GAGAL CEMENT WORKS

ACC Limited is India's foremost manufacturer of cement and concrete. ACC's operations are spread throughout the country with 3 regions, 14 modern cement factories, 19 Ready mix concrete plants, 19 sales offices, 54 area offices, 194 ware houses and several zonal offices. It has a workforce of about 9500 persons and a countrywide distribution network of over 10,000 dealers. Since its inception in 1936, the company has been a trendsetter and important benchmark for the cement industry in respect of its production, marketing and personnel management processes. ACC is among the first companies in India to include commitment to environmental protection as one of its corporate objectives, long before pollution control laws came into existence. The company installed pollution control equipment and high efficiency sophisticated electrostatic precipitators for cement kilns, raw mills, coal mills, power plants and coolers as far back as 1966. ACC demonstrates the practices of being a good corporate citizen undertaking a wide range of activities to improve the living conditions of the under-privileged classes living near its factories.

The history of ACC spans a wide canvas beginning with the lonely struggle of its pioneer F. E. Din Shaw. ACC was formed in 1936 when ten existing cement companies came together under one umbrella in a historic merger the countrys first notable merger at a time when the term mergers and acquisitions was not even coined. These companies belonged to four prominent business groups Tatas, Khataus, Killick Nixon and F E Dinshaw groups. ACC was formally established on August 1, 1936.

A STRATEGIC ALLIANCE The house of Tata was intimately associated with the heritage and history of ACC, right from its formation in 1936 upto 2000. Between the years 1999 and 2000, the Tata group sold all 14.45 per cent of its shareholding in ACC in three stages to subsidiary companies of Gujarat Ambuja Cements Ltd (GACL), who are now the largest single shareholder in ACC. This has enabled ACC to enter into a strategic alliance with GACL, a company reputed for its brand image and cost leadership in the cement industry.

HOLCIM A NEW PARTENERSHIP A new association was forged between ACC and the Holcim group of Switzerland in 2005. In January 2005, Holcim announced its plans to enter into a long-term strategic alliance with the Ambuja Group by acquiring a majority stake in Ambuja Cements India Ltd. (ACIL), which at the time held 13.8 per cent of the total equity shares in ACC. The company implemented an ERP system that has standardized business process to run SAP software called CONNECT INDIA system which is based on template that caters to readimix concrete business, cement and AFR process of the company with the assistance of Holcim group. The name of company was changed to ACC Limited from The Associated Cement Companies Limited with effect from September 1, 2006.

SAUDI ARABIA-YAMBU CEMENT COMPANY

Since 1979 ACC has been operating and managing a large cement plant owned by Yanbu Cement Company (YCC) and located near the port city of Yanbu in the Kingdom of Saudi Arabia. The Yambu plant incorporates sophisticated process control systems. YCC today has a capacity of over 3.30 million tonnes per annum. Cement production at this plant has continued to exceed the guaranteed quantum stipulated in the contract year after year.

NIGERIA- DANGOTE INDUSTRIES

ACC has been retained by M/s Dangote Industries, a leading diversified industrial group of Nigeria, to provide comprehensive engineering consultancy for setting up their proposed new green field cement plants of capacity 3 x 7000 TPD (tonnes per day) and for optimization and up gradation of their existing plants from 2x2000 TPD to 2x3500 TPD.

Gagal cement works is the most modern plant having IS/SO 9002 and IS/ISO 14001 environment management system certification and also the 18001- OHSAS (occupational health and safety assessment series) and also bagged various prestigious awards in the field of environment conservation and Indira Priyadarshini Vrikshamitra (IPVM) award, 1996 for extraordinary work in a forestation. LOCATION: The plant is located at Barmana on the National Highway no. 21, midway between the town of Bilaspur and Sunder agar on the bank of river Sutlej. The plant is at a height of 600 meters above sea level. AREA: 231.25 hectares

PROFILE: GCW is the largest plant of ACC according to production & profit data. GCW project was initiated in October 1978. On 12th march 1984 Gagal-1 was successfully commissioned and commercial production commenced with initial capacity of 5.6 lakh tons per annum. Gagal-2 was commissioned in 1994 and present capacity of the plant is 2.4 MTPA of cement. Gagal-1 and Gagal-2 units has installed eco friendly modes of material transporting system by adopting 2 km long over land belt conveying system for transporting crushed limestone from its mines.
EMPLOYEES: The strength of management staff and non Management Staff for Gagal Cement Works (GCW) is 140 and 613 respectively. Non Management Staff includes 406 daily paid and 207 monthly paid staff.

S. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

UNITS Bargarh Chaibasa Chanda Damodhar Gagal (I and II) Jamul Kymore Lakheri Madukkarai Sindri Wadi (I and II) New Wadi Plant Tikaria

STATE Orrisa Jharkhand Mahrashtra West Bengal Himachal Pradesh Chhatisgarh Madhya Pradesh Rajasthan Tamil nadu Jharkhand Karnataka Karnataka Uttar pradesh

CAPACITY (MTPA) 0.96 0.87 1.00 0.53 4.20 1.58 1.70 0.60 0.96 0.60 2.11 2.60 2.00

LEADERSHIP: Maintain Leadership of the Indian cement through continuous modernization expansion of our manufacturing facilities & activities, and through the establishment of wide and efficient marketing networks. PROFITABILITY: Achieve a reasonable and fair return on capital by promoting productivity through the company. GROWTH: Ensure a steady growth of business by strengthening the companys position in the cement section consistent with overall corporate. QUALITY: Maintains high quality of our products and services and ensure their supply at fair price.

EQUITY: Promote and maintain fair Industrial Relation and an environment for the effective involvement, welfare and development of staff at all levels. PIONEERING: Promote research and development efforts on the areas of product development and energy, and conservation and to innovate and optimize productivity. RESPONSIBILITY: Fulfil our obligation to society, especially in the areas of integrated rural development and in safeguarding the environment and ecological balance.

ACC's responsibilities towards employees go beyond providing a competitive wage ,salary and benefit payments and include many other elements such as attempting to maintain good working conditions, maximum opportunities to develop the full extent of their capacities, and relatively stable environment in which they can work together effectively. To have all times effective and well motivated employees at all the levels of the organization who are committed to attain organizational goals and help the company to remain a corporate leader in the country. A deep concern for the employees as individuals and a commitment to working for the balanced interest of all who depend on his company. It will be a endeavour to encourage by precept and especially by example, competition and a common practice of fairness ,honesty, and integrity- virtues that are hallmark of ACC.

ACC puts emphasis on value creation by delivering long term value to investors and other stake holders. 1. CUSTOMER DRIVEN ORGANISATION ACC has employees who are committed to delivering ultimate customer satisfaction. ACC delivers superior and consistent quality cement. ACC is the most preferred cement brand in India.

2. MOST EFFICIENT CEMENT PRODUCER ACC is the lowest cost producer and deliverer of cement. ACC is the most profitable cement manufacturer in India.

3. GREAT PLACE TO WORK ACC has HR policies which promote a healthy work culture. ACC rewards employees well based on profitability and performance. ACC cares for its employees welfare. ACC encourages team excellence. ACC encourage at the working level. 4. INSPIRES TRUST AND RESPECT ACC is a trusted and ethical organization. ACC is committed to environmental protection and the well being of the community.

5. LEARNING ORGANISATION ACC is alert to changes in the business environment and responds effectively. ACC adopts world class business practices to surpass global bench marks. ACC understands evolving customer needs and pioneers new product/services. ACC develops employees through need base learning.

Ensure continual improvement in environmental performance by carrying out periodic review of action plan. Prevent pollution & minimise fugitive missions. Comply with all applicable all legal and regulatory requirements. Conserve energy and mineral resources. Minimize waste generation and reutilize the source, if generated Creative environmental awareness among employees and continuity at large.

(Occupational Health & Security Policy) Do not override or interfere with any safety provision nor allow anyone else. Personal Protective Equipment (PPE) rules applicable to each task must be adhered to at all times. Isolation & Lock out procedure must always be followed i.e. LoToTo - Lock out, Tag out, Try out. No workman should be under the influence of alcohol or drugs while on job. All injuries and accidents must be reported. Each worker is supposed to gather at the emergency exit points when the emergency alarm rings. (There are total 6 emergency exit points.)

