CHAPTER 1

INTRODUCTION OF SUMMER TRAINING

1.1 INTRODUCTION

Cement is a capital-intensive, energy-consuming and critical sector for the

construction of nation-wide infrastructure. The international cement industry,
while constituting a limited share of the world’s output has been rising at an
increasing pace compared to the local demand in recent years. Cement is a blinder,
a substance used for construction that sets, hardens, and adheres to other materials
to blind them together. Cements are seldom used on its own, but rather to bind
sand and gravel together. The invention of Portland cement usually is attributed to
Joseph Aspdin of Leeds, Yorkshire, England, who in 1824 took out a patent for
material that was produced from a synthetic mixture of limestone and clay. India
entered into the Cement Era in 1914, when the India Cements ltd., started
manufacturing cement in Porbundar in Gujarat. But cement isn’t some sort of
naturally occurring organic material it’s manufactured through the chemical
combination of 8 main ingredients during the cement production process. Cement
is mainly used as a blinder in concrete, which is a basic material for all types of
construction, including housing, roads, schools, hospitals, dams and ports, as well
as for decorative applications (for patios, floors, staircases, driveways, pool decks)
and items like tables, sculptures or bookcase. Cement is manufactured through a
closely controlled chemical combination of calcium, silicon, aluminium, iron and
other ingredients. Common materials used to manufacture cement include
limestone, shells, and chalk or marl combines with shale, clay, slate, blast furnace
slag, silica sand, and iron. And the total 210 large cement plants in India, 77 are in
the states of Tamil Nadu, Andra Pradesh, and Rajasthan. In this project we will
clearly see about one of the important cement factory, The Ramco Cements Ltd.,

Figure 1.1: Industry Profile

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 Figure 1.2: Industrial Logo

Figure 1.3: Infrastructure

1.2 Importance of the study

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 The summer training program helped me to gain knowledge about the
industry. It provide students with real-world, hands-on experience in their field of
study. They allow students to apply the knowledge gained in the classroom to
practical situations, helping them develop a deeper understanding of their chosen
profession.

1.3 Objectives of study

❖ To study the function performed by various departments.
❖ To determine the factors influencing the choice of the customers.
❖ To know the organization, structure and communication network of
The Ramco Cements limited.,
❖ To study the worker’s attitude and their working environment nature.
❖ To find out the relation between employer and employees.
1.4 Scope of the study
This training help in finding out the various moment of truth that the
customer encounter during their interaction with the company, hence company can
us the findings to improve where it is Lagging.
Analysis of the customer response help in bringing out the areas where the
company is during very well and also areas in which it needs to be cautious about.
It will also help the organization to make and know the strengths and weakness of
the company can involve better strategies to overcome the weak areas.
As this training includes extensive study of various Factors influencing the
buying decision of the customer it will also help to rectify those factors where
company is lagging behind their company.
A learning management system is a software application for the
administration, documentation, tracking, reporting, automation and delivery of
educational courses, training programs, or learning and development programs.

1.5 Period of the study

The period of study starts from 26th June to 28th July(one month) in The
Ramco Cements limited (cement industry).The training provides a platform to
study about the function of various department.

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 CHAPTER 2
PROFILING OF THE INDUSTRY AND COMPANY
2.1 INDUSTRY PROFILE
Cement is a blinder, a substance used for construction that sets, hardens,
and adheres to other materials to bind them together. Cement is seldom used on its
own, but rather to bind sand and gravel together. Cement mixed with fine aggregate
produces mortar for masonry, or with sand and gravel, produces concrete. Cement
is mainly used as a blinder in concrete, which is a basic material for all type of
construction, including housing, roads, schools, hospitals, dams and ports.

The Cement industry is one of the main industries necessary for sustainable
development. It can be considered the backbone for development. Cement is
required by every industry cement is an important part of industrial infrastructure.
It provides direct and indirect employment to a large number of persons and
contributes a major part to Gross Domestic Product (GDP). India is the second
largest cement producer in the world and accounted for over 7% of the global
installed capacity. India’s overall cement production capacity was nearly 545
million tones (MT) in FY22. Of the total capacity, 98% lies with the private sector
and the rest with public sector.

The Cement industry holds some advantage that can allow it to meet this
demand, limit its carbon footprint and participate in the development of the regions
where it is established. Cement it cheap, adaptable and in strong demand. It can be
manufactured while improving itsenvironmental impact. It can play a significant
role in the economic growth as India has emerged as a major exporter of cement.

STRENGTH OF INDIAN CEMENT INDUSTRY

The Indian cement industry is now the second largest in the world after
China. It has a total installed capacity of 500 million tons (MT) and produces about
350 MT of cement per annum. The industry is highly competitive, with a large
number of domestic and multinational operators. The top 10 companies account
for 60% of total production.

