bokaro steel plant
TRANSCRIPT
BOKARO STEEL PLANT –AN INTRODUCTION
Bokaro steel plant was originally incorporated as a limited company on 29th January 1964. With the formation of the steel authority of India Limited (SAIL) ON 24 JANUARY 1973, it became a wholly owned subsidiary of SAIL and on 1st the formation of the steel authority of India Limited (SAIL) ON 24
JANUARY 1973, it became a wholly owned subsidiary of SAIL and on 1st may 1978 it was eventually merged with SAIL through the public sector Iron & Steel companies (Restructuring & Miscllany provision) act 1978.
The plant is hailed as the country’s first Swadeshi steel plant, built with maximum indigenous content in terms of equipment, material and know –how . Its first ohase of 1.7MT ingot steel commenced on 2nd October 1972 with the commissioning of the first Blast Furnace and completed on 26th February 1978 with the commissioning of the third blast Blast Furnace. All units of 4 MT stage have already been commissioned . The Plant plant is designed to produce flat products like Hot Rolled Coils, Hot Rolled Plates ,Hot Rolled sheets, Cold rolled sheets ,Tin mill black plates (TMBP) and galvanised plain and Corrugated (GP/GC) sheets. Bokaro has provided a strong raw material base for a variety of modern engineering industries including automobile, pipe and tube LPG cylinder ,barrel and drum producing industries.
BOKARO STEEL PLANT - A PARTNER IN NATION BUILDING
History
Bokaro Steel Plant - the fourth integrated plant in the Public Sector - started taking shape in 1965 in collaboration with the Soviet Union. It was originally incorporated as a limited company on 29th January 1964, and was later merged with SAIL, first as a susidiary and then as a unit, through the Public Sector Iron & Steel Companies (Restructuring & Miscellaneous Provisions) Act 1978. The construction work started on 6th April 1968.
The Plant is hailed as the country’s first Swadeshi steel plant, built with maximum indigenous content in terms of equipment, material and know-how. Its first Blast Furnace started on 2nd October 1972 and the first phase of 1.7 MT ingot steel was completed on 26th February 1978 with the commissioning of the third Blast Furnace. All units of 4 MT stage have already been commissioned and the 90s' modernisation has further upgraded this to 4.5 MT of liquid steel.
The new features added in modernisation of SMS-II include two twin-strand slab casters along with a Steel Refining Unit. The Steel Refining Unit was inaugurated on 19th September, 1997 and the Continuous Casting Machine on 25th April, 1998. The modernisation of the Hot Strip Mill saw addition of new features like high pressure de-scalers, work roll bending, hydraulic automatic gauge
control, quick work roll change, laminar cooling etc. New walking beam reheating furnaces are replacing the less efficient pusher type furnaces.
A new hydraulic coiler has been added and two of the existing ones revamped. With the completion of Hot Strip Mill modernisation, Bokaro is producing top quality hot rolled products that are well accepted in the global market.
Bokaro is designed to produce flat products like Hot Rolled Coils, Hot Rolled Plates, Hot Rolled Sheets, Cold Rolled Coils, Cold Rolled Sheets, Tin Mill Black Plates (TMBP) and Galvanised Plain and Corrugated (GP/GC) Sheets. Bokaro has provided a strong raw material base for a variety of modern engineering industries including automobile, pipe and tube, LPG cylinder, barrel and drum producing industries.
VISION
To be a respected world class corporation and the leader in Indian steel business in quality, productivity, profitability and customer satisfaction.
CREDO
We build lasting relationships with customers based on trust and mutual benefit.
We uphold highest ethical standards in conduct of our business.
We create and nurture a culture that supports flexibility, learning and is proactive to change.
We chart a challenging career for employees with opportunities for advancement and rewards.
We value the opportunity and responsibility to make a meaningful difference in people's lives.
OVERVIEW
As, we all know that Central Marketing Organisation of SAIL has got Sales Resident Manager offices at all the Plant locations. The Head of the department of such offices are called Sales Resident Managers. . Similarly, at Bokaro Steel Plant , Central Marketing Organisation has set up its office called SRMO. This is a very important assignment as Bokaro Steel Plant is the largest producers of saleable steel in India. Before, knowing more about SRMO working it becomes essential to know something about Bokaro Steel Plant, as SRMO has to work neck to neck with the Plant.
