Ohm ganapathayae namaha

1. Human resource department

Security,medical,

2. Mining department &Safety and training

3. Plant maintainence
4. finance
5. Production depart
6. Quality control department and Rand d
7. Purchase and store department
8. Marketing department
9. Resources
10.
CHAPTER -1

INTRODUCTION

1.1 Introduction about training

Training is teaching, or developing in oneself or others, any skills and knowledge or fitness that relate to specific useful competencies. Training has specific goals of
improving one's capability, capacity, productivity and performance.

1.2 INDUSTRY PROFILE

India is a country of large dimension. It spreads over a geographical area of 329 million square
kilometer, which is about 2.5 percent of the global and makes the country the seventh largest in
the world. Its population of over 1,000 million ranks it in the second largest only next to china.
India is Asia's third and world's eleventh largest economy .The metallurgical and mineral
industries constitute the bedrock of industrial development as they provide the basic raw
materials for most of the Industry.

Their aggregate production in 1999-2000 was about 550 million tones, contributed by over 3,100
mines (reporting mines) producing coal, lead, zinc etc. More than 80 percent of the mineral
production comes from open cast mines and therefore, one must add the quantity of overburden
to that of the mineral production. In order to access the total amount of annual excavation in
India's mining sector.

The mineral policy opened the gates of the Indian mineral industry to domestic to foreign
investment, much of which earlier reserved for the public sector. It aims to boost the country's
exploration and mining efforts and render the mineral industry more competitive. In October
1996, the ministry of steel and mines. Government of India issued guide of grant of large areas
for . aerial prospecting under the provision of -amended MM (R&D) Act. 1.2.1 History of
industry

The history of mineral development is as old as the civilization. In case of India, the mineral
production dates back to the ancient times as the mining activities can be traced as far back as
6,000years or so. The remains of some of the old mine workings are witness to this fact. A few
of these workings have led to the discovery of a number of significant mineral deposits, which
are being present in time. Realizing the significance of industrial development of the country,
Industrial policy resolution was promulgated in 1956 by the central government. The exploration
of the minerals was intensified and the geological survey of India was strengthened for the
purpose. The Indian Bureau of Mines (IBM) was established to look after the scientific
development and conservation of mineral resources. Later, in 1972 when the Mineral
Exploration corporation was established, this function was transferred to it. Under the Industrial
Policy Resolution 1956 ambitious program of developing several I industries (such as steel, on
ferrous metals, cement) were launched which required increasing quantities of minerals.

Rare Earth Elements or Rare Earth Metals are a collection of 17 elements namely
Scandium, Yttrium and Lanthanides (15 elements in the periodic table with atomic numbers 57
to 71 namely: Lanthanum (La), Cerium (Ce), Praseodymium (Pr), Neodymium (Nd),
Promethium (Pm), Samarium (Sm), Europium (eu), Adolinium (Gd), Terbium (Tb), Dysprosium
(Dy), Holmium (Ho), Erbium (Er), Thulium (Tm), Ytterbium (Yb) and Lutetium (Lu)), Rare
Earths are not rare in the sense of their abundance, but have earned this descriptive because they
are rarely concentrated enough for an easy recovery from their ores

In India, monazite is the principle source of rare earths, which is a prescribed substance
as per the notification under the Atomic Energy Act, 1962. Indian Rare Earths Limited (IREL)
has been the sole producer of Rare Earth compounds in the country. The recovery of Rare Earths
Elements from monazite has been restricted due to its thorium and uranium content. There is a
need for concerted efforts both by GSI and AMD to explore other primary sources of Rare Earth
Elements. In the face of competition from China and due to lack of domestic demand for
indigenous materials, IREL has stopped its production.

Given the concerns over China's flexing of its muscle on the international stage by
restricting Rare Earths exports, a wave of mining projects are revived worldwide to tap sizeable
deposits of Rare Earths IREL is also planning to restart production of REE.

Keeping this in view and increasing demand of these metals for high tech applications.
Ministry of Mines has stressed the need to incentivize exploration and process R&D for creating
indigenous production capacities. To achieve this, a high level Steering Committee has been
constituted to look into the current availability of rare Earths and to suggest short, medium and
long term strategies for exploration, production and processing, to ensure long term availability
of the raw material.

WORLD SCENARIO:

There are large amount of reserves of rare earths minerals in the world. China holds the
leading position among the producers of rare earths elements or lanthanide elements. Rare Earths
are also produced in India, Russia, Kazakhstan, Kyrgyzstan, Thailand, Malaysia, Brazil, Canada,
Vietnam, South Africa, Indonesia, Sri Lanka, Mongolia, North Korea, Saudi Arabia, Turkey,
Norway, Greece, Nigeria, Kenya, Tanzania, Burundi, Madagascar, Mozambique and Egypt.
Most recently it was found that Afghanistan have large deposits of Rare Earths Metals, estimated
to be worth US $ 89 billion. The rare earth deposits are on the south bank of the Helmand River
in southern Afghanistan.

Australia and Africa are the major producers of mineral sands containing Titanium
minerals and Zircon. A minor constituent of many mineral sands deposits is Monazite, which is
the main source of Thorium. As Thorium is radioactive, occupational health provisions are
required for handling materials containing Thorium.
 Australia and Africa have extensive deposits of mineral sand. These mineral sands are
in deposits which have been naturally concentrated by gravity. These have been mined since
1934 and Australia has a major share of the world market for both Titanium minerals and Zircon.

INDIAN SCENARIO:

The wide availability of minerals in' the form of abundant rich reserves made it very
conducive for the growth and development of the mining sector in India. The country is endowed
with huge resources of many metallic and non-metallic minerals. Mining sector is an important
segment of the Indian economy. Since Independence, there has been a pronounced growth in the
mineral production both in terms of quantity and value. India produces as many as 87 minerals,
which includes 4 fuels, 47 non-metallic, 3 atomic and 23 minor minerals (including building and
other materials).

In India, Monazite is the principal source of rare earths and thorium. The mineral
monazite is a prescribed substance as per the notification under the Atomic Energy Act, 1962.
AMD has been carrying out its resource evaluation for over five decades. It occurs in association
with other heavy minerals, such as Ilmenite, Rutile, Zircon, etc., in concentrations of 0.4-4.3% of
total heavies in the beach and inland placer deposits have been enhanced from 7.90 million tons
in 2002 to 10.21 million tons in 2005.

All India 10.21

Andhra Pradesh 0.22
bihar 1.37
orissa 1.82
Tamil Nadu 1.85
West Bengal 1.22
The World Production and its reserves of Rare Earth Elements are given in Table

Country Mining Production % of production Reserves % of total reserves

(Tons) (million tons )
United States 0 (no rare earth 0 13.0 13
mining)
China 120000 97 >36.0 36
Russia and other small <1 19.0 19
CIS Countries
Australia small 0 5.4 5
India 2700 2 3.1 3
Brazil 650 <1 small
Malaysia 380 - small
Other 270 - 22 22
Total 124000 >99

i.2.2 Overview of Indian mineral sector

The share of mining and minerals sector in real gross domestic product during 1993-1994 was
2.51% with its contribution of Rs.201 billion on the value of addition which grew to 252 billion
1998-1999. The mining leases hampering 9,244 are spend over 21 states on about 13,000 mineral
deposits occupying about 0.7 million hectares which is 0.21%of the total mars of the company.
The aggregate value of the mineral production 1999-2000 was more than production that fuel
minerals accounted for about 82%(of which solid fuels 44%and liquid/gaseous fuel is metallic
minerals about percentage).In recent times the impetus to the mineral development was imparted
in the country only after the political independence come in the year 1947 the significance of the
minerals was realized in national building production was merely Rs.0.58 billion and only few
minerals were mined and the country largely developed on imports of commodities such as
copper, lead, zinc, graphite, petroleum and their products.

113 Mineral industries world

Mineral Statistics dataset that underpins this publication is continuous from 1913 to the present
day, containing mineral production data by commodity, by country, in each of those years. The
dataset also contains import and export data for a large number of the commodities for the
majority of the last century

Although there have been many changes the past century, some of which are described within
the Centenary Edition, the rationale for collating, analyzing and publishing these statistics has
remained similar throughout: “to present as comprehensively and accurately as possible factual
data about the world mineral industry’s activities, which are essentially the end product of
geology and a measure of the unceasing contribution of the geological sciences to man's material
welfare and progress" (Preface to the 1977 edition of World Mineral Statistics).

"Resources of most minerals are sufficient to meet demand for the foreseeable future but the
uncertainties that surround the geographic patterns of production and trade mail the availability
of reliable statistics an essential tool for the analysis of activity in this sector.

3The process of collection, management and delivery of data has evolved and been refined in
response to the changing global political, economic, technological and social Conditions but
these statements remain true today. As the global economy recovers, mankind will need minerals
in increasing quantities and consequently, these statistics remain as important today as they have
always been.

1.2.4 Current status of mining industry in India

The country is having a well-developed mining sector, which has vast geological potential with
over 20,000 known mineral deposits. Up to the seventh plan period (1990), of mineral resources
in the country, this is amply depicted in the appreciation of mineral inventory. The Geological
survey of India, State Directories of Mining and Geology, Public sector units like NMDC, MEC,
HCL, CMPDI, HZL, BGML etc. are the agencies for surveying, mapping and exploration of new
deposits and reassessment of older deposits/mines. Out of the total area of 3.29 million sq.kms of
the country, systematic geological mapping of 3.15 million sq.kms have been carried out by
GSL. The rare elements with atomic numbers 57 through 71. In the early years these elements
were considered as rare earth metals. Later many elements in this group were found splendid but
their name remained unchanged. The primary source of the rare earth elements is greenish
yellow colored mineral sand, which is Monazite. Its availability in nature is confined to certain
beaches and rock found in certain country. Technology developed over the year has made the
beach sand minerals to be utilized in a variety of industrial and domestic applications. India has
the largest resources base of 278 million tons for Ilmenite. This is the single largest and Ilmenite
and least exploited mineral deposit in the world. However 10% of this is only mineral resources
base in India.

1.2.5 Mineral industry in Tamil Nadu.

Minerals are valuable, finite and nonrenewable resources and basic raw materials for industries
in modem days and hence the mineral wealth of a nation becomes the backbone of its economic
growth. Tamil Nadu is endowed with industrial minerals like lignite, limestone, magnetite,
feldspar, quartz, iron ore, molybdenum, graphite, rare earths, vermiculite, crude oil and natural
gas, granite, etc. Mineral exploration is necessary to identify the remote areas of occurrence of
valuable minerals and to adopt state-of-art technology for optimum use of the minerals. The
State aims at mineral explorations and locating of mineral deposits in the State which resulted in
setting up of several industries like cement plants, refractory, glass and ceramic industries. The
exploration wing is carrying out investigation for molybdenum, gold, silver, platinum State aims
at mineral explorations and locating of mineral deposits in the State which resulted in setting up
of several industries like cement plants, refractory, glass and ceramic industries. The exploration
wing is carrying out investigation for molybdenum, gold, silver, platinum group of elements,
cobalt, nickel, etc., in Salem and Namakkal districts. Mineral administration includes the grant of
mineral concessions for both the major and minor minerals in accordance with the relevant
provisions of the Act and Rules. The State ensures scientific mining without affecting the
environment, regulation of mining operations for the conservation and development of minerals,
prevention of illicit mining and transportation of minerals, collection of signage fee, royalty and
thereby enhancing the revenue prospects of the State.

