1. NewGate India
Hyderbad, Andhra Pradesh- 500038
Website: www.newgate.in
Email: contact@newgate.in
Slideshare URL : http://www.slideshare.net/newgateindia
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
Page 6

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
Page 8

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
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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
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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
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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%
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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
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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.
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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:
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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.
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