INTRODUCTION:

INDUSTRIAL PROFILE:

The manufacture of dyes began in India "in 1951" by some units with the use
of imported dye intermediates. Since 1965 the manufacture of intermediate also
commenced and subsequent. The dependence on imports considerably reduces to less
than 5%. At present, the dyestuff and intermediates are the fastest growing sector,
with the export of more than 20% of the overall export from the Indian chemical
industry. The entire Indian dyestuff industry production constitutes around 7-8% of
the aggregate production of about 12 Lakh tonnes per annum. India is one of the
major suppliers of dyes and dye intermediates from the Asian region with nearly
60,000/- tonnes per annum of exports, which constitutes about 50% of its total
production.

The dyestuff industry In India constitutes the backbone of the textile industry
and one of the major contributions to the national economy. Dyestuff in India is
primarily clustered in the industrial estates of Ahmadabad, Baroda, Vapi, and
Ankleshwar. The large coastline of Gujarat has the growth of the textile industry in
this belt due to the abundant availability of raw material as well as proximity to posts
of Kandala and Mumbai. Today the Market share of Gujarat is approximately 40-50%
of the nation's total output.

As the industry is one of the largest consumers of dyes and accounts for
nearly 80% of the total consumption in India, trends in the textile industry will
determine the demand pattern of various dyes in the country. In developed countries.
The dyestuff industry is increasingly perceived as a high-Cost, Low-return, labor-
intensive investment option. Faced with an increasing labor environment and keen to
move technology to high-profit areas-Several,

Developed countries slowly discharge from manufacturing dyestuff and source

their requirement from Asia.

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Though present India's share in the market is insignificant they offer immense scope
opportunities For Indian dyestuff exporters. In view fact that both U.S. European
countries consistently dropping production of range dyestuff, large gap likely creates
in the market, developed countries, establishment of manufacturing capacity is
unlikely. For reasons of economics, most organized sectors have stopped
manufacturing the full range of dyes and intermediates creating a large between
demand supplies.

2
CHAPTER 1:
AIM AND ESTABLISHMENT OF COMPANY.

COMPANY PROFILE

1 Corporat Spectrum Dyes& Chemical Privet Ltd.

e Office Plot No: 502&503, 484,National Highway
No. 8, Palsana - 394315, Dist: Surat
Tel No .91 9824407575,
+91 9824589088
2 Works Spectrum Dyes& Chemical Privet Ltd.
Plot No: 502&503, 484,National Highway
No. 8, Palsana - 394315, Dist: Surat
Tel No. 91 9824407575,
+91 9824589088
3 Name of the Shri Yogesh Gupta, A/707,
Managing Reen Avenue Apartment, Behind Union
Director Park, God Dod Road, Surat.
Tel(0) : 91-261-2895410,2895441
4 Name of the Shri Avneep Bansal,A/10,
Occupier Gokul Row House,
(Director) Parle Point, Surat.
Tel No.: 91-261-2895410,
2895441
5 Product Synthetic Organic Dyes
Dyes Intermediates

6 Manpower Officers Staff : 350

Workers Staff : 2000
Total Staff : 2350
7 Total
Investmen About Rs. 198 Corers
t
8 Capacity Disperse dyes : 700 MT/M
Intermediates : 1000 MT/M

9 Plan Area in 3 Hector

Hectors

Table 1.1

3
(1.1) Establishment:

FIGURE 1. 1

Spectrum is one of the largest producers of dispersed dyes in India. It is a non-

governmental company, incorporated on 06 Sep 1989. Having started its operation in
the year 1991, spectrum’s wide inventory of over 150 dyes, places it among one of
the very few manufacturers catering to almost all commercially available dispersed
dyes. M/s. Spectrum dyes & chemicals are backed by a strong R&D, eco laboratory,
and backward integration, thereby making it open to new challenges.

Spectrum is located at Palsana, Surat district, Gujarat State, India.

Spectrum delivers quality products of international standards to all customers.
Spectrum maintains laboratories in touch with the modern developmental needs,
manned by qualified technical personnel.

The assured quality of spectrum products has continuously increased the

demand for our products globally. The spectrum covers a wide band of an area in the
global arena including the south Asian countries, Middle East region countries, the
USA & central Americas. Spectrum desires to be in constant touch with the new
players, in the area of exploring new markets and end-users.

With a sustained growth rate, spectrum has established a clear place for itself in
business circles.

4
Spectrum is well-regarded for services in the market because of its alignment with the
quality, vision, and care to serve. Together with its global partners, spectrum
proactively explores the frontiers of sustainable solutions in manufacturing.

 CERTIFICATIONS & MEMBERSHIPS

 ISO 9001: 2015 Quality Management System

 ISO 14001: 2015 Environment Management System

 ISO 45001:2018 Occupational Health and Safety Management

Systems.

Blue sign System Partner

(1.2)Product profile:

Backed by a contemporary production facility, a modern comprehensive

laboratory, spectrum has developed the capability to manufacture almost all
commercially available dispersed dyes. Spectrum has over 150 dyes ex-stock at any
point in time to cater to the instant needs of the customers. We solicit inquiries for all
dispersed dyes and are also open to manufacturing customized requirements,
especially for those dyes that are challenging to synthesize.

This products range includes the following:

(1.2.1)Luminous series

We are the first manufacturer to commercially produce this range of dyes and are
more known for the same worldwide. These dyes are an innovation as a result of our
continued dedication towards our core strength – research and development.

