This report summarizes quality control efforts, kaizen improvements, and 5S practices at an Indian silica refractory plant. Quality control involved analyzing brick expansion data from kilns using statistical tools to better understand non-uniformity. Probability distributions examined likelihood of bricks meeting size standards. Relationships between apparent porosity and bulk density were derived. Kaizen suggestions included layout redesign, safety precautions, and housekeeping. Pictorial recommendations illustrated paths, signage and equipment changes. Excel tools simulated processes to allow flexible analysis. The aim was improving production quality and efficiency through data-driven methods.

1. NewGate India
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Report on
Quality Control,Kaizen & 5S
In Silica Plant

2. Table of Contents
1.Executive Summary .........................................................................................................................7
1.1 OVERVIEW OF QUALITY CONTROL done in OCL ....................................................................7
CHAMBER KILN: .............................................................................................................................7
EXPANSION PROBABILITY : .............................................................................................................7
APPARENT POSROSITY & BULK DENSITY .........................................................................................8
EXCEL SHEET SIMULATION ..............................................................................................................8
1.2 KAIZEN & 5S suggested ........................................................................................................8
PICTORIAL LAYOUTS .......................................................................................................................8
2.Introduction....................................................................................................................................9
2.1 INDUSTRY OVERVIEW ...............................................................................................................9
2.1.1 ABOUT OCL ............................................................................................................................9
2.1.1.1 CEMENT: .............................................................................................................................9
2.1.1.2 REFRACTORY.......................................................................................................................9
2.1.1.3 SPONGE IRON .....................................................................................................................9
2.1.1.4 IRON & STEEL .................................................................................................................... 10
2.1.2 EXECUTIVES & BORAD MEMBERS ......................................................................................... 10
DIRECTORS ............................................................................................................................... 10
PRESIDENT ............................................................................................................................... 10
2.1.3 VISION ................................................................................................................................. 10
2.1.4 MISSION .............................................................................................................................. 10
2.1.5 Quality Policy....................................................................................................................... 11
2.1.6 Safety Policy ........................................................................................................................ 11
2.1.7 Certification ......................................................................................................................... 11
2.1.8 AWARDS & RECOGNITION .................................................................................................... 12
2.1.8 Corporate Social Responsibility ............................................................................................ 12
EDUCATION .............................................................................................................................. 12
DRINKING WATER..................................................................................................................... 13
HEALTH .................................................................................................................................... 13
GAMES & SPORTS ..................................................................................................................... 14
COMMUNITY DVELOPMENT/DONATION/CHARITY .................................................................... 14
2.1.9 Summary of expenses incurred ............................................................................................ 15

3. 2.2 SWOT ANALYSIS ..................................................................................................................... 15
2.2.1 STRENGTH ........................................................................................................................... 15
2.2.2 WEAKNESS .......................................................................................................................... 16
2.2.3 OPPORTUNITY ..................................................................................................................... 16
2.2.4 THREAT ............................................................................................................................... 16
2.3 Company overview ................................................................................................................. 16
2.3.1 ABOUT REFRACTORY............................................................................................................ 16
2.3.2 MILESTONES YEAR WISE....................................................................................................... 17
2.3.3 REFRACTORY CAPACITY........................................................................................................ 18
2.3.4 GLOBALIZATION................................................................................................................... 18
2.3.5 PRODUCTS ........................................................................................................................... 19
2.3.5.1 Iron & Steel Making .......................................................................................................... 19
2.3.5.1 Non Ferrous ...................................................................................................................... 19
2.3.5.1 Glass ................................................................................................................................. 20
2.3.5.1 Hydrocaron ....................................................................................................................... 20
2.3.5.1 Cement ............................................................................................................................. 20
2.3.6 FEW MAJOR PRODUCTS STUDIED ......................................................................................... 20
2.3.6.1 COKE OVEN ....................................................................................................................... 20
2.3.6.2 BLAST FURNANE STOVE ..................................................................................................... 21
2.3.6.3 GLASS MELTING TANK ....................................................................................................... 21
2.3.6.4 BOF/LD Convertor ............................................................................................................. 22
2.3.6.5 MELTING & HOLDING FURNANCE ...................................................................................... 23
2.3.6.6 LF/VD & VAD .................................................................................................................... 24
2.3.6.7 QSL REACTOR .................................................................................................................... 24
2.3.6.8 REGENERATOR .................................................................................................................. 25
2.4. SILICA PLANT OVERVIEW........................................................................................................ 25
2.4.1 Silica Plant Operational Process Flow ................................................................................... 26
3.1 PROJECT PROFILE ....................................................................................................................... 28
3.1 Objectives of the Study ........................................................................................................... 28
3.2 Project Type & Tools ............................................................................................................... 28
 Production Operation Management .................................................................................. 28
3.3 Target..................................................................................................................................... 28
3.4 Sources of data:- ..................................................................................................................... 28
3.4.1 Primary data: ................................................................................................................... 28
3.4.2 Secondary data: ............................................................................................................... 29

4. 3.4.3 Sample design:- ................................................................................................................... 29
3.4.4 Sample size:-........................................................................................................................ 29
3.5 Details Of Work ...................................................................................................................... 29
3.5. 1 Initial Training :- ............................................................................................................. 29
3.5. 2 Office Work :....................................................................................................................... 30
3.5.3 Intial Onsite Work :- ............................................................................................................. 30
3.6 Working Hierarchy Model ....................................................................................................... 30
3.7 Pyramid of Problem Approach ................................................................................................ 31
3.2 Application to Company ............................................................................................................. 32
3.2.1 Application of quality control: .............................................................................................. 32
INDUSTRIAL APPLICATION:1 ( CHAMBER KILN) .............................................................................. 32
INDUSTRIAL APPLICATION:2 ( CHECKING)...................................................................................... 34
INDUSTRIAL APPLICATION:3 ( PRESS MACHINE) ............................................................................ 35
3.2.1 Application of Kaizen,Safety & 5S: ........................................................................................ 35
4.1 QUALITY CONTROL ..................................................................................................................... 37
4.1.1Quality control ..................................................................................................................... 37
4.1.2 Total quality control............................................................................................................. 37
4.1.3 Quality control in project management ................................................................................ 37
4.2 EXPANSION % of bricks ............................................................................................................... 37
4.2.1 METHODOLOGY ................................................................................................................... 37
Arithmetic mean (AM) .............................................................................................................. 38
4.2.2 OBSERVATION ..................................................................................................................... 39
BOX PLOT DIAGRAM .................................................................................................................... 40
4.2.3 ANALYSIS ............................................................................................................................. 43
4.2.4 Interpretation ...................................................................................................................... 46
Hozizontal expansion ................................................................................................................... 46
Vertical expansion ........................................................................................................................ 47
4.2.5 OVERALL FINDINGS .............................................................................................................. 47
4.2.5 RECCOMENDATION .............................................................................................................. 48
4.2.5 CONCLUSION ....................................................................................................................... 48
5.3 PROBABILITY DISTRIBUTION ....................................................................................................... 49
5.3.1 METHODOLOGY ................................................................................................................... 49
NORMAL PROBABILITY DISTRIBUTION .......................................................................................... 49
BINOMIAL PROBABILITY DISTRIBUTION ........................................................................................ 49
Probability mass function ......................................................................................................... 50

5. Mean and variance ....................................................................................................................... 51
Mode and median ........................................................................................................................ 52
Covariance between two binomials .............................................................................................. 52
5.3.2 OBSERVATION ..................................................................................................................... 53
5.3.3 ANALYSIS ............................................................................................................................. 55
5.3.4 Interpretation ...................................................................................................................... 57
5.3.5 OVERALL FINDINGS .............................................................................................................. 57
4.2.5 RECCOMENDATION .............................................................................................................. 57
4.2.5 CONCLUSION ....................................................................................................................... 57
5.3 Apparent Posrosity Versus Bulk Density ...................................................................................... 58
5.3.1 METHODOLOGY ................................................................................................................... 58
5.3.2OBSER VATION ..................................................................................................................... 61
5.3.3 ANALYSIS ............................................................................................................................. 62
5.3.3.1 DERIVATION ..................................................................................................................... 62
5.3.4 Interpretation ...................................................................................................................... 63
Apparent Porosity is inversely related to burnt Bulk Density. ........................................................ 63
5.3.5 FINDINGS............................................................................................................................. 64
4.2.5 RECCOMENDATION .............................................................................................................. 64
4.2.5 CONCLUSION ....................................................................................................................... 65
4.1 KAIZEN ....................................................................................................................................... 67
4.2 5S .............................................................................................................................................. 68
4.2.1 Phases of 5S......................................................................................................................... 68
Sorting (Seiri) ............................................................................................................................... 68
Straightening or setting in order / stabilize (Seiton) ....................................................................... 68
Sweeping or shining or cleanliness / systematic cleaning (Seiso) .................................................... 68
Standardizing (Seiketsu) ............................................................................................................... 68
Sustaining the discipline or self-discipline (Shitsuke) ..................................................................... 69
4.3 Safety ........................................................................................................................................ 69
4.4 Security ...................................................................................................................................... 69
4.5 SMALL IMPROVEMENT & SAFETY................................................................................................ 69
5.5.1 METHODOLOGY ................................................................................................................... 69
DRAWING LAYOUT ....................................................................................................................... 70
5.3.2 Observation ......................................................................................................................... 70
5.3.3 ANALYSIS ............................................................................................................................. 71
5.3.4 INTERPRETATION ................................................................................................................. 71

