand having an average at 40% heavy minerals is fed to the floating plant and updates it to 85 to 90% mineral content. The waste sand (Quarts) from DWUP is usedfor backfill the dredged area.
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DEPARTMENT STRUCTURE – MINING 
Fig:6.2
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PRODUCTION DEPARTMENT 
The act of making goods and services is called production. In everyday speech ‘Production’ refers to the act of creating something production involves the physical conversion of raw materials into tangible goods. 
In IRE raw sand is collected through mining process .The sand is filtered through spirals, cones and jigs to produce a bulk concentration of heavy drying, screening, electromagnetic and electrostatic processes and used for separation. Minerals found in coastal areas are collected either manually or mechanical means, productions starts from the mining process. 
DEPARTMENT STRUCTURE – PRODUCTION 
Fig:6.3
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MINING PROCESS 
The mining and processing of beach sand are achieved with a good mixture of modern mechanical devices and manual labour. Beach sand is collected from the surface of a depth of a meter with the help of dredgers. For a processing of beach sands, the difference in electric conductivity, magnetic susceptibility and specific gravity of their constituents are taken into consideration. The beach sand is treated by well gravity methods using spiral, cones and jigs to produce minerals. 
IRE collects raw sand in two different ways: 
1. Sea washing or beach washing 
2. Mechanical dredging 
MINERAL RECOVERY PLANT 
The mineral recovery plant consists of a floating dredging plant which could be moved from one area to another. This is called floating mineral recovery plant. The plant is placed in an area which has a water depth of 9 meters. The sand along with water is sucked into the main unit. First the mixture is send to a storage tank called Trammel. Then it is sending for separation. The waste sand and some quantity of water is pumped out. The mineral content is pumped from the MRP to concentrate Upgradation plant. The MRP dredges about 40-60 tones per shift. 
CONCENTRATE UPGRADING PLANT (CUP) 
The raw sand collected from different sources had different composition. They are further upgraded using the CUP. In the Concentrate Upgrading Plant enriches the concentrate from various sources to above 90% heavy minerals using spiral separators making use of gravity techniques. 
MINERAL SEPARATION PLANT (MSP) 
In the mineral separation plant individual minerals are separated making use of the following four properties of the minerals namely
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1) Electrical conductivity 
Electrostatic separation is used in electrical conductivity. 
2) Magnetic Susceptibility 
High and low intensity magnetic separators used. 
3) Density Difference 
Floater separation 
4) Surface Property 
Froth floatation. 
The concentrate from concentrate upgrading plant (CUP) having uniform composition with above 90% heavy minerals content is dried using Fluidised Bed Drier (FBD). This is then subjected to electrostatic separation using different type of electrostatic separators. There by it is separated into two fractions namely conducting and non- conducting fractions. 
PRODUCTION CAPACITY OF CHAVARA PLANT 
Ilmenite 
200000 tones 
Rutile 
114500 tones 
Zircon 
11750 tones 
Sillimanite 
10000 tones 
Zir flour & Microzir 
6000,300 tones 
Table:6.4
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ILMENITE: - Mainly used in the manufacture of Titanium dioxide, a white pigment by sulphate process also used in the production of synthetic Rutile and for the production of Ferro Titanium products. 
RUTILE: - Rutile used for coating of welding electrodes and also for the production of Titanium dioxide pigment by the chloride process and for the production of Titanium Tetra Chloride for the production of Titanium metal and sponge. 
SILLIMANITE: - Sillimanite mainly used in the manufacture of high temperature refractory. It is also used in ceramic industry. 
ZIRCON: - Zircon is used in foundries, ceramics and refractory. It is also used in the manufacture of zirconium chemicals, metals, alloys etc. 
ZIRCON FLOUR: - Zircon flour is used in foundries for high temperature castings. 
MONAZITE: - Monazite is used for the production of Thorium and rare earth’s base products.
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PRODUCTION PROCESS 
Fig:6.4
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QUALITY CONTROL DEPARTMENT 
IREL Chavara has got ISO 9001: 2000 Quality Systems established for mining, manufacturing and mineral products. 
One of the primary functions of the quality control department is to ensure quality products according to customer requirements. They harness beach sand in environmentally responsible manner to produce minerals and innovative value added products, which are used to make novel products required by customers. 
Secondly, they are responsible for maintaining consistant quality of products to the satisfaction of the customers through quality management system implementation. They also aim at further improvement of product, technology or process. 
The quality control department is also responsible for maintaining consistency in quality of raw materials during the processing, intermediate and finished product stages. They make use of chemical and mineralogical testing methods in each stage. 
In addition to these functions this department also conducts research and development activities to support flow shed development work and for solution to process related problems.
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DEPARTMENT STRUCTURE – QUALITY CONTROL 
Fig:6.5 
FUNCTIONS 
 To ensure that raw materials, in process and finished products confirms to specified requirements holding compliance with environment , health and safety requirements. 
 Ensuring compliance to health, safety and environmental requirements. 
INSPECTION AND TESTING PROCESS DETAILS 
Raw Sand:- 
1) The DWUP and HUP output and tailing are tested for total heavy mineral content as detailed in quality plan 
2) The raw sand feed to the QIL plant ie the dried HUP output is analysed as per quality plan. 
3) The raw sand being naturally occurring, the specifications are only desirable values. The variations in quality of raw sand do not affect the quality of final products. So no reduction of raw sand is resorted to, even if the analysis results are not as for the quality plan. 
HOD(QC) 
SH(Q C) 
Q C EXECUTIVCES 
Q C EXECUTIVES
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4) These tests are carried out only to make proper adjustments of the process parameters to set the final product of specified quality. 
In-Process Inspection 
In-process inspection of certain intermediate fraction as detailed in the quality plan is carried out as per quality plan. These process fractions are not rejectedeven if the analysis results do not confirm the desireable specifications. The inspection is only for subsequent adjustments in the process parameters. 
Finished Products:- 
1) The products under tests are identified by a yellow board indicating the date, shift and number of bags. Those products passed the tests are identified by a green board indicating date, shift and number of bags and rejected are identified as red board indicating “FOR REWORK”. 
2) Inspection and testing of finished products are carried out and records in the respective record as per quality plan. Only products confirming to the quality as detailed in the respective quality plan are taken in to stock. Rejected products are maintained with authorisation of HOD (Q.C). Inspection and test record clearly indicate whether the product is accepted or rejected.
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STORES AND DESPATCH DEPARTMENT 
The stores act as a store and supply chain, keeping inventory of the product produced on the hand and supplying requisite raw materials to the manifold department on the other hand. 
All the items in6 the IRE properly stored by this function area, including finished product inventory. It stores furnace oil, machine parts, office equipment and stationary etc. 
DEPARTMENT STRUCTURE – STORES & DESPATCH 
Fig:6.6 
Stores fall under two categories 
1. Capital Items 
2. Consumable Items 
Capital items, which give return for long term revenue items or a consumable item means that which are consumable only for a short period. 
HOD(S&D) 
SH(S&D) 
S&D EXECUTIVCES 
S&D EXECUTIVES
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Procurement of items of capital nature is to be made only after the approval by the competent authority duly verified by internal auditors with prior conclusion in the capital budget. 
Stores action is responsible for arranging procurement of all items or purchase requisitions shall from the basis for arranging procurement or other departments, complete in all respects and duly approved by the controlled authority. Stores are purchased indigenously and from foreign suppliers through the adoption it secure the most competitive tendering system is adopted to secure the most competitive tendering, the most competitive rates and eliminate chance of favour. 
The worth of production in the plant is currently between 6-7 Crores. Once in every 3 months inventory statistics is prepared and send to the head office in Mumbai. Stores follow Bin card and Cardex System. This department has three major functions as follows. 
RECEIPT: 
The consignment items are properly verified with the receipts and requested the particular department to made inspection on each items. 
STORAGE: 
The received items are stored in proper locations and preserve them until the issue. Each item has its own Bin card. The quantity received, material issued, total remaining are noted in the Bin cards. 
ISSUE:- 
The issue made in first in first out method. After the receipt of the material internal note from the department, the issues are made and same is recorded in the Bin card. 
INVENTORY CONTROLE 
Under the stores department the inventory control function is done. If excess stock is obtained, it is properly informed to the marketing department to promote sales and if any shortage obtained it is properly informed to production department to increase the
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production. Usually ABC inventory control methods is adopted in IRE Chavara for control of inventories. The principle types of inventories are: 
 Raw Material & Supply 
 Goods in Progress that is work in progress Finished Goods 
For reduction of inventories four steps are taken in the Stores and Despatch Department. They are doing computerization, codification, standardization and value addition. All the process in stores departments are computerised and inventory management software is used for this purpose. Coding is given to all inventories. For this, alphanumerical code is used. Material coding is help to realise what kind of inventories are stored. And location coding helps to find out where it is stored. By the use of standardisation, physical verification of inventories are to be done and to be check whether the invoice number and purchase order are equal. 
DESPATCH SECTION 
Despatch Section controls the transportation of the finished products o the outside company. When a customer made a complete settlement of money for purchasing of a particular product from the company the marketing department placed a delivery order to the despatch department. The despatch department then prepares an invoice and gave a copy to the customer. This department also prepares gate pass and state government declaration sheet.
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INTERNAL AUDIT DEPARTMENT 
Chief General Manager is directly looking after the functioning of Internal Audit Department. Manager (Internal Audit) is the head of the department. There are internal audit officers and administrative officers other than accountants and clerks working in this department. 
Internal audit department is not regular department in many of the companies. But in IREL this department is holding special privilege of auditing in to every accounting matters of IREL. It is functioning in accordance with finance department. It is necessary to get audit approved from internal audit department for the finalisation of anything concerned to accounts. The company management is approving all other accounts in the recommendation of this department. 
DEPARTMENT STRUCTURE – INTERNAL AUDIT 
Fig:6.7 
FUNCTIONS 
 Auditing all the financial transactions of the company. 
 Taking corrective measures to rectify audit objections. 
 Making report to Chief General Manager and Board of Directors. 
 Make sure that every deeds of finance department is in accordance with the accounting policies of the companies. 
 To participate in the functioning of store purchase committee. 
 To check the legal validity of the financial matters of projects committed by IRE Ltd. 
MANAGER 
INTERNAL AUDIT OFFICER 
PERSONNEL
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All the relevant policies of the company are as the basic policies of this department. Internal Audit Department is auditing the accounts quarterly and sending report to Chief General Manager regularly. 
RESEARCH & DEVELOPMENT DEPARTMENT 
The company has a well-equipped Research and Development facilities to support flow sheet development works and for solutions to process related problems. The laboratory is equipped with lab models of Magnetic Separator, High Tension Separators, Wet Shaking Tables and Froth Floatation Equipment etc. 
DEPARTMENT STRUCTURE – RESEARCH & DEVELOPMENT 
Fig:6.8 
FUNCTIONS 
 New product development. 
 New compound development. 
 Selection & Evaluation of alternative method. 
 Testing of new products. 
 To analysis and assist plants in problem solving. 
 Ensure quality of raw materials and finished products. 
 Maintain Quality. 
 Research & Development attempts.
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PROJECT & MAINTANANCE DEPARTMENT 
This section is looking after the projects and maintenance of technological aspects of affairs of the company. This is a section in which mechanical experts are working on different projects. This section takes over the responsibility of various projects taken up by IRE Ltd management. They are making efforts to expand the area of performance of the company. 
FUNCTIONS 
 To carry out preventive Maintenance to ensure continuous capability and to attend breakdown maintenance if any. 
 Projects on mining area of IREL. 
 Projects on technological development. 
 Project on quality assurance. 
DEPARTMENT STRUCTURE – PROJECT & MAINTANANCE DEPARTMENT 
Fig:6.9
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MARKETING & SALES DEPARTMENT 
Marketing is a social process by which individuals and groups obtain what they need and wants through creating, offering and freely exchanging products and services of value with others. It is the art of selling products. Marketing department is functioning under the control of General Manager of marketing department. 
Marketing occupies an important position in the organisation of any business unit. Marketing functions are not limited to the function of buying and selling but storage, risk bearing and after sales services etc. marketing is a vital connection link between the producer and customer. 
The marketing section in the IRE is under the direct control of chief General Manager and this section is headed by the deputy General Manager in his job. The marketing activities in the company are indirectly linked with the sales section. 
IRE has the monopoly in the field of rare earth products. IRE Ltd, Chavara is engaged in the production of minerals such as Illuminate, Rutile, Zircon, Sillimanite, and Brown Illuminate from naturally available beach sand products. It also produces value added products like Zirflour, Microzir. On specific requirements of customers the company also supplies Sillimanite powder by subcontracting. Among these Illuminate, Rutile, Zircon, Brown Illuminate are categorized as “Scheduled Minerals” for which the customer is required to obtain license from the Department of Atomic Energy (DAE) Mumbai for their purchase. 
Off late, more stress was given as the marketing activities of IRE, by the company, because of competition, which is growing in the international market and also in Indian market. A new era has been put up in the company for this purpose. 
The bye products of IRE are Zirflour and Monazite. They are mainly purchase by the Kundara ceramics for the manufacturing of ceramics. The main customers of IRE are the Government of India and other private company. The main foreign customers are USA, Canada, UK, France, West Germany, Japan etc.
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OBJECTIVES OF MARKETING DEPARTMENT 
 Maximum turnover Maximum profit 
 Maximum customer satisfaction 
 Maximum customer relationship 
The chief General Manager of IRE is having the control of topmost level in marketing department of this unit. There are four superintendents and a clerk engaged in the sales department. IRE Ltd is working under the administrative control of Department of Atomic Energy. The head office does the pricing of products. The customers of IRE Ltd are mainly heavy industries like plant, glass, refineries, ceramics etc for bulk purchases customer and provided discount. 
SALES AND DISTRIBUTION SYSTEM 
Here the organisation has been enjoying monopoly. That’s the reason why they don’t want to make a distribution network. Direct selling is the main system of organisation. The customer primarily pays the full amount as demand draft (DD) in advance and then the company gives the products. 
For domestic sales, order are received as 
 Through head office 
 Directly from the customers 
 Transferred from the units of IRE 
All (except Zirflour, Microzir and Sillimanite powder) are dispatched against permits obtained after payment of prescribed royalty by IRE in advance to the department if mining and geology, government of Kerala. 
Starting with general condition for sales, majority of the customers place orders directly with Chavara. Sometimes head office also fixes quota customers wise if necessary, for the supply of minerals and intimates time to time. If all the formalities are completed delivery instructions are given by the sales department to stores for delivery of the materials to the customers. 
Exporting 
Exporting contract between the seller (IRE) and the buyer (customer) is finalized at
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the head office and intimates Chavara regarding the export contract along with the copies of agreement, purchase order, proposed loading schedule and many other specific instructions for the execution of the order. Chavara sends samples and product specification to the customer if required by head office/ buyer. 
Exporting carried out through Neendakara but now its through Cochin port (Bagged Cargo only) shipment through Cochin port is done by C&S agents appointed by seller. 
Pricing 
Pricing is a very crucial decision in marketing management. The objective of the firm is to get maximum profit. This depends upon the correct decision in pricing. Pricing refers to the process of fixing the price (money value) of a product or service; pricing is an important function in marketing because it determines the sales volume and the amount of profit. A product is acceptable to the customer when it is reasonable priced. A sound pricing policy helps to satisfy customers and to yield profit. Determination of price is influenced by large number of factors such as cost of production, degree of competition, nature of the product, pricing objectives and policies of the firm etc. 