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 Figure 2.1.1: Industrial location

Oligopolistic Industry

The cement industry is an oligopolistic industry. Some of the conductive

industry forces that support long term attractiveness are:

Entry barriers: The entry barriers are high since huge capital investments
are required to present substantial barriers to entry and achieving economies of
scale.

Inter – firm rivalry: The inter firm rivalry is low since Indian cement market
is oligopolistic in nature, characterized by tacit collusion, where large players
partially control supply for better price discipline.

Substitute threat: The threat to Cement is low since practically cement has no
substitutes.

Buyer’s power: The influential power of the buyer is low since Substantial
Market concentration among large players ensures low bargaining power of buyers.

Supplier’s power: The influential power of the buyer is moderate since

cement players have to depend on the railways for carriage outward and local coal
companies for fuel, although diversification of freight options and fuel sources is
diminishing the suppliers’ power.

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Major Players in the industry are:

1. Ultratech cement
2. Ambuja cement
3. ACC
4. Shree cement
5. JP associate
6. Samruddhi cement
7. Prism cement
8. India cement
9. JK cement
10. Binani cement
11. Kesoram Cements
12. ACL Limited
13. Chettinad Cements

Figure 2.1.2: competitors

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2.2 COMPANY PROFILE

The Ramco Cements Limited (formerly Madras Cements Ltd) is India’s

leading cement company offering, “Right product for Right Application”, through
innovative cements and cement products. Ramco Cements Ltd is a company of the
Ramco group, a business group based in Chennai, India. The company also
produces ready-mix concrete and dry mortar products and operates wind farms.

STATUTORY INFORMATION:

Company name The Ramco Cements Ltd.,

Establishment 1961

Establishment place Ramasamy Raja Nagar, Virudhunagar, Tamil

Nadu.
Founder P A C Ramasamy Raja

Head / Corporate office Auras Corporate Centre,

98A, Dr. Radhakrishnan road
Mylapore, Chennai 04
Net worth INR 6793.53billion (2022-23)

Products Cements

Revenue INR 5405.64 Crores

CEO/MD P R Venkatrama Raja

Company status Active

Table 2.1: Company Details

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 The Ramco Cements Limited Company Vision is “To create value on a
sustained basis for all stakeholders of Ramco Cements through lofty standards of
transparency, accountability and responsibility, innovation and leadership in
cement manufacture.
The Mission is “The Ramco Cements will strive to remain a leader in the
manufacture of cement and establish itself as a preferred supplier of products and
services to its clients and enhance the brand value for all stakeholders”. As the
organization grows, as a responsible corporate citizen, Ramco Cements shall be
sensitive to the welfare and development needs of the society around it.
The Ramco Cements Limited has providing the CSR. That means Corporate
Social Responsibilities. The Company has spent INR 7.28 Crores on CSR, leaving
a shortfall an INR 0.68 Crores.
Eye check-up camps, Medical check-up camps (Siddha & Ayurveda)
conducted for monthly once, Give the kit for the disable persons, Free education
for the poor children, the company arranging the Suyamvaram function for the
Disable persons, the Ramco provides facilities like roads, street lights and
community hall to nearby villages.

2.2.2WORK SCHEDULE

Shift 1 2 3

Timing 11:00 P.M-07:00 07:00 A.M-03:00 P.M 03:00 P.M-11:00 P.M

A.M

Table 2.2: Work schedule

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2.2.3 VISION AND MISSION

1. To continuously improved productivity through quality, technology

renewal and customer focused operations.
2. To position ourselves in the cement business as a pace setter and grow in
the same and related business.
3. To seek green field locations for growth on the basis of developed synergies
of the existing operations.
4. To continuously seek quality enhancement in product, processes and
responses t ovarious stakeholders.
5. To update management practices on a continuous basis and maintain a
culture of professional management.
6. To conserve, protect and enhance quality of life for our employees and
community.
7. To preserve the credence in our motto “our real resources are the human
assets”.

2.2.4 CORE VALUES AND BENEFITS

Customers continued satisfaction and the sensitivity to the needs is our

source of strength and security. If there is no customer, there is no business. We do
not look at productivity as a game in numbers. We try to learn from others, be
committed to quality and always stay ahead in terms of technology.

