balasore alloys ltd Management discussions


MANAGEMENT DISCUSSION AND ANALYSIS

Global Economy

Onset of COVID- 19 pandemic in the year 2020 and subsequent lockdown imposed across the world to contain spread of virus led to unprecedented situations worldwide with domestic and global trade coming to a standstill.

Lockdown and border closures across the global Lockdown and border closures across key global markets paralysed economic activities including production and business operations all over the world. This pause in the global economic activity caused significant contraction of economies in the first half of 2020. Global trade was impacted by a significant margin in the first half of the year. With the easing of lockdown starting from June 2020 the world economy rebounded but still, as per IMF estimates, global economy contracted by 3.5% in 2020. When towards the end of 2020 it looked that world economy is bouncing back the second wave of pandemic embedded with new mutated variants emerged and have slowed down the speed of economic recovery. The global economy, as per IMF is projected to grow at 6% in 2021 reflecting additional fiscal support in a few large economies and expectations of vaccine powered recovery of economic activity.

Challenges

It has been several months since the COVID-19 pandemic engulfed the world and yet there is lot of uncertainty with respect to the extent of the economic contraction due to this crisis, and the subsequent pace of recovery. Advanced economies entered this crisis with interest rates at historical lows and Public debts, on average higher than they had been over the past 60 years. (IMF report on World Economic Outlook, April 2020 edition)

Outlook

Prospects for emerging market and developing economies have been marked down for 2022, especially for Emerging Asia. By contrast, the forecast for advanced economies is revised up. These revisions reflect pandemic developments and changes in policy support. The 0.5 percentage-point upgrade for 2022 derives largely from the forecast upgrade for advanced economies, particularly the United States, reflecting the anticipated legislation of additional fiscal support in the second half of 2022 and improved health metrics more broadly across the group. (IMF report on World Economic Outlook, July 2022 edition)

Indian Economy

India’s gross domestic product (GDP) shrank by 7.3% in FY22 due to Covid-19 pandemic omnicron virus which resulted in unprecedented lockdown disrupting supply chain and leading to collapse in demand. After sharp contraction in the first half of the fiscal year, GDP turned positive in the second half due to spurt in economic activities on the back of calibrated easing of restrictions and fiscal stimulus. According to IMF estimates, the Indian economy is expected to grow by 12.5% in FY22 making it the only major economy expected to register a doubledigit growth. While the economy continues to chart its pathway to recovery and revival, there is need for more supportive policy framework to support domestic demand and ensure sustainable and equitable economic growth.

Challenges

The Indian economy was already facing a slowdown before the COVID-19 pandemic hit, and the pandemic further exacerbated the problem. The country saw a contraction of 7.7% in GDP in the FY-2021, and the growth rate was expected to be muted in FY- 2022 as well. The government implemented various measures, such as stimulus packages and reforms, to revive the economy, but the results were slow to show the Indian economy faced significant challenges in FY-2022, driven by the pandemic- induced slowdown, unemployment, high fiscal deficit, inflation, and the need for structural reforms. The government implemented various measures to support the economy, but the impact was limited, and the long-term growth prospects of the economy remain uncertain. The economy requires significant reforms in various sectors to ensure sustainable growth.

Outlook

The COVID 19 pandemic has savaged the already weak consumption and a sharp decline in growth has been predicted for the Indian economy. India’s GDP shrank by 7.3 % in 2021-22 (The Hindu, 31st May, 2022). The Growth rate forecasted for India for 2022-23, the World Bank is an upward revision from its January forecast of 5.4%. (The Hindu, 08th June, 2022).

Industry Outlook

The chrome industry in India is expected to see a moderate growth rate in the FY- 2022. The demand for chrome ore is likely to be driven by the stainless steel industry, which accounts for about 80% of chrome consumption in India. The Indian stainless steel industry has been growing at a steady pace, and the trend is expected to continue in the coming years. In addition, the governments focus on infrastructure development and the implementation of the National Steel Policy 2017 is likely to provide further impetus to the chrome industry.