Bokaro Steel Plant bring out before ones eyes the vision of a massive giant in the steel marking. As the fourth steel plant in the Public Sector, conceived in 1959, it actually started taking shape in 1965 with the signing of an agreement with the Government of USSR on 25th of January 1965. Envisaging a capacity of 1.7 Mt in 1st stage and 4.0 Mt in second stage. The Plant has taken up modernisation with a view to introduce continuous casting facilities and updating the Hot Strip Mill, a major step towards providing the state of art technology for producing quality steel at international standards. Its main products are:
1. HR Coils, Plates & sheets2. CR Coils & Sheets3. GP/GC Sheets4. Tin Mill Black Plates
Some special qualities in different products:
HR Coil/Sheets IS 10748 Gr 1 SK Gr 2 SK
Gr 3 SK
Gr 4 SK
Gr I KId
CR COIL BARREL BITUMEN
GP/GC Class VIII to class IX LFQ
HR Plate Trimmed /untrimmed SAILCOR
ROLE AND FUNCTIONS IN SRM OFFICE
`The role and functions of SRM is very critical and important. Its important role is to coordinate with the plant for execution of orders booked by the various Branch Sales Offices all over India i.e. from Kashmir to Cochin. The role and functions of SRMO can be defined pointwise which are computed below:
1. To ascertain the availability of material at the Plant level and to intimate the same to the HQ/regional HODs.
2. To intimate the Demand Forecast for the next month received from HQ/CMO to plant in order to start making steel accordingly.
3. To receive the orders from Branches Regions and HQ’s (Direct and Stockyard.
4. To ascertain the despatches from plant location to the actual destination.
5. To help branches/customers in getting CA, DA, RR and Test Certificates available in short time with much accuracy.
6. Any Plant-related job of any branch of CMO is carried away through respective SRMO.
I.T. SYSTEM IN SRMO- BOKARO
The day today working in SRM O is fully dependent on i.t. set-up. branches feed the orders in OMS-II which passes through regional office and then HQ through system where the order gets approved and through SDC Hyderabad reaches to SRMO location where the same order is downloaded and through system only gets transferred to plant for execution of that particular order in other words we can say that everything is online at SRMO especially at bokaro. After material is dispatched to the respective locations the DA/RR/CA is prepared/generated by the plant and ftped to SMRo where the same details are being put on home page to facilitate the Customer /Branches regarding their dispatches of materials. this process is done through IPPs system. before going through IPPS system at Bokaro and other details of IPPS etc., we should know few things about computerization in SAIL which are the Primary or Fundamental requirements for developing such system.
INTRODUCTION
CMO had started the total computerization the total computerization activities during 1989 with the help of outside agencies. This was done in a planned manner encompassing the various functions of the organisation. During the course of the Past few years various systems were implemented and had reached a level of stabilization and the acceptance by the user. The various applications or branch and stockyard, SRM(plant interface) regional product planning, central product planning, payroll, branch transport and shipping. Headquarters T&S and headquarter finance system.
All the systems were developed keeping in view the geographical spread of the organisation. These were isolated system interacting with each other using variety of hardware and software depending on the need of the respective functional area of work. As such we have stand alone PC's, PC-based LAN's, dumb terminal based minis and super minis. However , each system depends upon another for its input. The regular flow of information forms a very crucial link for the different systems.
SAIL NET is to provide the networking facility by interconnection the various computers and applications running in these computers. The effective networking will include maintaining online and provide access to the distributed database as is currently available.
File transfer facility: The user will be able to send files from or printed document from one location to another.
E-mail Facility: A special software package has been implemented for sending and receiving electronic mails which helps to act speedily in the offices of SAIL & that too with effective cost reduction.
The information needs to be classified into 5 functional zones:
Zone A
This is the area where the information is generated e.g. Orders, delivery, orders challan etc. in the branches, moment plans in the SRM, price, product master at commercial division.
The online data capture at various locations is processed and used by the owner(where the actual data is generated ) for day to day activities, the same is also used for analysis and reports at the other levels of the management
Zone B
The information at Zone A is used by the zone for further processing and output of which forms the input to the other users. For instance the orders received from the branches are processed into movement plans and are sent to the plants where it is used as input for further processing.
The needs of the zones is to be catered by Zone A either by :
01. providing information data at basic level (raw data e.g. challan CMIS)
02. providing processed information (trial balance to HQs, Finance)
The frequency of the need of the various types of the information from Zone A is as follows:
1. Instant updates i.e. as and when transactions occur in Zone A.2. Frequent batch updates, may be daily or weekly to be decided by the respective
users (e.g. cash collection statements, daily sundry debtors statements.3. Batch updates which requires to be done only on monthly (e.g. stock cum sales
statement to plant and HQ Finance)
Zone-C
The Zone needs information generated by the Zone A for enquiries, analysis, reports, management information system. Zone A needs to provide information at the basis level as and when the transmission occurs. In a few cases batch updates need to be done periodically.
ZONE- D
This zone will be a broadcast type where the information will be sent to all the locations (e.g. price product master, circulars from personnel department).