 Fluorescent dyes for a bright shade

 Can be used as illuminates in printing

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 Robust to everyday processing variations

 Used for high visibility fabric

(1.2.2) General series

 General series dyes

 Based on azo

 A special type of chromophore range

 It covers an entire gamut of shades

(1.2.3) Anthraquinone series

 Based on anthraquinone

 Selective dyes are suitable for color discharge

 Good lightfastness

 Good stability to ph

(1.2.4) Rd series

 Compact dyeing process, suitable for rapid dyeing.

 High bath exhaustion and complete diffusion

 High operational reliability

 Substantial savings in time, energy, and chemicals

(1.2.5)Md series

 Excellent bright shades.

 Very good build-up properties.

 High productivity through optimized rapid dyeing

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 Excellent reproducibility and compatibility

(1.2.6)Xf series

 Designed for high wash fastness.

 Minimum staining to nylon

 Meets stringent washing fastness requirement

(1.2.7)Hw series

 Designed for good all-round fastness

 Minimum staining to nylon

 Good thermal migration

Low cross-staining and wide application in various blended fabrics.

figure 1. 2

7
(1.3) Vision & Mission:

Spectrum aspires to be a leading manufacturer & supplier of high quality products in-
line with our customer’s expectations & emerge to be a leading brand in textile dyes.

To innovate and adapt advance technology to make quality products and reach new
horizons through judicious decisions to produce standardized and certified products
with utmost care of the environment & nature.

Figure 1. 3

 The CSR Committee comprises of following members:

Shri Pramod Kumar Chaudhary, Chairman

Shri Yogesh Gupta, Member
Shri Avneep Bansal, Member
Shri Akshat Chaudhary, Member

The Board of Directors of the Company has approved

projects/programs/ activities as enumerated under Schedule VII of the
Companies Act, 2013

8
CHAPTER 2:
POLICY OF THE COMPANY

(2.1) PERSONAL POLICIES:

Recruitment Policy:

In the Recruitment procedure firstly assess the requirement from the plant or at any
place in the organization and check the no. of requirement against the work, then only
decided the actual no. of vacancy

For White Collar Job:

Advertisement in Newspaper

Recruitment by internal sources

Though recruitment agencies

For Blue Collar Job:

Contractor of Labour.

Casual Labour

9
Minimum Qualification needed for

Plant in charge M.Sc /B.Sc or B.E. with a minimum of 5

Years of experience
Chemist B.Sc Pass

Engineers B.E/ Diploma.

Fitters, Wireman, Welder ITI Passed Certificate.

Table 2. 1

(2.2) GENERAL POLICY:

The staff has compulsory one day off per week. The Staff members are
allowed to have 21 days' leave in a year (Voluntary) Salary is also given in advance if
required by the employee. Medical for each employee is provided and the employees
have to go for a medical check-up in a year.

Employees are allowed to come up to 20 minutes late for a reason. Except for
the manufacturing process of dyes & dye intermediates, all the work is done with
taking permission of the Environment & Department.

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Housing Policy:
Accommodation facilities are being provided for plant 1 charges, Engineers, and
officers. There is a building of group where they give accommodation.

Man Power Planning:

According to M/s SDC the requirement of the personnel for the plan is met with
keeping in view the following:

 The technical concept of a plant, including process

control and instrumentation. Smooth and efficient operation of the plant.
 Effective coordination between the various departments within the plant.
 An optimum organization with well-designed and judicious job distributions.
 Optimum utilization of different grades of a workman and supervisory staff
members.
 Maximum capacity utilization of capacity.
 Manpower planning is done formally by the different departments in charge.
The departments in charge send the requirement to the personnel department.
 Manpower planning is done generally through a workout that is the
requirement of the different departments is sent to the Personnel Department
and then future appropriate action is taken.
 At the time of expansion, the requirement of the plant in charge is fulfilled by
the erector so as have full and appropriate utilization of the capacity.
 For labor, manpower planning is done by the way as per the present
requirement and fulfilled by the labor contractor.
 It is simple terms, the requirement is understood as the process of searching
for the obtained application for jobs, from among whom the right people can
be selected.

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PROCESS FOR FULFILLING MEN'S POWER REQUIREMENT:

M/s. SDC has its way of recruiting people for general labour recruitment.

Casual Labour

Staff like chemists, engineers, and charged officials follows a particular process.

Step-1
The company advertised in a newspaper or through local sources to make the
candidate aware of a vacancy in the company with the qualification and experience
required.

Step-2

Then the applications fitting the company requirement come and collect the
application forms.

Step-3

Then after the forms are filled company takes an interview and written test for
the assessment of the theory knowledge.

Step-4
The company selected the candidates, by bifurcating the candidates
into two
parts.

(1) Whose score on exams high and passed the interview.

(2) Person who has passed the interview but scoring is a bed.

Step-5

The candidates then have to cross-practical interview and the one who is Found more
partial is then selected.

Step-6

The selected candidate is called to fulfill all legal requirements and asked for
induction training.
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(2.3)PERFORMANCE APPRAISAL PROCESS:
Employees are evaluated annually and performance appraisal is done
Hierarchical basis each department's head evaluates their subordinates: For workers
technicians’ fitter wireman electrician, supervisors, chemist engineers, etc. Are
evaluated by a relative plant in charges and the evaluating of in charges is done by
directors

Workers, technicians, Fitter's wireman, and electricians are evaluated based on

attendance and work disciplines.

For supervisors, chemists, engineers, and the plant in charge performance

appraisal form is prepared and the forms are filled on a hierarchical basis.