Chrome ore industry overview

Despite the positive outlook, the chrome industry in India faces some challenges that need to be addressed. One of the major challenges is the availability of high-quality chrome ore. India mostly imports chrome ore to meet its demand, and the quality of the imported ore is often inferior to the ore available in other countries. This affects the quality of the final product and increases the cost of production.

Another challenge is the environmental impact of chrome mining and processing. Chrome mining and processing can have a significant impact on the environment, and the industry needs to take steps to minimize this impact. The government has been taking steps to regulate the industry and enforce environmental norms, but more needs to be done.

Finally, the chrome industry in India is highly fragmented, with many small players operating in the market. This makes it difficult for the industry to compete on a global scale, as the economies of scale are not available to the smaller players. The industry needs to consolidate and improve its efficiency to compete with global players.

Overall, the chrome industry in India has a positive outlook for the FY-2022, but it also faces some challenges that need to be addressed to ensure sustainable growth.

Stainless steel sector

Global Overview

The global stainless steel sector witnessed a challenging year in FY-2021-22, impacted by the COVID-19 pandemic and global economic conditions. The decline in demand, production, and exports, the fluctuation in raw material prices, and the supply chain disruptions had a significant impact on the industrys performance. The industry requires continued support and reforms to ensure long-term sustainable growth and competitiveness. The technological advancements and the adoption of Industry 4.0 technologies are expected to provide opportunities for the industrys growth in the coming years.

Domestic Overview

A dynamic external environment, an enabling pricing scenario, and release of pent-up demand majorly defined FY 2021-22 for the Indian steel industry.

While the initial quarter of the fiscal proved to be unprecedented slowdown with the consecutive lockdowns, the rest of the year witnessed a highpowered demand revival in consumption industries such as automobiles. Demand for appliances improved due to the large-scale shift towards work-from-home, and construction activity picked up with government expenditure. This mirrored the global scenario, as demand picked up after liquidity was pumped into the economy together with a flurry of infrastructure project announcements. Indian steel consumption stood at 94.14 MnT at the end of FY 2020-21, down 6% y-o-y. In FY 2021-22, the demand is expected to touch 110 MnT, presenting an incremental requirement of 16 MnT over that of last year.

Ferrochrome sector

The global ferroalloys market is expected to grow on account of rising steel production around the world. The ferroalloys include ferrochrome, ferrosilicon, ferromanganese and ferromolybdenum, among others. Various types of ferroalloys have different purposes in the production of steel. For instance, ferrovanadium in steelmaking is used to provide strength against alkalis and acids such as sulphuric and hydrochloric acid.

It provides corrosion resistance and enhances tensile strength of casting & welding electrodes.

Nearly 85 to 90% of all the ferroalloys are used in the production of steel. Therefore, production and consumption of steel and related products have a huge impact on the pricing of ferroalloys and vice versa. Cost of ferroalloy is one of the key criteria for deciding suitable ferroalloy for the production of a particular grade of steel. Specification of steel is also an important factor while calculating the costs of steelmaking. For instance, specific grade of steel with low phosphorous can be manufactured using two methods viz. either by the use of normal steelmaking process, which uses expensive ferroalloys with low phosphorous content or by increasing the refining time and basicity of slag to reduce phosphorous at low levels.

As per the World Steel Association, the global production of crude steel reached 1,950.5 million tons in 2021, an increase of 3.7% from 2020. China was the leading producing country with production of 1,032.8 million tons in 2021. China was followed by India, Japan, the U.S., Russia, South Korea, Turkey and Germany. These leading countries are expected to remain the key markets for ferroalloy producers. (Grand View Research)

Future Prospects

The global ferroalloys market size was valued at USD 42.7 billion in 2021 and is expected to expand at a compound annual growth rate (CAGR) of 7.1% from 2021 to 2028. Incessant production of steel around the world is projected to benefit market growth. Ferroalloys are a group of materials consisting of iron and different alloying elements which are normally used for the production of steel. Ferroalloys are used in steelmaking to improve the specific properties of steel products. The properties such as fatigue strength, tensile strength, corrosion resistance, and ductility are improved through the addition of ferroalloys.