ZONE- E
This zone needs online access to all the other zones for problem solving, trouble shotting, updating enhancing software division (Software group only).
Based on the classification of the Zone, System, the information needs of the vrious functions of the SAIL CMO can be categorized broadly into:
CATEGORY 1: Branch and Stockyard, Commercial Division, ITD, BTSO, Finance, Personnel.
CATEGORY 2: Product Planning Group, Market Development Group, Regional Finance SRM office, PPC (Plant Interface System), T&S HQs and Finance HQs.
CATEGORY 3: Regional MIS, Finance HQs, MIS Personnel, Central MIS.
CATEGORY 4: Pricing Division, Personnel, Finance HQs.
CATEGORY 5: System's Software Group.
How are computer interconnected at Application level ?
To understand the method of connections it is necessary to take at top-down approach.
ZONE C
This zone will provide the complete MIS for SAIL CMO, plants and SAIL Corporate Office.
WHENEVER NECESSARY THE FUNCTIONARIES AT ZONE A AND B CAN VIEW INFORMATION FROM THIS ZONE (E.G. INFORMATION ON STOCK AVAILABILITY AT OTHER LOCATIONS DESPATCHES FROM PLANTS ETC.)
This zone will comprise of mini and super mini computer at the Regions quarters, SRM (Plant interface system) clustered together. These computers will work in tandem or together depending upon the need of the applications.
ZONE B
The computer belonging to this zone are directly linked to computers in the zone C. The information requirement of this zone is met by Zone A and Zone B.
ZONE A
This zone generates almost all the necessary information for use in the other Zones. The computers in this zone are more or less functioning independently but transmit the information generated by them via the linkages provided.
ZONE D
The computers in this zone will send data/information to all the locations which are connected to the network.
"HOW DOES SAILNET WORK"
Most of our applications are based on distributed database. For the integration of the applications the nodes (node is a computer in the network) do not interact with each other directly. They do so via dedicated communication server. This is meant to ease the application host server (Falcon Server in the branches, Regional mini computers etc.) from routine communication activities.
An integrated data communication system software has been developed to provide the exchange of information at pre determined internals among the applications. The application software has been also changed/modified to ensure that the SENDING AND RECEIVING DATA is in-built into the application software. Care has been taken to ensure that there is only minimal changes to the application software.
The main functions of the integrated data communication system are:-
a) To packetize out bound messages (each transaction is treated as a message) from the application server to the communication server.
b) To receive incoming messages from the communication server and either (i) update the application database immediately or (ii) store them in communication database for further use.
c) To acknowledge the receipt of data at the application server or send appropriate error message, wherever necessary.
d) To ensure that the message are routed to the correct destination computer.
VSAT is terminated or connected to one or more communication servers. The communication serves inturn are connected to the application servers or mini- computers or stand-alone computers. In addition to taking care of the sending and receiving messages, these Communication Servers also serve as mail servers (Mail-boxes) for a given location.
All transactions at the Branches or SRM etc. are also stored in a communication database, from where these are forwarded to the pre defined destination. Adequate fail safe software has been provided to take care of the various error conditions that may occur during transmission. The user is not required to put in any extra(manual) effort to send or recieve data, as the communication software has been designed to automatically update the database without human intervension. It is to be noted that a condense replica of all the transactions at the branches or SRM's etc. will be made available at the regions and CMIS-Kolkatta. Ofcourse, there are some changes to the working procedures which have been provided to the users during the time of implementation.
one of the most important aspect of networking is the security of the systems and the databases. This is a very great extend has been taken care of by the protocols and the communication software. However, the final control and maintaince of the security rests with the user only. This means that the use of various levels of login-identifications and passwords should be kept under strict control.
EXECUTION OF WORK IN SRM OFFICE IN IT CONTEXT
As already said that total working in SRMO Bokaro is carried away through system only in other words we can say that everything is online hereso we can call it as online system. There is one communication server with application server and another standby application server which are called database server also through which data flows for the whole time by way of recieving the data and sending the data. There are also four main workstations in addition to five secoundry work stations which are all connected with LAN as already mentioned branches of CMO feed the orders in their system through OMS, reaches the same orders to region and headquater for approval and through SDC Hydrabad to our location that is SRMO Bokaro where these orders or which we genrally call Planning Flow Through our system and after downloading these orders we convert them to moment plans. These moment plans are simultaneously transfered to plants through one plant server where material is being made as per MP's only and being further dispatched to the concered
location/ branches.At the end of the day the whole data is being transferred to the standby application server for upkeeping of the safety of the data and backup is taken. This is the day to day job of SRMO so far IT feild is concerned. The system through which all these things are done is called IPPS i.e. INTEGRATED PRODUCT PLANNING SYSTEM. Before laying more emphasis (information) on IPPS we should know about OMS (Order Management System) and other systems which are totally related/linked to the system installed at SRMO Bokaro.
