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Page 1: NEED ASSESMENT SURVEY - designclinicsmsme.orgdesignclinicsmsme.org/Design Awareness Programme Reports... · Asansol such as Chittaranjan Locomotive Works, Hindustan Cables Ltd., Disergarh

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

NEED ASSESMENT SURVEY

REPORT 2012

REFRACTORY CLUSTER Asansol, Purulia, Barakar

(WEST BENGAL)

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

NEEDS ASSESMENT SURVEY REPORT 2012

REFRACTORY CLUSTER

at

Asansol, Purulia, Barakar

Jointly Organised by

Micro & Small Scale Enterprises (Ancillary) Durgapur, Govt. of West Bengal &

Design Clinic, MSME, National Institute of Design Ahmadabad

by

Dr. Amiya K. Samanta.

Department of Civil Engineering

National Institute of Technology Durgapur

Durgapur – 713209

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

ACKNOWLEDGEMENT

I would like to thank Sri Ashoke Chakraborty, General Secretary, Refractory

Manufacturers Association(RMA), Station Road, Belgunia, PO-Barakar, Burwan-7132324,

West Bengal and his entire team for showing immense interest, support and organizing the

‘Design Clinic Scheme for MSMEs’ and showing me their work also letting me be part of

visiting their individual plants /worklife to accomplish the program of Need Assessment

Survey.

I would also like to thank Mr. Ashok Mondal, Co-cordinator, Design Clinic Scheme:

MSMEs, Eastern Regional Centre of National Institute of Design”, and Mr. Shashank Mehta,

Project Head, design Clinic Scheme for MSMEs, National Institute of Design, Ahmedabad.

for giving me the opportunity towards the successful extensive visit of the Refractory

Industry and to prepare an intensive report after realizing my strength and past experience on

understanding the potential of the same industry.

I would like to thank Dr.(Mrs) Mou Sen, Deputy Director, Micro & Small Scale Enterprises

(Ancillary) Durgapur, Govt. of West Bengal for arranging several meetings in support of the

MSME Scheme with the office bearers of the Durgapur Small Industries Association /

members of the General Engineering and Fabrication Cluster and her valuable suggestions /

supports towards execution of NAS for the said cluster. I am also thankful to Prof. Anup. K.

Saha, Professor-Department of Mechanical engineering, Chairman-Industry Institute Cell of

NIT Durgapur for his immense support in this regard.

My special thanks to each individual unit member of Refractory cluster /Association,

who has given me their great support during the survey /audit. I would have not been able to

understand cluster background & their present status without their kind involvement

/assistance /support. Thus I come up with such informative, structural, analytical and design

intervention opportunities.

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

PREFACE

Refractory Cluster plays a significant role in building the economy mostly in the area

of Asansol division as it contributes to employment generation and export earnings. The

‘Refractory Manufacturers Association’ covers a wide range of area including a part of

Barakar, Chittaranjan, Barabani, Salanpur, Purulia. There are many (around or even more

than 200) MSMEs at the cluster level, whose turn over varies widely throughout the year and

the area.

The importance of the cluster lies mainly in its good employment potential, lower

capital investment and higher value addition in the success of steel manufacturing industries.

Moreover, this cluster provides good employment to the persons mostly in the rural areas and

comparatively with lower educational background.

There are many small enterprises /units, which are employing the similar process of

manufacturing and producing similar products using older systems such as Down Draft(DD)

kiln and confessing similar opportunities and threats. There are also a few units which are

using coal fired /coke fired tunnel kiln, chamber kiln having quite high turn-over. This report

is a cluster level report of Interactive Study of around 22 units in the refractory Clusters using

the platform of ‘Refractory Manufacturers Association’ in Asansol area, under the premise of

MSME scheme

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

TABLE OF CONTENTS

No. Description of Item Page No.

Cover Page

Acknowledgement ............................................................................................... 3

Preface ................................................................................................................. 4

Need Assessment Survey ....................................................................................

(Objective /Methodology, Expected Deliverables, Duration)

6

1. Introduction ......................………………………………..............……..……... 8

Location …………………………………………...............................………………… 9

Climate .....………………………..........................................………………………….. 9

Water Resources .……………………………………………......................................… 9

Refractory …………………………….........................................................................… 10

Economy ………………………………........................................................................... 10

Geographical Location of Refractory ……………………………...............................… 11

Culture & Local Customs ……………………………….................................................. 12

History & Evolution of Refractory Industry ……………………….................................. 13

General Report on Industry Visit ………………………………...................................... 14

2. Cluster Level Information ………………………………..................……..…... 15

General Information ………………………........................................……………………... 16

Cluster Product …………………….………............................................................……… 18

Refractory Raw Materials …………………….............................................……………… 20

Refractory Manufacturing & Equipments ….......................................…………………… 21

Opportunity Mapping …………………….…………...................................................…… 23

Raw Material Storage …………………...................................................….……………… 24

Process …………………….…….........................................................................………… 25

Proposed Future Vision ……………................................................……….……………… 30

Observation & Recommendation …….................................……………….……………… 31

3. Design Audit Unitwise …………...………………...…………......................…… 32

Description of the Units (in brief) .................................................................................... 33

Identifying opportunity for technology, modernization, design collaboration ................ 45

Identifying Design opportunity in workstation and tooling design .................................. 50

Identifying Scope for Training, skill upgradation and Ergonomic and environment

factors. ................................................................................................................... ...........

54

Study of infrastructure setup from design perspective ..................................................... 58

Identifying Design opportunity for branding and packaging design ............................... 62

4. Analysis ………………………………....................................……………...… 66

SWOT Analysis .............................................................................................................. ... 67

Issues ....................................................................................................... ......................... 69

Recommendation ............................................................................................................. . 69

Conclusion ................................................................................. ....................................... 70

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

NEED OF ASSESSMENT SURVEY

Objective:

The objective of this need assessment survey is focussed to identify the need, to

explore design intervention opportunity and detailed refractory cluster information to

understand the core issues related to ;

Supply, availability of Raw Materials

Infrastructure setup

Practices and design techniques

Product type, shape and usage

Tools and technology in use

Capability of manufacturing unit

Scope of skill upgradation

Present Market status

Cutomer expectation and behaviour

Market Competitiveness /scenario

Packaging, logistics and storage

Exhibition, display and merchandising

Methodology:

Visit to individual units /plants

Questionnaire survey of the units.

Discussion with unit owner /partner /stake holder(s).

Techniques /Process observation.

Identifying tools and equipments.

Meeting and collecting feedbacks from different categories of workers

Self observation and analysis.

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

Expected Deliverables :

This design research /intervention program is intended to provide qualitative and

detail data of around 21 units in the refractory cluster to develope insights about this industry

/entrepreneurs, which would help to address the existing problems for their growth /survival

and future opportunity area or scopes which can be further workout and can be taken up

during the design clinic workshop and areas be taken up as design /research projects in an

interactive mode with the adjacent Academia.

Duration :

Present Need Assessment Survey(NAS) is based on extensive visits made to the

Individual Plants /unit for five days in different areas and further it was followed by five days

Design Clinic Workshops at Barakar.

Participant(s) :

The design /NAS survey was conducted by Dr. Amiya Kumar Samanta, a

Professional from Academia having an industrial experience of 7yrs.(approx) in association

with NID Ahmedabad and Micro & Small Scale Enterprises (Ancillary) Durgapur, Govt. of

West Bengal with the support of RMA, Barakar

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

CHAPTER-1

I N T R O D U C T I O N

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

Location :

Asansol is located on the valley of the River Damodar in the Burdwan District of

West Bengal in India surrounded by Bankura, Purulia and a part of Jharkhand. Being in close

proximity to Dhanbad, it’s a coal mining and industrial metropolis and one of the busiest

commercial centres in India. It is also one of the most ethnically and culturally diverse cities

in the state. It has good educational establishments, good transport connections by train

(eastern railway and NH-2), moderately high per capita income and land suitable for industry.

Its name ‘Asansol’ is derived from two different names, Asan -a species of tree found on the

bank of the river Damodar and Sol –Bhumi or land which is rich in minerals, particularly in

coal.

Climate :

In summers (from March to May) the city experiences a hot and humid weather

during the day time ranging from 400C to 50

0C. However, nights are comparatively cooler,

due to the cold breezes that blow at that time. The city also suffers heavy thunderstorms in

early summer. The summer season is comparatively longer than any other season in Asansol.

Monsoon (Between June and September), the city of Asansol witnesses monsoon with a

maximum rainfall up to 533 mm. In Asansol, winter comes with the arrival of November and

leaves by the end of February. During this time, the maximum temperature is around 200 C,

while the minimum temperature hovers at 40 C.