Domestic Overview

The Indian Ferrochrome sector witnessed a challenging year in FY-2021-22, impacted by the COVID-19 pandemic and global economic conditions. The decline in demand, production, and exports, the fluctuation in raw material prices, and the slowdown in the construction and infrastructure sectors had a significant impact on the industrys performance. The government policies and the technological advancements are expected to provide opportunities for the industrys growth in the coming years. The industry requires continued support and reforms to ensure long-term sustainable growth and competitiveness.

Opportunities & Threats

Opportunities

Stainless steel is the key demand driver for ferrochrome. This metal has now become an important raw material for the automotive, railway & transport (ATR) sector, Buildings & Construction, Clean energy production, Food processing, Medical science etc that can propel growth in future.

Threats

• COVID 19 pandemic.

• South African (SA) producers facing increasing power cost and Electricity rate in South Africa which have increased over 500% in last 10 years consequently, SA producers have become gradually uncompetitive. In SA, ferro chrome production is going down due to cost pressure and now they are producing and exporting more of Chrome ore to China and this gives advantage to China to become self-reliant gradually on their Ferro Chrome requirement. China expected to import less FeCr and encourage local production which is threat to Indian production.

BUSINESS STRENGTHENING INITIATIVES

On its pursuit towards excellence, the company continued its initiatives of TPM (Total Productive Maintenance) and Six Sigma. Several projects and activities have been carried to complement the cost reduction, process optimization and achieving operational efficiency targets and goal. After the adoption of Malcolm Baldrige business excellence model, the company leaped towards establishing the culture of excellence through its sustained implementation and its evaluation. Moreover, all the initiatives were categorically converted into systems and regular practices of the organization by the robust execution of the management systems through IMS (Integrated Management System). All business processes were linked to the excellence journey and further contributed towards sustenance of practices in the company.

THE ROADMAP OF BUSINESS EXCELLENCE

The Company has adopted the globally acclaimed Malcolm Baldrige Business Excellence Model of USA for long term competitiveness and business sustainability through strategy formulation and execution to achieve its stated Vision and Mission. The Baldrige Excellence Model empowers the organization to reach its goals, improve results, and become more competitive. The core values and concept are the foundation for integrating key performance and operational requirements within a results-oriented framework that creates a basis for action, feedback, and ongoing success.

Six Sigma:

The Six Sigma initiative has significantly contributed in transforming business by breaking myths of conventional wisdom. The Company has a well-designed process flow for driving Six Sigma initiative across the organization. The Six Sigma initiative continue to contribute significantly in process optimization, productivity, inventory reduction and quality improvement and significant cost reduction in the production of Ferro chrome.

Lean Management:

• The Lean management aims to maximize customer value while minimizing waste in the production.

• the Lean approach involves reducing waste in production processes by streamlining operations, optimizing resources, and minimizing inventory. This results in improved efficiency, better quality control, and increased profitability.

• Lean principles are applied by focusing on customer needs and continuously improving processes to meet those needs. This results in faster delivery times, better customer satisfaction, and reduced costs.

• the Lean approach is a customer-centric methodology that values efficiency, continuous improvement, and waste reduction.

• Value stream mapping technique used to analyze and improve the flow of materials and information through a process to identify inefficiencies, bottlenecks, and waste, and to develop plans for improvement.

Health Audit: Health Audit conducted by a cross-functional team to improve plant performance and optimize costs. Objective of the audit to help identify inefficiencies, redundancies, and areas where resources can be better allocated.

1) Identify opportunities to refine the existing maintenance processes

2) Identify opportunities for efficiency improvements within current practices

3) Identify opportunities to make better use of constrained resources.

4) Assess the damage to the existing structures and suggest remedial measures for strengthening.

5) To establish the reserve strength in the elements of structures for accommodating load bearing of higher capacity equipment.

6) To enhance life cycle of building by suggesting preventive and corrective measures like repairs and retrofitting

We have identified 239 improvement points across the shopfloor out of which 130 closed.

Integrated management systems (IMS)

IMS integrates all business processes across the value chain in addition to integrating the processes involved in Management Initiatives and all forms of ISO Management Systems like Quality Management System (QMS), Environment Management System (EMS), Occupational Health & Safety Management System (OHSAS), Energy Management System (EnMS), Information Security Management System (ISMS), Asset Management System (AMS) and Social Accountability Management System (SA).