IPPS(INTEGRATED PRODUCT PLANNING SYSTEM) has been implemented at SRMO Bokaro, Bhillai, Durgapur, Rourkela & PMG Ispat bhawan Kolkatta.\
Features:
1.The system has been designed with the of the art client/server technology.
2.First GUI(Graphical User Interface) based system in CMO.
3.The system can be used from remote locations also.
As mentioned above there are other system which are co related to IPPS in day to day work.
1.Order booking procedure via internet and Sailnet.
a.MP genration process against QDDP's
b.CA/DA data flow status report
DEMAND FORECAST SYSTEM(Order Management System)
All branches enter forecast for the next month in this system for branch key accounts as well as Sundry customers. Whereas for national key accounts, KAM's enter the forecast. these forecasts are consolidated at regions and then sent to PMG(FP/LP) after moderations. Plants(SRMs) indicate the availability for the next month is done and then allocation data is transferred back to regions. Further regions does branch wise allocations.
ORDER BOOKING SYSTEM- Procedures, (Order Management system- Phase 2)
This system provides facility to enter the actual orders. these orders may be given for a given forecastes or fresh(i.e. not covered under any forecasts). This system can be accessed via SAILNET as well as INTERNET(Tip: on top right of all screens one image of "HOME" appears. Select it to go back to main menu of the system.
How to access through SAILNET(Branches)
logon to demand forecast system( OMS- PHASE 1) being used to enter demand forecasts.elect "Order Banking" in menu screen. next screen will show following options. Enter fresh order or generate order for a given forecasts Enter Orders for a customer reference modify order.View Order DElete Order Reports & Inquiry Demand forecast menu. Logout.
Generate Orders
Select first option of the menu. next screen will show a selection list. Select "NEW" for fresh orders otherwise select forecast no if you want to generate Order for a forcast. If you are selecting "new" then one blank screen will appear. Fill up all the fields and choose OK. Second screen will also be a screen with blank fields. Fill up all the fields here and choose OK. Orders generated !!!! Please note down the order number for future reference. if you are selecting "forecast no" then forecast details will appear. Fill up blank fields, select appropriate grade and choose OK. Again one screen with blank fields will appear, enter/select appropriate values and choose OK. one more screen with blank field will appear, Select/Enter appropriate details and choose OK. ORDER generated !!!!Please note down the order number for future reference. in both to select a party you can follow (only) one of og the following ENER 13 character AI Party code of the party. If you dont know the AI Party code of the customer then select party name from the selection list. Take "Search AI Party Code" help. Enter few characters of the party name, division, payee or consignee. System will show you all parties matching with initials you entered. Select the appropriate one. Shortly more simplified procedure of party selection will be introduced and will be informed to all accordingly. NOTE: There are few TIPs to ease your job. Please consult once with respective SRMO also before using codes etc. given in this document.
1. While generating orders please note down Customer reference No & the Order no. for future reference.
2. To enter a fresh order user has to traverse two screens and has to enter a lot of information. Since there can be a lot of items for same customer & product but for different grade or size. Except grade, size & tonnage rest of the things may be common to all items. Hence, to minimise the data entry effort please select "next item" link given in the bottom of the page (the page which you get after entering one order). on selecting this link sustem [apart from TDCs, destination etc.). Rest of the things you need not to enter again and again.system will take rest of the values from the previous item.
3. Even you need not to enter all items in a single day. suppose you have entered 10 items out of 15 items given by the customer (or if you have entered all 15 items and customer given some more orders after few days for the same product but for different size & grade). Then select "NEW order
against Customer reference" from the menu. System will ask you to enter very few informations like grade/size/tonnage (apart from TDCs Destination etc.). Rest of the things ( like party details, its payement terms, PFA value etc.) you need not to enter again. this newly generated order will get linked to same customer reference number ( the one which you selected from menu).
4. some important points to be kept in mind during Order Entry in the above system are mentioned below:
a) Booking/Customer type codes: During order entry, please note that the Bokking type and Customer Type codes chosen are very critical since the installment Code number. Some branches may have doubts regarding the booking type of orders.For their easy reference, we are mentioning herewith some of the combinations to be used. (For a complete list, please refer to Help button in entry screen).
DIRECT ORDERS:
NOTE: Please consult once with respective SRMO also before using codes etc. given in this document.
Booking TypeCustomer TypeExplanation
MOUNKAOrders for National Key Account customers
MOUBKAOrders for Branch Key Account customers
MOUKEYOrders for MOU customers (but not NKA/BKA)
FRMGENOrders for non-MOU customers
LDCKEY or PROLD Clause orders (for Project LD Clause orders use PRO)
TNDPROOrders against Projects/Tenders but without LD Clause
NCOGEN/KEYDirect NCO releases (Key for key customers)
STOCKYARD ORDERS:
NOTE: Please consult once with respective SRMO also before using codes etc. given in this document.
