Quality Control & operations in Silica plant

1. Report on Quality Control,Kaizen & 5SIn Silica PlantPrepared bySUNAM PALRegistration No:10PG (J) 45Under the Guidance ofDr. Prasanna Mohan Raj MIn partial fulfilment of the Course-Industry Internship Programme (IIP) in Term IV of the Master of Business Administration(Batch: Jan. 2010 2012) Bangalore

2. Master of Business Administration: Jan.2010 2012Term IV: Industry Internship Programme (IIP)DeclarationThis is to declare that the Report entitled Quality Control,Kaizen & 5Sin Silica Plant has been made for the partial fulfilment of the Course:Industry Internship Programme (IIP) in Term IV (Batch: Jan. 2010-2012) byme at OCL INDIA LTD under the guidance of Dr. Prasanna Mohan Raj M.I confirm that this Report truly represents my work undertaken as apart of my Industry Internship Programme (IIP). This work is not a replicationof work done previously by any other person. I also confirm that the contentsof the report and the views contained therein have been discussed anddeliberated with the Faculty Guide.Signature of the Student:Name of the Student : SUNAM PALRegistration Number : 10PG (J) 45 3. Master of Business Administration: Jan.2010 2012Term IV: Industry Internship Programme (IIP) Certificate This is to certify that Mr. SUNAM PAL, Regn. No 10PG(J)45 hascompleted the Report entitled Quality Control,Kaizen & 5S in Silica Plantunder my guidance for the partial fulfilment of the Course: IndustryInternship Programme (IIP) in Term IV of the Post Graduate Programme inManagement (Batch: Jan. 2010 2012).Signature of Faculty Guide :Name of the Faculty Guide :Dr. Prasanna Mohan Raj M 4. Master of Business Administration: Jan.2010 2012 Term IV: Industry Internship Programme (IIP) ACKNOWELDGEMENTI am very much thankful to my college for giving me a firm base in statisticaltools/techniques that helped a lot during my project.I would like to thank Mr. R K Jha,Senior General Manager (Production), kOCL INDIA LTD-Refractory Division Division, Bangalore for giving me theopportunity to do my project at OCL INDIA LTD. I would also like toacknowledge his support and prudent guidance during the course of myproject.I would also like to thank Dr. Prasanna Mohan Raj M, Alliance BusinessSchool who as my Faculty Guide has always motivated me to put my best footforward by setting high standards for me.I am thankful to Dr. Madhumita GM ( Area Chair Person in GeneralManagement), whose class has not only given me an idea about quantitaiveability but to make business opertional stratigies in an efficient way.I am also thankful to Ms. Usha Rani (Chief Placement Officer) & ProfShekar V ( Chairperson of IDC) , for giving an opportunity to carry on withsuch industrial learning during the course.I am also thankful to my parents for giving me emmense support &encouragement by sharing their own work experience that led a foundtion totackle corporate challenges.Finally, I thank all the other executives and my fellow trainees who sharedvaluable information and insightsName of the Student: SUNAM PALRegistration Number: 10PG (J) 45 5. Contents1.Executive Summary ....................................................................................................................... 10 1.1 OVERVIEW OF QUALITY CONTROL done in OCL .................................................................. 10 CHAMBER KILN: ........................................................................................................................... 10 EXPANSION PROBABILITY : ........................................................................................................... 10 APPARENT POSROSITY & BULK DENSITY ....................................................................................... 11 EXCEL SHEET SIMULATION ............................................................................................................ 11 1.2 KAIZEN & 5S suggested ...................................................................................................... 11 PICTORIAL LAYOUTS ..................................................................................................................... 112.Introduction.................................................................................................................................. 12 2.1 INDUSTRY OVERVIEW ............................................................................................................. 12 2.1.1 ABOUT OCL .......................................................................................................................... 12 2.1.1.1 CEMENT:........................................................................................................................... 12 2.1.1.2 REFRACTORY..................................................................................................................... 12 2.1.1.3 SPONGE IRON ................................................................................................................... 12 2.1.1.4 IRON & STEEL .................................................................................................................... 13 2.1.2 EXECUTIVES & BORAD MEMBERS ......................................................................................... 13DIRECTORS ............................................................................................................................... 13PRESIDENT ............................................................................................................................... 13 2.1.3 VISION ................................................................................................................................. 13 2.1.4 MISSION .............................................................................................................................. 13 2.1.5 Quality Policy....................................................................................................................... 14 2.1.6 Safety Policy ........................................................................................................................ 14 2.1.7 Certification ......................................................................................................................... 14 2.1.8 AWARDS & RECOGNITION .................................................................................................... 15 2.1.8 Corporate Social Responsibility ............................................................................................ 15EDUCATION .............................................................................................................................. 15DRINKING WATER..................................................................................................................... 16HEALTH .................................................................................................................................... 16GAMES & SPORTS ..................................................................................................................... 17COMMUNITY DVELOPMENT/DONATION/CHARITY .................................................................... 17 2.1.9 Summary of expenses incurred ............................................................................................ 18 2.2 SWOT ANALYSIS ..................................................................................................................... 18 2.2.1 STRENGTH ........................................................................................................................... 18 2.2.2 WEAKNESS .......................................................................................................................... 19 6. 2.2.3 OPPORTUNITY ..................................................................................................................... 19 2.2.4 THREAT ............................................................................................................................... 19 2.3 Company overview ................................................................................................................. 19 2.3.1 ABOUT REFRACTORY............................................................................................................ 19 2.3.2 MILESTONES YEAR WISE....................................................................................................... 20 2.3.3 REFRACTORY CAPACITY ........................................................................................................ 21 2.3.4 GLOBALIZATION................................................................................................................... 21 2.3.5 PRODUCTS ........................................................................................................................... 22 2.3.5.1 Iron & Steel Making .......................................................................................................... 22 2.3.5.1 Non Ferrous ...................................................................................................................... 22 2.3.5.1 Glass ................................................................................................................................. 23 2.3.5.1 Hydrocaron ....................................................................................................................... 23 2.3.5.1 Cement ............................................................................................................................. 23 2.3.6 FEW MAJOR PRODUCTS STUDIED ......................................................................................... 23 2.3.6.1 COKE OVEN ....................................................................................................................... 23 2.3.6.2 BLAST FURNANE STOVE ..................................................................................................... 24 2.3.6.3 GLASS MELTING TANK ....................................................................................................... 24 2.3.6.4 BOF/LD Convertor ............................................................................................................. 25 2.3.6.5 MELTING & HOLDING FURNANCE ...................................................................................... 26 2.3.6.6 LF/VD & VAD .................................................................................................................... 27 2.3.6.7 QSL REACTOR .................................................................................................................... 27 2.3.6.8 REGENERATOR .................................................................................................................. 28 2.4. SILICA PLANT OVERVIEW........................................................................................................ 28 2.4.1 Silica Plant Operational Process Flow ................................................................................... 293.1 PROJECT PROFILE ....................................................................................................................... 