Samples to the customers 
Samples are sending to the customers on their request or as per the instructions from the head office for their evaluation of sustainability for their requirements. Free samples are send to the customers as per the following procedures. 
Up to 500 Gms: head of the department (marketing) intimates section head (QC) to preparesamples of required quantity along with the gate pass. 
501 Gms to 1 kg: head of the department (marketing) prior approval from the unit head andfollows the above procedures. 
Above 1 kg: head office approval with information to unit head and follows the above procedure. 
The sales department maintains the following records 
 Contract review checklist for domestic sale 
 Government of Kerala department of mining and geology and advance remittance and corresponding permit register.
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 Quotations 
 Performa invoice 
 Payment registers 
 DAE license register 
 Priority registers 
 Delivery registers 
 Sales register 
 Shipping register 
 Daily statement of production , sales and dispatch 
 Quarterly statement regarding export 
 Monthly report to cabinet 
 Production, sale and stock of minerals (monthly) 
 Performa for submitting quarterly export performance to federation of Indian exportOrganization 
 COB license 
 Bank receipt voucher 
 Cash receipts 
 DD register 
 Gate pass
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FINANCE DEPARTMENT 
Business finance is concerned with the acquisition and utilization of funds required to meet the financial needs of a business enterprise. Financing is the process of planning, acquiring, utilizing and controlling the funds used in any kind of business. Finance is the life blood of business. Every enterprise or company requires finance to start the work and grow. 
A company generally requires large amount of capital. A public company can raise huge capital through issue of shares. In addition to share capital it can utilize retained profit in the form of reserves. It can raise borrowed capital through denture and loans. Long term loans can be obtained from financial institutions. Short term loans are available from commercial banks. 
DEPARTMENT STRUCTURE – FINANCE 
Fig:6.10 
SOURCES OF A COMPANY 
 On the basis of time. 
 On the basis of purpose or use. 
 On the basis of source of finance. 
 On the basis of risk. 
Finance refers to money, cash or hand available for the operation of business. Finance may do defined as the requirement of funds wanted. It is the life blood of business activity. The business pulsates with life only through finance. Finance refers to money, 
HOD(FINANCE) 
SH(FINANCE) 
FINANCE EXECUTIVCES 
FINANCE EXECUTIVES
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cash or hand available for the operation of business. Financial management will include planning, organising, directing and controlling. 
The main functions of this department are:- 
 To collect all the receipts and make all the payments. 
 To record all the transactions and prepare the final accounts. 
 Maintain the accounts as per the provisions of the section 20(g) of the Companies Act 1956. 
 Provide depreciation at the rate prescribed in schedule 14 of the Companies Act 1956, on a straight line method. 
 To account excise duty on goods manufactured when it is dispatched. 
 To ascertain the accrued gratuity liability of the company on the date of balance sheet. 
 To value finished goods at cost or market price whichever is lower, stock of raw materials, spares and chemicals are valued at weighted average method. 
 Treat the claims against the company which are not admitted as contingent liability. 
CHIEF GENERAL MANAGER 
The finance department is headed by the Chief General Manager (Finance). A Deputy General Manager (Finance) is there to assist the Chief General Manager in the operations of the department. In addition to them the department consists of 3 senior finance officers, 8 deputy officers and attenders. 
AUTHORITY, RESPONSIBILITIES AND ROLES:- 
AUTHORITY 
 Approval of policy, objective and targets. 
 Approval of apex manual. 
 Defining responsibilities and authority of head of departments, management representatives. 
 Authorizing various committees 
 Approval training programs of financial commitment. 
 Authorization of decision taken at review meeting such as safety and environmental protection committee, environment management customer service and complaint
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redeemed and protection meetings. 
RESPONSIBILITIES 
 Overall responsibility for health and safety of IRE, Chavara unit. 
 Claiming the review meetings. 
 Responsibility of the head office from time to time. 
 Ensuring that unit has organized celebration including those related to health, safety and environment through concerned department. 
 Providing resources for the implementation main tenance and continued improvement of management systems (in consultation with HO required). 
 Implementation of directives received from HO / statutory agencies. 
 Ensuring smooth progress of project (including feedback of HO on the program). 
ROLES 
 Ensuring smooth day to day functioning organisation through concerned HOD / section head. 
 Role as head of the unit in the health, safety and environment related celebration. 
 Participation in emergency evaluation (Both mock / actual) 
 Compliance to safety related requirements including use of personal protection equipment as a role model for others.
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MEDICAL DEPARTMENT: 
An effective and efficient medical department is functioning in IREL Chavara. Every family member of the employee is eligible for free attendance and treatment in the dispensary. Cases beyond the scope of the dispensary will be referred to major hospitals which are centered in Kollam and Karunagappally. The whole payment is such cases are done by the company itself. The dispensary is working around the clock. 
FUNCTIONS 
 To carryout medical examination of employees and their family members. 
 Examining compliance to environmental requirements. 
Senior Manager (Medical) is the top most authority of the Medical department. Senior Manager is followed by a Section Head/Lady Doctor. The department comprises of two Doctors, three Pharmacists, three Nurses/Compounders, Laboratory Technician and an Ambulance Driver. 
DEPARTMENT STRUCTURE - MEDICAL 
Fig:6.11 
PROCESS INVOLVED IN MEDICAL DEPARTMENT 
1) Out Patient Service: 
a) Employees and their departments are provided free medical services. For this each employee has been allotted a personal dispensary file in which name of the dependants are included as per the family card issued by the welfare department. Proper recording of the ailment, investigation and treatment of the
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employees and the dependants are entered in the personal dispensary file. Unfit and fit certificate are issued by the medical officers in the prescribed form for availing sick leave and for rejoining the duty after sick leave. 
b) Patients who require specialist’s opinion/ detailed investigation are sent to recognised hospitals/govt. hospitals/ approved laboratories with a reference letter. List of approved hospitals/ laboratories as approved by HO is maintained by HOD (Medical). Patients are taken to recognised hospital only with the reference form issued by medical officer. In the absence of company medical officer, patients are issued a temporary reference card valid for one day by the duty Pharmacist/Nurse for immediate admission incase of emergency and within 24 Hrs the reference card issued by the medical officer is to be collected by the employee. 
2) Occupational Health Service (OHS): 
Pre-employment Medical Examination:- 
Normally recruited employees before joining are directed to undergo a medical examination by the medical officer. Medical examination is carried out as per the pre- employment medical examination report. The pre-employment medical examination report is send to the HOD (HRM) for implementing the recommendation of the HOD (Medical). 
3) Periodical Medical Examination 
In accordance with Atomic Energy Regulatory Board (AERB) periodical medical examination for all canteen workers and clarified radiation workers is carried out once in a year and for other radiation workers and other general workers, it is carried out once in five years. Employees aredirected to HOD (Medical) as per the list notified by the Administrative section. These who are exposed to high noise, loss of hearing bent are also conducted and feedback is given to the concerned department. 
4) Pre-retirement Medical Examination 
Concerned employee is given intimation from administration section at least two months before the date of retirement to carryout pre-retirement medical examination
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with a copy to HOD (Medical). Based on this, medical examination is carried out one month before the retirement of every employee and necessary advice is given to the employee for his future health maintenance. 
SECURITY DEPARTMENT 
Security of the company assets and premises is vested in the hands of the staffs of security department. The department is lead by Security Manager and he is assisted by 6 Head Security Officers and 26 Security Guards. 
DEPARTMENT STRUCTURE – SECURITY 
Fig:6.12 
FUNCTIONS 
 To give security to the company and its assets. 
 To monitor the entry of employees and visitors. 
 According to ISO procedures they maintain the discipline of the employees, their uniform etc. 
Two major threats presents in IREL are sabotage and theft. To prevent sabotage there is a control room and it accessible at every time. In case of emergency the systems will automatically shut down and emergency alarm will blow. At that time all the employees are required to assemble in the assembly points. Another security problem faced by IREL is theft. There is no clear boundary wall for the company. This may encourage persons to take away company assets without permission. 
HOD(SECURITY) 
SH(SECURITY) 
SECURITY GUARDS
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SAFETY AND ENVIRONMENT DEPARTMENT 
In the present day industrial scenario all the industries had acceptedthe fact that safely improves productivity.IREL Chavara has always been in the forefront in ensuring safety,welfare and better working environment to all its employees. Their safety slogan is“Let everyday be a safe day” 
DEPARTMENT STRUCTURE – SAFETY & ENVIRONMENT 
Fig:6.13 
MISSION AND POLICY OF THE DEPARTMENT 
MISSION 
The mission of IREL is to be a major supplier of beach sand minerals and rare earth compounds in the domestic and international market, develop and produce chemicals of strategic importance, value addition with due regard to resources utilization and safety protection. 
Consistent with this mission, IREL envisages a safety and environment protection policy that provides a safety working environment to prevent injury and ill health to its employees. It also ensures environmental protection by minimizing environmental input that may arise from its operations and provide appropriate environmental plans to maintain ecological balance and above all recognizes the use for safety culture man organisation to enhance the awareness and commitment of all employees to safety.
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POLICY 
IREL purpose to update and review the safety policy periodically taking into consideration its industrial experiences advances in the technology and regulatory requirements. 
ENVIRONMENTAL POLICY 
 IREL Chavara is committed to protect, conserve and improve the environment in which it operates for the continued existence in the business throughout 
 Conservation of natural resources 
 Minimising pollution 
 Compliance to applicable environmental rules and corporate guidelines, periodical health monitoring of employees and creation of environmental awareness among employees, customers and suppliers. 
SAFETY GUIDE 
IREL Chavara follows strict safety guidelines, which are given in the company’s safety guide. Safety team will update the safety guide as per the requirement to throw more clear light on the processes as well as equipments engaged in the plant, including procedures to ensure the safety of both men and machinery. 
There are Do’s and Don’ts enlisted in this guide and this will be quite helpful in averting the slightest possibility of accidents. 
SAFETY GUIDELINES 
In order to achieve the policy objective certain guidelines are used some of them 
are as follows. 
CORPORATE LEVEL SAFETY 
 An officer of the rank General Manager to co-ordinate at the corporate office all safety environment and training activities of various units and takes necessary steps for effective implementation of this policy. 
 GM (S&E) assisted by three senior officers at the head quarters on each of the safety, environment and training. 
 The corporate safety setup has been provided with adequate administration /
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financial support for coordinating safety policy. 
 He liaisons with various outside agencies like Atomic Energy regulatory board SARCOP health, physics division of BARC, DGM of mines safety, ministry of environment and forest etc for fulfilling the statutory requirements. 
 He assesses the training needs for various areas and granges for different categories of employees. 
 He interacts with safety teams / experts for carrying out safety audit / environment audits and assessment of safety performance for award of shield etc. 
UNIT LEVEL SAFETY SETUP 
 The head of each unit will be executive director / chief / GM. 
 He will be ex-office chairman of the plant level safety and environment protection committee which will review the monthly safety status of the plant. 
 He will implement all the applicable statutory provisions of safety and environmental control in the unit. 
 He will nominate senior level officer as safety and environmental control officer who will look after the safety and environmental control aspects of the unit. 
 He will ensure that operating procedures are followed strictly and technical specifications are not violated. 
SAFETY AND ENVIRONMENTAL PROTECTION COMMITTEE 
 The term of members of the committee will be two years and the committee members will be meeting once in a month. 
 The committee will organize safety day / environmental day / fire day and mines safety week annually and hold competition among the employees relating to safety and environment during the celebrations. 
 The committee will discuss the measures against the unsafe conditions and
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practices in the mine / plant as pointed out in the report of workmen’s inspectors. 
 The committee will consider safety and health measures to be taken before commencement of operations of any new electrical / mechanical equipment proposes. 
 Summary of minutes of the meeting will be sent to the GM (S&E) regulatory. 
STANDING ORDER FOR WORKMEN CONCERNING SAFETY 
IREL standing orders for workmen also envisages the safety of the organizationand relevant clauses. 
PERSONAL PROTECTIVE EQUIPMENTS 
It is divided into two categories 
 Personal protective equipment for the various parts of the body i.e. head, eye, ears, face, hand, arms. 
 Respiratory protective equipment required when workers exposed to atmospheric contaminants like dust, fuel, gases and chemicals let off in the air in the dangerous concentration. 
PROTECTION EQUIPMENTS USED ARE 
 Head protective 
 Respiratory protection devices 
 Safety belts and lifelines 
 Safety shoes 
 Dust respirators 
 Eyes and face protection 
 Ear muffs 
 Aprons 
 Gloves
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PURCHASE DEPARTMENT 
The main function of purchase department is procurement of materials at competitive price. All items including real materials other than raw sand are purchased by this department. In IRE Ltd the purchase department had prime importance. 
Formalities of purchase 
 Float enquiry to the right source 
 Scrutinize quotation 
 Obtaining approval of the finance department 
 Release an order 
 Follow up receipt at the store 
 Assistance to give payment in time 
Formalities of placing an order 
 Origination of intent 
 Tender enquires 
 Opening of tender on the data mentioned 
 Analysis of all tender 
 Technical evaluation of the tender 
 Selection of the best one 
 Negotiation with the party needed 
 Approval of the selected tender 
 Order placing 
 Follow up
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CIVIL DEPARTMENT 
Maintenance has a direct impact on everything that affects the overall health and welfare of the organisation. A sound maintenance strategy should therefore be considered a valuable tool used to assess equipment capability and the continuous improvement efforts of asset performance. 
Civil department consist of deputy manager (civil), two deputy officers and the work force. They frequently monitor company structures and maintain them properly. In case of new projects, the base infrastructure has to be erected by this department. 
DEPARTMENT STRUCTURE – CIVIL 
Fig:6.14
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CHAPTER 7 
SWOT ANALYSIS
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STRENGTHS 
 Highly skilled managers and experienced workmen having excellent knowledge and experience about mining and production process. 
 Constant Upgradation of technology. 
 A strong and symbiotic relationship between the top level management and the lower level employees. 
 Technological collaboration with the Australian company, ROCHE, one of the largest mineral technology providers in the world. 
 Abundance of raw materials in the company premises itself. 
 Support from government of India and the department of atomic energy. 
 High concern towards the employees and environment. 
WEAKNESS 
 Mining problem. 
 Diminishing supply of raw sand. 
 The inability of the management to control effectively, the resistance raised by the local people in resource crises. 
 Excess number of civil workers. 
 High labour charges. 
 Due to monopoly promotional activities are less. 
 Decision making process is highly time consuming and complicated. 
 Shortage of power
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OPPORTUNITIES 
 High demand for products. 
 Growing demand for Titanium, Zircon, Thorium, Rutile, Ilmenite in international market. 
 Faster growth rate of markets in Asian countries where extraction facilities are limited. 
 The recent efforts to tie-up with other mining companies like KMML, Chavara 
 The favorable state government policies like prohibiting the entry of private companies into the mining sector. 
 As a strategically important company it is always backed by the central government. 
THREATS 
 Entry of private players such as TATA group into the area of black sand mining. 
 Over intervention of external political groups in company affairs. 
 Fluctuating in the value of currency which adversely affects the export income. 
 Increasing transportation cost. 
 Protect form environment activists. 
 Rapid technological changes in production process. 
 Changes in government policies.
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CHAPTER 8 
PORTERS FIVE FORCE MODEL
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RIVALRY BETWEEN SUPPLIERS 
 In the current scenario IREL is free from rivalry between suppliers. 
 As beach sand is the raw material for IREL, there is no chance to depend external suppliers. 
 IREL has a mining area of 20 km from neendakara tokayamkulam, and mining is done by the mining department of IREL. 