6. 5.3.5 KEY FINDINGS ...................................................................................................................... 72
5.3.6 RECCOMENDATION .............................................................................................................. 72
5.3.7 CONCLUSION ....................................................................................................................... 73
6.EXCEL SIMULATION TOOL .............................................................................................................. 75
6.1 Tool-1 ..................................................................................................................................... 75
6. 2 Tool-2 .................................................................................................................................... 76
6.3 Tool-3 ..................................................................................................................................... 77
6.4 Tool-4 ..................................................................................................................................... 78
6.5 Tool-5 ..................................................................................................................................... 79
6.6 Tool-6 ..................................................................................................................................... 79
7.PICTORIAL RECCOMENDATION ...................................................................................................... 81
7.1 Suggestion 1: .......................................................................................................................... 81
7.2 Suggestion 2: .......................................................................................................................... 81
7.3 Suggestion 3: .......................................................................................................................... 82
7.4 Suggestion 4: .......................................................................................................................... 82
7.5 Suggestion 5: .......................................................................................................................... 83
7.6 Suggestion 6: 7.7 Suggestion 7:........................................................ 83
7.8 Suggestion 8: .......................................................................................................................... 84
7.9 Suggestion 9: .......................................................................................................................... 84
7.10 Suggestion 10: ...................................................................................................................... 85
7.11 Suggestion 11: ...................................................................................................................... 85
7.12 Suggestion 12: ...................................................................................................................... 86
7.13 Suggestion 13: ...................................................................................................................... 86
8. LEARNING OUTCOME: .................................................................................................................. 87
8.1 QUALITY CONTROL PROJECT: .................................................................................................. 87
8.2 KAIZEN,5S & SAFETY PROJECT ................................................................................................. 87
APPENDIX-1 ..................................................................................................................................... 88
PROBABILITY DISTRIBUTION ......................................................................................................... 88
APPENDIX-2 ..................................................................................................................................... 89
EXPANSION % LAYER WISE ........................................................................................................... 89
APPENDIX-3 ..................................................................................................................................... 90
AP-BD table.................................................................................................................................. 90
APPENDIX-4 ..................................................................................................................................... 95
Brick Expansion % Data ................................................................................................................ 95
APPENDIX-5 ..................................................................................................................................... 96
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7. Box Plot diagram of Expansion % Data .......................................................................................... 96
APPENDIX-6 ..................................................................................................................................... 97
Stock Data:................................................................................................................................... 97
APPENDIX-7 ..................................................................................................................................... 98
A7.1 TOTAL ASSETS of OCL ( 2007,2008,2009) ............................................................................... 98
A7.2 DEBT & NET WORTH of OCL ( 2007,2008,2009) ...................................................................... 98
APPENDIX-8 ..................................................................................................................................... 99
A8.1CREDIT RISK .......................................................................................................................... 99
A8.2 TOTAL LIABILILTIES ............................................................................................................... 99
APPENDIX-9 ................................................................................................................................... 100
A9.1 TOTAL INCOME................................................................................................................... 100
A9.2 TOTAL EXPENDITURE .......................................................................................................... 100
APPENDIX-10 ................................................................................................................................. 101
A10.1 OPERATING PROFIT .......................................................................................................... 101
A10.2 PROFIT AFTER TAX ............................................................................................................ 101
GLOSSARY & ABBREVIATION .......................................................................................................... 102
BIBLIOGRAPHY............................................................................................................................... 103
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8. 1.Executive Summary
The Project was focused on quality control using various statistical tool/techniques.
1.1 OVERVIEW OF QUALITY CONTROL done in OCL
CHAMBER KILN:
OCL Silica Refractory has 8 kilns.Eack Kiln has 22 to 28 chambers. Again each chamber has
4 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 differed
across length & height.Position of bricks inside a kiln mattered a lot.So a very microscopic
obsevation was done using statistical tools & techniques. For this experiment 2700 raw data of
bricks were taken.
It was an assumption that the bricks inside the kiln expanded by 4.2% after firing. So our
motive was to observe if the assumption was accurate & how the bricks expanded at very
microssopic 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 the
same parameter the probability that the bricks expanded to a defined level varied.Many times
it deviated from its expected size. So probability distribution was done to estimate the
occurence 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.
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9. APPARENT POSROSITY & BULK DENSITY
It is important to know apparent porosity needed for a particular green bulk density.Orders are
placed in terms of maximum apparent posrosity.So it is importnat to know, what should be
the pressure applied by the press machine to maintain a proper bulk density, keeping in mind
the 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 BD
EXCEL SHEET SIMULATION
It has been developed to make observation user friendly and flexible in case of any
change 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 Management
PICTORIAL LAYOUTS
It has been developed to make observation user friendly to lay man for whom
understanding technical terms becomes difficult
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10. 2.Introduction
2.1 INDUSTRY OVERVIEW
OCL INDIA LTD
OCL
Refractor Cement Sponge
yryct Iron
2.1.1 ABOUT OCL
OCL 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 wet
process technology under the brand name of "Konark". Keeping a steady progress with
time and technology it has modernized to fully automated dry process plant in 1988. OCL
commands the position of market leadership in the state of Orissa since its inception and
today it is the premier lead brand in the state of Orissa. ‘Konark' brand cement enjoys
brand advantage in the region. It is a name cemented to Quality.
2.1.1.2 REFRACTORY
OCL diversified from Cement to the field of Refractories in 1954. Over the years, it has
become one of the largest and well-equipped state of the art Refractory plant in India
covering a wide range of products for use in the Ferrous & the non-ferrous Industries. Its
customer base spreads from iron and steel to cement, aluminum, glass, copper, chemicals
and hydrocarbon industries. Today, OCL enjoys a huge market share in India and overseas
extending to five continents across the globe.
2.1.1.3 SPONGE IRON
During the year 2001-02 OCL diversified its activities into Sponge Iron and now forayed
further into Steel making. In line with this vision, the Company has already installed a
Captive Power plant and is going to commission 0.25 million tons steel billet plant.
Page 9

11. 2.1.1.4 IRON & STEEL
OCL, as per scheme of arrangement approved by the honourable High Court of Orissa
demerged its Steel undertaking and Real Estate undertaking by transferring the assets
and liabilities as on 1st January 2007 into “OCL Iron and Steel Ltd.” and
“Landmark 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 1st
July 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 Overview
2.1.2 EXECUTIVES & BORAD MEMBERS
DIRECTORS
 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. Dalmia
2.1.3 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 society
2.1.4 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 multiskilling
Page 10

12. 2.1.5 Quality Policy
OCL, 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
»
improvement
2.1.6 Safety Policy
OCL INDIA LIMITED considers all its employees as primary asset and attaches utmost
importance to their safety and health. To promote safety & health in all its factories and
mines, the company makes all possible efforts and will continue to do so by which safety
and health of all its employees will be ensured. T
They are committed to:
» Consider eliminating safety and health hazard while planning, designing and
adopting any process or system
» Select and deploy plant machinery which are safe and free of hazard
Maintain and upgrade the facilities and operations to ensure safety on continuous
»
basis
» Provide the knowledge & necessary skills to employees, contractors & other agency
through planned training & awareness programs
» Periodically review safety & health performance to achieve continual
improvements 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 necessary
2.1.7 Certification
 ISO 9001:2008 ( Quality Management System)
 ISO 14001:2004 ( Environment )
 ISO 18001:2007 ( Occupational Health and Safety Assement Series)
Page 11

13. 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 Company’s 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 Responsibility
In its 57 years of untiring service to Nation, OCL has always given priority to community
development. In its endeavor to uplift the conditions of poor and hapless tribals of this
locality, OCL has undertaken various developmental activities in peripheral areas of
Rajgangpur and Lanjiberna. The activities are mainly focused on areas like Health,
Education, Drinking Water, Games and Sports etc. Some of the major activities undertaken
during last three years are given below :
EDUCATION
» Constructed one big hall and made drinking water
supply arrangement in Gopabandhu High School,
Rajgangpur
» Constructed boundary wall of Primary School in village
Kunmuru
» Constructed boundary wall and an additional room in
Jampali High School
» Continuing Literacy programs in different villages
» Renovated school building of Bastia M E School, I T
Colony, Rajgangpur
» Donated Rs. 1,00,000/- to Saraswati Sishu Mandir for
construction of school building in Rajgangpur
» Repaired school building in Saliameta and Kheramuta,
Lanjiberna
» Repaired roof of Nodal U P School in Lanjiberna
Page 12

14. » Renovated the school building of Municipal Gandhi Girl’s
High School, Rajgangpur
» Constructed three new rooms and supplied desk and
bench for students in M E School, Teleimunda
» Renovated the school building of Santa Devi High
School, Khatang
» Made drinking water supply arrangement in Lanjiberna
Shramik High School, Lanjiberna
» Repaired the school play ground in Ramabahal
» Making payment of salary to four adhoc teachers in
Lanjiberna Shramik High School, Lanjiberna
DRINKING WATER
» Sunk 44 Tube wells in Rajgangpur, Lanjiberna and its
surrounding villages
» Repaired 7 Tube wells in Lanjiberna
» Supplying water to five villages in Lanjiberna for
irrigation
» Arranged drinking water supply system in the premises
of Bar Association, Rajgangpur
» Donated Rs.17,000/- on behalf of villagers of Khatang to
Village Water and Sanitation Committee for arranging
drinking water facility under “Sajal Dhara Scheme’ of
Govt. of Orissa
» Donated Rs.50,000/- on behalf of villagers of Dharuda
(Kukuda GP) to Village Water and Sanitation Committee
for arranging drinking water facility under “Sajal Dhara
Scheme’ of Govt. of Orissa
HEALTH
» Providing medical facilities including supply of medicine
to villagers in Lanjiberna from OCL Dispensary
» Providing ambulance for shifting serious patients to
nearby hospitals in Rajgangpur and Lanjiberna
» Operating charitable homoeopathic dispensary in
Rajgangpur 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 Seva
Sansthan, New Delhi for running a charitable dispensary
at Sonakhan
» Operating mobile health unit (homeopathic) in different
villages in Rajgangpur and Lanjiberna
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15. » Operating one mobile health unit (allopathic) for senior
citizens through “Help Age-India” in different villages of
Jagatsinghpur
» Organised health check-up camp for villagers in
Lanjiberna
» Organised Eye, E & T and Dental Camp in Rajgangpur
» Organised awareness program on “Maleria, Dengu and
Chikungunia” and distributed 300 mosquito nets to
villagers in Lanjiberna
GAMES & SPORTS
» Conducted Inter-village Dalmia Cup Football and Hockey Tournament
» Providing games materials like football, volley ball, hockey sticks etc to villagers
COMMUNITY
DVELOPMENT/DONATION/CHARITY
» Operating ‘SWAYAMPRABHA”, a tailoring centre for
providing training to poor women and providing swing
machine free of cost in Lanjiberna
» Provided electricity in two villages i.e, Bihabandha
Rehabilitated Colony and Tungritoli in Lanjiberna
» Provided financial assistance to Bharatiya Jana Seva
Sansthan, New Delhi for implementing Gram Mangla
Yogna in 50 villages in Rajgangpur & Lanjiberna
» Distributed 500 blankets to old and poor people in
Rajgangpur and Lanjiberna
» Donated Rs. 19,00,000/- to District Peripheral
Development Committee for undertaking various
developmental activities in the District
» Donated Rs. 3,50,000/- to “HOPE” for construction of
school building for mentally retarded children in
Rajgangpur
» Donated Rs. 31,00,000/- for construction of “Community
Kalyan Mandap” in Rajgangpur
Page 14