Water Resources :

Asansol is located in the Damodar valley of West Bengal and the subdivision lies on

exposed Gondwana rocks and consists mostly of undulating laterite soil. It is located between

two mighty rivers, Damodar and Ajay. Another river, Barakar, joins the Damodar near

Dishergarh. A small rivulet, Nunia, flows past Asansol. But the Poor water management and

exploitation of groundwater systems along with the rocky nature of soil threatens agriculture

in the entire belt. This scarcity of quality water resources has prompted the residents of this

belt to go for setting up industries with the availability /support of fuels (coals) from the

nearby mining area.

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

Refractory :

Refractory is a class of product that are extraordinarily resistant to heat and wear. The

most commonly ingredients are niobium, molybdenum, tantalum, tungsten, and rhenium,

which have melting point above 2000 °C, high hardness, chemically inert. Some of their

applications include tools to work metals at high temperatures, steel manufacturing units,

casting moulds, and chemical reaction vessels in corrosive environments. Partly due to the

high melting point, refractory products are stable against creep deformation to very high

temperatures.

Economy :

Being one of major industrial hubs of the state of West Bengal, the area’s economy is

based on the rail, coal and steel industries. Asansol, which is the second largest city in West

Bengal, is known for being the “coal mining” city, as the entire region of Asansol sits of

layers and layers of coal. Although majority of Asansol’s economy is based on its highly

prosperous coal, there are also large iron and steel industries in Asansol. Asansol is also a

very important centre for railway activity.

The largest companies working in Asansol include the Eastern Coalfields, which is a

subsidiary of Coal India Limited. The IISCO Steel Plant of Steel Authority of India Limited

is another major company to work for in Asansol. Of course, there are other big companies in

Asansol such as Chittaranjan Locomotive Works, Hindustan Cables Ltd., Disergarh Power

Supply, Damodar Valley Corporation, Burn Standard, Reckitt and Coleman, along with

cement companies such as Burnpur Cement.

Situated in the Damodar River valley, the city has evolved and expanded over time to

a good population. It is located about 200 km from Kolkata one of the 42nd fastest growing

city in the country.

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

Geographical Location of Refractory :

The production units of refractory products are widely spread over the region of

sub-division of Asansol in the district of Burdwan in West Bengal and surrounding areas,

they are as follows:

• Asansol

• Burnpur

• Barakar

• Chittaranjan

• Barabani

• Purulia

• Gorandi

1

1

2

1

3

1

4

1 5

1

6

1

7

1

8

1

9

1 10

1

11

1

22

1

21

20

0 15

13

14

12

19

16

17

18

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

Culture & Local customs :

Being a part of West Bengal, Asansol is predominantly a Bengali speaking city today.

But Asansol has mixed population of Bengali, Hindi and Urdu speaking people. After the

railway establishment, there was a substantial British and Anglo-Indian population. English

medium schools started to impart education in English from as early as 1877. The first

Christian Brother School in India St. Patrick's School was started in 1891. The students from

this and other English medium schools provided the elite work force that was needed to

operate the British Indian Railways, the British Indian Army, the Indian Civil Services and

the coal mines area.

A Bihari woman performing Bengali

Rituals during Durga Puja

Chhath Puja is being performed by Biharis

but Bengalis are present there too

The community living in Asansol now is multicultural as there are a large number of

Biharis, Punjabis, Marwaris, Gujaratis, Muslims and other non Bengalis. There is no Indian

festival that is not celebrated in Asansol and the people of all communities take part in them

with equal fervour

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

History and Evolution of Refractory Industry :

In 19th

Century, Asansol became an important centre of railway activity, where

European and Anglo-Indian communities settled and played a pivotal role for its growth.

Asansol. Durand Institute (now renamed Swami Vivekananda Institute), reputed to be the

oldest railway institute in Asia, was a major centre of European and Anglo-Indian activity.

There is an imposing structure of tall column (memorial tower) in front of Durand Institute

commemorating the memories of the supreme sacrifice of those European soldiers and

commanders who laid down their lives in the First World War (1914–1918). It is as good as a

landmark of Asansol, reminder of the European legacy of the place and it is so high that it is

easily visible from the railway station. Asansol has emerged as an important centre of East

Indian Railway, ultimately becoming the divisional headquarters in 1925. It is now the

headquarter of Divisional Railway Manager (DRM) Asansol, the post previously designated

as Divisional Superintendent.

The refractory industry

shaped the way the

Industrial Revolution

progressed, from

bloomeries to iron and

steel works. Harris and

Pearson's brickyard was

one of several dozen that

made what can be termed

standard items from the

best fireclay that could

be found

. They were making retorts, pressed bricks, and wirecut bricks, items for glass works,

items for steel works, and many more trades, but so were Homer Hill works, the Delph

Works, Amblecote Works, John Hall Refractories, Harper and Moores, Timmis, Himley Fire

and Red Brick Co. All these Refractory industry were set up with the coal mines nearby and

growth of various industry set up in early 19th

century and now more than200 such units are

existing in the Asansol belt.

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

General Report on Industry Visit.:

Interviewee(s)

1. Mr. B. P. Biyani

2. Mr. Tushar Upadhaya

3. Mr. Subhankar Roy

4. Mr. Sanjiv Khemka

5. Mr. H. L. Prasad.

6. Mr. Aniridhha Rakshit

7. Mr. B. Jalan

8. Mr. Sudipta Chatterjee

9. Mr. Amit Gupta

10. Mr. R. S. Bansal.

11. Mr. Pankaj Bansal.

12. Mr. R. S. Gandhi.

13. Mr. Bansi Bansal.

14. Mr. Akash Sharma.

15. Mr. Subhas Roy.

16. Mr. Pradip Roy.

17. Mr. Ashoke Kr. Das.

18. Mr. Vinod Keshri.

19. Mr. Pinaki Mukheree

20. Mr. Gourav Majumdar

21. Mr. Biswajit Maharaj

22. Mr. Dinabandhu Rooj.

The field work of the NAS was conducted between 7-23rd

July 2012 in Asansol,

Burnpur, Barakar, Dishergarh, Chittaranjan, Gorandi, Barboni in Burdwan district and

Manpura area of Purulia district in the state of West Bengal, India. The purpose of the survey

was to gather detailed information by observing the process of manufacture, by meeting and

interviewing mainly the owner(s) /Partner(s) involved in this profession /entrepreneurship

and to identify their problems in running the plants. All the finding was recorded in the form

of questionnaires /notes /pictures /company profiles /owners’ brief profile.

Views of various parties were taken into accounts to get a better understanding of the

scenario, of course with the support of a coordinator from the refractory manufactures

association while visiting different units during the survey.

The people I interviewed were from different age groups, ranging from 25 to 70 years

and were from different income groups as well. What I found common was that most of them

have a good turn-over and have received good education ranging from graduation

(Gen/Engg.) to MBA. Both male and female workers (skilled /unskilled) are involved in the

profession; few of them are coming from their home while few of them are staying inside the

plant even with welfare facilities from the owner’s end.

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

CHAPTER-2

CLUSTER LEVEL INFORMATION

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

General Information :

Sl.

no. Name of Unit(s) Contact person Contact Details

1. Burnpur Ceramics Mr. B. P. Biyani Vill.- Bartoria, P.O.- Mithani, Burdwan – 713 371, W.B. Mob. No. : +91 9434025307 [email protected]

2. Maa Sharada Refractories & Ceramics

Mr. Tushar Upadhaya Vill.- Bansoradihi, Palsdihi Road, Asansol, Burdwan – 713 302, W.B. Mob. No. : +91 9233312037 [email protected]

3. Royson’s Refractory Mr. Subhankar Roy Vill.- Amdiha, P.O.- Lalgange, PS-Barabani, Burdwan – 713 359, W.B. Mob. No. : +91 9832147585 [email protected]

4. Raimata Ceramics Mr. Sanjiv Khemka Vill.+ P.O.- Banra, Purulia – 713 312, W.B. Mob. No. : +91 9679300574 [email protected]

5. Royal Refractories Mr. H. L. Prasad. Vill.+ P.O.- Bartoria, Purulia – 723121, W.B Mob. No. : +91 434115132 [email protected]

6. Maa Chinnamasta Ceramics

Mr. Aniridhha Rakshit Vill.- Pochara, P.O.- Digha, Purulia – 723121, W.B. Mob. No. : +91 9732006162 [email protected]

7. Apodicitc Ceramics Mr. B. Jalan Vill.- Manpura, P.O.- Digha, Purulia – 723 121, W.B. Mob. No. : +91 9431124482 [email protected]

8. Baba Baidnath Refractories

Mr. Sudipta Chatterjee

Parbelia, Hijuli Road, P.O.- Saltore, Purulia – 723121, W.B. Mob. No. : +91 9732387637 [email protected]

9. Silicon Ceramics Mr. Amit Gupta. Biridangal, P.O.- Barakar, Burdwan – 713 324, W.B. Mob. No. : +91 9832195100 [email protected]

10. Shree Kishan Refractories

Mr. R. S. Bansal. Hanuman Charai, P.O.- Barakar, Burdwan – 713 324, W.B. Mob. No. : +91 9749734444 [email protected]

