Documente Academic
Documente Profesional
Documente Cultură
A REPORT
ON
SUBMITTED BY:
1
Table of contents:
Sl No Particulars
1 Executive Summary
2 Preface
3 Certificate of Authenticity
4 Acknowledgement
5 Objective
6 Introduction of the Company
6.1 Bhushan power & steel at Orissa…..
6.2 Mission, Values & Their Commitments
6.3 History of the Company
6.4 Management (Board of Director)
7 From the MD’s desk
8 Job done in M/S Bhushan Power & steel Ltd
8.1 Store Department
8.1.1 Basic documents required in Store Department
8.1.2 Process of Material Outward from the store
8.1.3 Process of unloading of a TRUCK
8.1.4 Auditing of books in stores
8.2 Purchase Department
8.2.1 Types of Purchase
8.2.2 Process of Purchase (for Maintenance)
8.2.3 Process of Purchase (for Consumables)
8.2.4 List of few Suppliers
8.2.5 List of few Materials for SMS-1
8.2.6 List of few Materials for SMS-2
8.3 Bill Passing Department
8.3.1 Format of a Supplier’s Bill
8.3.2 Format of Inward Security Pass
8.3.3 Format of Materials Receipt Note
8.3.4 Format of Raw Materials Analysis Report
8.3.5 Format of Debit / Credit Note
8.4 Audit Department
8.4.1 Basic concept of Auditing
8.4.2 Internal Auditing
8.4.2.1 History of internal auditing
2
8.4.2.2 Independence in Internal Audit
8.4.2.3 Internal Audit and Internal Control
8.4.2.4.1 Internal Audit in corporate governance
8.4.2.4.2 Key Financial Associates
8.4.2.5 Nature of the internal audit activity
8.4.2.6 Reporting of critical findings
8.4.3 Audit in M/S Bhushan Power & Steel Ltd
8.4.3.1 Audit for Logistic Department
8.4.4 Audit report submitted to the Management
8.4.4.1 Final Audit Report for Iron Ore
8.4.4.2 Final Audit Report for Coal
8.4.5 Audit for Purchase Department
9. Financial Analysis of M/S Bhushan Power & Steel Ltd.
9.1 Significant Accounting Policies
9.2 P/L Account for the year ended 31st March 2008
9.3 Balance sheet as at 31st March 2008
9.4 Details of Schedules maintained by the company
9.5 Key Financial Indicators
9.5.1 Gross Sales
9.5.2 Export Sales
9.5.3 Net Profit
9.5.4 Cash Profit after Tax
9.5.5 Net worth
9.5.6 Debt Equity Ratio
9.5.7 Current Ratio
9.5.8 Interest Coverage Ratio
9.5.9 Debt Service Coverage Ratio
9.5.10 Earning per Share (EPS)
10 Steel Manufacturing
10.1 History of Steel Production
10.2 Raw Materials for Steel Production
10.3 Classification of Steel
10.4 Heat Treatment of Steel
10.5 Process of Steel Production
10.6 World production of Steel
11 Conclusions
12 Bibliographies
3
1. Executive Summary
This project is intended to help those people who want to study the Standard
operating procedure of material procurement, movement, accounting, Auditing and
their financial implication of M/S Bhushan power & steel ltd. In this project I have
tried to give some recommendation best of my knowledge so I have tried to cover
almost all aspect of M/S Bhushan Power & steel Ltd. In this project I am using
BPSL as the abbreviation of M/S Bhushan Power & steel Ltd.
4
2. Preface
In present scenario Steel and Power is an important aspect for the development of
nation. So M/S Bhushan Power & steel Ltd is doing a great job by producing and
supplying these two resources. Secondly in this context comparative study of M/S
Bhushan Power & Steel Industry is a great opportunity for me to do as summer
training.
Summer project is one of the essential parts towards the partial fulfillment of the
requirement of two year full time PGDM programme. In this line I had an
opportunity to undergo practical training of two months in M/S Bhushan Power &
steel Ltd which is a steel manufacturing and Power generating Industry
This project was undertaken to study vital aspect of financial books of the
company with physical verification and verification of the books. This project is
divided in two parts. First I will discuss how I have studied the system of the
organization and secondly I will discuss how I have investigated and verified the
books of accounts which in other words known as Auditing.
I visited different sites of the Plant like Iron, Steel and Power sections. I visited all
the departments of the organization and also sat at the gate in order to see the
system and audited the books of accounts in order to get the practical knowledge.
5
3.
Certificate of Authenticity
This is certify that the project work was done on “Standard operating procedure
in partial fulfillment the requirement for the award of Post Graduate diploma in
Steel Ltd’ at Jharsuguda in Orissa. I declare that the form and the content of
the above mentioned project are original and have not been submitted in part or
full, for any other degree or diploma of this or any other Organization/ Institute/
University.
6
4. ACKNOWLEDGEMENT
Our prestigious organization Accman Institute of Management gave me a great
opportunity to learn and experience the corporate world. The summer training
programme was great experience for me. This project is the result of time, efforts
and knowledge contributed by various members of the Organization .I pursued my
summer training from M/S Bhushan Power & steel Ltd, a steel manufacturing and
power generating Industry and I would like to extend my sincere gratitude to
Mr. V. R. Sharma (Joint Managing Director) to give me a valuable opportunity
to work with such a renowned organization. I would like to extend my sincere
thanks to Mr. B.M Sharma (VP Commercial) and Mr. Anil Kumar Singh
(GM-Audit & Costing) for assigning me a project on ‘Standard operating
procedure of material procurement, movement, accounting, Auditing and
their financial implication’ of M/S Bhushan Power & Steel Ltd. They have been
a source of guide and motivation for the completion of project.
7
Who were always available for my support and important guidance. They
were source of Motivation and guidance for me.
8
5. Objective
Presently Steel and Power are two important pillars for the development of a
nation. So M/S Bhushan Power & steel Ltd is doing a great job by producing and
supplying these two resources. This study has been developed for those of you who
are keen to acquire some basic but key information about steel industry as an initial
step towards becoming a more informed individual. I hope this module will act as a
means of satisfying some of your initial queries on this industry.
9
6. Introduction of the Company
Bhushan Power & Steel Limited, a fully integrated 1.5 Million TPA
Steel making Company with turnover of INR3873 Crores (USD 950
Million) and 7 World Class ISO 9000 Certified State of the Art Plants
at Chandigarh, Derabassi, Kolkata and Orissa in India.
10
6.1 M/S Bhushan Power & Steel Ltd at Orissa…
It combines our deep expertise with the best technology that the world
offers to integrate the entire steel manufacturing process – from
mining to the production of value-added products. It also generates
captive power using gases from the process.
Features
• Proposed facilities in close proximity of two bulk inputs i.e. iron ore
and coal to minimize input freight
• Already been allotted two adjoining non-coking coal blocks at
nearby Jamkhani and Bijhan in Orissa, and has got one coking coal
block at Rohne in Jharkhand, providing added logistic advantage in
mining. Allotment of iron ore mines is under process.
• Captive and inexpensive power generation using hot gases from
sponge iron kilns and unusable coal
• Operating synergy enhanced by captive coal washery that processes
locally available coal to ensure uninterrupted supplies and lower costs
• Use of Iron Ore fines in making sinter, for use in blast furnace.
• With hot metal infusion into EAF, exothermic reaction gives quicker
steel production and enhances capacity without additional capex.
• Captive coke oven plant to reduce import costs
• The power consumption for EAF Steel melting reduces from around
800 units/pmt to about 400 units, providing cost efficiency.
• Large reduction in consumption of expensive consumables like
electrodes and refractories.
• With added capacities for both long and flat products, Bhushan
Power & Steel will emerge as a completely integrated, wider range
player with a long term competitive edge.
11
6.2 Mission, Values & Their Commitments:
In pursuing their mission, we at M/S Bhushan Power & steel Ltd. are
guided by the following values :
Their Commitments:
12
• To improve the quality of their products and complete integration
of various stages of production.
• To be conscious towards quality and pricing of their products. We
strive by continuous research and development to make their
products world class, having distinct identity and uniqueness. Their
customers get best value for their money.
• To run the company profitably year after year.
• A workforce motivated, skilled and well looked after.
• A workplace safe, secure and hygienic.
• To make their Environment Clean, Healthy and Hospitable.