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2.3 PRODUCT PROFILE

The Ramco Company has producing the cement products. I will explain the some
kind of cements in product profile. The cement manufacturing basic raw material
is Lime stone. The raw material was collected from Ramco’s own mines in
Pandalkudi at Tuticorin. Cement is a type that many say. But cement is divided into
several types. Certain types of cement are produced for various needs in
construction. There are:

1. Ordinary Portland Cement (OPC)

Ordinary Portland Cement (OPC) is a general purpose Portland
cement suitable for all uses where the special properties of other type are
not required. It is used where cementor concrete is not subject to specific
exposures, such as sulphate attack from soil or water, or to an objectionable
temperature rise to head generated by hydration.

2. Portland Pozzolona Cement (PPC)

Portland Pozzolona Cement (PPC) is special blended cement useful
in general construction work and is especially suitable for applications in
aggressive environmental conditions. It can be confidently employed in
construction of hydraulic structures, marine works, mass concreting such
as dams, dykes, and retaining wall foundation and sewage pipes.

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2.3.1 RAMCO SUPER GRADE
World over Ramco Super grade is preferred due to its ability to produce
a durable concrete where the life of a concrete structure is given more importance.
Ramco Super grade produces less heat of hydration and offers greater resistance to
the attack of aggressive watersthan normal Portland cement.

Figure 2.3.1 Ramco Super Grade

2.3.2 RAMCO SUPER CRETE

Ramco Supercrete is a light weight Autoclaved Aerated Concrete (AAC)

building material which is factor cut into Blocks, Panels and special elements for
a wide variety of building applications, both load bearing and non-load bearing.
Ramco Supercrete is a specially formulated blended cement manufactured as per
IS 1489 which has been used to make high performance concrete. This cement is
the culmination of R&D efforts, our experience of supplying cement to critical
projects and feedback from Civil Engineers.

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 Figure 2.3.2: Ramco Super Crete

2.3.3 RAMCO SUPER PLASTER

Ramco Super Plaster is a value added mortar product, engineered
purely for plastering and brickwork. The product provides increased coverage
and better crack resistance to the walls. It also gives excellent workability with
M-Sand.

Figure 2.3.3: Ramco Super Plaster

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2.3.4 DRY MORTAR PRODUCTS
RAMCO ECO PLAST
Features
100% avoidance of curing , Saves 15,000 litres of water for a 1000 sq. ft
house .Better crack resistance , Reduction in labour cost , Premixed with well-
graded sand .
Applications
For plastering ceilings and walls – Internal and External | Suitable for
Bricks, Concrete Blocks, and all types of AAC blocks.

Figure 2.3.4: Ramco Eco Plast

2.3.5 Ramco Tile Fix

Features
Improved cohesive strength, Longer open time, Excellent adhesion
property, Excellent resistance to water absorption
Applications
For fixing ceramic tile wall, floor & vitrified tile floor, For fixing tile on
tile , For fixing granite and marble , For underwater applications like swimming
pools , For fixing glass mosaic

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 Figure 2.3.5: Ramco Tile Fix
2.3.6 Ramco Block Fix
Features
Excellent adhesion strength , Self curing, No shrinkage cracks
Applications
For fixing AAC / solid blocks

Figure 2.3.6: Ramco Block Fix

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2.3.7 Ramco Tile Grout
Features
Higher flexibility, Improved abrasion resistance, Higher hydrophobicity
Applications
Interior and Exterior, Floor and Wall tiles

Figure 2.3.7: Ramco Tile Grout

OBJECTIVES OF TRANINING

1. To gather knowledge about The Ramco Cements Limited.

2. To know about the production process of The Ramco Cements Limited.
3. To know about the various department of The Ramco Cements Limited.

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2.6 ORGANIZATIONAL STRUCTURE

Figure 2.6.1: Organizational Structure

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2.7 PESTEL Analysis
PESTEL Analysis is a strategic management tool that The Ramco Cements
management can use to make better decisions. PESTEL stands for – Political,
Social, Economic, Technological, Environmental and Legal factors that impact the
macro environment of the firm that it operates in.
Political
• Government resource allocation and time scale
• Importance of local governments in India
• Regulatory Practices
• Governance System
• Government of India has come under increasing global pressures to
adhere to World Trade Organization’s regulations on Construction.
• Political stability in the existing markets
Economic
• Economic Cycles
• Exchange rate
• Efficiency of financial markets in India
• Skill level of workforce in India market
• Downward pressure on consumer spending
Social
• Power structure
• Attitude towards health and safety
• Leisure interests
• Societal norms and hierarchy
Technology
• Technology transfer and licensing issues for The Ramco Cements
• Maturity of technology -The technology in the Construction
• 5G and its potential
• Research and development investment at both macro level and micro
level in India
• Lowering cost of production