31 3.1 Objectives of the Study ........................................................................................................... 31 3.2 Project Type & Tools ............................................................................................................... 31Production Operation Management .................................................................................. 31 3.3 Target..................................................................................................................................... 31 3.4 Sources of data:- ..................................................................................................................... 313.4.1 Primary data: ................................................................................................................... 313.4.2 Secondary data: ............................................................................................................... 32 3.4.3 Sample design:- ................................................................................................................... 32 3.4.4 Sample size:-........................................................................................................................ 32 3.5 Details Of Work ...................................................................................................................... 32Page 5 7. 3.5. 1 Initial Training :- ............................................................................................................. 32 3.5. 2 Office Work :....................................................................................................................... 33 3.5.3 Intial Onsite Work :- ............................................................................................................. 33 3.6 Working Hierarchy Model ....................................................................................................... 33 3.7 Pyramid of Problem Approach ................................................................................................ 343.2 Application to Company ............................................................................................................. 35 3.2.1 Application of quality control: .............................................................................................. 35 INDUSTRIAL APPLICATION:1 ( CHAMBER KILN) .............................................................................. 35 INDUSTRIAL APPLICATION:2 ( CHECKING)...................................................................................... 37 INDUSTRIAL APPLICATION:3 ( PRESS MACHINE) ............................................................................ 38 3.2.1 Application of Kaizen,Safety & 5S: ........................................................................................ 384.1 QUALITY CONTROL ..................................................................................................................... 40 4.1.1Quality control ..................................................................................................................... 40 4.1.2 Total quality control............................................................................................................. 40 4.1.3 Quality control in project management ................................................................................ 404.2 EXPANSION % of bricks ............................................................................................................... 40 4.2.1 METHODOLOGY ................................................................................................................... 40Arithmetic mean (AM) .............................................................................................................. 41 4.2.2 OBSERVATION ..................................................................................................................... 42 BOX PLOT DIAGRAM .................................................................................................................... 43 4.2.3 ANALYSIS ............................................................................................................................. 46 4.2.4 Interpretation ...................................................................................................................... 49 Hozizontal expansion ................................................................................................................... 49 Vertical expansion ........................................................................................................................ 50 4.2.5 OVERALL FINDINGS .............................................................................................................. 50 4.2.5 RECCOMENDATION .............................................................................................................. 51 4.2.5 CONCLUSION ....................................................................................................................... 515.3 PROBABILITY DISTRIBUTION ....................................................................................................... 52 5.3.1 METHODOLOGY ................................................................................................................... 52 NORMAL PROBABILITY DISTRIBUTION .......................................................................................... 52 BINOMIAL PROBABILITY DISTRIBUTION ........................................................................................ 52Probability mass function ......................................................................................................... 53 Mean and variance ....................................................................................................................... 54 Mode and median ........................................................................................................................ 55 Covariance between two binomials .............................................................................................. 55 Page 6 8. 5.3.2 OBSERVATION ..................................................................................................................... 56 5.3.3 ANALYSIS ............................................................................................................................. 58 5.3.4 Interpretation ...................................................................................................................... 60 5.3.5 OVERALL FINDINGS .............................................................................................................. 60 4.2.5 RECCOMENDATION .............................................................................................................. 60 4.2.5 CONCLUSION ....................................................................................................................... 605.3 Apparent Posrosity Versus Bulk Density ...................................................................................... 61 5.3.1 METHODOLOGY ................................................................................................................... 61 5.3.2OBSER VATION ..................................................................................................................... 64 5.3.3 ANALYSIS ............................................................................................................................. 65 5.3.3.1 DERIVATION ..................................................................................................................... 65 5.3.4 Interpretation ...................................................................................................................... 66 Apparent Porosity is inversely related to burnt Bulk Density. ........................................................ 66 5.3.5 FINDINGS............................................................................................................................. 67 4.2.5 RECCOMENDATION .............................................................................................................. 67 4.2.5 CONCLUSION ....................................................................................................................... 684.1 KAIZEN ....................................................................................................................................... 704.2 5S .............................................................................................................................................. 71 4.2.1 Phases of 5S......................................................................................................................... 71 Sorting (Seiri) ............................................................................................................................... 71 Straightening or setting in order / stabilize (Seiton) ....................................................................... 71 Sweeping or shining or cleanliness / systematic cleaning (Seiso) .................................................... 71 Standardizing (Seiketsu) ............................................................................................................... 71 Sustaining the discipline or self-discipline (Shitsuke) ..................................................................... 724.3 Safety ........................................................................................................................................ 724.4 Security ...................................................................................................................................... 724.5 SMALL IMPROVEMENT & SAFETY................................................................................................ 72 5.5.1 METHODOLOGY ................................................................................................................... 72 DRAWING LAYOUT ....................................................................................................................... 73 5.3.2 Observation ......................................................................................................................... 73 5.3.3 ANALYSIS ............................................................................................................................. 74 5.3.4 INTERPRETATION ................................................................................................................. 74 5.3.5 KEY FINDINGS ...................................................................................................................... 75 5.3.6 RECCOMENDATION .............................................................................................................. 75 5.3.7 CONCLUSION ....................................................................................................................... 76 Page 7 9. 