Exploration and Development :

Apart from monazite, India needs to expect more rare earth elements from the primary
source of rock. In India the concentration of REE in hard rock has been recorded in association
with carbonatites, syenites, albitites, granites,pegmatite, apatite and phosphorites and
carbonaceous schists. The Geological Survey of India has carried out a preliminary search for
REE in carbonatite in Koraput and Kalahandi Districts of Orissa. Pegmatite and the granite
terrain have been covered in Bhilwara, Ajmer and Udaipur districts of Rajasthan. Carbonatites of
Tamilnadu, West Bengal, Meghalaya and Assam were also sampled. So far, Bastnaesite has been
reported in association with Carbonatite from Puruliadistt, West Bengal and Monazite has been
reported from Carbonatite occurrence of Sung Valley (Meghalaya), Sevattur (Tamilnadu) and
Samchampi (Assam).In additionActiva GSI has to examine all the data generated from the
proterozoic and younger granites andIron oxide- copper-gold (IOCG) type deposits and also their
supergene/ of existing data and data generated from National Geochemical Mapping Program
can also help to locate the suitable target area for further research of REE. Field Investigation
carried out by ADM for rare metal pegmatites in the last few years has led to the discovery of
significant raremetal pegmatites at Pandikimal,Jangapara,Bhurpidungri etc. in Jharsugudadistrict
of Orissa and Kawargakn, Bodenar, Metapal,Challanpara etc. in Bastar district of Chhattisgarh
apart from the known and established pegmatite fields of Bihar ,Rajasthan and Karnataka. These
pegmatites were assessed and evaluated for their economic exploitability and considerable
tonnage was proved with significant ROM grade. Some of them viz .Pandikimal, Jangaparain
Jharsuguda andBodenar in Bastar district are under recovery for Columbite-Tantalite. Beryl i s
also recovered as a by-product. Columbite-Tantalite from Jharsuguda area, Orissa is niobium
rich whereas those of Bastar region, Chhattisgarh are tantalum rich. In Southern India, a survey
by AMD has resulted in locating new pegmatitic occurrences in Holenarispur and Nagmangala
Schist Belts of Karnataka. Similarly in Central India Bastar- Koraputpegmatitic belt (BKPB) and
pegmatites around Limboi in Sabarkantha Dist .,Gujarat’s rare metal bearing. Marllagalla
pegmatite in Nagamangala Schist Belts forms the single largest NbTa deposit containing
economic grades of Ta205, which has produced substantial Ta deposit containing economic
grades of Ta205, which has produced substantial tonnage of Columbite- Tantalite and
Spodumene(lithium bearing mineral).Apart from pegmatites, the granitic occurrences of Nb-Ta
minerals near Kanigiri,Prakasamdistrict,Andhra Pradesh was also located and evaluated.The
carbonatite bodie of Tamilnadu and Meghalaya were reassessed for their pyrochlorecontent.
Samchampi Alkali Complex in Mikir Hills of Assam is another potential area for Nb-Ta
minerals. The Niobium deposit at the SamchampiCarbonatite Complex, Assam, and India
extends over a considerable stretch. High content of Nb, La, Y and Zr have also been reported
for the first time in rhyolitic dykes associated with Deccan basalt from Alec Hills, Gujarat. The
anomalous content in these rocks is due to the presence of xenotime, ilmenite and monazite. The
non pegmatitic resources for rare metals are low and have problems of beneficiation which are
being studied by AMD.

Key Success For the sand mineral industry are:

● Increase the Ilmenite capacity to reach economic scale of production.

● Value addition project in minerals and rare earths compounds.

● Initiate action to develop new mining areas.

 ● Forward integrate thoughstake in world leaders in the pigment Industry like Tinfoss,
DuPont or selling up a pigments plant.
● Explore other mining options in neighbouring countries.

A review of applications, occurrence, exploration, analysis,

recycling, and environmental impact:

 Rare earth elements (REE) include the lanthanide series elements (La, Ce, Pr, Nd, Pm,
Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, and Lu) plus Sc and Y.

 Currently these metals have become very critical to several modern technologies ranging
from cell phones and televisions to LED light bulbs and wind turbines.

The occurrence of these metals in the Earth's crust, their mineralogy, different
types of deposits both on land and oceans from the standpoint of the new data with more
examples from the Indian subcontinent. In addition to their utility to understand the
formation of the major Earth reservoirs, multi-faceted updates on the applications of REE
in agriculture and medicine including new emerging ones are presented.

Environmental hazards including human health issues due to REE mining and
large-scale dumping of e-waste containing significant concentrations of REE are
summarized. New strategies for the future supply of REE including recent developments
in the extraction of REE from coal fired ash and recycling from e-waste are presented.
Recent developments in individual REE separation technologies in both metallurgical and
recycling operations have been highlighted. An outline of the analytical methods for their
precise and accurate determinations required in all these studies, such as, X-ray
fluorescence spectrometry (XRF), laser induced breakdown spectroscopy (LIBS),
instrumental neutron activation analysis (INAA), inductively coupled plasma optical
emission spectrometry (ICP-OES), glow discharge mass spectrometry (GD-MS),
inductively coupled plasma mass spectrometry (including ICP-MS, ICP-TOF-MS, HR-
ICP-MS with laser ablation as well as solution nebulization) and other instrumental
techniques, in different types of materials are presented.

+
CHAPTER – II
COMPANY PROFILE:

IREL (India) Ltd. Formerly known as Indian Rare Earths Ltd (IREL) was incorporated on
August 18, 1950 as a private limited company jointly owned by the Government of India and the
Government of Travancore. Cochin subsequently in year 1963; It became a fully-fledged
government of India undertaking under the administrative control of department of atomic
energy. IREL is a pioneer in the field of mining and processing of beach sand minerals such as
Ilmenite, Rutile, Zircon, Monazite, Garnet and Sillimanite etc. It is operating three mining and
mineral processing units. At Chavara (Kerala), Manavalakurchi, (Tamil Nadu) and Chatrapur
(Orissa).lt is also operating a chemical plant, rare earth division at Udyogamandal (Kerala)
forprocessing monazite and producing rare earths compounds with several diversification plans
in progress, including modernization of exiting plant and machinery the company is poised for
further growth from its current level of sales turnover of approx. Rs.2900 million with foreign
exchange earning of approx. Rs. 1000 million. Apart from meeting the domestic demand, IREL
alters to the international markets viz. USA, Canada, Austria, France, Norway, Germany, Japan,
South Korea, China, and Ukraine etc even under several global competitions. Besides providing
raw materials to the basic industries and the core sector of the country. IREL also plays a
strategic and unique role in the strategic atomic energy program of the country. It is the only
producer of the monazite mineral containing thorium and uranium. Since incorporation of the
company at Mumbai in 1950, the company has growing steadily during the post 50 years and the
sales turnover 350 crore, 2000-2001 reached all-time highly of race 2591 Million. IREL has own
bear eloquent testimony to its consistent export performance over the decades. IREL has built up
a corporation imaged in the world marker as a reliable supplier of beach minerals and rare earths
compound. The ISO 9002 certification received by all four operating units of IREL bears fürther
testimony to commitment of the company for equality and customer satisfaction. The company's
pride lies in its harmonious cordial relationship with the employee for several years. The
production plants of IREL have adapted highest level of safety standards along with
environmental friendly technique to exploit the obediently available minerals hum the beaches of
eastern and western part of Indian.
History of IREL:

In the year 1909, Herr Schimberg a German Chemist realized that the shinning yellowish brown
sand particles sticking to the consignments of coir, a coconut fibre shipped from Cochin Port in
South India contained Monazite. This sparked 'the discovery of vast deposits of Monazite as a
rich source of rare earths, a group of elements with variety of uses in industry and science.
Thereafter, the Germans put up facilities to concentrate the naturally found beach washing by
employing manual labour by winnowing for further processing and production of Monazite in
Germany. This industry was taken over by the British and the minerals like Ilmenite, Monazite
and occasionally some Zircon were produced.

The Government of India set up the Atomic Energy Commission under the Chairmanship of Dr.
Homi J. Bhabha in the year 1948. The export of Monazite was stopped and the possibility of
setting up facilities to process Monazite for the production of rare earth was examined. During
the year 1950, IREL was established at Bombay. In 1951, IREL became a fully-fledged Central
Government undertaking under the DAE and began the construction of its Rare Earths Plant in
Udyogamandal in Kerala.

The Department of Atomic Energy (DAE) is a department directly under the Prime Minister of
India with headquarters in Mumbai, Maharashtra, India. DAE was established in 1954 by a
Presidential Order. DAE has been engaged in the development of nuclear power technology,
applications of radiation technologies in the fields of agriculture, medicine, industry and basic
research. DAE comprises five research centres, three industrial organisations, five public sector
undertakings and three service organisations. It has under its aegis two boards for promoting and
funding extramural research in nuclear and allied fields, mathematics and a national institute
(deemed university). It also supports eight institutes of international repute engaged in research
in basic sciences, astronomy, astrophysics, cancer research and education. It also has in its fold
an educational society that provides educational facilities for children of DAE employees. The
important programs of the DAE are directed towards:

Enhancing the share of nuclear power in the Power Sector by deployment Of indigenous md
other proven technologies, and to develop fast breeder reactors, as well as thorium-based reactors
with associated fuel cycle facilities;Building and operating of research reactors for the
production of radioisotopes, building other sources of radiation such as accelerators and lasers,
and developing and deploying radiation technology applications in the fields of medicine,
agriculture, industTY and basic research.Developing advanced technologies such as accelerators,
lasers, supercomputers, robotics, areas related to Fusion research, strategic materials and
instrumentation, and encouraging the transfer of technology to industry.Carrying out and
supporting basic research in nuclear energy and related frontier areas of science; interaction with
universities and academic institutions; support to research and development projects having a
bearing on DAE's program, and international cooperation in related advanced areas of research
and contribution to national security.
IREL/ is a government-owned corporation in India based in Mumbai. IREL was incorporated on
August 18, 1950 with its first unit Rare Earths Division (RED), Aluva in Kerala. It was
incorporated with the primary intention of taking up commercial scale processing of monazite
sand at its first unit namely Rare Earths Division (RED), Aluva for the recovery of thorium. It
became a full-fledged Government of India Undertaking, under the administrative control of
Department of Atomic Energy (DAE) in year 1963 and took over companies engaged in mining
and separation of beach sand minerals in southern part of the country, by establishing two more
divisions one at Chavara, Kerala and the other at Manavalakuichi (MK),Tamil Nadu.