13
6.3 History of the Company
Growing from strength to strength
1970 - Started with very small initial outlay for manufacturing Door Hinges & later
on, Rail Track Fasteners.
1973 - Manufacturing facilities set up for Tor Steel and Wire Rod in Chandigarh.
1981 - Rolling Mill Project commissioned at Chandigarh for Round and Narrow
Strips.
1986 - Upgrading of Mini Steel Plant with continuous casting and ladle furnace
facilities. 1997 - Commissioning of Narrow Width Cold Rolling Project at
Chandigarh.
14
2001 - Commissioning of Cold Rolling & Galvanizing Complex at Kolkata.
2003 - Expansion of wide width Cold Rolling facilities, ERW Water Pipes &
Tubes down stream facilities at Kolkata.
15
6.4 Management
BOARD OF DIRECTORS
16
7. From the MD’s desk
Dear Shareholders,
Once again it’s time for all of us to take a look at the previous year and yet look beyond!
I would like to take this opportunity to greet all our esteemed shareholders and place on
record my gratitude for their continued support and
valued guidance. I am also pleased to present Your
Company’s achievements in the last one year.
The year 2007-08 has been one of winning challenges,
setting standards and all-round growth. In Your
Company’s performance, I perceive a new world
focused on transforming India’s steel landscape
through operational excellence, skill enhancement and
competitive value additions. One of your Company’s
achievements in the recent months stems from our
aspirations to seize the opportunities and move closer
to the growing market.
Regards
Sanjay Singal
Chairman & Managing Director
18
8. Job done in M/S Bhushan Power & steel Ltd
In the company my job has been divided in two parts Firstly I was asked to check
the entire system of different department physically:
• Store
• Purchas
• Bill passing
• Marketing
• Personnel
• Accounts
19
8.1 Store Department:
There are two type of storage system in the company first one is Central Store and
second one is Site. It can be shown as under:
Material
Storing
s
Central Site
Store
Job Project
Site Site
Now in the central store they generally store those materials which are not going to
be used immediately in other words they are going to be used in future. The Site
storing mainly consists of two parts Job site storing and Project site storing. Now
the Job site storing means storing of materials in the site where actually the
manufacturing is going on. Project site is the site where manufacturing is not going
on but the construction of a manufacturing plant or other thing is going on. In order
to complete the construction some materials are required and those materials are
stored in the project site.
20
8.1.1 Basic documents required in Store Department:
In order to get some practical knowledge about the document that is maintained in
the store I sat at the gate along with the employee just to see how everything is
working then I observed that there are basically two types of documents are being
maintained at the gate. Material Inward and Material Outward, further Material
Inward is been divided into three parts namely INWARD STORE (Iron ore),
INWARD STORE (Coal), INWARD STORE (Miscellaneous). For more clarity of
the concept one can see the picture as under:
Bhushan Power & Steel as the name suggest is the power generating and steel
manufacturing plant and the two basic raw materials required is Coal and Iron Ore.
These two materials are required in huge quantity. Almost thousands of trucks,
carrying these two materials, come everyday so that is the reason they maintained a
separate document INWARD STORE (coal) INWARD STORE (Iron Ore) for
these two materials. And rests of the materials are recorded in INWARD STORE
21
(Misc). In case of materials or anything else which is going out of the plant
gate has to be recorded in MATERIALS OUTWARD. The pictures of all these
documents are given as under:
22
Format of INWARD STORE (Iron Ore):
23
After seeing the format of different INWARD STOREs documents now its
time to discuss about the MATERIALS OUTWARD. It is the document which is
also maintained at the store and it is mainly prepared at the gate of the plant. Any
vehicles carrying any materials are going outside the plant gate have to show the
relevant documents so that the officer at the gate can fill up the Materials Outward
book. Now take an example of empty LPG Cylinders which had been used at the
guest house going outside for refilling must have to be recorded in Materials
Outward book. So we can see that whether the item is related to business or not,
which was inside the plant premises (whole township), going outside should be
properly recorded in the books. All the outgoing materials are divided into two
parts:
a. Returnable
b. Non returnable (chargeable)
Returnable items are those items which after going out will return back. For
example empty LPG Cylinders, empty Oxygen Cylinders. And Non returnable
items are those items which are going out but will not return back. Example Steel
& Iron (end product), any rejected materials. Let’s see the format of materials
outward.
24
Process Of Material outward
From the store
8.1.2
Empty Truck
Loading
Dispatch with….
Recheck/Reweight
Truck allowed to go 25
The above given diagram is showing the process of Material Outward from
the store. That means how does the material go out from the store? The above
given diagram is self explanatory. An empty truck comes into the store get the
materials loaded and then the store keeper prepare four documents which are as
under:
• Challan
• Way bill
• Transport bill
• OGP (Outward Gate Pass)
After preparing all this documents the concerned authority give
these documents to the driver of the truck. The truck driver carries those
documents to the exit gate where some entries have been made. Out of these four
documents the OGP has been kept at the gate for their record and later on this OGP
is sent to store department for their record. Now after completing the process of
documentation the materials in the vehicles are recheck or reweight and if it is
found ok then the vehicles are allowed to exit.
26
8.1.3 Process of unloading of a TRUCK:
BHUSHAN POWER & STEEL, SAMBALPUR
GATE
EXIT ENTRY
T
R
PARKING U
C
SPACE K
TRUCKS
WEIGH WEIGH
BRIDGE BRIDGE
4 1
T
R
T U
R C
U K
C
K
WEIGH WEIGH
BRIDGE BRIDGE
3 2
T T
R R
U U
C C
K K
CHECK
POINT
T R U C K
UNLOADING
POINT (SMS1) T R U C K
27
The above given picture is showing the process of unloading of trucks at the
job site or the project site. Although the above given picture is looking a bit
complicated but it is very easy to understand. Now in order to see the process
practically I personally sat in a truck and saw the entire process. The process that I
observed is a truck after submitting the required documents at the gate gets the
entry and then the entire truck along with the material has to stand in the Weigh
Bridge 1 in order to get the measurement (Truck + Materials). Here the
measurement of materials is considered along with the truck weight. After that the
measurement is taken second time in Weigh Bridge 2. The difference in weight up
to ±50 kgs is acceptable. Now the truck unloads the materials at the concerned site
and then it comes back. Now the empty truck is measured again twice (Weigh
Bridge 3 & the Weigh Bridge 4). After that the weight of empty truck is deducted
from the weight of truck along with materials and then they get the final weight of
the materials. After the measurement of empty truck it has to wait in the parking
space for further documentation. And if the document is ok then the truck is
allowed to exit from the gate.
28
8.1.4 Auditing of books in stores
I went to the stores department where I got the opportunity to audit the books of
accounts of the store. I verified one month’s books that are books of April 2009.
Mainly I verified two types of documents- one is INWARD STORE
MISCELLENEOUS and another one is OUTWARD GATE PASS (OGP). At the
time of verifying the INWARD RECEIPT I have to verify it with the MATERIAL
RECEIPT NOTE (MRN). If both INWARD RECEIPT and MRN get matched then
we can say that the books are all right, if the two are not getting matched then we
have to understand that there is a problem. Not only did I verify the books but also
I made a physical verification of the stock in the store. While auditing the books I
came up with certain problems like-
On 1/4/09 there was an entry in the INWARD STORE (MISC) books but the
same entry was not there in MRN. When I asked them about that entry I was
told that it was a mistake done by them and later they searched it in the
computer which was there in the database and made a printout of that copy
and put that into the MRN.
On 14/4/09 the vehicle number which was written in the INWARD STORE
RECEIPT was not matching with the one written in MRN. That was also a
clerical mistake done by them and later I went to the record room where the
concerned person searched the data and made the correction in the MRN
books which was written wrongly. The record rooms are that room where all
the documents when made finally are kept preserved there.
On 18/4/09 there were two items which were there in the INWARD STORE
RECEIPT but were missing from the MRN. That entry was checked in the
computer where I was showed that the two items which were missing from
the MRN books had been entered correctly in the computer but that was a
clerical mistake and so those were missing from the MRN books. The
concerned person came up with a print out copy of that entry and put it in
the MRN.
29
On 25/4/09 there was a problem like this
Here by looking at these figures we can say that in the INWARD STORE
BOOKS the F/Wt and E/wt is not matching with the figures written in MRN.