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 Environment
• Environmental norms are also altering the priorities of product
Innovation.
• Customer activism
• Extreme weather is also adding to the cost of operation
• Recycling is fast emerging as a norm rather than a good thing to
do In India economy.
• Regular scrutiny by environmental agencies
Legal factor
• Business Laws
• Health and safety norms in the India
• Employment law in the India and how they are impacting the
business
• model of the Construction
• Legal protection of intellectual property, patents, copyrights, and
other IPR rights in India
• Data protection laws
• Time take for business cases in court
2.6 CORPORATE SOCIAL RESPONSIBILITY
Corporate Social Responsibility (CSR) of a company is aimed to improve
social welfare around the company, then to get good relationship among people in
the society as well as between society and the company itself for the sustainability.

social responsibility in cement industry

Corporate Social Responsibility (CSR) has become an important strategic
initiative that every corporate establishment needs to understand and implement. It
can be defined in simple terms as the intentional inclusion of public or social
interest into business strategy. It has been adopted by the corporate world to ensure
that every decision taken by a business is of the highest ethical value along with
respect to the society, legal compliance and being responsible for the environment.
Some experts believe that, treating employees & other humans respectfully,
operating with integrity and protecting the environment for future generations are
all part of the CSR initiatives.

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 Many companies across the world are implementing CSR initiatives and
encouraging their employees to take part. Some of the companies try to adopt the
concept focusing more on their core business vertical. Indian companies have also
been showing keen interest in CSR activities in the past decade. According to a
report by Indian Brand Equity Foundation (IBEF), nearly all-leading companies
are involving themselves in CSR programmes in the areas of education, healthcare,
skills development and empowerment of weaker sections of the society. In fact, the
Tata group and Aditya Birla group have been doing business with a focus on society
for decades, long before CSR became a popular activity.

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 CHAPTER 3
ACTIVITIES OF VARIOUS DEPARTMENTS
3.0 FUNCTIONAL DEPARTMENTS
The Ramco Cements limited company is one of the most important
manufacturing plants in India. So the company consists of 5 important
departments. These departments are:

1. HR Department
2. Safety Department
3. Accounts Department
4. Production and Operating (CCR) Department
5. Purchase and Material Department
6. Information Technology Department
7. Stores Department
8. Packaging Department

3.1 HR DEPARTMENT

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 Organizational structure

Unit Head
R.R.Nagar plant

Head of the
Department Human
Resource

Assistant General Manager

Human Resource

Assistant manager Time Officers

Human Resource Human Resource

Figure 3.1.1: Human Resource Department -Organizational structure

The Human Resource Department in Ramco Cements Limited handles

many necessary functions. It mainly focuses in providing labour law compliance,
record keeping, hiring and training. The HR is the person who appoints employees
and workers in the company; he plays a key role in employee’s work force. HR

21
advertised the job posting, source candidates, screen applicants, conducts
preliminary interviews.

The HR Department manage man, money, material and machines. The main
responsibility of this department is to provide welfare measures to the workers and
employees and recruiting employees.

The Ramco Cements Limited selection process is based on the employee’s

qualification, work experience and have in good communication skills. Age limits
also measured related to based on the work or job. They mostly prefer employee
who have completed any degree with well knowledgeable and without arrears on
qualified UG or PG courses. Only full time jobs are available.

Training program also provided for the fresher’s about the introduction of
the company rules and policies, explanation about safety measures through every
department available in the organization.

They maintain employee’s attendance register in the form of digital way

and also they maintaining written format of registration and they submit the
attendance register to the head office at the every end of the day. Salary is provided
to the employer and worker based on their attendance in the organization.

Employees and workers in the organization they must strictly wear shoes,
head wear and safety jacket for their safety purpose to avoid any accident during
their work.

Recruitment and Selection

Recruitment and Selection is the process of identifying the need for a job,
defining the requirements of the position and the job holder, advertising the
position and choosing the most appropriate person for the job. First of all the
Ramco Cements Limited, the technical workers only can recruit in the company.
And the process of the recruitment is

1. Fill the Recruitment application

2. Certificate verification

3. Aptitude test

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4. Face to Face interview

5. Practical test

6. Confirmation letter

7. Medical Check-up

8. Training

9. Indication

10. Confirmation for work

Training and Development

Training and Development initiatives are educational activities within an

organization that are designed to improve the job performance of an individual or
group. These programs typically involve advancing a worker’s knowledge and skill
sets and instilling greater motivation to enhance job performance. T&D process is
an organizational activity aimed at improving the performance of the individuals
and groups of employees in the organizational settings. It is an organized activity
for increasing the knowledge and skills of the employees.