11. Shiva Refractories Mr. Pankaj Bansal. Deepu Dangal, P.O.- Barakar,

Burdwan – 713 324, W.B. Mob. No. : +91 9434744595 [email protected]

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

Sl.

no. Name of Unit(s) Contact person Contact Details

12. Jaya Ceramics Mr. Dinabandhu Rooj.

Badradi, Siakulberia, PS-Salanpur, Burdwan – 713 335, W.B. Mob. No. : +91 9474910009 [email protected]

13. Liberty Refractories Pvt. Ltd.

Mr. R. S. Gandhi. NH-2 byepass, Salanpur, Burdwan – 713 357, W.B. Mob. No. : +91 9333719097

14. Shree Bhim Refractories

Mr. Bansi Bansal. NH-2 byepass, Sabanpur, Burdwan , W.B. Mob. No. : +91 9832195155 [email protected]

15. Salanpur Ceramics Mr. Akash Sharma. Nimtala, PO- Salanpur, Burdwan ,W.B. Mob. No. : +91 9547416227 [email protected]

16. Anant Ceramics. Mr. Subhas Roy. Vill.- Angaria, P.O.- Ethora, Burdwan – 713 359, W.B. Mob. No. : +91 9434009220 [email protected]

17. S. P. Refractories Mr. Pradip Roy. Vill-Monohar Bahal, P.O.- Ethora, Burdwan – 713 359, W.B. Mob. No. : +91 9832194127 [email protected]

18. Madhusudan Refractories

Mr. Ashoke Kr. Das. Vill-Monohar Bahal, P.O.- Ethora, Burdwan – 713 359, W.B. Mob. No. : +91 9832132690 [email protected]

19. Keshri Industries Mr. Vinod Keshri. G.T. Road(NH2), P.O.- Searsole Rajbari, Burdwan – 713 358, W.B. Mob. No. : +91 9832164442 [email protected]

20. National Refractories Mr. Pinaki Mukheree P.O.- Salanpur, Burdwan – 713 357, W.B. Mob. No. : +91 9434039039 [email protected]

21. Dutta & Dutta Ceramik Works

Mr. Biswajit Maharaj P.O.- Jamgram, Burdwan – 713 315, W.B. Mob. No. : +91 9434163387 -------

22. SB Steel Refractories P. Ltd.

Mr. Gourav Majumdar

Jamgram, Via-Panuria, Lalgang,

Burdwan – 713 315, W.B. Mob. No. : +91 9830658176

[email protected]

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

Cluster Product (Types) :

1. Fire clay bricks (Alumna 30% to 90%)

2. Acid proof bricks

3. Insulation bricks

4. Refractory Castables

5. Monolithic /Mortar /shapes

6. Bottom pouring sets /pouring

refractories 7. Nozzle bricks

8. Mortar bed materials

9. Ladle sleeves

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

Refractory Raw Materials :

In general, two types of raw materials are required to make refractory products ;

1)naturally occurring clay and 2)synthetically prepared materials. The raw materials used in

refractory industry mostly are inorganic nonmetallic crystalline solid formed by complexes

geological processes. Plastic /non-plastic Clay, quartzite, bauxite, sillimanite, dolomite,

zircon, chromite, dolomite etc. are naturally available raw materials while synthetically

prepared materials are mullite, calcined and tabular alumina, fused silica etc.

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

Refractory Manufacturing and Equipments :

Refractory products are made from different raw materials depending on their type

and quality. Although the raw materials are different, the processing of the raw materials in

manufacturing refractories remain almost similar. A common refractory manufacturing

process with different type of equipment are as below :

Crushing of Raw materials

(manual or Semi /automatic using Impact crusher)

Batching (using Vats)

Grinding

(using Jaw Crusher)

Sieving /Pulverisation

(manual or Semi /automatic)

Magnetic separation of iron particles, if any

(using magnetic separator)

1

2

3

4

5

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

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Batch weighing /Mixing

(using Muller mixture or U-mixer)

Hand Moulding

(using Dye)

Casting in Screw /hydraulic Presses

Drying of formed shapes

Charging /Firing of

shaped products in

the kiln.

Packaging & Transportation

6

7A

A

8

9

10

7B

A

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

Opportunity Mapping :

Raw material Process Display /branding

Temporary /low cost

material storage yard may

be planned. In absence

good quality polythene

sheets may be used.

Barricading with

minimum flooring option

may be explored to avoid

contamination of soil

/earth

A common local

community store may be

planned to facilitate

nearby units.

.

Upgradation of Owner

/Partner through

awareness programme.

Skill upgradation of

worker through intensive

training.

Safety norms for

industries may be imposed

upon.

Problems related to

pollution control device

installation and

maintenance.

Connectivity of roads for

running heavy traffic.

Cooperation in sharing

facilities

Kiln type upgradation for

efficient and economic use

of fuel

Installation of renewable

energy sources to cut

down water and electricity

consumption.

Display of end products in

most of the units required

May be encouraged for

quality products so that

they may find interesting

to go for

Packaging facility unit

may be developed

/improved at the unit level.

Common testing facility

centre may be developed

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

Raw Material Storage :

Observation - 1 Observation - 2

Observation - 3 Observation - 4

Recommendation

Awareness programme

for skilled staff /Owner

/Partner may be helpful

in avoiding such wrong

idea of storing material

Recommendation Recommendation

Recommendation

A kind of temporary

cover used but not for all

types of raw material. If

possible, similar kind

can save material

wastage

Huge wastages of raw

material due to absence

of material stock yard. A

proper road layout of

plant and flooring is

recommended.

Suitable low cost

material stacking yard

may improve mixing of

undesirable impurities to

have better quality

product

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

1. Process :

Observation - 1 Observation - 2

Observation - 3 Observation - 4

Recommendation

Automation that would

replace the manual

processes for both

batching & mixing to

supply time bound

products.

Recommendation

Recommendation Recommendation

Dedusting system

installation may help to

run an efficient

environment friendly set

up and loss of material

be avoided too.

Semi automatic process

may help to reduce area

/land requirement and

loss of intermediate

product along with its

desired water content.

Automatic temperature

control device may help

to get quality product

along with better fuel

efficiency and loss of

waste product.

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

Observation - 5 Observation - 6

Observation - 7 Observation - 8

Recommendation

Safety devices

(breathing) may be

provided by the Owners

in regard to comply the

labour welfare policy of

the Government.

Recommendation

Recommendation Recommendation

The addition of water in

composition is based on

approximation and needs

to be handled by skilled

staff to ensure quality

product and establish brand

value.

Safety shoes may be

provided by the Owners

in regard to comply the

labour welfare policy of

the Government.

Suitable moisture

content /control

mechanism be

maintained /followed as

soon as the mix is

prepared in the U-mixer.

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

Observation - 9 Observation - 10

Observation - 11 Observation - 12

Recommendation

Manual screening be

replaced by mechanical

/automatic screening in

the present age of

technological advancement

Recommendation Recommendation

Recommendation

If possible, recycling of

mixture may be done in

U-mixer avoiding

manual procedure for

better quality control.

Safety norm may be

imposed and

simultaneously be

checked that it is highly

in action too.

Huge wastage of semi-

products leads to poor

turn-over and attention

of staff training be given

due importance.

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

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Observation - 13 Observation - 14

Observation - 15 Observation - 16

Recommendation

Dyes left abandoned in

the yard. Suitable

mechanism required for

effective utilisation, by

the neighbouring

refractories.

Recommendation Recommendation

Recommendation

Insufficient test lab

facility, its poor

maintenance and quality

consciousness be

improved.

Suitable pollution

control device be

installed mandatorily

and also supported by

technical experts to

check its functionality.

Use of skilled workers

necessary for loading the

trolley to be fired in

tunnel kiln to avoid

incurring higher loos

factor.

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

Observation - 17 Observation - 18

Recommendation

Unit affected by

demand-supply chain,

improper trading

mechanism leading to

large stacking of end

products.

Recommendation

Lack in labour supply

(due to 100 days’ work)

has lead the owner to

no-hope situation. Units

grossly affected. Govt.

Policy be reframed.

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

Proposed Future Vision

Raw Materials Process & Labour

Source LabourSupply of tested

& standardised

Raw materials

Motivation &

Govt. Policy

Transportation Skill

Employment

opportunity

Skill Upgradation

& Training

Storage Safety

Storage space &

system

Norms be

implemented

Treatment Welfare

Required

Intervention

System be set up

to attract workers

Technical

Expertise needed

Owners needs

training

Pollution

IssuesBranding

Producer gas

/Pulversied coke

Enhancing scope

for business

Tunnel

/Shuttle Kiln

Exhibition

/DisplayEfficiency &

Fueling

Technique

For production of

Quality product

Kiln &Fuel Market

Chamber

KilnResearch

Precision level be

improved

Collaborative

Students' Project

DD KilnAcademic

Institution

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

Observation & Recommendation :

The above observations and recommendations are related to aspects that requires

design intervention. However, there are other problem areas which may not in the scope of

this project. I would also like to mention a few other areas where the refractory industry is

also facing difficulties in general. The policy of State Government /ECL towards the cluster

is discouraging and hence not getting the fuel at economic prices, also the quality fuel is not

available at convenience. Regarding getting the raw material, they have proposed /asked to

various mining agencies but not getting any kind of support. The mining agencies are

extracting the soil layer(which may be used as raw materials) for the purpose of mining coal,

but not supplying to the refractory manufacturing units but wasting it which may be useful to

them. Another issue is fuel efficiency they getting out of oldest firing system of DD kiln

mostly used by the units. Of course few of them are using pulverized coal fired tunnel kiln,

chamber kiln or producer gas fired tunnel kiln. The other issue is that they are have mostly

installed pollution device in the flue gas extraction system, but many a times it does not

function properly and they are also unable to locate ./find out suitable technical expert to

resolve the issue.