But finally we can say that N/Wt is coming same. F/wt is the full weight of
the loaded truck which comes with the materials. E/wt is the weight of the
empty truck which is excluding the materials. N/wt is the net weight of the
materials which is coming inside the plant. Finally we found that it was a
clerical mistake.
On 25/4/09 I found that the challan quantity which was there in the
INWARD STORE books was not matching with the MRN. Finally I found
that it was not a mistake. Actually what happened was that the quantity of
materials ordered to the supplier was less than it actually came. Suppose the
quantity of materials ordered was 36000 kg. But the supplier by mistake sent
36120 kg. This excess 120 kg was not recorded in the books and the
payment would be made according to the materials ordered. The payment
for the excess quantity would not be made to the supplier.
30
8.2 Purchase Department:
After completing the work in store department I moved to Purchase department. It
is also one of the busiest departments of the company. Even in this department I
wanted to understand the entire process physically and then do it practically and
then check its financial implication. According to my observation I found that the
entire work of this department has been divided into three parts i.e. Purchase of
materials relating to MAINTAINANCE, CONSUMABLE AND LUBRICNT. It
can be shown with the help of diagram which is as under.
Purchase Process
31
The purchase of Raw Materials and other materials are taken place either
from the head office (Delhi, Kolkata) or from the plant itself. The core materials
for steel and power generation is being ordered from the Head Office. The core
materials are as under Iron ore Coal, Dolomite, Quartzite, Limestone and Coal
Bridge. But the other materials which are Project Materials, Consumables,
Lubricant, Maintenance, Fabrication, Civil Maintenance and others.
In plant the different job of purchase have been divided into different officers Mr.
Rnjan Soni is taking care of ‘Maintenance Items’, Mr. J. Behera is taking care of
‘Consumable Items’ and Mr. Verma is accountable for the purchase of material
related to ‘Lubricant Items’. Staying in this department and understanding the
process is good experience for me. They all helped me a lot in understanding the
process, which I will discuss in later topics, and gave me the format of all the
required documents. They assign me some jobs in this department so that I can
understand it practically.
32
8.2.2 Process of Purchase (for Maintenance)
Requisition
Indent
generation
K Store
E
Indent from P
Indenter T Purchase
(3copies) by
Indenter
Enquiry to Suppliers
Comparative Statement
of Quotations
After making all these verifications, the purchase department put an enquiry to the
suppliers. They put the enquiry either through mail or through phone. After the
enquiries are made, the suppliers send a list of quotations of materials to the
purchase department either through mail or through post. Then getting the
quotations from different suppliers a comparative statement is been made where all
the quotation price of the materials send by the suppliers are put and which quality
of materials they will supply are also been put. After that the price and the quality
is compared and later on a decision is been taken whom to give the purchase order
that is which supplier will get the purchase order. This whole process is the
purchasing process of materials done by the purchase department.
(A format of an original purchase order is given in annexure – 1)
34
8.2.3 Process of Purchase (for Consumables)
Enquiry To Suppliers
Comparative Statement of
Quotations
While doing the audit of the purchase department I came across the under given
lists of few Suppliers and Raw Materials (SMS- I & II).
[A complete list of suppliers along with their address and contact number of
concerned person is given in Annexure – 2]
36
8.2.4.1 List of few Suppliers
37
8.2.4.2 Key Financial Associates:
38
8.2.5 List of few Materials for SMS-1
Boric Acid
Ferro aluminum
Ferro Manganese
Sodium silicate
Met Coke
Slide Plate
Laddle Nozzle
Collector Nozzle
Porous Plug
Mag. Carbon Bricks
Asbestos sheet
Asbestos Rope
Lancing Pipe
L.P.G. Cylinder
Argon Cylinder
Oxygen Cylinder
Gear Oil
Hydraulic Oil
Rapseed oil
Copper Mould Tube
Tundish Board
Sen Well Block
Mono Block Stopper
Casting Powder
Mortar
Cal. Pet coke
Gr. Electrodes
Castable- 90A1
Castable-90AH
Castable-95H
39
8.2.6 List of few Materials for SMS-2
40
8.3 Bill Passing Department:
Bill passing is also one of the important departments of M/S Bhushan Power &
Steel Ltd. It is basically a checking department and busy with the job of checking
the different documents. The main job of this department is to tally the different
figure of MRN (Materials Receipt Note), Bill of Supplier and Inward Security Pass
with the figure of Purchase order. When everything found to be correct then after
an entry has to be made into the computer and the bunch of documents is send to
the Accounts Departments for making vouchers. A bunch of documents can
contain the under mention documents.
Supplier’s Bill
Inward Security Pass
Weight Bill
MRN
Purchase Order (Photocopy)
Comparative Statement of Quotation (Photocopy)
(See an original copy in Annexure - 5)
Indent (Photocopy)
Transporter’s Bill
Raw Material Analysis Report
Debit Note / Credit Note
Shortage/Rejection Memo
41
8.3.1 Format of a Supplier’s Bill
42
8.3.2 Format of Inward Security Pass
43
8.3.3 Format of Materials Receipt Note
Wt SL No A: Wt SL No B : Wt SL No C : Wt SL No D :
WB Wt A : WB Wt B : WB Wt C : WB Wt D :
Inspection Note
Prepared by Inspected by Inspection Charge HOD
(Receipt section) (Stores)
44
8.3.4 Format of Raw Materials Analysis Report:
Entry No Dated
Material Truck No
Quantity Location
Suppliers name
(Store In-charge)
Remarks
45
8.3.5 Format of Debit / Credit Note:
46
8.4 Audit Department:
Before starting our basic discussion regarding this department at M/S Bhushan
Power & Steel Ltd. we should try to understand some basic concept of auditing.
Financial Audit
Statutory Audit
Tax Audit
Excise Audit
External Audit
Internal Audit
Cost Audit
Purchase Audit
Logistic Audit
Store Audit & ETC
Here I am going to concentrate mainly on the Internal audit because I was the
proud member of the Internal Auditing Team. Apart from this I will also discuss
some of the above given types of audit. Let us begin with them
47
Financial Audit:
Statutory Auditing:
Every company registered in India has to get his accounts audited from a chartered
accountant every year.
Tax Auditing:
Every assessee, whose turnover of a business exceeds Rs.40 Lakhs or total receipts
from any profession exceeds Rs.10 Lakhs in any previous year, is required to get
his accounts audited and report as per section 44AB of the income tax act.
The scope of internal auditing within an organization is broad and may involve
topics such as the efficacy of operations, the reliability of financial reporting,
deterring and investigating fraud, safeguarding assets, and compliance with laws
and regulations.
48
responsibilities. As a result of their broad scope of involvement, internal
auditors may have a variety of higher educational and professional backgrounds.
49
8.4.2.3 Internal Audit and Internal Control:
Internal auditing activity is primarily directed at improving internal control.
Internal control is broadly defined as a process, effected by an entity's board of
directors, management, and other personnel, designed to provide reasonable
assurance regarding the achievement of objectives in the following internal control
categories:
50
8.4.2.5 Nature of the internal audit activity:
Based on a risk assessment of the organization, internal auditors, management and
oversight Boards determine where to focus internal auditing efforts. Internal
auditing activity is generally conducted as one or more discrete projects. A typical
internal audit project involves the following steps:
i. Establish and communicate the scope and objectives for the audit to
appropriate management.
ii. Develop an understanding of the business area under review. This includes
objectives, measurements, and key transaction types. This involves review
of documents and interviews. Flowcharts and narratives may be created if
necessary.
iii. Describe the key risks facing the business activities within the scope of the
audit.
iv. Identify control procedures used to ensure each key risk and transaction type
is properly controlled and monitored.
v. Develop and execute a risk-based sampling and testing approach to
determine whether the most important controls are operating as intended.
vi. Report problems identified and negotiate action plans with management to
address the problems.
vii. Follow-up on reported findings at appropriate intervals. Internal audit
departments maintain a follow-up database for this purpose.
Project length varies based on the complexity of the activity being audited and
48Internal Audit resources available. Many of the above steps are iterative and
may not all occur in the sequence indicated.
51
8.4.3 Audit in M/S Bhushan Power & Steel Ltd.
This is the newly established department in the company. Since the entire company
is in a project mode so it is optional for the company to audit the books or system.