(Corporate Social Responsibility Policy)

The company shall continue to have among its objectives the promotion and growth of the national economy through increased productivity, effective utilisation of materials and manpower resources and continued application of modern scientific and managerial techniques, in keeping with the national aspirations; and the company shall continue to be mindful of its social & moral responsibilities to consumers, employers, shareholders, society & local community. In pursuance of the above objective, ACC acknowledges the importance of the concept of inter-dependence of all sections of society. In particular its focus revolves around the community residing in the immediate vicinity of its cement plants and mines where it seeks to actively assist in improving the quality of life and making this community self-reliant. In line with its abiding concern for preservation of ecological balance and safeguarding the health of the community, ACC has always actively demonstrated its firm resolve to protect the environment. Mindful of its great tradition, ACC is deeply committed to enhancing its reputation & respect built over the years, in the industry and society for its professional style of management based on philosophy of the best in business ethics.

(Alternative Fuel & Raw Materials policy) 1. ELEMENTS OF SUSTAINABILITY Act as a partner to society by offering waste management solutions. Keep our environment safe. Add value to our core business. 2. WHAT WE WILL DO Ensure OH & S. Refuse the listed banned products. Guarantee the quality of our products. 3. HOW WE WILL DO IT Comply with the relevant regulations and promote best practices. Monitor and control the inputs, process, products and emissions. Communicate transparently.

STRENGTHS: It is having a good image and brand loyalty among consumers. Service is good. They have same price prevailing for wholesale at dealers/stockiest retailers end. WEAKNESS: The competitors are doing much promotional activity rather than ACC Limited that is why it is facing more problems in selling of product in the market. Lack of awareness program for consumers.

OPPORTUNITY: Rapid growth is taking place in Bihar and Madhya Pradesh. People are opting for more stable structures and intensive use of cement is taking place, even government is spending heavily on infrastructure projects. Thus, this is the right time to fully tap these markets. As Indian core industry is also growing at rate of nearly 10% per annum, it is having a good future. Foreign direct investment in infrastructure sector going to increase in coming years, which will increase the demand of cement. Roads are undergoing through the transformation process through which the traditional method of road building will be replaced by modern concrete roads.

THREATS: Large number of players in cement industry makes it more competitive for ACC to carefully price its product and at the same time satisfy its dealers and customers. Players such as Jaypee Cement, Prism Cement, and Birla Samrat are eating up considerable market share. Due to Indias exponential growth many new international cement companies are expected in coming years which will bring a tide of change and can start price war. The emergence of small players in this market may increase the competition and start the malpractices, and heavy discounts to retailers. They can also influence many retailers by giving better profit margin, and other Benefits.

ENVIRONMENTAL PROFILE: ACC Ltd. follows an echo friendly environment policy and a CSR policy which is designed in such a manner that the people residing in surrounding areas and its workmen do not face any problems because of pollution emitted from the plant and for that following points are taken care of: Ensure continual improvement in environmental performance by carrying out periodic review of action plan. Prevent pollution & minimise fugitive missions. Comply with all applicable all legal and regulatory requirements. Conserve energy and mineral resources. Minimize waste generation and reutilize the source, if generated. Creative environmental awareness among employees and continuity . They have installed a bag house and ECB for pollution control.

OPPORTUNITY PROFILE: Rapid growth is taking place in Bihar and Madhya Pradesh. People are opting for more stable structures and intensive use of cement is taking place, even government is spending heavily on infrastructure projects. Thus, this is the right time to fully tap these markets. As Indian core industry is also growing at rate of nearly 10% per annum, It is having a good future. Foreign direct investment in infrastructure sector going to increase in coming years, which will increase the demand of cement. Roads are undergoing through the transformation process through which the traditional method of road building will be replaced by modern concrete roads.

POLITICAL ANALYSIS: The Company maintains a ratio of 70:30 in recruitment i.e70% of workmen are hired from the nearby/local areas. ECONONMIC ANALYSIS: the only problem at GCW is that they have to use road transportation because of no railway service and which results in expensive transportation. SOCIAL ANALYSIS: Gagal cement works runs a private hospital and a school where special concessions are provided to the employees and their children. The company also facilitates home loans and utility loans on very less interest rates. TECHNOLOGICAL ANALYSIS: GCW is following the latest technologies like ESB, bag house etc.