In 1965, IREL took over the erstwhile Travancore Minerals at Manavalakurich.i. Shn. AR
Mohapatra was appointed as the Head and General Manager and set up processing facilities for
prodtrtion of Ilmenite, Rutile, Zircon, Monazite, and Garnet which were in the raw materials.
Later, the BARC IBhabha Atomic Research CenÜeJ developed the flow sheets of all the
minemls was alsoDuring the 1970-1971, major changes in the flow sheets were incorporated and
the Plant capacity of 400 TPD of deed was achieved and the resources of products were also
increased. The entire Monazite required for captive consumption at Rare Earths Plant was
supplied by Manavalakurichi Plant. In 1979, a pre-concentration facility was installed to treat the
lean graded raw materials so as to improve the overall productivity and recovery of all minerals.

During 1985, a Dredge & Wet Concentration Plant was established near the Valliyar Plants with
a view to exploit deposits in the in-land areas and deposits below water table. The IREL-MK
Plants are one of the biggest organizations situated in Kanyakumari District, Tamil Nadu. Heavy
beach sand minerals were discovered along the sea cost of Manavalakurichi in 1909. These
deposits were enclosed with valuable minerals like illmenite, Monazite, Zircon, Rutile and
Garnet. There deposits are due to the disintegration and weathering of the crystalline rocks of the
earlier origin occurred in the Western Ghats and Nilgiri. They are carried out during the
monsoon season dovvn to the sea, instead of being swept away to the sea, they are deposited on
the beach, due to particular extends over a sand deposits at Manavalakurichi extends over a
stretch of 2 to 3 kms. Originally, these two plants Manavalakurichi engaged in the separation of
minerals and such as the Travancore minerals division.

A British Firm got long lease from the Government of Tra',ancore to mine sand from the branch
extending from the Cape corner in Kanyakumari. Around 1935, another company was extended
known as M.S.HOPKINS & WILLIAM LTD which turned their attention to inland deposits
containing 80% of the minerals.

During the 1940, the Travancore minerals started another company at Chavara in Kerala with
least machineries for the separation of all minerals. Similarly, in 1947, M.S. HOPKIN &
WILLIAM LTD also started a very big plant at Chavara. The Travancore minerals at
Manavalakurichi were in a dilapidated condition and the Government of Travancore started
repairing the building, Due to the reorganization of the state in 1956, the Kanyakumari District
was in the Chennai State.

The plant was owned by the Government of Chennai. By this time the owners of M.S. HOPKIN
& WILLIAM LTD left India leaving the 2 plants ---- Manavalakurichi and Chavara in the year
1956. The Government of India took these 2 plants at Chavara and Manavalakurichi in J 956,
The plants function under the common name 'Indian Rare Earths Limited (IREL)'.

1.3.1 Milestones of IREL

 1950: IREL is incorporated as a private company jointly owned by the GOI & Govt. of
Travancore, Cochin.
 1998, 1999, and 2000: The unit was the recipient of the AERB industry safety awards.
 1999 & 2005: The Kerala and Tamil Nadu Mines Safety Association have declared MK
unit as the winner for the overall safety performance.

DIVISION OF IREL:

1.Mineral Division Chavara

Chavara mineral separation plant is located 10 kms north of Kollam and 85 kms from
Thiruvananthapuram the Capital of Kerala. It is about 135 kms from Kochi, the major port in
Kerala. The nearest airport is at Thiruvananthapuram. The adjacent area of Chavara is blessed
with one of the best mineral sand deposits in the country – the renowned “Q” Grade minerals.

The Chavara mines contain as high as 40% heavy minerals extending over a stretch of 23 kms in
the coastal belt of Neendakara and Kayamkulam, The deposits is quite rich with Ilmenite, Rutile,
Zircon, Sillimanite and is unique with weathered variety having 60% TiO2 Ilmenite.

The plant has a capacity to produce 2,35,900 tpa of Ilmenite and associated minerals such as
Rutile, Zircon and Sillimanite. It has a facility to produce Zirflor in sizes (-300 and -200) in the
zircon opacifier plant.

The plant operates on an advanced modular design with state of the art equipments in mineral
separation and has a well - equipped Quality Control Lab for quality assurance. It is certified for
ISO 9001:2008, 14001:2004 and 18001:2007.

2..OSCOM Orissa
Orissa Sands Complex (OSCOM) is one of IREL’s flagship units located at Chatrapur in the
district of Ganjam, which is about 150 kilometers from Bhubaneswar, the Capital of Odisha. All-
weather Gopalpur port is situated beside the OSCOM plant complex. The nearest airport is in
Bhubaneswar. At present, beach sand mining and mineral separation activity are carried out over
the mining lease area of 2464 hectares to produce 2,65,400 tonnes per annum (tpa) of Ilmenite
and other associated minerals such as Rutile, Zircon, Sillimanite and Garnet.

OSCOM deposit contains an average grade of 14% to 16% of heavy minerals over the entire
mineable coastal stretch. The unit is in the process of expanding its mining and mineral
Separation activities to achieve the Ilmenite production to the tune of 4,70,000 tpa. OSCOM is
doing dredging for mining operations. Simultaneously, OSCOM also adopts dry-mining
activities for supplementing the production requirement for the mineral separation plant.
Mining and Mineral separation activities are carried out in an environment friendly and
sustainable manner.

Rare Earth processing unit having installed capacity of 11200 tpa mixed Rare Earth Chlorides
was commissioned in the year 2015-16.

The plant has a well-equipped Technical Services section for Research & Development and
quality assurance for products and services. It is certified for ISO 9001:2015, 14001:2015 and
18001:2007.

3.Rare Earths Division Aluva

Rare Earths Division (RED), Udyogamandal, Aluva is located on the banks of river Periyar in
Kerala at a distance of 12 kms from the port city of Kochi and 15 kms from Kochi International
Airport. RED is an exclusive value adding chemical plant, wherein high pure individual rare
earth compounds are produced. This plant, the first Unit of IREL, was made operational way
back in 1952 for processing of 1400 tons per annum (tpa) of monazite, which subsequently
increased to 3600 tpa.

In the year 2012, the plant was refurbished to process mixed Rare Earths chloride. It produces
high pure individual rare earth compounds of Lanthanum and Cerium in carbonate form, and that
of Neodymium-Praseodymium, Samarium, Gadolinium and Yttrium in oxalate form (with more
than 99% purity). RED also produces strategic material for the Department of Atomic Energy.

4.IRERC Research Centre Kollam

Corporate Research Centre is located at Kollam, Kerala and carries out research in the field of
value-added products from beach sand minerals, undertakes consultancy projects on mineral
separation and flow-sheet development, carrying out mineral analysis and caters to the needs of
internal and external customers. It is engaged in various R&D activities such as processing of
Monazite by alternate route, processing of nano rare earth materials and other value addition on
minerals with the ultimate objective of commercialization. The Research centre also coordinates
the research activities of RED, Aluva and Technical Services Division at OSCOM, Chatrapur,
Orissa. This Research Centre was earlier known as Mineral Research and Development Centre
since 1991 and later renamed as Indian Rare Earths Research Centre from July 2003. This Centre
is also certified with ISO 9001.

With the objective of promoting Industrial scale R&D that would be beneficial to its overall
program in terms of nuclear and related materials. IREL (India) Limited Technology
Development Council (IRELTDC) was constituted in 2006 by the Secretary, DAE with members
from BARC, IGCAR, CSIR and other leading Institutions. The Chairperson of this Council is the
Scientific Advisor to Director, BARC and Co-Chairperson is the CMD of IREL. The Head,
IRERC is its Member Secretary.

The Research Centre is equipped with various equipments and instruments like magnetic,
gravity, electrostatic separators, floatation cells, grinding mills, vacuum filters, mixer settlers, ion
exchange columns, particle size analyzer, XRD/XRF, thermal analyzer, ICP atomic absorption
spectrometers, UV spectrometers, petrological microscopes, etc. for various analytical and
research purposes.

The annual safety audit of all the operating units is carried out every year with the objective of
improving the overall safety standards and increasing safety awareness among the employees.
The Audit Committee, consisting of External experts, Heads of safety from all the units and the
Head of the Corporate Safety, recommends for the CMD’s Shield in various categories; Safety,
Housekeeping, Environment & Energy.

5.Rare Earths Extraction Plant (REEP).OSCOM

IREL has set up a Rare Earth Extraction plant (REEP) producing mixed Rare Earth chloride
(MRCL) Tri-sodium phosphate etc, at its unit OSCOM Odisha. MRCL produced from the above
plant is processed at IREL’s plant at Rare Earth Division (RED) in Aluva Kerala for producing
separated High Pure Rare Earth (HPRE) minerals.

Rare Earth processing unit having installed capacity of 11200 tpa mixed Rare Earth Chlorides
was commissioned in the year 2015-16.

6.Indian Rare Earths Limited Manavalakurichi:

Manavalakurichi unit (MK) is located at a distance of 25 km North of Kanyakumari (erstwhile

Cape Comorin) in Tamil Nadu. All weather major seaport “Toothukudi” is located at a distance
of 100 km and the nearest Aiport at Thiruvananthapuram is located at a distance of 65 km from
the MK plant site. Nagercoil, the district headquarter located at a distance of 18 km from the
plant is the closest major Railway station.

The entire coastal stretch of Kanyakumari District is blessed with rich heavy mineral deposits.
Annual production capacity of MK mineral separation plan is 91,200 tones per annum (TPA) of
ilmenite and other associated minerals such as Rutile, Zircon and Garnet.The IREL
Manavalakurichi Unit was established in the year 1966.The IREL- MK does mining and heavy
beach sand mineral separation for the Department of Atomic Energy[DAE]. The products
received through mining an separation is used for the atomic energy Purposes. The IREL-MK is
registered under the MINES ACT, 1952. At present, the Manavalakurichi unit of IREL has a
total strength of 244 employees. Out of which, there are 180 workers and 64 officers. Also, there
are around 200 contract based workers to engage in the non-core or peripheral activities of
IREL-MK.

The IREL-MK is committed to :

 Customer satisfaction
 A healthy environment
 Occupational health and safety to all concerned through

1) Quality products
2) Continual improvement
3)Compliance with legal requirements
4) Conservation of rata resources
5) Maintenance of safe and healthy work practices
6) Motivation, training and awareness of employees

Facilities at MK unit:

Dredge & wet concentration plant(DWCP).The inland deposits containing about 10% to
25% heavy minerals(HM) are dredged and concentrating using spiral concentration to get about
90% HM goals.