Booking TypeCustomer TypeExplanation
MBSNKAOrders for National Key Accounts customer
MBSKAOrders for branch Key Accounts customers
PMGBRMOther Deemed Direct/Critical orders(but not NKA/BKA)
LDCBRM or PROLD Clause (for Project LD Clause orders use PRO)
TNDPROOrders against Projects/Tenders but without LD Clause
PMGNSYOrders through other/nodal stockyards (incl LD Clause)
***
SPQBRMSpecial quality Orders (but not NKA/BKA/LD Clause)
BRQBRMGeneral Branch requisitions
NCOBRMNCO releases
ADHBRMAdhoc releases
*** e.g.: Cochin branch orders to be despatched to coimbatore/Chennai stockyard or pune releases to be sent to nagpur stockyard and so on. In this case, please give Booking type PMG and customer type NSY and destination code of the stockyard siding where material is to be despatched from plant. Please take utmost care in giving the right codes fo respective cases.
b) Size Entry: Some illustrative examples of size are as follows:
0.63x 920: Please enter as follows:
Dimensions indicator: “Only Primary Dimensions”
Primary Dimensions: 0.63x 920 Leave secondary Dimensions & alternate size as blank.
0.63x 900/920: Please enter as follows
Dimensions indicator: “Either Primary or secondary Dimensions”
Dimensions: 0.63x 900
Secondary Dimensions: 0.63x 920
Leave Alternate size as blank.
0.40-2.00 x AW: Please enter as follows:
Dimension Indicator : “Any Dimensions between primary & Secondary Dimensions” Dimensions : 0.40 x 88888 Rebate : 1500.00 secondary dimensions : 0.50 x 88888 leave alternate size as blank. Apart from the above if you want to specify one more alternate size, enter it in Alternate size fields. Standard width can be specified as “SW” and Standard can be specified as “AW” and Any length can be specified as “AL”. Whereas
c) Rebate Entry (for all order of BSP&DSP) : Please enter rebate in rebate (long products) field given in the screen(for all orders of RSP & BSL) : Please take due care while entering rebates since Invoicing in BSL is automatically done on the basis of data fed in system. For all flat “Rebate for FP” only. Some illustrative examples of examples of entry are: 0.63x 920 OSK : Please enter as follows: Quality : IS513 GR OSK OILED Alt. Quality: no need to select anything Dimension indicator: “Only Primary Dimensions” dimensions: 0.63x 920 Rebate : 1500.00 Secondary dimensions : 0.63x 920, 0.63x 900/920 OSK: please enter as follows: Quality : IS513 GR OSK OILED Alt. Quality: no need to select anything Dimension indicator: “Only Primary Dimensions” dimensions: 0.63x 900 Rebate: 1500.00 Secondary dimensions : 0.63x 920, 0.40-2.00 x AW: Please enter as follows:
a) Alt. Quality: UNTESTED OILED Dimensions Indicators: ‘Any Dimension between Primary & Secondary Dimensions” Dimensions: 0.40 x AW Rebate: 1500.00 secondary dimensions 0.50 x AW. b) Secondary entry; Quality; IS513 GR OSK OILED Alt. Quality; UNTESTED OILED, Dimension indicator; “any dimension between primary & secondary dimension”. Dimension ; 0.51 x AW rebate ; 1900.00 Secondary Dimension 2.00 x AW 5-10 x AW x AL GR A/B/ COMM1/OG untrimmed: Please enter as follows:
a ) FIRST ENTRY: Quality: IS2062 GR SK UNTRIMM
Alt. Quality: IS2062 GR SK UNTRIMMED Dimension Indicator: “Any Dimension between Primary & Secondary Dimensions” Dimensions: 0.51 x AW Rebate: 1900.00 Secondary dimensions: 2.00x AW 5-10 x AW x AL Rebate: 2000.00 Secondary Dimensions: 10.00x AWx AL
b) SECOND ENTRY: Quality: IS1977/99 FE 290 UNTRIMMEDAlt. Quality: OFFGRADE UNTRIMMED Dimensions Indicator: “Any Dimension between Primary & Secondary Dimensions” Dimensions: 5.00 x AW x AL rebate : 1800.00 Secondary Dimensions : 10.00x AWx AL
c) Grades: For any order you can specify one primary grade (quality) & three alternate grades (qualities).
d) Sales Tax Type: For every Direct Despatch Order, please do enter the type of Sales tax (Central/ local) as well as the percentage to be changed.