Employees are motivated by awarding annual increment/promotions etc the

annual promotion to be awarded to the individual employee accordingly to their
seniority, grades, pay scale, performance efficacy punctuality attendance

Performance appraisal of marketing agent is done based on monthly

performance and discipline in payment schedule in payment schedule (Within 15
days)

(2.4)TRAINING AND DEVELOPMENT

For all the new employee's staff induction training as given in plant new

Employees had to work general shifts until the plant in charge feel that the new
employee is responsible for the shift duty. All employees' monthly related training or
lecture are given by the safety executive or by an outside lecturer

For in charge various training or lecturer about maintenance, planning, the best
utilization of workers and maintenance, cost reduction is giving

 Celebration of National Safety Day i.e. 4 March + Company provides for

supervisor for housing facilities.
 The company provides Schools; Banks, Transport, Games, Club, Cultural
 Programmers etc. and facilities provide their employees.

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(2.5) SAFETY STANDADS & HEALTH DEPARTMENT
M/s SDC is a chemical company so there were many hazards Reactions took
place so that the safety and health of all the employees and workers in the prior
concern for M/s. SDC.

+M/s. SDC takes due care to ensure safety aspects in conformity to various
applicable low rules thereunder to offer safe and healthy work culture within the plant.

+ The entire employee in the plant safety measure is must like the helmet,
goggles, gumboot, mask, and est.'s application.

+Safety health & Environment policy has been formulated and is integrated
into the plant activated.

+ The company has a fully-fledged safety department and has appointed

qualified safety officers who are monitoring day-to-day activities concerning safety.

+ Permit to work system strictly followed and the job is initiated only after
ensuring the safe work environment.

+ Personnel protective equipment is a must for all plant personnel to prevent

exposure/injury during work.

+Adequate application is provided to each plant in ready-to-use condition.

+ A detailed safety audit is a condition at regular intervals by the expert

agency,

+ Safety committee meets on regular basis to review the safety aspect.

+ Safe& open place in the company for the emergency accident.

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(2.6 )HEALTH DEPARTMENT:
+ M/s. SDC is very conscious about the health of the employee and therefore
maintains OHC within the plant premise.

+ Qualified Doctor is appointed as Factory Medical Officer.

+ Company has its ambulance facilities equipped with all necessary life-saving
equipment.

+ Stock of sufficient medicine and necessary antidotes are always kept at OHC.

+ The first aid boxes with necessary medicine are kept by the factory medical officer
at the internal of six months and again by an external expert agency every year.

+ Training programmers on first aid is frequently conducted by factory

Medical officers to train the plant personnel.

(2.7)WAGES & SALARY ADMINISTRATION:

Wages & Salary Administration refers to the establishment and
implementation of sound policies and practices of employee compensation generally
the wages are the compensation that is given to the worker categories.

For staff it includes:

+ Basic Salary

+ Medical Allowanced

+Housing Allowanced

+Inflation Allowanced

For workers it includes:

+ Basic Salary

+ Medical Allowanced

+ Overtime
15
Salary and Karachi are given regularly to all the workers from the cashier in
the company staff salary was made by cheque of Bank of Baroda, Baleshwar Branch.
Date if the salary is fixed i.e. 7th & For Karachi, it is 22 of every month or the new
employee there is a scheme first one year bond with the company and in salary, there
was a deduction of 50 % salary for two months and then 15-20% for the next 10
Months, This deduction amount was credited in the account of the concerned
employee.

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CHAPTER 3 :
ORGANIZATIONAL STRUCTURE OF THE COMPANY.

3.1 Organizational Chart of the Company.

Figure 3. 1

17
2. Identify Various Departments.
There are mainly four departments in the company.

1. FINANCE DEPARTMENT.

2. PRODUCTION DEPARTMENT.

3. MARKETING DEPARTMENT.

4. HUMAN RESOURCE DEPARTMENT.

3.2.1 Finance Department.

Accounting policies.

Significant accounting policies.

1. Basis of Accounting.

The financial statements have been prepared on the historical cost basis and the
accounting principle of going concerns.

Accounting principal not specifically referred to are otherwise consistent and in

consonance with generally accepted accounting policies.

2. Revenue Recognition.

All the income and expenditures are accounted for on an accrual basis in consonance
with general accounting policies. Sales are inclusive of excise duties and sales tax.

3. Fixed Assets and Depreciation.

Fixed assets are stated at cost of acquisition (NET OF CENVAT CREDIT

AVAILED, IF ANY)Cost of acquisition comprises purchase price and other
attributable costs and allocation of pre-operative expenses.

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Depreciation is provided on the strait line method as per section 205(2) (b) of the
companies act, 1956 and in the manner so prescribed under schedule XIV to the
companies act, 1956.

4. Investment.

Investments are stated at cost.

5. Inventories.

Raw materials are valued at cost on a FIFO basis.

Work-in-progress is valued at the raw material cost.

Finished goods are valued at cost or net realizable

value whichever is lower.

6. Foreign currency transaction.

Sales and purchases are accounted at the exchange rate prevailing on the date of
transaction and the difference if any on realization payment is adjusted to the profit
and loss account current assets and liabilities in foreign currencies as of the balance
sheet date are reconverted at the rate prevailing at the year and the resultant net gains
and losses are adjusted in the profit and loss accounting.

7. Retirement benefits.

The company has taken a policy under group gratuity with L.I.C. of India for which
the company is paying the annual premium.