After an extensive / interactive session and study in the cluster it is found that most of

the units are manufacturing the same variety of products, by applying the same techniques

and few are also exporting their products abroad mostly through trading. Development of

various community schemes could be the only way to uplift the growth of the refractory

cluster. Apart from these, the cluster needs to be aware and educated regarding common

technical expertise, government scopes /policies for better /improved product.. These are

necessary for motivating new design and enhancing product development.

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

CHAPTER-3

DESIGN AUDIT unitwise

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

Description of the

Units visited

(in brief) :

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

Unit-1

NAME & ADDRESS OF MSME UNIT :

M/s Burnpur Ceramics (1975) Vill.- Bartoria, P.O.- Mithani, Burdwan – 713 371, WB.

CONTACT PERSON WITH DESIGNATION & CONTACT DETAILS :

Name : Mr. B. P. Biyani.,

Qualification : B.Sc.

Age : 67 Yrs.

Mob. No. : +91 9434025307

Email : [email protected]

PRODUCT RANGE : Refractory /Fire clay bricks (Alumna 30% to 90%), Acid proof /Insulation bricks, Castables.

TURN OVER : Approx. 2 Crores

PRODUCTION VOL. : 3000 MT p.a. (Capacity - 7000 MT p.a.)

MAJOR CLIET(S) : Govt. Steel Plants (Durgapur, Bokaro, Bhillai, Rourkela)

MAJOR MACHINARIES : Jaw Crusher, Disintegrator, Muller mixer(3MT/hr., 1.5MT/hr.), Magnetic iron separator, Friction Screw Press(FSP 150MT-2nos., 110MT-2nos.), Chamber(18) Kiln.

PLANT AREA : Approx. 5 acres.

REGISTRATION NO. : 1900 9120 0349

Unit-2

NAME & ADDRESS OF MSME UNIT :

Maa Sharada Refractories & Ceramics (2002) Vill.- Bansoradihi, Palsdihi Road, Asansol, Burdwan – 713 302, W.B.

CONTACT PERSON WITH DESIGNATION & CONTACT DETAILS :

Name : Mr. Tushar Upadhaya,

Qualification : B Com.

Age : 40 Yrs.

Mob. No. : +91 9233312037

Email : [email protected]

PRODUCT RANGE : Fire bricks, insulation/castables/mortar.

TURN OVER : Approx. 1.5 Cr.

PRODUCTION VOL. : 3600 MT p.a. (Capacity - 6000 MT p.a.)

MAJOR CLIET(S) : IISCO, HINDALCO (Remcol), Export to Australia, Bangladesh, Middle East

MAJOR MACHINARIES : Impact Mill, Distregator, Friction Screw Press, Hydraulic Press, U-Mixer, DD kiln(3nos.), Muler Mixer, Pulveriser, Magnetic Roller.

REGISTRATION NO. : 1200 9110 3017

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

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Unit-3

NAME & ADDRESS OF MSME UNIT :

Royson’s Refractory (2005) Vill.- Amdiha, P.O.- Lalgange, PS-Barabani, Burdwan – 713 359, W.B.

CONTACT PERSON WITH DESIGNATION & CONTACT DETAILS :

Name : Mr. Subhankar Roy,

Qualification : B Tech.

Age : 26 Yrs.

Mob. No. : +91 9832147585

Email : [email protected]

PRODUCT RANGE : Fire bricks(upto 70% Al2O3)/mortar/castables.

TURN OVER : 1.3 Cr.

PRODUCTION VOL. : 400MT p.a.

MAJOR CLIET(S) : Trading only

MAJOR MACHINARIES : Pulveriser, Disintegrator, Jaw Crusher, Rotary Screen, Friction Screw Press(110, 150MT), Hydralic press(150MT), Muller Mixer, U-mixer, DD kiln(3 nos.)

PLANT AREA : 3 Acres.

REGISTRATION NO. : 190091100830 of 2008

Unit-4

NAME & ADDRESS OF MSME UNIT :

Raimata Ceramics (2005) Vill.+ P.O.- Banra, Purulia – 713 312, W.B.

CONTACT PERSON WITH DESIGNATION & CONTACT DETAILS :

Name : Mr. Sanjiv Khemka,

Qualification : B Com.

Age : 31 Yrs.

Mob. No. : +91 9679300574

Email : [email protected]

PRODUCT RANGE : Bottom pouring sets, Fire clay/files,Standard bricks, Nozzles bricks.

TURN OVER : Approx. 35 lacs.

PRODUCTION VOL. : 1800 MT p.a. (Capacity - 5400 MT p.a.)

MAJOR CLIET(S) : Marks Steeel etc. and through Kolkata traders

MAJOR MACHINARIES : Direct manufacturer

PLANT AREA : Approx 2.5 acres

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

Unit-5

NAME & ADDRESS OF MSME UNIT :

Royal Refractories (1995) Vill.+ P.O.- Bartoria, Purulia – 723121, W.B

CONTACT PERSON WITH DESIGNATION & CONTACT DETAILS :

Name : Mr. H. L. Prasad,

Qualification : B Tech.(ME-BHU)

Age : 71 Yrs.

Mob. No. : +91 434115132

Email : [email protected]

PRODUCT RANGE : Only acid proof bricks.

TURN OVER : 60 lacs.

PRODUCTION VOL. : 1200MT p.a (Capacity- 2000MT p.a)

MAJOR CLIET(S) : Mostly being exported through traders

MAJOR MACHINARIES : Shuttle kiln being installed.

PLANT AREA : 2.5 Acres.

Unit-6

NAME & ADDRESS OF MSME UNIT :

Maa Chinnamasta Ceramics (2003) Vill.- Pochara, P.O.- Digha, Purulia – 723121, W.B.

CONTACT PERSON WITH DESIGNATION & CONTACT DETAILS :

NAME: Mr. Aniridhha Rakshit.

Qualification : B Com.

Age : 32 Yrs. Mob. No. : +91 9732006162

Email : [email protected]

PRODUCT RANGE : IS6/IS8, 50%-70% high alumina SILLIMITE acid proof bricks, Mortar.

TURN OVER : 1.5 Cr.

PRODUCTION VOL. : 4000MT p.a(Capacity:- 7000 MT p.a)

MAJOR CLIET(S) : Steel Industries in WB, Orissa maily, rarely exported.

MAJOR MACHINARIES : Disintegrator, lump breaker, Jaw crusher, Muller & U-Mixer, Friction Screw press(3 nos. 80, 125, 150MT) Hydraulic press(150MT), Weigh bridge, Lathe machine, Generator, High temp. petro coke fired tunnel kiln.

PLANT AREA : 5 Acres

REGISTRATION NO. : 211610544

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

Unit-7

NAME & ADDRESS OF MSME UNIT :

Apodicitc Ceramics (2004) Vill.- Manpura, P.O.- Digha, Purulia – 723 121, W.B.

CONTACT PERSON WITH DESIGNATION & CONTACT DETAILS :

NAME: Mr. B. Jalan.

Qualification : B Com.

Age : 57Yrs. Mob. No. : +91 9431124482

Email : [email protected]

PRODUCT RANGE : Refractories (all types, Laddle, high Alumina including insulation type, Acid proof), Castables, Mortars.

TURN OVER : 3.5 Cr.

PRODUCTION VOL. : 2500MT p.a(Capacity- 9000MT p.a)

MAJOR CLIET(S) : SAIL (ASP, BSP), Bhusan Steel, DPL, Jindal Steel, Jai Balaji, SPS, Shyam, TATA steel, Usha Martin

MAJOR MACHINARIES : DD Kiln-2, Disintegrator-1, Friction Screw press-4, U-mixer-1, Hydraulic press-1, Friction press-2

Unit-8

NAME & ADDRESS OF MSME UNIT :

Baba Baidnath Refractories.(2005) Parbelia, Hijuli Road, P.O.- Saltore, Purulia – 723121, W.B.

CONTACT PERSON WITH DESIGNATION & CONTACT DETAILS :

NAME: Mr. Sudipta Chatterjee.

Qualification :

Age :

Mob. No. : +91 9732387637

Email : [email protected]

PRODUCT RANGE : Acid proof bricks.

