ANALYZING MANAGEMENT INFORMATION SYSTEMS OF THE JAMUNA FERTILIZER COMPANY LIMITED: A CASE STUDY Md. Mamunur Rashid* *Management Counsellor, Bangladesh Institute of Management (BIM), Dhaka. E-mail:[email protected]Abstract: Through this study I have endeavored to emphasize on the need to analyze the management information systems (MIS) in Jamuna Fertilizer Company Limited (JFCL) especially to identify the potential areas where the MIS could be applied and effective use of MIS in the company. Computers are one component of a management information system (MIS) or computer information system (CIS). MIS or CIS consists of five related components: hardware, software, people, procedure, and collections of data. The term (IT) information technology represents the various types of hardware and software used in information systems, including computers and networking equipments. According to the above explanation of MIS/CIS/IT, there is no business solving networking equipments. So, there is no real application of MIS in JFCL. In this paper, daily report of production and other data are listed. Key Words: 1.Introduction 1.1Background of the Study The Jamuna Fertilizer Company Limited (JFCL) is an enterprise of Bangladesh Chemical Industries Corporation (BCIC). JFCL has been established in 1991 to facilitate the agriculture growth of Bangladesh through producing granular urea. JFCL is situated on the bank of the river Jamuna in the district of Jamalpur. Its urea production capacity is 1700 metric ton per day (MTPD) designed by SNAMPROGETTI and Ammonia is 1078 MTPD designed by HALDORTOPSOE of Denmark and constructed by Mitsubishi Heavy Industries Limited (MHI) of Japan. Bangladesh is an agrarian economy. In order to meet the increasing demand of food grain in the country, timely supply of fertilizer is one of the main inputs to agricultural sector. It is an essential prerequisite to increase food production. Bangladesh Chemical Industries Corporation (BCIC) is one of the biggest
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ANALYZING MANAGEMENT INFORMATION SYSTEMS OF THE JAMUNA FERTILIZER COMPANY LIMITED: A
CASE STUDY
Md. Mamunur Rashid**Management Counsellor, Bangladesh Institute of Management (BIM), Dhaka.
Abstract: Through this study I have endeavored to emphasize on the need to analyze the management information systems (MIS) in Jamuna Fertilizer Company Limited (JFCL) especially to identify the potential areas where the MIS could be applied and effective use of MIS in the company. Computers are one component of a management information system (MIS) or computer information system (CIS). MIS or CIS consists of five related components: hardware, software, people, procedure, and collections of data. The term (IT) information technology represents the various types of hardware and software used in information systems, including computers and networking equipments. According to the above explanation of MIS/CIS/IT, there is no business solving networking equipments. So, there is no real application of MIS in JFCL. In this paper, daily report of production and other data are listed.
Key Words:
1.Introduction1.1Background of the Study
The Jamuna Fertilizer Company Limited (JFCL) is an enterprise of Bangladesh Chemical
Industries Corporation (BCIC). JFCL has been established in 1991 to facilitate the
agriculture growth of Bangladesh through producing granular urea. JFCL is situated on
the bank of the river Jamuna in the district of Jamalpur. Its urea production capacity is
1700 metric ton per day (MTPD) designed by SNAMPROGETTI and Ammonia is 1078
MTPD designed by HALDORTOPSOE of Denmark and constructed by Mitsubishi
Heavy Industries Limited (MHI) of Japan. Bangladesh is an agrarian economy. In order
to meet the increasing demand of food grain in the country, timely supply of fertilizer is
one of the main inputs to agricultural sector. It is an essential prerequisite to increase food
production. Bangladesh Chemical Industries Corporation (BCIC) is one of the biggest
industrial organizations in the public sector under Ministry of Industries, Government of
the Peoples’ Republic of Bangladesh. The head office of BCIC is primarily concerned
with the setting of objectives, approval of budget, monitoring of actual performance and
rendering expertise assistance. The JFCL management has been delegated with required
administrative, technical, commercial and financial authority to operate efficiently and
dynamically. In the plant of JFCL, every moment data is generated by reformers, boilers,
heat exchangers, power generation units both steam turbine generator (STG) and gas
turbine generator (GTG), ion-exchangers, coolers, HP stripper, urea reactor, turbines,
compressors, pumps, agitators, fans, blowers in the running plant. Besides these, sales,
Mechanical Central Workshop, 5) Instrument Maintenance & 6) Solid Handling System
Maintenance. Above these I have worked in the following sections: (a.) Plant
Maintenance, May 31, 97 to August 21,99. (b.) Solid Handling System Maintenance,
August 22,99 to August 17,01. As a X-En (Mechanical) in-charge, April 26,2001 to
August 17,2001 ( c.) Machinery Maintenance, August 18,2001 to November 11, 2002.