16. 2.1.9 Summary of expenses incurred
Under different heads during 2004-05 and 2005-06 are
given below :
AREA 2004-05 2005-06 2007-08
EDUCATION RS. 7,60,320.00 RS. 7,60,320.00 RS. 9,90,347.00
DRINKING WATER RS. 11,51,509.00 RS. 8,95,309.00 RS. 1,69,301.00
HEALTH RS. 6,35,000.00 RS. 13,52,984.00 RS. 15,76,002.00
GAMES & SPORTS RS. 20,845.00 RS. 54,000.00 RS. 76,760.00
CHARITY & DONATIONS RS. 13,58,537.00 RS. 46,15,540.00 RS. 11,81,725.00
TOTAL RS. 39,26,211.00 RS. 73,80,325.00 RS. 39,94,135.00
Besides, OCL has also donated generously to Prime Minister’s and Chief Minister’s Relief
Fund 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 ANALYSIS
2.2.1 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 of
quality rating its Ranked – 1 and there is no company which can bid OCL in eastern
world.
 Rapid industrialization at Jharsuguda ( 55 Km) from OCL and other industrial
places like
Jamashedpur,Rourkela,bilaspur,durg,Raipur,Raigarh,Durgapur,Bokaro by
companies like RSP,L&T,VEDANTA,Bhusan Steel,MCL,Birla
cement,Jindal,Tata will create more demands.
Page 15

17. 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.
 Refractory’s 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 OCL’s 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 overview
2.3.1 ABOUT REFRACTORY
OCL diversified from Cement to the field of Refractories in 1954. Over the years, it has
become one of the largest and state of the art Refractory plants in India with an annual
capacity of 80,000 Mt, covering a wide range of products for use in the ferrous & the non-
ferrous Industries.
Page 16

18. The initial technical know how came from M/S Dr.C.Otto of Germany for Coke Oven Silica
bricks 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 with
ever-growing expectation of customers for quality Refractories, our highly experienced &
well-equipped technology & research teams upgrade these on a continuous basis. With
intensive 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, by
RWTUV 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 & D
orientation towards its customer both in product and in services. It has a long-term vision
to 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 17

19. 2.3.3 REFRACTORY CAPACITY
PRODUCTION CAPACITY
SILICA BRICKS 30,000 MT / YR
BASIC BURNT BRICKS 22,000 MT / YR
MAGNESIA CARBON BRICKS 8,000 MT / YR
FIRECLAY & HIGH ALUMINA BRICKS 25,000 MT / YR
CONTINUOUS CASTING 2,000 MT / YR
SLIDE GATE REFRACTORIES 2,000
CASTABLES & PRECAST BLOCKS 11,000 MT / YR
BASIC, SILICA & HIGH ALUMINA 6,400 MT / YR
RAMMING MASSES / MORTARS
TOTAL 106,400 MT / YR
2.3.4 GLOBALIZATION
OCL is among the market leaders & undisputedly, one of the best in world in the segment of
Silica bricks for Coke ovens & Blast Furnace stoves having extraordinary supply references
all through the globe. With aggressive thrust on the exports of special Refractories like
Continuos casting, Slide plates & Purging Refractories for the Steel Sector, Direct bonded
Mag-Chrome bricks for the Copper and Fireclay & High Alumina bricks for the Aluminum
Industries, 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 in
Canada, USA, Brazil, UK, Sweden, Netherlands, Hungary, Spain, Italy, Turkey, Japan,
South Korea, China, Thailand, Malaysia, Indonesia, Australia, Egypt, Kenya, South
Africa, Saudi Arabia, Jordan, Qatar, Iran, UAE, Kuwait, Pakistan, Bangladesh, Sri
Lanka & many more.
Page 18

20. 2.3.5 PRODUCTS
OCL refractory has various products mainly classified in to 5 categories
PRODUCT CATEGORY
IRON & NON GLASS HYDROCA CEMENT
STEEL FERROUS RBON
MAKING
2.3.5.1 Iron & Steel Making
 Coke Oven
 Sponge/DRI
 Blast Furnance
 Hot Metal Transport
 Hot Metal Mixer
 Ladles
 BOF/LD Convertor
 Electric Arc Convertor
 Slide Gate Category
2.3.5.1 Non Ferrous
 Aluminium
o Anode Baking Furnance
o Melting & Holding Furnance
 Copper Industries
o Flash Smeltor
o ISA Smeltor
o Flash Convertor
o Noranda Reactor
o Reverberatory Furnance
o Top Blown Roatary convertor
o RS Convertor
o TEINITE Convertor
o Slag Cleaning Furnance
o Anode Converter
Page 19

21.  NICKEL,ZINC & LEAD
o Lead Roatart Furnance
o QSL Reactor
o KIVCET Proces
2.3.5.1 Glass
 Glass melting tank
 Glass regenerator
2.3.5.1 Hydrocaron
2.3.5.1 Cement
2.3.6 FEW MAJOR PRODUCTS STUDIED
2.3.6.1 COKE OVEN
OCL through its initial know-how from Dr. C. OTTO and subsequent intensive R&D efforts
has established itself as a leading silica coke oven manufacturer in the world. With its
installed capacity of 30000Tons/year OCL has to its credit an impressive list of supply
references for Coke Oven, both in domestic and overseas markets. With its wide experience
OCL can supply silica refractories to all international specifications such as DIN, JIS, BS, NSC
and 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 20

22. 2.3.6.2 BLAST FURNANE STOVE
With its initial experience in manufacturing silica bricks for coke oven, OCL developed
world class silica bricks for heavy duty Blast Furnace Stoves. Winning the confidence of
world known stove designers like DCE, DME, Siemen-VAI, NSC. OCL has supplied silica, fire
clay and high alumina refractories for a number of projects worldwide.
OCL India has experience of over four decades for the manufacture of High Duty
Silica bricks having very low flux factor & residual quartz.OCL has received wide
appreciation from overseas customers for timely delivery, god packing and dimensional
accuracy of the product.
2.3.6.3 GLASS MELTING TANK
Glass melting furnaces, particularly of high pulling rate, are lined with various high quality
refractories.Most glass manufacturers have been preferring super duty Silica Bricks for the
crown because crown constructed with Super Duty Silica Bricks can be insulated, resulting
in saving of 10-12% input energy.The advantage of Super Duty Silica bricks over
conventional 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 Silica
bricks having very low flux factor & residual quartz.These bricks are having very high
refractoriness under load & shows excellent volume stability at service temperature.
OCL's Silica insulating bricks have very low thermal conductivity which results in excellent
thermal insulation.
Page 21

23. 2.3.6.4 BOF/LD Convertor
New Lining
Different quality Magnesia carbon bricks with improved carbon bonding and having special
characteristics as regard to corrosion resistance, erosion resistance, oxidation resistance
and thermal shock resistance are used in different zones for balanced/ uniform erosion and
cost effective lining.
Maintenance
Tailor made gunning material and hot patching mass is applied for prevention as well as
repair 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 customers’
requirement
» 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 purpose
Page 22

24. 2.3.6.5 MELTING & HOLDING FURNANCE
PRECAST SHAPES
These are tailor-made to different shapes and sizes manufactured as per specific customer
requirement.
BURNER BLOCKS (EXCELCAST 70 D)
High thermal spalling resistance, corrosion and abrasion resistance and volume stability at
the operating temperature.
FLOORING BLOCKS (EXCELCAST 45 A)
Precast flooring blocks in variety of sizes and thickness to withstand impact and abuse of
dross 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 CO
disintegration.
CASTABLES
Castables are manufactured for varied application in casthouse, holding furnace
door and roof etc.
Page 23

25. 2.3.6.6 LF/VD & VAD
Zone 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 coked
porosity, high coked CCS, excellent corrosion, erosion, thermal shock and oxidation resistance
and high hot strength have been developed and given for different zones depending on
operational severity and cost effectiveness.
Alumina magnesia carbon bricks having controlled residual expansion are recommended for the
MZ and bottom of ladle furnaces to prevent joint erosion and metal penetration. Specially for
impact resistance in striker pad area AMC-3 bricks are preferred.
2.3.6.7 QSL REACTOR
This is a cylindrical horizontal oxygen reactor where bullion is produced from lead
concentrate. This is a special type of reactor which is characterised by extremely short
mixing 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 a
heterogeneous mixture of molten lead, slag, PbO & charge material where oxygen is blown
to form SO2, sulphate content flue dust and PbO and carbothermal reduction of lead oxide
slag by means of coal dust.
OCL’s direct bonded bricks have excellent resistance to PbO containing slag and SO2.
Page 24

26. 2.3.6.8 REGENERATOR
OCL India has series of products for regenerator in Basic & high Alumina quality. In recent
years, Mag-zir quality is added to its range of product. Mag-zir quality chimney blocks in
top course of regenerator shows superior resistance to Silica carry over attack & V2O5
attack as the matrix is completely converted to forsterite and enriched with tiny Zirconia
grains. In the middle course of regenerator Mag-zir shows superior resistance to Alkalies,
Sulphate attack & deposition as the Magnesite grains are enveloped with tiny Zirconia
grains.
2.4. SILICA PLANT OVERVIEW
Silica has 3 palnts
 Silica-1
 Silica-2
 Silica-3
Page 25

27. 2.4.1 Silica Plant Operational Process Flow
Continued ............Next Page
Page 26

28. Page 27

29. 3.1 PROJECT PROFILE
3.1 Objectives of the Study
1) Quality Control in chamber kiln.
2) Kaizan,5S & Safety plan inside the the silica plant
3.2 Project Type & Tools
 Production Operation Management
 Statistical Tools:
o Regression analysis
o Correlation
o Probability Distribution
o Binomial Probability Distribution
o Normal Probability Distribution
o Central Tendencies: Mean,Median,Mode,Quartiles
o Skewness,Kurtosis,Standard Deviation, Variance
o Ranges, Outliers & box plot diagrams
 Concepts Applied
o Density & weight relationship
o Heat phenomenon
o Volumetric Expansion of bricks
3.3 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 company
3.4 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 data
Page 28

30. 3.4.2 Secondary data:
The main source of secondary data was recorded from
 Company’s Resorce allocation book
 Company’s Monthly bricks Checking records
 Slica Brick Failure record
 Bricks dimension layout bulletin
 Mould house specifications
 Laboratory checking results
 Advise of experienced & experts
3.4.3 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 time
3.4.4 Sample size:-
 For target:1, 2700 data were taken
 For target:2, 2700 data were taken
 For target:3, 200 data were taken
3.5 Details Of Work
3.5. 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 company’s 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 29

31. 3.5. 2 Office Work :
 We had to report twice in office regarding our work , then we had a discussion with OCL’s
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 choose
particular area (example kiln),then we have to cover there every block to know
opertations
 At first, We had to meet with the person incharge of that operational zone , then we had to
introduce ourselves & what was our purpose of visting.
 After that, we had to meet with manager,executives & workers to undersand the
operations better.
 They gave us only information about company . Sometimes as i predict they couldn’t give
the right answer to our query
 Sometime we used to get appointment with opertational managers/executiuve
manager/ to dicuss on any particulr topic.
 Company which have tied up with ICICI & Syndicate bank , they are not so satisfied, so in
that case they want to meet with manager for further discussion of opening a current or
salary A/C .
3.6 Working Hierarchy Model
Human
Resource
Senior General
Manager
Chief Deputy
Manager Manager
Internship Engineering Management Project vocational
Trainee Trainee Trainee Trainee Trainee
Page 30