TURN OVER : 65 lacs

PRODUCTION VOL. : 1320MT p.a(Capacity- 3960MT p.a)

MAJOR CLIET(S) : Direct Manufactuer

MAJOR MACHINARIES : FS Press-2 nos., Disintegrator /Grinder, Muller, U-mixer, Pulveriser, DD kiln-2nos.

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

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Unit-9

NAME & ADDRESS OF MSME UNIT :

Silicon Ceramics (1998) Biridangal, P.O.- Barakar, Burdwan – 713 324, W.B

.

CONTACT PERSON WITH DESIGNATION & CONTACT DETAILS :

NAME: Mr. Amit Gupta..

Qualification :

Age : 31Yrs. Mob. No. : +91 9832195100

Email : [email protected]

PRODUCT RANGE : Bot pouring set(fire bricks), High Alumina bricks(upto 70% al2o3), Mortar.

TURN OVER : 42 lacs.

PRODUCTION VOL. : 1800MT p.a(Capacity- 4500MT p.a).

MAJOR CLIET(S) : Direct Manufacturing

MAJOR MACHINARIES : FS Press-3 nos., Disintegrator /Grinder, Muller, U-mixer, Pulveriser, Elevator, Ball mill.

REGISTRATION NO. : 190091101061

Unit-10 NAME & ADDRESS OF MSME UNIT :

Shree Kishan Refractories (1982) Hanuman Charai, P.O.- Barakar, Burdwan – 713 324, W.B.

CONTACT PERSON WITH DESIGNATION & CONTACT DETAILS :

Name : Mr. R. S. Bansal,

Qualification : Matriculation.

Age : 64 Yrs.

Mob. No. : +91 9749734444

Email : [email protected]

PRODUCT RANGE : Pouring refractories

TURN OVER : Approx. 60 lacs.

PRODUCTION VOL. : 2000 MT p.a. (Capacity - 3600 MT p.a.)

MAJOR CLIET(S) : Mini Steel Plants at Up, Assam, Kolkata through traders

MAJOR MACHINARIES : Disintrigator, U-mixer, Hydrolic press 2ws, cooling fan, Pollution device, Dd Kiln 3ws, Friction Screw press-2nos.

REGISTRATION NO. : 190091100516

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

Unit-11 NAME & ADDRESS OF MSME UNIT :

Shiva Refractories (1993) Deepu Dangal, P.O.- Barakar, Burdwan – 713 324, W.B.

CONTACT PERSON WITH DESIGNATION & CONTACT DETAILS :

Name : Mr. Pankaj Bansal,

Qualification : MBA.

Age : 27 Yrs. Mob. No. : +91 9434744595

Email : [email protected]

PRODUCT RANGE : Nozzles, Mortar, Bed Materials.

TURN OVER : 1.2 Cr.

PRODUCTION VOL. : 2400MT p.a (Capacity- 3000MT p.a)

MAJOR CLIET(S) : Direct Manufacturing

MAJOR MACHINARIES : DD Kiln-2, Disintegrator-1, Screw press-1, U-mixer-1, H-press-1, Friction press-2.

REGISTRATION NO. : 190091106091

Unit-12 NAME & ADDRESS OF MSME UNIT :

Jaya Ceramics (2010) Badradi, Siakulberia, PS-Salanpur Burdwan – 713 335, WB.

CONTACT PERSON WITH DESIGNATION & CONTACT DETAILS :

NAME: Mr. Dinabandhu Rooj.

Qualification : Graduate.

Age : 72 Yrs. Mob. No. : +91 9474910009

Email : [email protected]

PRODUCT RANGE : Pouring refractories and 156

TURN OVER : 48 lacs.

PRODUCTION VOL. : 2000MT p.a(Capacity:- 4000 MT p.a)

MAJOR CLIET(S) :

MAJOR MACHINARIES : DD kiln-2, Disintegration, U-mixer 10’ long-1, Muller-1, Press-friction screw & Hand press.

PLANT AREA : 3 acres

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

Unit-13 NAME & ADDRESS OF MSME UNIT :

Liberty Refractories Pvt. Ltd.(2000) NH-2 byepass, Salanpur, Burdwan – 713 357, W.B.

CONTACT PERSON WITH DESIGNATION & CONTACT DETAILS :

NAME: Mr. R. S. Gandhi.

Qualification : BA.

Age : 45Yrs.

Mob. No. : +91 9333719097

Email : --

PRODUCT RANGE : Bot pouring set, Standard series.

TURN OVER : 36 lacs

PRODUCTION VOL. : 1440MT p.a(Capacity- 2400MT p.a)

MAJOR CLIET(S) : Direct Manufacturing

MAJOR MACHINARIES : Dislegrator, U-Mixer, FS Press-2(100 & 80MT), Hand press-1(30MT).

REGISTRATION NO. : 190091200572

Unit-14 NAME & ADDRESS OF MSME UNIT :

Shree Bhim Refractories (1997) NH-2 byepass, Sabanpur, Burdwan , W.B.

CONTACT PERSON WITH DESIGNATION & CONTACT DETAILS :

NAME: Mr. Bansi Bansal..

Qualification : B Com.

Age : 42Yrs.

Mob. No. : +91 9832195155

Email : [email protected]

PRODUCT RANGE : B P Set,pour refractories, fire clay mortar, fire bricks.

TURN OVER : 1 Cr.

PRODUCTION VOL. : 4000MT p.a(Capacity- 6000MT p.a)

MAJOR CLIET(S) : Direct Manufacturing + trading

MAJOR MACHINARIES : Dislegrator, U-Mixer, FS Press-2(110 & 80MT), Hydrolic press(30MT), Muller mixer, Jaw crasher, Pulvensiv.

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

Unit-15 NAME & ADDRESS OF MSME UNIT :

Salanpur Ceramics.(2002)

Nimtala, PO- Salanpur, Burdwan ,W.B.

CONTACT PERSON WITH DESIGNATION & CONTACT DETAILS :

NAME: Mr. Akash Sharma.

Qualification : MBA.

Age : 28Yrs.

Mob. No. : +91 9547416227

Email : [email protected]

PRODUCT RANGE : Fire bricks,monolithic(mortar)..

TURN OVER : 1.3 Cr.

PRODUCTION VOL. : 3000MT p.a

MAJOR CLIET(S) : Direct Manufacturing + trading

MAJOR MACHINARIES : Dislegrator, U-Mixer, FS Press-2(110, 80 & 60MT), Muller, Pulvensiv, Crusher.

REGISTRATION NO. : 190091100564

Unit-16 NAME & ADDRESS OF MSME UNIT :

M/s Anant Ceramics (2009) Vill.- Angaria, P.O.- Ethora, Burdwan – 713 359, W.B.

CONTACT PERSON WITH DESIGNATION & CONTACT DETAILS :

Name : Mr. Subhas Roy,

Qualification : B.A.

Age : 50 Yrs.

Mob. No. : +91 9434009220

Email : [email protected]

PRODUCT RANGE : Standard bricks, shapes-mortar.

TURN OVER : Approx. 85 lac.

PRODUCTION VOL. : 4200 MT p.a. (Capacity - 4800 MT p.a.)

MAJOR CLIET(S) : Direct Manufacturing + trading

MAJOR MACHINARIES : Shade 7500 sq. Feet, Down Draft Klin, 22 feet dia. 2 nos., 20feet dia. 1 nos,Office building 600sq/ft, 125 ton press 1 no.,80 ton press 1 no, Hydrolic press 60 ton capacity 1 no, Dicendicator 1 nos. 36 inch, U mixture 1 nos.

REGISTRATION NO. : 190091403939

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

Unit-17

NAME & ADDRESS OF MSME UNIT :

S.P Refractory (2010) Vill-Monohar Bahal, P.O.- Ethora, Burdwan – 713 359, W.B.

CONTACT PERSON WITH DESIGNATION & CONTACT DETAILS :

Name : Mr. Pradip Roy,

Qualification : B.A.

Age : 54 Yrs.

Mob. No. : +91 9832194127

Email : [email protected]

PRODUCT RANGE : Raw material to refractories from steel plant grog(bricks).

TURN OVER : Initial Set Up

MAJOR MACHINARIES : Single DD kiln calcination

Unit-18

NAME & ADDRESS OF MSME UNIT :

Madhusudan Refractories (2004)

Vill-Monohar Bahal, P.O.- Ethora,

Burdwan – 713 359, W.B.

CONTACT PERSON WITH DESIGNATION & CONTACT DETAILS :

NAME:Mr. Ashoke Kr. Das.

Qualification : B.Sc.

Age : 42 Yrs.

Mob. No. : +91 9832132690

Email : [email protected]

PRODUCT RANGE : All types of refractories/castables/mortar

TURN OVER : 1.5 Cr.