6.EXCEL SIMULATION TOOL .............................................................................................................. 78 6.1 Tool-1 ..................................................................................................................................... 78 6. 2 Tool-2 .................................................................................................................................... 79 6.3 Tool-3 ..................................................................................................................................... 80 6.4 Tool-4 ..................................................................................................................................... 81 6.5 Tool-5 ..................................................................................................................................... 82 6.6 Tool-6 ..................................................................................................................................... 827.PICTORIAL RECCOMENDATION ...................................................................................................... 84 7.1 Suggestion 1: .......................................................................................................................... 84 7.2 Suggestion 2: .......................................................................................................................... 84 7.3 Suggestion 3: .......................................................................................................................... 85 7.4 Suggestion 4: .......................................................................................................................... 85 7.5 Suggestion 5: .......................................................................................................................... 86 7.6 Suggestion 6: 7.7 Suggestion 7:........................................................ 86 7.8 Suggestion 8: .......................................................................................................................... 87 7.9 Suggestion 9: .......................................................................................................................... 87 7.10 Suggestion 10: ...................................................................................................................... 88 7.11 Suggestion 11: ...................................................................................................................... 88 7.12 Suggestion 12: ...................................................................................................................... 89 7.13 Suggestion 13: ...................................................................................................................... 898. LEARNING OUTCOME: .................................................................................................................. 90 8.1 QUALITY CONTROL PROJECT: .................................................................................................. 90 8.2 KAIZEN,5S & SAFETY PROJECT ................................................................................................. 90APPENDIX-1 ..................................................................................................................................... 91 PROBABILITY DISTRIBUTION ......................................................................................................... 91APPENDIX-2 ..................................................................................................................................... 92 EXPANSION % LAYER WISE ........................................................................................................... 92APPENDIX-3 ..................................................................................................................................... 93 AP-BD table.................................................................................................................................. 93APPENDIX-4 ..................................................................................................................................... 98 Brick Expansion % Data ................................................................................................................ 98APPENDIX-5 ..................................................................................................................................... 99 Box Plot diagram of Expansion % Data .......................................................................................... 99APPENDIX-6 ................................................................................................................................... 100 Stock Data:................................................................................................................................. 100 Page 8 10. APPENDIX-7 ................................................................................................................................... 101 A7.1 TOTAL ASSETS of OCL ( 2007,2008,2009) ............................................................................. 101 A7.2 DEBT & NET WORTH of OCL ( 2007,2008,2009) .................................................................... 101APPENDIX-8 ................................................................................................................................... 102 A8.1CREDIT RISK ........................................................................................................................ 102 A8.2 TOTAL LIABILILTIES ............................................................................................................. 102APPENDIX-9 ................................................................................................................................... 103 A9.1 TOTAL INCOME................................................................................................................... 103 A9.2 TOTAL EXPENDITURE .......................................................................................................... 103APPENDIX-10 ................................................................................................................................. 104 A10.1 OPERATING PROFIT .......................................................................................................... 104 A10.2 PROFIT AFTER TAX ............................................................................................................ 104GLOSSARY & ABBREVIATION .......................................................................................................... 105BIBLIOGRAPHY............................................................................................................................... 106 Page 9 11. 1.Executive Summary The Project was focused on quality control using various statistical tool/techniques. 1.1 OVERVIEW OF QUALITY CONTROL done in OCLCHAMBER KILN:OCL Silica Refractory has 8 kilns.Eack Kiln has 22 to 28 chambers. Again each chamber has4 benches (A,B,C,D) across length & 5 layers ( Top,4th,Middle,2nd,Bottom) across height.Experiemntally it was found that the bricks size within the same chamber of a kiln differedacross length & height.Position of bricks inside a kiln mattered a lot.So a very microscopicobsevation was done using statistical tools & techniques. For this experiment 2700 raw data ofbricks were taken.It was an assumption that the bricks inside the kiln expanded by 4.2% after firing. So ourmotive was to observe if the assumption was accurate & how the bricks expanded at verymicrossopic level.Following were the findings & observation. Expansion of silica bricks at Macroscopic level at various physical Parameters. Expansion of silica bricks & heat phenemenon at horizontal & vertical direction inside a kiln Expansion of bricks in each benches inside the kiln. Expansion of bricks in each layers inside the kiln.EXPANSION PROBABILITY :Not only bricks expansion was different across different physical parameters but at thesame parameter the probability that the bricks expanded to a defined level varied.Many timesit deviated from its expected size. So probability distribution was done to estimate theoccurence of various sized bricks.Following were the findings & observation. Probability distribution of expansion of bricks to a defined size Probaility of deviation Probability that a particular lot failed to pass.Page 10 12. APPARENT POSROSITY & BULK DENSITYIt is important to know apparent porosity needed for a particular green bulk density.Orders areplaced in terms of maximum apparent posrosity.So it is importnat to know, what should bethe pressure applied by the press machine to maintain a proper bulk density, keeping in mindthe expansion factor & moisture loss due to which density reduces.Following were the findings & observation. Relation between AP & Burnt BD Relation between AP & Green BD Relation between Burnt BD & Green BDEXCEL SHEET SIMULATIONIt has been developed to make observation user friendly and flexible in case of anychange of situation and it will be of immense help to our company.1.2 KAIZEN & 5S suggested Small stratigic improvement & safety is an important concern for any company. IMPROVEMENT Following were the findings & observation. Designing layouts of plant,roads & machinery What Operational startigies can be implemented Safety precautions Optimization of paths & tracks Housekeeping Prioritizing the task Kiln operation SAFETY Following were the findings & observation. Trolley safety Mixer Bucket pulling Chair Car safety Road safety Plant Safety Disaster ManagementPICTORIAL LAYOUTSIt has been developed to make observation user friendly to lay man for whomunderstanding technical terms becomes difficult Page 11 13. 2.Introduction2.1 INDUSTRY OVERVIEW OCL INDIA LTDOCLRefractor Cement Spongeyryct Iron2.1.1 ABOUT OCLOCL INDIA LIMITED, formerly "Orissa Cement Limited" and better known as "OCL",2.1.1.1 CEMENT:Itwas established in the year 1949, which started producing Cement through wetprocess technology under the brand name of "Konark". Keeping a steady progress withtime and technology it has modernized to fully automated dry process plant in 1988. OCLcommands the position of market leadership in the state of Orissa since its inception andtoday it is the premier lead brand in the state of Orissa. Konark brand cement enjoysbrand advantage in the region. It is a name cemented to Quality.2.1.1.2 REFRACTORYOCL diversified from Cement to the field of Refractories in 1954. Over the years, it hasbecome one of the largest and well-equipped state of the art Refractory plant in Indiacovering a wide range of products for use in the Ferrous & the non-ferrous Industries. Itscustomer base spreads from iron and steel to cement, aluminum, glass, copper, chemicalsand hydrocarbon industries. Today, OCL enjoys a huge market share in India and overseasextending to five continents across the globe.2.1.1.3 SPONGE IRONDuring the year 2001-02 OCL diversified its activities into Sponge Iron and now forayedfurther into Steel making. In line with this vision, the Company has already installed aCaptive Power plant and is going to commission 0.25 million tons steel billet plant.Page 12 14. 