32. 3.7 Pyramid of Problem Approach
It shows how a client is approached & finally the deal is made in 7 stages.
prepare
report
Excel
simulation/pict
orial diagrams
Derive
conclusion,recommend
ations
Observe & analize the
results obtained
Apply statistical tools &
techniques
compare both the data & check if
they match
Collect primary & secondary data
Design the plan & methods
Know the problem statement
Page 31

33. 3.2 Application to Company
3.2.1 Application of quality control:
INDUSTRIAL APPLICATION:1 ( CHAMBER KILN)
Refractory has three types of kiln
KILN
TUNNEL CHAMBER BELL
In this klin the Heat is In this klin the Heat is In this klin the bricks
constant & Bricks rotates & Bricks are are static & the kiln
move inside the kiln. static the kiln. itself movable.
Specifically we did observation for chamber kiln.
KILN CHAMBER
FB 1 to 24
Kiln-1 1 to 24
Kiln-2 1 to 24
Kiln-3 1 to 22
Kiln-4 1 to 26
Kiln-5 1 to 28
Kiln-6 1 to 28
Kiln-2A 1 to 28
Page 32

34. CHAMBER KILN
CHAMBERS
OCL Silica Refractory has 8 kilns.Eack Kiln has 22 to 28 chambers. Again each chamber has
4 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 differed
across length & height.Position of bricks inside a kiln mattered a lot.So a very microscopic
obsevation was done using statistical tools & techniques. For this experiment 2700 raw data of
bricks were taken.
It was an assumption that the bricks inside the kiln expanded by 4.2% after firing. So our motive
was to observe if the assumption was accurate & how the bricks expanded at very microssopic
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.
Page 33

35. CHAMBER LAYOUT
TOP layer
4th layer
Middle
layer
2nd layer
Bottom
layer
BENCH-A BENCH-B BENCH-C BENCH-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 34

36. INDUSTRIAL APPLICATION:3 ( PRESS MACHINE)
Apprarnt Posrosity α Bulk Density
Density = Weight / Volume
Volume reduces increases in Kiln reducing the Bulk Density
Weight is lost reducing the Bulk Density
In PRESS MACHINE It is a very complicated process to detect apparent porosity needed for
a particular green bulk density.Orders are placed in terms of maximum apparent
posrosity.So its an importnat that what should be the pressure applied by the press
machine 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 35

37. QUALITY
CONTROL
Page 36

38. 4.1 QUALITY CONTROL
4.1.1Quality control
It is a process by which entities review the quality of all factors involved in production. This
approach places an emphasis on three aspects:
1. Elements such as controls, job management, defined and well managed
processes, 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 to
management who make the decision to allow or deny the release, whereas quality
assurance attempts to improve and stabilize production, and associated processes, to
avoid, or at least minimize, issues that led to the defects in the first place
4.1.2 Total quality control
"Total quality control" is a measure used in cases where, despite statistical quality control
techniques or quality improvements implemented, sales decrease. If the original
specification does not reflect the correct quality requirements, quality cannot be inspected
or manufactured into the product. For instance, the parameters for a pressure vessel
should include not only the material and dimensions, but also operating, environmental,
safety, reliability and maintainability requirements.
4.1.3 Quality control in project management
In project management, quality control requires the project manager and the project team
to inspect the accomplished work to ensure that it's aligned with the project scope. In
practice, projects typically have a dedicated quality control team which focuses on this
area.
4.2 EXPANSION % of bricks
4.2.1 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 37

39. Arithmetic mean (AM)
Main article: Arithmetic mean
The 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 percentile
The 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 data
points 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).
Variance
If a random variable X has the expected value (mean) μ = E[X], then the variance of X is
given by:
BOX PLOT
Box and whisker plots are uniform in their use of the box: the bottom and top of the box are
always the 25th and 75th percentile (the lower and upper quartiles, respectively), and the
band near the middle of the box is always the 50th percentile (the median). But the ends of
the whiskers can represent several possible alternative values, among them:
Page 38

40.  the minimum and maximum of all the data
 the lowest datum still within 1.5 IQR of the lower quartile, and the highest datum
still 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 percentile
4.2.2 OBSERVATION
AGGREGATE of ALL BENCHES BENCH-A
4.165504359 Mean 4.1271941
Standard Error 0.005251262 Standard Error 0.0127295
Median 4.2 Median 4.2
Mode 4 Mode 4
Standard Deviation 0.257740157 Standard Deviation 0.3620653
Sample Variance 0.066429988 Sample Variance 0.1310913
Kurtosis -0.36200066 Kurtosis 2.0335368
Skewness 0.063940314 Skewness -1.1046595
Range 1.3 Range 2.1
Minimum 3.6 Minimum 2.8
Maximum 4.9 Maximum 4.9
Sum 10034.7 Sum 3338.9
Count 2409 Count 809
Largest(1) 4.9 Largest(1) 4.9
Smallest(1) 3.6 Smallest(1) 2.8
Confidence Confidence
0.01029746 0.0249869
Level(95.0%) Level(95.0%)
Q1 Mean Q1 4
Q2 4.2 Q2 4.2
Q3 4.3 Q3 4.4
% distribution % distribution
above 4.2 50% above 4.2 50%
Below 4.2 50% Below 4.2 50%
b/w 3.55 to 4 25% 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 4.75 25% b/w 4.4 to 5 25%
IQR 0.3 IQR 0.4
Upper 4.75 Upper 5
Lower 3.55 Lower 3.6
Page 39

41. BOX PLOT DIAGRAM
AGGREGATE BENCH-A
Max Val 5 Upper 5
Upper Max Val
4.75 4.9
Q3 4.3 Q3 4.4
Q2 4.2 Q2 4.2
Q1 4 Q1 4
Lower Lower
3.55 3.6
Min Val Min Val
1.7 2.8
Page 40

42. BENCH-C BENCH-D
Mean 4.124333 Mean 4.1451852
Standard Error 0.012193 Standard Error 0.0096234
Median 4.2 Median 4.2
Mode 4 Mode 4
Standard Deviation 0.365803 Standard Deviation 0.2738866
Sample Variance 0.133812 Sample Variance 0.0750139
Kurtosis 13.36301 Kurtosis 6.0016874
Skewness -2.13153 Skewness -0.94433
Range 3.2 Range 2.8
Minimum 1.7 Minimum 2.2
Maximum 4.9 Maximum 5
Sum 3711.9 Sum 3357.6
Count 900 Count 810
Largest(1) 4.9 Largest(1) 5
Smallest(1) 1.7 Smallest(1) 2.2
Confidence Confidence
0.023931 0.0188898
Level(95.0%) Level(95.0%)
Q1 4 Q1 0.3164508
Q2 4.2 Q2 4.2
Q3 4.3 Q3 4.3
% distribution % distribution
above 4.2 50% above 4.2 50%
Below 4.2 50% Below 4.2 50%
b/w 3.55 to 4 25% b/w 3.55 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 4.3 25%
b/w 4.3 to 4.75 25% b/w 4.3 to 4.75 25%
IQR 0.3 IQR 0.3
Upper 4.75 Upper 4.75
Lower 3.55 Lower 3.55
Page 41

43. BENCH-C BENCH-D
Max Val 4.9 Max Val 5
Upper Upper
4.75 4.75
Q3 4.3 Q3 4.3
Q2 4.2 Q2 4.2
Q1 4 Q1 4
Lower Lower
3.55 3.55
Min Val Min Val
1.7 2.2
Page 42

44. 4.2.3 ANALYSIS
Bench-A
4.3 4.3
4.25
4.25 y = -0.075x + 4.347 4.2
4.2
R² = 0.864 4.15
4.1 Top,
4.15 4.05 4.283333 4th,
4 333 4.195061 3rd,
4.1 3.95 728 4.138888
3.9 889 2nd, Bottom,
4.05 4.018518
3.85 3.966666
3.8 667 519
4
Top 4th
3.95 3rd 2nd
Bottom
0 1 2 Axis3Title 4 5 6
Bench-C
4.3
4.3
4.25
4.2
4.2
4.1
4.15
4th,
4
4.1 Top, 4.2444444 3rd, 2nd,
4.1916666
4.05 3.9 4.0855555 44 4.1666666
67
56 67
4 y = -0.038x + 4.239 3.8 bottom,
3.9333333
3.95 R² = 0.248 3.7 33
Top 4th
3.9 3rd 2nd
0 1 2 3 4 5 6 bottom
Page 43

45. AGGREGATE OF BENCH - A,C & D
4.25
4.25
4.2 4.2
y = -0.044x + 4.262 4.15
4.15 R² = 0.682 4.1
4.05
4.1 4
3.95
4.05
3.9
3.85
4 Top 4th 3rd
2nd
Bottom
3.95 Axis Title
0 2 4 6
Bench-D
4.35
y = -0.018x + 4.2
4.3
4.3
R² = 0.046
4.25
4.25 4.2
4.15
4.2 4.1
4.15 4.05
4
4.1 3.95
4.05 3.9
3.85
4 3.8
3.75
3.95
Top 4th
3.9 3rd
2nd
0 1 2 3 4 5 6 bottom
Page 44

46. Layer-Top Layer-4th
4.3 4.25
4.24
4.25
y = -0.0491x + 4.2828 4.23
4.2 R² = 0.2463
4.22
4.15
4.21 y = 0.0191x + 4.186
R² = 0.5456
4.1
4.2
4.05 4.19
0 1 2 3 4 0 1 2 3 4
Layer-3 Layer-2nd
4.25 4.35
y = 0.1599x + 3.8202
4.2 4.3
R² = 0.9794
4.25
4.15
4.2
4.1
4.15
4.05
4.1
4 y = -0.0926x + 4.2799
R² = 0.549 4.05
3.95 4
3.9 3.95
0 1 2 3 4 0 1 2 3 4
Page 45