8. Sales.

The company has changed the accounting policy in presence to general classification
(GC) -3/2002 on as - 9 revenue recognition issued by the Accounting standard Board
of I.C.A.I. by excluding the excise duty sales tax from sales. However, there is no
effect on the profit & Loss Account.

19
9. Income tax.

Tax expenses for the year comprising current tax and deferred tax are included in
determining the net profit for the year. Differed Tax, assets, and liabilities are
recognized for the future tax consequences of the temporary difference between the
carrying value of assets and liabilities and their respective tax bases, and operating
loss carries forward. Deferred tax assets are recognized subject to management's
judgment that realization is more likely than not. Deferred tax, assets, and liabilities
are measured using enacted tax rates expected to apply to taxable income in the year
in which temporary differences are expected to be received or settled.

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INTERNAL AUDIT POLICIES

The company has a very effective internal control system covering both accounting
and administrative control. An internal audit by outside agencies has further assisted
in the assessment and effectiveness and also the implementation of the internal control
system. The company has an adequate and proper system of internal control to ensure
that all the assets are safeguarded against loss from unauthorized, recorded, and
reported correctly.

An audit committee is constituted in M/s. SDC. The Committee members are

well versed in financial matters, accounts, company law, and general business
practices. The constitution of the audit committee also meets the requirement under
section 292A of the companies act, 1956.

 Other terms and references of the Audit Committee Include:

 To oversee the company's financial reporting process and disclosure of

financial information.

 To recommend the appointment of statutory and fixation of the audit

fee.

 To apprise the board of the impact of accounting policies, auditing standards,

and legislation.

 To hold periodical discussions with statutory auditors on the scope and content
of the audit.

 To receive the company's financial and risk management policies.

 To receive the quarterly, half-yearly, and annual financial statement before

submission to the board of directors.

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3.2.2 Production Department.

Structure of production department.

Figure 3. 2

22
 PRODUCTION PLANNING AND MRP.

In M/s SDC two months of advance production planning is given to each production
department by top management. This planning schedule is given in the chart from to
plant in charge and according to their plant in charge made their schedule and
requirements of the raw material list.

Production planning is the process to decide which products the company is going to
manufacture on which day in what quantity. It is also helpful to decide on Material
Requirement Planning and Raw Material Purchase Planning.

M/s SDC has adopted a batch production system because the company produces
various kinds of dispersed dyes. Most the products are manufactured based on orders
of the company do sales forecast also, and there are various kinds of colors which are
continuously demanded in the market, those continuously demanded colors
manufacture regularly in the plant.

 MATERIAL REQUIREMENT PLANNING

When the production planning is being prepared and various informants like dyes
available, the material available are calculated then the requirement of raw material is
calculated. After deduction of available stock from the total requirement of materials,
and then the order is placed for the raw material the minimum 10 days is kept and
thus the material required plan is purchased for that they make a bill of material
(BOM).

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 PROCESS DESCRIPTION.

1. CHARGING

Charge requires a quantity of water, HCL, primary amine (PAC, OCPNA, PHA), and
stirrer to the smooth slurry. Heat to require temp and maintain for two hours, if
required, Add remaining quantity HCL and stir for 12 how to make HCL.

2. DIAZOTIZATION

Add required quantity of water and ice and bring down the temp to 0-5 cents,
Meanwhile prepare sodium nitrate soln and add as slowly as consumed er per product
required,

3. COUPLING

Prepare coupler soln in a coupling tank and cool 0-5 cents by addition of ice. Transfer
the entire diazo very slowly in this stream with effective stirring to the coupler soln
always maintaining positive coupling reacting.

4. FILTERATION

Meanwhile make proper arrangement for filter press pump and lines, Filter the batch
on a press wash the cake for the completely free of acid and impurities, Dry press
cake with compressed air and dumped the wet cake in a drum.

FORMULATION PLANT.

1. HOMOGENIZER

Transfer the wet cake to the homogenizer (turbo tank and add required a quantity of
dispersing agent Diatom DF, stirrer at high speed for 8 hours, and transfer to the sand
mill.

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2. SAND MILLING

Meanwhile, completely clean the sand mills and all its vessel and their accessories.
Charge the homogenous slurry and stars milling in the sand mill with specific glass
beds for about 2 days.

3. SPRAY DRYER

Meanwhile, completely clean the spray dryer of all contamination. The slurry from a
sand mill is fed in a dryer at the required temp. The slurry is connected with hot air
and converted into dry powder form.

4. CYCLONE SEPARATOR

This is connected with a spray dryer at the bottom. Due to the creation of vacuums
product is passing in the cyclone separator. So dye particles are mixed with water and
collected at bottom of a scrubber, and hot air is exhausted by the chimney of the
atmosphere.

5. PACKING

This dispersed dye product is then packed.

 NKS PLANT.

6. RAW MATERIAL

 Naphthalene
 Oleum
 Sulfuric Acid
 Formaldehyde
 Caustic lye
 Water

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2. PROCESS DESCRIPTION

Naphthalene is available in solid form so first naphthalene melting is necessary. The

melting point of naphthalene is 80? C. Solid naphthalene is fed in stainless steel
vessel which is surrounded by a steam jacket, where sulfuric acid and oleum are
added and temp increases. The output taken from MSGL is fed into MSLLFRP.

3. FILTER PRESS

Slurry taken from the MSLLFRP vessel is fed in the center of the filter
press. In this case, the liquid is a product and the solid is wasted.

4. SPRAY DRYER:

Meanwhile, completely clean the spray dryer of all contamination and then dry the
entire batch in the spray at the required temp. Vacuum is created by using supply fan
and exhaust fan, inlet temp. of 230-260 centigram.