But thanks to the management for setting up an exclusively independent internal
audit system. Here audit department mainly consists of Cost audit, Logistic audit,
Excise audit, Store audit, Purchase Audit and ETC. Before establishing this
department auditor from the Head Office (which is in Chandigarh) or corporate
office (which is in Delhi) comes to the plant and audit randomly. But establishing
this internal audit department in the plant is itself a good move which will help in
keeping a good control over the entire system. In my two month SIP Programme at
M/S Bhushan Power & Steel Ltd I spent almost 20 days in this department.
Basically I manage to audit for two departments which was Logistic department
and purchase department. Now I will discuss separately what exactly I did and
what exactly I found in these two departments one by one. Apart from this I will
also discuss what audit report did I submit to the management.
Logistic department is mainly deals in receiving of the raw materials that they have
ordered for. Volume of work is very high here. In a power and steel plant a huge
quantity of coal and iron ore is required so almost thousands of trucks carrying
Coal and Iron Ore come to the factory every day. This department is a 24x7
department that means this department works for 24 hours a day, 7 days a week
and 365 days in a year it is because the steel plant can not stop for a single minute,
if it does so then it will cost crores of rupees to restart it. In this department I was
given total 7 items for audit they are as under:
i. Coal
ii. Iron Ore
iii. Dolomite
iv. Manganese
v. Quartz
vi. Lime Stone
vii. Coal Bridge
In this department I was mainly checking the MRN (Material Receipt Note)
quantity with weight slip, delivery challan and transporter’s freight slip. Since the
52
volume of work was very high so I along with my another colleague of the
institute checked almost 15000 (Fifteen thousands) MRNs. After completing the
audit of coal and iron ore we submitted the under given report to the management.
53
54
55
8.4.4.2 Final Audit Report for Coal:
56
8.4.5 Audit for Purchase Department:
I also got the opportunity to audit the books of the purchase department. In other
words I can say that I have done a purchase audit. When I started auditing I got a
file which contains various documents related to purchase of materials. There was
a copy of the purchase order, indenters copy, Enquiries copy, Quotations copy sent
by the suppliers, and lastly a comparative statement. In order to check these
documents my work was to first check the indenters copy where the specific
description of the materials were stated which the indenter require. After that
enquiries copy were to be checked in order to see whether correct enquiries have
been sent to the suppliers by the purchase officer about the material. Next I have to
read the quotation of that supplier very minutely who got the order to supply the
material. The terms and conditions mentioned in the quotation of that supplier
should match with that in the purchase order. If by any chance there is a mismatch
of conditions mentioned in quotations with that in the purchase order then there is
a mistake. I also have to check the comparative statement very carefully. In the
Comparative statement different prices of the suppliers have been quoted. I have to
check whether the supplier who quoted the least landed price for the material got
the order or not. There were some cases where the least landed price quoted
supplier did not get the order. In that case when I asked the purchase officer about
that case then he told me that sometimes they also have to look into the quality of
materials and not price. So some of the suppliers are there who charges a higher
price in comparison with other suppliers but the quality of materials which the
supply is better.
57
9.Financial Analysis of M/S Bhushan Power
& Steel Ltd.
In this section I am going to make a financial analysis of M/S Bhushan Power &
Steel Ltd. Here I am going to discuss their Accounting Policies, Balance Sheet,
Profit & Loss Account, 15 Schedules and different Financial Indicators.
Fixed Assets are stated at cost, net of VAT/ MODVAT/ CENVAT, less
accumulated depreciation. All costs including borrowing costs till
commencement of commercial production and adjustment arising from
exchange rate variations relating to borrowings attributable to the fixed
assets are capitalized. Capital expenditure on assets by company is
reflected in capital work in progress account till the period of completion
and thereafter in the fixed assets. Machinery spares that can be used only
in connection with an item of fixed asset and their use is expected to be
irregular are capitalized. Replacement of such spares is charged to
revenue.
58
III. INTANGIBLE ASSETS
VI. DEPRECIATION
VIII. INVESTMENTS
60
IX. DIVIDEND INCOME
X. SALES
Sales are inclusive of trial run sales, excise duty and net of sales tax/ vat.
Provision for current income tax is made after taking credit for
allowances and exemptions. In case of matters under appeal, due to
disallowance or otherwise, provision is made when the said liabilities are
accepted by the company.
In accordance with the Accounting Standard 22-Accounting for Taxes
on income issued by Institute of Chartered Accountants of India, the
deferred tax for timing differences between the book & tax profit for the
period is accounted for using the tax rates and the tax laws that have
been enacted or substantively enacted as of the balance sheet date.
Deferred tax assets arising from temporary timing difference are
recognized to the extent there is virtual certainty that the asset will be
realized in future. Provision for fringe benefit tax is made on fringe
benefits taxable under the Income Tax Act, 1961.
61
XIII. BORROWING COST
XV. CLAIMS
62
iii. Company’s contribution to state plans namely Employees
State Insurance Fund is charged to revenue every year.
iv. The Company has defined benefits plans namely Leave
encashment / Compensated absence and Gratuity, the liability for
which is determined on the basis of Actuarial valuation at the end
of the year. Gratuity Trust is administered through “Life Insurance
Corporation of India”.
v. Termination benefits are recognized as an expense immediately.
vi. Gain or Loss arising out of actuarial valuation are recognized
immediately in the profit and loss account as income or expense.
63
9.2 Profit or Loss Account
for the year ended 31st March 2008
SCHEDULE 2008 2007
INCOME
Sale of Products 12 3,87,349.07 3,01,786.23
Less Excise Duty 39691.06 30015.56
Net Sales 3,47,658.01 2,71,770.67
Other Income 5039.29 1121.47
3,52,697.30 2,72,892.14
EXPENDITURE
Manufacturing & Other
13 2,79,944.82 2,26,475.53
Expenses
Profit Before Interest,
72752.48 46416.61
Depreciation and Tax
Interest & Financial Charges 14 17303.69 10605.85
Profit Before Depreciation &
55448.79 35810.76
Tax
Depreciation 16712.74 10438.47
Profit Before Tax 38736.05 25372.29
Less: Income Tax Expense ;
- Current Tax 4400.00 2850.00
- Mat Adjustment 4400.00 2350.00
0.00 500.00
- Deferred Tax 6077.16 4500.00
6077.16 5000.00
- Fringe Benefit Tax 110.00 77.00
6187.16 5077.00
- Earlier years -2.65 183.93
- Wealth Tax 10.50 6195.01 8.21 5,269.14
Profit After Tax 32541.04 20103.15
Balance Brought Forward from
29562.97 27098.96
Previous Year
Impact of Transitional Provision
32.71
of Employee
Benefits as per AS -15 —
64
Profit Available for 62136.72 47202.11
Appropriation
APPROPRIATIONS
General Reserve 20000.00 10000.00
Transferred to Debenture
— 7567.00
Redemption Reserve
Proposed Dividend 68.03 61.66
Dividend Tax 11.56 10.48
Balance Carried to Balance
42057.13 29562.97
Sheet
62136.72 47202.11
Basic earning per share 23.92 16.30
Diluted earning per share 23.73 16.30
Nominal value of Equity Shares
10.00 10.00
in (Rs.)
Significant Accounting
15
Policies
Notes forming part of
16
Accounts
65
9.3 Balance sheet
as at 31st March 2008
66
9.4 Details of Schedules maintained by the company:
(Rs in Lacs)
2008 2007
SCHEDULE-1
SHARE CAPITAL
Authorized
20,00,00,000, Equity Shares of Rs.10/- each 20000.00 20000.00
20000.00 20000.00
Issued
13,60,51,665 Equity Shares of Rs.10/- each 13605.17 13605.17
13605.17 13605.17
Subscribed & Paid Up
13,60,51,665, Equity Shares of Rs.10/- each fully
13605.17 13605.17
paid up.
13605.17 13605.17
Above includes 3,51,52,240 Equity Shares of Rs.
10/- each fully paid up issued pursuant to the
scheme of Amalgamation of Bhushan Industries
Ltd., Bhushan Metallics Ltd. and Decor Steel Ltd
with the company.