BARRIERS TO ENTRY/THREAT OF NEW ENTRY 
 IREL, incorporated in the year 1950 at Mumbai and chavara plant opened in the year 1970. 
 For the last thirty nine years IREL chavara could make its own demand in the industry. 
 Q –grade is considered as the first quality in all over the world.hence opening barrier is nil in the case of IREL. 
BUYER POWER 
Major buyers are 
 Cochin minerals & rutile ltd 
 Travancore titanium products 
 Tum chemicals ltd 
 Tuticorinkolmak chemicals ltd,Kolkata 
Because of high requirement of heavy minerals for the buyers IREL can maintain the demand of the products above benchmark more and more companies are opened in plastic and paint industry as the result of globalisation .hence buyers policies is less,and it is an advantage for IREL.
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SUPPLIER POWER 
For IREL ,the supply of raw material is done by its own mining department so the influence external suppliers are nill hence supplier power is favourable to IREL. 
THREAT OF SUBSTITUTES 
RUTILE,ZIRCON,MONAZITE,SILLIMANITE,ILMENITE are the major products of IREL .in these products none of them has substitutes. hence the supplier power is favourable to IREL
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CHAPTER 9 
PEST ANALYSIS
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POLITICAL ENVIRONMENT 
 Influence of political trade unions in IREL –labor unions are well co-operate with the management to achieve the common objective of the organisation. 
 Environmental policies of state and central government are opted to ensure healthy environmental condition .so IREL is forced to keep eco- friendly standards for mining and related process. 
 Ten policies is favourable to IREL. 
 The stable political conditions in state and central government are favourable to IREL. 
ECONOMIC ENVIRONMENT 
 The effect of inflation did not directly affect the sales volume because of the constant demand of its products. 
 In the present scenario, the exchange rate of Indian currency is comparatively steady ;it will be an advantage for Indian industries. 
SOCIAL ENVIRONMENT 
 IREL gives employment to hundreds of people directly or indirectly.so IREL has a good acceptance among local society. 
 People in the coastal regions make some problems when new mining process opens. 
 It is difficult to attach those lands because of the interference of local leaders who are argued for environment protection.
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TECHNOLOGICAL ENVIRONMENT 
 Technological factors are favourable to IREL .because IREL uses modern machinery for production. 
 The internal communication system of IREL is most modern.that include WIFI network,remote accessing&voip.it helps the managers to maintain healthy and effective administration.
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CHAPTER 10 
FINDINGS, SUGGESTIONS & CONCLUSION
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FINDINGS 
 The intervention by the external policies parties continues to be a disturbance in formulating labor practices. 
 IREL had strong and symbiotic relationship between the top level management and lower level employees. 
 The company had a strong financial position. 
 Constant upgradation of technology. 
 IREL had a good support from government of INDIA and the department of atomic energy. 
 Since, IREL is a monopoly the promotional activities are less. 
 Unavailability of land for the expansion of the unit capacity. 
 Higher labour charges. 
 Since the company is located 4km away from NH(national highway) the time consuming and the transportation cost is very high 
SUGGESTIONS AND RECOMMENDATIONS 
 The company can adopt different mode of sales other than the direct sales which is mainly done in IREL. 
 The government policies can change any time and so there is a possibility for the entry of privet players .so the company should always be careful to maintain its product quality ,brand identity, customer relationship etc 
 IREL should take advantage of the growing demand for heavy minerals by increasing the production. 
 The management should sustain the faith of the local people by constantly communicating and explaining the company’s policies to them. The trust of the local people can be ensured and sustained by constant interaction and communication with them. The company can achieve them by undertaking more socially responsible activities. This may be in the form of medical
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facilities running schools, assistance at the time of sea erosion and trawling ban. They can also provide water and electricity supply to the local people. 
 The company should try to minimize the external interventions of various political parties. 
CONCLUSION 
IREL is one among well performing companies in Kerala, engaged in the process of processing rare earth products available among the coastal belts. IRE is reaching new boundaries with its performance. IRE was incorporated on 18th august 1950 as a private limited company under the Indian company’s act of 1913 jointly by the government of India and the government of Travancore Cochin. In 1951, IREL became a public sector undertaking and two mineral separation plants, one at Manavalakurichi in Tamilnadu (1967) and the other at Chavara in Kerala state (1970) were setup. 
The organisation study at IRE ltd was an unforgettable experience. The organizational atmosphere prevailing at IRE is not that of a public sector unit. The concern for the environment and social responsibility are worth studying. The study helped in having a practical exposure to real practice in organisation. The study provides insight into the functioning and coordination of departments in an effective organization.
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Appendices 
BALANCE SHEET AS AT 31ST MARCH, 2013 
Year ended 31stmarch,2013 
Yearended 31st march,2012 
Year ended 31st march,2011 
EQUITY & LIABILITIES 
1) Shareholders’ Funds 
a) Share Capital 
b) Reserves and Surplus 
Total 
2) Non-Current Liabilities 
a) Other long term liabilities 
b) Long term provisions 
Total 
3) Current Liabilities 
a) Trade payables 
b) Other current liabilities 
c) Short term provisions 
Total 
TOTAL OF EQUITY & LIABILITIES 
ASSETS 
1) Non-Current Assets 
a) Fixed Assets 
(1) Tangible assets 
(2) Intangible assets 
(3) Capital work-in-progress 
Total 
b) Non-Current Investment 
c) Deferred Tax Assets (Net) 
d) Long Term Loans and advances 
e) Other Non-Current Assets 
Total 
2) Current Assets 
a) Inventories 
b) Trade receivable 
c) Cash and bank balance 
d) Short term loans and advances 
e) Other current assets 
Total 
TOTAL OF ASSETS 
8636.50 
65054.35 
73690.85 
5414.01 
4616.81 
10030.82 
1122.56 
10107.83 
14552.22 
25782.61 
8636.50 
53139.57 
61776.07 
5515.31 
3934.95 
9450.26 
1031.54 
7041.15 
12569.81 
20642.50 
8636.50 
40104.33 
48740.83 
5397.70 
2451.16 
7848.86 
1011.46 
6851.74 
4514.55 
12377.75 
109504.28 
91868.83 
68967.44 
16323.20 
35.74 
9796.51 
26155.45 
1.42 
5488.20 
4226.50 
1827.05 
11543.17 
13140.49 
192.19 
52781.18 
3662.07 
2029.73 
71805.66 
17773.93 
34.64 
2624.80 
20433.37 
1.42 
4002.46 
5035.40 
511.53 
9550.81 
6822.13 
237.71 
50847.82 
1723.01 
2253.98 
61884.65 
19146.66 
20.89 
1355.03 
20522.58 
1.42 
1300.43 
4412.89 
3020.46 
8735.20 
4572.71 
180.14 
31342.02 
1523.45 
2091.34 
39709.66 
109504.28 
91868.83 
68967.44
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STATEMENT OF PROFIT AND LOSS FOR THE YEAR ENDED 31ST MARCH, 2013 
Year ended 31st march, 2013 
Year ended 31st march, 2012 
Year ended 31st march, 2011 
REVENUE 
a) Revenue from operations 
b) Other income 
TOTAL REVENUE 
EXPENSES 
a) Cost of material consumed 
b) Charges in inventories of finished goods, Work-in- progress and stock-in trade 
c) Employee benefits expenses 
d) Finance cost 
e) Depreciation and amortization expenses 
f) Other expenses 
TOTAL EXPENSES 
Profit before prior period adjustments (net), exceptional items, extraordinary items and tax 
Prior period adjustments (Net) 
Profit before exceptional items, extraordinary items and tax 
Exceptional items 
Profit before extraordinary items and tax 
Extraordinary items 
Profit before tax 
Tax expenses 
a) Current tax 
b) Deferred tax asset(or liability) 
PROFIT FOR THE PERIOD 
52765.79 
6617.22 
59383.01 
2890.00 
(6087.08) 
19876.05 
800 
1907.71 
15321.44 
34709.03 
24673.98 
63.53 
24610.45 
866.09 
23744.36 
- 
23744.36 
9571.48 
(1485.74) 
63218.22 
4897.28 
68115.50 
3612.94 
(1805.94) 
19920.03 
141.38 
2063.37 
14498.98 
38428.76 
29686.74 
391.53 
29295.21 
4311.10 
24984.11 
- 
24984.11 
10641.22 
(2702.03) 
39975.91 
3031.53 
43007.44 
3767.16 
1776.35 
17549.09 
150.869 
2025.11 
12379.85 
37648.25 
5359.19 
115.45 
5243.74 
- 
5243.74 
- 
5243.74 
1260.78 
793.60 
15658.62 
17044.92 
3189.36
Organisation Study on IREL Chavara 90 
DC School of Management and Technology | Trivandrum 
BIBLIOGRAPHY 
1. C.R. Kothari – Research Methodology methods and Techniques. 
2. Prasad L.M – Principals and practice of management. 
3. Kottler Philip – Marketing Management. 
4. Rejimon.P.M – Indian rare earth is going to expand. 
5. Rejimon.P.M – 50 Crores rupees expansion program in IRE. 
6. IREL Broucher – Apex manual and departmental procedures of IREL. 
7. http://www.indianrareearths.com 
8. http://www.irel.gov.in 
9. Annual Reports and Journals

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ORGANISATION STUDY @ KOLLAM IREL(KERALA UNIVERSITY)

  • 1. Organisation Study on IREL Chavara 1 DC School of Management and Technology | Trivandrum Summer Internship Program On Organization Study of INDIAN RARE EARTHS LIMITED, CHAVARA AKHIL P U (Reg. no. 13460007) MBA 2013-15 KERALA UNIVERSITY Under the Guidance of
  • 2. Organisation Study on IREL Chavara 2 DC School of Management and Technology | Trivandrum Certificate (of the Institution) This is to certify that the report entitled “An organisation study on Indian Rare Earth Ltd” submitted here is a bonafide record of the work done by AKHIL P U, under the guidance and this work has not been submitted by them for the award of any other degree, diploma or title of recognition earlier. DC School of Management and Technology (sd) Date:……………………….. (Seal)
  • 3. Organisation Study on IREL Chavara 3 DC School of Management and Technology | Trivandrum Certificate ( of the Organisation) This is to certify that AKHIL P U,2nd semester MBA student of DC School of Management and Technology has done a project work on “organisation study” in our organization under the supervision of Mr Chandrasekhar, Sr. Manager safety and Environment Department during the period from 21 April 2014 to He has successfully completed the work. (Seal) (sd) Place and Date
  • 4. Organisation Study on IREL Chavara 4 DC School of Management and Technology | Trivandrum DECLARATION We, AKHIL P U 2nd semester MBA student of DC School of Management and Technology, do hereby declare that this organization study titled “An Organization Study onINDIAN RARE EARTHS LIMITED, CHAVARA”under the guidance of Mr. RAJENDRANis the result of original work during the organization study time. We have not submitted the same for the award of any degree, diploma. All the data both primary and secondary are true to the best of my knowledge . AKHIL P U Place: Kollam Date:
  • 5. Organisation Study on IREL Chavara 5 DC School of Management and Technology | Trivandrum ACKNOWLEDGEMENT First of all we wish to express my deep gratitude and thanks to God who helped us in completing the organisation study successfully. We shall remain grateful to Dr. P.S Mohana Kumar for his amble guidance and encouragement for completing the organization study. We are also extremely grateful to faculty member for their valuable suggestions and 2advice regarding this work. We are more obliged to Dr. VeeranKuttyDirector, Dc School of Management and Technology for given helpful suggestions and valuable guidance It is our pleasure to express a deep sense of grateful to Mr jayapalan(Deputy generalmanager),Mr Chandrasekhar, Sr. Manager( safety and Environment & QMSDepartment ),Mr SatyabhusanSamantaSr.Manager(Finance) without their untiring efforts and tremendous background information this work would not have materialized. We express our sincere thanks to all the staff of IREL, Chavara for their co-operation during my study in the company. Last but not least we thank to all the staff members of the DC School of Management and Technology for the encouragement rendered for the completion of the research work and also we extend our gratitude to all staff and workers in IREL, Chavara for their support in our organization study.
  • 6. Organisation Study on IREL Chavara 6 DC School of Management and Technology | Trivandrum LIST OF CONTENTS Subject Page Number Chapter 1 Introduction 9-12 Chapter 2 Industry profile 13-19 Chapter 3 Company Profile 20-24 Chapter 4 Product Profile 25-27 Chapter 5 Customer profile 28-30 Chapter 6 Functional areas of IREL 31-75 Chapter 7 Swot Analysis 76-78 Chapter 8 Porter’s Five Force Analysis 79-81 Chapter 9 PEST Analysis 82-84 Chapter 10 Findings, Recommendations, Conclusion 85-87
  • 7. Organisation Study on IREL Chavara 7 DC School of Management and Technology | Trivandrum LIST OF TABLES & CHARTS Table No Subject Page no. 2.1 World production reserves 16 2.2 Resources of Monazite in India 17 2.3 Potential RE markets 19 4.1 Product profile 26 4.2 Uses of the product 27 6.1 Manpower strength 34 6.2 Contract workers 34 6.3 Pay scale for Workers and officers 37 6.4 Production capacity of chavara plant 48 Balance sheet 89 Statement of profit and loss account 90
  • 8. Organisation Study on IREL Chavara 8 DC School of Management and Technology | Trivandrum LIST OF FIGURES Fig no. subject Page no 1.1 Corporate structure 11 6.1 Department structure -HRM 32 6.2 Department structure -Mining 45 6.3 Department structure -Production 46 6.4 Production process 50 6.5 Department structure –Quality control 52 6.6 Department structure –Stores and Despatch 54 6.7 Department structure –Internal Audit 57 6.8 Department structure –R&D 58 6.9 Department structure –Project& maintenance 59 6.10 Department structure –Finance 64 6.11 Department structure –Medical 67 6.12 Department structure –Security 69 6.13 Department structure –Safety& Environment 70 6.14 Department structure -Civil 75
  • 9. Organisation Study on IREL Chavara 9 DC School of Management and Technology | Trivandrum CHAPTER 1 INTRODUCTION
  • 10. Organisation Study on IREL Chavara 10 DC School of Management and Technology | Trivandrum INTRODUTION Each and every organisation has its own importance in the economic wealth of the nation. Different organisation meets different needs of people by offering different products and services. Due to globalisation the world has changed into a global village. In this fast and changing business scenario, it is imperative for every entrepreneur to have a vivid understanding of the functional application of the new age business. As a part of the academic curriculum each student has to undertake an organisational study to get practical exposure. This study is conducted at Indian Rare Earths Limited, Chavara. IREL Chavara is located 10 km north of Kerala and 85 km from Trivandrum, capital of Kerala and 135 by road from Cochin is perhaps blessed with the best mineral sand deposit of the country. The plant operates on a mining area containing as high as 40% heavy minerals and extending over a length of 22 kms in the belt of Neendakara and Kayamkulam. The deposit is quite rich with respect to Ilmenite, Rutile and Zircon and the mineral Ilmenite happens to be of weathered variety analysing 60% Titanium Dioxide (TiO2). The present annual production capacity of Chavara unit engaged in dry as well as wet (dredging / Up gradation) mining and mineral separation stands at 2,00,000 tonsof Ilmenite, 1,14,500tons of Rutile, 11,750 tons of Zircons and 10,000 tons of Sillimanite. In addition to that, the plant has facilities for annual production of ground Zircon called Zirflour and Microzir of the order of 6,000 tones and 300 tonsrespectively. IREL Chavara is one of the oldest and leading public sector undertakings under the Department of Atomic Energy (DAE). It is an ISO 14001: 2000; OHSAS 18000 certified company supplies beach sand minerals to the foreign and domestic market. It caters the requirements of developed countries like U.S.A, U.K, Germany, Australia, Japan etc. The major mineral products of IREL are Ilmenite, Rutile, Sillimanite and Zirflour.