Performance appraisal

The term performance appraisal refers to the regular review of an

employee’s job performance and overall contribution to a company. Also known
as an annual review, performance review or evaluation or employee 25 appraisal,
a performance appraisal evaluates an employee’s skills, achievements and growth
or lack.

3.2 SAFETY DEPARTMENT

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 Unit Head
R.R.Nagar Plant

Deputy General Manager

Human Resource

Safety

Environmental
Advisor Safety Supervisor Safety Advisor

Figure 3.2.1: Safety Department - Organizational structure

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 Industrial safety is primarily a management activity which is concerned with
reducing, controlling and eliminating hazards from the industries or industrial
units. The Safety management have concerned the Four E’s. There are

1. Engineering – Safety at the design, equipment installation stage.

2. Education – Education of employees in safe practices.
3. Enlistment – It concerned the attitude of the employees and management
towards the programmed and its purpose. This necessary arose the interest of
employees in accident prevention and safety consciousness.
4. Encouragement – to enforce adherence to safe rules and practices.

Safety inspection procedures of the safety department in Cement company:

1. Safety audit – A Safety audit subjects each area of a company’s activity

to a systematic critical examination with the object of minimizing loss.

2. Safety survey – A Safety survey is a detailed examination in depth of a

narrower field of activity.

3. Safety inspection – A routine scheduled inspection of a unit or

department, which may be, carried out by some (may be a safety
representative) from within the unit, accompanied by the safety advisor.
The Inspection would check maintenance standard.

The Ramco Cements Limited Company was provided the Helmet, Shoes
and Jacket for the technical worker, clerical employees and technical engineers.
Any sick for the employees or workers or engineers immediately they took
treatment to the Industry Hospital.

3.3 ACCOUNTS DEPARTMENT

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 Figure 3.3.1: Accounts Department- Organizational structure

Accounts department in The Ramco Cements Limited manages to measure the

financial needs of the organization and managers take a decision towards allocation

26
of funds for the organization based on the past performance and predicting the
future terms. Ensure that there are adequate funds to help the organization achieve
its objectives. They establish and control profitability level and also prepare final
accounts for every half year used for the report purpose submitted towards top level
management.
The Accounts maintained in the accounts department by the accountant and
some financial decisions are taken by the CFO (Chief Financial Officer) by the
consultation from top level management of the organization. Preparing daily
financial report of the organization and voucher maintenance are handled over by
the Accountant. The report can be submitted by the Accountant to the DGM
(Deputy General Manager). They collect payment receipts and bank statements for
their evidence to calculate daily income and expenses.
They analyze profit or loss for every financial year end. They fix a product
price on the basis of quality of cement. The product price has including GST (Good
and Service Tax) and freight charges for product per ton.
The Ramco Cements Limited Company’s Accounts department used Ramco
Virtual Works for accounts purpose. It is their own software. This software was
designed by ERP. There are 11 employer was worked in the Accounts department.
The Accounting department plays a vital role in running the Ramco Cements
Limited. It helps track revenue (money in) and expenses (money out) while
ensuring compliance with all statutory requirements. It also provides quantitative
financial information to management, lenders, investors, and other stakeholders,
who use it to make informed business decisions.
A Billing group assembles information from the shipping and customer order
departments to create invoices that are sent to the company’s customers it is
essential to issue billing on time,in order to enhance cash flows.
The department assists the rest of the company with the formulation of a
company-wide budget, which is used to plan for expenditure in the coming year,
including the purchase of fixed assets. The previous year’s budget may be used as
a baseline to formulate the budget for the next year. And every year 30 while
preparing the budget, the accounts department prepares 5% more than the previous
year’s budget amount.

3.4 PRODUCTION AND OPERATING DEPARTMENT (CCR)

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Figure 3.4.1: Production and Operating (CCR) Department- Organizational
structure

28
The Ramco Cements Limited was produced the Cement products. There are four
stages in manufacturing of cement.

1. Crushing and grinding the raw material

2. Blending the materials in the correct proportions

3. Burning the prepared mix in a kiln, and

4. Grinding the burned product, known as “clinker”, together with some

5 percent of gypsum

Figure3.4.2: Cement Process

CEMENT PRODUCTION PROCESS

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30
Figure 3.4.3: Cement Production Process

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3.5 PURCHASE AND MATERIAL DEPARTMENT

Figure 3.5.1: Purchase and Material Department

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 The main raw material of cement is Limestone. The raw material is mined
from Pandalkudi municipality and surrounding villages in Tuticorin district, own
asset of Ramco Cement Limited.

