History of Fact: The Beginning
History of Fact: The Beginning
History of Fact: The Beginning
the production of sulphuric acid, phosphoric acid and Urea was started.
In 1979 Production of NPK was commercialized.
Technical Divisions
FACT Engineering and Design Organization (FEDO) was established in
1965 to meet the emerging need for indigenous capabilities in vital areas
of engineering, design and consultancy for establishing large and modern
fertilizer plants. FEDO has since then diversified into Petrochemicals and
other areas also. It offers multifarious services from project identification
and evaluation stage to plant design, procurement project management,
site supervision, commissioning and operating new plants as well as
revamping and modernization of old plants. FEDO received international
accreditation ISO 9001 2004 for quality system standards covering areas
of consultancy, design & engineering services for construction of large
fertilizer, petrochemicals, chemicals and related projects including
purchasing, construction, supervior, inspection and expediting services.
FACT Engineering Works (FEW) was established on 13 th April 1966 as a
unit to fabricate and install equipment for fertilizer plants. FEW was
originally conceived as a unit to fabricate and install equipment for
FACTs own plants. Over the year it developed capabilities in the
manufacture of class I pressure vessels, heat exchangers, rail mounted
LPG tank wagons etc. It has a well equipped workshop approved by
Lloyds Register of Shipping, further; this division has excelled in laying
cross country piping fabrication and installation of large penstocks for
hydel units in Kerala. The Cochin Division of FACT, the 2nd production
unit was set up at Ambalamedu and the 1st phase was commissioned in
1973. The 2nd phase of FACT Cochin Division was commissioned in
1976. The project
was designed to produce Ammonia which would be converted to Urea
and also to produce high analysis, water soluble NP fertilizers. This
division corprises of a number of large capacity plants to produce
Ammonia, Urea, Sulphuric Acid, Phosphoric Acid and Fertilizers like
FACTAMPHOS 20-20 and DAP 18-46. FACT has also a Research &
development Department which carries out research related to fertilizers.
This Division is also capable of doing fundamental research in areas of
fertilizers and chemicals technology. So far FACT R & D has taken 17
Vision of FACT
To emerge as a leading company in the business of providing quality
agriculture and industrial inputs and providing engineering services for
industrial and infrastructural facilities.
CORPORATE OBJECTIVES
1.
To be of service to the nation and to contribute effectively to its
economic well being and growth through the production and marketing
of fertilizers and chemicals and through the acquisitions/development
and dissemination of engineering technology know-how and skills.
2. To sustain and improve its pioneering role in the development of
indigenous engineering and technology through research and
development.
3. To improve productivity and maintain high standards of quality and
adopt effective measures for controlling cost and minimizing dependence
on imports.
4. To ensure for its customers the availability of its products and services
on reasonable terms, for its shareholders a fair return on capital invested
and, for itself, development of adequate internal resources for continual
growth and expansion.
5. To actively work for rural uplift through guidance, advice and service
to the farmers in co-operation with all other agencies working for
agriculture development and allied activities.
6. To develop, train and maintain a team of motivated and disciplined
personnel with required skills and abilities, and to encourage innovation
and to create a condition for their functioning and career development so
as to improve their overall quality of life
7. To project a favorable image of the company and its operations, in the
society in which it operates, amongst its customers and suppliers and
amongst the public in general.
8. To continuously plan its future operations for sustained growth and
stability for meeting the needs of the country.
CORPORATE GOALS
1. To achieve a net profit of 200 crore per year with a turnover of Rs.2100
crore by the year of 2010
2. To focus on cost reduction and technology up gradation in order to
become competitive in each line of business.
3. To constantly innovate and develop new products and services to
satisfy customer requirements.
4. To invest in new business lines, where profit can be made on
sustainable basis over the long term.
5. To compete through speed, agility and flexibility in recognizing and
capturing opportunities in existing markets.
6. To invest sufficiently to stay in the game but avoid premature
commitments.
OWNERSHIP PATTERN
DIVISIONS OF F.A.C.T
Udyogamandal Division
FACT commenced operation at Udyogamandal with the commissioning of
a 50,000 tonnes per annum Ammonium Sulphate Plant in 1947. In the
decades that followed multi stage expansion programs were undertaken
bringing in the latest technologies of the day which were quickly
mastered and successfully implemented. Today the division is 40 year old
small capacity plants and 10 year old state of the art technologyplants.