  • 11. Organisation Study on IREL Chavara 11 DC School of Management and Technology | Trivandrum CORPORATE STRUCTURE Fig:1.1 RESEARCH DESIGN A research design is a plan of the proposed research work. The research designs simply a specific presentation of the various steps in the process of research. Design means adopting that type or technique which is most suited for the research and study of the problem. It is a plan, structure and strategy of investigation conceived so as to obtain answers to research questions and to control variance. OBJECTIVE OF THE STUDY The main objective of the study is to familiarize with the organisational functions in the organisation, there are many other minor objectives also. They are the following:-  To understand about how an organisation’s system is performing.  To know about various departments and their functions in an organisation.  To study the managerial activities performed in an organisation.  To know how an organisation coordinates its activities.  To get a practical exposure as the future manager. OSCOM Plant Orissa Corporate & Registered Office at Mumbai Rare Earths Division Udyogamandal Mineral Division Manavalakurichi Mineral Division Chavara
  • 12. Organisation Study on IREL Chavara 12 DC School of Management and Technology | Trivandrum SCOPE OF THE STUDY The scope of the study is to know about the organisation, its structure, the functions performed by various departments and to know the overall performance of the organisation. The study will help the management students to get a practical exposure. METHODOLOGY Both primary and secondary data were used for this study. 1. Primary Data:- The primary data can be obtained either through observation or through direct communication with respondents in one form or another or through personal interviews. There are several methods for collecting primary data. They are observation method, interview method, through questionnaire, through schedule etc. Here primary data were obtained from direct interviews made on with managers, officers and workers of the firm. 2. Secondary Data:- Secondary data means data that are already available ie: - they refer to the data which have already been collected by someone else. Here secondary data were collected from company brouchers, manuals and other records LIMITATIONS OF THE STUDY  The study is limited to my experience and knowledge.  Lack of availability of secondary data from published journals and reports.  Secrecy of the organisation prevents them from giving some of the details regarding the firm.  Employees were busy in their work so they could not give more information.  There may be errors due to the bias of the respondents.  Time is a major limitation in the course of study.
  • 13. Organisation Study on IREL Chavara 13 DC School of Management and Technology | Trivandrum CHAPTER-2 INDUSTRY PROFILE
  • 14. Organisation Study on IREL Chavara 14 DC School of Management and Technology | Trivandrum INDUSTRY PROFILE Rare Earth Elements or Rare Earth Metals are a collection of 17 elements namely scandium, yttrium and lanthanides (15 elements in the periodic table with atomic numbers 57 to 71 namely: lanthanum (La), cerium (Ce), praseodymium (Pr), neodymium (Nd), promethium (Pm), samarium (Sm), europium (Eu), gadolinium (Gd), terbium (Tb), dysprosium (Dy), holmium (Ho), erbium (Er), thulium (Tm), ytterbium (Yb) and lutetium (Lu)). Rare earths are not rare in the sense of their abundance, but have earned this descriptive because they are rarely concentrated enough for an easy recovery from their ores. In India, monazite is the principal source of rare earths, which is a prescribed substance as per the notification under the Atomic Energy Act, 1962. Indian Rare Earths Limited (IREL) has been the sole producer of Rare Earth compounds in the country. The recovery of Rare Earth Elements (REE) from Monazite has been restricted due to its thorium and uranium content. There is a need for concerted efforts both by GSI and AMD to explore other primary sources of Rare Earth Elements. In the face of competition from China and due to lack of domestic demand for indigenous materials, IREL had stopped its production. Given the concerns over China’ s flexing of its muscle on the international stage by restricting Rare Earths exports, a wave of Mining projects are revived worldwide to tap sizeable deposits of Rare Earths. IREL is also planning to restart production of REE. Keeping this in view and increasing demand of these metals for high tech applications, Ministry of Mines has stressed the need to incentivize exploration & process R&D for creating indigenous production capacities. To achieve this, a high level Steering Committee has been constituted to look into the current availability of Rare Earths and to suggest short, medium and long term strategies for exploration, production and processing, to ensure long term availability of the raw material
  • 15. Organisation Study on IREL Chavara 15 DC School of Management and Technology | Trivandrum WORLD SCEANARIO OF RARE EARTH ELEMENTS (REEs) There is large amount of reserves of rare earths minerals in the world. China holds the leading position among producers of the rare earths elements or lanthanide elements. Rare earths are also produced in India, Russia, Kazakhstan, Kyrgyzstan, Thailand, Malaysia, Russian Federation, Brazil, Canada, Vietnam, South Africa, Indonesia, Sri Lanka, Mongolia, North Korea, Saudi Arabia, Turkey, Norway, Greece, Nigeria, Kenya, Tanzania, Burundi, Madagascar, Mozambique and Egypt. Most recently, it was discovered that Afghanistan may have large deposits of rare earth metals, estimated to be worth US$89 billion. The rare earth deposits are on the south bank of the Helmand River in southern Afghanistan. Given the concerns over China’ s flexing of its muscle on the international stage by restricting Rare Earth exports, a wave of Mining projects are reviewed worldwide to tap sizable deposits of Rare Earth. LynaCorporation’s new mining operation in Australia and Molycorop’s plan to restart Mothballed Mountain Pass Mines is a step in this direction. It has also encouraged further exploration and spurring more recycling of Rare Earths.
  • 16. Organisation Study on IREL Chavara 16 DC School of Management and Technology | Trivandrum The World production and reserves of Rare Earth Elements are given in table. Table:2.1Rare Earth Elements – World Production and Reserves (2009) INDIAN SCENARIO In India, monazite is the principal source of rare earths and thorium. The mineral monazite is a prescribed substance as per the notification under the Atomic Energy Act, 1962. AMD has been carrying out its resource evaluation for over five decades. It occurs in association with other heavy minerals, such as ilmenite, rutile, zircon, etc. in concentrations of 0.4 - 4.3% of total heavies in the beach and inland placer deposits of the country. The resource estimates of monazite in the beach and inland placer deposits have been enhanced from 7.90 million tonnes in 2002 to 10.21 million tonnes in 2005. Country Mine Production (tonnes) % of production Reserves (million tonnes) % of Total reserve United States 0 (no rare earth mining) 0 13.0 13 China 120000 97 >36.0 36 Russia (and other CIS countries) small <1 19.0 19 Australia small 0 5.4 5 India 2700 2 3.1 3 Brazil 650 <1 small Malaysia 380 - small Other 270 - 22.0 22 Total 124000 >99.0
  • 17. Organisation Study on IREL Chavara 17 DC School of Management and Technology | Trivandrum The state wise resources are given below: All India 10.21 Andhra Pradesh 3.73 Bihar 0.22 Kerala 1.37 Orissa 1.82 Tamil Nadu 1.85 West Bengal 1.22 Table:2.2Resources of Monazite (In million tonnes) Exploration & Development Apart from Monazite sands, India has to look for rare earths from the primarysource rocks. In India, concentration of REE in hard rock has been recorded in association with carbonatites, syenites, albitites, granites, pegmatite, apatite and phosphorites and carbonaceous schists. Geological Survey of India has carried out preliminary search for REE in carbonatite in Koraput and Kalahandi districts of Orissa. Pegmatite and the granite terrain have been covered in Bhilwara, Ajmer and Udaipur districts of Rajasthan. Carbonatites of Tamilnadu, West Bengal, Meghalaya and Assam were also sampled. So far, Bastnaesite has been reported in association with Carbonatite from Puruliadistt,West Bengal and Monazite has been reported from Carbonatite occurrence of Sung Valley (Meghalaya),Sevattur (Tamilnadu) and Samchampi (Assam).In addition GSI has to examine all the data generated from the proterozoic and younger granites andIron oxide-copper-gold (IOCG) type deposits and also their supergene/ lateriteprofiles. Proper evaluation of existing data and data generated from National Geochemical Mapping Programme can also help in locating suitable target areas for further search of REE. Field investigations carried out by AMD for rare metal
  • 18. Organisation Study on IREL Chavara 18 DC School of Management and Technology | Trivandrum pegmatites in the last few years has led to the discovery of significant raremetal pegmatites at Pandikimal, Jangapara, Bhurpidungri etc. in Jharsugudadistrict of Orissa and Kawargaon, Bodenar, Metapal, Challanpara etc. in Bastar district of Chhattisgarh apart from the known and established pegmatite fieldsof Bihar , Rajasthan and Karnataka. These pegmatites were assessed and evaluated for their economic exploitability and considerable tonnage wasproved with significant ROM grade. Some of them viz., Pandikimal, Jangaparain Jharsuguda andBodenar in Bastar district are under recovery for Columbite-Tantalite. Beryl i s also recovered as a by-product. Columbite-Tantalite from Jharsuguda area, Orissa is niobium rich whereas those of Bastar region, Chhattisgarh are tantalum rich. In Southern India, a survey by AMD has resulted in locating new pegmatitic occurrences in Holenarispur and Nagmangala Schist Belts of Karnataka. Similarly in Central India Bastar-Koraputpegmatitic belt (BKPB) and pegmatites around Limboi in Sabarkantha Dist., Gujaratis rare metal bearing. Marllagalla pegmatite in Nagamangla Schist Belts forms the single largest Nb- Ta deposit containing economic grades of Ta2O5, which has produced substantial tonnage of Columbite-Tantalite and Spodumene(lithium bearing mineral).Apart from pegmatites, the granitic occurrences of Nb-Ta minerals near Kanigiri, Prakasamdistrict, Andhra Pradesh was also located and evaluated. The carbonatite bodies of Tamilnadu and Meghalaya were reassessed for their pyrochlorecontent. Samchampi Alkali Complex in Mikir Hills of Assam is another potential area for Nb-Ta minerals. The Niobium deposit at the SamchampiCarbonatite Complex, Assam, and India extends over a considerable stretch. High content of Nb, La, Y and Zr have also been reported for the first time in rhyolitic dykes associated with Deccan basalt from Alechhills, Gujarat. The anomalous content in these rocks is due to the presence of xenotime, ilmenorutile and monazite. The non pegmatitic resources for rare metals are low and have problems of beneficiation which are being studied by AMD. Key successes for the beach sand mineral industry are:-  Increase the Ilmenite capacity to reach economic scale of production.  Value addition project in minerals and rare earths compound.
  • 19. Organisation Study on IREL Chavara 19 DC School of Management and Technology | Trivandrum  Initiate action to develop new mining areas.  Forward integrate through stake in world leader in pigment Industry likeTinfoss, DuPont or selling up a pigments plant.  Explore other mining options in neighbouring countries. Potential RE Markets Table:2.3 End Use RE required Present Status Expected (2030) Magnets for wind turbines Nd , Pr, Dy, Tb (high strength magnets have 30 % RE) 12,000 MW of wind ~ capacity ~ 50,000 MW EV, Hybrid vehicles (batteries, motor, catalytic converter) La (15 kg per car) Nd (1 kg per car), Dy, Tb, Ce Negligible EV Perhaps up to 1 million vehicles LED Y, Eu, Tb Negligible LED Being promoted by government, could reach ~ 1 million bulbs Al, Steel, Mg industry, grain refinement Ce, La , mischmetal Huge growth rate Screens brighteners (cell phone, computers, TV screen) Eu mostly imported Huge growing market Other magnets Pr, Sm, Gd mostly imported Computer hard disks, microphones
  • 20. Organisation Study on IREL Chavara 20 DC School of Management and Technology | Trivandrum CHAPTER 3 COMPANY PROFILE
  • 21. Organisation Study on IREL Chavara 21 DC School of Management and Technology | Trivandrum COMPANY PROFILE On August 18, 1950 Indian Rare Earths Limited (IREL) was incorporated as a private limited company jointly owned by the govt. of India and Govt. of Travancore, Cochin with the primary intention of taking up commercial scale processing of monazite sand at its first unit namely Rare Earths Division (RED) Aluva and Kerala for the recovery of thorium. After becoming a full-fledged central govt. undertaking in 1963 under the administrative control of Department of Atomic Energy (DAE), IREL took over a number of private companies engaged in mining and separation of beach sand minerals in southern part of the country and established two more divisions one at Chavara, Kerala and other at Manavalakurichi(MK), Tamilnadu. After a gap of 20 years IREL commissioned its largest division called Orissa Sand Complex (OSCOM) at Chatrapur, Orissa. Today IREL operates these four units with corporate office in Mumbai and produces/ sells six heavy minerals namely Ilmenite, Rutile, Zircon, Monazite, Sillimanite and Garnet as well as various value added products IREL is making profit for the last 6 years with its sales turnover reaching a peak exceeding Rs: 2600 million in 2000-01, with export component of above Rs: 1000 million. Chavara plant is engaged in the processing of beach deposits available on the coastal belt of Neendakara- Kayamkulam HISTORY OF THE ORGANISATION IREL’s history should not be narrated without mentioning the name of the Germen chemist Mr. Herr Schomberg who has realised that the shining yellowish brown
  • 22. Organisation Study on IREL Chavara 22 DC School of Management and Technology | Trivandrum particles sticking to coir, a coconut fiber shipped from India (1909) contained Monazite. This sparkled the discovery of vast deposit of monazite a rich source of rare earths a group of elements with a wide variety of uses in industry and science. A few plants were operating at Chavara and Manavalakurichi for the separation of monazite. 1948:- The govt. of India setup atomic energy commission under the chairmanship of Dr: HomiBhabha. The export of Monazite was stopped and the possibility of setting up a facility to process the beach sand mineral for the production of Rare Earths was examined. 1950:- IREL was incorporated at Bombay 1951:- IREL become the full-fledged govt. undertaking under the Department of Atomic Energy and commissioned construction of its rare earths plants at Udyogamandal in Kerala. 1952:- Rare earth plant was dedicated to the nation on Dec 24 by the Jawaharlal Nehru. 1955:- Opening Thorium factory of Bombay. 1965:- Opening mineral division at Kollam in Kerala state with manufacturing facilities at Chavara in Kerala and Manavalakurichi in Tamilnadu and a giant mineral sand separation and synthetic Rutile plant at Chatrapur in Orissa. VISION OF IREL 1. To be a leading supplier of beach sand minerals from Asia by supplying 10% of the world demand for beach sand minerals over the next 7-10 years. It would be achieving by maximum utilisation of existing capacities, new capacity addition, capturing major portion of the incremental growth in the global TiO2 feedstock demand and by developing competitive value added Rutile, Zircon, Sillimanite and Garnet products that make handsome contribution to revenue and profits.
  • 23. Organisation Study on IREL Chavara 23 DC School of Management and Technology | Trivandrum 2. To become the preferred rare earths products supplier (Producer and/ or Marketer) for domestic customers to ensure long term sentences and profitability of rare earths business and to achieve adequate efficiency in monazite processing as long as it is necessary / worthwhile. MISSION OF IREL 1. To harness beach sands in an environmentally and socially responsible manner for efficiently producing minerals and their traditional and innovative value added products of world class quality that are used to make increasingly superior/ novel products required by customers. 2. To play a dominant role in developing domestic rare earths market by producing and/ or marketing the quality value added products to realise maximum potential or rare earths in a range of applications. 3. To build a professional, creative and committed workforce and nurture an environment that fosters learning, sharing and development. OBJECTIVES OF IREL  To become nationally and globally competitive player in beach sand minerals.  To improve productivity, capacity utilization and cost effectiveness.  To maximise shareholders value.  To strive for optimum value addition through obtaining technology for improving international market share and growth in domestic market.  To undertake by itself or through independent expert agencies , investigation into new products as well as beach sand erosion and related phenomena of company’s operation.  To evolve and implement eco-friendly policies, programmes and projects within the AERD regulation.