2.1.1.4 IRON & STEELOCL, as per scheme of arrangement approved by the honourable High Court of Orissademerged its Steel undertaking and Real Estate undertaking by transferring the assetsand liabilities as on 1st January 2007 into OCL Iron and Steel Ltd. andLandmark Property Development Company Ltd(formerly Konark Minerals Ltd.)respectively. The scheme of arrangement also involved merger of the business of Dalmia Cement(Meghalaya) Limited, a wholly owned subsidiary of Dalmia Cement (Bharat) Ltd, as on 1stJuly 2007 with the approval of the honourable Court of Guwahati. OCL is a globally focussed organization with presence in key areas of infrastructure development. With its range of product and strong R & D orientation it enjoys a strong customer and brand loyalty.2.2 Refractory Overview2.1.2 EXECUTIVES & BORAD MEMBERSDIRECTORS Shri Pradip Kumar Khaitan (Chairman) Shri V.D. Jhunjhunwala Shri D.N. Davar Shri Puneet Dalmia Dr. Ramesh C. Vaish Dr. S.R. Jain Shri V.P. Sood (Whole time Director & CEO)PRESIDENT ;Shri M.H. Dalmia2.1.3 VISION Grow profitably with commitment to customer satisfaction Strive for excellence Be in chosen areas Continuously develop a committed team of people Build good corporate image & high customer esteem Endeavour to serve society2.1.4 MISSION OCL is in the business of Cement and Refractories. These will continue to be our prime business focus areas We shall strive to improve our image in the eyes of all stakeholders - present and potential We shall endeavour to build a vibrant and responsive organization with a team of motivated people driving for excellence, achievement and high performance We will create conditions and climate for empowerment through enhancement of Knowledge, Attitudes and Skills with emphasis on multiskillingPage 13 15. 2.1.5 Quality PolicyOCL, believes and aim at Total Quality in their products and services to satisfy Customers,and are committed to: Adhere strictly to quality parameters at all stages to provide products / services conforming to customer requirements Meet Requirements of Quality management System and strive to continually improve its effectiveness Develop competent human resource through planned training Establish Quality Objectives and review periodically to achieve continual improvement2.1.6 Safety PolicyOCL INDIA LIMITED considers all its employees as primary asset and attaches utmostimportance to their safety and health. To promote safety & health in all its factories andmines, the company makes all possible efforts and will continue to do so by which safetyand health of all its employees will be ensured. TThey are committed to: Consider eliminating safety and health hazard while planning, designing andadopting any process or system Select and deploy plant machinery which are safe and free of hazardMaintain and upgrade the facilities and operations to ensure safety on continuousbasis Provide the knowledge & necessary skills to employees, contractors & other agencythrough planned training & awareness programs Periodically review safety & health performance to achieve continualimprovements thereon Implement & abide by all statutory rules & regulations Make available adequate resource for promotion of safety and health Review the policy periodically and revise as necessary2.1.7 Certification ISO 9001:2008 ( Quality Management System) ISO 14001:2004 ( Environment ) ISO 18001:2007 ( Occupational Health and Safety Assement Series) Page 14 16. 2.1.8 AWARDS & RECOGNITION In 2007-08 the Quality circle UTPADAN of Cement Division bagged Silver Medal Award in International convention of Quality circle held in BEIJING, CHINA. The Quality Circle ANVESHAN of Cement Division was awarded Par Excellent Presentation Award in CCQC held at Rourkela Achieved Excellent Award in National convention of Quality Circle held in Kolkata for their case study presentation during the year 2007-08. In 2007-08 one of the Companys Quality Circles KAMYAB bagged award of Golden Trophy and Gold medal in International Chapter Quality Circle (ICQC) held at Indonesia. Quality circle Nirjharani was recognized as par excellence and other two QC teams UTPADAN and TALASH were recognized as EXCELLENT in National Chapter Quality Circle(NCQC) at Kanpur. Engineering personnel won 3 prizes in National Supervisory competition organized by IIPM, Khansbahal.2.1.8 Corporate Social ResponsibilityIn its 57 years of untiring service to Nation, OCL has always given priority to communitydevelopment. In its endeavor to uplift the conditions of poor and hapless tribals of thislocality, OCL has undertaken various developmental activities in peripheral areas ofRajgangpur and Lanjiberna. The activities are mainly focused on areas like Health,Education, Drinking Water, Games and Sports etc. Some of the major activities undertakenduring last three years are given below : EDUCATION Constructed one big hall and made drinking watersupply arrangement in Gopabandhu High School,Rajgangpur Constructed boundary wall of Primary School in villageKunmuru Constructed boundary wall and an additional room inJampali High School Continuing Literacy programs in different villages Renovated school building of Bastia M E School, I TColony, Rajgangpur Donated Rs. 1,00,000/- to Saraswati Sishu Mandir forconstruction of school building in Rajgangpur Repaired school building in Saliameta and Kheramuta,Lanjiberna Repaired roof of Nodal U P School in Lanjiberna Page 15 17. Renovated the school building of Municipal Gandhi GirlsHigh School, Rajgangpur Constructed three new rooms and supplied desk andbench for students in M E School, Teleimunda Renovated the school building of Santa Devi HighSchool, Khatang Made drinking water supply arrangement in LanjibernaShramik High School, Lanjiberna Repaired the school play ground in Ramabahal Making payment of salary to four adhoc teachers inLanjiberna Shramik High School, LanjibernaDRINKING WATER Sunk 44 Tube wells in Rajgangpur, Lanjiberna and itssurrounding villages Repaired 7 Tube wells in Lanjiberna Supplying water to five villages in Lanjiberna forirrigation Arranged drinking water supply system in the premisesof Bar Association, Rajgangpur Donated Rs.17,000/- on behalf of villagers of Khatang toVillage Water and Sanitation Committee for arrangingdrinking water facility under Sajal Dhara Scheme ofGovt. of Orissa Donated Rs.50,000/- on behalf of villagers of Dharuda(Kukuda GP) to Village Water and Sanitation Committeefor arranging drinking water facility under Sajal DharaScheme of Govt. of OrissaHEALTH Providing medical facilities including supply of medicineto villagers in Lanjiberna from OCL Dispensary Providing ambulance for shifting serious patients tonearby hospitals in Rajgangpur and Lanjiberna Operating charitable homoeopathic dispensary inRajgangpur and Lanjiberna Carried out renovation work in RGP. Govt. Hospital,planted neem trees, arranged water supply system,constructed additional toilets etc. Provided financial assistance to Bharatiya Jana SevaSansthan, New Delhi for running a charitable dispensaryat Sonakhan Operating mobile health unit (homeopathic) in differentvillages in Rajgangpur and LanjibernaPage 16 18. Operating one mobile health unit (allopathic) for seniorcitizens through Help Age-India in different villages ofJagatsinghpur Organised health check-up camp for villagers inLanjiberna Organised Eye, E & T and Dental Camp in Rajgangpur Organised awareness program on Maleria, Dengu andChikungunia and distributed 300 mosquito nets tovillagers in LanjibernaGAMES & SPORTS Conducted Inter-village Dalmia Cup Football and Hockey Tournament Providing games materials like football, volley ball, hockey sticks etc to villagersCOMMUNITYDVELOPMENT/DONATION/CHARITY Operating SWAYAMPRABHA, a tailoring centre forproviding training to poor women and providing swingmachine free of cost in Lanjiberna Provided electricity in two villages i.e, BihabandhaRehabilitated Colony and Tungritoli in Lanjiberna Provided financial assistance to Bharatiya Jana SevaSansthan, New Delhi for implementing Gram ManglaYogna in 50 villages in Rajgangpur & Lanjiberna Distributed 500 blankets to old and poor people inRajgangpur and Lanjiberna Donated Rs. 19,00,000/- to District PeripheralDevelopment Committee for undertaking variousdevelopmental activities in the District Donated Rs. 3,50,000/- to HOPE for construction ofschool building for mentally retarded children inRajgangpur Donated Rs. 31,00,000/- for construction of CommunityKalyan Mandap in RajgangpurPage 17 19. 2.1.9 Summary of expenses incurredUnder different heads during 2004-05 and 2005-06 aregiven below : AREA 2004-05 2005-06 2007-08 EDUCATIONRS. 7,60,320.00RS. 7,60,320.00RS. 9,90,347.00 DRINKING WATER RS. 11,51,509.00 RS. 8,95,309.00RS. 1,69,301.00 HEALTH RS. 6,35,000.00RS. 13,52,984.00 RS. 15,76,002.00 GAMES & SPORTS RS. 20,845.00RS. 54,000.00RS. 76,760.00 CHARITY & DONATIONSRS. 13,58,537.00 RS. 46,15,540.00 RS. 11,81,725.00TOTAL RS. 39,26,211.00 RS. 73,80,325.00 RS. 39,94,135.00Besides, OCL has also donated generously to Prime Ministers and Chief Ministers ReliefFund when natural calamities like cyclone, flood etc struck the Nation.OCL pledges to continue its endeavor in the above direction more vigorously in future.2.2 SWOT ANALYSIS2.2.1 STRENGTH OCL cement factory produces its brand Konark cement which has exceeded so much of its order that, today this factory has more order than what actually it can produce. Customers are having more demand than its capacity.Demand > Supply. OCL Refractory produces the best quality products all over Asia. On the basis ofquality rating its Ranked 1 and there is no company which can bid OCL in easternworld. Rapid industrialization at Jharsuguda ( 55 Km) from OCL and other industrialplaces likeJamashedpur,Rourkela,bilaspur,durg,Raipur,Raigarh,Durgapur,Bokaro bycompanies like RSP,L&T,VEDANTA,Bhusan Steel,MCL,Birlacement,Jindal,Tata will create more demands. Page 18 20. 