Capacity:114600MT.

PRODUCT PROFILE:

 Ilemenite
 Rutile
 Zircon
 Sillimanite
 Garnet
 Monozite

PRODUCT SPECIFICATION SPECIFIC DENSITY PACKAGING

GRAVITY
Ilmenite FeOTiO3 4.54

Rutile Ti02 4.25

 Zircon Zr02 Si02 4.65

Sillimanite Al203 Si02 3.24

Garnet 3FeO Al203 SiO2 4.11

Monozite (Ce,La,Nd,Th) 5.24

(PO4,SiO4)

1.Ilemenite

General Information:

 Chemical formula : FeOTiO3.

 Color: Black.
 Properties: Magnetic and Conducting.

Uses:

 Mainly used for the manufacture of titanium dioxide (a white pigment) which in term
used in paints, paper, rubber, textiles etc.
 It is also the raw material for the manufacture of titanium alloys which is used in the
aerospace and chemical industries by virtue of its light weight, toughness, heat and
chemical resistance.
 Also used fist the production of the synthetic Rutile.

2.Rutile:
General Information:

 Chemical formula: Ti02

 Color: Brownish black.
 Properties: Non-Magnetic and Conductivity

Uses:

 Used for coating of welding electrodes.

 Also for the production of titanium dioxide and titanium tetrachloride.
 Used for the production of titanium metal sponge.

Zircon:

General Information:

 Chemical formula: Zr02 Si02.

 Color: Yellowish golden.
 Properties: Non-magnetic and Non-conducting.

Uses

 Used in foundries, ceramics and refractory.

 Also used as the raw material for the manufacture of Zirconium oxide.
 Its compounds, metal and alloys of Zirconium which find application in many chemical,
electronic and nuclear industries.

Sillimanite

:
General Information:

 Chemical formula: Al203 Si02 .

 Color: Brownish white.
 Properties :Magnetic and Non-conducting

Uses:

 Mainly used in the manufacturing of high temperature refractories, insulators

 In ceramic industries

5. Monazite

General Information:

 Chemical formula . cc, La) Pm.

 Color :Greenish Yellow
 Properties: Feebly magnetic and Non-conducting

Uses:

 Extraction of thorium concentrate and rare earth compounds used in various chemicals
and electronic industries.
 Used for the manufacture of thorium nitrate used in gas mantles.
 They are useful for defense applications, painting and chemical industries
 It is the source of thorium and uranium for nuclear reaction.

6.Garnet

General Information:
  Chemical Formula: 3FeO Al203 SiO2(Almandine).
 Color: Yellowish brown.
 Properties: Magnetic and Non-Conducting.

Uses:

 Mixed with high pressure water ,garnet is used to cut steel.

 Used in the manufacturing of abrasives, grinding wheels.
 For polishing glass/TV tubes ,as sand blasting media in water filtration.
 In water get cutting and in antiskid surfaces.

OBJECTIVE:

IREL (INDIA) LIMITED, Manavalakurichi in line with ISO 9001:2015,ISO 14001:2015&ISO

450001:2018 for “Mining, Production and supply of Minerals and their Products”.

VISION:

 To be a significant contributor of strategic materials to Department of Atomic

Energy. To carry out operations in an environmentally sustainable manner and
become a leading supplier of heavy minerals.

Mission:

 Sustainable contribution to nuclear power and energy security of the country

through rare earth products and other strategic materials.
 Develop value added products of heavy minerals in an environmentally and
socially responsible manner.
 Lay an emphasis on continuous Improvement and foster professional growth and
development of our employees.

Annual production capacity of MK plant:

Capacity of MK plant : 1,14,600 MT

Ilmenite 90000MT
Rutile 3600MT
Zircon 10,000MT
Monazite 5000MT
Garnet 10,000MT

 IREL EMPLOYEES:
 OFFICERS MALE FEMALE TOTAL

Supervisor 12 4 16

Clerical 4 2 6

Skilled 79 - 79
TYPES OF
unskilled 50 4 54 WORKERS

Total 182 12 194 Permanent

Apprentices 21 3 24 Probationary

Temporary

Substitutive

Apprentice

Permanent:

Permenant employees,regular employees are the directly employed work for an employer and are
paid directly by the employer.In addition to their wage,they often receive benefits like
subsidized health care ,paid vacations,holidays,sick leave and contributions to retirement plans.

Probationary:

Probationary is usually defined in a company’s employee handbook,which is given to workers

when they first begin a job.The probationary period also allows an employer to terminate an
employee who is not doing well at their job or is otherwise deemed not suitable for a particular
posiyion.

TEMPERARY:

Temperory employement refers to an employement situation where the working period is limited
to a certain period of time based on needs of the employing organization.

SUBSTITUTE:

Substitute employee is any person employed to replace any classified employee who is
temporarily absent from duty.

APPRENTICE:

Asystem of training a new generation of practiotioners of a trade or profession with on the job
training and often some accompanying study
WORKING HOURS:

3 shifts

 1st shift 7 am to 3 pm.

 2nd shift 3pm to 11 pm.
 3rd shift 11 pm to 7 am.

GENERAL SHIFT

8 am to 4 pm.

 9 am to 5 pm.
 9:30 am to 5 pm.

TARGET CUSTOMER:

Ilmenite:

Ilmenite is supplied to TiO2, Synthetic Rutile and Titanium Slag producers in bulk. Some
quantity of the material is supplied to welding electrode and Ferro titanium producers.

Rutile:

Rutile is supplied to the welding electrode industry.

Zircon:

Zircon is supplied to ceramics, refractories, foundries and zirconium chemicals industry.

Garnet:

Garnet is supplied to industries for sandblasting operation. Other major industrial segments
consuming Garnet are water jet cutting, glass polishing and manufacturers of abrasives.

Sillimanite:

Refractory manufacturers are the main customers of Sillimanite. In addition, some quantity is
used by ceramic manufacturers.

Illemnite DCW Ltd,TTPL

Garnet Domestic: Grind Well Norton

Export: Paduan Global-Malaysia

Al Ansari- Oman

Trans gold Minerals,UAE

Rutile VNC Electrodes

Thirumala Electrodes
Zircon Nuclear Fuel Complex (NFC)
Monazite OSCOM

ORGANIZATION CHART:

UNIT HEAD, GM
HOD-HRM HOD-Min & HOD-Plant Maint HOD- Fin HOD- elec, HOD-QC
DGM(HR&A S&T (DGM) DGM(Mech.Maint DGM (F&A) Pur & store(DGM) &R&D

HOD- HOD-marketing HOD-Res CM (F&CT) CM(Pur.&Store AM (QC)

Production. M (Sales) CM (Res) s) DO (QC)
DO(Petrolog

DM (Accts.&Banking)
AM (Accounts) CM (Elect.)
I/c-MSP I/c-HUP AM (costg.& fin.vet.)
CM (P) CM (P) DO (Acccounts)

M (Electrical) AM (Tech.) DO
M (Mech)
DO (HRM) (Tech.)
DM (Mech) CM (P) SM M(Mech
AM (R&D)
AM (Tech)
DO (Tech) AM (Pur)
DO (Tech) DO (F&S) DO Pur)
DO (Tech) DO (Pur)

Security, fire safety &MIS

CM (Sec.)
AM
DM
(Marketin
Medical (Mining)
g))
DM (M) DO (Mkt)
DO (Stores

M (Pers)
DMC (Estt.II)
AM (Admn) AM (Tech.) DO (Tech.)
SM
M DO (T) DO (Tech.)
(Hindi)
(L&ER)

HR&A- Human resource & administration F&A- Finance and accounts Res-Resources SM-senior manager
S&T- safety and training QC & R&D- Quality control &research development M-Manager
Min- Mining Pur.- Purchase GM- General manager DM- Deputy manager
Mech.Maint- Mechanical maintenance Elect- Electrical DGM- Dy.General manager AM-Assistant manager
P-Production, Tech- Technical L&ER- legal & employee CM- Chief Manager DO-Deputy officer
1. HUMAN RESOURCE DEPARTRMENT Relation

INTRODUCTION:
Human resources is the set of people who make up the workforce of an organization, business
sector, industry, or economy. A narrower concept is human capital, the knowledge and skills
which the individuals command. Similar terms include manpower, labor, personnel, associates or
simply: people.
The Human Resources department (HR department) of an organization performs human resource
management, overseeing various aspects of employment, such as compliance with labor law and
employment standards, interviewing, administration of employee benefits, organizing of
employee files with the required documents for future reference, and some aspects
of recruitment (also known as talent acquisition) and employee offboarding.They serve as the
link between an organization's management and its employees.A human resource department is
involved with making sure the company has a solid roster of employees, who are trained to fulfill
their roles and compensated appropriately for doing so.

The human resource department provides effective policies, procedures, and

people-friendly guidelines and support. Additionally, the human resource function serves to
make sure that the company's mission, vision, and values are part of the company culture.

Main objectives of HR Departments:

 Contribute to the company’s business objectives.

 Attract and retain the best talent.

 Improves employee’s quality of life.

 Improve productivity.

 Ensure compliance with regulation.

Role of HR department:

 Job Design & Analysis

 Human Resource Planning
 Human Resource Recruitment
 Training and Development
 Orientation & Placement(Induction)
 Career Planning and Development
 Performance Management.
 Employee satisfaction (Reward and motivation).
 Communication.
 Supervision.
 Health and Safety at work place.
 Labour Relations.
 Disciplining.
 Compensation and Benefit.
 Termination Of contracts.
  Human Resource Account &Audit.
 Human Resource Information system.
 Human Resource Policies & Procedures.

OPERATIONS OF HR DEPARTMENT OF IREL:

IREL Manavalakurichi takes places it’s highly motivated and trained human resources
that has maximized its performance and their by its growth and profit. Morale of the employees
remains facilitating smooth working of the company. Skill requirement related to different
disciplines are identified and training programs and workshops are provided for the efficiency of
the human resources.
 DEPARTMENT STRUCTURE:

UNIT HEAD

HOD

Medical Security

HRM

Section head Section Head

(Medical) (Security)

Establishment Welfare General Time office Legal SO (legal)

administrative
SO(HRM)

Section Head (HRM)

Deputy Manager
Canteen
(HRM)

Medical staff Canteen staff HRM Staff Time office staff Security Guard
 HR department lead by General Manager and two Deputy Manager assisted him. The
Security Department and Time Office are working under the General Manager of HR
Department. Deputy Officers and Clerical staffs are working under the Deputy Managers.

People are the most important resources of an organization.