SCHEDULE-2
RESERVES AND SURPLUS (Rs in Lacs)
Capital Reserve 1.00 1.00
Capital Redemption Reserve 13.50 13.50
Debenture Redemption Reserve
As Per Last Balance Sheet 8167.00 3100.00
Add : Transferred from Profit and Loss Account -- 7567.00
8167.00 -- 10667.00
Less : Transferred To General Reserve 8167.00 2500.00 8167.00
Securities Premium Account
As Per Last Balance Sheet 43285.96 7682.39
Add : Received during the year -- 43285.96 35603.57 43285.96
67
General Reserve
As Per Last Balance Sheet 32500.00 20000.00
Add : Transferred from Profit & Loss Account 20000.00 10000.00
Add : Transferred from Debenture Redemption
8167.00 60667.00 2500.00 32500.00
Reserve
Profit & Loss Account 42057.13 29562.97
1,46,024.59 1,13,530.43
SCHEDULE-3
LOAN FUNDS (Rs in Lacs)
SECURED LOANS
Debentures
-NIL (Previous Year 100), 9% Redeemable Non
-- 667.00
Convertible
Debentures of Rs.10,00,000/-each
-NIL (Previous Year 1500), G-Sec Redeemable -- 15000.00
Non-Convertible Debentures of Rs.10,00,000/-
each
Working Capital Loans from *
- Banks
- Rupee Loan 67168.46 49984.80
- Foreign Currency Loan 5795.65 --
Term Loans From **
- Banks
- Rupee Loan 3,65,628.61 2,25,794.54
- Foreign currency Loan 57151.11 50242.15
- Financial Institutions
- Rupee Loan 2425.00 5240.00
Deferred Credits from ***
- Banks 2345.71 1038.37
Loans From Banks Against F.D.R -- 1085.80
5,00,514.54 3,49,052.66
68
SCHEDULE-4
FIXED ASSETS (Rs in Lacs)
GROSS BLOCK DEPRECIATION NET BLOCK
Sale / Writt
DESCRIPTI Cost Adjus Cost As Adjustm en Total
Addition As At For As At As At
ON OF As At ts At ent back upto
s during 01.04. the 31.03.20 31.03.20
FIXED 01.04.0 durin 31.03.20 during durin 31.03.20
the Year 07 year 08 07
ASSETS 7 g the 08 the year g the 08
Year year
Freehold
3493.99 2593.78 — 6087.77 — — — — — 6087.77 3493.99
Land
Leasehold
3540.18 4.18 — 3544.36 — — — — — 3544.36 3540.18
Land
30783.2 669.8 36638.1 4048.1 2173.3 31062.3 26735.1
Building 6524.74 642.28 3.38 5575.82
9 7 6 7 1 4 2
Railway
2136.62 544.04 — 2680.66 78.66 119.9 — — 198.56 2482.10 2057.96
Siding
Plant & 1,46,74 1,70,855 794.7 3,16,809 40649. 14582. 335.3 54700.4 2,62,109 1,06,099
196.40
Machinery 8.44 .96 2 .68 41 84 8 7 .21 .03
Furniture &
1071.67 288.49 72.45 1287.71 135.07 125.41 44.90 6.43 209.15 1078.56 936.60
Fixture
Vehicles 1935.61 664.28 93.67 2506.22 638.02 206.35 30.42 10.60 803.35 1702.87 1297.59
Intangible Assets
Technical
127.64 — — 127.64 29.18 25.53 — — 54.71 72.93 98.46
Knowhow
Assets Not
Owned by
1966.98 — — 1966.98 799.12 393.4 — — 1192.52 774.46 1167.86
the
Company
1,91,804. 1,81,475 1630. 3,71,649 46377. 17626. 355.7 62734.5 3,08,914 1,45,426
Total 914.00
42 .47 71 .18 63 74 9 8 .60 .79
Previous 1,50,518. 42189.9 903.7 1,91,804 36029. 11177. 46377.6
739.12 90.48
Year 18 7 3 .42 64 59 3
3,26,381 3,07,733
Capital Work in progress
.70 .86
6,35,296 4,53,160
Total
.30 .65
69
I. Capital work in progress includes expenditure incurred during
construction period, capital stores, advances amounting to Rs.
18,681.18 Lacs ( Previous year Rs. 13,962.36 lacs) paid against
capital expenditure (unsecured, considered good)
II. Addition & capital work in progress include loss of Rs. 2,731.90
Lacs (Previous year loss of Rs. 2,104.77 Lacs ) adjustment on
account of exchange difference.
III. No write off has been done for lease hold land since acquired on
lease of 90 years & above.
IV. Sales / Adjustment and Depreciation for the year include Rs.
914.00 Lacs (Previous year Rs. 714.57 Lacs) charged to capital
work in progress Rs. Nil (Previous year Rs. 24.55 Lacs) charged to
trial run expenses and Rs. 16,712.74 Lacs (Previous year
Rs.10,438.47 Lacs) charged to profit & loss account.
V. Sale/ Adjustment includes land Rs. Nil (Previous year Rs. 6.00
lacs) being the amount of land of rehabilitation colony transferred
to various persons.
VI. The intangible assets have been amortized on pro-rata basis over a
period of five years.
70
2008 2007
SCHEDULE-5
INVESTMENT
Long Term, Trade, Unquoted, At Cost
ATMA RAM HOUSE INVESTMENT (P) LTD.
1,020 (Previous Year NIL) Equity Shares of Rs.100/-each Fully Paid Up 10723.11 --
Current, Non-Trade, Quoted
INDUSIND BANK
10 (Previous Year NIL) Unsecured, Non Convertible Bond of Rs. 10 Lacs each,
100.00 --
Fully Paid Up
10823.11 --
(Market Value of quoted Investment Rs. 100 Lacs)
2008 2007
SCHEDULE-6
INVENTORIES
(As taken, valued and certified by the Management)
Raw Material 53153.65 31672.93
Finished Goods 29255.78 12597.42
Work-in-Progress 4291.03 449.54
Scrap 657.58 145.2
Stores & Spares 3106.14 2556.31
Material-in-Transit 4453.53 1448.25
94917.71 48869.65
71
2008 2007
SCHEDULE-7
SUNDRY DEBTORS
(Unsecured)
- Outstanding for a period exceeding six months
- Considered good 2200.24 1691.39
- Considered doubtful 357.54 223.23
2557.78 1914.62
Less : Provision made for doubtful debts 357.54 223.23
2200.24 1691.39
Others - Considered good 74632.55 52594.13
76832.79 54285.52
2008 2007
SCHEDULE-8
CASH AND BANK BALANCES
Cash in Hand (including cheques-in-hand Rs. 50.00 lacs Previous Year Rs.
151.85 60.41
NIL)
Balances with Scheduled Banks :
- In Current Accounts 4758.14 707.01
- In Fixed Deposit Accounts (Including Interest Accrued) 6180.80 1880.73
Under Lien amounting to Rs. 960.23 lacs (Previous Year Rs. 1461.63 lacs)
11090.80 2648.15
72
2008 2007
SCHEDULE-9
LOANS AND ADVANCES
(Unsecured, Considered Good)
Advances recoverable in cash or in kind or
for value to be received* 17442.19 8921.95
Inter Corporate Deposits 3775.55 15462.34
Balance with Excise Authorities 11.25 35.75
Balance of Modvat / Cenvat / Service Tax/ Vat 16411.14 16901.11
Mat Recoverable 6750.00 2350.00
Advance Tax (Net) 4.62 --
44394.75 43671.15
2008 2007
SCHEDULE-10
CURRENT LIABILITIES
Sundry Creditors 62677.19 43884.00
Creditors For Capital Goods/Expenditures 9757.71 21192.77
Interest accrued but not due on loans 826.74 415.18
Due to Directors 1.24 0.94
73262.88 65492.89
2008 2007
SCHEDULE-11
PROVISIONS
Proposed Dividend 68.03 61.66
Dividend Tax 11.56 10.48
Retirement Benefits 737.60 577.68
Provision For Tax (Net) -- 31.16
817.19 680.98
73
SCHEDULE-12
SALE OF PRODUCTS & OTHER INCOME
2008 2007
Sales including Excise Duty 3,87,349.07 3,01,734.62
Commission * -- 51.61
3,87,349.07 3,01,786.23
Other Income
Interest (other than investments) ** 689.74 1061.02
Misc. Income 122.57 57.10
Exchange Fluctuation 775.75 --
Profit on Treasury Operations 3432.98 --
Profit on Sale of Investment 14.83 --
Dividend (on Short term, Current and Non Trade Investment ) 3.42 --
Profit on sale of Fixed Assets (Net) -- 3.35
5039.29 1121.47
* Tax Deducted at Source Rs.NIL (Previous Year Rs. 8.69 Lacs)
** Tax Deducted at source Rs.96.26 Lacs (Previous Year Rs.219.58
Lacs)and Interest includes Rs.314.22 Lacs (Previous Year Rs.417.96
Lacs) on Inter CorporateDeposits, Rs.185.06 Lacs (Previous Year
Rs.542.13 Lacs) on Fixed Deposits with banks,Rs. 5.23 Lacs
(Previous Year Rs. NIL) on bonds of Bank.