  • 24. Organisation Study on IREL Chavara 24 DC School of Management and Technology | Trivandrum  To develop the human resources of the company by optimising their number, capabilities and quality of life  To strengthen R&D for achieving the above mentioned objectives QUALITY POLICY IREL is committed to provide products of consistent quality to their satisfaction of the customers through Quality Management Systems (QMS) implementation. TECHNICAL EXCELLENCE IREL uses state of art technology in mining and mineral processing. The rich experience and professional expertise of people who are one among the best in the industry and strict compliances to quality standards has enabled IREL to remain as the leading supplier of heavy minerals to the nation and abroad. IREL is always been driven by innovation and sound manufacturing practices, be it in product, technology or process.
  • 25. Organisation Study on IREL Chavara 25 DC School of Management and Technology | Trivandrum CHAPTER 4 PRODUCT PROFILE
  • 26. Organisation Study on IREL Chavara 26 DC School of Management and Technology | Trivandrum PRODUCT PROFILE Product means to the goods and services combination the company offers to the target market. Product Specification Specific Gravity Density Packaging Ilmenite TiO2 - 58% 4.45- 4.54 2600- 2630 In bulk HLP bags with Polithine liner Rutile Q Grade TiO2 - 95% 4.18-4.24 2630-2650 In bulk 50kg HLP bags with Polithine liner Zircon Special Grade ZrO2 - 58% 4.60-4.70 2900-3000 In bulk 50kg HLP bags with Politine liner Sillimanite Q Grade Al2O3 3.20-3.25 1950-2050 50kg jute bags Zirflour ZrO2- 64% - 1800-1850 50kg laminated HLP bags with Polithine liner Microzir ZrO2- 63.5% - - Liner 20kg laminated Polithine bags Table:4.1
  • 27. Organisation Study on IREL Chavara 27 DC School of Management and Technology | Trivandrum Products Uses Ilmenite Manufacturing of TiO2 pigment synthetic Rutile and Titanium slag Rutile Fluxes for welding electrodes Zircon sand Ceramics, Refractories and foundries. Zircon Flour Ceramics and foundries. Microzir Pacifier in Ceramics Sillimanite Refractories Garnet Abrasive for sand blasting, water jet cutting and glass polishing. Monazite Raw material for production of Rare earth Component Composite RE Chloride Catalyst, Paint driers, basic raw material for Misc. metal which used as lighter frint& mantles. Thorium Nitrate Gas Mantles TABLE:4.2
  • 28. Organisation Study on IREL Chavara 28 DC School of Management and Technology | Trivandrum CHAPTER 5 CUSTOMER PROFILE
  • 29. Organisation Study on IREL Chavara 29 DC School of Management and Technology | Trivandrum CUSTOMER PROFILE Prime customers of the major products of the company are the following:- A. ILLMENITE:- 1 KOCHIN MINERALS AND RUTILE LTD. KOCHI. 2 DCW LTD. TUTICORN. 3 TRAVANCORE TITANIUM PRODUCTS LTD. 4 KILBURN CHEMICALS LTD. TUTICORN. 5 KOLMAK CHEMICALS LTD. KOLKOTA. B. RUTILE:- 1 ESAB INDIA LTD, CHENNAI/ KHARDAH. 2 ADOR WELDING LTD., MUMBAI/CHENNAI. 3 D & H SECHERON ELECTRONICS (I) LTD., INDORE 4 MARUTHI WELD LTD., GURGAON. 5 ROYAL ARC ELECTRODES PVT. LTD.VASAI, THANNE DIST. C. ZIRCON:- 1. THIRUPATHI MICROTECH (P) LTD., UDAIPUR. 2. RUBY CERAMICS PVT LTD., PUNE. 3. ASTRON CERA, SALAL DIST, SABARKANTHA. 4. JOHNSON MATTHAEY CERAMICS INDIA LTD, HOSUR, TN 5. FOUR FIELD, PUNE. D. ZIRFLOUR:- 1. FOSECO INDIA LTD., PUNE. 2. VIDEOCON NARMADA GLASS, BHARUCH. 3. H & R JOHNSON (I) LTD., MUMBAI. 4. NAHAR COLOUR & COATING LTD., UDAIPUR 5. BHANU CERGLAZE P.LTD.
  • 30. Organisation Study on IREL Chavara 30 DC School of Management and Technology | Trivandrum E. SILLIMANITE:- 1. MAITHAN CERAMICS PVT. LTD., CHIRKUNDA, JHARKHAND 2. MANISHRI REFRACTORIES, CUTTACK. 3. ASSOCIATED CERAMICS, CHIRKUNDA, JHARKHAND. 4. TATA REFRACTORIES, BELPAHAR, ORISSA. 5. ASSOCIATED CEMENT COMPANIES LTD., NAGPUR/KATNI. F. RARE EARTHS CHLORIDE:- 1. CIBA SPECIALITY CHEMICALS, UDYOG NAGAR, GUJRAT. 2. DHIRAJ INTERMEDIARIES P LTD., VAPI, GUJRAT. 3. RAVESHIA PIGMENTS LTD., VAPI, GUJRAT. 4. ANUPAM COLOURS, VAPI, GUJRAT. 5. BERGER PAINTS INDIA LTD., VAPI, GUJRAT. G. THORIUM NITATE:- 1. FARGO MANTLE PRODUCTS LTD., MUMBAI. 2. MAKANI PRODUCTS LTD., MUMBAI. 3. B.K SHAW INDUSTRIES (P) LTD., KOLKATA. 4. A.D.C MANTLE MANUFACTURING CO., MUMBAI. 5. ELITE INDUSTRIES, MUMBAI.
  • 31. Organisation Study on IREL Chavara 31 DC School of Management and Technology | Trivandrum CHAPTER 6 FUNCTIONAL AREAS
  • 32. Organisation Study on IREL Chavara 32 DC School of Management and Technology | Trivandrum DEPARTMENTS I. HUMAN RESOURCE DEPARTMENT:- IREL Chavara takes place it’s highly motivated and trained human resource that has maximised its performance and their by its growth and profit. Morale of the employees remains facilitating smooth working of the company. Skill requirement related to different disciplines are identified and training programs and workshops are efficiency of the human resource. Fig:6.1 HR department lead by HOD & Section Head to assist him. The Security Department and Time Office are working under the HOD of HR Department.Executives & Personnels are working under section head of HRM.People are the most important resources of an organization. The main functions of HR Department are:- 1. Administration 2. Industrial Relations 3. Training and Employee Welfare 4. Time Management 1. ADMINISTRATION The administrative functions of HR department include a) Manpower planning b) Recruitment policy HOD(HRM) SECTION HEAD(HRM) HRM Executives HRM Personnel
  • 33. Organisation Study on IREL Chavara 33 DC School of Management and Technology | Trivandrum c) Performance appraisal d) Salary and wages administration e) Industrial discipline f) Maintaining service book and personnel file g) Maintaining reservation register a) Manpower Planning:- Manpower Planning is important for any type of organisation. It is the process which determines how an organisation should move from its current manpower position to its desired manpower position. For this purpose, the HR department at IRE collects feedback from all department inorder to identify their manpower requirements of various departments and then the HR department crosscheck whether there is any overstaffing in any of the departments. If these departments have excess of staff, they are transferred to those departments where there is a shortage. The company considers the number of employees presently as significantly high. There is a problem that sometime the VRS can lead to scarcity to workers for particular job. At IREL using the process of multitasking the employees are made fit to work in other function also. By the VRS scheme more than 100 employees have been sent out within span of 3 years.
  • 34. Organisation Study on IREL Chavara 34 DC School of Management and Technology | Trivandrum Manpower of the company There are 386 employees in the company. Total executives are 102 and workmen are 284.The number of contract workers are 632. Details showed as below. Manpower strength MALE FEMALE TOTAL EXECUTIVES 86 16 102 WORKMEN 260 24 284 TOTAL 346 40 386 Table:6.1 CONTRACT WORKERS LOADING 35 CIVIL 42 MINING 120 BAGGING 110 CANTEEN 12 TOTAL 319 Table:6.2 b) Recruitment policy:- Recruitment in Chavara Plant is done through local employment exchange for find out prospective workers. The office staffs and managers are recruited by the Head Office through tests and Interviews. Recruitment Criteria For the recruitment of candidates, the candidates should be above 18 years of age.
  • 35. Organisation Study on IREL Chavara 35 DC School of Management and Technology | Trivandrum The following steps are taken before the recruitment of employees. They are govt. guidelines, the recruitment only through employment exchange, notification in internet and advertisement in newspaper should be needed. Application will be scrutinised with the help of a selection committee and eligible candidates are called for an interview. Selection:- The steps followed in the selection process are; 1. Inviting and receiving applications 2. Scrutinizing the applications 3. Selection Test: - The selection tests of employees are a) Aptitude Test b) Personality Test c) Achievement Test d) Trade Test Appointment will be based on certain criteria’s like they are medically tested after that induction training should be given. After training for a period of one year or more they will be put as permanent employees. c) Performance Appraisal:- Appraisal is the evaluation of work quality or merit. In the case of IRE performance appraisal is a systematic evaluation of employees by supervisors or other familiar with their performance. 1) Straight ranking method:- Under this method men as a whole are compares from other men and ranked on the basis of overall performance. 2) Grading method:- Under this method certain categories of work such as excellent, very good, average, poor, very poor are established and defined actual performance of each employee then compared with the grade definitions and ranked to evaluate the performance of the employees. Last grade employees that are 8th& 9th grade, their work performance have been observed by supervisors. But in the case of executives MBO’s are observed their
  • 36. Organisation Study on IREL Chavara 36 DC School of Management and Technology | Trivandrum performance and efficiency. In IRE performance appraisal is done on a yearly basis to assess the performance of the employees. The appraisal is done by three persons. 1. Reporting Officer. 2. Reviewing Officer. 3. Evaluating Officer. Firstly the employees themselves do an appraisal and this is given to the reporting officer and the person who has done the Key Appraisal together identifies the Key Result Areas and weightage is allotted to each one of them. This is usually done at the beginning of the year. The reporting officer checks whether the result areas set where met by the appraisal or if there any deviation from it. And this is to be sent to reviewing officer and then evaluating officer. Various other factors such as the appraiser’s managerial skills like job knowledge, interpersonal skills are also included and guided and that is allotted in the appraisal and there promotion is based solely seniority. Promotion: In IREL promotion is given seniority based or based on experience. Promotion is a transfer of an employee to a job that pay more money or that enjoys some preferred status. Sometimes the company is considering the length of the service, education, training courses completed, previous work history etc. Sometimes the company is also considered ability, hard work, co-operation, honesty etc. Condition for getting Promotion:- 1. Average leave should not exist more than 15 days. 2. Any disciplinary actions should not be taken during the service of periods. 3. Should not apply for job in any other organisation. d) Salary and Wages Administration:- Wages in the widest sense means any economic compensation paid by the employer under some contract to his workers for the service rendered by them. Acts Followed: 1. Workmen Compensation Act 1923 Sec 2(m).
  • 37. Organisation Study on IREL Chavara 37 DC School of Management and Technology | Trivandrum 2. Payment of Wages Act 1936 Sec 2 (VI) 3. Payment of Wages Act 1948 PAY SCALE The monthly remuneration received by each of the employees including system of compensation. FOR WORKMEN Scale of Pay:- Grade Scale of Pay W - I Rs: 8340-23470 W - II Rs: 8440-23750 W - III Rs: 8550-24060 W - VI Rs: 8670-24400 W - V Rs: 8800-24770 W - VI Rs: 8940-25160 W - VII Rs: 9090-25580 W - VIII Rs: 9250-26030 W - XI Rs: 9420-28968 Table:6.3 FOR OFFICERS code Designation Pay Scale E-0 Deputy Officer 12600-32500 E-1 Officer 16400-40500 E-2 Senior Officer 20600-46500 E-3 Deputy Manager 24900-50500 E-4 Manager 29100-54500 E-5 Senior Manager 32900-58000 E-6 Deputy General Manager 36600-62000 E-7 General Manager 43200-66000 E-8 Chief General Manager 51300-73000
  • 38. Organisation Study on IREL Chavara 38 DC School of Management and Technology | Trivandrum e) Industrial Discipline:- Disciplinary actions are taken in the HR department. Procedure for disciplinary actions is on receiving a complaint about a particular employee, explanation is asked. Employee will give an explanation before 15 days. If the explanation is not satisfactory he will be given a charge sheet and will also conduct a domestic enquiry. For this purpose an enquiry officer is placed. After conducting the enquiry the report should be sent to the disciplinary committee and if necessary certain punishment may also give. 2. INDUSTRIAL RELATION Most of the disputes will be settled by the company and trade unions. If it is not cleared, they can approach to the government. The Trade Unions active in IRE are:- 1. United Trade Union Congress (UTUC) 2. Indian National Trade Union Congress (INTUC) 3. All India Trade Union Congress (AITUC) 4. Travancore Mineral Workers Union (UTUC (B)) 5. Indian Employees Rare Earth Federation (CITU) 6. Indian Rare Earth Mazdoor (BMS) These are the recognised unions. There are some criteria for recognizing a union; the union will have 15% of employees as their members. Also some participative forum is present; they are plants committee, safety committee and House building committee. These committees will have the equal participation. 3. TRAINING & EMPLOYEE WELFARE Training and Development:- “Training is the act of increasing the knowledge and skills of an employee for during a particular job”. Indian Rare Earth Ltd adopted various techniques of training for increasing the mass productivity. The training program is restructured regularly in IRE. The objective of training and development in IRE
  • 39. Organisation Study on IREL Chavara 39 DC School of Management and Technology | Trivandrum 1. Increase the efficiency 2. Increase the moral of the people 3. Reduce the absenteeism Procedure for Training 1. Identifying the training needs. The company identifies the training needs through 3 ways: - a. Organisation Analysis b. Task Analysis c. Man Analysis 2 Executives themselves will discuss the training needs 3 Charting out the training plan for a period 4 Based on feedback individual training is given Training Methods IRE has mainly four types of training methods. 1. In-house Training 2. External Training 3. Vocational raining 4. First Aid Training The training method can be grouped on the basis of level of personnel in the organisation. 1. In-house Training: - Otherwise known as on the job training. In this method expert from outside come to the organisation and give training. 2. External Training: - Also known as off job training is given outside the organisation. 3. Vocational Training: - At least 20% of the employees should be trained every year. 4. First Aid Training: - 30 people in one batch and give them training.
