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OM A PAPAD MANUFACTURING COMPANY process industry The process industries are those industries where the primary production processes are either continuous, or occur on a batch of materials that is indistinguishable. For example, a food processing company making sauce may make the sauce in a continuous, uninterrupted flow from receipt of ingredients through packaging. Or batches may be produced depending on the cook kettle sizes but immediately combined and re-routed. In either case, there is no concept of a unit of sauce while it is being processed. Examples of the process industries include food, beverages, chemicals, pharmaceuticals, petroleum, ceramics, base metals, coal, plastics, rubber, textiles, tobacco, wood and wood products, paper and paper products, etc. Om papads Papad is a popular and tasty food item in the Indian diet since many centuries. It is essentially a wafer-like product, round in shape and made from dough of powdered pulses, spices, powdered chilly and salt. Variety of pulses and proportion of pulses and spices varies from region to region depending upon preferences of local people whereas certain varieties are popular on a larger scale. Papad is a favorite item with Indians and is used as taste enricher with the main course and as a snack item. Since it is made from pulses, it is easy to digest and nutritious as well. It is very easy to make instant food item and is either fried in edible oil or simply roasted before serving. Traditionally this activity was confined to household papad making but in view of increasing demand and availability of machinery (mechanization) it has now been developed in cottage and small scale sector. OWNER’S PROFILE Mr chenna venkatesh, owner of the om papads (India), Visakhapatanam has been into the manufacturing and selling of papads for about 3 decades. It’s a family owned business and its run by his wife and two of his sons. The eldest son Mr Nag suresh looks into the marketing of the raw materials and the manufacturing of the papads. The other Mr Rajesh looks into the selling and the marketing of the papads to various other shops, restaurants and caterers. MANUFACTURING PROCESS a) Raw material: They make two types of papads, one is the plain papad and the other is the masala papad. For the plain papad the raw materials required are urad dal, salt and water. And for the masala papad the raw materials required are urad dal, black pepper, red chillies, sesame seeds and water. These products are easily available in the local markets, to get these products for a cheaper price they buy them in lots and keep them in there storage room. These materials are brought once in a week and kept in their storage rooms. b) Mixing: The urad dal is powdered in the grinders and the powder is mixed in appropriate proportions in the mixer grinders. The mixing is done in the electric grinder which has a capacity of mixing 15-20 kgs per hour. The mixing is done by adding salt water and the dough is formed, the salt is added to the water and is mixed well before it is mixed with the urad dal powder. The dough is then taken and rolled into the papad making machine. c) Machine and packing: The dough is put in the pedal operated papad press whish is the machine for the making the papads. The dough is rolled and is placed in line on the machine, the roller belt will move it through the papad press and the dough ball is rolled flat and later its edges are cut to get the round shape or the desired shape. They are then allowed to be dried in an oven and once they are dried 15 papads are packed in each packet. These packing are done either in polythene cover or in paper covers and is sold to the local retailers and supplied to the caterers and local restaurants. d) Man power: The man power required for the manufacturing of papads is 2 skilled labour and 3 helpers. The skilled labour and the helpers mix the appropriate quantities for the exact mix and using the papad press and drying them in the oven and put them for packing. The manpower used in this industry are all ladies as it is a household business and they are more economical as they are paid moderately on a daily wages. They check the papads weigh them and then pack them into the packets. STRENGTHS: The strengths regarding this product is the good will of the customers gained by Mr Venkatesh. With years of experience in the business and having contacts with the major restaurants and retailers in the areas and importantly keeping in contact and maintaining the quality. WEAKNESS: The weakness are as the business is of a very moderate price it can be started by anyone trying to maintain the quality and a good relation with the vendors. The only way to continue the business and gain profits in the business is only through trust and faith of the customers which is always very difficult to maintain as the market keeps changing and the attitude of the customers. OPPURTUNITIES: As he has been doing the business for a long time, it’s good to introduce other products and not depend only upon the manufacturing of papads, as he has the good will of the customers it is always good to attract the old customers rather the new ones. As they already have a good name in the local markets they have to try to improvise their thoughts upon extending the business further rather than limiting themselves to the local markets. Try to publicise their product into other regions and areas and investing some money for advertisement rather than always going in person and talking to retailers . THREATS: The threats there is lot of competition regarding the manufacturing of papads major companies like lijjat papada, Marwari,Swadhist and many other companies spend a lot of money on advertisement as a result they attract more number of customers. So major companies and lack of advertisements play as a major threat to these small scale industries. Mass production Mass production is the name given to the method of producing goods in large quantities at low cost per unit. But mass production, although allowing lower prices, does not have to mean low-quality production. Instead, mass-produced goods are standardized by means of precision-manufactured, interchangeable parts. The mass production process itself is characterized by mechanization to achieve high volume, elaborate organization of materials flow through various stages of manufacturing, careful supervision of quality standards, and minute division of labour. To make it worthwhile, mass production requires mass consumption. Until relatively recent times the only large-scale demand for