(d.) Solid Handling System Maintenance, November 12, 2002 to October14, 2003. (e.)
Central Workshop, October 15, 2003 to February15, 2004. I am supervised directly
activities like-maintenance, operation, trouble-shooting jobs and development jobs of
programmable logic controller (PLC), automatic controller, mechatronics of Jamuna
Fertilizer Company Ltd., Jamalpur. I followed the rules & regulations of the
administration, commercial, purchase, finance, technical systems & process engineering
& maintenance procedures to achieve maximum production at minimum cost with less
maintenance. I gained sufficient knowledge & experience to carryout all factory jobs &
activities for betterment of the factory in the fields of economic, financial, safety &
environmental consideration. I acquired a knowledge and understanding of the progress
of technology through innovation through training, seminar, convention, paper meet and
higher studies. I obtained dynamic leadership, articulate and clear thinking. I am
confident to proceed my duties and responsibilities as well as development of the factory
and for the nation by my acquired knowledge & experience. I carried out the maintenance
job, repairing job, development and modification jobs, administrative job, budgetary
controls, material planning & procurement job. I am capable to run the computer related
jobs. I attached with the optimum safety and easy operation & maintenance of plant and
it’s troubleshooting. I coordinated with operation and other related divisions, scheduling
and preparing of start-up, shut down activities, maintenance, procurement & overhauling
job. As an Assistant Engineer (Mechanical), duties & responsibilities are involved in the
field of Personal, Engineering, Management & Economics, Environment, Health &
Safety
5.0 AREAS WHERE MIS HAS BEEN APPLIED IN JFCL
There is no direct digital control system (DDCS) or distributed control system (DCS) in
JFCL. But in JFCL, programmable logic controller (PLC) has been applied in following
areas:
Sl. No
Location Model Number
Manufacturer Qty. in Use
1 6.6 KV Power distribution
A1NCPU Mitshubishi Electric Corporation
01 (one)
2. 400 V Power distribution, IGG plant, Ammonia & Urea Plant.
A2NCPU Mitsubishi Electric Corporation 03 (Three)
3. Water Intake Plant A3NCPU Mitsubishi Electric Corporation 01 (One)
4. Water Treatment Plant 115U CPU941Simatic S5 PS 3A
Siemens 1 (One)
3 (three)
5. Diesel Generator Simatic S5 100UCPU 100
Siemens 1 (one)
6. Gas Turbine 5/15 processor
Allen Bradley 01 (One)
7. Solid Handling System i. TSX-30j ) TSX-47k) TSX-67l) TSX-69
TelemechanicServices “Licences Logiciels”
07 (Seven)
Total 18
The programmable logic controller is the replacement of conventional sequence system
such as electromechanical relays , timers, counters etc. A PLC is a digitally operating
electronic system like microcomputer. Normally it receives ON or OFF type input signals
through its many input signals through its many input ports. Then it processes the
received signals in accordance with the instructions (software package or the program),
which have been stored into its memory previously. Then it produces ON or OFF type
output signals according the instructions. It uses a programmable memory for the internal
storage of instructions. Some PLC can process the varying signals as well as ON/OFF
signals. There are different methods for developing the PLC program. Ladder diagram
and logic instruction are two most common methods for program development. It is used
for the control of start-up sequence and shut-down sequence; for annunciation of normal
and/or abnormal operation; for taking safety actions; for implementing sequencing,
timing, counting and arithmetic functions of different process of modern industries like
JFCL. Features of PLC are rugged, noise immune equipment, modular plug in
construction, allowing easy replacement or addition of units, Standard input & output
connections and signal levels, Easily understood programming language, Ease of
programming and reprogramming in plant, Capable of communicating with other PLCs,
computers and intelligent devices, Competitive in both cost and space occupied as
compared with relay and solid-state logic systems. If DCS was applied, we would get the
following advantages: The system is speedy & reliable. In case failure of any
microprocessor, part of the process may be out of control , not the whole process. In case
console failure, all field instruments remain alive. It is easy to change the control program
of the process, because program is done
5.1 The Potential areas where the MIS could be applied and effective use of MIS in JFCL
MIS for online monitoring systems will be valuable tools for machine maintenance in
JFCL. These systems will be recognized as a useful means of increasing availability and
reducing operating costs of JFCL. Online monitoring systems will be frequently helped to
fill the gaps that result when cost saving measures lead to personnel downsizing. Early
detection of equipment damage and accurate fault diagnosis will be helped operators to
locate and repair problems fast, thus permitting efficient use of available resources.