5. CYCLONE SEPARATOR:

For the collection of dry powder after drying in the spray dryer, the air is separated
from the dry powder by centrifugal action, and spent is exhausted to a scrubber.
Cleaning doors are provided on the shoulder of the cyclone separator for easy
cleaning.

 PLANT LOCATION:

The Production Plant of M/s SDC is situated at plots no: 502 & 503, N.H.No - 8,
Palsana, Dist: Surat in the state of Gujarat in India at about 21.06' N latitude 72.59' E
longitudes. The area of the existing plant site is about 1.855 hectares. developed land,
roads, communication, machinery, and all other facilities for the plant. The site is well
connected by road N.H. 8 and rail Western Railway.

26
About 70 villages are falling within the area of Km radius with the site as the center
Delhi-Mumbai route Railway passes from the western side at a distance of 15-Km,
N.H.No. 8s about 0.07-Km away from the unit. According to the sitting criteria laid in
the guidelines, the industry should be at least 500 meters away from National and
state Highway, but since the industry was established in 11989 and the laws enforcing
the establishment of the unit beyond a distance of 500 meters from the highway was
enacted n 1994.

27
 ACTUAL SITTING OF THE PLANT OF SDC:

There are no metropolitan cities within 25 Km of the project side.

 No national park or wildlife sanctuary falls within 25 Km of the project site.

 No ecologically sensitive areas such as tropical forests, biosphere reserves,
important takes, or coastal areas rich in coral formation fail within 25 Km of
the plant side.

 Doesn't fall within the approach tunnel of the runway,

 There is no defense installation within 25 Km of the plant site.
 No forest area or prime agricultural land is required for the plant or any
related activitN.H.8 is about 0.07 Km away from the Unit. But since the
industry was established in 1589 and the law enforcing the establishment
beyond a distance of 500 meters from the highway was enacted in 1994.

 MAIN REASON FOR CHOOSING THE PLANT IN PALSANA

AREA:

 The Plant is situated in the subsidiary area.

 All the infrastructural facilities like road, railway,
communication, transportation, etc. are well available at Palsana
 Local Labour is available at a cheaper rate.
 Local staff is available.
 Incoming raw material octroi did not pay because Palsana is outside of the
octroi zone.
 Non-octroi places were available near the Palsana.

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 MATERIAL HANDLING & STORAGE DEVICES

 Material Handling

Material Handling is defined as the control movement of material from the site of
material, during storage and production operation up to the disposal of a finished
product, It is concerned with all types of material like raw material work in progress,
finished product, scraped and surplus material and capital types of equipment, There
are mainly two objectives of material handling,

1. Storage of material.
2. shifting of material from one location to another production unit,
It is not concerned with the external movement of material. It is covered by a separate
Discipline called "Logistics".
In M/s SDC material handling is done by pipelines, trolleys, lifts, drums, and
manually also. It depends on the form of material. The following table will help in
undertaking.
TYPE OF MATERIAL MATERIALHANDLING EQUIPMENT
Liquid Pipelines
Powder Trolleys, lifts(with manual help)
Ice Drums (with manual help)

Table 3. 1

 Storage Device:

Storage Devices are devices in which all types of material are stored in M/s SDC
storage devices like vessels, drums, bags, and tanks are used. It is also based on the
form of material.
TYPE OF MATERIAL STORAGE DEVICE
Liquid Vessels, Drums, and Tanks.
Power Bags

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Table 3. 2

 PURCHASE PROCEDURE

When production planning and material requirement planning are being prepared then
it also decides when and from whom materials should purchase and in what quantity.
Intermediates are also manufactured in m/s SDC. So those materials are manufactured
before the production of dyes is to be commenced. Those materials, which are
manufactured in the company, are stored in the raw material store. Other material
company purchases from outside. Most of the materials company can purchase in the
local market or from near cities like Ankleshwar, Baroda, Vapi, Mumbai, etc. is done
by the purchase & store manager.
In M/s SDC after the requirement of raw materials are estimated supplies delivery
time when material required that checked, it is M/s SDC policy that before 24 hours
of starting of the required material should be in material store. Some material
purchases from abroad and accordingly from those material order is placed.
Most of the order takes place through Fax or Currier. For orders, the form of an order
has been prepared. For in-home and out-home intermediates plant in charge issued
with material issue slip. The materials are received by the Transport Company's
supplier's vehicles and the inward LRs are filled. The out-home materials are first
tested in the quality control laboratory. And if the material match with M/s SDC
standards then the purchase take place, otherwise material will return back to and
supplier. The payment of purchased materials is completed 90 to 120 days. After the
payment purchased procedure gets over.

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3.2.3Marketing Department.

 Hierarchy of organization.

MANAGER

ASSISTANT MANAGER

SENIOR EXECUTIVE OFFICER

EXECUTIVE OFFICER

SENIOR ASSISTANT

JUNIOR ASSISTANT

TECHNICIAL

WORKMAN

Fgure 3. 3

 PRODUCT CLASSIFICATION& COMPETETITORS

SDC produces more than 140 colours. The product is globally known as Dyes. Dyes
are the chemical name of colours. Disperse Dyes are dyes which are prepared by
acidic reaction. SDC produces disperse dyes mainly known as Synthetic Organic
Dyes, there dyes are the disperse dyestuff suitable for polyester materials selective
side can also be applied on Nylon & Acetate materials.