2.2.2 WEAKNESS Though the quality of refractory products is good, the cost of product is very high. Though other companies have managed to reduce the overall price but OCL refractory has not shown much interest on it OCL sponge iron has not been very contributing and needs to improve its quality.2.2.3 OPPORTUNITY VEDANTA, OCL, Rourkela Steel plant are in a continuous process of recycling the products. The by-product of one company is a raw material for other company. Profit and turnover has increased over period of time. Orders have increased to such extent that OCL cement factory is coming up with a new plant as cement factory line- 2, that will enhance the productivity of company and meet its emerging customers. Refractorys high quality bricks & silica will be the major point of target to countries like Japan, Korea as they are in scarce of this product. Moreover its competitor in Germany, is far distant from Japan than India which reduces the transportation cost of good from India to Japan rather than Germany to Japan.2.2.4 THREAT The Refractory companies of china are coming up with same products at very cheaper rates. Their product is more subjective to alteration. Refractory at Belpahar of TATA industries is located very near to it which is more automated than OCLs manual production. Its competitors in Germany also targets the same type of market , controlling half of the globe like Europe,Africa,America thus creating hindrance to OCL to go for globalization in western countries.2.3 Company overview2.3.1 ABOUT REFRACTORYOCL diversified from Cement to the field of Refractories in 1954. Over the years, it hasbecome one of the largest and state of the art Refractory plants in India with an annualcapacity of 80,000 Mt, covering a wide range of products for use in the ferrous & the non-ferrous Industries. Page 19 21. The initial technical know how came from M/S Dr.C.Otto of Germany for Coke Oven Silicabricks and from M/S TYK Corporation of Japan for Magnesia-Carbon, Alumina-Mag-Carbon,Alumina-Silicon Carbide-Carbon, Concast Refractories, Lance-pipe, Precast, Purging Plug, &BF Runner castables. All the other products were developed in-house. To keep pace withever-growing expectation of customers for quality Refractories, our highly experienced &well-equipped technology & research teams upgrade these on a continuous basis. Withintensive R&D efforts, OCL has registered a number of patents to its credit.OCL happens to be the first Refractory Company in India to be certified under ISO 9001, byRWTUV of Germany in 1994, now updated to 2000 version for all range of its products.OCL is a globally focussed organization with a large range of product and strong R & Dorientation towards its customer both in product and in services. It has a long-term visionto emerge as a globally accepted refractory solution provider.2.3.2 MILESTONES YEAR WISE YEAR MILESTONES 1949 Established as Orissa Cement Limited 1954 Diversified into refractories 1956 Commissioning of firebricks plant 1958 Commissioning of silica plant 1959 Commissioning of burnt basic brick plant 1962 Manufacture of chemically bonded basic bricks 1963 Manufacture of coke oven silica 1972 Expansion of silica plant 1986 Manufacture of MG-C brick 1986 Manufacture of slide plate 1992 Commissioning of concast plant 1992 Commissioning of castable & precast plant 1992 Export of silica bricks 1994 ISO 9001 certification 1997 Further expansion of silica plant 1999 Manufacture of directional purging element 2000 Modernisation of concast plant 2001 Modernisation of castable & precast plant 2004 Further modernisation of concast started 2005 Modernisation of concast plant in process Page 20 22. 2.3.3 REFRACTORY CAPACITY PRODUCTION CAPACITYSILICA BRICKS30,000 MT / YRBASIC BURNT BRICKS 22,000 MT / YRMAGNESIA CARBON BRICKS 8,000MT / YRFIRECLAY & HIGH ALUMINA BRICKS 25,000 MT / YRCONTINUOUS CASTING 2,000MT / YRSLIDE GATE REFRACTORIES2,000CASTABLES & PRECAST BLOCKS 11,000 MT / YRBASIC, SILICA & HIGH ALUMINA 6,400MT / YRRAMMING MASSES / MORTARS TOTAL 106,400MT / YR2.3.4 GLOBALIZATIONOCL is among the market leaders & undisputedly, one of the best in world in the segment ofSilica bricks for Coke ovens & Blast Furnace stoves having extraordinary supply referencesall through the globe. With aggressive thrust on the exports of special Refractories likeContinuos casting, Slide plates & Purging Refractories for the Steel Sector, Direct bondedMag-Chrome bricks for the Copper and Fireclay & High Alumina bricks for the AluminumIndustries, it enjoys clientele of reputed overseas customers.OCL is reckoned to be in the big league of reputed refractory suppliers in the world market.OCL refractories has been used in the largest Steel plants & other non-ferrous plants inCanada, USA, Brazil, UK, Sweden, Netherlands, Hungary, Spain, Italy, Turkey, Japan,South Korea, China, Thailand, Malaysia, Indonesia, Australia, Egypt, Kenya, SouthAfrica, Saudi Arabia, Jordan, Qatar, Iran, UAE, Kuwait, Pakistan, Bangladesh, SriLanka & many more. Page 21 23. 2.3.5 PRODUCTSOCL refractory has various products mainly classified in to 5 categories PRODUCT CATEGORYIRON &NONGLASS HYDROCA CEMENTSTEEL FERROUS RBONMAKING2.3.5.1 Iron & Steel Making Coke Oven Sponge/DRI Blast Furnance Hot Metal Transport Hot Metal Mixer Ladles BOF/LD Convertor Electric Arc Convertor Slide Gate Category2.3.5.1 Non Ferrous Aluminiumo Anode Baking Furnanceo Melting & Holding Furnance Copper Industrieso Flash Smeltoro ISA Smeltoro Flash Convertoro Noranda Reactoro Reverberatory Furnanceo Top Blown Roatary convertoro RS Convertoro TEINITE Convertoro Slag Cleaning Furnanceo Anode ConverterPage 22 24. NICKEL,ZINC & LEAD o Lead Roatart Furnance o QSL Reactor o KIVCET Proces2.3.5.1 Glass Glass melting tank Glass regenerator2.3.5.1 Hydrocaron2.3.5.1 Cement2.3.6 FEW MAJOR PRODUCTS STUDIED2.3.6.1 COKE OVENOCL through its initial know-how from Dr. C. OTTO and subsequent intensive R&D effortshas established itself as a leading silica coke oven manufacturer in the world. With itsinstalled capacity of 30000Tons/year OCL has to its credit an impressive list of supplyreferences for Coke Oven, both in domestic and overseas markets. With its wide experienceOCL can supply silica refractories to all international specifications such as DIN, JIS, BS, NSCand also all international designs.The special features of OCL silica bricks for Coke Oven are : Low residual quartz Low creep Consistent thermal expansion characteristics High hot strength Low statistical variation in property data ensured by quality assurance system High dimensional accuracy enabling accurate and fast construction.Page 23 25. 2.3.6.2 BLAST FURNANE STOVEWith its initial experience in manufacturing silica bricks for coke oven, OCL developedworld class silica bricks for heavy duty Blast Furnace Stoves. Winning the confidence ofworld known stove designers like DCE, DME, Siemen-VAI, NSC. OCL has supplied silica, fireclay and high alumina refractories for a number of projects worldwide.OCL India has experience of over four decades for the manufacture of High DutySilica bricks having very low flux factor & residual quartz.OCL has received wideappreciation from overseas customers for timely delivery, god packing and dimensionalaccuracy of the product.2.3.6.3 GLASS MELTING TANKGlass melting furnaces, particularly of high pulling rate, are lined with various high qualityrefractories.Most glass manufacturers have been preferring super duty Silica Bricks for thecrown because crown constructed with Super Duty Silica Bricks can be insulated, resultingin saving of 10-12% input energy.The advantage of Super Duty Silica bricks overconventional quality is due to its low Alumina, Titania & Alkali content, its high P.C.E. value,high resistance to penetration of Alkali vapour encountered during furnace operation &volume stability at furnace operating temperature.OCL India has experience of over four decades for the manufacture of High Duty Silicabricks having very low flux factor & residual quartz.These bricks are having very highrefractoriness under load & shows excellent volume stability at service temperature.OCLs Silica insulating bricks have very low thermal conductivity which results in excellentthermal insulation.Page 24 26. 2.3.6.4 BOF/LD ConvertorNew LiningDifferent quality Magnesia carbon bricks with improved carbon bonding and having specialcharacteristics as regard to corrosion resistance, erosion resistance, oxidation resistanceand thermal shock resistance are used in different zones for balanced/ uniform erosion andcost effective lining.MaintenanceTailor made gunning material and hot patching mass is applied for prevention as well asrepair maintenance of BOFs. The characteristics of these materials are-- Gunning Mass Easy steakability with low rebound loss and high corrosion and erosion resistance Hot patching Mass High flowability, steakability, corrosion and erosion resistance Tap Hole Sleeve Assembly Characterised by excellent corrosion, abrasion and thermal shock resistance Available in single piece made by CIP and also in segmented assembled form Produce different designs of Tap hole sleeve assembly as per customersrequirement Tap Hole Fixing Mass Magnesia ramming mass is applied in between Tap hole block and tap hole sleeves by very high purity gunning material having high bonding strength. Our products OC tap ram M95 and OC Tap Ram M95S are specially designed for this purposePage 25 27. 2.3.6.5 MELTING & HOLDING FURNANCEPRECAST SHAPESThese are tailor-made to different shapes and sizes manufactured as per specific customerrequirement.BURNER BLOCKS (EXCELCAST 70 D)High thermal spalling resistance, corrosion and abrasion resistance and volume stability atthe operating temperature.FLOORING BLOCKS (EXCELCAST 45 A)Precast flooring blocks in variety of sizes and thickness to withstand impact and abuse ofdross handling pots and equipment.Special features Superior mechanical strength to withstand the load of heavy machinery and equipment movement over it. Resistant to liquid Aluminum penetration.MONOBLOCK FOR FLUEWALL TOP (EXCELCAST 45N)Superior thermal spalling resistance and high degree of volume stability. Resistant to COdisintegration.CASTABLES Castables are manufactured for varied application in casthouse, holding furnace door and roof etc. Page 26 28. 2.3.6.6 LF/VD & VADZone and Bottom varies with different operating conditions such as LRF, VD and VAD.Magnesia carbon bricks with improved carbon bonding and special characteristics like low cokedporosity, high coked CCS, excellent corrosion, erosion, thermal shock and oxidation resistanceand high hot strength have been developed and given for different zones depending onoperational severity and cost effectiveness.Alumina magnesia carbon bricks having controlled residual expansion are recommended for theMZ and bottom of ladle furnaces to prevent joint erosion and metal penetration. Specially forimpact resistance in striker pad area AMC-3 bricks are preferred.2.3.6.7 QSL REACTORThis is a cylindrical horizontal oxygen reactor where bullion is produced from leadconcentrate. This is a special type of reactor which is characterised by extremely shortmixing time, high turbulence, short reaction time but very high resistance time.Wet or air dry pellets of concentrated flux and flue dust are fed to reactor and drop in to aheterogeneous mixture of molten lead, slag, PbO & charge material where oxygen is blownto form SO2, sulphate content flue dust and PbO and carbothermal reduction of lead oxideslag by means of coal dust.OCLs direct bonded bricks have excellent resistance to PbO containing slag and SO2.Page 27 29. 2.3.6.8 REGENERATOROCL India has series of products for regenerator in Basic & high Alumina quality. In recentyears, Mag-zir quality is added to its range of product. Mag-zir quality chimney blocks intop course of regenerator shows superior resistance to Silica carry over attack & V2O5attack as the matrix is completely converted to forsterite and enriched with tiny Zirconiagrains. In the middle course of regenerator Mag-zir shows superior resistance to Alkalies,Sulphate attack & deposition as the Magnesite grains are enveloped with tiny Zirconiagrains.2.4. SILICA PLANT OVERVIEWSilica has 3 palnts Silica-1 Silica-2 Silica-3 Page 28 30. 