Existing monitoring systems are primarily designed for the needs of plants of JFCL,
detecting serious damage well timed to prevent the machine from catastrophic, costly
failures. Thus, new systems concentrate as monitoring the most essential parts and
functions of JFCL to make online monitoring affordable for every compressor, turbine,
pump, equipment and every business unit. A check of limit values can generate three
different status conditions, which can be indicated by the following three colors: Normal
(green), First alarm stage (yellow) and second alarm stage (red). These three colors are
shown in the graphic display to indicate the status in the various machine sections. Since
users are unable to monitor the monitoring system continuously, alarm messages must
be sent automatically by the system if an extraordinary event occurs. Several options for
relaying alarm message are LAN, E-mail, Fax, Pager, Voice message etc. & Control
systems. Design of a modern online monitoring system consists of different areas i.e.
the explosion-proof zone, the switch room and the maintenance office. The
decentralized data acquisition equipment is installed in the hazardous area. The
intrinsically safe sensors (indicator pressure, rod drop) that are installed on the
compressor are connected directly to the data acquisition unit. The measured value data
are transmitted to the interface unit (IU) via the bus line. The IU and server are installed
in the switch room. The server captures the data from the equipment; the PLC and the
control system perform diagnosis of the measured value and then store them. The
server is connected to the company’s internal network (LAN/WAN) and by modem to the
telephone network. This modem enables remote access to the system as well as tale -
maintenance and general support. Because the server is fully integrated into the network,
it can be displayed and operated via computer in the maintenance office. For example-
Compressor conditioning monitoring (CCM) system (Server) can be installed on
compressors both with and without electronic step less control. Cost reduction is
particularly significant here for compressors with these types of controllers because of the
shared hardware platform. Online data analysis and diagnosis and monitoring of piston
rod position signals of compressors. Indicator pressure analysis monitoring piston rod
load is important for safe operation of reciprocating compressors especially when
pressure and load condition vary. Process Data Analysis is done by MIS. So, depending
on configuration of an individual compressor, the following parameters can be included
in the monitoring and diagnostic preferences: suction and discharge pressure, suction
and discharge temperature, discharge capacity, valve nest temperatures, leakage gas flow,
motor power consumption oil and bearing temperature etc. Trend Value Analysis is also
done by MIS. So, Measured values and parameters are stored as trend values thus
providing a standard data basis; we can also set bookmarks in the trend analysis to
document such events as inspections or equipment damage. In JFCL actually IT is not
used, computers are used only for data entry. IT can be used in every business unit of
JFCL. JFCL can use IT for supplier, vendor, and licensor of process, foreign expert,
foreign & local purchase, process optimization, internationalization & HRD.
6.0 Summary Of Main Findings & Achievements
Analyzing Management Information System of Jamuna Fertilizer Company Limited has
been studied existing information flow systems inside and outside of JFCL.
The main findings are summarized below:
1. There are 21 computers for data entry & 18 programmable logic controllers (PLC) to
control plant in JFCL.
2. MIS consists of hardware, software, people, procedures and collection of data through
networking. These components work together to provide information and help managers
run the company, solve problems, and make decisions. JFCL is now under process to
implement networking in each business unit. There is no distributed control system
(DCS) even there is no plan or process to implement DCS in JFCL.