47. Layer-Bottom Aggregate of All layers
4.08 4.15
4.06 y = 0.0244x + 3.9576 4.145 y = 0.012x + 4.105
R² = 0.1293 R² = 0.863
4.04
4.14
4.02
4.135
4
4.13
3.98
4.125
3.96
3.94 4.12
3.92 4.115
0 1 2 3 4 0 1 2 3 4
4.2.4 Interpretation
Hozizontal expansion
Bench-A
 The expansion is exceptionaly high or low in the 3rd layer of Bench-A. The
temperature at 3rd layer vastly differs from its neighbouring layer.Most of the
graphs takes a upward or downward turn in this layer. Somewhat 2nd layer also
shows same characteristics.
Bench-C
 The expansion is exceptionaly high or low in the 3rd layer of Bench-B. The
temperature at 3rd layer vastly differs from its neighbouring layer.Most of the
graphs takes a upward or downward turn in this layer. Somewhat 2nd layer also
shows same characteristics.
Bench-D
 The expansion is exceptionaly low in the 3rd layer of Bench-C. The temperature
at 3rd layer vastly differs from its neighbouring layer.Most of the graphs takes a
upward or downward turn in this layer. 2nd layers also shows exceptonally high
value
Page 46

48. Vertical expansion
Layer Top:
Expansion Max at :C
Expansion Min at :A
Expansion Average at: D
A to C: upward steep slope
C to D: Curve U turn shape
Layer 4th:
Expansion Max at :C
Expansion Min at :A
Expansion Average at: D
A to C: upward steep slope
C to D: Curve U turn shape
Layer Middle:
Expansion Max at :C
Expansion Min at :D
Expansion Average at: A
C to D: Downward steep slope
Layer 2nd:
Expansion Max at :D
Expansion Min at :C
Expansion Average at: A
A to D: Straight line,steep,upward with slope 0.98
Layer Bottom:
Expansion Max at :D
Expansion Min at :C
Expansion Average at: A
A to C: Downward steep slope
C to D: Curve U turn shape
4.2.5 OVERALL FINDINGS
 Expansion is maximum at 4th layer.The expansion gradually increases from
top to 4th layer,maintains a flat structure till the 2nd layer .In between curve
goes slight down taking a turn in middle( 3rd layer).Curve gradually falls from 2nd
layer 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 47

49. 4.2.5 RECCOMENDATION
 The bricks which are very sensitive can be put in the 2nd layer as it is highly
predictable.
 The bricks at Bench-A also can be predicted to large extent with respect to its
distance from ground.
 The bricks that require minimum expansion can be placed in bottom layer
of bench-A
 The bricks that require maximum expansion can be placed in Top layer or 4th layer
of bench-D
 The bricks which are least sensitive can be put in the bottom layer as it is least
predictable.
 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 with
correlation 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 as
its trend is very variable with correlation r<0.8
 Standard average expansion of bricks is 4.165%
Page 48

50. 5.3 PROBABILITY DISTRIBUTION
5.3.1 METHODOLOGY
 Collecting 2700 raw datas from kiln
 % containt in whole sum
 Finding Binomial Probabilty distribution
 Finding Normal Distribution
 Comparative Analysis
 Graphical Analysis
NORMAL PROBABILITY DISTRIBUTION
In probability theory, the normal (or Gaussian) distribution, is a continuous probability
distribution that is often used as a first approximation to describe real-valued random
variables that tend to cluster around a single mean value. The graph of the associated
probability density function is “bell”-shaped, and is known as the Gaussian function or bell
curve:
Where parameter μ is the mean (location of the peak) and σ 2 is the variance (the measure
of the width of the distribution). The distribution with μ = 0 and σ 2 = 1 is called the
standard normal.
BINOMIAL PROBABILITY DISTRIBUTION
probability theory and statistics, the binomial distribution is the discrete probability
distribution of the number of successes in a sequence of n independent yes/no
experiments, each of which yields success with probability p. Such a success/failure
experiment is also called a Bernoulli experiment or Bernoulli trial. In fact, when n = 1, the
Page 49

51. binomial distribution is a Bernoulli distribution. The binomial distribution is the basis for
the popular binomial test of statistical significance
Probability mass function
In general, if the random variable K follows the binomial distribution with parameters n
and p, we write K ~ B(n, p). The probability of getting exactly k successes in n trials is given
by the probability mass function:
For k = 0, 1, 2, ..., n, where
is the binomial coefficient (hence the name of the distribution) "n choose k", also denoted
C(n, k), nCk, or nCk. The formula can be understood as follows: we want k successes (pk) and
n − k failures (1 − p)n − k. However, the k successes can occur anywhere among the n trials,
and there are C(n, k) different ways of distributing k successes in a sequence of n trials.
In creating reference tables for binomial distribution probability, usually the table is filled
in up to n/2 values. This is because for k > n/2, the probability can be calculated by its
complement as
So, one must look to a different k and a different p (the binomial is not symmetrical in
general). However, its behavior is not arbitrary. There is always an integer m that satisfies
As a function of k, the expression ƒ(k; n, p) is monotone increasing for k < m and monotone
decreasing for k > m, with the exception of one case where (n + 1)p is an integer. In this
case, there are two maximum values for m = (n + 1)p and m − 1. m is known as the most
probable (most likely) outcome of Bernoulli trials. Note that the probability of it occurring
can be fairly small.
The cumulative distribution function can be expressed as:
where is the "floor" under x, i.e. the greatest integer less than or equal to x.
Page 50

52. 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. In
particular, Hoeffding's inequality yields the bound
and Chernoff's inequality can be used to derive the bound
Moreover, these bounds are reasonably tight when p = 1/2, since the following expression
holds for all k ≥ 3n/8
Mean and variance
If X ~ B(n, p) (that is, X is a binomially distributed random variable), then the expected
value of X is
and the variance is
This 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 the
second having probability 1 − p. The expected value in this trial will be equal to μ = 1 · p +
0 · (1−p) = p. The variance in this trial is calculated similarly: σ2 = (1−p)2·p + (0−p)2·(1−p) =
p(1 − p).
The generic binomial distribution is a sum of n independent Bernoulli trials. The mean and
the variance of such distributions are equal to the sums of means and variances of each
individual trial:
Page 51

53. Mode and median
Usually the mode of a binomial B(n, p) distribution is equal to ⌊(n + 1)p⌋, where ⌊ ⌋ is the
floor function. However when (n + 1)p is an integer and p is neither 0 nor 1, then the
distribution has two modes: (n + 1)p and (n + 1)p − 1. When p is equal to 0 or 1, the mode
will 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 it
may 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 = ½ and n is odd)
 When p = 1/2 and n is odd, any number m in the interval ½(n − 1) ≤ m ≤ ½(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 binomials
If two binomially distributed random variables X and Y are observed together, estimating
their covariance can be useful. Using the definition of covariance, in the case n = 1 we have
The first term is non-zero only when both X and Y are one, and μX and μY are equal to the
two probabilities. Defining pB as the probability of both happening at the same time, this
gives
and for n such trials again due to independence
If X and Y are the same variable, this reduces to the variance formula given above.
Page 52

54. 5.3.2 OBSERVATION
BENCH-A
Brick with Numbers Total %
Expansion % Found Inspected Found
3.6 27.5 810 3.3951 %
3.8 53 810 6.5432 %
4 225 810 27.778 %
4.2 180 810 22.222 %
4.4 166 810 20.494 %
4.6 89 810 10.988 %
4.8 15.5 810 1.9136 %
5 0.5 810 0.0617 %
Total 93.395 %
BENCH-C
Brick with
Numbers Total %
Expansion
Found Inspected Found
%
3.6 40 900 4.444 %
3.8 113 900 12.56 %
4 250.5 900 27.83 %
4.2 217 900 24.11 %
4.4 150 900 16.67 %
4.6 63.5 900 7.056 %
4.8 29.5 900 3.278 %
5 4 900 0.444 %
Total 96.39 %
Page 53

55. BENCH-D
Brick with
Numbers Total %
Expansion
Found Inspected Found
%
3.6 15 810 1.8519 %
3.8 47.5 810 5.8642 %
4 230 810 28.395 %
4.2 253 810 31.235 %
4.4 166 810 20.494 %
4.6 46.5 810 5.7407 %
4.8 28.5 810 3.5185 %
5 3 810 0.3704 %
Total 97.469 %
Aggregate of Bench-A,C & D
Brick with
Numbers Total %
Expansion
Found Inspected Found
%
3.6 102.5 2520 4.0675 %
3.8 228.5 2520 9.0675 %
4 704.5 2520 27.956 %
4.2 650.5 2520 25.813 %
4.4 367.5 2520 14.583 %
4.6 204 2520 8.0952 %
4.8 78 2520 3.0952 %
5 7 2520 0.2778 %
Total 92.956 %
Page 54

56. 5.3.3 ANALYSIS
Bench-A
250 250
225
200 200
180
166
150 150
225
100 100
89 180
166
50 53 50 89
27.5 53
15.5 27.5 15.5
0 0.5 0 0.5
3.6 3.8 4 4.2 4.4 4.6 4.8 5 3.6 3.8 4 4.2 4.4 4.6 4.8 5
Bench-C
300 300
250 250.5 250
217
200 200
150 150 150
250.5
113 217
100 100
150
63.5
50 50 113
40
29.5 63.5
40 29.5
0 4 0 4
3.6 3.8 4 4.2 4.4 4.6 4.8 5 3.6 3.8 4 4.2 4.4 4.6 4.8 5
Page 55

57. Bench-D
300 300
250 253 250
230
200 200
166
150 150
253
230
100 100
166
50 47.5 46.5 50
28.5 47.5 46.5
15 28.5
0 3 0 15 3
3.6 3.8 4 4.2 4.4 4.6 4.8 5 3.6 3.8 4 4.2 4.4 4.6 4.8 5
Aggregate of All benches
800 800
700 704.5 700
650.5
600 600
500 500
400 400
367.5 704.5
650.5
300 300
228.5
200 204 200 367.5
100 102.5 100 228.5 204
78
102.5 78
0 7 0 7
3.6 3.8 4 4.2 4.4 4.6 4.8 5 3.6 3.8 4 4.2 4.4 4.6 4.8 5
Page 56

58. 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 by
4.2%,4.4%.
 The probability of getting bricks is low at both the extremes of expansion that is
3.6 % & 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 of
firing 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 inter
quartile 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 57

59. 5.3 Apparent Posrosity Versus Bulk Density
5.3.1 METHODOLOGY
 Collecting 150 raw datas from kiln
 Regression analysis
 Correlation Analysis
 Graphical Analysis
Regression Analysis
In linear regression, the model specification is that the dependent variable, yi is a linear
combination of the parameters (but need not be linear in the independent variables). For
example, in simple linear regression for modeling n data points there is one independent
variable: xi, and two parameters, β0 and β1:
straight line:
In multiple linear regression, there are several independent variables or functions of
independent 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 in
the independent variable xi, it is linear in the parameters β0, β1 and β2.
In both cases, is an error term and the subscript i indexes a particular observation. Given
a random sample from the population, we estimate the population parameters and obtain
the sample linear regression model:
The residual, , is the difference between the value of the dependent variable
predicted by the model, and the true value of the dependent variable yi. One method of
estimation is ordinary least squares. This method obtains parameter estimates that
minimize the sum of squared residuals, SSE:
Page 58