2.4.1 Silica Plant Operational Process FlowContinued ............Next PagePage 29 31. Page 30 32. 3.1 PROJECT PROFILE3.1 Objectives of the Study 1) Quality Control in chamber kiln. 2) Kaizan,5S & Safety plan inside the the silica plant3.2 Project Type & Tools Production Operation Management Statistical Tools:o Regression analysiso Correlationo Probability Distributiono Binomial Probability Distributiono Normal Probability Distributiono Central Tendencies: Mean,Median,Mode,Quartileso Skewness,Kurtosis,Standard Deviation, Varianceo Ranges, Outliers & box plot diagrams Concepts Appliedo Density & weight relationshipo Heat phenomenono Volumetric Expansion of bricks3.3 Target 1. Studying Expansion of bricks 2. Probability distribution of bricks 3. Deriving relationship between porosity & bulk density 4. Kaizen a. Desigining Layouts b. Suggesting techniques c. Safety techniques d. Possible improvement within company3.4 Sources of data:-3.4.1 Primary data: The main source of primary data was recorded from Observing few samples alone Attending checking department while checking Deriving relations scientifically to generate data from given above collected dataPage 31 33. 3.4.2 Secondary data: The main source of secondary data was recorded from Companys Resorce allocation book Companys Monthly bricks Checking records Slica Brick Failure record Bricks dimension layout bulletin Mould house specifications Laboratory checking results Advise of experienced & experts3.4.3 Sample design:- The sample design used for the purpose of the research was randomly taken such that it covered all the kilns, chambers type, bench & layer type. The sample were taken based on different days & different point of time3.4.4 Sample size:- For target:1, 2700 data were taken For target:2, 2700 data were taken For target:3, 200 data were taken3.5 Details Of Work3.5. 1 Initial Training :- During first week of our internship we went through training in OCL INDIA LTD regarding operation flow & how silica plant functions .In those period we did following thing At first , We went through the PPT of OCL INDIA LTD which contained some product information and overview of plant. We anailzed companys website carefully After that they gave us brief introduction about their company,plant,machinery,safety measures to be taken and told us some consequence regarding their current operation . They also shared their some experience with us . They told us that safety is the main motive and suggested us some tips that how would can be safe Page 32 34. 3.5. 2 Office Work :We had to report twice in office regarding our work , then we had a discussion with OCLs manager .They try to guide us in perfect manner so whatever mistake we have done so far that will not be committed again and how can we sharply develop ourselves for future .We had to give them regular updates related to our work.3.5.3 Intial Onsite Work :- We had to start in morning around 8 A.M. , then for a particular day we had to chooseparticular area (example kiln),then we have to cover there every block to knowopertations At first, We had to meet with the person incharge of that operational zone , then we had tointroduce ourselves & what was our purpose of visting. After that, we had to meet with manager,executives & workers to undersand theoperations better. They gave us only information about company . Sometimes as i predict they couldnt givethe right answer to our query Sometime we used to get appointment with opertational managers/executiuvemanager/ to dicuss on any particulr topic. Company which have tied up with ICICI & Syndicate bank , they are not so satisfied, so inthat case they want to meet with manager for further discussion of opening a current orsalary A/C .3.6 Working Hierarchy Model HumanResource Senior GeneralManagerChiefDeputy Manager ManagerInternshipEngineeringManagement Project vocational TraineeTraineeTraineeTraineeTrainee Page 33 35. 3.7 Pyramid of Problem ApproachIt shows how a client is approached & finally the deal is made in 7 stages.prepare report Excel simulation/pictorial diagramsDeriveconclusion,recommendations Observe & analize the results obtainedApply statistical tools &techniquescompare both the data & check if they matchCollect primary & secondary data Design the plan & methods Know the problem statementPage 34 36. 3.2 Application to Company3.2.1 Application of quality control:INDUSTRIAL APPLICATION:1 ( CHAMBER KILN)Refractory has three types of kilnKILN TUNNEL CHAMBERBELL In this klin the Heat is In this klin the Heat isIn this klin the bricks constant & Bricksrotates & Bricks areare static & the kiln move inside the kiln.static the kiln.itself movable. Specifically we did observation for chamber kiln.KILN CHAMBERFB 1 to 24Kiln-1 1 to 24Kiln-2 1 to 24Kiln-3 1 to 22Kiln-4 1 to 26Kiln-5 1 to 28Kiln-6 1 to 28 Kiln-2A 1 to 28Page 35 37. CHAMBER KILN CHAMBERSOCL Silica Refractory has 8 kilns.Eack Kiln has 22 to 28 chambers. Again each chamber has4 benches (A,B,C,D) across length & 5 layers ( Top,4th,Middle,2nd,Bottom) across height.Experiemntally it was found that the bricks size within the same chamber of a kiln differedacross length & height.Position of bricks inside a kiln mattered a lot.So a very microscopicobsevation was done using statistical tools & techniques. For this experiment 2700 raw data ofbricks were taken.It was an assumption that the bricks inside the kiln expanded by 4.2% after firing. So our motivewas to observe if the assumption was accurate & how the bricks expanded at very microssopiclevel.Following were the findings & observation. Expansion of silica bricks at Macroscopic level at various physical Parameters. Expansion of silica bricks & heat phenemenon at horizontal & vertical direction inside a kiln Expansion of bricks in each benches inside the kiln. Expansion of bricks in each layers inside the kiln.Page 36 38. CHAMBER LAYOUTTOP layer4th layer Middle layer2nd layer Bottomlayer BENCH-A BENCH-BBENCH-CBENCH-D To check whether Expansion % mean is 4.2 How the expansion differs over benches & Layers.INDUSTRIAL APPLICATION:2 ( CHECKING)CHECKING PHYSICAL LABORATORY To know probabilty of failure Probability of brick size deviating Probability disribution of occurence of bricks with defined size Occurence of a particular type out of whole set Page 37 39. INDUSTRIAL APPLICATION:3 ( PRESS MACHINE) Apprarnt Posrosity Bulk DensityDensity = Weight / VolumeVolume reduces increases in Kiln reducing the Bulk Density Weight is lost reducing the Bulk DensityIn PRESS MACHINE It is a very complicated process to detect apparent porosity needed fora particular green bulk density.Orders are placed in terms of maximum apparentposrosity.So its an importnat that what should be the pressure applied by the pressmachine to maintain a proper bulk density, keeping in mind the expansion factor &moisture loss, due to which density reduces. To Know relation between AP & BD To know what BD should be maintained for the ordered AP How BD depends on Expansion % of bricks.3.2.1 Application of Kaizen,Safety & 5S: To maintain proper house keeping Proper synergy in factory Improved quality & efficiency Maintain Discipine Advantage at the time of inspection Give a better feel inside the comapny Page 38 40. QUALITYCONTROLPage 39 41. 4.1 QUALITY CONTROL4.1.1Quality controlIt is a process by which entities review the quality of all factors involved in production. Thisapproach places an emphasis on three aspects: 1. Elements such as controls, job management, defined and well managedprocesses, performance and integrity criteria, and identification of records 2. Competence, such as knowledge, skills, experience, and qualifications 3. Soft elements, such as personnel integrity, confidence, organizational culture,motivation, team spirit, and quality relationships.The quality of the outputs is at risk if any of these three aspects is deficient in any way.Quality control emphasizes testing of products to uncover defects, and reporting tomanagement who make the decision to allow or deny the release, whereas qualityassurance attempts to improve and stabilize production, and associated processes, toavoid, or at least minimize, issues that led to the defects in the first place4.1.2 Total quality control"Total quality control" is a measure used in cases where, despite statistical quality controltechniques or quality improvements implemented, sales decrease. If the originalspecification does not reflect the correct quality requirements, quality cannot be inspectedor manufactured into the product. For instance, the parameters for a pressure vesselshould include not only the material and dimensions, but also operating, environmental,safety, reliability and maintainability requirements.4.1.3 Quality control in project managementIn project management, quality control requires the project manager and the project teamto inspect the accomplished work to ensure that its aligned with the project scope. Inpractice, projects typically have a dedicated quality control team which focuses on thisarea.4.2 EXPANSION % of bricks4.2.1 METHODOLOGY Collecting 2700 raw datas from kiln Finding Central Tendencies Mean,Mode,Median,Quartiles Calculating Standard deviation,Variance,Skewness Calculating Range,Outliers,IQR Making Box plot Diagram. Comparative Analysis Graphical Analysis Page 40 42. Arithmetic mean (AM)Main article: Arithmetic meanThe arithmetic mean is the "standard" average, often simply called the "mean".Quartile: first quartile (designated Q1) = lower quartile = cuts off lowest 25% of data = 25th percentile second quartile (designated Q2) = median = cuts data set in half = 50th percentile third quartile (designated Q3) = upper quartile = cuts off highest 25% of data, or lowest 75% = 75th percentileThe difference between the upper and lower quartiles is called the inter quartile range.There is no universal agreement on choosing the quartile values.The formula for locating the position of the observation at a given percentile, y, with n datapoints sorted in ascending order is: Case 1: If L is a whole number, then the value will be found halfway between positions L and L+1. Case 2: If L is a decimal, round to the nearest whole number. (for example, L = 1.2 becomes 1).VarianceIf a random variable X has the expected value (mean) = E[X], then the variance of X isgiven by:BOX PLOTBox and whisker plots are uniform in their use of the box: the bottom and top of the box arealways the 25th and 75th percentile (the lower and upper quartiles, respectively), and theband near the middle of the box is always the 50th percentile (the median). But the ends ofthe whiskers can represent several possible alternative values, among them: Page 41 43. the minimum and maximum of all the data the lowest datum still within 1.5 IQR of the lower quartile, and the highest datumstill within 1.5 IQR of the upper quartile one standard deviation above and below the mean of the data the 9th percentile and the 91st percentile the 2nd percentile