standardized, uniform products came from military organizations. The major experiments that eventually led to mass production were first performed under the aegis of the military. VIZAG STEEL PLANT Steel has always been the backbone of nation's economy. From an annual production of 13 million ton in 1900, global steel production raised to 300 million ton in 1950 and to 842 million ton in 2000. India produces 30 million ton per annum from 9 major plants. The major steel plants contribute 19 million tones and the rest is contributed by secondary sector. Visakhapatnam Steel Plant is one of the 6 integrated steel plants contributing 3.51 million ton of liquid steel per annum. It is the only steel plant in India accredited with ISO 9001, ISO 14001, and OHSAS 18001 certificates for Quality environment and Safety aspects of the steel making activities. With the improvement in operating performance of major units and efficient maintenance and material handling system the plant has made a turn around and achieved net profit of 2100 crore rupees during the current fiscal 2004-05. LOCATION: The plant is located in Visakhapatnam City, which is on the coast of Bay of Bengal. Visakhapatnam city is an important commercial center of Andhra Pradesh. It has the deepest port and is one of the principal outlets for country's exporting Iron ore. THE DEPARTMENTS: There are altogether 25 departments in Vizag Steel Plant. These have been divided into two categories as Core Zone and Service Zone. Some of them are as follows: Core Zone: Blast Furnace, Coke Ovens, Steel Melt Shop, Mills, Sinter Plant, and Raw Material Handling Plant. Service Zone: Thermal Power Plant, Calcined Refractory Manufacturing Plant Coke Ovens Coal Chemical Plant: Coking coal after selective crushing and proper blending is subjected to destructive distillation (heating in the absence of air) in the Coke Ovens. After heating for nearly a period of 16-18 hours at a temperature of about 1100°C, coke is obtained and is used as a fuel as well as reducing agent in the Blast Furnace. The Coke Ovens of VSP are engineering feats by themselves. They are the tallest ovens constructed in the country. There are three batteries, each having 67 ovens. Each oven is having a volume of 41.6 cu.m and can hold 31.6 T of dry coal charge. The carbonization time is 16 hours. A mixture of blast furnace gas and coke oven gas having a calorific value of 1000 Kcal/NM3 supplies the heat for carbonization. Another feature is the dry cooling of coke carried out by the inert gas nitrogen thus, reducing pollution considerably. Besides, a bio-chemical plant separately undertakes the treatment of effluents. By-products like benzene, toluene, xylene, naphthalene, coal tar, creosote oil, pitch, ammonium sulphate and benzol products are also recovered from the coke ovens gas. VSP produces, among other by-products, pushkala a prime fertilizer based on ammonium sulphate. Sinter Plant: Iron ore fines, coke breeze, limestone and dolomite along with recycled metallurgical wastes are converted into agglomerated mass at the Sinter Plant, which forms 80% of iron bearing charge in the Blast Furnace. The Sinter Plant comprises of two sinter machines each having 312 square metres of grate area with a total , production capacity of 5.256 million tons per annum. Hot sinter, discharged ITom sintering machine at 900 degrees centigrade, is crushed to 15mm size in a spiked single roll crusher with a 1300 X 4200 mm rotor. Unsintered grains are liberated as sinter returns. Blast Furnace: VSP has two Blast Furnaces with a useful volume of 3200 cu. m. each. Blast Furnace is charged with coke, iron ore and sinter ITom the top and produces about 5000 tons of molten iron per day. Its novel circular cast house with four tap holes ensures continuous tapping of hot metal. There are four hot blast stoves for each furnace with a total heating surface of 224000 square metre. The dome is heated to a temperature of 1450 degrees maximum, while the waste flue temperature is 400degrees centigrade. The stoves are capable of giving a blast temperature up to 1300degrees centigrade. A mixture of blast furnace gas and coke oven gas having a calorific value of 1100 KcalINM3 heats stoves. Gas mixing station is provided to mix BF gas and coke oven gas in required proportion and to get the necessary calorific value. Separate stations are provided for each furnace. The annual production capacity of these Blast Furnaces is 3.4 million tons of liquid lron. Steel Melt Shoo & Continuous CastinS!: Three topblown converters, each of 133 cu.m. Volume, produce a total of 3.51 million tons of liquid steel per annum. This liquid steel thus produced is casted in six-4 strand bloom casters. A special feature in energy conservation is the collection of Converter gas to be used as a fuel in the plant. The entire molten steel at VSP is continuously cast at the radial type continuous casting machines resulting in significant energy conservation and better quality steel. 100% Continuous casting on such a large scale has been conceived for the first time in India. RollinS! Mills: The cast blooms trom continuous casting department are heated and rolled in the three high speed and fully automated rolling mills namely Light & Medium Merchant Mill, Wire Rod Mill and Medium Merchant & Structural Mill, to produce various long products like reinforcement bars, rounds, squares, flats, angles, channels, billets, wire rods etc. Technologies adopted at Rolling Mills include world-class Stelmor and Tempcore processes. Product Mix: The product mix of VIZAG Steel Plant . Wire Rods .Bars .Angles .Channels .Beams .Rounds The Plant also produces Pig Iron, Granulated Slag and Coal Chemicals. The rolled products find extensive usage in the Construction, Inftastructure, Railways, Power, Oil, defense, and Transport and Ship Building sectors. Bars and Rods are used mainly for re-inforced concrete work for housing, construction of dams, buildings & factories, manufacture of agricultural implements, fabrication of light engineering components. The Wire Rods are used in Wire Drawing industry for electrodes, transmission lines and weld ability requirements. The structurals find application in engineering, house building, agricultural implements, machinery, transmission towers, etc. The tap-to-tap cycle time is Timing in min. . Charging of scrap 3 . Charging of hot metal 4 . Oxygen blowing 18 . Intermediate slag off 3 . Sampling, temperature recording etc. 5 . Steel tapping 6 . Draining of slag 2 . Preparation of converter 3 . Unforeseen days 6 Total: 50 Provision is kept for production of 59 heats per day. Process flow chart