A bottom-up growth initiative

FACES 2004

The continuous improvement in the production process and in the quality of the product were the main targets when R Mukundan, chief operating officer of Tata Chemicals, introduced the concept of 'Manthan' at the company's plant at Mithapur in Jamnagar district of Gujarat last year.

As part of the scheme, various ideas are received from employees to improve the product/ processes. These are studied for their viability in terms of cost and implementability.

The accepted ideas are implemented, resulting in huge savings. This was an initiative with a bottom-up approach with the total support of the top management.

After the successful launch of the idea, the year 2004 is crucial for Mukundan and his company which expects to reap rich dividends from the novel scheme.

The Mithapur plant has already got several awards during Mukundan's tenure.

Its salt works won the Rotating Shield and Certificate of Honour on the basis of its safety record and performance, symbolizing the inbuilt safety culture cultivated by TCL.

It also won the Gujarat State Safety Award - 2002 and the RBNQA (Ramkrishna Bajaj National Quality Award) Commendation Certificate, ISO 18001 Certification for Township.

Tata Chemicals Mithapur plant has also achieved excellent results in terms of operational efficiency and human resources in 2003. It earned Rs 1000 crore revenues in 2003.

"The programme (Manthan) was launched a year-and-a-half back and we have achieved the best performance in consumer satisfaction, operational efficiency and other operational parameters.

"These include implementation of ideas of the employees and executives in the effective operational management," said Mukundan.

The company enjoys brand leadership in the branded salt segment with close to half a million tonne of salt produced.

It is also the largest producer the soda ash in the country, accounting for 35 per cent of the domestic demand.

This year, the company hopes to export 1.5 million tonne of soda ash. Soda ash finds use in the industries such as detergents, glass, paper, photographic products, textiles dyes and petroleum refining.

There was a chemical leak from the plant last year and TCL has also geared itself up to strengthen its contribution to the betterment of the environment.

The company is working on preventing/ minimising pollution and occupational health and safety risks through improvements in processes and ensuring compliance with all statutes and regulations pertaining to environmental health and safety (EHS) management.

"We are the first company to have an affluent discharge system with less then 500 ppm efficiency. We have a filter system which converts the affluent into cakes, which is used as a feed stock for the cement plant.

"This makes the area around the plant eco friendly," Mukundan said.

"The company's power plant is also a unique example of our commitment to ensuring a better environment. We use enviro coal, with low sulphur content. The salt works have also been developed as a natural habitat for thousands of aquatic birds," he added.

Tata Chemicals has committed itself to fostering development that is sustainable and integrated.

Be it helping with natural resources management, livelihood support, or building health and education infrastructure, the company aims to improve the lives of rural citizens.