The Pet coke is imported on auction basis from three fuel companies namely
HP, Indiane and Bharat petroleum. Pet coke is called, abbreviated coke or
petroleum coke. It is final carbon – rich solid material that derives from oil
refining, and is one type of group of fuels referred to as cokes. In the Cement
industry, Pet coke is used as an energy source. Some cement plants use 100
percent Pet coke instead of Coal, where the SO2 released from the thermal
decomposition is absorbed by the limestone.

The Coal was imported from the many countries. The Countries are Australia,
Indonesia, Sri lanka and Russia. The Ramco Cement Limited was used the
Lignite type of coal. Because Lignite coal is used as an energy source in cement
production industries. Large amount of energy are required to produce cement.
Kilns usually burn coal in the form of powder and consume around 450g of coal
for about 900g of cement produced.

Figure 3.5.2: Coal

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 Figure 3.5.3: Pet Coke

Figure 3.5.4: Lime Stone

These are the major purchase product and material of the Ramco Cements
Limited Company. The Company has bought for yearly basis. But the lime stone
was took from their own mine at Pandalkudi in Tuticorin. And the Purchase
department in Ramco Cements Limited was followed by the 5R’s. The 5R’s are
Right quality, Right quantity, Right time, Right place and Right price. It is major
role of the Purchase department in all sector.

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3.6 INFORMATION TECHNOLOGY DEPARTMENT

Figure 3.6.1: Information Technology Department- Organization structure

35
 Information Technology (IT) in the Ramco Cements Limited company, it is a
technology that deals with computing as well as hardware, software, tele
communications andcommunications. In today’s world there’s massive role of
Information Technology in Industry.

IT also includes the management of data, whether it text, voice, image, audio,
etc., It can involve things related to the Internet. Information Technology is used
to create, store or manipulate information.

Everything now changed due to advancement of technology. IT helps the

transfer of data, soit makes sense that the internet would be a part of it. It’s become
a vicinity of our daily lives. In Organizations, the role of It is to communicate
among employees, customers and business partners. It communicates via email,
video conferencing, and video chat services such as Skype, Zoom etc. Now, in
every industry have digitized their data because it is secure.

Role of Information Technology in industry are different in different industry.

There are some roles in the different industries. IT helps in every industry to
manage their data as well as work of the requirement.

3.7 STORES DEPARTMENT

36
Figure 3.7.: Stores Department- Organizational structure

37
 Stores department in the Ramco Cements Limited, the auxiliary process of
store is the stock control also known as inventory control. In Ramco Cements
Limited, this process of receiving, keeping in custody and issuing forms a cyclic
process which runs on continuous basis. All the item are stored at one place.
Materials are received by & issued from one store or supplier. It is ideal from
control point of view. Most of the business concerns have a practice to follow this
system Centralised Stores. Many department stores used a product organizational
structure. Because their department carry many different lines of products. They
group their department by various product types.

Stores department is making procurement of Stock/Non Stock items required

for safe running of trains, proper upkeep/maintenance or rolling stock and
infrastructure, operation of assets. It is the function of the Stores department.

• To ensure uninterrupted supply of materials and stores without delay to

various production and service departments of the organizations.

• To prevent over-stocking and under-stocking of materials.

• To check all materials in terms of quality and quantity.

• To ensure safe handling of materials and prevent their damage.

• To minimize the cost of storage.

• To ensure most effective utilization of available storage space.

• To optimize the efficiency of the personnel engaged in the store.

Ensure the safety of all items and materials whilst in the store which means
protecting them from pilferage, theft, damage, deterioration and fire. Efficiently
and economically provide the right materials at the time when it is required and in
the condition in which it is required.

3.8 PACKING PLANT

38
 Unit Head
R.R.Nagar

Deputy General Manager

Packing plant

Assistant General Manager

Shift Mechanical Civil

Attenders Engineers Engineers

Machine Technical
Operator workers

Contract Contract
workers workers

Figure 3.8.1: Packaging Department- Organizational structure

CEMENT PACKAGING PROCESS

39
Figure 3.8.2: Cement Packaging Process

40
 Cement packing machine is a kind of cement equipment which is necessary
for the production of bagged cement. It is mainly used to complete the automatic
packing cement and other powder materials with good fluidity such as fly ash,
gypsum powder, cement additives. Cement is extracted from the silo bottom by
aeration and transported to electronic packing machines by air slides and bucket
elevators. Cement is packed in 50kg packs, and HDPV bags or paper bags are used
as per the customer’s requirement.

The Ramco Cements Limited was used the BX Rotary cement packing
machine for packing process. The BX Rotary packing machine has some structure.
There are:

• Feeding device

• Main transmission device

• Power supply system

• Rotary bin

• Weighting mechanism

• Bagging weighting frame

• Dust collecting plate

Cement powder is first conveyed to the vibrating screen by the bucket

elevator after it is screened out of impurities, it enters the intermediate bin for
storage. When all of these preparatory measures are finished, cement storage in the
bin is fed into the feeding device of the packaging machine.