60. Minimization of this function results in a set of normal equations, a set of simultaneous
linear 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 are
where is the mean (average) of the x values and is the mean of the y values. See simple
linear regression for a derivation of these formulas and a numerical example. Under the
assumption that the population error term has a constant variance, the estimate of that
variance is given by:
This is called the mean square error (MSE) of the regression. The standard errors of the
parameter estimates are given by
Page 59

61. Under the further assumption that the population error term is normally distributed, the
researcher can use these estimated standard errors to create confidence intervals and
conduct hypothesis tests about the population parameters.
Correlation
The population correlation coefficient ρX,Y between two random variables X and Y with
expecte values μX and μY and standard deviations σX and σY is defined as:
where E is the expected value operator, cov means covariance, and, corr a widely used
alternative notation for Pearson's correlation.
The Pearson correlation is defined only if both of the standard deviations are finite and
both of them are nonzero. It is a corollary of the Cauchy–Schwarz inequality that the
correlation cannot exceed 1 in absolute value. The correlation coefficient is symmetric:
corr(X,Y) = corr(Y,X).
Page 60

62. 5.3.2OBSER VATION
AP Vs BD
2
1.95
y = -0.0207x + 2.2537
1.9 R² = 0.9051
1.85
1.8
1.75
1.7
1.65
0 5 10 15 20 25 30
∑ e² 0.07238
N 150
AP Vs GGBD
2.4
2.35
y = -0.0249x + 2.7098
2.3
R² = 0.9051
2.25
GGBD
2.2
2.15
2.1
2.05
2
0 5 10 15 20 25 30
∑ e² 0.1
N 150
Page 61

63. 5.3.3 ANALYSIS
5.3.3.1 DERIVATION
Page 62

64. Applying X% = 4.1699% expansion as per the standards from target1
Applying L% = 6% ,loss of moisture as per the laboratory standard
BBD = -0.02 AP + 2.253
FGBD = -0.0251 AP + 2.8246
GGBD= -0.024 AP + 2.709
AGBD= -0.0245 AP + 2.7668
BBD = 0.7976 FGBD
FGBD = 1.2537 BBD
5.3.4 Interpretation
Apparent Porosity is inversely related to burnt Bulk Density.
BBD α 1/ AP
BBD = - K * AP + C
where K is the rate at which BBD decreases with increase in AP.C is a constant
Rate is 0.020 change per unit alteration
Formula Accuracy: 90.5%
Green Burnt Bulk density is directly related to Burnt Bulk Density
GBD α BBD
GBD = M* BBD + C
Page 63

65. where M is the rate at which BBD increases with increase in AP.
Again
M = (1 + X°)/ (1-L°)
X° = X/100; L° = L /100
X is Expansion % of bricks
L is % Loss in weight
Formula Accuracy: 100 %
Apparent Porosity is inversely related to burnt Bulk Density.
GBD α 1/ AP
GBD = - L * AP + C
where L is the rate at which BBD decreases with increase in AP.C is a constant
Again
L = { 0.020 (1 + X°)} / (1-L°)
X° = X/100; L° = L /100
X is Expansion % of bricks
L is % Loss in weight
Formula 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.
 R² > 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.
 R² > 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 situation
4.2.5 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 64

66.  The composition of powder put in press machine must be ensured, otherwise
wrong composition may produce wrong data due to variation in standard
density,leading to altered apparent porosity.
4.2.5 CONCLUSION
 When the weight loss %increases , the apparent porosity for the same
pressure applied increases.
L% α AP
 When the expansion % increases , the apparent porosity for the same
pressure applied increases.
X% α AP
.
Page 65

67. KAIZEN
&
5S
Page 66

68. 4.1 KAIZEN
Kaizen (Japanese for "improvement" or "change for the better") refers to philosophy or
practices that focus upon continuous improvement of processes in manufacturing,
engineering, supporting business processes, and management. It has been applied in
healthcare, psychotherapy, life-coaching, government, banking, and many other industries.
When used in the business sense and applied to the workplace, kaizen refers to activities
that continually improve all functions, and involves all employees from the CEO to the
assembly line workers. It also applies to processes, such as purchasing and logistics, that
cross organizational boundaries into the supply chain.By improving standardized activities
and processes, kaizen aims to eliminate waste (see lean manufacturing). Kaizen was first
implemented in several Japanese businesses after the Second World War, influenced in part
by American business and quality management teachers who visited the country. It has
since spread throughout the world and is now being implemented in many other venues
besides 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 infinitum
This is also known as the Shewhart cycle, Deming cycle, or PDCA.
Page 67

69. 4.2 5S
5S is the name of a workplace organization methodology that uses a list of five Japanese
words which are seiri, seiton, seiso, seiketsu and shitsuke. Transliterated or translated
into English, they all start with the letter "S". The list describes how items are stored and
how the new order is maintained. The decision-making process usually comes from a
dialogue about standardization which builds a clear understanding among employees of
how work should be done. It also instills ownership of the process in each employee.
4.2.1 Phases of 5S
There are 5 primary phases of 5S: sorting, straightening, systematic cleaning,
standardizing, and sustaining. Additionally, there are two other phases sometimes
included, 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 not
required, 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 place
for each item should be clearly labeled or demarcated. Items should be arranged in a
manner that promotes efficient work flow. Workers should not have to bend repetitively to
access materials. Each tool, part, supply, or piece of equipment should be kept close to
where it will be used – in other words, straightening the flow path. Seiton is one of the
features that distinguish 5S from "standardized cleanup". This phase can also be referred to
as Simplifying
Sweeping or shining or cleanliness / systematic cleaning (Seiso)
Keep the workplace tidy and organized. At the end of each shift, clean the work area and
be sure everything is restored to its place. This makes it easy to know what goes where and
ensures that everything is where it belongs. A key point is that maintaining cleanliness
should be part of the daily work – not an occasional activity initiated when things get too
messy.
Standardizing (Seiketsu)
Work practices should be consistent and standardized. Everyone should know exactly
what his or her responsibilities are for adhering to the first 3 S's.
Page 68

70. Sustaining the discipline or self-discipline (Shitsuke)
Maintain and review standards. Once the previous 4 S's have been established, they
become the new way to operate. Maintain focus on this new way and do not allow a gradual
decline back to the old ways. While thinking about the new way, also be thinking about yet
better ways. When an issue arises such as a suggested improvement, a new way of working,
a new tool or a new output requirement, review the first 4 S's and make changes as
appropriate.
4.3 Safety
A sixth phase, "Safety", is sometimes added. While it is reasonable to assume that a
properly planned and executed 5S program will improve workplace safety, some argue
that explicitly including this sixth "S" ensures that workplace safety is given at least a
secondary consideration.
4.4 Security
A seventh phase, "Security", can also be added. In order to leverage security as an
investment rather than an expense, the seventh "S" identifies and addresses risks to key
business categories including fixed assets (PP&E), material, human capital, brand
equity, intellectual property, information technology, assets-in-transit and the extended
supply chain.
It is important to have continuous education about maintaining standards. When there are
changes that affect the 5S program such as new equipment, new products or new work
rules, it is essential to make changes in the standards and provide training. Companies
embracing 5S often use posters and signs as a way of educating employees and maintaining
standards.
4.5 SMALL IMPROVEMENT & SAFETY
5.5.1 METHODOLOGY
 Identifying the problem
 Drawing layout & Analizing it
 Observational analysis
 Deriving Solution & Suggestion
Page 69

71. DRAWING LAYOUT
5.3.2 Observation
 Different Work stations were observed
 Operations of machinery items & how the workers operated it was observed
 Plant layout including traffic system was Observed
 All safety plans & precautionary measures were understood
 All instructions in the boards were read & noted down
 The vesting area, seminar hall, executive desks etc were observed
 Timings,meetings,shifts time etc were recorded
 All old accidental records were noted down irrespective of whether it was major
or minor
 The company management hierarchy was also observed
Page 70

72. 5.3.3 ANALYSIS
TASK PRIORITY
5.3.4 INTERPRETATION
 It was difficult to identify which are the high alert & risky zones within the plant
 Cautions & safety measures were not conveyed each & every part of the company
 Safety plan were their for third part but not for those who directly were in thaw
work station
 Road safety was a major concern, as people & cranes moved on the same road
 Road were covered with producer gas hot steam chambers that generated hot coal
residue with touched the corner of road
 Minor accidents with mixer buckets falling or trolleys derailing occurred
 Transfer cars were driven fast.
 Transfer car jam on the rail was a major concern because of bidirectional movement
on one single rail track
 Machines that were operating & non operating was difficult to be identified by
inspectors, outsiders & new comers.
 During loading & unloading of kiln the routes become very busy
 Telephone extension code should was not written on the telephone itself.
 Refractory layout was so big & identical that reaching & identifying a particular
work station from other was very difficult. New Comers would get confused that in
which plant they are working.
Page 71

73. 5.3.5 KEY FINDINGS
 Most of the workers were so uneducated that they didn’t know how to read a
digital machine
 Most of the workers didn’t have time to attend training on safety techniques
 Though saftety plans were made, most of the workers were not aware of it
 Importnace & priority towards safety was a less concern
 Safety is not about taking measures but making a habit
5.3.6 RECCOMENDATION
 There should be various safety zones within a work station. Safe Zone, Highly
Alert Zone & Core member zone.
 Different Colour codes should be used to represent each zone
 Safety plan should be made with the help of industry layout
.
 Road safety layout is a must, having different passage for employee walking &
cranes that are moving.
 Transfer cars should be handled properly, driven slowly & only pushed. No
pulling effort should be given. Alert message should be written on transfer car.
 Chamber kiln operation status should be labeled
 Operation status of almost all work station should be mentioned whether
operating/not operating
 Name & contact number of person who holds in charge of that particular work
station should be mentioned.
 Busy routes should be tackled by creating passage from alternate routes that are
free with the help of direction board mentioning stipulated time till it will remain
busy.
 All desk should have purpose mentioned on there table. All work station should
have note of what they do.
 Name of the person should be mentioned on their cabin desk.
 Telephone extension code should be written on the telephone itself.
 We should prioritize our task according to how urgent or important or both it is,
on the basis of that we should arrange our table & documents for the day.
Page 72