31
 REPORTING AND CONTROLLING SYSTEM

No specific controlling & reporting system of sales staff is prepared by SDC because
gent have to sales certain amount of product during decides period. The limit is decide
as market situation number of costumers etc. other than that evolution of agents
performance is done on the basis of promptly payments, sales orders, new clients etc.

 FOLLOWING RECORDS ARE PREPARED BY SALES

STAFF:
 Sales Book.
 Agent wise sales book.
 Trouble shoots records & their feedback.
 Sales expenses records.
 Visit record & their feedback.

 Distribution network & order procedures.

 Distribution network.

Figure 3. 3

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In include market all materials are sold through Agents. They get commission for that.
Commission a based on selling quantity the agents work it to get order, supply of
product and payment of order. They sate products at company's name. It is rule that
agent have to pay their payment within payment within 15 days to the company

The company is currently supplying finished dye products in countries like

Czechoslovakia, Singapore, Syria, Zimbabwe, Nepal, Bangladesh, Pakistan, China,
and Hong Kong. Other then the local market at Surat, the company is biting its
products to the cities like Mumbai, Ahmadabad, Hyderabad, Bilwara, Ichalkaranji,
Jodhpur, Meerut, Ludhiana, Gorakhpur, Noida, and Mathura, at all above places
expert Surat and Mumbai Four agents have selected due to big market. All agents can
sale products in agent's territory.

 Order procedures.

The order of procedures of M/s SDC is as follow.

Figure 3. 4

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 CUSTOMER SEGEMTS :

These dyes are the disperse dyestuff suitable for polyester material selective.
Spectrum Dyes can also on Nylon and Acetate categories.
The customers of M/s SDC can be classified into following categories.

 Films manufacture (sun control films).

 Dying Units? Composite Mills.
 Sinners.
 Chips manufacture (Fiber bodies).

 ADVERTISING AND PROMOTION:

No specific advertising effort is done various promotion activities are done by NDC.

 Quality discounts are offered.

 Separate technical service division is made for customers, their work are
trouble shooting of the customer and customer specified requirement and new
shade and trend development.
 SDC allow paying after 15 days.

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HUMAN RESOURCE DEPARTMENT.

 Man power planning

According to M/s SDC the requirement of the personnel for the plant is met with
keeping in view of following:

 Technical concept of plant, Including process control and instrumentation.

Smooth and efficient operation of plant.
 Effective co-ordination between the various departments within the plant.
 Optimum organization with well designed and judicious job distribution.
 Optimum utilization of different grades of workmen and supervisory staff
members.
 Maximum capacity utilization of capacity.

Man power planning is done formally by the different departments in charges. The
department in charge sends the requirement to the Personal Department.

Man power planning is done generally through workout that are the requirements of
different department is send to personal department and then further appropriate
action is taken. At the time of expansion the requirement of the plant in charge is
fulfilled by erector so as to have a full and appropriate utilization of the capacity. For
Labours Man power planning is done by way as per the present requirement and
fulfilled by Labour Contractor

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 RECRUITMENT AND SELECTION PROCESS

It is simple terns, recruitment is understand as the process of searching for the and
obtaining application for jobs, from among whom the right people can be selected.

The man power requirement is fulfilled by local sources or advertisement in News

papers. Before deciding above the person to be recruiting, the company takes various
criteria into consideration.
 Employee's physical fitness to the job. The employee's health is the most Prior
thing.
 Employees Bio-Data.
 Employee’s education qualification.
 Employee work experience.
 His image in society.

 Salary and Benefits.

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CHAPTER 4 :

DESCRIPTION OF WORK RESPONSIBILITIES TAKEN.

 PROCESS DESCRIPTION.

1. PRIMARY TREATMENT
Impurities coming from the all plant are fed in oil or gas removal. Where oil or light
impurities removed and remaining is fed in collection tank one and two. Overflow is
collected in primary lamella settling of very small solid particles takes place.

2. SECONDARY TREATMENT

From primary lamella, overflow is collected in aeration tank-1(AT-1), AT-2 and AT-3
where air supplied from the bottom of tank to activate the bacteria.Also aeration tank
is necessary to decrease BOD and COD up to certain level.

3. TRETIARY TREATMENT

Some of the impurities are present in secondary treatment, are fed in sand bed where
impurity are removed by passing through sand also 10% color is removed in it.

 Layout of the office.

 Plant layout.

A plant lay-out refers to the arrangement of machinery, equipment and other

industrial facility such as receiving and shipping departments, tool rooms, and
maintenance room and employee amenities - for the purpose of achieving the quickest
and smoothest production at the least cost.

A plant lay-out is a floor plant for determining and arranging the desired machinery
and equipment of a plant, whether established or contemplated, in the one best place

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to permit the quickest flow of material at the lowest cost and with the least amount of
handballing in processing the product from the receipt of the raw material to the
shipment of the finished product.

M/s. SDC has such a wonderful arrangement of their production plant. In all the plant
the starting point of the process is at the top floor and end is at the ground floor and at
the basement, here in the plant all the process is being on the continues basis so the
arrangement of wesseles, coupler, etc. are very crucial.

 Principle of layout

Here in M/s SDC most of the principle of the layout is been covered, i.e.

1. Principle of Minimum travel.

2. Principle of Sequence.
3. Principle of Usage.
4. Principle of Compactness.
5. Principle of safety and satisfactory.

 Principle of flexibility

Plant layout is the strategic decision and it is decided on the basis of following
questions

1. What manufacture? (Product)

2. How to manufacture? (Technology)
3. How much to manufacture? (Capacity)
4. Where to manufacture? (Location)

The answer of first three question decide manufacturing philosophy production

system because company is producing various kind of disperse dyes on a continues
basis.