The main functions of HR Department are:

1. Administration.
2. Industrial Relations.
3. Training and Employee Welfare.
4. Time Management.

1.ADMINISTRATION

The administrative functions of HR department include

a) Manpower planning
b) Recruitment planning
c) Performance appraisal
d) Salary & wages administration
e) Industrial discipline
f) Maintenance service books & personal file
g) Maintaining reservation register

a) Manpower planning

Manpower planning is important for any type of organization. It is the process

which determines how an organization should move from its current manpower position to its
desired manpower position. For this purpose, the HR department at IRE collects feedback from
the entire department in order to identify their manpower requirements of various departments
and then the HR department cross check whether there is any overstaffing in any of the
departments. If these departments have excess of staff, they are transferred to those departments
whether there is a shortage.
 The company considers the number of employees presently as significantly high. There is a
problem that sometimes the VRS can lead to security to worker for particular job. At IREL
using the process of multi-tasking the employees are made fit to work in other function also. By
the VRS scheme more than 100 employees have been sent out within span of 3 years.

MANPOWER STRENGTH:

TOTAL STRENGTH 194

EXECUTIVES 55 WORKMEN 139

Grade Desig. Nos. Grade Nos

E7 GM 1 MALE 49 MALE 133 W10 29
E6 DGM 4 W9 30
E5 CM 11 W8 23
E4 SM 0 FEMALE 6 FEMALE6 W7 26
E3 M 6 W6 7
E2 DM 7 W5 9
E1 AM 10 W4 6
E0 DO 16 W3 5
W2 2
W1 2
Trainee 0

b)Recruitment planning

Recruitment in MK plant is done through local employment exchange for find out perspective
workers. The office staffs and managers are recruited by the head office through tests and
interviews.

Recruitment criteria & selection process

 For the recruitment of candidate should be above 18 years of age.

 The following steps are taken before the recruitment of employees. They are Government
guidelines, the recruitment only through employment exchange. Notification in internet
and advertisement in newspaper should be needed. Application will be scrutinized with
the help of a selection committee and eligible candidates are called for an interview
Selection:
The steps followed in the selection process are:
 Inviting and receiving application.
 Scrutinizing the application.
 Selection test of the employees are:
1. Aptitude test.
2. Personality test.
3. Achievement test
4. Trade Test

Appointment will be based on certain criteria’s like they are medically tested after that
induction training should be given. After training for a period of one year or more they will be
put as permanent employees.

c)Performance appraisal:

Appraisal is the evaluation of work quality or merit, in the case of IREL performance
appraisal is a systematic evaluation of employees by supervisor or other familiar with their
performance.

1. Straight ranking method:

Under this method men as a whole are compares from other men and ranked on the basis
of overall performance.
2. Grading method.
Under this method certain categories of work such as excellent ,very good, average, poor,
very poor are established AND DEFINED ACTUAL performance of each employees
were compared with grades definitions and ranked to evaluate the performance of the
employees.
 In IREL performance appraisel is done on a yearly basis to access the performance of the
employees.

Promotion:

In IREL promotion is given seniority based or based on experience. Promotion is a transfer

of an employee to a job that pay more money or that enjoys some preferred status. Sometimes
the company is considering the length of service,education, training courses completed, work
history etc.

Conditions for getting Promotion;

1. Should not apply for job in any other organization.

2. Average leave should not exist more than 15 days.
3. Any disciplinary actions should not be taken during the service of periods.

d)Salary and wages administration:

Wages is the widest sense means any economic compensation paid by the employer under some
contract to his workers for the service rendered by them.

Acts Followed:

 The Workmen compensation act 1923

 The Payment of wages act 1948
 The Industrial Dispute Act 1947
 The Apprentice Act 1961
 The Maternity Benefit Act 1961
 The payment of Gratuity Act 1972
 The Mines Act 1952
 The Contract Labor Act 1970
 The Minimum wages Act 1948

e)Industrial Discipline:
Disciplinary actions are taken in the HR department .Procedure for disciplinary actions is on
receiving a complaint about a particular employee, explanation is asked. Employee will give an
explanation before 15 days .If the explanation is not satisfactory he will give a charge sheet and
will also conduct a domestic enquiry. For this purpose an enquiry officer is placed. After
conducting the enquiry the report should be sent to the disciplinary committee and if necessary
certain punishment may also given.

2.INDUSTRIAL RELATION

Most of the disputes will be settled by the company and trade union .If it is not cleared ,they can
approach to the government. The Trade Unions active in IREL are:

 Indian National Trade Union Congress(INTUC)

 All India Trade Union Congress(AITUC)
 Mineral Workers Staff Union
 IRE Mineral Tozhilalar Munnetra Sangham
 IREL Mazdoor sangham(BMS)

4.TRAINING &EMPLOYEE WELFARE:

“Training is the act of increasing the knowledge and skills of an employee during a
particular job”

Indian Rare Earths Ltd adopted various techniques of training for increasing the mass
productivity. The training program in restructured regularly in IREL.The objective of
training and development in IREL

 Increase the efficiency

 Increase the moral of the people
 Reduce the absenteeism

Types of training:

 Induction Training
 Skill Development Training
 Vocational Training
  Training to Contract Workers

WELFARE MEASURES

 House Building Advance(HBA)

 Hire Purchase Advance
 All India Leave Travel Concession (LTC) Availment
 All India Leave Travel Concession (LTC)Encashment
 GSLI Scheme Membership & Settlement
 Post Retirement Medical Scheme(PRMS)
 Outpatient Treatment Benefit(OPBT)
 Family Relief Scheme
 New Pension Scheme for workmen(NPS)
 Gratuity –Nomination & Settlement
 Provident Fund Nomination and Settlement
 Group Saving Linked Insurance

1.1TIME OFFICE:

There is a fully fledged office headed by Deputy administrative officer .It follows a punch card
system. Different allowances for employees are provided mainly on the basis of attendance. It is
provided according to the report from the time office. The time office is working under the HRM
department. The main function of this department is to maintain attendance records, leaves and
service records etc. The various allowances, attendance bonus all these records are maintained by
the time office department.

The time office collects attendance from concerned authority also and matches with the punching
system and avoids swapping .Time office has three centre’s for punching systems for the
convenience of employees. Finally the attendance record will be sent to finance department for
providing salary.
1.2MEDICAL OFFICE:

An effective and efficient medical department is functioning in

IREL Manavalakurichi. Every family member of the employee is eligible for free medical
treatment in the dispensary. Cases beyond the scope of the dispensary will be sent to nearby tie-
up hospitals. The whole payment in such cases is done by the company itself. The dispensary is
working around the clock.

FUNCTIONS:

 To carryout medical examinations of employees and their family members.

 Examining compliance to environmental requirements.

PROCESS INVOLVED IN MEDICAL DEPARTMENT

A. Out Patient Service:

a) Employees and their departments are provided free medical services. For
this each employee has been allotted a personal dispensary file in which name of the dependants
are included as per the family card issued by the welfare department. Proper recording of the
ailment, investigation and treatment of the employees and the dependants are entered in the
personal dispensary tile. Unfit and fit certificate are issued by the medical officers in the
prescribed form for availing sick leave and for rejoining the duty after sick leave.
b) Patients who require specialist's opinion/detailed investigation are sent to
recognized hospital/ govt. hospitals/ approved laboratories with a reference letter. List of
approved hospitals/ laboratories as approved by HO is maintained by HOD (Medical). Patients
are taken to recognized hospital only with the reference form issued by medical officer. In the
absence of company medical officer patients are issued a temporary reference card valid for one
day by the duty Pharmacist/ Nurse for immediate admission in case of emergency and within 24
hours the reference card issued by the medical officer is to be collected by the employee.

B. Occupational Health Service (OHS)

Pre-employment Medical Examination:

Normally recruited employees before joining are directed to undergo a medical examination by
the medical officer. Medical examination is carried out as per the pre-employment medical
examination report. The pre-employment medical examination report is send to the HOD (HRM)
for implementing the recommendation of the HOD (Medical).
C. Periodical Medical Examination:-
In accordance with Atomic Energy Regulatory Board (AERB) periodical medical
examination for all canteen workers and clarified radiation workers is carried out once in a year
and for other radiation workers and other general workers, it is carried out once in five years.
Employees are directed to HOD (Medical) as per the list notified by the Administrative section.
These who are exposed to high noise, loss of bearing bent are also conducted and feedback is
given to the concerned department.

D. Pre-retirement Medical Examination

Concerned employee is given intimation from administration section at least two
months before the date of retirement to carryout pre-retirement medical examination with a copy
to HOD (Medical).Based on this ,medical examination is carried out one month before the
retirement of every employee and necessary advice is given to the employee for his future health
maintenance.
SECURITY :

Security of the company assets and premises is vested in the hands of the staffs of the security
department.

FUNCTIONS:

1. To give security to the company and its assets.

2. To monitor the entry of employees and visitors.
3. According to ISO procedures they maintain the discipline of the employees ,their uniform
etc.

Two major threats present in IREL are sabotage and theft. To prevent sabotage
there is a control room and it is accessible at every time. In case of emergency an alarm will
blow. Another security problem faced by IREL is theft. There is no clear boundary wall for the
company .This may encourage persons to take away company assets with out permission.

OBSERVATION:

The Human Resource Department is responsible for administration, providing human resources
necessary for the smooth running of production, supervision of time office ,security and medical
office.

In the time office the attendance of all the employees were maintained from which their salary
and all other allowances are provided, each month attendance sheet will be analyzed .

security office they are responsible for each and every one entering the company .separate passes
will be issued including their details ,purpose and which officer to visit their entering time and
leaving time will be printed on the temporary pass .A detailed checking will be done by the
security officers to make sure that they are not taking any electronic gadgets inside the company.
Seperate security officers will be their at the entrance of each department .After the visit they
have to return the pass with the signature of the desired department’s head.
In the medical office all the health records of the permanent employees and retired employees
were maintained. There is a pharmacy containing all the necessary medicines in stock. Once in
every three years full body checkups will be done for all the permanent employees. Family
members of the permanent employees can also undergo medical checkups. In case of any
emergency, first aid will be provided at the medical office and later will be send to their tie up
hospitals. The HR Manger is responsible for maintaining all the records of the employees
starting from the first day till the last day at the company. Details regarding their personal
information, their attendance, issuing salary, monitoring their performance, ensuring whether
healthy and safety working environment is provided for employees.

FEEDBACK/OUTCOMES/:

PROBLEMS IDENTIFIED:
2.PRODUCTION DEPARTMENT:

A production department is a group of functions within a business that is responsible

for the manufacture of goods. This can include just a few specialized functions with all other
work outsourced, or a fully functioning department that converts raw materials, assembles
components into finished goods, and packages them.

The production department can be the largest organization within a business. It may employee
mechanics, machine setup specialists, maintenance personnel, and machine operators.

A key focus of the production department is efficiency. To that end, the bottleneck operation
within the facility is closely monitored and supported so that throughput (revenue minus
variable costs) is maximized. While it is generally profitable to reduce costs where possible in
this department, that is not the case with the bottleneck operation, which should be fully
supported at all times.