Modify Orders
Enter the order no and select “OK”. Modify value in subsequent screens. When you have finished then don’t forget to note down order amendment number vieworder Enter the order number and select “OK”. Details of the order will be available on the screen. Delete orders enter the order number and select “OK”. Order will be deleted only if it is not approved by region and PMG. Once order is approved it cannot be deleted.
Specific order using this option you can enter 8 order in single screen. But all these order must be of specific size and grade and should belong to only one customer. You can enter a number of items in multiples of 8(or less than 8) for different products.
How to access through SAILNET(region)
A) Scenario 1 : If regionwise productwise allocation for Region has already been done by PMG then in such a case, you can go to the option “ Allocation forecast for Branches” option in order management system (OMS-I) and do the allocation for each branch directly by giving the criteria in the screen which open up. (branchwise ALLOCATIONs can be done subject to the total of Branchwise allocation doesn’t cross the regionwise PMG Allocation). Once the branchwise allocation is done, all order which have been booked so far will be approved depending upon size, grade & customer type(NKA/BKA/OTHERS). If the total order Quantity (i.e. extra orders) can be approved one by one,(see the procedure given below).
B) Scenario 2 : regionwise productwise allocation for Region has not yet been done by PMG: in such case, you will have to approves each other individually. This can be done by using the “approve Order” option of menu screen. On selecting approve order option a screen opens up where you can either choose the order no if u know it (lower part of the screen), or you can choose certain criteria and see all the order which match that criteria and approve each other in turn. (please see step wise procedure given below) PROCEDURE OF APPROVING ORDERs logon to demand forecast system(OMS- Phase 1) being used to enter demand forecasts. Select “Order Booking” in menu screen.Select ”Approve Order” option. Next screen will prompt you to select few parameters likes product, branch, dates, despatch type etc. Select appropriate values and choose “OK”. This screen also allows user to select specific order number to approve. If specific order no. is selected then orders details will come on the screen followed by three buttons namely “ACCEPT”, “REJECT”, and “KEEP IN PENDING”. Choose appropriate button. If you are not specific order no. in Step 4 the next screen will show a list of all orders, pending for clearance by region. Click on the order number to view its details. Next screen will pop up which shows complete orders details followed by three buttons namely “ACCEPT” , “REJECT” and “KEEP IN PENDING”. Choose appropriate button.
How to access through SAILNET(PMG) Logon to Demand Forecast System being used to enter demand forecasts. Select “APPROVE Order” option. Next screen will prompt you to select few parameters like product, branch, dates, despatch type etc. Select appropriate values and choose “OK”. Next screen will show a list of all orders pending foe clearance by PMG. To approve orders go back to demand forecast module and modify allocations. After modifying these allocation regions will have To reallocate quantities for the branch. After reallocation by regions, order will get approved.
How to access internet (all location) logon to www.sail-steel.com. Select “order booking for CMO”. Login with your user id & password. Order booking menu will appear(in the menu link for Demand forecast system i.e. OMS Phase 1will not be abvailable).next screen will show following : FOR BRANCHES Enter fresh orders or generate order for a given forecasts Enter orders for a customer reference modify order
View Order
Delete Order
Reports & Inquiry
Demand Forecast Menu
Logout
FOR REGIONS
Approve Order
Reports & Inquiry
Demand Forecast Menu
Logout
FOR PMG
Approve Order
Reports & Inquiry
Demand Forecast Menu
Logout
Now follow the steps given above (in how to access via SAILNET)
HOW TO GENERATE MOVEMENT PLAN(only for SRMOs) Download “splngmod.r”, “ppl115.r”, from IPPS Emergency page. Copy all these programs in IPPS directory of the workstations Start the “startflow” script of the serve after bringing up the database. Order entered by branches will flow to SRMOs in IPPS database. Don’t come of this screen will show you all orders flown from branches to your IPPS database.
To stop database at the end of the day, please login in F11 as “IPPS”. Run “./stopreceiver and visit for the shutdown message. Login to IPPS system of your workstations. Choose “planning module” button. Choose “gen. MP” button. This will open a screen where all order can be seen in browser. Select the order anc choose “Show Details”. Next screen will show full details of the order. Choose “generate movement plan” to generate MP. Note down MP ID for future reference. Please note that modification of order will come as amendments (a new order with same order id but with a different amend no.). While applying amendments please take care that amendments are being applied in increasing order. In other words if in
an order amendment no. ”5” has been applied then in any case don’t process original order or any other amendment of the same order with amendment no less than “5”.
“THIS IS THE DAY-TODAY WORKING OG SRM OFFICES FOR ALL THE 365 DAYS OF THE YEAR. I WOULD LIKE TO ADD ONE SAYING IN CONTEXT YO IPPS-DATA-FLOW”MEN MAY COME AND MEN MAY GO BUT I GO ON FOREVER”.