National Award for outstanding performance in promoting rural and agricultural development by ASSOCHAM Sword of Honour - by British Safety Council, United Kingdom for excellence in safety performance. Indira Priyadarshini Vrikshamitra Award --- by The Ministry of Environment and Forests for "extraordinary work" carried out in the area of afforestation. FICCI Award --- for innovative measures for control of pollution, waste management & conservation of mineral resources in mines and plant. Subh Karan Sarawagi Environment Award - by The Federation of Indian Mineral Industries for environment protection measures. Drona Trophy - By Indian Bureau Of Mines for extra ordinary efforts in protection of Environment and mineral conservation in the large mechanized mines sector.

Indo German Greentech Environment Excellence Award Golden Peacock Environment Management Special Award - for outstanding efforts in Environment Management in the large manufacturing sector. Indira Gandhi Memorial National Award - for excellent performance in prevention of pollution and ecological development Excellence in Management of Health, Safety and Environment : Certificate of Merit by Indian Chemical Manufacturers Association Vishwakarma Rashtriya Puraskar trophy for outstanding performance in safety and mine working Good Corporate Citizen Award - by PHD Chamber of Commerce and Industry

Greentech Safety Gold and Silver Awards - for outstanding performance in Safety management systems by Greentech Foundation FIMI National Award - for valuable contribution in Mining activities from the Federation of Indian Mineral Industry under the Ministry of Coal. National Award for Fly Ash Utilization - by Ministry of Power, Ministry of Environment & Forests and Dept. of Science & Technology, Govt of India - for manufacture of Portland Pozzolana Cement. Good Corporate Citizen Award-Bombay Chamber of Commerce and Industry for working towards an environmentally sustainable industry while pursuing the objective of creation of a better society. National Award for Excellence in Water Management - by the Confederation of Indian Industry (CII)

MANAGEMENT STAFF

MONTHLY PAID STAFF

DAILY PAID STAFF

ACC has migrated from current classical grade structure to Job (size) Based Grade structure by Hay Methodology. Job Based Grade Structure focuses on specific accountabilities for each role. Hay methodology provides specific point/score which will determine the size of the job role. Different jobs have been slotted into a grade hierarchy based on Job size. Each grade hierarchy is known as ACC JOB BAND (AJB).
AJB

DESIGNATION
Chief Executive Chief Officer Director Director Head Head Head Chief Manager Chief Manager Manager Associative Manager Sr. Executive / Sr. Engineer Executive / Engineer Jr. Executive / Jr. Engineer

AJB-24 AJB-23 AJB-22 AJB-21 AJB-20 AJB-19 AJB-18 AJB-17 AJB-16 AJB-15 AJB-14 AJB-13 AJB-12 AJB-11

Training

and Development at Gagal Cement Works

Training is a learning process that involves the acquisition of knowledge, sharpening of skills, concepts, rules, or changing of attitudes and behaviours to enhance the performance of employees.

Training is an activity leading to skilled behaviour.

TRAINING AND DEVELOPMENT is a subsystem of an organization. It ensures that randomness is reduced and learning or behavioural change takes place in structured format.

SAMPLE SIZE: 50
SAMPLE TECHNIQUE: Random Sampling

RESEARCH INSTRUMENT: Questionnaire

STATISTICAL TOOLS USED: The main statistical tools used for the collection and analyses of data in this project are: 1. Pie Charts 2. Tables

The major conclusions of this study are enumerated as follows: 1. Training is considered as a positive step towards augmentation of the knowledge base by the respondents. 2. The objectives of the training programs were broadly known to the respondents before attending them. 3. The training programs were adequately designed to cater to the developmental needs of the respondents. 4. Some of the respondents suggested that the time period of the training methods will enhance the effectiveness of the training program which means that the duration of present training programs is not sufficient. 5. Some respondents believe that the training sessions could be made more exciting if the sessions had been more interactive and in-line with the current practices of the market. 6. The training aids used were helpful in improving the overall effectiveness of the training programs. 7. The number of training programs conducted annually is not sufficient as respondents said.