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The plant layout of M/s SDC has designed in such a way that the entire departments
in the production plant are easily connected. The plant designed in such a way that air
ventilation be easy. The pipelines of water, various liquid, chemicals and acids are
well connected with procedure places. It designed in such a way less manual material
handling works will arise. It's a chemical-based company. The most hazardous plants
are in enough distance that will not affect other manufacturing process. At each
department fire extinguishers, emergency bath showers and other safety related item
are provided.

 Plant location.

The Production Plant of M/s SDC is situated at plots no: 502 & 503, N.H.No - 8,
Palsana, Dist.: Surat in the state of Gujarat in India at about 21.06' N latitude and
72.59' E longitudes. The area of the existing plant site about 1.855 hectors. The
developed land, roads, communication, machinery and all other facilities necessary
for the plant. The site is well connected by road N.H. 8 and rail Western Railway.

There are about 70 villages falling within the area of 10- km radius with the site as
centre Delhi - Mumbai rout of Western Railway passes from the western side at a
distance of 15- km, N.H. No - 8 is about 0.07- km, away from the unit. According to
the sitting criteria laid in the guidelines, industry should be at least 500 meters away
from National and State Highway, but since industry was established I 1989 and the
laws enforcing the establishment of unite beyond distance of 500 meters from the
highway was enacted in 1994.

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 Actual Sitting of the Plant of M/s SDC:

There are no any metropolitan cities within 25 km of the project site.

 No National park or wildlife sanctuary falls within 25 km of the project site.

 No ecologically sensitive areas such as tropical forests, biosphere reserves, important
takes or coastal area rich in coral formation fail within 25 km of plant site.
 The site does not fall within the approach tunnel of any runway.
 There are no sensitive places of archaeological, historical, cultural, and religious or
tourist importance within 10 km from the plant site.
 There are no defence installations within 25 km of the plant site.
 No forest area or prime agricultural land is required for the plant or any related
activity

 Store functions (raw material department) & records

In Raw Material Department first step is planning work that is for production
studying past trend of several years which is month wise and also the product wise
then decision are taken for each product that which material is required in how much
quantity.

 There are mainly three function of store of materials:

 Receipt of Materials.
 Storage and Maintenance of materials.
 Issue of materials.

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 There are three stores in the plant of M/s SDC:

 Raw Material Store.

 Finished Goods Store.
 Spare Part Store.

In M/s SDC Raw Material Store and Finished Goods Store are controlled by Purchase
Manager. Under him two assistance works, one in raw material store and one in
finished goods store. They daily report all the receipts and issues of materials and
finished goods to purchase manager and store manager.

 Receiving of Material.

Security will verify the challan and entry in gate inward register then they inform the
store manager regarding the material. Then inspection of physical quantity with
challan copy and quality checking are done. If that will ok then material received by
store assistance then he inform to purchase manager.

 Storage and Maintenance.

For the storage of materials the FIFO is being followed. For maintenance of material
everyday inspections are done by purchase manager. In store fire extinguishers are
provided, Store builder in such a way that air ventilation will then store keeper will
allow to issue of materials.

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 Issue of Materials.

For issue of material issue slip should be signed by the required plant in charge
and then store keeper will allow to issue of materials.

 Store Manager files various records such as:

 Material issue record.
 Stock register.
 Gates pass register.
 Pending purchase order.
 Purchase indents register.
 Inventory Control.
 In M/s SDC various efforts are mad for inventory control.
 Control over issue of materials.
 Control over unwanted items at the time of purchase Control over stocks.
 Control over movement of items.
 The stock level is maintained at a substantial level.

 RECORDS AND CONTROL SYSTEM.

 Record system.

The plants like Disperse Dye Crude plant, Anthraquinone plant (AQ- Plant it includes
solvent - Recovery plant, Chlorination plant and Cynation Plant). E. O. condensate
plant (Ethylene Oxide), Dispersing Agent Plant (NKS Plant), Formulation Plant
prepare following records.

 Material consumption record.

 Three dyes planning record.
 Quality checking report.
 Workers attendance record Workers leave permission records.

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 Maintenance record.
 Received material record.
 Plants end product production records.
 Accident records.
 Other occasional records.

Ice plants are located in DD Plant, AQ Plant, EO Plant, NKS Plant, so it's record S3
prepared by responsible Plant. Other utility plants are work under AGM. (Engg. &
Maint.) Like Power plant, Air compressor plant, Steam Boiler plant, Mechanical and

 Electrical department, Prepare following records:

 Complains records.
 Safety permits records.
 Used materials records.
 Inspection records.
 Workers attendance records.
 Workers leave permission records.
 Accident records.
 Other Occasional records.

 CONTROL SYSTEM

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The plants like Disperse Dyes Crude Plant, Anthraqulnone Plant (AQ Plant, it
includes
Solvent - Recovery Plant, Chlorination Plant and Cynation plant) EO Condensate
Plant (Ethylene Oxide), Dispersing Agent Plant (NKS Plant), Formulation Plant has
following hierarchical controlling system:
 Material Consumption record.
 Three dyes planning record.
 Workers attendance record.
 Maintenance record.
 Received order record.
 Accident record.

Responsible Ice Power plants Plant, are plant. Air located Compressor Other in DD
utility plant, Plant, plants AQ Steam are plant, work Boiler EO under plant, Plant so
AGM. Mechanical its record (Engg. & S3 and Maintenance) prepared Electrical Like

 Department , prepare following records:

 Complains Records.
 Safety Permit Records.
 Used Material Records.
 Inspection Record.