M.P. GENERATION PROCESS AGAINST QDDP’S
Following options/measures are required for MP Generation process against QDDP- Direct despatch & Stockyard
Copy QDDP Files in C:\Progress directory of W/s.
Login IPPS System
Select planning module
Now how to generate MP?
Select update MP Sources in next screen.
Select QDDP as MP Sources in next frame.
Select load QDDP
Select validation option
Generate QDDP Reject report
DMP Generate
Generate MP
CA/DA DATA FLOW STATUS REPORT
This report show the status of data at different SRMO’s
Sent data position
Pending data position
Current data position
SUGGESTIONS
Following are the main suggestions for having smooth and trouble free system in the office.
1. Keep the procedure for bringing up and down the systems readily available.2. Please ensure that the communication server is kept on during the period the work is in
progress.3. Please ensure that the V-sat is working.4. Please follow the procedures laid down for smooth flow of data.5. Please ensure that the regular archiving is done in the communication database. If not
done regularly then the flow of information becomes uneven. The integrity of the database in SRMO is disrupted. Archiving needs to be done on daily basis.
6. Please check with regional EDP or SDC for any clarification. Don’t try to do on trial basis if not sure at the time of any problem.’
7. Please don’t give your root password of A/S or C/S to any one except to regional EDP or SDC.
8. Please keep procedure for starting and stopping servers ready ensure 2 or 3 persons know about these.
9. Check the connectivity regularly.
Some more important points to be noted
Following steps to be taken at regular interval to create space in the IPPS DB Server.
1. When IPPS DB is down only then give the following command: “rm—i/usr/ipps/nohup.out” may be done once in every week or more often. This creates space in /usr/ipps/filesystem.
2. In SAILCOM login, go to option a) administration b) archive communication database c) clean archive directories. This deletes all archived data in arc_cd directory. This should be done once in three month. (if possible not too often since archived CA data also gets deleted which branches same time ask for). But even if we do it is not a problem. This creates space in /home/sailcom/filesystem.
3. In Sailcom login, go to a) Administration b) Cleanup message log. This deletes system.log. This should be done regularly or alternatively or more often. This creates space in /home/sailcom/filesystems.
Raw material & material handling plant
The raw materials and material handling plant receives blends, stores and supplies different raw materials to Blast Furnace, sinter plant and Refractory Materials plant as per their requirements a buffer stock to take care of any supply interruptions.
Coke ovens 7 By-product plant
The Coke Oven Complex at Bokaro converts prime coking coal from Jharia, Dugda and Moonidih and medium coking coal from Kargali and Mahuda, blended with imported coal, into high quality coke for the Blast Furnaces , recovering valuable by-products like anthracene Oil, Benzene , Tolune , Light Solvent Naphtha, Ammonium Sulphate and Extra –hard Pitch in the process. Bokaro is situated in the prime coal belt of the country.
The coke Oven battery has 8 batteries with 69 ovens each,maintained meticulously in terms of fugitive emission control, use of phenolic water and other pollution control measures.
Blast furnacesbokaro has five 2000 cubic metres blast furnaces that produce molten iron -hot metal –for steel making . bell less top charging , modernised double cast houses, cold dust injections and cast house slag granulation technology have been deployed in the furnaces. The process of iron making is automated, using PLC charging system and computer controlled supervision system. The waste products like balst furnace slag and gas are either used directly within plant or processed for recycling /reused.
Hot strip mill
Slabs from CCS and slabbing mills are processed in the state of the art hot strip mill.the fully automatic hot strip mill with an annual capacity of 3.363 million toones has a wide range of products .the mill is equipped with state of the art automation and controls using advanced systems for
process optimization with online real time computer control, PLC’S and technological control systems.
Hot dip galvanising complex
The hot dip galvanising complex integrated with the CRM produces zinc coated cold rolled strips resistant to atmospheric,liquid and soil corrosion. This complex made certain innovations for higher productivity to help rebuild earthquake - ravaged Gujrat.
WHO OWNS SAIL?
SAIL is public sector undertaking of the government of India which holds 85.82% of equity . other major shareholders are financial institution with 7.57% stake and individuals with 3.68% stake.
For complete details see share holding pattern.
MARKETING STRATEGY OF SAIL
Qualitative improvements in service besides the products.
Marketing channel optimisation to take advantage of logistics.
Demand for small lots in remote areas.
Sail today
SAIL today is one of the largest industrial entities in India.Its strength has been the diversified range of quality steel products catering to the domestic , as well as the export markets and a large pool of technical and professional expertise. The total turn over of the company was an all time high of Rs 39,188.66 crores during 2006-07, a growth of 21% as compared to 2005-06.