PRODUCTION VOL. : 5000MT p.a (Capacity:- 7500 MT p.a)

MAJOR CLIET(S) : Direct Manufacturing + Export to Bangladesh through trader

MAJOR MACHINARIES : Crusher, Grinder, U-mixer, Muller mixer, FSPress(4 nos.), DD kiln(3 nos.), Generator.

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

Unit-19

NAME & ADDRESS OF MSME UNIT :

Keshri Industries (1985) G.T. Road(NH2), P.O.- Searsole Rajbari, Burdwan – 713 358, W.B.

CONTACT PERSON WITH DESIGNATION & CONTACT DETAILS :

NAME: Mr. Vinod Keshri.

Qualification : Diploma in ME Donbosco.

Age : 37 Yrs.

Mob. No. : +91 9832164442

Email : [email protected]

PRODUCT RANGE : B P set, ladle sleeves, shapes, mortar

MAJOR MACHINARIES : Dislegrator, U-Mixer, FSP-2(110,80MT), Pllution Device-1, Kiln DD(2)

REGISTRATION NO. : 190091103975

Unit-20

NAME & ADDRESS OF MSME UNIT :

National Refractories (1970) P.O.- Salanpur, Burdwan – 713 357, W.B.

CONTACT PERSON WITH DESIGNATION & CONTACT DETAILS :

Name : Mr. Pinaki Mukheree,

Qualification : Msc(Chemistry).

Age : 64 Yrs.

Mob. No. : +91 9434039039

Email : [email protected]

PRODUCT RANGE : High brog/Alumina brick, insulation/156(30% Alumina).

TURN OVER : Approx. 30 Cr.

PRODUCTION VOL. : (1600-1800)MT*12 p.a. (Capacity - 36000 MT p.a.)

MAJOR CLIET(S) : SAIL units (DSP, RSP, BSP, IISCO, ASP, RINL, TATA steel, SPS steel, TATA Metaliks etc.), NALCO, BALCO, DPL, Graphite India, Vedanta Aluminium, EIL, MECON and export to Egypt, Nepal, Bagladesh

MAJOR MACHINARIES : Friction Screw Press-12nos., Hydraulic Press-4nos., Producer oil fired Shuttle kiln-1 no. And tunnel kiln-3nos., various material handling unite(fork lift, pay loade, mobilr hyd crane), lathe machine, DG sets,

PLANT AREA : 154750 Sqm.

REGISTRATION NO. : 3565/S1A/iM0/2005(Ministry of commerce and industry).

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

Unit-21

NAME & ADDRESS OF MSME UNIT :

Datta & Datta Ceramics Works (2000) P.o- Jamgram, Burdwan- 713315, W.B.

CONTACT PERSON WITH DESIGNATION & CONTACT DETAILS :

Name : Mr. Biswajit Maharaj,

Qualification :

Age : 48 Yrs.

Mob. No. : +91 9434163387

Email :

PRODUCT RANGE : 156/158 upto 70% Al2O3- Bricks/Shapes, Insulation.

TURN OVER : Approx:- 75 lacs.

PRODUCTION VOL. : 2500-3000MT p.a.

MAJOR CLIET(S) : RSD Ceramics, Minerex India, Ganapati Udyog and export through traders

MAJOR MACHINARIES : DD Kiln-4, Disintegrator-2, FSP-3, Hydrolic press-1, U-mixer-1, Multer-3, Pulvension-1, Crusher-1.

PLANT AREA : 2.85 Acre

REGISTRATION NO. : 190091100751

Unit-22

NAME & ADDRESS OF MSME UNIT :

SB Steel Refractories P. Ltd. (1979) Jamgram, Via-Panuria, Lalgang, Burdwan – 713 315, W.B.

CONTACT PERSON WITH DESIGNATION & CONTACT DETAILS :

Mr. Gourav Majumdar.

Qualification : BBA.

Age : 31 Yrs.

Mob. No. : +91 9830658176

Email : [email protected]

PRODUCT RANGE : Fire bricks,, mortar, crustables.

TURN OVER : 125 lacs.

MAJOR CLIET(S) : SAIL/DSP/ASP/IISCO, Rourkela Steel Plant, Bhilai Steel Plant, Bokaro Steel Plant Jindal Steel Plant, Jai Balaji Steel Ltd.

MAJOR MACHINARIES : Friction Screw Press (200MT, 150MT-2nos.), Hydraulic Press(100MT), Muller Mixer, Pug Mixer, Pulveriser, DD kiln.

PLANT AREA : 6.3 Acre

REGISTRATION NO. : 19000 91100376

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

[1]

Identifying Design Opportunity

for

Technology, Modernization and

Design Collaborations

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

Unit-1 : M/s Burnpur Ceramics

a) Basic Input /Data

Sl. no.

Opportunity areas for Design Intervention

Has it been covered

Remarks /Suggestion

1. Product Design, Redesign,

Product Development

Fair Tailor made products,

sometimes as per Client.

2. Technology, Modernisation,

Collaboration

No

3. Research and development directions for

future initiatives.

Fair Home made

4. Innovation in process and related areas for

design intervention.

Fair

5. Workstation & Tooling Design yes

6. Market & competitive study for design

advantage and distinction

Yes

7. Training and skill upgradation No

8. Ergonomic and environment factors Fair Pollution device installed, but

not functioning properly.

9. Packaging, logistics and storage related

design opportunities

No

10. Infrastructure and capability enhancement

from design perspective

No

11. Exhibition /Display design opportunities Not frequently Only in NSIC /MSME

12. Visual identity and branding from

communication design point of view

No Only embossing is done

13. Inter cluster communication Excellent

14. To create a visible impact and effectively

develop the capabilities of MSME

Excellent Raw Materials available easily.

15. To improve the process of manufacturing and

productivity

Good

16. To increase the market share and profitability Good Being handled by Association at

present.

17. To reduce rejections, wastages in material,

process, resources and the drudgery on labor

Fair Wastages are being recycled.

18. To improve product manufacturability,

serviceability, manufacturing process,

packaging, logistics operations etc.

Unsatisfactory

Not being done in a planned

manner.

19. To add value to the products or services

concerned and increase their competitiveness

Excellent Has own test lab and experts are

being hired time to time.

20. To create positive difference to the MSME,

either in absolute revenues(indicating higher

profits) or in percentage terms)

Fair Opportunities open.

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

b) Observation and area of intervention :

Observation :

No safety dress /shoe, manual batching, more

workers, less output.

Recommendation :

Installation of Semi-automatic /fully automatic

system may not require to follow safety norms,

improved output with less wastage of raw

materials

Observation :

Huge dust in the work environment /equipments,

de-dusting system in function not working

properly, not being monitored.

Recommendation :

Intervention of technical experts required to

resolve the issue and make the owners /partners

fully aware.

Observation :

Huge dust in the work environment /equipments

may cause fatal disease for the workers, loss of

materials.

Recommendation : Design intervention needed for process

improvement, covered conveying systems at low

cost be installed and directly be fed to the Muller

or U-mixer, as necessary.

Observation :

Workers in front of heavy machinery /Screw

press without following safety norms /dress .

Recommendation :

Workshop should be conducted for the workers

to demonstrate the use and make them realise the

importance of using standardized equipments.

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

Observation :

Due poor quality manpower, there are huge

wastage of green samples.

Recommendation : Time-to-time skill upgradtion of manpower or

training of labours are necessary.

Observation :

Low level of maintenance of kiln and no

thunderstorm prevention equipment, problem of

uneven firing, non-uniform temperature control,

which increases percentage of rejection.

Recommendation :

This Kiln is coal based and suffers from the

unavailability of coal. Even though the use of

coal in firing abundantly is not appreciable.

Substitute kiln system may be opted for.

Observation :

Coal ash after firing is considered as waste and

not utilized considering zero value.

Recommendation : The same further be utilized in consultation with

scientists so that a value could be added and the

unit may run with more profit.

Observation :

Pollution control device in operation not

successful .

Recommendation :

Technical expertise required to test and improve

the same or to look for alternate device to save

the environment.

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

c) Scope for research and development direction for future initiatives

Remedial Design Solution Suggested, if any

1. Common Support (technical know how /testing etc.) for the cluster is highly demanding.

2. NIT Durgapur may provide necessary support (Technical /management etc.) as and when needed by the respective unit in the form of Project(s) being funded by NID/MSME.

3. Different socioeconomic issues may be addressed /discussed in the workshop for feasible outcome.

d) Scope for Interventions- Summarized :

Purchased Samples be housed in low cost temporary Sheds to minimise various losses

Pollution device be tested in and upgraded technologically

Safety norms be followed strictly and workers be trained for minimum loss.

Skilled worker be employed

aiming at proper sorting and

timely /quality production.

Minimum welfare facilities to comply with labour welfare commission of GOI.

Minimum wastage for green & finished samples. Coal ash be properly utilized.

Raw Materials

Storage

Manual Mould Casting

Press Mould Casting

Chamber Kiln

Loading into Kiln

Firing in the Kiln

Pollution

Unloading

Source

Sorting Technique

Labour Welfare

Wastage & Ash

Samples be tested after collection from various sources, be standardised and a data bank be prepared

Moulding be done at close proximity to U-mixer, muller mixer to maintain proper water content in the green samples

Proper maintenance & Technology

upgradation is required in consultation with

R& D Institution.