  • 40. Organisation Study on IREL Chavara 40 DC School of Management and Technology | Trivandrum Employees Welfare:- Two types of employee’s welfare are present in IREL. They are; 1. Statutory welfare and 2. Non Statutory Welfare Gratuity, Provident Fund, Pension, Canteen, Medical Allowance is included in the statutory welfare. Festival Allowance, LTC, Recreation, Tour Facilities are included in the no statutory welfare. Also the IREL give some kind of allowances. They are; Shift Allowance For employees working in shifts expect general shifts will get anallowance as follows 1st Shift (6 am to 2 pm) -Rs: 25/day 2nd Shift (2 pm to 10 pm) -Rs: 15/day 3rd Shift (10 pm to 6 am) -Rs: 35/day Hard Shift Allowance Since the plant handles sand for its production, it creates a dust in the atmosphere. Considering this hardship in work every employees of Chavara plant gets Rs: 135/-month as hardship allowance. Uniform Allowance Every employee is provided with two pairs of uniform in every year. Rs: 100/ month as washing allowances is granted for all employees. Transportation Allowance Every employee (except officers) gets Rs: 1200/- per month as conveyance allowance. Officers will get 10% of their basic pay as their Transportation Allowance. Canteen A round the clock canteen is provided for the employees. Company will charge Rs: 6/day from each employee. The canteen is under the control of company. Attendance Bonus To increase attendance in the company gives annual bonus of 12 days wages for every employee who have minimum 268 days presents.
  • 41. Organisation Study on IREL Chavara 41 DC School of Management and Technology | Trivandrum Production Incentives Every employee gets an amount of Rs: 525/ year as Production Incentive from the profit. Leave facilities available in IRE Casual Leave - 15 days/ year Sick Leave - 10/year (workers) 10 full/20 half (Officers) Earned Leave - 33 days (It can be maximum of 240 days) Surrender Leave - Each employee can surrender maximum 90 Days/year or 75% of earned leave. Other Benefits  750 ml milk/ day 4  pears soap/month  One Turkey or Towel/year  Shoes (1 pair)/ year  One Umbrella/year  House loan up to 7.5 Lakhs  Medical Facilities  Educational Allowances to workers children  Festival Allowance  Group Insurance Scheme  Holiday Facility Leave Travel Concession (LTC) 4. TIME OFFICE There is a full-fledged office headed by Deputy administrative officer. It follows a punch card system. Different allowances of employees are given and it is mainly depend on attendance. It is providing according to the report from the time office. The time office is working under the HRM department. The main function of this department is to maintain attendance records, leave and service records etc. The various allowances, attendance
  • 42. Organisation Study on IREL Chavara 42 DC School of Management and Technology | Trivandrum bonus all these records are maintained by the time office department. Also yearly attendance bonus is given to the employees. Attendance of 265 days/ year -12 day’s salary Attendance of 262 days/ year -10 day’s salary Attendance of 243 days/ year -7 day’s salary Structure of the time office as follows; Fig:6.1.1 For recording attendance punching system followed here. The attendance register usually keep in time office. The time office collects attendance from concerned authority also and match with the punching system and avoiding swapping. Time office has three centers for punching in convenience of employees. In mining area, in dredging plant also keep mechanical punching machine. For the purpose of salaries the time office is sending the records to the finance department. If the finance department asks for any clarification they will do it. HOD(HRM) SECTION HEAD(TIME OFFICE) TIME OFFICE(PERSONNEL)
  • 43. Organisation Study on IREL Chavara 43 DC School of Management and Technology | Trivandrum TRANSFER POLICIES OF IREL, CHAVARA Transfer is the movement of an employee from one job to another without involving any substantial change in his duties, responsibilities. The company is following 4 methods. 1. Production Transfer:- When a particular department or job is faced with the pressure of works, its strength may supplement through from other departments. Such transfers are generally made where any department is overstaffed and other is short of manpower. 2. Replacement Transfer:- A replacement transfer is the transfer of a senior employee to replace with a junior employee or new one. 3. Shift Transfer:- When units in shifts,employees are transferred from oneshift to another on similar job. 4. Department Transfer:- Transfer from one department to another within the plant or within the organisation.
  • 44. Organisation Study on IREL Chavara 44 DC School of Management and Technology | Trivandrum MINING DEPARTMENT In IRE the raw materials for production process are collected through mining process. The production process starts with the collection of beach sand from various places. For collecting this beach sand IRE uses the following two methods: Sea Washing and Dredging. SEA WASHING Raw sand is collected from sites where deposits are occurred due to natural beach washing. Presently IRE owns two sites one at Vellanathuruthu/Ponmana and one at 132 mining area. There is a heavy mineral deposit over a length of 22.5 Km. They are found over or coastal belt having an average width of 800 meters. The sea waves deposits the minerals sand on the beach line and it is collected. Then it is send to the mineral separation plant. DREDGING The plant DWUP used for the mechanised recovery of minerals from the beach sand. The DWUP consist of a floating dredging plant operating hydraulically and electrically which could be moved from one place to another based on the requirement. The plant is floating in an area having a water depth of 6 meters. The sand along with water in the form of slurry (a mixture of sand and water) is pumped to the heavy Upgradation equipments. The equipment consist of a series of transfer bin rotating screens called Trommer, Spiral Separators, Hydro cyclones, pumps etc all being electrically operated. The DWUP can dredge about 40 to 60 tons per hour. The raw sand having an average at 40% heavy minerals is fed to the floating plant and updates it to 85 to 90% mineral content. The waste sand (Quarts) from DWUP is usedfor backfill the dredged area.
  • 45. Organisation Study on IREL Chavara 45 DC School of Management and Technology | Trivandrum DEPARTMENT STRUCTURE – MINING Fig:6.2
  • 46. Organisation Study on IREL Chavara 46 DC School of Management and Technology | Trivandrum PRODUCTION DEPARTMENT The act of making goods and services is called production. In everyday speech ‘Production’ refers to the act of creating something production involves the physical conversion of raw materials into tangible goods. In IRE raw sand is collected through mining process .The sand is filtered through spirals, cones and jigs to produce a bulk concentration of heavy drying, screening, electromagnetic and electrostatic processes and used for separation. Minerals found in coastal areas are collected either manually or mechanical means, productions starts from the mining process. DEPARTMENT STRUCTURE – PRODUCTION Fig:6.3
  • 47. Organisation Study on IREL Chavara 47 DC School of Management and Technology | Trivandrum MINING PROCESS The mining and processing of beach sand are achieved with a good mixture of modern mechanical devices and manual labour. Beach sand is collected from the surface of a depth of a meter with the help of dredgers. For a processing of beach sands, the difference in electric conductivity, magnetic susceptibility and specific gravity of their constituents are taken into consideration. The beach sand is treated by well gravity methods using spiral, cones and jigs to produce minerals. IRE collects raw sand in two different ways: 1. Sea washing or beach washing 2. Mechanical dredging MINERAL RECOVERY PLANT The mineral recovery plant consists of a floating dredging plant which could be moved from one area to another. This is called floating mineral recovery plant. The plant is placed in an area which has a water depth of 9 meters. The sand along with water is sucked into the main unit. First the mixture is send to a storage tank called Trammel. Then it is sending for separation. The waste sand and some quantity of water is pumped out. The mineral content is pumped from the MRP to concentrate Upgradation plant. The MRP dredges about 40-60 tones per shift. CONCENTRATE UPGRADING PLANT (CUP) The raw sand collected from different sources had different composition. They are further upgraded using the CUP. In the Concentrate Upgrading Plant enriches the concentrate from various sources to above 90% heavy minerals using spiral separators making use of gravity techniques. MINERAL SEPARATION PLANT (MSP) In the mineral separation plant individual minerals are separated making use of the following four properties of the minerals namely
  • 48. Organisation Study on IREL Chavara 48 DC School of Management and Technology | Trivandrum 1) Electrical conductivity Electrostatic separation is used in electrical conductivity. 2) Magnetic Susceptibility High and low intensity magnetic separators used. 3) Density Difference Floater separation 4) Surface Property Froth floatation. The concentrate from concentrate upgrading plant (CUP) having uniform composition with above 90% heavy minerals content is dried using Fluidised Bed Drier (FBD). This is then subjected to electrostatic separation using different type of electrostatic separators. There by it is separated into two fractions namely conducting and non- conducting fractions. PRODUCTION CAPACITY OF CHAVARA PLANT Ilmenite 200000 tones Rutile 114500 tones Zircon 11750 tones Sillimanite 10000 tones Zir flour & Microzir 6000,300 tones Table:6.4
  • 49. Organisation Study on IREL Chavara 49 DC School of Management and Technology | Trivandrum ILMENITE: - Mainly used in the manufacture of Titanium dioxide, a white pigment by sulphate process also used in the production of synthetic Rutile and for the production of Ferro Titanium products. RUTILE: - Rutile used for coating of welding electrodes and also for the production of Titanium dioxide pigment by the chloride process and for the production of Titanium Tetra Chloride for the production of Titanium metal and sponge. SILLIMANITE: - Sillimanite mainly used in the manufacture of high temperature refractory. It is also used in ceramic industry. ZIRCON: - Zircon is used in foundries, ceramics and refractory. It is also used in the manufacture of zirconium chemicals, metals, alloys etc. ZIRCON FLOUR: - Zircon flour is used in foundries for high temperature castings. MONAZITE: - Monazite is used for the production of Thorium and rare earth’s base products.
  • 50. Organisation Study on IREL Chavara 50 DC School of Management and Technology | Trivandrum PRODUCTION PROCESS Fig:6.4
  • 51. Organisation Study on IREL Chavara 51 DC School of Management and Technology | Trivandrum QUALITY CONTROL DEPARTMENT IREL Chavara has got ISO 9001: 2000 Quality Systems established for mining, manufacturing and mineral products. One of the primary functions of the quality control department is to ensure quality products according to customer requirements. They harness beach sand in environmentally responsible manner to produce minerals and innovative value added products, which are used to make novel products required by customers. Secondly, they are responsible for maintaining consistant quality of products to the satisfaction of the customers through quality management system implementation. They also aim at further improvement of product, technology or process. The quality control department is also responsible for maintaining consistency in quality of raw materials during the processing, intermediate and finished product stages. They make use of chemical and mineralogical testing methods in each stage. In addition to these functions this department also conducts research and development activities to support flow shed development work and for solution to process related problems.
  • 52. Organisation Study on IREL Chavara 52 DC School of Management and Technology | Trivandrum DEPARTMENT STRUCTURE – QUALITY CONTROL Fig:6.5 FUNCTIONS  To ensure that raw materials, in process and finished products confirms to specified requirements holding compliance with environment , health and safety requirements.  Ensuring compliance to health, safety and environmental requirements. INSPECTION AND TESTING PROCESS DETAILS Raw Sand:- 1) The DWUP and HUP output and tailing are tested for total heavy mineral content as detailed in quality plan 2) The raw sand feed to the QIL plant ie the dried HUP output is analysed as per quality plan. 3) The raw sand being naturally occurring, the specifications are only desirable values. The variations in quality of raw sand do not affect the quality of final products. So no reduction of raw sand is resorted to, even if the analysis results are not as for the quality plan. HOD(QC) SH(Q C) Q C EXECUTIVCES Q C EXECUTIVES
  • 53. Organisation Study on IREL Chavara 53 DC School of Management and Technology | Trivandrum 4) These tests are carried out only to make proper adjustments of the process parameters to set the final product of specified quality. In-Process Inspection In-process inspection of certain intermediate fraction as detailed in the quality plan is carried out as per quality plan. These process fractions are not rejectedeven if the analysis results do not confirm the desireable specifications. The inspection is only for subsequent adjustments in the process parameters. Finished Products:- 1) The products under tests are identified by a yellow board indicating the date, shift and number of bags. Those products passed the tests are identified by a green board indicating date, shift and number of bags and rejected are identified as red board indicating “FOR REWORK”. 2) Inspection and testing of finished products are carried out and records in the respective record as per quality plan. Only products confirming to the quality as detailed in the respective quality plan are taken in to stock. Rejected products are maintained with authorisation of HOD (Q.C). Inspection and test record clearly indicate whether the product is accepted or rejected.
  • 54. Organisation Study on IREL Chavara 54 DC School of Management and Technology | Trivandrum STORES AND DESPATCH DEPARTMENT The stores act as a store and supply chain, keeping inventory of the product produced on the hand and supplying requisite raw materials to the manifold department on the other hand. All the items in6 the IRE properly stored by this function area, including finished product inventory. It stores furnace oil, machine parts, office equipment and stationary etc. DEPARTMENT STRUCTURE – STORES & DESPATCH Fig:6.6 Stores fall under two categories 1. Capital Items 2. Consumable Items Capital items, which give return for long term revenue items or a consumable item means that which are consumable only for a short period. HOD(S&D) SH(S&D) S&D EXECUTIVCES S&D EXECUTIVES
  • 55. Organisation Study on IREL Chavara 55 DC School of Management and Technology | Trivandrum Procurement of items of capital nature is to be made only after the approval by the competent authority duly verified by internal auditors with prior conclusion in the capital budget. Stores action is responsible for arranging procurement of all items or purchase requisitions shall from the basis for arranging procurement or other departments, complete in all respects and duly approved by the controlled authority. Stores are purchased indigenously and from foreign suppliers through the adoption it secure the most competitive tendering system is adopted to secure the most competitive tendering, the most competitive rates and eliminate chance of favour. The worth of production in the plant is currently between 6-7 Crores. Once in every 3 months inventory statistics is prepared and send to the head office in Mumbai. Stores follow Bin card and Cardex System. This department has three major functions as follows. RECEIPT: The consignment items are properly verified with the receipts and requested the particular department to made inspection on each items. STORAGE: The received items are stored in proper locations and preserve them until the issue. Each item has its own Bin card. The quantity received, material issued, total remaining are noted in the Bin cards. ISSUE:- The issue made in first in first out method. After the receipt of the material internal note from the department, the issues are made and same is recorded in the Bin card. INVENTORY CONTROLE Under the stores department the inventory control function is done. If excess stock is obtained, it is properly informed to the marketing department to promote sales and if any shortage obtained it is properly informed to production department to increase the
  • 56. Organisation Study on IREL Chavara 56 DC School of Management and Technology | Trivandrum production. Usually ABC inventory control methods is adopted in IRE Chavara for control of inventories. The principle types of inventories are:  Raw Material & Supply  Goods in Progress that is work in progress Finished Goods For reduction of inventories four steps are taken in the Stores and Despatch Department. They are doing computerization, codification, standardization and value addition. All the process in stores departments are computerised and inventory management software is used for this purpose. Coding is given to all inventories. For this, alphanumerical code is used. Material coding is help to realise what kind of inventories are stored. And location coding helps to find out where it is stored. By the use of standardisation, physical verification of inventories are to be done and to be check whether the invoice number and purchase order are equal. DESPATCH SECTION Despatch Section controls the transportation of the finished products o the outside company. When a customer made a complete settlement of money for purchasing of a particular product from the company the marketing department placed a delivery order to the despatch department. The despatch department then prepares an invoice and gave a copy to the customer. This department also prepares gate pass and state government declaration sheet.