During the financial year, Our Company continued to have latest certification of ISO 9001:2015 (QMS), ISO 14001:2015(EMS), ISO 55001:2014 (AMS), ISO 27001:2013 (ISMS) and SA8000:2014(SA), ISO45001 :2018 (OHSAS) and ISO 50001:2011 (EnMS) System. Mines also continued with latest certification of ISO 9001:2015 (QMS), ISO 14001:2015 (EMS), OHSAS 18001:2007 (OHSAS) and SA8000:2014 (SA) System.

As a result the business processes/ systems are getting through Evaluation and Integration (E & I) cycles and thus processes/ systems are standardized and become more robust. Process based approach has been strengthen by establishing and implementation of the process control plan throughout the manufacturing processes.

Information Technology

The company adopts the most advanced technologies into all of its manufacturing processes to ensure desired quality and of its products while ensuring On Time In Full (OTIF). The advanced process technology and sophisticated equipment have been acquired from World leaders of Metals & Ferro Alloy equipment like ELKEM, MINTEK, Tenova-Pyromet.

The manufacturing process is fully automated using advanced control systems acquired from Rockwell Automation. SCADA systems were introduced in 1989 that has been upgraded to new generation "control Logix" system of Rockwell Automation 2007 to facilitate operation of furnace electrode, weighing and batching system to maintain the consistency of the operation.

A highly sophisticated real-time computerized system enables better monitoring and control of all aspects of furnace operation in real-time. Sophisticated web-based realtime monitoring systems enable the production team to visualize the process from anywhere across the globe.

With an objective of improved business process, the company has implemented SAP ECC 6.0 in order to meet the changing and growing needs of the business. This technology solution automates business processes and facilitates accurate and realtime data acquisition across the organization for a faster and informed decisionmaking. In order to keep pace with changing technology, the company is investing in several digital initiatives and business transformation projects. The business runs seamlessly on SAP with Disaster Recovery Site located in western India. The company has been front runner in implementing SD WAN network.

The company has also implemented and is certified Information Security Management System (ISO27001) to ensure confidentiality, Integrity and availability of all its electronic information systems and physical records in order to manage information risk effectively.

QUALITY ASSURANCE

Balasore Alloys Ltd is a ISO 9001:2015 (Quality Management System) certified company and became the first Ferro Alloys Company in the world to receive the prestigious certificate on JIS G2303: 1998 for our product & manufacturing process from Japan Quality Assurance Organization (JAPAN). Company is already certified for BIS 1170: 1992 from Bureau of Indian standards and also having DIN.: 17565 registration from DIN CERTCO, GERMAN. The Quality Control R&D Lab has been accredited to ISO 17025:2017 by NABL (National accreditation Board for testing & Calibration Laboratories) - a watermark of aligning it’s products standards to global benchmarks.

ENVIRONMENT AND SAFETY

Balasore Alloys accord top priority to the safety of its people and safeguarding of the environment.

Environment management:

The Company has institutionalized a structured environmental management system as per ISO 14001:2015, which ensures that it complies with all waste discharge standards, specified by various regulatory bodies.

The Company operates on a zero-discharge concept for liquid waste - wastewater is treated and recycled for dust suppression and horticulture purposes etc. The Company has also implemented rainwater harvesting & artificial recharge systems for increasing the ground water table and installation of Piezometers for measuring the ground water level.

Installed Continuous Ambient Air Quality Monitoring Station (CAAQMS) is a Real time & Robust monitoring system, which helps in assessing the level of pollution w.r.t ambient air quality & thus we can better control over the functioning of equipments meant for reducing the Air Pollution Level.

Solid waste is used in various construction activities, as a replacement for stone chips. Gas cleaning units attached with every furnace facilitates in adhering to the prescribed standard of stack gas emission.

Hazardous & Other Wastes like Used Oil, Used Battery, E-Waste and Plastic Waste are disposed through authorized recyclers or as per prescribed norms of Pollution Board. Flue Dust (Gas Cleaning Plant Dust) is being reused within our Plant Premises.

Green cover:

The Company continued its plantation programme at local villages along with initiating sizeable plantation drives at its mines and manufacturing facility. In addition, the Company facilitated avenue plantation in the nearby peripheral area.