The latest addition to this unit was a 900 tonnes per day Ammonia
Complex set up with an investment of RS 618 crores. FACT
Udyogamandal division is certified to ISO 14001, the environmental
system standards.
Cochin Division
FACT Cochin Division was set up in the 1970's at Ambalamedu, 30 km
from Udyogamandal and adjacent to the Cochin Refineries. Phase-I of the
division saw the setting up of an integrated Ammonia urea complex
utilizing Indian Engineering skills. A large scale complex fertilizer plant of
485,000 TPA was set up as phase-II. Sulphuric acid and Phosphoric acid
plant of economy scale were also set up.
Petrochemical Division
FUNCTIONS OF HR DEPARTMENT
1. Organizational human resource planning & development
2. Retirement & selection
3. Wage & Salary administration
4.
5.
6.
7.
8.
9.
PROCESS OF HR DEPARTMENT
The human resource department has 3 blocks which are:
Establishment Section
The main functions are:
1. Recruitment & selection
2. Transfer, rotation and placement of employees in consultation with
divisional heads
3. Wage and salary administration
4. Performance Appraisal
5. Retrenchment
Industrial Relation
Industrial relation operates only within the Organization. The
Interorganizational relation is handled by the corporate cadre. 60 to 70 %
of management time is lost in resolving IR issues. Therefore the H.R
department is of paramount importance. The main functions are:
1.
2.
3.
4.
5.
6.
7.
Welfare
PERFORMANCE APPRAISAL
Performance Appraisal in FACT started in 1962. In 1984, the system was
further revised to include potential assessment, assessment of training
needs and performance counseling.
The main functions are:
1.
2.
3.
4.
5.
6.
MANPOWER OF FACT
As part of cost reduction measures, from 1998 onwards FACT reduced its
employee strength. FACT had more than 9000 employees earlier, but it is
now reduced to less than 4000 employees by the successful
implementation of VRS. FACT has several divisions, which all together
consist of 3817 employees now. The following table shows the division
wise employee strength of FACT during April 2008
Acting on complaints
Anonymous and pseudonymous complaints are not taken cognizance of
survey of employees suspected of indulging in corruption is undertaken
YES/NO
Take action
Inspecting high value
files
Fraud
Detected
Receipts of complaints
Suspicious
Actions
Acting on complaints and on getting reliable information their names are
included in the agreed list for keeping a close vigil on their activities.
Suspicious action of employees
The Fertiliser and Chemicals Travancore Ltd Shri K Sreenivasa Karayalar, reviews
activities
Addressing the Twenty first Annual General Meeting held at the Registered Office,
Udyogamandal, on 30th September 1965, Shri K Sreenivasa Karayalar said:
Gentlemen, I am glad to welcome you to this, the 21st Annual General Meeting of
the Company and to present to you the accounts of the Company and the Report of
the Directors for the year ended 31st March, 1965. As in the past few years, the
company had to face a severe power cut ranging from 32% to 70% in the first three
months of the year under review. This cost the Company a loss of production of the
order of Rs. 10 million. In November last year an tinfortunate explosion occurred in
the Ammonia Synthesis Plant due to the failure of a high pressure pipeline. In
addition to causing the death of three of the company's loyal workers, the accident
also resulted in one of the ammonia stream going out of production for the rest of
the year. The high pressure pipe that failed was a special chrome molybdenum alloy.
New pipelines were ordered immediately from abroad. They arrived a few weeks
ago and the ammonia stream would be back in production in a few days. The
families of the workers who lost their lives were granted liberal assistance. On
account of this explosion the company lost Rs. 7.5 million worth of production
during the year. In addition to these setbacks, there was also a shortage of imported
raw materials in the last quarter of the year on account of the critical foreign
exchange situation. Depreciation also went up on account of the need for making an
extra allowance for the third shift working. The total depreciation charged for the
year amounted to Rs. 6.74 million as against Rs. 5.63 million in the previous year.