Competitors of SAIL
1. Tisco
Sales turnover 3791 crores, increase of over 13 % over last year.
Sales volume 2052 MT ,increase of over 10% over last year.
Exports Rs 700 crores
Market share increased from 2-12%.
Modernisation to the tune of Rs 4000 crores underway.
Expanding product mix
2. RINL
Sales turnover Rs 1900 crores ,increased by 52% .
Sales volume 2.36 MT , increased 67%.
Exports Rs 600 crores
Growth in domestic market by 26% over last year
Market share increased from 5% to 21%.
3. Ispat
Started in 1976 by setting up multi crore ISP in Indonesia ; today its one of the fastest growing company’s in the world .
Sales turnover Rs 600 crores
Capacity 4.2 MT.
Other competitors
4. Essar steel 5. Jindal steel6. Sesa goa 7. Nipon Denro ispat8. Usha ispat
CUSTOMER LIST
Ma Durga Udyog , bokaro Bokaro Industrial Development area Katike Ispat Pvt ltd ,kanpur Amit steel corporaton, hawra Diwan steel ,new delhi Nenu mal and sons , kanpur Bhawani matels , B.S city Birma industrial and business enterprises pvt ltd, Ranu Pandey brothers , Chas Chinar steel segments ,B.S city Mangal pvt ltd , Bokaro United IRO corporation , Dhanbad Bharat supply company, kolkatta
BANKERS
State bank of India Central bank of India UCO bank of India State bank of mysore IDBI bank ltd Bank of Baroda State bank of Patiala
Capital Expenditure
Amount spent on Expansion Plan and other Capital Schemes of SAIL (incl. subsidiary) during last 3 years are as follows:
Year Total
(Rs./Crore)
2007-08 2181
2008-09 5233
2009-10 10606
PRODUCT PROFILE
PRODUCTS
IN Bokaro steel plant , finished products are categorised into 3 parts:
1. Prime products :- These are actual products , which are originally produced for example; blooms, billets , channels, rounds, angles etc.
2. By products:- These products are not originally produced by bokaro Steel plant , but are outcomes while producing the primary products.
3. Secondary products:- these are the defectives or rejected materials due to improper mixing of chemical components or fail to meet the optimum requirements. Scraps generated inside plant are also termed as Secondary products. The secondary products used here in after will mean ferrous materials generated from various production units which can either suitably be used foe re-melting to produce iron and products or offered for sale if rendered surplus, rod cutting, scrap etc.
Secondry and By- products of Bokaro steel plant:
Apart from the core steel products there are a number of other products which are obtained during processes of steel making. Some of the products are recycled to be reused and rest is sold in the market.
Products :
MRCP5-45 MM
DEFECTIVE FM SLAB
DEFECTIVE GC SHEET
CR COIL ENDS FROM SPM I& II
OLD MX HR & CR
DEFECTIVE CCD SLAB
BY PRODUCTS:
These are the products which are formed while making of the core product. They are produced simultaneously with the main product and are useful for the processes of plant and can earn revenue also.
These are the main by-products sold by the plant:-
1. Benzyl products ( Benzene)2. Toluene (nitration grade)3. Xylene4. Light solvent pitch5. Extra hard pitch6. Soft pitch
Marketing
SAIL/Marketing
Product
Primary(specific parameter) secondary /By-products
CMO(HQ-KOLKATA) UNITS-BSL,RSP,DSP,etc
BSL Marketing
Method of selling
E-auction fixed price sale
(item like sludge,carbide sludge
Frrous sludge)
ORGANISATION
BSL MARKETING
MAIN SECTION
STEEL chemical Slag Idle assets Pricing MIS
& &
By products waste products
VISION
To be a respected world class corporation and the leader in Indian steel business in quality, productivity, profitability and customer satisfaction.
CREDO
We build lasting relationships with customers based on trust and mutual benefit.
We uphold highest ethical standards in conduct of our business.
We create and nurture a culture that supports flexibility, learning and is proactive to change.
We chart a challenging career for employees with opportunities for advancement and rewards.
We value the opportunity and responsibility to make a meaningful difference in people's lives.
Category 1 Category 2 Category 3 Category 40
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Series 2Series 1
Organisation chart of SAIL
CHAIRMAN
DIRECTOR (TECH) MANAGING DIRECTOR,BSL
DIRECTOR PERSONAL MANAGING DIRECTOR,RSP
DIRECTOR FINANCE MANAGING DIRECTOR,DSP
CHIEF VIGILANCE OFFICER
EXE. DIRECTOR, VISL
EXE. DIRECTOR (OPERATIONS)
EXE. DIRECTOR, SSP
EXE. DIR.(IA) EXE.DIRECTOR,ASP