DUTIES OF PRODUCTION DEPARTMENT:

The production department is responsible for converting raw materials and other inputs
into finished goods or services. In between the processes of production, the department works
to improve the efficiency of the production or assembly line so that it can meet the output
targets set by company management and ensure finished products offer consumers the best
value and quality.

Identifying inputs

A business determines the quantity or volume of goods that should be produced within
a certain time frame and passes the information to the production department. To meet
production targets, the department establishes the quantity of raw materials and types of
machinery and equipment required to achieve the desired output level, and may collaborate with
the purchasing department to source the inputs. If there isn't sufficient manpower to support
productions process, the production department asks the firm to hire more personnel.

Scheduling Production

With the inputs ready, the production department schedules production processes. This
involves planning the tasks to be completed along the production line and allocating the tasks
to various production workers. In a woodworking business, for example, the department
determines how long lumber will be allowed to dry before being moved to the machining stage
for sawing and bending into shape – and finally through the assembly and finishing stages.
Minimizing Production Costs

The production department is tasked with finding effective ways to lower production costs. One
simple way to do this is to keep the production machinery and equipment well-maintained so the
firm does not regularly incur repair costs. Along with advising the business to adopt newer
technologies, the department can also assess the production line to identify opportunities for cost
reduction. For example, if the type of wood used a long time to air-dry – requiring an investment in
wood dryers – it could be less costly for a furniture manufacturer to purchase dried lumber.

Ensuring Product Quality

A production department must ensure finished goods meet minimum quality standards. Apart
from checking all products for faults as they move through the production process, the
department must perform rigorous tests on prototypes for new products to ensure they meet
quality benchmarks before undergoing mass production. Techniques such as waste elimination
and process standardization also help to ensure and improve product quality.

Improve Existing Products

From time to time, the production department will furnish the research and development
department with information it can use to improve existing products. For example, when the
production department of a smart phone manufacturer notices that the material it uses to make
phone casings bends when subjected to some pressure, the department must advise the research
team so that it can seek stronger materials.

Types of production:

There are 4 different types of productions which are most commonly used. Which type of
production should be used by the company depends on the type of product being manufactured,
the demand of the product as well as the supply of raw materials. Taking these factors into
consideration, below are the 4 types of Production.

Unit or job type production:

This type of production is most commonly observed when to produce one single
unit of a product ,where items are made individually and each item is finished before the next
one is started.

Batch type production:

Batch production is a method used to produce similar items in groups, stage by stage. In batch
production, the product goes through each stage of the process together before moving on to the
next stage. The degree to which workers are involved in this type of production depends on the
type of product.
Mass production:

Mass production is the manufacturing of large quantities of standardized products, often

using assembly lines or automation technology. Mass production facilitates the efficient
production of a large number of similar products. Mass production is also referred to as flow
production, repetitive flow production, series production, or serial production.

Continuous production or process production:

Continuous production is a type of production system in which materials being processed are
continuous in motion.

OPERATION OF PRODUCTION DEPARTMENT OF IREL:

Department structure:

Deputy G.M

Senior manager

Deputy Manager

Shift engineers Shift Head(Process

control)

Officers
Attainder

Workers
 Production process :
Raw sand from mining areas

(10-20% Heavies)

Wet gravity separation

(90-95% heavies)
Electrostatic separation

Conducting Non-conducting

Magnetic separation High intensity Magnetic separation

Magnetic Non magnetic

Magnetic Non-magnetic

Low intensity magnetic Conducting Dry gravity separation

Ilmenite Rutile separation
(Tails)

Magnetic Non-magnetic Conducting Wet gravity

separation
Garnet Monazite

(Mids)

Floatation

(Float)

Sillimanite
Zircon
MINING PROCESS:

The mining and processing of beach sand are achieved with a good mixture of modern
mechanical devices and manual labor. Beach sand is collected from the surface of a deph of
ammeter with the help of dredgers. For a processing of beach sands, the difference in electrical
conductivity, magnetic susceptibility and specific gravity of their constituents are taken into
considerations. The beach sand is treated by well gravity methods using spirals, cones and jigs to
produce minerals.

MINERAL RECOVERY PLANT (MRP)

It consists of a floating dredging plant which could be moved from one area to another.
This is called floating mineral recovery plant .This plant is placed in an area which has a water
depth of 9 meters. The sand along With water is sucked into the main unit. First the mixture is
send to a storage tank called trammel. Then it is sending for separation. The waste sand of some
quantity of water is pumped out .The MRP dredges about 40-60 tones per shift,

HEAVY UPGRADING PLANT (HUP)

The raw sand collected from different sources had different composition. They are
further upgraded using the HUP. In the heavy upgrading plant enriches the concentration from
various sources to above heavy minerals using spiral separators making use of gravity
techniques.

MINERAL SEPARATION PLANT (MS)

The concentrate from the HUP is dried and separated into individual minerals using the
differences in the physical properties of the minerals, such as electrical conductivity, magnetic
susceptibility, specific gravity, grain size, etc. High tension separators, electrostatic separators,
cross-belt magnetic separators, spirals. wet tables, air tables, flotation cells, etc. are the major
separation equipments of the plants.

ROLE OF PRODUCTION MANAGER IN MANUFACTURING UNIT

 Forecasting the requirements of the production in order to achieve the production target.
 Making most efficient utilization of the available source of production.
 Minimizing "throughout time" & "work in progress inventory". This is achieved by
systematic production planning & also by very efficient execution of plans.
One of the most important responsibility of a production manager deals with reducing material
handling cost, which generally is achieved by the use of efficient material handling system &
also by using plant layouts which is developed in a proper or current way.

Reducing the quality cost with the help of analysis of non-conformances on periodic basis& also
by following suitable actions(both corrective & preventive)

FUNCTION OF PRODUCTION DEPARTMENT

Production is the functional area responsible for turning inputs into finished outputs
through a series of production process. Production manager is responsible for making sure that
raw materials are provided & made into finished goods effectively.

PRODUCTION PLAN

The production department prepares monthly production plan, which is based on the report of
marketing department. Based on this report the production target, the production plan will be
prepared at the end of the month, the production department analysis the production details for
the month.

The company being as ISO certified should maintain daily shift reports and monthly production
report.

ISO CERTIFICATIONS:

 ISO 9000-2008 since 1998 (quality)

 ISO 14001-2004 since 2004 (environment)
 OHSAS 18001-2007 since 2005 (occupational health and safety performance)

PLANT LAYOUT

The efficiency of production depends on how well the various machine production
facilities and employees amenities are located in a plant. Only the properly laid out plant can
ensure the smooth and rapid movement of material, from the raw material stage to the end
product stage. Plant layout encompasses new layout as well as improvement in existing layout. It
may be defined as a technique of locating machine, process and plant services within the factory
so as to achieve the right quantity and quality of output at the lowest possible cost of
manufacturing. It involves a judicious arrangement of production facilities. So that work flow is
direct as far as small business is concerned, it requires a smaller area or space and can be located
in any kind of building as long as the space is available and convenient. Plant layout for small
scale business is closely linked with the factory buildings and built up area.

Observation:

Outcomes/findings/feedbacks:

Problems identified:
3.QUALITY CONTROL DEPARTMENT:

Quality control (QC) is a process by which entities review the quality of all factors involved in
production. ISO 9000 defines quality control as "A part of quality management focused on
fulfilling quality requirements".

The Quality Control Department is responsible of monitoring and ensuring that each stage
of production is followed by all the necessary procedures for safe use of machinery and
that each product coming out of the production process, complies with
all standards and specifications that have been defined so to ensure a smooth and trouble
free operation.
The Quality Control Department is also responsible for the proper maintenance of all
production machinery and installation vehicles.
At the end of every project a special certification – guarantee for the proper installation and
proper functioning of products is provided by the Quality Control Department to the
customer.
Functions of Quality Control Department
Purpose :
To provide an instruction for functions of quality control department.
Objective :
To provide a documented procedure for functions of quality control department.
Scope:
This procedure is applicable for functions of quality control department
--- Pharmaceuticals Ltd,
Responsibility :
 Primary: QC Chemist / QC-Officer.
 Secondary : Overall: QC – In charge
Procedure:
List of activities of quality control department.
 Testing and release or rejection of all incoming raw materials, packing materials, in-
process / intermediates and finished products as per specified specifications.
 Maintaining testing records as per standard procedures for raw materials, packing
materials, in-process / intermediates and finished products.
 Calibration of laboratory instrument / equipment.
 Performing stability study.
 Control sample storage.
 Analytical method validation.
 Preparation of standard volumetric solutions and maintain standardization record.
 Maintain Labeling procedure at all the stages and records.
  Maintain working / reference standard record of products.
 Analysis of complaint samples as and when required.
 To conduct technical audit / self-inspection.
 Follow safety norms at all the stage during handling of chemicals and using instruments.
 Follow good laboratory practices.

OPERATIONS OF QUALITY CONTROL DEPARTMENT IN IREL:

IREL has got ISO 9001: Quality Systems established for mining, manufacturing and mineral
products.

One of the primary functions of the quality control department is to ensure quality products
according to customer requirements.

Secondly, they are responsible for maintaining consistent quality of products to the satisfaction
of the customers through quality management systems implementation. They also aim at further
improvement of products technology &process. They aim on the quality of raw materials during
the processing, intermediate &finished product stages.

They make use of chemicals and mineralogical testing methods in each stage. In addition to these
functions this department activities support flow shed development work and for solution to
process related problems.

DEPARTMENT STRUCTURE:

FUNCTIONS:

 To ensure that raw materials in process and finished products confirms to specified
requirements holding compliances with environment ,health and sasfety requirements.
 Ensuring compliance to health ,safety and environmental requirements

INSPECTION AND TESTING PROCESS DETAILS

Raw Sand:

1. The DWUP and HUP output and tailing are tested for total heavy mineral
content as detailed in quality plan.
2. The raw sand feed to the QIL plant ie the dried HUP output is analysed as per
quality plan
3. The raw sand being naturally occurring the specifications are only desirable
values. The variations in quality of raw sand do not affect the quality of final
products. So no reduction of raw sand is resorted to even if the analysis results
are not as for the quality plan.
 4. These tests are carried out only to make proper adjustments of the process
parameters to set the final product of specified quality

In-Process Inspection

In-process inspection of certain intermediate fraction as detailed in the quality plan is

carried out as per quality plan. These process fractions are not rejected even if the analysis
results do not confirm the desirable specifications. The inspection is only for subsequent
adjustments in the process parameters.

Finished Products:

1. The products under tests are identified by a yellow board indicating the date, shift
and number of bags. Those products passed the tests are identified by a green
board indicating date, shift and number of bags and rejected are identified as red
board indicating “FOR REWORK"
2. Inspection and testing of finished products are carried out and record in the
respective record as per quality plan. Only products confirming to the quality as
detailed in the respective quality plan are taken in to stock. Rejected products are
maintained with authorization oh HOD (QC).Inspection and test record clearly
indicate whether the product is accepted or rejected.