Energy Conservation:

To conserve energy and optimize our energy performance & continual improvement of energy efficiency, company has implemented an Energy Management System in accordance with ISO 50001:2011.

Surveillance audit of ISO 50001:2011, Energy management system successfully completed with Zero nonconformity by Bureau Veritas auditor in Balasore plant and Recommended for Continuation of Certificate Energy management software (EnMS Software) tool is used to measure, monitor, control, and optimize the performance of Transmission/Distribution systems in Balasore Plant. Implementation of EnMS enables Real-Time data acquisition, Removal of Manual error, Analyze the electrical Load profile, Auto report/ Alarms, Notifications and Maintaining required Maximum Demand and Power factor of the plant.

Safety: Safety is one of the core values of our organisation. Safety of employees and interested parties are of the prime concern of the management. Company has implemented best safety practices in its occupational health & safety management in compliance to International Standard IS 45001:2018) to ensure that safety standards are regularly followed across its facilities (mines and manufacturing units). Contingency plans are developed and implemented to prevent, mitigate and control occupational health and safety hazards.

Hazard Identification and Risk Assessment (HIRA) of each and every activity is done and reviewed in regular interval. Accordingly, counter measures are taken on significant activities to eliminate or minimise the hazards associated with it. Generally manual works are more prone to injury. To minimise the human intervention manual works are converted to mechanised and semi-mechanised work. Safety poka yokes (Mistake proofing) and kaizens implemented at various areas as proactive approach to improve safe workplace. New improved safety management programmes are undertaken to create safer work environment.

In addition, on-site and audio-visual safety trainings are more focussed by the management to create awareness among the workers. The entire team for emergency preparedness are exercised for Mock drills in periodic interval to handle any such emergency situation.

The BAL plant has been covered by fire hydrant facility and fire detectors have been installed at all the buildings and fire prone areas. To raise the awareness among the employees about health and safety many promotional events like national safety week, fire safety week, road safety week are organized and wholehearted participation of the employees has been observed. Also annual medical check-up of all employees is being carried out to ensure their fitness and avoiding any occupational health hazards.

HUMAN RESOURCES

A sound foundation of intellectual capital lies at the core of the competitive advantage of the Company. This capital comprises a rich mix of experience and youth, thereby creating a wholesome culture of excellence.

The Company’s people philosophy has played the prime role in shaping the company into a passionate, learning oriented and high performing organization. The management accords special focus in areas like role clarity, organisation development, employee engagement, team work to facilitate a performance driven culture.

The Company’s focus on growing the knowledge curve of its people has facilitated in developing a vibrant workforce capable of meeting present and future requirements. The Company has conducted 360-degree competency assessment and designed Individual Development Plan (IDP) for the senior management personnel to be ready during organization’s organic & inorganic growth and develop Individual’s competency.

The Board records its appreciation for the support of employees at all levels and looks forward to their total involvement in the growth process of the Company.

The total income of the company for the year ended March 31,2022 was Rs 11223.20 Lakhs and exports of Rs 20.68 Lakhs.

There has been decrease in the cost of consumption of raw materials from Rs 3311.37 Lac to Rs 1575.22 Lac.

Shareholders’ funds (Net worth) decreased from Rs 78680.43 Lakhs to Rs 71123.01 Lakhs as on March, 2022, registering a decline from the previous year.

Particulars

Financial year ended 31st March, 2022

Financial year ended 31st March, 2021

Standalone

Total Income (net of excise duty)

11223.20

10556.44

Profit/(Loss) Before Interest, Depreciation &Tax (PBIDT)

(1273.31)

(1267.85)

Finance Charges

2710.32

3776.00

Depreciation

2629.57

2862.04

Exceptional Items

0.00

0.00

Provision for Income T ax (Including for earlier years)

(803.44)

(1308.37)

Net Profit After Tax

(5809.76)

(4061.83)

Other Comprehensive Income

252.34

785.46

Total Comprehensive Income for the Year

(5557.42)

(3276.37)

Profit brought forward from Previous Years

58492.45

62554.28

Profit Carried to Balance Sheet

52682.69

58492.45

INTERNAL CONTROL SYSTEMS

Internal Control can be defined as a system designed, introduced and maintained by the company to provide a substantial degree of assurance in achieving business objective, within a framework of adequate checks and balances and to prevent misuse of power, facilitate timely management of change and ensure effective management of risk.