41
5s METHOD IN RAMCO CEMENTS LIMITED

5s is one of the first tools that can be applied in a company that is starting
down the path of the continuous improvement culture. A 5s implementation helps
to define the first rules to eliminate was and maintain an efficient, safe and clean
work environment. The 5s methodology is easy for everyone to start using. It
doesn’t require any technical analysis and can be implemented globally in all type
of companies, ranging from manufacturing plants to offices, small business to
large multinational organizations.

5s is the perfect tool to identify the first improvement projects in your

company to eliminate waste. Although sometimes viewed as a house keeping
technique, it is actually an innovative management system that helps people think
lead, paving the way for adoption of lead principles in the organizations. Under
5s methodology is one of the foundation of Six sigma principles, and can be
extremely beneficial for organizational of all kinds.

The name 5s refers to a set of five terms borrowed from Japanese, all
beginning with the letter S when transliterated. The equivalent terms in English
also begin with an S. in essence; these five terms represent the five steps toward
operational and process excellence.

Seiri / Sort

Seiton / Store

Seiso / Shine

Seiketsu / Standardize

Shitsuke / Sustain

Figure 3.8.3: Term of 5s

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• Seiri / Sort

Separate required tools, materials and instruction from those that are not
needed. Remove everything that is not necessary from the work area.

• Seiton / Store

Store and organize all tools, equipment, files, data, material and resources
for quick, easy location and use. Label all storage location, tools and equipment.

• Seiso / Shine

Set new standards for cleanliness. Clean and remove all trash, grease and
dirt. Everything must be clean, tidy and neatly put in its appropriate place.
Cleanliness provides a safe workplace and make potential problems noticeable.
E.g., equipment leaks, loose parts, missing guards, loose paperwork or materials

. • Seiketsu / Standardize

Engage the workforce to systematically perform step 1,2 and 3 above daily, to
maintain the workplace in perfect condition as a standard process. Establish
schedules and set expectations for adherence.

• Shitsuke / Sustain

Make 5s part of our culture and incorporate it into the corporate philosophy.
Build organizational commitment so that 5s becomes one of the organizational
values so that everyone develops 5s as a habit. Integrate the 5s methodology into
the performance management system.

Figure 3.8.4: 5S certificate

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 CHAPTER 4
SWOT ANALYSIS
4.1 Strength
• Experienced Employees: The Company have a pool of well experienced
employees of which some of them have more than 30 years of work experience in
the company.

• Dedicated IT team: A team from Ramco Systems Ltd (sister concern of the
company) that exclusively work for the company’s IT developments and solutions.

• Self-developed ERP: The ERP software which is much cheaper than other
similar ones. It can be customized according to the requirement of the company.

• Well established supply chain: The Company have a well-established supply

chain in south India which include packing units and grinding units thereby
making the supply of the product easier.

• R& D: Well-functioning R& D center which is engaged to improve the product

quality.

• Brand name and quality of products : Certifications like ISO 9001, ISO
14001and ISO 18001 which makes the company distinct from others and is a
symbol of quality

Figure 4.1.1: certificates of ISO 9001, ISO 14001and ISO 18001

44
4.2 Weakness

• Wastage of raw materials: There is wastage of raw materials especially

imported coal and pet coke due to improper drainage system in the coal handling
unit.

• Declining per unit revenue for The Ramco Cements - competitiveness in the
Construction - Raw Materials industry is putting downward pressure on the
profitability. A starting guide to manage this situation for company name is
objectively assessing the present value propositions of the various products.

• Niche markets and local monopolies that companies such as The Ramco
Cements able to exploit are fast disappearing. The customer network that The
Ramco Cements has promoted is proving less and less effective.

4.3 Opportunities

• Local Collaboration - Tie-up with local players can also provide opportunities
of growth for the The Ramco Cements in international markets. The local players
have local expertise while The Ramco Cements can bring global processes and
execution expertise on table.

• Increasing customer base in lower segments - As customers have to migrate

from unorganized operators in the Capital Goods industry to licensed players. It
will provide The Ramco Cements an opportunity to penetrate entry level market
with a no-frill offering.

• Lower inflation rate - The low inflation rate bring more stability in the market,
enable credit at lower interest rate to the customers of The Ramco Cements. This
will increase the consumption of The Ramco Cements products.

• Lowering of the cost of new product launches through third party retail
partners and dedicated social network. The Ramco Cements can use the emerging
trend to start small before scaling up after initial success of a new product.