and the 98th percentile4.2.2 OBSERVATIONAGGREGATE of ALL BENCHESBENCH-A 4.165504359Mean4.1271941Standard Error 0.005251262Standard Error0.0127295Median4.2 Median 4.2Mode4 Mode 4Standard Deviation 0.257740157Standard Deviation0.3620653Sample Variance0.066429988Sample Variance 0.1310913Kurtosis -0.36200066Kurtosis2.0335368Skewness 0.063940314Skewness -1.1046595Range 1.3 Range2.1Minimum 3.6 Minimum2.8Maximum 4.9 Maximum4.9Sum 10034.7 Sum 3338.9Count 2409Count 809Largest(1)4.9 Largest(1) 4.9Smallest(1) 3.6 Smallest(1)2.8 ConfidenceConfidence 0.010297460.0249869Level(95.0%)Level(95.0%)Q1MeanQ14Q24.2 Q24.2Q34.3 Q34.4 % distribution % distributionabove 4.250%above 4.250%Below 4.250%Below 4.250%b/w 3.55 to 425%b/w 3.6 to 4 25%b/w 4 to 4.2 25%b/w 4 to 4.2 25%b/w 4.2 to 4.3 25%b/w 4.2 to 4.4 25%b/w 4.3 to 4.7525%b/w 4.4 to 5 25%IQR0.3IQR 0.4Upper 4.75Upper 5Lower 3.55Lower 3.6Page 42 44. BOX PLOT DIAGRAMAGGREGATE BENCH-AMax Val 5Upper 5 Upper Max Val 4.75 4.9Q34.3Q34.4Q24.2Q24.2Q14Q14 LowerLower 3.553.6Min ValMin Val1.7 2.8 Page 43 45. BENCH-CBENCH-DMean 4.124333 Mean 4.1451852Standard Error 0.012193 Standard Error 0.0096234Median4.2 Median4.2Mode4 Mode4Standard Deviation 0.365803 Standard Deviation 0.2738866Sample Variance0.133812 Sample Variance0.0750139Kurtosis 13.36301 Kurtosis 6.0016874Skewness -2.13153 Skewness -0.94433Range 3.2 Range 2.8Minimum 1.7 Minimum 2.2Maximum 4.9 Maximum 5Sum3711.9 Sum3357.6Count 900 Count 810Largest(1)4.9 Largest(1)5Smallest(1) 1.7 Smallest(1) 2.2Confidence Confidence 0.0239310.0188898 Level(95.0%) Level(95.0%)Q14 Q1 0.3164508Q24.2 Q24.2Q34.3 Q34.3% distribution% distributionabove 4.250%above 4.2 50%Below 4.250%Below 4.2 50%b/w 3.55 to 425%b/w 3.55 to 4 25%b/w 4 to 4.2 25%b/w 4 to 4.225%b/w 4.2 to 4.3 25%b/w 4.2 to 4.325%b/w 4.3 to 4.7525%b/w 4.3 to 4.75 25%IQR 0.3 IQR0.3Upper4.75 Upper 4.75Lower3.55 Lower 3.55Page 44 46. BENCH-CBENCH-DMax Val4.9Max Val5Upper Upper4.754.75 Q34.3Q3 4.3 Q24.2Q2 4.2 Q14Q1 4Lower Lower3.553.55Min Val Min Val1.7 2.2Page 45 47. 4.2.3 ANALYSISBench-A4.34.34.254.25 y = -0.075x + 4.3474.24.2R = 0.8644.154.1Top,4.154.05 4.283333 4th, 4333 4.195061 3rd,4.13.95728 4.138888 3.9889 2nd, Bottom,4.05 4.018518 3.85 3.966666 3.8 667519 4Top 4th3.95 3rd 2nd Bottom01 2 Axis3Title 4 5 6Bench-C 4.34.34.254.2 4.24.14.15 4th,4 4.1 Top, 4.2444444 3rd,2nd,4.19166664.053.9 4.0855555 44 4.16666666756 674 y = -0.038x + 4.239 3.8 bottom, 3.93333333.95 R = 0.248 3.733 Top 4th 3.9 3rd2nd01 23 4 5 6 bottom Page 46 48. AGGREGATE OF BENCH - A,C & D4.254.25 4.2 4.2y = -0.044x + 4.262 4.154.15 R = 0.6824.14.05 4.1 43.954.053.9 3.854Top 4th 3rd2ndBottom3.95 Axis Title0 246Bench-D4.35 y = -0.018x + 4.2 4.34.3R = 0.0464.254.25 4.24.154.2 4.14.154.0544.13.954.053.9 3.85 4 3.8 3.753.95 Top 4th3.93rd2nd0 1 23 45 6 bottom Page 47 49. Layer-TopLayer-4th4.34.25 4.24 4.25 y = -0.0491x + 4.2828 4.234.2R = 0.2463 4.22 4.15 4.21y = 0.0191x + 4.186 R = 0.54564.14.2 4.054.190 1 2 340 12 3 4Layer-3 Layer-2nd 4.254.35y = 0.1599x + 3.82024.2 4.3 R = 0.9794 4.25 4.154.24.1 4.15 4.054.1 4y = -0.0926x + 4.2799R = 0.549 4.05 3.9543.93.950 1 2 340 1 23 4 Page 48 50. Layer-Bottom Aggregate of All layers 4.08 4.15 4.06 y = 0.0244x + 3.9576 4.145 y = 0.012x + 4.105 R = 0.1293 R = 0.863 4.044.14 4.02 4.135 44.13 3.98 4.125 3.96 3.94 4.12 3.924.1150 1 23 4 0 1 2 3 44.2.4 InterpretationHozizontal expansionBench-A The expansion is exceptionaly high or low in the 3rd layer of Bench-A. Thetemperature at 3rd layer vastly differs from its neighbouring layer.Most of thegraphs takes a upward or downward turn in this layer. Somewhat 2nd layer alsoshows same characteristics.Bench-C The expansion is exceptionaly high or low in the 3rd layer of Bench-B. Thetemperature at 3rd layer vastly differs from its neighbouring layer.Most of thegraphs takes a upward or downward turn in this layer. Somewhat 2nd layer alsoshows same characteristics.Bench-D The expansion is exceptionaly low in the 3rd layer of Bench-C. The temperatureat 3rd layer vastly differs from its neighbouring layer.Most of the graphs takes aupward or downward turn in this layer. 2nd layers also shows exceptonally highvalue Page 49 51. Vertical expansionLayer Top:Expansion Max at :CExpansion Min at :AExpansion Average at: DA to C: upward steep slopeC to D: Curve U turn shapeLayer 4th:Expansion Max at :CExpansion Min at :AExpansion Average at: DA to C: upward steep slopeC to D: Curve U turn shapeLayer Middle:Expansion Max at :CExpansion Min at :DExpansion Average at: AC to D: Downward steep slopeLayer 2nd:Expansion Max at :DExpansion Min at :CExpansion Average at: AA to D: Straight line,steep,upward with slope 0.98Layer Bottom:Expansion Max at :DExpansion Min at :CExpansion Average at: AA to C: Downward steep slopeC to D: Curve U turn shape4.2.5 OVERALL FINDINGS Expansion is maximum at 4th layer.The expansion gradually increases fromtop to 4th layer,maintains a flat structure till the 2nd layer .In between curvegoes slight down taking a turn in middle( 3rd layer).Curve gradually falls from 2ndlayer to bottom layer. The overall trend is quite similar to the trend of 2nd layer Expansion Max at :bench-D Expansion Min at :bench-C Expansion Average at: bench-A A to C: Downward steep slope C to D: upward steep slope U turn at C Page 50 52. 4.2.5 RECCOMENDATION The bricks which are very sensitive can be put in the 2nd layer as it is highlypredictable. The bricks at Bench-A also can be predicted to large extent with respect to itsdistance from ground. The bricks that require minimum expansion can be placed in bottom layerof bench-A The bricks that require maximum expansion can be placed in Top layer or 4th layerof bench-D The bricks which are least sensitive can be put in the bottom layer as it is leastpredictable. The bricks at Bench-D should be those to whom high tolerance level is allowed.4.2.5 CONCLUSION Bricks are highly predictable layer wise in horizontal direction withcorrelation r>0.8 and thus demosnstrate a stable trend to be followed. Bricks at vertical direction that is bench wise is very risky while predicting asits trend is very variable with correlation r n/2, the probability can be calculated by itscomplement asSo, one must look to a different k and a different p (the binomial is not symmetrical ingeneral). However, its behavior is not arbitrary. There is always an integer m that satisfiesAs a function of k, the expression (k; n, p) is monotone increasing for k < m and monotonedecreasing for k > m, with the exception of one case where (n + 1)p is an integer. In thiscase, there are two maximum values for m = (n + 1)p and m 1. m is known as the mostprobable (most likely) outcome of Bernoulli trials. Note that the probability of it occurringcan be fairly small.The cumulative distribution function can be expressed as:whereis the "floor" under x, i.e. the greatest integer less than or equal to x.Page 53 55. It can also be represented in terms of the regularized incomplete beta function, as follows:For k np, upper bounds for the lower tail of the distribution function can be derived. Inparticular, Hoeffdings inequality yields the boundand Chernoffs inequality can be used to derive the boundMoreover, these bounds are reasonably tight when p = 1/2, since the following expressionholds for all k 3n/8Mean and varianceIf X ~ B(n, p) (that is, X is a binomially distributed random variable), then the expectedvalue of X isand the variance isThis fact is easily proven as follows. Suppose first that we have a single Bernoulli trial.There are two possible outcomes: 1 and 0, the first occurring with probability p and thesecond having probability 1 p. The expected value in this trial will be equal to = 1p +0(1p) = p. The variance in this trial is calculated similarly: 2 = (1p)2p + (0p)2(1p) =p(1p).The generic binomial distribution is a sum of n independent Bernoulli trials. The mean andthe variance of such distributions are equal to the sums of means and variances of eachindividual trial:Page 54 56. Mode and medianUsually the mode of a binomial B(n,p) distribution is equal to (n + 1)p, where is thefloor function. However when (n + 1)p is an integer and p is neither 0 nor 1, then thedistribution has two modes: (n + 1)p and (n + 1)p 1. When p is equal to 0 or 1, the modewill be 0 and n correspondingly. These cases can be summarized as follows:In general, there is no single formula to find the median for a binomial distribution, and itmay even be non-unique. However several special results have been established: If np is an integer, then the mean, median, and mode coincide. Any median m must lie within the interval np m np. A median m cannot lie too far away from the mean: |m np| min{ln 2, max{p, 1 p}}. The median is unique and equal to m = round(np) in cases when either p 1 ln 2 or p ln 2 or |m np| min{p, 1 p} (except for the case when p = and n is odd) When p = 1/2 and n is odd, any number m in the interval (n 1) m (n + 1) is a median of the binomial distribution. If p = 1/2 and n is even, then m = n/2 is the unique median.Covariance between two binomialsIf two binomially distributed random variables X and Y are observed together, estimatingtheir covariance can be useful. Using the definition of covariance, in the case n = 1 we haveThe first term is non-zero only when both X and Y are one, and X and Y are equal to thetwo probabilities. Defining pB as the probability of both happening at the same time, thisgivesand for n such trials again due to independenceIf X and Y are the same variable, this reduces to the variance formula given above.Page 55 57. 5.3.2 OBSERVATION BENCH-A Brick withNumbers Total %Expansion % FoundInspected Found 3.627.58103.3951 % 3.8538106.5432 % 4225 81027.778 % 4.2180 81022.222 % 4.4166 81020.494 % 4.68981010.988 % 4.815.58101.9136 % 50.5 8100.0617 % Total 93.395 % BENCH-C Brick withNumbers Total % Expansion FoundInspected Found %3.640 9004.444%3.811390012.56%4250.590027.83%4.221790024.11%4.415090016.67%4.663.5 9007.056%4.829.5 9003.278%549000.444% Total 96.39%Page 56 58. BENCH-D Brick with NumbersTotal% ExpansionFound InspectedFound %3.6 158101.8519 %3.8 47.58105.8642 %4 230 81028.395 %4.2 253 81031.235 %4.4 166 81020.494 %4.6 46.58105.7407 %4.8 28.58103.5185 %5 3 8100.3704 % Total 97.469 %Aggregate of Bench-A,C & D Brick withNumbersTotal% Expansion Found InspectedFound %3.6 102.52520 4.0675%3.8 228.52520 9.0675%4 704.52520 27.956%4.2 650.52520 25.813%4.4 367.52520 14.583%4.6 2042520 8.0952%4.8 78 2520 3.0952%5 72520 0.2778% Total92.956%Page 57 59. 5.3.3 ANALYSISBench-A250250225200200 180166150150 225100100 89 180 1665053 50 8927.5 53 15.5 27.515.5 0 0.50 0.53.63.8 4 4.24.44.6 4.8 53.6 3.8 4 4.24.44.64.8 5Bench-C300300250250.5 250217200200150150 150250.5113 217100100 150 63.5 5050 113 40 29.5 63.54029.50404 3.63.844.24.4 4.6 4.85 3.6 3.844.24.44.6 4.85 Page 58 60. Bench-D300 300250253250 230200 200 166150 150253230100 10016650 47.546.550 28.5 47.546.51528.5 03 0 1533.63.844.2 4.4 4.6 4.85 3.6 3.844.2 4.4 4.6 4.8 5Aggregate of All benches800 800700704.5700 650.5600 600500 500400 400 367.5704.5650.5300 300 228.5200204200 367.5100 102.5 100 228.5204 78102.5 78 07 0 73.63.844.2 4.4 4.6 4.853.6 3.8 4 4.2 4.44.6 4.8 5Page 59 61. 