Based on that premise, the Company remained committed to ensure the prevalence of an effective internal control environment, commensurate with its size and nature of business that provides reliable financial and operational information, to ensure compliance of corporate policies and applicable statutory regulations and safeguard Company’s assets. The internal audit process includes review and evaluation of effectiveness of the existing processes, controls and compliances. It also ensures adherence to policies and systems and mitigation of the operational risks perceived for each area under audit.

The system encompasses the major processes to ensure reliability of financial reporting, compliance with policies, procedures, laws and regulations, safeguarding of assets and economical and efficient use of resources. The Company has a comprehensive system of internal controls that enables efficient operations, optimal resource utilisation and compliance with all applicable laws and regulations. Each of these internal controls strengthens the Company and protects loss or unauthorised use of assets by providing adequate checks and balances. The Company authorises, records and reports all transactions.

The Company has carried out an assessment of the adequacy and effectiveness of the Companys Internal Financial Control System by an independent Consultant who did a thorough examination on each and every financial control persisting in the Organisation through TOD (Test of Design) and TOE (Test Of Effectiveness) methodology to analysis the effectiveness of laid down policies, processes, Standard Operating Procedures (SOPs) etc for Internal Controls defined in the Company.

The Statutory Auditors of the Company has also reviewed the Internal Financial Control system implemented by the Company on financial reporting and in their opinion, the company has, in all material aspects, adequate Internal Financial Control System over Financial reporting and such Internal Financial Controls were operating effectively as on 31st March 2022.

For effective business control, there is a full-fledged internal audit function, which is supported by a firm of independent Chartered Accountants to monitor adherence to all internal policies and procedures as well as compliance with all external regulatory guidelines. The Company has an elaborate financial reporting process, which ensures timely review of all financial information. Periodic reviews are undertaken through internal and external audit teams to monitor efficacy of the prevalent systems. Independence of the audit and compliance function is ensured by a direct line of reporting to the Audit Committee comprising of all Independent Directors as members to maintain the objectivity.

The Audit Committee of the Board provides re-assurance to the Board on the existence of effective internal control environment.

MANAGING BUSINESS RISKS AND CONCERNS

Every prospect comes with its fair share of risks and concerns. Yet, we consider it our responsibility to minimize instances of risks in our business.

The Framework:

Our integrated risk management system is the core of our risk mitigation strategy, and focuses largely on prudential norms, structured reporting and control. Hence, even though our risk management is initiated at the senior management level, it still gets decentralised across the organisation, reaching key managers at various organisational levels, which in turn prepares them to mitigate risks at every level.

The company’s Risk Management Framework is designed to provide reasonable assurance that objectives are met by integrating management control into the daily operations, by ensuring compliance with legal requirements and by safeguarding the integrity of the company’s financial reporting and its related disclosures.

Classification of Risks:

By segregating all our risks in separate sections, namely potential, operational, financial, strategic, growth and execution we have been able to bring about company-wide reviews by linking the fore mentioned risks with the Annual Business Plans of the Company.

The Risk Review: The risk management procedures are clearly defined and periodically reviewed by the Board of Directors with a view to strengthen the risk management framework and to continuously review and reassess the risk that the Company may confront with. This helps us to ensure the adequacy of our risk mitigation systems in this ever-changing business landscape.

CAUTIONARY STATEMENT

Statements in this Management Discussion and Analysis report detailing the Company’s objectives, projections, estimates, expectations or predictions may be "forward looking statements" within the meaning of applicable securities laws and regulations. Actual results could differ materially from those expressed or implied. Important factors that could make a difference to the Company’s operations include global and Indian demand supply conditions, raw material prices, finished goods prices, cyclical demand and pricing in the Company’s products and their principal markets, changes in Government regulations, tax regimes, economic developments within India and the countries with which the Company conducts business and other factors such as litigation and / or labour negotiations.