Another difficulty arose on account of the arbitrary fixation by the Government of
India of the retention price for ammonium sulphate, the major product of your
Company. The price fixed for both 1963-64 and the year under review were well
below the fair price the Company was entitled to, The matter was represented to
the Government of India for reconsideration. Their decision is awaited. As a result of
all these adverse factors, the company incurred a net loss of Rs. 4.88 million. This
loss can be made up as the new plants installed during the third stage of expansion
will be going into production shortly. In these circumstances, it has not been
possible to recommend any dividend for the year. The current year also started
badly as the ammonia stream referred to earlier continued to be out of commission
awaiting the arrival of the special high pressure pipes, Power shortage also affected
production adversely in June/July, Yet the company was hopeful of making up these
losses in production as the new plants installed during the third stage of expansion
were being got ready for commissioning. It was at this time that the Employees'
Association decided to go on a strike. For some months in the past, the Employees'
Association had been taking a belligerent attitude. The Association started
interfering with disciplinary proceedings initiated in the normal course. The
Association leadership also carried on a systematic campaign advising the
employees not to carry out the instructions issued by their superiors. Things came
to a. head when the new plants installed during the third stage of expansion had to
be commissioned. The necessary personnel for operating and maintaining the
plants were posted and commissioning work was about, to begin. The
commissioning engineers had arrived from abroad. The Association leadership
thereupon advised the workers to go on a tools down strike from the 2nd of August
1965. The Association also gave a notice of strike on the 4th of August. As a public
utility undertaking, the company was entitled to a clear fourteen days' notice. Yet,
the sectional strikes which started on the 2nd of August, even before the notice was
served, continued to spread from one section to another during the currency of the
notice period and at 1 a.m. on 24th August there was a complete stoppage of work.
On the advice of the Association, leadership the workers took possession of the
plant and shut them down between I a.m. and 6,30 a.m. on the 24th. The
Superintendents and other Managers could go inside the factory only at 6,30 a.m.
under Police escort. The strike went on for thirteen days. A conciliation agreement
was arrived on the 5th of September as a result of which the strike was withdrawn
from the noon of 6th September. I am glad to say that the terms of the agreement
are satisfactory from the company's point of view. The strike staged by the workers
on the advice of the Employees' Association was most untimely and illconceived.
Whatever disputes were there between the Management and the Association were
the subject matter of conciliation proceedings before the Labour Commissioner. For
the past six years and more, all disputes that arose between the Management and
the Employees' Association were arbitrated by the Labour Commissioner in
accordance with the terms of the long term agreement and both parties accepted
his decision. The Management was prepared to abide by the Labour Commissioner's
decisions in respect of all pending items of dispute. Although the Labour
Commissioner held several meetings with the Association leadership, no agreement
could be arrived at as the Association started raising new issues every time.
According to the settlement now arrived at, negotiations on the pending issues
commenced on the 20th of September 1965, between the Management and the
Association. Commissioning work of the third stage plants has begun. It is expected
that all the plants will be commissioned by December this year. You will remember
that the third stage expansion programme was taken up only in 1962. It is indeed
gratifying to state here that the work has been completed with speed, enabling, the
commissioning of the plants well within the target dates. Once these plants go into
full production your company will be producing 200,000 tonnes of ammonium
sulphate. 135,000 tonnes of ammonium phosphate (16:20) grade, 25,000 tonnes
tonammonium chloride and 14,000 tonnes of superphosphate in addition to being
able to make and supply 350,000 tonnes of NPK Mixtures. Full production however is
dependant'on two factors availability of power and raw materials. The additional
power required for operating the new plants is of the order of 20,000 KW, The Kerala
State Electricity Board has advised us that they would be able to supply that power
only in July 1966. Consequently we arc forced to make some adjustments until such
time full power is available. The emergency arising out of the armed conflict
imposed on us by Pakistan has had its effect on the availability of imported raw
materials and spares. A ship carrying large quantities of material for Us has been
confiscated at Karachi. Every effort is being made to secure law materials and to
keep the plants in operation. It should be remembered that we are almost entirely
dependant on imported raw materials like sulphur, and rock phosphate. Naphtha is
also produced at present out of imported crude oil. Continued operation of plants to
capacity will be therefore dependant on the conditions arising out of the emergency
so far as imports are concerned. Although the immediate future is beset with
difficulties on account of the shortage of power and a possible lack of raw materials,
the future promises an era of prosperity for your company. Modern technology
demands a minimum economic capacity of 600 tonnes a day for single stream
ammonia plants. Al l the new ammonia plants proposed to be set up in the country
during the Fourth Plan period are of a daily capacity of 600 tonnes or more. When
such plants come into being, units like the 260 tonne one belonging to your