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Figure 4 . 1

45
Other utility plants are work under AGM. (Eng. & Maint.) like Power Plant, Air
Compressor Plant, Steam Boiler Plant, Mechanical and Electrical Department, EHS
Departments. They have following controlling system:

Figure 4. 2

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 MAINTENANCE PLANNING AND SYSTEM

In simple words, maintenance may be understood as a set of activities which help

keep plant machinery and other facilities in good condition. In formal definition of
maintenance is that function of manufacturing management that isconcerned with the
day-to-day problem of keeping the physical plant in good operating condition. It is an
essential activity in every manufacturing establishment, because it is necessary to
insure the availability of the machines, building and services needed by other parts of
the organization for the performance of their function at an optimum return on the
investment, whether this investment is in machinery, materials or employees.

There is a separate discipline called maintenance planning. According to this science

there can be two extreme approaches.

1. Preventive Maintenance Planning.

2. Corrective Maintenance Planning.

In first planning company periodic serving the all department machinery after two
month. In second approaches it is unplanned and done when there is requirement.
There is a formal procedure for this type of maintenance work called permit book
which divided in to two categories:

3. Hot Work: Inside the plant or chemical pipelines.

4. Cold Work: Outside the plant.

In Hot Work permit mainly tree parties is concerned one where it requires second the
safety department to check the condition for oxygen level 7 etc. and the third party is
the maintenance department.

In Cold Work permit only two party is concerned that not the safety department.

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CHAPTER 5:
EXPERIENCE GAINED AND PROBLEMS FACED.

 EXPERIENCE GAINED THROGH THE INTERNSHIP

At Spectrum dyes. We had experienced various departments of work field held in

Company every day. It consists of Human resource department, Production
department, Service department, marketing department and Finance department. The
purpose of the internship was to gain practical experience of the real world.
And we hope that we have accomplished that objective. We have learnt that quality is
the thing that matters the most. Spectrum has a rich history of corporate social
responsibility, a history that has grown and evolved to meet the complexities of
today’s business world and the challenges of a global society. We are proud of our
progress, but there is still much we can do.

Quality in the products always satisfies your customers. During production, problems
could be added to the product at any level. In order to solve the problems you must
make sure that you are not leaving any loopholes behind. In order to get to the root of
the problem try to inspect the process of production on every level.

This internship will help us in different field of life performing several activities in
future. The industry visit at Spectrum dyes helped us in understanding through the
process of making disperse dyes from raw material. The process is very vast and
spectacular for understanding.

Firstly we met Mr. Pundlik bhavsar. We discuss about the human recourses
department of company, he explained us about the work structure of all the staff
members and employees. Next we met Mr. Neel Vadhera who is safety officer of
Spectrum dyes and chemical. He gave us brief information about the safety of each
and every workers and staff members,

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Later on we met Mr.jay Panchal who guided us in the factory visit. This led
us to know about various functions of production of disperse dyes. We learned that
every problem is solved with a systematic process like from the root of the problem.

During our internship we were informed that in case of any emergency

situation or any accident occurs then there were several emergency numbers written
on a board at several place in the company.

 PROBLEM FACED

Throughout this internship which held for 32 days we as BBA students got to learn
very new and undiscovered area of chemical industries.

 By going in production unit there was risk of getting touched by some harmful
chemicals.
 There was very much dirt around in the area where there is public interaction.
 Constant heat was generating through different kind of machine.
 Several chemical did smell bad which could make us hard to breath in that
area. As we were not much familiar with that.

To avoid this kind of problem Company has to do several steps:

 They could mention by some symbol or letter that some of chemical are
harmful
 Cleanliness in old place or old office was much needed.
 Exhaust system should be maintained properly so that hear can go outside
easily and worker could work in little mild weather
 Mask should be distributed to all the people who go through such places
which have unhealthy smelling chemicals

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CHAPTER 6 :
CONCLUSION, SUMMARY AND RECOMMENDATIONS

We found this training was very effective to our personal and professional life
without any doubt Spectrum dyes and Chemicals Ltd is among the top chemical
manufacturers in Indian They hold different awards in plants safety as well as in
management. Spectrum Dyes and Chemicals Ltd has changed their technology from
mercury cell to membrane technology.

Spectrum Dyes and Chemicals have strict codes of safety and management.
Our visit to Spectrum Dyes and Chemicals ltd. was no doubt very well. The plant is
constantly monitored by the team of highly trained engineers.

No doubt that the plant has best safety rules. The plant is very vast in terms
of area and there were several units working at a time. Also the industry provides us
with safety helmets as the others were wearing. They have their safety team on guard
all the time as any time any emergency situation can possibly rise. The company have
their personal medical service department as well for any medical emergency.

The only problem was that, the company got cleaned every 1 year so
throughout the year because of continuous work and mobility of workers the floor
really get slippery and it should be the matter of concern for the company. The
company should really work on that. Inspite of this there’s no such matter of concern.

We are fortunate enough that we got the opportunity to work as interns at

spectrum dyes and chemicals and it was such a wonderful experience to work with
such cooperative staff. We learned a lot from this opportunity.

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BIBLIOGRAPHY

www.spectrumdyes.com

Spectrum-Dyes-India-ISO-9001.pdf

Spectrum-Dyes-India-ISO-14001.pdf

Spectrum-Dyes-India-ISO-

45001.pdf

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