OBSERVATION:

In the quality control lab the pre and post quality control checks were performed. The raw sand
taken from the beach and inland areas before feeding into the feeder they a pre quality check will
be done to know how much percentage of heavy minerals they get . Samples were collected and
the chemist undergoes a chemical process to separate the heavy minerals from the sand and the
rate of illuminate, silimanite, zircon, monazite garnet will be taken. In the same way after the
production the sand sample will be taken again and post quality check will be done. Again the
same chemical process is repeated and the rate of heavy minerals obtained will be noted .Then
both the pre and post quality rate will be analyzed and make sure that both the rate of heavy
minerals were same or not, if there is any difference between both the quality checks then the r
and d department will undergo a research to find the reason for the difference pre and post
quality checks.

3.2RESERCH AND DEVELPOEMENT DEPARTMENT:

INTRODUCTION:

Research and development (R&D) include activities that companies undertake to innovate and
introduce new products and services. It is often the first stage in the development process.
Research and development is the generation of new knowledge. In a business context, it is an
activity that companies undertake in order to develop new products, processes or services, or
improve those that already exist. In order to do this, businesses often take on risk. This is because
uncertainties exist around if what they are attempting is technologically feasible, or, more
commonly, they don’t know how they will achieve their objectives in practical terms.

Some businesses will have a small team responsible for R&D or just pick up R&D activities
across various teams and individuals on a more ad hoc basis. Other companies have a dedicated
R&D department. Larger companies may even establish R&D centers – these can give them
access to local R&D leaders and specialized R&D functions

An R&D department can contain a whole range of professionals, from R&D engineers and
chemists to R&D managers responsible for the outputs. Sometimes you will have R&D leaders
that look to drive the R&D department in a business.

FUNCTION DESCRIPTIONS OF THE RESEARCH & DEVELOPMENT DEPARTMENT:

 New Product Research

Before a new product is developed, a research and development department conducts a

thorough study to support the project. The research phase includes determining product
specifications, production costs and a production time line. The research also is likely to
include an evaluation of the need for the product before the design begins to ensure it is a
functional product that customers want to use.

 New Product Development

The research paves the way for the development phase. This is the time when the new product
is actually developed based on the requirements and ideas created during the research phase.
The developed product must meet the product guidelines and any regulatory specifications.

 Existing Product Updates

Existing products of the company also fall under the scope of research and development. The
department regularly evaluates the products offered by the company to ensure they are still
functional. Potential changes or upgrades are considered. In some cases, the research and
development department is asked to resolve a problem with an existing product that
malfunctions or to find a new solution if the manufacturing process must change.

 Quality Control Checks

In many companies, the research and development team handles the quality checks on products
created by the company. The department has an intimate knowledge of the requirements and
specifications of a particular project. This allows team members to ensure the products meet
those standards so the company puts out quality products. If the company also has a quality
assurance team, it may collaborate with research and development on quality checks.

 Innovation and Staying Ahead of Treads

The research and development team aids the company in staying competitive with others in the
industry. The department is able to research and analyze the products other businesses are
creating, as well as the new trends within the industry. This research aids the department in
developing and updating the products created by the company. The team helps direct the future
of the company based on the information it provides and products it creates.

Types of Research and Development

R and D can involve basic research or applied research.

Basic research aims to a comprehensive understanding of a subject, and to build a body of
knowledge relating to it. As such it may not have an immediate practical or commercial
application, but it still can be of interest to a business or organisation.
It is the sort of research that might then initiate further concepts and lead to applied research.
Applied research is much more specific with a set of objectives related to a particular customer
or industry need or requirement. Under applied research, any investigations will focus on
commercial objectives to do with processes or products.

The Importance of Innovation:

The main role of the R and D department is to help a company or organisation to maintain its
competitiveness. This means keeping an eye on developing trends, and on what the competition
is doing.
R&D is therefore also about analysis and a sound understanding of current conditions within a
specific sector or market.
The Research & Development department can help direct the future of a business because it
provides essential information and ideas that support strategic decision-making.
By investing in R&D, a company is investing in technology and future capabilities, transforming
these into new processes, products and services.
The influx of knowledge that R&D brings can be hugely valuable in developing product lines or
enhancing processes. At a basic level, R&D is a tool, but it has the potential to be an enormously
effective one.
OPERATIONS OF R&D DEPARTMENT IN IREL:
The company has a well equipped Research and Development facilities to support flow sheet
development works and for solutions to process related problems. The laboratory is equipped
with lab models of Magnetic separator, High Tension separators, Wet shaking tables and Froth
Floatation Equipment etc.
DEPARTMENT STRUCTURE:

Unit Head

Quality control

HOD

R & D In charge

Petrologists

Assistances

FUNCTIONS:
 New product Development.
 New compound development.
 Selection& evaluation of alternative method
 Testing new products
 R and D attempts.
 To analysis& assist plants in problem solving
 Ensure quality of raw materials& finished products
 Maintain quality

The department has well mentioned quality objectives& well-practiced quality

awareness and quality improvement program. The department uses mineralogical testing
methods for maintaining consistency in quality of raw material, finished products and
work in progress.
OBSERVATION:

In the research and development department there is a research lab containing dummy mineral
separator equipment with small capacity .The main aim of the R and D department is to
analyze the rate of wastage of heavy minerals during separation process. The quality control
lab will undergo a pre and post quality check and they predict the rate of heavy minerals that
they get from the raw sand .The R and D analyze the observed rate with the expected rate and
find the rate of rate of wastage and undergo the research to reduce the wastage of minerals
during the production process.

FEEDBACK:

PROBLEMS IDENTIFIED:
4. PURCHASE AND STORES DEPARTMENT:

Purchasing departments are at the centre of successful supply chain management.

Typically, they help other departments identify their needs, manage the requisition process and
on source competitive prices, and generally act as controllers to ensure adherence to budgets.

OPERATIONS OF PURCHASE DEPARTMENT IN IREL:

The main function of the purchase department is the procurement of the minerals at
competitive price and purchasing other materials related to work order .The purchase department
has prime importance. Nowadays the purchase in IREL is done by online. The plgchasc is dorr
only when the approval is released by the authority approved by the purchase general manger
based on the request from other department,

Purchase indent (PR) is prepared by the department what are the items to be Purchased is done
when the company receives at least 3 tender from supplier.

DEPARTMENT STRUCTURE:

UNIT HEAD

HOD (Purchase)

Chief Manager

Assistant Manager

Staff

FORMALITIES OF PURCHASE

 Float enquires to the right source

 Scrutinize quotation
 Obtaining approval of the financial department
 Release an order
 Follow up receipts at store
 Assistance to give payment in time
PROCESS:

(FLOW CHART)

FORMALITIES OF PLACING AN ORDER

 Origination of intent
 Tender enquires
 Opening of tender on the date mentioned
 Analysis of the tall tender
 Section of the best
 Approval of the selected tender
 Order placing
 Follow up

APPROVAL FOR PURCHASING THE PRODUCT

PURCHASE ORDER:
STORES DEPARTMENT:

The stores act as a store and supply chains, keeping inventory of the product
produced on the hand and supplying required raw materials to the manifold department on the
other hand.
All the in the IREL is properly stored by this function area, including finished product inventory.
It stores furnace oil, machine parts, office equipments and stationary etc.

DEPARTMENT STRUCTURE:

UNIT HEAD

HOD (Stores)

Deputy General
Manager

Chief Manager

Staff
Stores fall under 2 categories

1. Capital items
2. Consumable items

Capital items which give return for long term revenue items or a consumable item means
that which are consumable only for a short period. Procurement of items of capital nature is to be
made only after the approval by the competent authority duty verified by internal auditors with
prior conclusion the capital budget.
Stores action is responsible arranging procurement of all items or purchase requisition
shall from the basis for arranging procurement or other departments, complete in all respects and
duty approved by the controlled authority. The worth of production in the plant is currently
between 6-7 crore. Once in every 3 months inventory statistics is prepared and send to the head
office in Mumbai. Stores follow bin card &ledger system. This department has 3 major functions
as follows
RECEIPT
The consignment items are properly verified with receipts are requested the
particular department to make inspection on each items.
STORAGE
The received items are stored in proper locations and preserve them until the issue
Each item has its own Bin Card. The quantity received, material issued, total remaining are noted
in the Bin Cards
ISSUE
The issue made in first in first out method. After the receipt of the material internal
note from the department the issues are made and same is recorded in the Bin Card.

INVENTORY CONTROLE:

Under the stores department the inventory control function is done .If excess stock is
obtained, it is properly informed to the marketing department to promote sales and if any
shortage obtained it is also properly informed to the production department to increase the
production. Usually ABC inventory control method is adopted in IREL for control of
inventories. The principle types of inventories are:

 Raw Material & Supply

 Goods in progress that is work in progress
 Finished goods

For reduction of inventories four steps are taken in the stores and Dispatch department. They are
doing computerization, codification, standardization and value addition .All the process in stores
departments are computerized and inventory management software is used for this purpose.
Coding is given to all inventories .For this alphanumerical code is used .Material coding is used
to realize what kind of inventories are stored and location coding helps to find out where it is
stored. By the use of standardization, physical verification of inventories are to be done and to
check whether the invoice number and purchase order are equal.

DISPATCH SECTION

Dispatch section controls the transportation of the finished products to the outside company.
When a customer make a complete settlement of money for purchasing of a particular product
from the company the marketing department place a delivery order to the dispatch department.
The dispatch department then prepares a invoice and give a copy to the customer. The
department also prepares gate pass and state government declaration sheet.
5.MARKETING & SALES DEPARTMENT:-

INTRODUCTON:

Marketing is a social process by which individuals and groups obtain what they need and wants
through creating, offering and freely exchanging products and services of value with others. It is
an art of selling products Marketing department is functioning under the control of General
Manager of marketing department. Marketing occupies an important position in the organisation
of any business unit.

Marketing functions are not limited to the function of buying and selling but storage,
risk bearing and after sales services et marketing is a vital connection link between the producer
and customer.

OPERATION OF MARKETING AND SALES DEPARTMENT OF IREL:

The marketing section in the IREL is under the direct control of chief General Manager
and this section is headed by the deputy General Manager in his job. The marketing activities in
the company are indirectly linked with the sales section.

IRE has the monopoly in the field of rare earth products. IRE Ltd.. engaged in the
production of minerals such as lluminate,Rutile, Zircon, Silimanite, Garnet and Monozite from
naturally available beach and products. On specific requirements of customers the company also
supplies Sallimente powder by subcontracting Among these Illuminate. Rutile. Zircon. Browa
laminate are categorized as "Scheduled Minerals for which the customer is required to obtain
license from the Department Atomic Energy (DAE) Mumbai for their purchase Off late, more
stress was given as the marketing activities of IRE by the company, because of competition,
which is growing in the international market and also in Indian market. A rewen has been put up
in the company for this purpose.