74.  Map & additional information should be provided inside the plant.
 Caution & Danger symbol must be well defined.
 Mixer bucket should be operated carefully. Helmet is a must. While string pulls up,
the person should leave the station area & close the gate. Whistle before operation
starts to create alert.
 Use of railway tracks should be optimized to reduce the traffic
5.3.7 CONCLUSION
 The safety plan was developed with the help of pictorial layouts
 List of recommendations were suggested with pictorial diagrams
 Small startegic improvement plans were proposed
All plans were implemented & specially with the help of pictures so that they can
be understood by the lay man & those worker who didn’t understand.
The layouts should be brought out in three languages English,Hindi & Oriya (
state lenguage)
Page 73

75. EXCEL
SIMULATION
TOOL
Page 74

76. 6.EXCEL SIMULATION TOOL
6.1 Tool-1
CHECK ABNORMAL CASES HELP
0
Check Output
5 NORMAL
Enter Expansion
REMARK 0.806
Value %
Deviation
OK
A from MEAN %
STATUS
Enter Bench
After entering press
ENTER KEY
This tool will give an idea about
1) Maximum possible expansion %
2) Minimum possible expansion %
3) Average expansion %
USER GUIDE
* In left hand side top enter the sigma σ
level to fix standard deviation
* Press ENTER to see the result at right hand
side
Page 75

77. 6. 2 Tool-2
CALCULATE Expansion % Range HELP
Check Output
2 4.680984672 % %
Sigma Level σ
Maximum Expansion
4.165504359
3.650024045 %
After entering press Average
ENTER KEY Minimum Expansion
CALCULATE Bench wise Expansion % Range HELP
Check Output
3.8 5.190651846 % %
Enter Maximum Expansion 4.692610691
Sigma Level σ
4.194569536 %
a
Average
Enter Bench Minimum Expansion
After entering press
ENTER KEY
Page 76

78. 6.3 Tool-3
Check Output
EQUATION IS
A Y= -0.075 X + 4.347
Y -> Expansion %
ENTER BENCH
-0.075
NO X-> Layer Number
After entering
press SLOPE
ENTER KEY
57.96 4.347
Meets at X-axix Meets Y-
at Axix at
A Intercept
85.71085 ° 175.71085 °
Check Output
1 Angle with Y-axix
ENTER LAYER Function Increasing
NO
After entering
press 4.272 % 86.4 %
ENTER KEY Expansion Accuracy
Page 77

79. 6.4 Tool-4
CHECK
VERTICAL
HELP
VARIATION
Check Output
45 4.23633333 %
Enter Height in
Expansion 0.070828975 %
mm
Deviation
68.2 % from MEAN
After entering press ACCURACY
ENTER KEY
Page 78

80. 6.5 Tool-5
Enter Bench No Enter Bench No
Bench Comaprision T T
After entering press After entering press
ENTER KEY ENTER KEY
Enter Bench Number at Top
shown with Arrow Mark . Enter
both the entries.
*Brench No should be : A,B,C
D.
* ENTER 'T' in case to see the
aggregate summary of all
benches together
* Press Enter to see the results
down
6.6 Tool-6
%
ENTER Expansion 5
Loss in
Weight 6 %
ENTER
Page 79

81. PICTORIAL
RECOMMENDATION
Page 80

82. 7.PICTORIAL RECCOMENDATION
7.1 Suggestion 1:
7.2 Suggestion 2:
Page 81

83. 7.3 Suggestion 3:
7.4 Suggestion 4:
Page 82

84. 7.5 Suggestion 5:
7.6 Suggestion 6: 7.7 Suggestion 7:
Page 83

85. 7.8 Suggestion 8:
7.9 Suggestion 9:
Page 84

86. 7.10 Suggestion 10:
7.11 Suggestion 11:
Page 85

87. 7.12 Suggestion 12:
7.13 Suggestion 13:
Page 86

88. 8. LEARNING OUTCOME:
Follwoing were the learning & notions that i got from my internship project,that would be
careerd by me wherever I work further.
8.1 QUALITY CONTROL PROJECT:
1. Microscopic level observation is very important though it may not be helpful in
broader sense, beacuse it is always important to know the scientific reasons
behind any happenings
2. Predicting future results statistically helps taking neccessary action before hand.
3. Statistical tools used efficiently makes our work easy,systematic,fast & gives a new
perception & way to look at existing things
4. But results derived statistically has to be updated on timely basis & should be
improved,croscheckd,re calculated with the evolutionof new tools & techniques &
modernization in technology.
5. Quality ensures how much value we add to our customers & satisfy them , resulting
in better return on investment & loyal relationship with them
8.2 KAIZEN,5S & SAFETY PROJECT
1. Safety is has to be a major priority
2. Smaller level strategic operational improvement make a comany shine longer
3. House keeping gives a good impression to outsiders,visitors & brings a feel good
factor within the emplyees
4. Safety is not about taking measures,following instructions,obeying,cautioning
ourselves or becoming carefull.It should be made unconditional habit within each
employee.Instructions may be skipped but nature of habit decides certain actions
which a person cannot skip even when he is busy,absence minded & is not thinking
deep into it. This is how company should position & implement safety policy within
its employees.
5. Adopting Safety policy should be a culture within a company.
6. It helps developing better relationship between the company & employee.
Page 87

89. APPENDIX-1
PROBABILITY DISTRIBUTION
Brick with
Numbers Total %
Expansion
Found Inspected Found
%
3.6 102.5 2520 4.0675 %
3.8 228.5 2520 9.0675 %
4 704.5 2520 27.956 %
4.2 650.5 2520 25.813 %
4.4 367.5 2520 14.583 %
4.6 204 2520 8.0952 %
4.8 78 2520 3.0952 %
5 7 2520 0.2778 %
Total 92.956 %
SAMPLE SIZE
Sample No of Sample
Distribution samples type Type
Bench Wise 850/bench Bench A,C & D
540/layer Top,bottom,
Layer wise Layer
type 2nd,3rd,4th
Each Half of 425/half 1st half &
Partiion
bench bench 2nd half
CAPACITY
Bottom Layer : 0.8 Tone
2nd Layer : 1.0 Tone
3rd Layer : 2.0 Tone
4th Layer : 1.5 Tone
Top Layer : 0.5 Tone
Page 88

90. APPENDIX-2
EXPANSION % LAYER WISE
1st Half
Top 4th 3rd 2nd Bottom
4.29876543 4.17160494 4.19259259 4.01728395 4.008642
4.04555556 4.20888889 4.19222222 4.17111111 3.926667
4.11358025 4.20740741 3.9691358 4.29506173 4.046914
Total 4.15263374 4.19596708 4.11798354 4.16115226 3.994074
2nd Half
Top 4th 3rd 2nd Bottom
4.12555556 4.28 4.19111111 4.16222222 3.94
4.26790123 4.21851852 4.08518519 3.91604938 4.028395
4.25679012 4.25925926 3.9382716 4.27777778 4.087654
Total 4.21674897 4.25259259 4.07152263 4.11868313 4.018683
Aggregate
Top 4th 3rd 2nd Bottom
4.18518519 4.23333333 3.9537037 4.28641975 4.067284
4.28333333 4.19506173 4.13888889 3.96666667 4.018519
4.08555556 4.24444444 4.19166667 4.16666667 3.933333
Total 4.18469136 4.22427984 4.09475309 4.1399177 4.006379
EXPANSION % BENCH WISE
Layer Bench-
Bench-C Bench-D
A
Top Layer 4.28333 4.08556 4.18519
4.19506 4.24444 4.23333
4th Layer
3rd Layer 4.13889 4.19167 3.9537
2ndLayer 3.96667 4.16667 4.28642
Bottom Layer 4.01852 3.93333 4.06728
Total 4.194 4.149 4.155
Page 89

91. APPENDIX-3
At 6% wieght loss
5% Expansion
AP-BD table
BBD FGBD GGBD AGBD
AP %
gm/CC gm/CC gm/CC gm/CC
14 1.973 2.429780984 2.373 2.4013905
14.1 1.971 2.427317952 2.3706 2.398959
14.2 1.969 2.42485492 2.3682 2.3965275
14.3 1.967 2.422391888 2.3658 2.3940959
14.4 1.965 2.419928856 2.3634 2.3916644
14.5 1.963 2.417465824 2.361 2.3892329
14.6 1.961 2.415002793 2.3586 2.3868014
14.7 1.959 2.412539761 2.3562 2.3843699
14.8 1.957 2.410076729 2.3538 2.3819384
14.9 1.955 2.407613697 2.3514 2.3795068
15 1.953 2.405150665 2.349 2.3770753
15.1 1.951 2.402687633 2.3466 2.3746438
15.2 1.949 2.400224601 2.3442 2.3722123
15.3 1.947 2.397761569 2.3418 2.3697808
15.4 1.945 2.395298537 2.3394 2.3673493
15.5 1.943 2.392835505 2.337 2.3649178
15.6 1.941 2.390372473 2.3346 2.3624862
15.7 1.939 2.387909441 2.3322 2.3600547
15.8 1.937 2.38544641 2.3298 2.3576232
15.9 1.935 2.382983378 2.3274 2.3551917
16 1.933 2.380520346 2.325 2.3527602
16.1 1.931 2.378057314 2.3226 2.3503287
16.2 1.929 2.375594282 2.3202 2.3478971
16.3 1.927 2.37313125 2.3178 2.3454656
16.4 1.925 2.370668218 2.3154 2.3430341
Page 90

92. 16.5 1.923 2.368205186 2.313 2.3406026
16.6 1.921 2.365742154 2.3106 2.3381711
16.7 1.919 2.363279122 2.3082 2.3357396
16.8 1.917 2.36081609 2.3058 2.333308
16.9 1.915 2.358353059 2.3034 2.3308765
17 1.913 2.355890027 2.301 2.328445
17.1 1.911 2.353426995 2.2986 2.3260135
17.2 1.909 2.350963963 2.2962 2.323582
17.3 1.907 2.348500931 2.2938 2.3211505
17.4 1.905 2.346037899 2.2914 2.3187189
17.5 1.903 2.343574867 2.289 2.3162874
17.6 1.901 2.341111835 2.2866 2.3138559
17.7 1.899 2.338648803 2.2842 2.3114244
17.8 1.897 2.336185771 2.2818 2.3089929
17.9 1.895 2.333722739 2.2794 2.3065614
18 1.893 2.331259707 2.277 2.3041299
18.1 1.891 2.328796676 2.2746 2.3016983
18.2 1.889 2.326333644 2.2722 2.2992668
18.3 1.887 2.323870612 2.2698 2.2968353
18.4 1.885 2.32140758 2.2674 2.2944038
18.5 1.883 2.318944548 2.265 2.2919723
18.6 1.881 2.316481516 2.2626 2.2895408
18.7 1.879 2.314018484 2.2602 2.2871092
18.8 1.877 2.311555452 2.2578 2.2846777
18.9 1.875 2.30909242 2.2554 2.2822462
19 1.873 2.306629388 2.253 2.2798147
19.1 1.871 2.304166356 2.2506 2.2773832
19.2 1.869 2.301703324 2.2482 2.2749517
19.3 1.867 2.299240293 2.2458 2.2725201
19.4 1.865 2.296777261 2.2434 2.2700886
19.5 1.863 2.294314229 2.241 2.2676571
19.6 1.861 2.291851197 2.2386 2.2652256
19.7 1.859 2.289388165 2.2362 2.2627941
19.8 1.857 2.286925133 2.2338 2.2603626
Page 91