  • 57. Organisation Study on IREL Chavara 57 DC School of Management and Technology | Trivandrum INTERNAL AUDIT DEPARTMENT Chief General Manager is directly looking after the functioning of Internal Audit Department. Manager (Internal Audit) is the head of the department. There are internal audit officers and administrative officers other than accountants and clerks working in this department. Internal audit department is not regular department in many of the companies. But in IREL this department is holding special privilege of auditing in to every accounting matters of IREL. It is functioning in accordance with finance department. It is necessary to get audit approved from internal audit department for the finalisation of anything concerned to accounts. The company management is approving all other accounts in the recommendation of this department. DEPARTMENT STRUCTURE – INTERNAL AUDIT Fig:6.7 FUNCTIONS  Auditing all the financial transactions of the company.  Taking corrective measures to rectify audit objections.  Making report to Chief General Manager and Board of Directors.  Make sure that every deeds of finance department is in accordance with the accounting policies of the companies.  To participate in the functioning of store purchase committee.  To check the legal validity of the financial matters of projects committed by IRE Ltd. MANAGER INTERNAL AUDIT OFFICER PERSONNEL
  • 58. Organisation Study on IREL Chavara 58 DC School of Management and Technology | Trivandrum All the relevant policies of the company are as the basic policies of this department. Internal Audit Department is auditing the accounts quarterly and sending report to Chief General Manager regularly. RESEARCH & DEVELOPMENT DEPARTMENT The company has a well-equipped Research and Development facilities to support flow sheet development works and for solutions to process related problems. The laboratory is equipped with lab models of Magnetic Separator, High Tension Separators, Wet Shaking Tables and Froth Floatation Equipment etc. DEPARTMENT STRUCTURE – RESEARCH & DEVELOPMENT Fig:6.8 FUNCTIONS  New product development.  New compound development.  Selection & Evaluation of alternative method.  Testing of new products.  To analysis and assist plants in problem solving.  Ensure quality of raw materials and finished products.  Maintain Quality.  Research & Development attempts.
  • 59. Organisation Study on IREL Chavara 59 DC School of Management and Technology | Trivandrum PROJECT & MAINTANANCE DEPARTMENT This section is looking after the projects and maintenance of technological aspects of affairs of the company. This is a section in which mechanical experts are working on different projects. This section takes over the responsibility of various projects taken up by IRE Ltd management. They are making efforts to expand the area of performance of the company. FUNCTIONS  To carry out preventive Maintenance to ensure continuous capability and to attend breakdown maintenance if any.  Projects on mining area of IREL.  Projects on technological development.  Project on quality assurance. DEPARTMENT STRUCTURE – PROJECT & MAINTANANCE DEPARTMENT Fig:6.9
  • 60. Organisation Study on IREL Chavara 60 DC School of Management and Technology | Trivandrum MARKETING & SALES DEPARTMENT Marketing is a social process by which individuals and groups obtain what they need and wants through creating, offering and freely exchanging products and services of value with others. It is the art of selling products. Marketing department is functioning under the control of General Manager of marketing department. Marketing occupies an important position in the organisation of any business unit. Marketing functions are not limited to the function of buying and selling but storage, risk bearing and after sales services etc. marketing is a vital connection link between the producer and customer. The marketing section in the IRE is under the direct control of chief General Manager and this section is headed by the deputy General Manager in his job. The marketing activities in the company are indirectly linked with the sales section. IRE has the monopoly in the field of rare earth products. IRE Ltd, Chavara is engaged in the production of minerals such as Illuminate, Rutile, Zircon, Sillimanite, and Brown Illuminate from naturally available beach sand products. It also produces value added products like Zirflour, Microzir. On specific requirements of customers the company also supplies Sillimanite powder by subcontracting. Among these Illuminate, Rutile, Zircon, Brown Illuminate are categorized as “Scheduled Minerals” for which the customer is required to obtain license from the Department of Atomic Energy (DAE) Mumbai for their purchase. Off late, more stress was given as the marketing activities of IRE, by the company, because of competition, which is growing in the international market and also in Indian market. A new era has been put up in the company for this purpose. The bye products of IRE are Zirflour and Monazite. They are mainly purchase by the Kundara ceramics for the manufacturing of ceramics. The main customers of IRE are the Government of India and other private company. The main foreign customers are USA, Canada, UK, France, West Germany, Japan etc.
  • 61. Organisation Study on IREL Chavara 61 DC School of Management and Technology | Trivandrum OBJECTIVES OF MARKETING DEPARTMENT  Maximum turnover Maximum profit  Maximum customer satisfaction  Maximum customer relationship The chief General Manager of IRE is having the control of topmost level in marketing department of this unit. There are four superintendents and a clerk engaged in the sales department. IRE Ltd is working under the administrative control of Department of Atomic Energy. The head office does the pricing of products. The customers of IRE Ltd are mainly heavy industries like plant, glass, refineries, ceramics etc for bulk purchases customer and provided discount. SALES AND DISTRIBUTION SYSTEM Here the organisation has been enjoying monopoly. That’s the reason why they don’t want to make a distribution network. Direct selling is the main system of organisation. The customer primarily pays the full amount as demand draft (DD) in advance and then the company gives the products. For domestic sales, order are received as  Through head office  Directly from the customers  Transferred from the units of IRE All (except Zirflour, Microzir and Sillimanite powder) are dispatched against permits obtained after payment of prescribed royalty by IRE in advance to the department if mining and geology, government of Kerala. Starting with general condition for sales, majority of the customers place orders directly with Chavara. Sometimes head office also fixes quota customers wise if necessary, for the supply of minerals and intimates time to time. If all the formalities are completed delivery instructions are given by the sales department to stores for delivery of the materials to the customers. Exporting Exporting contract between the seller (IRE) and the buyer (customer) is finalized at
  • 62. Organisation Study on IREL Chavara 62 DC School of Management and Technology | Trivandrum the head office and intimates Chavara regarding the export contract along with the copies of agreement, purchase order, proposed loading schedule and many other specific instructions for the execution of the order. Chavara sends samples and product specification to the customer if required by head office/ buyer. Exporting carried out through Neendakara but now its through Cochin port (Bagged Cargo only) shipment through Cochin port is done by C&S agents appointed by seller. Pricing Pricing is a very crucial decision in marketing management. The objective of the firm is to get maximum profit. This depends upon the correct decision in pricing. Pricing refers to the process of fixing the price (money value) of a product or service; pricing is an important function in marketing because it determines the sales volume and the amount of profit. A product is acceptable to the customer when it is reasonable priced. A sound pricing policy helps to satisfy customers and to yield profit. Determination of price is influenced by large number of factors such as cost of production, degree of competition, nature of the product, pricing objectives and policies of the firm etc. Samples to the customers Samples are sending to the customers on their request or as per the instructions from the head office for their evaluation of sustainability for their requirements. Free samples are send to the customers as per the following procedures. Up to 500 Gms: head of the department (marketing) intimates section head (QC) to preparesamples of required quantity along with the gate pass. 501 Gms to 1 kg: head of the department (marketing) prior approval from the unit head andfollows the above procedures. Above 1 kg: head office approval with information to unit head and follows the above procedure. The sales department maintains the following records  Contract review checklist for domestic sale  Government of Kerala department of mining and geology and advance remittance and corresponding permit register.
  • 63. Organisation Study on IREL Chavara 63 DC School of Management and Technology | Trivandrum  Quotations  Performa invoice  Payment registers  DAE license register  Priority registers  Delivery registers  Sales register  Shipping register  Daily statement of production , sales and dispatch  Quarterly statement regarding export  Monthly report to cabinet  Production, sale and stock of minerals (monthly)  Performa for submitting quarterly export performance to federation of Indian exportOrganization  COB license  Bank receipt voucher  Cash receipts  DD register  Gate pass
  • 64. Organisation Study on IREL Chavara 64 DC School of Management and Technology | Trivandrum FINANCE DEPARTMENT Business finance is concerned with the acquisition and utilization of funds required to meet the financial needs of a business enterprise. Financing is the process of planning, acquiring, utilizing and controlling the funds used in any kind of business. Finance is the life blood of business. Every enterprise or company requires finance to start the work and grow. A company generally requires large amount of capital. A public company can raise huge capital through issue of shares. In addition to share capital it can utilize retained profit in the form of reserves. It can raise borrowed capital through denture and loans. Long term loans can be obtained from financial institutions. Short term loans are available from commercial banks. DEPARTMENT STRUCTURE – FINANCE Fig:6.10 SOURCES OF A COMPANY  On the basis of time.  On the basis of purpose or use.  On the basis of source of finance.  On the basis of risk. Finance refers to money, cash or hand available for the operation of business. Finance may do defined as the requirement of funds wanted. It is the life blood of business activity. The business pulsates with life only through finance. Finance refers to money, HOD(FINANCE) SH(FINANCE) FINANCE EXECUTIVCES FINANCE EXECUTIVES
  • 65. Organisation Study on IREL Chavara 65 DC School of Management and Technology | Trivandrum cash or hand available for the operation of business. Financial management will include planning, organising, directing and controlling. The main functions of this department are:-  To collect all the receipts and make all the payments.  To record all the transactions and prepare the final accounts.  Maintain the accounts as per the provisions of the section 20(g) of the Companies Act 1956.  Provide depreciation at the rate prescribed in schedule 14 of the Companies Act 1956, on a straight line method.  To account excise duty on goods manufactured when it is dispatched.  To ascertain the accrued gratuity liability of the company on the date of balance sheet.  To value finished goods at cost or market price whichever is lower, stock of raw materials, spares and chemicals are valued at weighted average method.  Treat the claims against the company which are not admitted as contingent liability. CHIEF GENERAL MANAGER The finance department is headed by the Chief General Manager (Finance). A Deputy General Manager (Finance) is there to assist the Chief General Manager in the operations of the department. In addition to them the department consists of 3 senior finance officers, 8 deputy officers and attenders. AUTHORITY, RESPONSIBILITIES AND ROLES:- AUTHORITY  Approval of policy, objective and targets.  Approval of apex manual.  Defining responsibilities and authority of head of departments, management representatives.  Authorizing various committees  Approval training programs of financial commitment.  Authorization of decision taken at review meeting such as safety and environmental protection committee, environment management customer service and complaint
  • 66. Organisation Study on IREL Chavara 66 DC School of Management and Technology | Trivandrum redeemed and protection meetings. RESPONSIBILITIES  Overall responsibility for health and safety of IRE, Chavara unit.  Claiming the review meetings.  Responsibility of the head office from time to time.  Ensuring that unit has organized celebration including those related to health, safety and environment through concerned department.  Providing resources for the implementation main tenance and continued improvement of management systems (in consultation with HO required).  Implementation of directives received from HO / statutory agencies.  Ensuring smooth progress of project (including feedback of HO on the program). ROLES  Ensuring smooth day to day functioning organisation through concerned HOD / section head.  Role as head of the unit in the health, safety and environment related celebration.  Participation in emergency evaluation (Both mock / actual)  Compliance to safety related requirements including use of personal protection equipment as a role model for others.
  • 67. Organisation Study on IREL Chavara 67 DC School of Management and Technology | Trivandrum MEDICAL DEPARTMENT: An effective and efficient medical department is functioning in IREL Chavara. Every family member of the employee is eligible for free attendance and treatment in the dispensary. Cases beyond the scope of the dispensary will be referred to major hospitals which are centered in Kollam and Karunagappally. The whole payment is such cases are done by the company itself. The dispensary is working around the clock. FUNCTIONS  To carryout medical examination of employees and their family members.  Examining compliance to environmental requirements. Senior Manager (Medical) is the top most authority of the Medical department. Senior Manager is followed by a Section Head/Lady Doctor. The department comprises of two Doctors, three Pharmacists, three Nurses/Compounders, Laboratory Technician and an Ambulance Driver. DEPARTMENT STRUCTURE - MEDICAL Fig:6.11 PROCESS INVOLVED IN MEDICAL DEPARTMENT 1) Out Patient Service: a) Employees and their departments are provided free medical services. For this each employee has been allotted a personal dispensary file in which name of the dependants are included as per the family card issued by the welfare department. Proper recording of the ailment, investigation and treatment of the
  • 68. Organisation Study on IREL Chavara 68 DC School of Management and Technology | Trivandrum employees and the dependants are entered in the personal dispensary file. Unfit and fit certificate are issued by the medical officers in the prescribed form for availing sick leave and for rejoining the duty after sick leave. b) Patients who require specialist’s opinion/ detailed investigation are sent to recognised hospitals/govt. hospitals/ approved laboratories with a reference letter. List of approved hospitals/ laboratories as approved by HO is maintained by HOD (Medical). Patients are taken to recognised hospital only with the reference form issued by medical officer. In the absence of company medical officer, patients are issued a temporary reference card valid for one day by the duty Pharmacist/Nurse for immediate admission incase of emergency and within 24 Hrs the reference card issued by the medical officer is to be collected by the employee. 2) Occupational Health Service (OHS): Pre-employment Medical Examination:- Normally recruited employees before joining are directed to undergo a medical examination by the medical officer. Medical examination is carried out as per the pre- employment medical examination report. The pre-employment medical examination report is send to the HOD (HRM) for implementing the recommendation of the HOD (Medical). 3) Periodical Medical Examination In accordance with Atomic Energy Regulatory Board (AERB) periodical medical examination for all canteen workers and clarified radiation workers is carried out once in a year and for other radiation workers and other general workers, it is carried out once in five years. Employees aredirected to HOD (Medical) as per the list notified by the Administrative section. These who are exposed to high noise, loss of hearing bent are also conducted and feedback is given to the concerned department. 4) Pre-retirement Medical Examination Concerned employee is given intimation from administration section at least two months before the date of retirement to carryout pre-retirement medical examination
  • 69. Organisation Study on IREL Chavara 69 DC School of Management and Technology | Trivandrum with a copy to HOD (Medical). Based on this, medical examination is carried out one month before the retirement of every employee and necessary advice is given to the employee for his future health maintenance. SECURITY DEPARTMENT Security of the company assets and premises is vested in the hands of the staffs of security department. The department is lead by Security Manager and he is assisted by 6 Head Security Officers and 26 Security Guards. DEPARTMENT STRUCTURE – SECURITY Fig:6.12 FUNCTIONS  To give security to the company and its assets.  To monitor the entry of employees and visitors.  According to ISO procedures they maintain the discipline of the employees, their uniform etc. Two major threats presents in IREL are sabotage and theft. To prevent sabotage there is a control room and it accessible at every time. In case of emergency the systems will automatically shut down and emergency alarm will blow. At that time all the employees are required to assemble in the assembly points. Another security problem faced by IREL is theft. There is no clear boundary wall for the company. This may encourage persons to take away company assets without permission. HOD(SECURITY) SH(SECURITY) SECURITY GUARDS
  • 70. Organisation Study on IREL Chavara 70 DC School of Management and Technology | Trivandrum SAFETY AND ENVIRONMENT DEPARTMENT In the present day industrial scenario all the industries had acceptedthe fact that safely improves productivity.IREL Chavara has always been in the forefront in ensuring safety,welfare and better working environment to all its employees. Their safety slogan is“Let everyday be a safe day” DEPARTMENT STRUCTURE – SAFETY & ENVIRONMENT Fig:6.13 MISSION AND POLICY OF THE DEPARTMENT MISSION The mission of IREL is to be a major supplier of beach sand minerals and rare earth compounds in the domestic and international market, develop and produce chemicals of strategic importance, value addition with due regard to resources utilization and safety protection. Consistent with this mission, IREL envisages a safety and environment protection policy that provides a safety working environment to prevent injury and ill health to its employees. It also ensures environmental protection by minimizing environmental input that may arise from its operations and provide appropriate environmental plans to maintain ecological balance and above all recognizes the use for safety culture man organisation to enhance the awareness and commitment of all employees to safety.