• Trend of customers migrating to higher end products - It represents great

opportunity for The Ramco Cements, as the firm has strong brand recognition in
the premium segment, customers have experience with excellent customer
services provided by The Ramco Cements brands in the lower segment. It can be

45
a win-win for the company and provides an opportunity to increase the
profitability.

• Increasing government regulations are making it difficult for un-organized

players to operate in the Construction - Raw Materials industry. This can provide
The Ramco Cements an opportunity to increase the customer base.

4.4 Threats

• Growing technological expertise of local players in the export market - One

of the biggest threat of tie-up with the local players in the export market for The
Ramco Cements is threat of losing IPR. The intellectual property rights framework
is not very strong in emerging markets especially in China.

• Competitors catching up with the product development - Even though at

present The Ramco Cements is still leader in product innovation in the
Construction - Raw Materials segment. It is facing stiff challenges from
international and local competitors.

• Competitive pressures - As the new product launch cycles are reducing in the
Capital Goods industry. It has put additional competitive pressures on players such
as The Ramco Cements. Given the large customer base, The Ramco Cements can't
respond quickly to the needs of the niche markets that disruptors are focusing on.

• Changing political environment with US and China trade war, Brexit

impacting European Union, and overall instability in the middle east can impact
The Ramco Cements business both in local market and in international market.

• Distrust of institutions and increasing threat of legal actions for The Ramco
Cements As the WTO regulations and laws are difficult to enforce in various
markets. Legal procedures have become expensive and long drawn process. It can
lead to less investment into emerging markets by The Ramco Cements thus
resulting in slower growth.

• Commoditization of the product segment - The biggest challenge for The

Ramco Cements and other players in the industry is the increasing
commoditization of the products in Capital Goods industry.

WORKERS FACILITIES:

Safety

46
 • Emergency vehicles
• First aid box
• Nursing staffs
• Fire safety equipment
Wages and salary

All operative workers expect casual are paid monthly wages. The employees
get type leave. If any employee is sick he will get 60% of daily wages. If he goes
on accident leave then he will paid 90% of wages.

Employee state insurance (ESI)

ESI benefit is given to permanent workers. It is a self-financing social security

and health insurance scheme for Indian workers. This fund is managed by the
Employee’s state insurance Corporation (ESIC) according to rules and regulations
stipulated there in the ESI Act 1948.

Provident find(pf)

It is a form of social safety net into which workers must contribute a

percentage from their salary and the companies also contribute a 12% as PF to
their workers.

Canteen facility

Canteen facility is available to workers and staff. Canteen slip/tokens was

given to them to get lunch, tea etc

Figure 4.1.2: Canteen tokens

Safety measures

47
 The administration takes a great care about the safety of the workers. The
cement industry provides number of fire-buckets and helmets and training for fire
break-down.

Bonus

The company provides bonus facilities to their employees like any other
concerns. The worker’s are receiving their bonus at the time of the festivals
seasons.

First aid facilities

The company provides the first aid facilities to the employees by means of
providing the first aid boxes and timely nursing helps to all departments

CHAPTER 5

48
 LEARNING FROM SUMMER TRAINING

5.1 Summer training

The summer training provides an opportunity for the training to understand the
administration and operations of The Ramco Cements Ltd., RR Nagar for one
month training to fulfill the general requirement for my course. That is to provide
students the opportunity to consolidate the theorical foundation through practical
experience. A major component of this experience is the formation of a
professional attitude .On this summer training knowledge about real time work
culture of these organizations and how to deal with the people at work place.

The objectives of a summer training:

❖ Explore career alternatives prior to graduation  Integrate theory and

practice.
❖ Assess interests and abilities in their field of study
❖ Learn to appreciate work and its function in the economy
❖ Develop work habits and attitudes necessary for job success.
❖ Develop communication, interpersonal and other critical skills in the job
interview process.

5.2 Benefits of summer training

❖ To understanding the workplace culture

❖ To gain the benefits of networking  To know how to put my knowledge
and skills into practice  To make myself know how important the good
communication.

CHAPTER 6

49
6.1 CONCLUSION

Through this training the trainee understood “The Ramco Cements Limited
Company” and its functions. It gave chance to learn about Cement Industry as a
whole. It gave more practical exposure and offers the chance to know functions of
different department like Human Resource, Accounts, Safety, Production and
Operation, Purchase and Materials, Stores, Information Technology etc., I have
gathered knowledge about the different types of cements. And I have some training
from the Human Resource and Accounts Departments.

BIBILOGRAPHY

50
Book resources:

Research methodology-CR-Kothari

Web resources:

http://www.ramcocements.in

http://www.ramcocements.wikipedia.com

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