74
2008 2007
SCHEDULE-13
MANUFACTURING & OTHER EXPENSES
Raw Material Consumed 2,32,913.78 1,83,433.47
Purchase of Goods traded 18515.92 13267.39
Stores Consumed 8342.27 4208.86
Power & Fuel 17366.04 14310.00
Salary, Wages & Bonus 8073.79 5903.23
Contribution to PF & Other Funds 220.60 129.54
Staff Benefits 436.33 251.54
Excise Duty Provided on Stock (Net) 2904.81 -145.41
Rates and Taxes 243.56 182.67
Legal & Professional Charges 298.17 176.01
Insurance 50.92 67.24
Auditors’ Remuneration 34.96 31.95
Travelling & Conveyance 825.85 625.82
Advertisement & Sales Promotion 73.21 51.19
Postage, Telegrams & Telephone 303.04 297.32
Utility & Facility 407.66 433.94
Rebate and Discount 1578.55 1205.50
Selling and Distribution Expenses 9882.42 9239.40
Selling Commission 178.85 277.38
Repair and Maintenance
- Building 16.64 30.04
- Machinery 2569.60 2226.11
- Vehicle 458.10 373.63
Lease Rent 20.11 18.61
Other Administrative Expenses 296.83 259.72
Provision for doubtful debts 134.30 97.97
Loss on Sale of Assets (Net) 27.23 --
Loss of Assets By Fire 9.55 --
Loss on forward / options / swaps -- 936.56
Exchange Fluctuation -- 104.05
Bad Debts -- 33.38
3,06,183.09 2,38,027.11
75
(INCREASE) /DECREASE IN INVENTORIES
Opening Stock
Finished Goods 12597.42 9124.44
Work-In-Progress 449.54 2328.09
Scrap 145.2 137.6
13192.16 11590.13
Closing Stock
Finished Goods 29255.78 12597.42
Work-In-Progress 4291.03 449.54
Scrap 657.58 145.20
34204.39 13192.16
Net (Increase)/Decrease in Inventory -21012.23 -1602.03
2,85,170.86 2,36,425.08
Less :
-Transferred to Projects Commissioned /Under Commissioning /Trial
4692.59 9146.31
Run
- Cost of Material Transferred to Project 533.45 803.24
2,79,944.82 2,26,475.53
2008 2007
SCHEDULE-14
INTEREST & FINANCIAL CHARGES
Interest
- On Debentures 335.93 1057.59
- On Term Loans 42413.37 23388.23
- On Others 7251.22 4471.22
Commission & Bank Charges 2277.53 1483.22
Exchange Fluctuation 2752.16 1536.01
55030.21 31936.27
Less :
-Transferred to Projects Commissioned /Under Commissioning /Trial
37726.52 21330.42
Run
17303.69 10605.85
76
9.5 Key Financial Indicators:
77
9.5.1 Gross Sales:
3018
2419
2030
1503
2004
2005
2006
2007
2008
Gross sale is a sale before deducting the excise duty but including the export sale.
As the above diagram is showing that the gross sale has increased from Rs 1503
crore in 2004 to Rs 3873 crore in 2008. From 2004 to 2005, 2005 to 2006, 2006 to
2007 and 2007 to 2008 it increased by 35.06%, 19.16%, 24.76%, and 28.33%
respectively. In average we can say that there is a 26.83% growth in the gross sale
in last four years.
78
9.5.2 Export Sales:
500
325
400
300
200
100
0
2004 2005 2006 2007 2008
As the above diagram is showing that the export sale has increased from Rs 325
crore in 2004 to Rs 756 crore in 2008. From 2004 to 2005, 2005 to 2006, 2006 to
2007 and 2007 to 2008 it increased by 67%, 6.81%, 12.93%, and 15.41%
respectively. In average we can say that there is a 25.54% growth in the export sale
in last four years.
79
9.5.3 Net Profit:
As above we have seen that the gross sales and the export sales is increasing year
after year so the net profit is also increasing. As the above diagram is showing that
the Net Profit has increased from Rs 71 crore in 2004 to Rs 325 crore in 2008.
From 2004 to 2005, 2005 to 2006, 2006 to 2007 and 2007 to 2008 it increased by
35.21%, 77.08%, 18.24%, and 61.69% respectively. In average we can say that
there is a 48% growth in the export sale in last four years.
80
9.5.4 Cash Profit after Tax:
500
350
400
256
300
176
130
200
100
0
2004 2005 2006 2007 2008
As the above diagram is showing that the export sale has increased from Rs 36
crore in 2004 to Rs 350 crore in 2008. From 2004 to 2005, 2005 to 2006, 2006 to
2007 and 2007 to 2008 it increased by 261%, 35%, 45.45%, and 36% respectively.
In average we can say that there is a 94% growth in the Cash Profit in last four
years.
81
9.5.5 Net worth:
(Rs in crore)
Net worth includes Shareholders’ equity capital plus reserves and surplus. As the
above diagram is showing that the Net worth has increased from Rs 371 crore in
2004 to Rs 2142 crore in 2008. From 2004 to 2005, 2005 to 2006, 2006 to 2007
and 2007 to 2008 it increased to 48%, 42%, 80%, and 52.34% respectively. In
average we can say that there is an 55.50% growth in the Net worth in last four
years.
82
9.5.6 Debt Equity Ratio:
The desirable/ ideal proportion of the two components (high or low ratio) varies
from industry to industry.
As the above diagram is showing that the Debt Equity has increased from .99 in
2004 to 2.21 in 2008. From 2004 to 2005, 2005 to 2006, 2007 to 2008 it increased
by 57.57%, 33.33%, 15.70%, respectively and a decrease in the year 2006-2007 by
8.17%. In average we can say that there is a 24.45% growth in the Debt Equity
Ratio in last four years. Ideally the debt equity ratio should be 2:1 that means the
debt should be double of equity. So from the above diagram we can say that the
debt equity ratio is ideal in year 2006 and 2007.
83
9.5.7 Current Ratio:
The current ratio measures the ability of the firm to meet its current liabilities from
the current assets. Higher the current ratio, greater the short-term solvency
(i.e. larger is the amount of rupees available per rupee of liability).As the above
diagram is showing that the export sale has decreased from 1.41 in 2004 to 1.34 in
2008. From 2004 to 2005, there is a decrease of 5%, from 2005 to 2006 there is an
increase of 1.50%, from 2006 to 2007 there is no change and from 2007 to 2008
there is a decrease of 1.5%. In average we can say that there is a decrease of
1.25%%.
84
9.5.8 Interest Coverage Ratio:
Higher the interest coverage ratio better is the firm’s ability to meet its interest
burden. The lenders use this ratio to assess debt servicing capacity of a firm.
As the above diagram is showing that the Interest coverage ratio has increased
from 3.52 in 2004 to 4.2 in 2008. From 2004 to 2005, 2005 to 2006 there is an
increase of 13% and 20.35% respectively, from 2006 to 2007 and from 2007 to
2008 there is a decrease of 8% and 4% respectively In average we can say that
there is a 5.33% growth in the Interest Coverage Ratio in last four years.
85
9.5.9 Debt Service Coverage Ratio:
Debt Service Coverage Ratio (DSCR) is a more comprehensive and apt to compute
debt service capacity of a firm. Financial institutions calculate the average DSCR
for the period during which the term loan for the project is repayable. The Debt
Service Coverage Ratio is defined as follows:
Profit after tax+ Depreciation+ other Non cash Items+ Interest on term loan
Interest on term loan+ repayment of term loan
In the above diagram we can see that there is an Increase/ Decrease in the debt
service coverage ratio. From 2004 to 2005 it has decreased by 0.09 then it has
increased by 0.1 in 2006. Again it Ha decreased by 0.21and at the year of 2008 it
has increased by 0.1.