Fuel /coal /coke efficiency be improved. Alternative fuelling system be explored

Minimum Breakage be ensured and quality management

To adopt healthy packaging material and technique and to install a separate packaging unit.

Breakage in picking and handing green samples be avoided with the support of trained supervisor.

Testing & Packaging

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

[2]

Identifying Design Opportunity

in

Workstation and Tooling design

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

Unit-7 : Apodicitc Ceramics

a) Basic Input /Data

Sl. no.

Opportunity areas for Design Intervention

Has it been covered

Remarks /Suggestion

1. Product Design, Redesign, Product Development

Fair Tailor made products. (as per Client).

2. Research and development directions for future initiatives.

Fair Home made, no sharing /collaboration

3. Innovation in process and related areas for design intervention.

Yes

4. Workstation & Tooling Design Not adequate

5. Market & competitive study for design advantage and distinction

Yes

6. Training and skill upgradation No

7. Ergonomic and environment factors Fair Pollution device not functioning properly.

8. Packaging, logistics and storage related design opportunities

Fair

9. Exhibition /Display design opportunities Not frequently Only in NSIC /MSME

10. Inter cluster communication Excellent

11. To create a visible impact and effectively develop the capabilities of MSME

Excellent Raw Materials available easily & locally.

12. To improve the process of manufacturing and productivity

Good

13. To increase the market share and profitability

Fair

14. To reduce rejections, wastages in material, process, resources and the drudgery on labor

Fair

15. To improve product manufacturability, serviceability, manufacturing process, packaging, logistics operations etc.

Unsatisfactory

Not being done in a planned manner.

16. To add value to the products or services concerned and increase their competitiveness

Excellent Has own test lab and not sufficient, hence dependent on other units.

17. To create positive difference to the MSME, either in absolute revenues(indicating higher profits) or in percentage terms)

Fair Opportunities open.

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

b) Observation and area of intervention :

Observation :

Huge dust in the work station, may cause fatal

disease for the workers, loss of materials.

Recommendation :

Design intervention needed for process

improvement, covered conveying systems at low

cost be installed so as to transport the mix

directly to the manual mould preparation unit.

Observation :

Material vats are made up of assemblage of

brinks without mortar, very weak, leading to

costly production.

Recommendation :

Owners /partners not fully aware, training in

regard to tooling design needed to supply quality

product and establish brand name /value.

Observation :

No safety device for labours working in close

proximity to high capacity screw press.

Recommendation : Design intervention in workstation improvement

needed for process improvement, also welfare to

the workers.

Observation :

Labours working in a very congested area

leading to poor quality manoeuvring of end

products

Recommendation :

A slightly better work environment may help the

work force to act promptly and efficiently.

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

c) Scope for research and development direction for future initiatives

Remedial Design Solution Suggested, if any

1. Common Support (technical know how /testing etc.) for the cluster may help improve.

2. The unit has good capacity and quality production, but unsteady requirement in demand-supply chain has led the unit not to improve much. The highlighted area in regard to the work station may help the unit leading to higher export probability.

d) Scope for Interventions- Summarized :

Storage station required aiming at minimisation of raw material purchased

Pollution device performance is not satisfactory, be checked with technical experts

Safety norms be followed strictly and workers be trained for minimum loss.

Be enlighten to different market

survey to have better

understanding and productivity.

Minimum welfare facilities to comply with labour welfare commission of GOI.

Minimum wastage for green & finished samples. Coal ash be properly utilized.

Raw Materials

Storage

Manual Mould Casting

Press Mould Casting

DD Kiln

Firing in the Kiln

Pollution

Exhibition /Display

Labour Welfare

Wastage & Ash

Moulding be done at close proximity to U-mixer, muller mixer to maintain proper water content in the green samples

Proper maintenance & Technology

upgradation is required in consultation with

R& D Institution.

coal is used as fuel at present. Alternative fuelling system /tooling be explored.

To adopt healthy packaging material and technique and to install a separate packaging unit. Testing & Packaging

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

[3] Identifying Scope

for

Training, Skill Upgradation and

Ergonomic factors.

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

Unit-2 : Maa Sharada Refractories & Ceramics

a) Basic Input /Data

Sl. no.

Opportunity areas for Design Intervention

Has it been covered

Remarks /Suggestion

1. Product Design, Redesign, Product Development

Fair Tailor made products, sometimes as per Client.

2. Technology, Modernisation, Collaboration

Fair

3. Research and development directions for future initiatives.

Fair Home made

4. Innovation in process and related areas for design intervention.

Yes

5. Workstation & Tooling Design yes

6. Market & competitive study for design advantage and distinction

Yes

7. Training and skill upgradation No Highly needed

8. Ergonomic and environment factors Fair Pollution device installed, but not functioning.

9. Packaging, logistics and storage related design opportunities

No

10. Infrastructure and capability enhancement from design perspective

No

11. Inter cluster communication Excellent

12. To create a visible impact and effectively develop the capabilities of MSME

Excellent Raw Materials available easily.

13. To improve the process of manufacturing and productivity

Good

14. To increase the market share and profitability

Good

15. To reduce rejections, wastages in material, process, resources and the drudgery on labor

Fair

16. To add value to the products or services concerned and increase their competitiveness

Excellent Has own quality test lab and experienced lab attendant.

17. To create positive difference to the MSME, either in absolute revenues(indicating higher profits) or in percentage terms)

Fair Owner has to make effort with resolve to improve productivity.

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2012

b) Observation and area of intervention :

Observation :

Although process is semi automatic, still found

very much unhealthy, difficult to work by the

labours due to unplanned stacking of materials.

Recommendation : Time-to-time training of owners /partners

necessary for proper ergonomic support to the

workers.

Observation :

Low level of maintenance of kiln and chimney

/pollution device user for existing DD kiln, as a

result work environment is unhealty.

Recommendation :

This Kiln is coal based and poor quality coal is

being used for firing. Recommendation of

pollution expert must be sought for and or

Substitute kiln system may be opted for.

Observation : The process that is usually practiced firing

ergonomically very unhealthy. The

uncomfortable posture may be a threat to the

worker leading to low production rate.

Recommendation : Providing proper sitting /training

arrangement and tools will help the worker in

increasing production per person

Observation :

Highly dust Pollution in and around working

area, may lead to fatal diseases to the laours.

Recommendation :

Technical expertise or installation of dedusting

system is required to bring down pollution level

and to save the environment.

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

c) Scope for research and development direction for future initiatives

Remedial Design Solution Suggested, if any

1. Running well but, attempt to solidify the technical know how may help to perform better.

2. NIT Durgapur may provide necessary support (Technical /management etc.) as and when needed by the respective unit in the form of Project(s) being funded by NID/MSME.

3. Different socioeconomic issues (land /pollution /fuel supply etc.) may be addressed /discussed in the workshop for feasible outcome.

d) Scope for Interventions- Summarized :

Purchased Samples be housed in low cost temporary Sheds to minimise various losses

Pollution device be tested in and upgraded technologically

Safety norms be followed strictly and workers be trained for minimum loss.

Skilled worker be employed

aiming at proper sorting and

timely /quality production.

Minimum welfare facilities to comply with labour welfare commission of GOI.

Minimum wastage for green & finished samples. Coal ash be properly utilized.

Raw Materials

Storage

Manual Mould Casting

Press Mould Casting

DD Kiln

Loading into Kiln

Firing in the Kiln

Pollution

Unloading

Source

Sorting Technique

Labour Welfare

Wastage & Ash

Samples be tested after collection from various sources, be standardised and a data bank be prepared

Moulding be done at close proximity to U-mixer, muller mixer to maintain proper water content in the green samples

Proper maintenance & Technology

upgradation is required in consultation with

R& D Institution.

Fuel /coal /coke efficiency be improved. Alternative fuelling system be explored

Minimum Breakage be ensured and quality management

To adopt healthy packaging material and technique and to install a separate packaging unit.

Breakage in picking and handing green samples be avoided with the support of trained supervisor.

Testing & Packaging

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

[4] Study of Infrastructure Setup

from

Design Perspective

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2012

Unit-12 : Jaya Ceramics

a) Basic Input /Data

Sl. no.

Opportunity areas for Design Intervention

Has it been covered

Remarks /Suggestion

1. Product Design, Redesign, Product Development

Fair Tailor made products,

2. Technology, Modernisation, Collaboration

No

3. Research and development directions for future initiatives.

Fair Home made

4. Innovation in process and related areas for design intervention.

Fair

5. Market & competitive study for design advantage and distinction

Fair

6. Packaging, logistics and storage related design opportunities

No

7. Infrastructure and capability enhancement from design perspective

No

8. Exhibition /Display design opportunities Not frequently

9. Visual identity and branding from communication design point of view

No

10. Inter cluster communication Excellent

11. To create a visible impact and effectively develop the capabilities of MSME

Excellent Raw Materials available easily.