93. 19.9 1.855 2.284462101 2.2314 2.2579311
20 1.853 2.281999069 2.229 2.2554995
20.1 1.851 2.279536037 2.2266 2.253068
20.2 1.849 2.277073005 2.2242 2.2506365
20.3 1.847 2.274609973 2.2218 2.248205
20.4 1.845 2.272146941 2.2194 2.2457735
20.5 1.843 2.26968391 2.217 2.243342
20.6 1.841 2.267220878 2.2146 2.2409104
20.7 1.839 2.264757846 2.2122 2.2384789
20.8 1.837 2.262294814 2.2098 2.2360474
20.9 1.835 2.259831782 2.2074 2.2336159
21 1.833 2.25736875 2.205 2.2311844
21.1 1.831 2.254905718 2.2026 2.2287529
21.2 1.829 2.252442686 2.2002 2.2263213
21.3 1.827 2.249979654 2.1978 2.2238898
21.4 1.825 2.247516622 2.1954 2.2214583
21.5 1.823 2.24505359 2.193 2.2190268
21.6 1.821 2.242590559 2.1906 2.2165953
21.7 1.819 2.240127527 2.1882 2.2141638
21.8 1.817 2.237664495 2.1858 2.2117322
21.9 1.815 2.235201463 2.1834 2.2093007
22 1.813 2.232738431 2.181 2.2068692
22.1 1.811 2.230275399 2.1786 2.2044377
22.2 1.809 2.227812367 2.1762 2.2020062
22.3 1.807 2.225349335 2.1738 2.1995747
22.4 1.805 2.222886303 2.1714 2.1971432
22.5 1.803 2.220423271 2.169 2.1947116
22.6 1.801 2.217960239 2.1666 2.1922801
22.7 1.799 2.215497207 2.1642 2.1898486
22.8 1.797 2.213034176 2.1618 2.1874171
22.9 1.795 2.210571144 2.1594 2.1849856
23 1.793 2.208108112 2.157 2.1825541
23.1 1.791 2.20564508 2.1546 2.1801225
23.2 1.789 2.203182048 2.1522 2.177691
Page 92

94. 23.3 1.787 2.200719016 2.1498 2.1752595
23.4 1.785 2.198255984 2.1474 2.172828
23.5 1.783 2.195792952 2.145 2.1703965
23.6 1.781 2.19332992 2.1426 2.167965
23.7 1.779 2.190866888 2.1402 2.1655334
23.8 1.777 2.188403856 2.1378 2.1631019
23.9 1.775 2.185940824 2.1354 2.1606704
24 1.773 2.183477793 2.133 2.1582389
24.1 1.771 2.181014761 2.1306 2.1558074
24.2 1.769 2.178551729 2.1282 2.1533759
24.3 1.767 2.176088697 2.1258 2.1509443
24.4 1.765 2.173625665 2.1234 2.1485128
24.5 1.763 2.171162633 2.121 2.1460813
24.6 1.761 2.168699601 2.1186 2.1436498
24.7 1.759 2.166236569 2.1162 2.1412183
24.8 1.757 2.163773537 2.1138 2.1387868
24.9 1.755 2.161310505 2.1114 2.1363553
25 1.753 2.158847473 2.109 2.1339237
25.1 1.751 2.156384441 2.1066 2.1314922
25.2 1.749 2.15392141 2.1042 2.1290607
25.3 1.747 2.151458378 2.1018 2.1266292
25.4 1.745 2.148995346 2.0994 2.1241977
25.5 1.743 2.146532314 2.097 2.1217662
25.6 1.741 2.144069282 2.0946 2.1193346
25.7 1.739 2.14160625 2.0922 2.1169031
25.8 1.737 2.139143218 2.0898 2.1144716
25.9 1.735 2.136680186 2.0874 2.1120401
26 1.733 2.134217154 2.085 2.1096086
26.1 1.731 2.131754122 2.0826 2.1071771
26.2 1.729 2.12929109 2.0802 2.1047455
26.3 1.727 2.126828059 2.0778 2.102314
26.4 1.725 2.124365027 2.0754 2.0998825
26.5 1.723 2.121901995 2.073 2.097451
26.6 1.721 2.119438963 2.0706 2.0950195
Page 93

95. 26.7 1.719 2.116975931 2.0682 2.092588
26.8 1.717 2.114512899 2.0658 2.0901564
26.9 1.715 2.112049867 2.0634 2.0877249
27 1.713 2.109586835 2.061 2.0852934
27.1 1.711 2.107123803 2.0586 2.0828619
27.2 1.709 2.104660771 2.0562 2.0804304
27.3 1.707 2.102197739 2.0538 2.0779989
27.4 1.705 2.099734707 2.0514 2.0755674
27.5 1.703 2.097271676 2.049 2.0731358
Page 94

96. APPENDIX-4
Brick Expansion % Data
Consolidated
Data % distribution
above 4.2 50%
Chamber Kiln Below 4.2 50%
b/w 3.55 to 4 25%
Mean 4.165504359 b/w 4 to 4.2 25%
Standard Error 0.005251262 b/w 4.2 to 4.3 25%
Median 4.2 b/w 4.3 to 4.75 25%
Mode 4
Standard Deviation 0.257740157 IQR 0.3
Sample Variance 0.066429988 Lower 4.75
Kurtosis -0.362000657 Upper 3.55
Skewness 0.063940314
Range 1.3
Minimum 3.6
Maximum 4.9
Sum 10034.7
Count 2409
Largest(1) 4.9
Smallest(1) 3.6
Confidence
Level(95.0%) 0.01029746
Q1 4
Q2 4.2
Q3 4.3
Page 95

97. APPENDIX-5
Box Plot diagram of Expansion % Data
Max Val 5
Upper
4.75
Q3 4.3
Q2 4.2
Q1 4
Lower
3.55
Min Val
1.7
Page 96

98. APPENDIX-6
Stock Data: Recent Stock Performance:
Current Price (11/5/2010): 137.40 1 Week 4.3% 13 Weeks -1.2%
(Figures in Indian Rupees) 4 Weeks 5.3% 52 Weeks 24.5%
OCL India Ltd Key Data:
Ticker: OCL Country: INDIA
Exchanges: BOM Major Industry: Construction
Sub Industry: Cement Producers
13,696,185,000
2010 Sales Employees: N/A
(Year Ending Jan 2011).
Currency: Indian Rupees Market Cap: 7,818,060,000
Fiscal Yr Ends: March Shares Outstanding: 56,900,000
Share Type: Ordinary Closely Held Shares: 11,399,293
Page 97

99. APPENDIX-7
A7.1 TOTAL ASSETS of OCL ( 2007,2008,2009)
2007
Total Current Assets
2008
Total Assets
2009
0% 20% 40% 60% 80% 100%
Total Asset = Total Current Asset + Total Fixed Assets
900
800
700
600
Net Block
500
Capital Work in Progress
400
Investments
300
200
100
0
1 2 3
A7.2 DEBT & NET WORTH of OCL ( 2007,2008,2009)
100%
90%
80%
70%
60% Total Debt
50%
Total Shareholders Funds
40%
30%
20%
10%
0%
1 2 3
Page 98

100. APPENDIX-8
A8.1CREDIT RISK
Secured
Loans Secured
Loans 1 2
Unsecured
Loans
2009 2008 2007
Figure 2.4
A8.2 TOTAL LIABILILTIES
2009
Share Capital
0%
Equity Share
Warrants
Reserves Total 0% Equity
Total Liabilities 16%
Application
33% Total Shareholders Money
Funds 0%
16%
Secured Loans
Total Debt
17%
17%
Unsecured Loans
1%
Page 99

101. APPENDIX-9
A9.1 TOTAL INCOME
Total Income
1,400.00
1,200.00
1,000.00
Total Income,
Axis Title
800.00 841.16
600.00
400.00
200.00
0.00
2009 2008 2007
Figure 2.5
Total Income has increased at an average rate of (22.3 %)
With time both income and expenditure have increased. Rise was also found in tax as well as
depreciation charges and interest charged upon various items.
A9.2 TOTAL EXPENDITURE
Total Expenditure
1000
900
800
700
600
500
Total Expenditure
400
300
200
100
0
2009 2008 2007
Figure 2.6
Total expenditure has increased at an average rate of ( 26.7 %)
Page 100

102. APPENDIX-10
A10.1 OPERATING PROFIT
Operating Profit
300
250
200
Axis Title
150
Operating Profit
100
50
0
1 2 3
Figure 2.7
Total operating profit has increased at an average by ( 9.5 %)
A10.2 PROFIT AFTER TAX
Reported Net Profit
140
120
100
80
60 Reported Net Profit
40
20
0
1 2 3
Total Income has increased at an average by ( 7.32 %)
Page 101

103. GLOSSARY & ABBREVIATION
1 AGBD Average Green Bulk Density
2 AP Apparent Posrosity
3 BBD Burnt Bulk Density
4 BD Bulk Density
5 BENCH: Each chamber has 4 benches A,B,C and D
6 CHAMBER: Eack kilns are further partitioned to chamber
7 FGBD Formula Based Green Bulk Density
8 GBD Green Bulk Density
9 GGBD Graphical Green Bulk Density
10 KILN It is long chamber where bricks are being fired
11 LAYER: Each bench has 5 layers, Top,4th,Middle,2nd & bottom
It is used to transfer mixed materials used by press
12 MIXER BUCKET:
machines.
13 TRANSFER CAR It is used to transfer trolleys between two work stations
It is used to transfer bricks bewteen two work stations or
14 TRANSFER CAR
between work station & transfer car
Page 102

104. BIBLIOGRAPHY
Websites
www.ocl.in
www.wikipedia.org
www.mathstool.com
www.probabilitytool.com
www.yahoosearch.com
www.google/images.com
Books/Journal
Mathematics Plus 2 ( By Dr. R. D. Sharma,2008 edition,Tata Mcgrawhil Publication)
Stastistics for Business & Economics(Andreson,Sweney,William,11th edition,Prentice
hall publication)
Production operation management ( by Sheetal Banasari,5th edition,Vikas
publication)
Total Quality control ( by OCL India Ltd,2005 edition)
Page 103