The bye products of IRE we Zuflour and Moazite. They are mainly purchase by the
Kundara cenamics for the manufacturing of ceramis. The main customers of RE are the
Government of India and other private company.

The chief General Manager of IRE is having the control of topmost level in marketing
department of this unit. There are four superintendents and a clerk engaged in the sales
department. IRE Ltd is working under the administrative control of Department of Atomic
Energy. The head office does the pricing of products. The customers of IRE Lid are mainly
heavy industries like plant, glass, refineries, ceramics ete for bulk purchases customer and
provided discount
DEPARTMENT STRUCTURE:

UNIT HEAD

HOD (Marketing)

Assistant manager
(Marketing)

Officer

Staff

MARKETING FUNCTIONS:

 Developing marketing strategies.

 Capturing marketing insight.
 Connecting the customers.
 Building strong image between customers.
 Delivering values of customers.

OBJECTIVES OF MARKETING DEPARTMENT

 Maximum turner.
 Maximum profit.
 Maximum customer satisfaction.
 Maximum customer relationship.

RESPONSIBILITIES OF MARKETING MANAGER:

 Researching & reporting on external oppurtunities

 Understanding current & potential customers.
 Developing marketing strategies.
 Managing budget.
 Ensuring timely delivery.
 Developing guidelines.
Sales & dispatching

Enquiry from
Order processing Acceptances Payment
customer

Cust
omer complaints while receiving the minerals
1. Product complaints
2. Quality complaints
3. Package complaints
4. Quantity complaints

After receiving those complaints these are taken into quality control department for checking the
products. Here, the Quality control department plays a major role.

SALES AND DISTRIBUTION SYSTEM

Here the organisation has been enjoying monopoly. That's the reason why they don't want to
make a distribution network. Direct selling is the main system of organisation. The customer
primarily pays the full amount as demand draft (DD) in advance and then the company gives the
products

For domestic sales, order are received as

1. Through head office.

2. Directly from the customers.

3. Transferred from the units of IREL.

All are dispatched against permits obtained after payment of prescribed royalty by
IRE in advance to the department of mining and geology, government of Kerala. Starting with
general condition for sales, majority of the customers place orders directly. Sometimes head
office also fixes quota customers wise if necessary, for the supply of minerals and intimates time
 to time. If all the formalities are completed delivery instructions are given by the sales
department to stores for delivery of the materials to the customers.

6.MAINTAINENCE DEPARTMENT:

The maintenance department is responsible and accountable for maintenance .It is

responsible for the way of equipment runs and looks and for the costs to achieve the required
level of performance.

STRUCTURE:

Unit head

Deputy General
Manager

Mechanical civil Plant maintainemce

Workshop

Maintenance is the combination of all technical and associated administration actions intended to
retain or restore it to ,a state which it can perform its requirement and function. This company is
seeking to gain competitive advantages, with respect to cost, quality and on time deliveries. The
effect of maintenance on these variables have increased attention to the maintenance area as
integral part of productivity in the maintenance is rapidly involving into a major contributor to
the performance and profitability of manufacturing systems.

PROCEDURES FOLLOWED IN MAINTENANCE DEPARTMENT

PREVENTIVE MAINTENANCE

The prevention of equipment breakdown before the happen. This includes inspections,
adjustments, regular service and planned shut downs.

REPAIR WORK

Repairing equipment and troubleshooting malfunctions in an effort o return the equipment

to its previous conditions. These repairs maybe reactive or preventive.

IMPROVEMENT WORK

Searching for better materials and improved design changes to facilities equipment reliability.
Repair work soften a part of improvement work.

SCHEDULE MAINTAINED

Preventive maintenance schedule has been prepared ad implemented. Suitable checklist

prepared for the maintenance. It is carried out on the bases of intimation received from the
production department. Expeditions taken for breakdown maintenance, So that should not affect
production.

Maintenance department of IREL are responsible of goods condition of the plant and equipment
in good condition.

7. MINING DEPAETMENT AND SAFETY AND TRAINING:

DEPARTMENT STRUCTURE:

UNIT HEAD

HOD

Deputy General
Manager

Deputy Manager

Workmen

In IREL the raw materials for production process are collected through mining process. The
production process starts with the collection of beach sand from various places. For collecting
this beach sand IREL uses the following two methods :

 Sea Washing.
 Dredging.
Mining villages:

 Chinnavilai
 Periyavillai
 Kottilpadu
 Kurumpanai
 Puthur

Methods:

Raw sand is collected from the sights where deposits are occurred due to natural beach
washing. Presently, IREL owns 7 main sites at Kanyakumari and other areas. It has high
deposits of heavy minerals over a length of heavy minerals over a length of 2km they are found
over or coaster belt having an average width of 800meters. The waves deposit the minerals sand
on the beach line and it is collected. Then it is send to the HUP (Heavy up gradation plant) to
increases the purity of heavy minerals.

It is done by supervision of manger. The beach sand is collected by manual labors in mining
region which comes under MK plant. In land mining is done by open cost mining.

Beach sand is collected from the surface of a depth of a meter with the help of dredgers for a
processing of beach sand, the difference in electric conductivity. Magnetic susceptibility and
specific gravity of their constituents are taken into consideration. The beach sand is treated by
well gravity methods using spiral, cones jigs to produce minerals.

HEALTH PHYSICS UNIT

A health physics unit of bhabha atomic research centre is established in 2003 to monitor the
health & safety of the worker men & the environment. Persons working in the plant are provided
with TLD( Thermo Luminescent Dosimeter). Badges in order to monitor & control the radiation
dose received by them.

SAFETY & TRAINING DEPARTMENT

Organized efforts & procedures for identifying workplace hazards& reducing accidents &
exposure to harmful situations & substances. It also includes training of personnel in accident
prevention, accident response, emergency preparedness and use of protective clothing &
equipment.

IREL is committed to provide a safe& healthy environment for the protection

& well-being of the employees & the general public by means of safe & healthy system of work.
Safety is given paramount considered right from the conceptual stage of all the projects,
modifications & day to day operations. The company is one of the belief the accidents are
preventable and the creation of the safe& healthy working conditions is an important as
production. The purpose of personal protection equipment is to reduce employee exposure to
hazards when engineering & administrative controls & not feasible to effective to reduce these
risks to accept levels.

The department comes under this is

 VT centre
 Fire production
 Project & development
 Resources
 Hindi cell
 MIS

VT CENTRE

In the VT centre the main activity carried out is providing training. The training is given to the
employee by senior manager resource. Trainings are

 Providing safety training for refreshment

 Fire safety training
 External faculty training
 Yoga training
 Training to all the people in nearby areas
 Training to apprentice
 Explanation of do's & don't in the company

FIRE PROTECTION

This division has the full control of safety of the system. It has automatic alarm system during
emergency. Each department has individual safety system to protect themselves from accidents

PROJECT& DEVELOPMENT

The project & development is functioning by three project senior manager o They prepare
drawings which are based on the requirements of other department They involved in tender
preparation This division looks after the erection, correction, commission & rectifying the fault
in the plant They prepare plan for new project of company.
FINANCE DEPARTMENT:

Finance is the life blood of business. The business functions of a finance department
typically include planning, organizing, auditing, accounting and controlling its company’s
finances. The finance department also usually produces the company’s financial statement.

Finance Department is the part of an organization that is responsible for acquiring funds for the
firm, managing funds within the organization and planning for the expenditure of funds on
various assets.

Business finance is concerned with the acquisition and utilization of funds

required to meet the firscial needs of a business enterprise. Financing is the
process of planning, acquiring, utilizing and controlling the funds used in any
kind of business Finance is the life Head of business. Every calerprise or
company requires finance to start the work and grow .

A company generally requires large amount of capital A public company can

mise huge capital through issue of shares. In addition to share capital it can
utilize retained profit in the form of reserves. It can raise borrowed capital
through denture and loans. Long term loans can be obtained from financial
institutions. Short term loans are available from commercial heaks

DEPARTMENT STRUCTURE:

UNIT HEAD

HOD
 Chief General
Manager (Finance)

Deputy General Manager

Senior Finance
Manager

Deputy Finance Manager

Assistants

SOURCES OF A COMPANY(MK UNIT)

 On the basis of time.

 On the basis of purpose or use.
 On the basis of source of finance.
 On the basis of risk.

Finance refers to money, cash or hand available for the operation of business. Finance may do
defined as the requirement of funds wanted. It is the life blood of business activity. The business
pulsates with life only through finance. Finance refers to money, cash or hand available for the
operation of business. Financial management will include planning, organizing, directing and
controlling.

The main functions of this department are:-

 To collect all the receipts and make all the payments.

 To record all the transactions and prepare the final accounts.

 Maintain the accounts as per the provisions of the section 20(g) of the Companies Act
1956.
  Provide depreciation at the rate prescribed in schedule 14 of the Companies Act 1956, on
a straight line method.

 To account excise duty on goods manufactured when it is dispatched.

 To ascertain the accrued gratuity liability of the company on the date of balance sheet.

 To value finished goods at cost or market price whichever is lower, stock of raw
materials, spares and chemicals are valued at weighted average method.

 Treat the claims against the company which are not admitted as contingent liability.

CHIEF GENERAL MANAGER

The finance department is headed by the Chief General Manager (Finance). A Deputy General
Manager (Finance) is there to assist the Chief General Manager in the operations of the
department. In addition to them the department consists of 3 senior finance officers, 8 deputy
officers and attenders.

AUTHORITY, RESPONSIBILITIES AND ROLES:AUTHORITY

 Approval of policy, objective and targets.

 Approval of apex manual.

 Defining responsibilities and authority of head of departments, management

representatives.

 Authorizing various committees

 Approval training programs of financial commitment.

 Authorization of decision taken at review meeting such as safety and environmental

protection committee, environment management customer service and complaint
redeemed and protection meetings.

RESPONSIBILITIES

 Overall responsibility for health and safety of IRE,Manavalakurichu unit.

 Claiming the review meetings.

 Responsibility of the head office from time to time.

 Ensuring that unit has organized celebration including those related to health, safety and
environment through concerned department.
  Providing resources for the implementation maintenance and continued improvement of
management systems (in consultation with HO required).

 Implementation of directives received from HO / statutory agencies.

 Ensuring smooth progress of project (including feedback of HO on the program).

ROLES

 Ensuring smooth day to day functioning organization through concerned HOD / section
head.

 Role as head of the unit in the health, safety and environment related celebration.

 Participation in emergency evaluation (Both mock / actual)

 Compliance to safety related requirements including use of personal protection

equipment as a role model for others.