  • 71. Organisation Study on IREL Chavara 71 DC School of Management and Technology | Trivandrum POLICY IREL purpose to update and review the safety policy periodically taking into consideration its industrial experiences advances in the technology and regulatory requirements. ENVIRONMENTAL POLICY  IREL Chavara is committed to protect, conserve and improve the environment in which it operates for the continued existence in the business throughout  Conservation of natural resources  Minimising pollution  Compliance to applicable environmental rules and corporate guidelines, periodical health monitoring of employees and creation of environmental awareness among employees, customers and suppliers. SAFETY GUIDE IREL Chavara follows strict safety guidelines, which are given in the company’s safety guide. Safety team will update the safety guide as per the requirement to throw more clear light on the processes as well as equipments engaged in the plant, including procedures to ensure the safety of both men and machinery. There are Do’s and Don’ts enlisted in this guide and this will be quite helpful in averting the slightest possibility of accidents. SAFETY GUIDELINES In order to achieve the policy objective certain guidelines are used some of them are as follows. CORPORATE LEVEL SAFETY  An officer of the rank General Manager to co-ordinate at the corporate office all safety environment and training activities of various units and takes necessary steps for effective implementation of this policy.  GM (S&E) assisted by three senior officers at the head quarters on each of the safety, environment and training.  The corporate safety setup has been provided with adequate administration /
  • 72. Organisation Study on IREL Chavara 72 DC School of Management and Technology | Trivandrum financial support for coordinating safety policy.  He liaisons with various outside agencies like Atomic Energy regulatory board SARCOP health, physics division of BARC, DGM of mines safety, ministry of environment and forest etc for fulfilling the statutory requirements.  He assesses the training needs for various areas and granges for different categories of employees.  He interacts with safety teams / experts for carrying out safety audit / environment audits and assessment of safety performance for award of shield etc. UNIT LEVEL SAFETY SETUP  The head of each unit will be executive director / chief / GM.  He will be ex-office chairman of the plant level safety and environment protection committee which will review the monthly safety status of the plant.  He will implement all the applicable statutory provisions of safety and environmental control in the unit.  He will nominate senior level officer as safety and environmental control officer who will look after the safety and environmental control aspects of the unit.  He will ensure that operating procedures are followed strictly and technical specifications are not violated. SAFETY AND ENVIRONMENTAL PROTECTION COMMITTEE  The term of members of the committee will be two years and the committee members will be meeting once in a month.  The committee will organize safety day / environmental day / fire day and mines safety week annually and hold competition among the employees relating to safety and environment during the celebrations.  The committee will discuss the measures against the unsafe conditions and
  • 73. Organisation Study on IREL Chavara 73 DC School of Management and Technology | Trivandrum practices in the mine / plant as pointed out in the report of workmen’s inspectors.  The committee will consider safety and health measures to be taken before commencement of operations of any new electrical / mechanical equipment proposes.  Summary of minutes of the meeting will be sent to the GM (S&E) regulatory. STANDING ORDER FOR WORKMEN CONCERNING SAFETY IREL standing orders for workmen also envisages the safety of the organizationand relevant clauses. PERSONAL PROTECTIVE EQUIPMENTS It is divided into two categories  Personal protective equipment for the various parts of the body i.e. head, eye, ears, face, hand, arms.  Respiratory protective equipment required when workers exposed to atmospheric contaminants like dust, fuel, gases and chemicals let off in the air in the dangerous concentration. PROTECTION EQUIPMENTS USED ARE  Head protective  Respiratory protection devices  Safety belts and lifelines  Safety shoes  Dust respirators  Eyes and face protection  Ear muffs  Aprons  Gloves
  • 74. Organisation Study on IREL Chavara 74 DC School of Management and Technology | Trivandrum PURCHASE DEPARTMENT The main function of purchase department is procurement of materials at competitive price. All items including real materials other than raw sand are purchased by this department. In IRE Ltd the purchase department had prime importance. Formalities of purchase  Float enquiry to the right source  Scrutinize quotation  Obtaining approval of the finance department  Release an order  Follow up receipt at the store  Assistance to give payment in time Formalities of placing an order  Origination of intent  Tender enquires  Opening of tender on the data mentioned  Analysis of all tender  Technical evaluation of the tender  Selection of the best one  Negotiation with the party needed  Approval of the selected tender  Order placing  Follow up
  • 75. Organisation Study on IREL Chavara 75 DC School of Management and Technology | Trivandrum CIVIL DEPARTMENT Maintenance has a direct impact on everything that affects the overall health and welfare of the organisation. A sound maintenance strategy should therefore be considered a valuable tool used to assess equipment capability and the continuous improvement efforts of asset performance. Civil department consist of deputy manager (civil), two deputy officers and the work force. They frequently monitor company structures and maintain them properly. In case of new projects, the base infrastructure has to be erected by this department. DEPARTMENT STRUCTURE – CIVIL Fig:6.14
  • 76. Organisation Study on IREL Chavara 76 DC School of Management and Technology | Trivandrum CHAPTER 7 SWOT ANALYSIS
  • 77. Organisation Study on IREL Chavara 77 DC School of Management and Technology | Trivandrum STRENGTHS  Highly skilled managers and experienced workmen having excellent knowledge and experience about mining and production process.  Constant Upgradation of technology.  A strong and symbiotic relationship between the top level management and the lower level employees.  Technological collaboration with the Australian company, ROCHE, one of the largest mineral technology providers in the world.  Abundance of raw materials in the company premises itself.  Support from government of India and the department of atomic energy.  High concern towards the employees and environment. WEAKNESS  Mining problem.  Diminishing supply of raw sand.  The inability of the management to control effectively, the resistance raised by the local people in resource crises.  Excess number of civil workers.  High labour charges.  Due to monopoly promotional activities are less.  Decision making process is highly time consuming and complicated.  Shortage of power
  • 78. Organisation Study on IREL Chavara 78 DC School of Management and Technology | Trivandrum OPPORTUNITIES  High demand for products.  Growing demand for Titanium, Zircon, Thorium, Rutile, Ilmenite in international market.  Faster growth rate of markets in Asian countries where extraction facilities are limited.  The recent efforts to tie-up with other mining companies like KMML, Chavara  The favorable state government policies like prohibiting the entry of private companies into the mining sector.  As a strategically important company it is always backed by the central government. THREATS  Entry of private players such as TATA group into the area of black sand mining.  Over intervention of external political groups in company affairs.  Fluctuating in the value of currency which adversely affects the export income.  Increasing transportation cost.  Protect form environment activists.  Rapid technological changes in production process.  Changes in government policies.
  • 79. Organisation Study on IREL Chavara 79 DC School of Management and Technology | Trivandrum CHAPTER 8 PORTERS FIVE FORCE MODEL
  • 80. Organisation Study on IREL Chavara 80 DC School of Management and Technology | Trivandrum RIVALRY BETWEEN SUPPLIERS  In the current scenario IREL is free from rivalry between suppliers.  As beach sand is the raw material for IREL, there is no chance to depend external suppliers.  IREL has a mining area of 20 km from neendakara tokayamkulam, and mining is done by the mining department of IREL. BARRIERS TO ENTRY/THREAT OF NEW ENTRY  IREL, incorporated in the year 1950 at Mumbai and chavara plant opened in the year 1970.  For the last thirty nine years IREL chavara could make its own demand in the industry.  Q –grade is considered as the first quality in all over the world.hence opening barrier is nil in the case of IREL. BUYER POWER Major buyers are  Cochin minerals & rutile ltd  Travancore titanium products  Tum chemicals ltd  Tuticorinkolmak chemicals ltd,Kolkata Because of high requirement of heavy minerals for the buyers IREL can maintain the demand of the products above benchmark more and more companies are opened in plastic and paint industry as the result of globalisation .hence buyers policies is less,and it is an advantage for IREL.
  • 81. Organisation Study on IREL Chavara 81 DC School of Management and Technology | Trivandrum SUPPLIER POWER For IREL ,the supply of raw material is done by its own mining department so the influence external suppliers are nill hence supplier power is favourable to IREL. THREAT OF SUBSTITUTES RUTILE,ZIRCON,MONAZITE,SILLIMANITE,ILMENITE are the major products of IREL .in these products none of them has substitutes. hence the supplier power is favourable to IREL
  • 82. Organisation Study on IREL Chavara 82 DC School of Management and Technology | Trivandrum CHAPTER 9 PEST ANALYSIS
  • 83. Organisation Study on IREL Chavara 83 DC School of Management and Technology | Trivandrum POLITICAL ENVIRONMENT  Influence of political trade unions in IREL –labor unions are well co-operate with the management to achieve the common objective of the organisation.  Environmental policies of state and central government are opted to ensure healthy environmental condition .so IREL is forced to keep eco- friendly standards for mining and related process.  Ten policies is favourable to IREL.  The stable political conditions in state and central government are favourable to IREL. ECONOMIC ENVIRONMENT  The effect of inflation did not directly affect the sales volume because of the constant demand of its products.  In the present scenario, the exchange rate of Indian currency is comparatively steady ;it will be an advantage for Indian industries. SOCIAL ENVIRONMENT  IREL gives employment to hundreds of people directly or indirectly.so IREL has a good acceptance among local society.  People in the coastal regions make some problems when new mining process opens.  It is difficult to attach those lands because of the interference of local leaders who are argued for environment protection.
  • 84. Organisation Study on IREL Chavara 84 DC School of Management and Technology | Trivandrum TECHNOLOGICAL ENVIRONMENT  Technological factors are favourable to IREL .because IREL uses modern machinery for production.  The internal communication system of IREL is most modern.that include WIFI network,remote accessing&voip.it helps the managers to maintain healthy and effective administration.
  • 85. Organisation Study on IREL Chavara 85 DC School of Management and Technology | Trivandrum CHAPTER 10 FINDINGS, SUGGESTIONS & CONCLUSION
  • 86. Organisation Study on IREL Chavara 86 DC School of Management and Technology | Trivandrum FINDINGS  The intervention by the external policies parties continues to be a disturbance in formulating labor practices.  IREL had strong and symbiotic relationship between the top level management and lower level employees.  The company had a strong financial position.  Constant upgradation of technology.  IREL had a good support from government of INDIA and the department of atomic energy.  Since, IREL is a monopoly the promotional activities are less.  Unavailability of land for the expansion of the unit capacity.  Higher labour charges.  Since the company is located 4km away from NH(national highway) the time consuming and the transportation cost is very high SUGGESTIONS AND RECOMMENDATIONS  The company can adopt different mode of sales other than the direct sales which is mainly done in IREL.  The government policies can change any time and so there is a possibility for the entry of privet players .so the company should always be careful to maintain its product quality ,brand identity, customer relationship etc  IREL should take advantage of the growing demand for heavy minerals by increasing the production.  The management should sustain the faith of the local people by constantly communicating and explaining the company’s policies to them. The trust of the local people can be ensured and sustained by constant interaction and communication with them. The company can achieve them by undertaking more socially responsible activities. This may be in the form of medical
  • 87. Organisation Study on IREL Chavara 87 DC School of Management and Technology | Trivandrum facilities running schools, assistance at the time of sea erosion and trawling ban. They can also provide water and electricity supply to the local people.  The company should try to minimize the external interventions of various political parties. CONCLUSION IREL is one among well performing companies in Kerala, engaged in the process of processing rare earth products available among the coastal belts. IRE is reaching new boundaries with its performance. IRE was incorporated on 18th august 1950 as a private limited company under the Indian company’s act of 1913 jointly by the government of India and the government of Travancore Cochin. In 1951, IREL became a public sector undertaking and two mineral separation plants, one at Manavalakurichi in Tamilnadu (1967) and the other at Chavara in Kerala state (1970) were setup. The organisation study at IRE ltd was an unforgettable experience. The organizational atmosphere prevailing at IRE is not that of a public sector unit. The concern for the environment and social responsibility are worth studying. The study helped in having a practical exposure to real practice in organisation. The study provides insight into the functioning and coordination of departments in an effective organization.
  • 88. Organisation Study on IREL Chavara 88 DC School of Management and Technology | Trivandrum Appendices BALANCE SHEET AS AT 31ST MARCH, 2013 Year ended 31stmarch,2013 Yearended 31st march,2012 Year ended 31st march,2011 EQUITY & LIABILITIES 1) Shareholders’ Funds a) Share Capital b) Reserves and Surplus Total 2) Non-Current Liabilities a) Other long term liabilities b) Long term provisions Total 3) Current Liabilities a) Trade payables b) Other current liabilities c) Short term provisions Total TOTAL OF EQUITY & LIABILITIES ASSETS 1) Non-Current Assets a) Fixed Assets (1) Tangible assets (2) Intangible assets (3) Capital work-in-progress Total b) Non-Current Investment c) Deferred Tax Assets (Net) d) Long Term Loans and advances e) Other Non-Current Assets Total 2) Current Assets a) Inventories b) Trade receivable c) Cash and bank balance d) Short term loans and advances e) Other current assets Total TOTAL OF ASSETS 8636.50 65054.35 73690.85 5414.01 4616.81 10030.82 1122.56 10107.83 14552.22 25782.61 8636.50 53139.57 61776.07 5515.31 3934.95 9450.26 1031.54 7041.15 12569.81 20642.50 8636.50 40104.33 48740.83 5397.70 2451.16 7848.86 1011.46 6851.74 4514.55 12377.75 109504.28 91868.83 68967.44 16323.20 35.74 9796.51 26155.45 1.42 5488.20 4226.50 1827.05 11543.17 13140.49 192.19 52781.18 3662.07 2029.73 71805.66 17773.93 34.64 2624.80 20433.37 1.42 4002.46 5035.40 511.53 9550.81 6822.13 237.71 50847.82 1723.01 2253.98 61884.65 19146.66 20.89 1355.03 20522.58 1.42 1300.43 4412.89 3020.46 8735.20 4572.71 180.14 31342.02 1523.45 2091.34 39709.66 109504.28 91868.83 68967.44
  • 89. Organisation Study on IREL Chavara 89 DC School of Management and Technology | Trivandrum STATEMENT OF PROFIT AND LOSS FOR THE YEAR ENDED 31ST MARCH, 2013 Year ended 31st march, 2013 Year ended 31st march, 2012 Year ended 31st march, 2011 REVENUE a) Revenue from operations b) Other income TOTAL REVENUE EXPENSES a) Cost of material consumed b) Charges in inventories of finished goods, Work-in- progress and stock-in trade c) Employee benefits expenses d) Finance cost e) Depreciation and amortization expenses f) Other expenses TOTAL EXPENSES Profit before prior period adjustments (net), exceptional items, extraordinary items and tax Prior period adjustments (Net) Profit before exceptional items, extraordinary items and tax Exceptional items Profit before extraordinary items and tax Extraordinary items Profit before tax Tax expenses a) Current tax b) Deferred tax asset(or liability) PROFIT FOR THE PERIOD 52765.79 6617.22 59383.01 2890.00 (6087.08) 19876.05 800 1907.71 15321.44 34709.03 24673.98 63.53 24610.45 866.09 23744.36 - 23744.36 9571.48 (1485.74) 63218.22 4897.28 68115.50 3612.94 (1805.94) 19920.03 141.38 2063.37 14498.98 38428.76 29686.74 391.53 29295.21 4311.10 24984.11 - 24984.11 10641.22 (2702.03) 39975.91 3031.53 43007.44 3767.16 1776.35 17549.09 150.869 2025.11 12379.85 37648.25 5359.19 115.45 5243.74 - 5243.74 - 5243.74 1260.78 793.60 15658.62 17044.92 3189.36
  • 90. Organisation Study on IREL Chavara 90 DC School of Management and Technology | Trivandrum BIBLIOGRAPHY 1. C.R. Kothari – Research Methodology methods and Techniques. 2. Prasad L.M – Principals and practice of management. 3. Kottler Philip – Marketing Management. 4. Rejimon.P.M – Indian rare earth is going to expand. 5. Rejimon.P.M – 50 Crores rupees expansion program in IRE. 6. IREL Broucher – Apex manual and departmental procedures of IREL. 7. http://www.indianrareearths.com 8. http://www.irel.gov.in 9. Annual Reports and Journals