86
9.5.10 Earning per Share (EPS):
24
23
25
20
16 16
13
15
10
0
2004 2005 2006 2007 2008
Earnings per Share measures the profit available to the equity shareholders per
share, that is, the amount that they can get on every share held. It is calculated by
dividing the profits available to the shareholders by number of outstanding shares.
The profits available to the ordinary shareholders are arrived at by net profits after
taxes and preference dividend. It indicates the value of equity in the market.
87
10. Steel Manufacturing:
Since I have got the opportunity to do my SIP in a steel and power generating
company so I manage to accumulate some information regarding the steel
manufacturing process after visiting the steel plant. Now before discussing the
process of steel production let us discuss some other aspect of the steel.
The exact date at which people discovered the technique of smelting iron ore to
produce usable metal is not known. The earliest iron implements discovered by
archaeologists in Egypt date from about 3000 BC, and iron ornaments were used
even earlier; the comparatively advanced technique of hardening iron weapons by
heat treatment was known to the Greeks about 1000 BC.
The alloys produced by early iron workers and, indeed, all the iron alloys made
until about the 14th century AD would be classified today as wrought iron. They
were made by heating a mass of iron ore and charcoal in a forge or furnace having
a forced draught. Under this treatment the ore was reduced to a spongy mass of
metallic iron filled with a slag composed of metallic impurities and charcoal ash.
This sponge of iron was removed from the furnace while still incandescent and
beaten with heavy sledgehammers to drive out the slag and to weld and consolidate
the iron. The iron produced under these conditions usually contained about 3 per
cent of slag particles and 0.1 per cent of other impurities. Occasionally this
technique of iron making produced, by accident, a true steel rather than wrought
iron. Ironworkers learned to make steel by heating wrought iron and charcoal in
clay boxes for a period of several days. By this process the iron absorbed enough
carbon to become a true steel.
After the 12th century the furnaces used in smelting were increased in size, and
increased draught was used to force the combustion gases through the “charge”,
the mixture of raw materials. In these larger furnaces the iron ore in the upper part
of the furnace was first reduced to metallic iron and then took on more carbon as a
result of the gases forced through it by the blast. The product of these furnaces was
pig iron, an alloy that melts at a lower temperature than steel or wrought iron. Pig
iron (so called because it was usually cast in stubby blocks fed from a central
88
runner, reminiscent of piglets suckling from a sow) was then further refined
to make wrought iron.
Modern steel making employs blast furnaces that are refinements of the furnaces
used by the old ironworkers, but which are much taller, use superheated air, and
operate at much higher pressures, yielding a hundredfold increase in production.
The process of refining molten iron with blasts of air was accomplished by the
British inventor Henry Bessemer, who developed the Bessemer furnace, or
converter, in 1855. Since the 1960s, several so-called mini mills have been
producing steel from scrap metal in electric furnaces. The giant steel mills remain
essential for the production of steel from iron ore
89
10.2 Raw Materials for Steel Production:
The ores used in making iron and steel are iron oxides, which are compounds of
iron and oxygen. The major iron oxide ores are hematite, which is the most
plentiful, limonite, also called brown ore, taconite, and magnetite, a black ore.
Magnetite is named for its magnetic property and has the highest iron content.
Taconite, named for the Taconic Mountains in the northeastern United States, is a
low-grade, but important ore, which contains both magnetite and hematite.
Iron making furnaces require at least a 50% iron content ore for efficient operation.
Also, the cost of shipping iron ores from the mine to the smelter can be greatly
reduced if the unwanted rock and other impurities can be removed prior to
shipment. This requires that the ores undergo several processes called
"beneficiation." These processes include crushing, screening, tumbling, floatation,
and magnetic separation. The refined ore is enriched to over 60% iron by these
processes and is often formed into pellets before shipping. Taconite ore powder,
after beneficiation, is mixed with coal dust and a binder and rolled into small balls
in a drum pelletizer where it is then baked to hardness. About two tons of
unwanted material is removed for each ton of taconite pellets shipped.
The three raw materials used in making pig iron (which is the raw material needed
to make steel) are the processed iron ore, coke (residue left after heating coal in the
absence of air, generally containing up to 90% carbon) and limestone (CaCO3) or
burnt lime (CaO), which are added to the blast furnace at intervals, making the
process continuous. The limestone or burnt lime is used as a fluxing material that
forms a slag on top of the liquid metal. This has an oxidizing effect on the liquid
metal underneath which helps to remove impurities. Approximately two tons of
ore, one ton of coke, and a half ton of limestone are required to produce one ton of
iron.
There are several basic elements which can be found in all commercial steels.
Carbon is a very important element in steel since it allows the steel to be hardened
by heat treatment. Only a small amount of carbon is needed to produce steel: up to
0.25% for low carbon steel, 0.25-0.50% for medium carbon steel, and 0.50-1.25%
for high carbon steel. Steel can contain up to 2% carbon, but over that amount it is
considered to be cast iron, in which the excess carbon forms graphite. The metal
90
manganese is used in small amounts (0.03-1.0%) to remove unwanted
oxygen and to control sulfur. Sulfur is difficult to remove from steel and the form
it takes in steel (iron sulfide, FeS) allows the steel to become brittle, or hot-short,
when forged or rolled at elevated temperatures. Sulfur content in commercial steels
is usually kept below 0.05%. A small quantity of phosphorus (usually below
0.04%) is present, which tends to dissolve in the iron, slightly increasing the
strength and hardness. Phosphorus in larger quantities reduces the ductility or
formability of steel and can cause the material to crack when cold worked in a
rolling mill, making it cold-short. Silicon is another element present in steel,
usually between 0.5-0.3%. The silicon dissolves in the iron and increases the
strength and toughness of the steel without greatly reducing ductility. The silicon
also deoxidizes the molten steel through the formation of silicon dioxide (SiO2),
which makes for stronger, less porous castings. Another element that plays an
important part in the processing of steel is oxygen. Some large steel mills have
installed their own oxygen plants, which are located near basic oxygen furnaces.
Oxygen injected into the mix or furnace "charge" improves and speeds up steel
production.
Steel can be given many different and useful properties by alloying the iron with
other metals such as chromium, molybdenum, nickel, aluminum, cobalt, tungsten,
vanadium, and titanium, and with nonmetals such as boron and silicon.
91
10.3 Classification of Steel:
i. Carbon Steels
More than 90 per cent of all steels are carbon steels. They contain varying amounts
of carbon. Steels to make sheet for car bodies, domestic appliances, cans, and so on
have very low carbon contents, typically 0.04 per cent or less. Structural steels and
steels for engineering applications have carbon levels up to about 0.8 per cent,
while very hard steels for applications such as hand-working tools may have
carbon contents up to 1.4 per cent. Other elements present are: manganese at not
more than 1.65 per cent, 0.60 per cent silicon, and small amounts of sulphur and
phosphorus. In steels made from 100 per cent scrap there are also significant levels
of copper and tin, which are detrimental to their properties. Machines, car bodies,
most structural steel for buildings, ship hulls, bedsprings, and hairgrips are among
the products made of carbon steels.
92
engine to pull. Numerous buildings are now being constructed with
frameworks of HSLA steels. Girders can be made thinner without sacrificing their
strength, so that additional interior space is left in the building.
v. Tool Steels
These steels are made into many types of tools for use in powered machinery such
as drills, lathes, milling machines, and metal-cutting saws, where friction during
use causes the temperature of the tool to rise as high as 500° C (930° F). They
contain tungsten, molybdenum, and other alloying elements that give them extra
strength, hardness, and resistance to wear at high temperatures.
93
10.4 Heat Treatment of Steel:
The basic process of hardening steel by heat treatment consists of heating the metal
to a temperature a little above that at which all the ferrite is transformed into
austenite, usually about 760° to 870° C (1400° to 1600° F), the precise value
depending on the carbon content of the steel. The steel is then held for a time to
take all of the cementite into solution, then rapidly cooled (quenched) in water or
oil. Such hardening treatments, which form martensite, set up large internal
stresses in the metal, and these are relieved by tempering, which consists of
reheating the steel to a temperature below that at which austenite forms. Tempering
results in a decrease in hardness and strength and an increase in ductility and
toughness.
The primary purpose of the heat-treating process is to control the amount, size,
shape, and distribution of the cementite particles in the ferrite, which in turn
determines the physical properties of the steel.