3. In JFCL divide the organization into three decision levels: operations, tactics and
strategy. Here 327 officers’ work for management in these three decision levels.
Among them about 250 officers work in operation level. The operations level consists
of day-to-day operations and decisions. But there is no plan of JFCL to computerize the
operation level. Next tactical decision level involves changes to the company without
altering the overall structure. In JFCL, this type of decision is taken by sectional &
divisional heads. A plan is under process, that all sectional & divisional heads, i.e. about
50 business units will be taken under computer network. Then comes strategic decision.
Strategic decision can alter the entire firm or even the industry. This type of decision can
be taken by chief executive officer of a company. In JFCL, Managing Director can take
strategic decision on behalf of BCIC Board, JFCL Company BOARD and BCIC.
4. In JFCL, data entry works through computer side-by-side type machine have been
running since 2000 in a limited manner. As a result, now, daily productions report,
inspection report, technical minutes, different process data sheet of urea, ammonia &
utility plant are done through computer easily.
5. Computerized MIS has not been implemented in this company, by using computers and
many jobs are done manually
6. JFCL is an enterprise of BCIC has departments of MIS and computers. MIS
department of BCIC collects data, information from BCIC's enterprises & offices. After
compiling this data circulates them to the concern ministries, all enterprises of BCIC, all
directors and the chairman.
7. There is no section named MIS in JFCL. But in JFCL technical services section under
technical division works all kinds of reporting, which is required by BCIC.
6.1 Recommendations
I recommended the following points to implement MIS in JFCL.
1. In such places, where computers are not installed, henceforth, it is needed to introduce
computers in each business unit of JFCL for quality decision.
2. It is needed to connect networking system to provide sufficient budget.
3. JFCL should setup server to connect network in the computer room with LAN and
WAN facilities.
4. It is needed to approve setup for computer system section in order to link network
management, security administration & data base management.
5. It may be connected Internet with computer server of JFCL to BCIC head office's
computer server & abroad in order to communicate information.
6. JFCL authority should design network system of computerization to implement
assigned activities.
7. JFCL should develop computer program for designing computer-networking system.
8. Necessary actions should be taken to implement the whole networking system.
9. Special software can be collected from outside of JFCL and BCIC.
10. JFCL can able to use a training facility, which is organized by BCIC central
computers' department.
11. JFCL should provide the most effective networking infrastructure and logistic
support.
12. The plant can be provided with enough computers for supporting the engineering and
technical personnel for different engineering and technical analyses.
13. The plant can be provided with Internet facilities. It will make procurement competive
through speeding up communication and having access to recent technical literature.
14. The plant shall make an effort to incorporate recent technological changes in respect
of process, plant machinery and control strategy in consultation with consultation with
process licensors, vendors and engineering contractors through MIS.
15. JFCL need to find out what technological changes have been incorporated in similar
plants in neighboring countries built about the same time through MIS.
16. To maximize the utilization of existing workshop facilities, common material bank
can be created by BCIC to make spares and components for JFCL and other plants,
thereby, ensuring speedy maintenance of the plants to interchange information with other
plants of BCIC through MIS.
6.2 Conclusion
A management information system (MIS) is an organized method of providing past,
present, and projected information related to internal operations and external intelligence.
It supports the planning, control and operational function of an organization in the proper
time frame to assist the decision making process. A MIS can provide any organization
with significant information at a minimum cost with a minimum time delay and for
maximum benefit. It can provide the desired information in the proper form, to proper
people and at a proper time. Now, there is no organized MIS to collect data to take better
decision in JFCL. For this reason, the chairman of BCIC advised to the management of
JFCL to implement MIS in this factory within a very short time. Today developed
industrial countries increased the productivity by applying modern MIS. The results of
this study may facilitate in better decision for increasing productivity of the company.
This paper is a guideline of analyzing management information system of Jamuna
Fertilizer Company Limited. Through this study, I have developed some technical
information about management information system to implement in JFCL. MIS helps to
take quality and proper decision timely. The management of JFCL of BCIC should
rapidly implement MIS system to meet global demand by proper, educated and skilled
personnel who have sufficient knowledge of MIS.
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