5.3.4 Interpretation The curve of bench-A is like a bell curve with maximum probability at 4.0%.Followed by 4.2%,4.4%.The probability is low at both the extremes that is 3.6 % &5.0% The curve of bench-C is like a bell curve with maximum probability at 4.0%.Followed by 4.2%,4.4%.The probability is low at both the extremes that is 3.6 % &5.0% The curve of bench-D is like a bell curve with maximum probability at 4.2%.Followed by 4.0%,4.4%.The probability is low at both the extremes that is 3.6 % &5.0%5.3.5 OVERALL FINDINGS Maximum probability is of getting a brick with 4.0% expansion,followed by4.2%,4.4%. The probability of getting bricks is low at both the extremes of expansion that is3.6 % & 5.0% The probability that bricks will expand only between 3.6% to 5.0% is 92.9%4.2.5 RECCOMENDATION Bricks should be monitored carefully that what is their expansion %. If the number of bricks falling above 5.0% & below 3.6% goes more than 7.1%,the situation can be considered alarming and hence the whole process offiring in kiln should be reevaluated & reviewed.4.2.5 CONCLUSION 92.9% of bricks as per the box plot diagram falls within the 1.5 times of interquartile ranges.( expansion between 3.6 % to 5%) 7.1% of bricks can be outliers ( expansion below 3.6% & above 5.0%) Most common expansion figure expected is 4.0%Page 60 62. 5.3 Apparent Posrosity Versus Bulk Density5.3.1 METHODOLOGY Collecting 150 raw datas from kiln Regression analysis Correlation Analysis Graphical AnalysisRegression AnalysisIn linear regression, the model specification is that the dependent variable, yi is a linearcombination of the parameters (but need not be linear in the independent variables). Forexample, in simple linear regression for modeling n data points there is one independentvariable: xi, and two parameters, 0 and 1: straight line:In multiple linear regression, there are several independent variables or functions ofindependent variables. For example, adding a term in xi2 to the preceding regression gives: parabola:This is still linear regression; although the expression on the right hand side is quadratic inthe independent variable xi, it is linear in the parameters 0, 1 and 2.In both cases, is an error term and the subscript i indexes a particular observation. Givena random sample from the population, we estimate the population parameters and obtainthe sample linear regression model:The residual,, is the difference between the value of the dependent variablepredicted by the model, and the true value of the dependent variable yi. One method ofestimation is ordinary least squares. This method obtains parameter estimates thatminimize the sum of squared residuals, SSE:Page 61 63. Minimization of this function results in a set of normal equations, a set of simultaneouslinear equations in the parameters, which are solved to yield the parameter estimators, .Illustration of linear regression on a data set.In the case of simple regression, the formulas for the least squares estimates arewhere is the mean (average) of the x values and is the mean of the y values. See simplelinear regression for a derivation of these formulas and a numerical example. Under theassumption that the population error term has a constant variance, the estimate of thatvariance is given by:This is called the mean square error (MSE) of the regression. The standard errors of theparameter estimates are given by Page 62 64. Under the further assumption that the population error term is normally distributed, theresearcher can use these estimated standard errors to create confidence intervals andconduct hypothesis tests about the population parameters.CorrelationThe population correlation coefficient X,Y between two random variables X and Y withexpecte values X and Y and standard deviations X and Y is defined as:where E is the expected value operator, cov means covariance, and, corr a widely usedalternative notation for Pearsons correlation.The Pearson correlation is defined only if both of the standard deviations are finite andboth of them are nonzero. It is a corollary of the CauchySchwarz inequality that thecorrelation cannot exceed 1 in absolute value. The correlation coefficient is symmetric:corr(X,Y) = corr(Y,X).Page 63 65. 5.3.2OBSER VATION AP Vs BD 2 1.95 y = -0.0207x + 2.25371.9R = 0.9051 1.851.8 1.751.7 1.650 5 1015202530 e0.07238N 150 AP Vs GGBD2.4 2.35y = -0.0249x + 2.70982.3R = 0.9051 2.25GGBD2.2 2.152.1 2.05 20 5 10 15 20 2530 e0.1N 150Page 64 66. 5.3.3 ANALYSIS5.3.3.1 DERIVATION Page 65 67. Applying X% = 4.1699% expansion as per the standards from target1Applying L% = 6% ,loss of moisture as per the laboratory standardBBD = -0.02 AP + 2.253 FGBD = -0.0251 AP + 2.8246 GGBD=-0.024 AP +2.709 AGBD= -0.0245 AP + 2.7668BBD = 0.7976 FGBD FGBD = 1.2537 BBD5.3.4 InterpretationApparent Porosity is inversely related to burnt Bulk Density.BBD 1/ APBBD = - K * AP + Cwhere K is the rate at which BBD decreases with increase in AP.C is a constantRate is 0.020 change per unit alterationFormula Accuracy: 90.5%Green Burnt Bulk density is directly related to Burnt Bulk DensityGBD BBDGBD = M* BBD + C Page 66 68. where M is the rate at which BBD increases with increase in AP.Again M = (1 + X)/ (1-L)X = X/100; L = L /100X is Expansion % of bricksL is % Loss in weightFormula Accuracy: 100 %Apparent Porosity is inversely related to burnt Bulk Density.GBD 1/ APGBD = - L * AP + Cwhere L is the rate at which BBD decreases with increase in AP.C is a constantAgain L = { 0.020 (1 + X)} / (1-L) X = X/100; L = L /100X is Expansion % of bricksL is % Loss in weightFormula Accuracy: 90.5 %5.3.5 FINDINGS AP vs GGBD is a linearly decreasing function where GGBD is inversely proportional to AP. GGBD decreases with increase in AP. Slope is negative. R > 0.8, suggest that AP & GGBD are well correlated & forms a property. AP vs. BBD is a linearly decreasing function where BBD is inversely proportional to AP. BBD decreases with increase in AP. Slope is negative. R > 0.8, suggest that AP & BBD are well correlated & forms a property Moisture loss ( weight loss) & expansion in kiln is an important parameter to get apparent porosity because density decreases in both of above situation4.2.5 RECCOMENDATION Weight loss % due to moisture loss should be reviewed on monthly basis by the laboratory & also when their is some changes done to the operation of kiln temperature as it can alter the existing the AP and BBD relationship Expansion % due to firing isnide kiln should be reviewed as it can alter the existing the AP and BBD relationship. Page 67 69. The composition of powder put in press machine must be ensured, otherwisewrong composition may produce wrong data due to variation in standarddensity,leading to altered apparent porosity.4.2.5 CONCLUSION When the weight loss %increases , the apparent porosity for the samepressure applied increases.L% AP When the expansion % increases , the apparent porosity for the samepressure applied increases.X% AP. Page 68 70. KAIZEN&5S Page 69 71. 4.1 KAIZENKaizen (Japanese for "improvement" or "change for the better") refers to philosophy orpractices that focus upon continuous improvement of processes in manufacturing,engineering, supporting business processes, and management. It has been applied inhealthcare, psychotherapy, life-coaching, government, banking, and many other industries.When used in the business sense and applied to the workplace, kaizen refers to activitiesthat continually improve all functions, and involves all employees from the CEO to theassembly line workers. It also applies to processes, such as purchasing and logistics, thatcross organizational boundaries into the supply chain.By improving standardized activitiesand processes, kaizen aims to eliminate waste (see lean manufacturing). Kaizen was firstimplemented in several Japanese businesses after the Second World War, influenced in partby American business and quality management teachers who visited the country. It hassince spread throughout the world and is now being implemented in many other venuesbesides just business and productivity.The cycle of kaizen activity can be defined as: Standardize an operation Measure the standardized operation (find cycle time and amount of in-process inventory) Gauge measurements against requirements Innovate to meet requirements and increase productivity Standardize the new, improved operations Continue cycle ad infinitumThis is also known as the Shewhart cycle, Deming cycle, or PDCA. Page 70 72. 4.2 5S5S is the name of a workplace organization methodology that uses a list of five Japanesewords which are seiri, seiton, seiso, seiketsu and shitsuke. Transliterated or translatedinto English, they all start with the letter "S". The list describes how items are stored andhow the new order is maintained. The decision-making process usually comes from adialogue about standardization which builds a clear understanding among employees ofhow work should be done. It also instills ownership of the process in each employee.4.2.1 Phases of 5SThere are 5 primary phases of 5S: sorting, straightening, systematic cleaning,standardizing, and sustaining. Additionally, there are two other phases sometimesincluded, safety & security.Sorting (Seiri)Eliminate all unnecessary tools, parts, and instructions. Go through all tools, materials,and so forth in the plant and work area. Keep only essential items and eliminate what is notrequired, prioritizing things as per requirements and keeping them in approachable places.Everything else is stored or discarded.Straightening or setting in order / stabilize (Seiton)There should be a place for everything and everything should be in its place. The placefor each item should be clearly labeled or demarcated. Items should be arranged in amanner that promotes efficient work flow. Workers should not have to bend repetitively toaccess materials. Each tool, part, supply, or piece of equipment should be kept close towhere it will be used in other words, straightening the flow path. Seiton is one of thefeatures that distinguish 5S from "standardized cleanup". This phase can also be referred toas SimplifyingSweeping or shining or cleanliness / systematic cleaning (Seiso)Keep the workplace tidy and organized. At the end of each shift, clean the work area andbe sure everything is restored to its place. This makes it easy to know what goes where andensures that everything is where it belongs. A key point is that maintaining cleanlinessshould be part of the daily work not an occasional activity initiated when things get toomessy.Standardizing (Seiketsu)Work practices should be consistent and standardized. Everyone should know exactlywhat his or her responsibilities are for adhering to the first 3 Ss. Page 71 73. Sustaining the discipline or self-discipline (Shitsuke)Maintain and review standards. Once the previous 4 Ss have been established, theybecome the new way to operate. Maintain focus on this new way and do not allow a gradualdecline back to the old wa

Quality Control & operations in Silica plant

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