Many variations of the basic process are practised. Metallurgists have discovered
that the change from austenite to martensite occurs during the latter part of the
cooling period and that this change is accompanied by a change in volume that
may crack the metal if the cooling is too swift. Three comparatively new processes
have been developed to avoid cracking. In time-quenching the steel is withdrawn
from the quenching bath when it has reached the temperature at which the
martensite begins to form, and is then cooled slowly in air. In martempering the
steel is withdrawn from the quench at the same point, and is then placed in a
constant-temperature bath until it attains a uniform temperature throughout its
cross-section. The steel is then allowed to cool in air through the temperature range
of martensite formation, which for most steels is the range from about 288° C
(550° F) to room temperature. In austempering the steel is quenched in a bath of
metal or salt maintained at the constant temperature at which the desired structural
change occurs, and is held in this bath until the change is complete, before being
subjected to the final cooling.
94
in a bath of molten cyanide salt to form both carbides and nitrides, though
this method is less common today because of the expense involved in safely
disposing of the used salts. In nitriding steels of special composition are hardened
by heating them in ammonia gas, or in a plasma produced by striking an arc in the
presence of argon and a nitriding gas, to form alloy nitrides.
95
10.5 Process of Steel Production:
96
In the above picture I am trying to show how exactly the steel is being
produced and how from the alloy steel different finished product is being made. At
first iron ore and lime stone are put into the blast furnace and get it melt after
passing through the converter it goes to the Ladle. On the other hand pig iron,
sponge iron or scrap is put into the Electronic Arc Furnace to get it melt. After
getting melt the entire liquid thing goes to the ladle furnace and finally goes to the
Ladle. Then the entire liquid that has been accumulated in the ladle poured into the
‘continuous casting’ from where the liquid stuff is converted into the Billets. the
billets again passes through the reheating furnace, rolling mills, finishing units and
from where it can be put into different items e.g., wire rod, nails, bar and rods etc.
Crude steel production in the European Union 27 fell by 45.3% in March to 10.3
million tones compared to March 2008, and was 43.8% down in the quarter at 30.2
million tones. German steel production was 50% down in March and 39.4% down
in the three months to 7.3 million tones. Italian production decreased by 42.7% in
March, and by 40.9% in the quarter to 4.9 million tones. French steel production
dropped by 36.7% in March, bringing the year to date total down 39.7% to 2.9
million tones. Spanish steel production decreased by 41.2% in March, and by
42.7% in the three months to 2.8 million tones. UK steel production showed a drop
of 43% in March, and 43.7% in the year to date to 2.1 million tones. Romania
showed the largest fall at 67.8% in the month and 66.3% in the quarter; with
Belgian production down 60.2% in the month, and 72% in the quarter.
In the former USSR, Russia showed a decrease in steel production of 30.9% in the
month and 33% in the quarter to 12.9 million tones. In the Ukraine production fell
by 38.5% in March, and by 37.9% in the quarter to 6.8 million tones. Production in
Kazakhstan showed a 22.6% drop in March, with the three months total down by
20% to 865 thousand tones. While exports from both Russia and Ukraine in the
first two months of 2009 were down, 19.2% for Russia and 24.7% for the Ukraine,
monthly exports have actually picked up from the low point in November 2008.
Semis accounted for just under half of Russia's exports in 2009, and just over half
of Ukraine's exports.
Crude steel production in the USA was just 4.1 million tones in March, a decrease
of 52.7%, bringing the first quarter total up 52.5% to 12.1 million tones. Mexican
production fell by 51.2% in the month, with the three months total down 49.1% to
2.4 million tones. Canadian steel production dropped by 55% in March and by
55.4% in the year to date to 1.9 million tones. US imports of steel in February
dropped to their lowest level since October 1995 at just under 1.5 million tones.
Seamless and welded tubes in particular showed a sharp drop compared to recent
months. Imports of semis have also dropped off markedly. US exports have also
fallen significantly, down 34% to 613 thousand tones compared to February 2008,
and the lowest monthly export total since September 2004. 74% of exports went to
Canada and Mexico with a further 10% going to other Central and South American
countries, which is a similar percentage as in previous years. South America is
dominated by Brazil where steel production decreased by 41.5% in March with the
year to date down 42% at 5.0 million tones. In Argentina production was 49.5%
down in the month bringing the year to date to 798 thousand tones, a fall of 41.7%
on the first quarter of 2008. Venezuelan steel production, on the other hand,
98
actually rose by 63% in March, and by 19.6% in the three months to over 1.1
million tones.
In Africa, the South African three month total fell by 26.9% to 1.6 million tones,
while the Egyptian total fell 26.2% to 1.3 million tones. In the Middle East Iranian
steel production rose by 14% in March, bringing the first quarter total up 17.9% to
2.9 million tones, while Saudi Arabian steel production decreased by 5.3% in
March, bringing the three months total down 26.5% to 938 thousand tones.
The five major Asian countries for which monthly crude steel production data are
available showed increased production in both March and the year to date except
for China. Chinese steel production was very slightly down in March at 45.1
million tones, while the three months total rose by 1.4% to 127.4 million tones,
48% of the world total in 2009. Japan's production fell by 46.7% in March, with
first quarter production down 42.9% to 17.6 million tones. Indian steel production
in March was 7.5% lower, with the three months total down 7.9% to 13.2 million
tones. Production in South Korea decreased by 21.2% in March, with the year to
date total down 22.9% to 10.5 million tones. Taiwanese production fell by 21% in
the month, bringing the first quarter total to 4.2 million tones, a drop of 23.2% on
January to March 2008.
Chinese exports of steel actually rose slightly in March to 1.6 million tones,
although this was still below the January total of 1.9 million tones. Imports,
however, jumped to over 1.7 million tones, the highest monthly total since March
2006, and making China's balance of trade negative for the first time since
November 2005. The large rise in imports was due in part to the jump in the
imports of semis, 465 thousand tones, which was almost double the amount
imported in the whole of 2008. Some 900 thousand tones of semis were imported
in the first three months of 2009 of which 91% were low carbon billets and slabs.
They came primarily from Russia, Taiwan, South Korea and Mexico, which
together accounted for 80% of the total. Most Chinese imports rose in March
compared to February, with CR at 318 thousand tones and HR wide coil at 287
thousand tones.
Japanese exports in March 2009 jumped by 38% to 2.5 million tones compared to
February 2009, although they were still a third down on the same month in 2008.
99
11 Conclusion:
Flowchart for Materials Procurement and Movement
Laboratory
Bill Clearance of Materials Sent
testing of
supplier by Bill To Store
materials
Passing Dptmt
Accounting Entries
made by Accounts
Dptmt
Payment to 100
Supplier
In the above figure we can see the whole process of material procurement by the
company and how these things are being done by the individual departments of the
organization. Firstly a material is procured on demand of the indenter. So the
Indent is being raised by the Indenter in order to purchase the material. After the
indent is being raised it is not that the material will be purchased immediately. It
will be checked in the store whether that material is available in the store or not. If
it is available in the store then the material will be issued from the store if not
available in the store then further proceedings will be done. The purchase
department will send an enquiry to the suppliers through mail in order to send their
Quotations of the material. The suppliers send the Quotations either through mail
or post. Based on the Quotations send by the suppliers a Comparative statement is
been prepared. The supplier who quotes the least price gets the order of material to
supply. So after deciding which supplier to get the order a Purchase Order is been
issued by the purchase department to the supplier.
Now after the purchase order is been issued it is time for the suppliers to
supply the materials. When the materials reach the Company a security check is
been done at the gate and after that the material is allowed to enter inside the
factory. Then as the material loaded truck enters there are two Weigh Bridges
where weight of the material is measured. After that the truck reaches the
fabrication area to unload the materials. While returning from the unloading point
again the empty truck is being weighed by another two Weigh Bridges.
After the materials are supplied by the supplier it is not used immediately. A
sample of material is been sent to the Laboratory in order to have a Lab Test. After
testing the material it is been sent to the store. The Bill Clearance is been done by
the Bill passing department and the bill is been sent to the Accounts department
where the vouchers are being prepared and the accounting entries are made. After
the entries are made the Accounts Department makes payment to the supplier.
101
12 Bibliography:
www.bpsl.net
www.scribd.com
Information collected from the representative of individual departments.
Microsoft Encarta Encyclopedia.
www.nseindia.com (capital market module)
102