12. To improve the process of manufacturing and productivity

Good

13. To reduce rejections, wastages in material, process, resources and the drudgery on labor

Fair

14. To improve product manufacturability, serviceability, manufacturing process, packaging, logistics operations etc.

Unsatisfactory

15. To add value to the products or services concerned and increase their competitiveness

Excellent Owner is gradually setting up test lab within the compound.

16. To create positive difference to the MSME, either in absolute revenues(indicating higher profits) or in percentage terms)

Fair Opportunities open.

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b) Observation and area of intervention :

Observation :

No safety dress /shoe, manual batching, more

workers, less output.

Recommendation :

Installation of Semi-automatic /fully automatic

system may not require to follow safety norms,

improved output with less wastage of raw

materials

Observation :

Immatured girl worker in action, not essential, be

avoided at all cost.

Recommendation :

Design intervention in regard to the process

/workers is needed and make the owners

/partners fully aware.

Observation :

Pollution device yet to be installed /completed

for this old system of DD kiln.

Recommendation : Design intervention needed for process

/performance improvement of this low cost

pollution device.

Observation :

Huge piling of end products in the open air.

Manufacturing of regular items not sold for long

time.

Recommendation :

Market survey by the owner is not proper leading

to such a condition of the unit. Connectivity to

the traders be mobilised from design

perspective.

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c) Scope for research and development direction for future initiatives

Remedial Design Solution Suggested, if any

1. Common Support (technical know how /testing etc.) for the cluster is highly demanding.

2. NIT Durgapur may provide necessary support (Technical /management etc.) as and when needed by the respective unit in the form of Project(s) being funded by NID/MSME.

3. Different socioeconomic issues may be addressed /discussed in the workshop for feasible outcome.

d) Scope for Interventions- Summarized :

Purchased Samples be housed in low cost temporary Sheds to minimise various losses

Pollution device be tested in and upgraded technologically

Safety norms be followed strictly and workers be trained for minimum loss.

Skilled worker be employed

aiming at proper sorting and

timely /quality production.

Minimum wastage for green & finished samples. Coal ash be properly utilized.

Raw Materials

Storage

Manual Mould Casting

Press Mould Casting

DD Kiln

Loading into Kiln

Firing in the Kiln

Pollution

Unloading

Source

Sorting Technique

Wastage & Ash

Samples be tested after collection from various sources, be standardised and a data bank be prepared

Moulding be done at close proximity to U-mixer, muller mixer to maintain proper water content in the green samples

Proper maintenance & Technology

upgradation is required in consultation with

R& D Institution.

Fuel /coal /coke efficiency be improved. Alternative fuelling system be explored

Minimum Breakage be ensured and quality management

To adopt healthy packaging material and technique and to install a separate packaging unit.

Breakage in picking and handing green samples be avoided with the support of trained supervisor.

Testing & Packaging

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[5] Identifying Design opportunity

for

Branding & Packaging Design

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Unit-6 : Maa Chinnamasta Ceramics

a) Basic Input /Data

Sl. no.

Opportunity areas for Design Intervention

Has it been covered

Remarks /Suggestion

1. Product Design, Redesign, Product Development

Fair Tailor made products, sometimes as per Client.

2. Technology, Modernisation, Collaboration

No

3. Research and development directions for future initiatives.

Fair Home made

4. Innovation in process and related areas for design intervention.

Yes

5. Workstation & Tooling Design yes

6. Ergonomic and environment factors Fair Pollution device not functioning properly.

7. Packaging, logistics and storage related design opportunities

No

8. Exhibition /Display design opportunities Not frequently

9. Visual identity and branding from communication design point of view

No

10. Inter cluster communication Excellent

11. To create a visible impact and effectively develop the capabilities of MSME

Excellent Raw Materials available easily.

12. To improve the process of manufacturing and productivity

Good

13. To increase the market share and profitability

Good Being handled by Association at present.

14. To reduce rejections, wastages in material, process, resources and the drudgery on labor

Fair

15. To improve product manufacturability, serviceability, manufacturing process, packaging, logistics operations etc.

Unsatisfactory

16. To add value to the products or services concerned and increase their competitiveness

Excellent Has own test lab and experts are being hired time to time.

17. To create positive difference to the MSME, either in absolute revenuesor in percentage terms)

Fair Opportunities open.

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b) Observation and area of intervention :

Observation :

Huge gaseous pollution in this area of entry of

green samples to the petro coke fired tunnel kiln.

Recommendation :

Notice /placard be installed to save lives of

labours and necessary pollution device be

installed with a support from technical experts in

the area concerned.

Observation :

System being semi automatic, dust in the work

environment /equipments, not being monitored

with care and hence affecting the brand value.

Recommendation :

Intervention of technical experts required to

resolve the issue and make the owners /partners

fully aware.

Observation :

Placard is installed , but not in action.

Recommendation : Design intervention needed for process

improvement and to establish proper brand value

of the unit, as necessary.

Observation :

Good /appreciable display of end products

(worked /working on) in the unit to.

Recommendation :

The same may be displayed in exhibition

organaized by MSME or similar unit promoting

such entrepreneurships.

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c) Scope for research and development direction for future initiatives

Remedial Design Solution Suggested, if any

1. Necessary support (Technical /management etc.) as and when needed by the respective unit in the form of Project(s) be funded by NID/MSME and be sort for.

2. Different socioeconomic issues may be addressed /discussed in the workshop for feasible outcome.

d) Scope for Interventions- Summarized :

Purchased Samples be housed in low cost temporary Sheds to minimise various losses

Pollution device be tested in and upgraded technologically

Safety norms be followed strictly and workers be trained for minimum loss.

Skilled worker be employed

aiming at proper sorting and

timely /quality production.

Minimum welfare facilities to comply with labour welfare commission of GOI.

Minimum wastage of finished samples.

Raw Materials

Storage

Manual Mould Casting

Press Mould Casting

Tunnel Kiln

Loading into Kiln

Firing in the Kiln

Pollution

Unloading

Source

Sorting Technique

Labour Welfare

Wastage & Ash

Samples be tested after collection from various sources, be standardised and a data bank be prepared

Moulding be done at close proximity to U-mixer, muller mixer to maintain proper water content in the green samples

Proper maintenance & Technology

upgradation is required in consultation with

R& D Institution.

Fuel (petro coke) efficiency be improved. Alternative fuelling system be explored

Minimum Breakage be ensured and quality management

To adopt healthy packaging material and technique and to install a separate packaging unit.

Breakage in arranging and handing green samples be avoided with the support of trained supervisor.

Branding & Packaging

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CHAPTER-4

A N A L Y S I S

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SWOT Analysis

S – Strength

Low to Medium Industry.

Needs average investment infrastructure and high income.

Easy availability of Raw materials and labour

Easy availability of fuel such as coal from nearby mines.

Raw material is available at low cost

High demand from steel manufacturing industries located nearby area.

It has a high demand in both in India and aboard market

Easy Export facility available directly /indirectly through trading

W- Weaknesses

No proper storage system required in general.

Unhealthy competition exists due to numerous units in close proximity

Mostly process is manual, not semi-automatic or fully automatic

Unitwise test lab is not available.

Quality inspection not regular as is done with inhouse facilities

Most units have no branding

Unit is run by not well qualified /technically sound owners

Not enough aware or conscious about new trends and market

Not regularly participating in display /exhibition of products

Due to unawareness, owners are not able to avail the benefits of government policies.

Mostly are using oldest type DD kiln

Pollution level of flue gas not firmly maintained.

Unstable market demand has led to steady/good production units to store refractory

products stored inand outside the plant.

Collaborative efforts with Academic /R&D institution is missing.

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O- Opportunity

Common facility centre may be developed for Standard quality of raw materials, fuel and

testing facilities.

Scope of research and product development.available

More production using or applying skill up gradation

Visual identity of product.

Interior roadway.

Proper training on packaging

Expansion from local market to global market

Skill upgradation of labours

Training for use of recycled /waste materials

Awareness program on quality of raw materials, fuels for better production.

More scope for employment of people.

Awareness programme for setting up of new plants or upgradation with the help of

Provision of loan and profitable policies for small units.

T- Threats

Absence of quality inspection has led to waste and low export market.

Technology for efficient use of fuel /firing

Due to 100 days work facility of government, sometimes labours become unavailable.

Due less awareness about market competitiveness and quality consciousness, selling price

of the products becomes marginal.

In-efficient use of fuels in the oldest category of DD kiln in mostly all units.

Market of refractories dependent directly on steel manufacturing units demand.

Very few young entrepreneurs in the profession.

Pollution device installed mostly but not functioning properly due local technology.

Most plants are old, inherited and not motivated enough for future development.

Systematic plan for future intervention /development from Government agencies missing.

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ISSUES

Unit Level Cluster Level National Level

Owner’s vision

Management Efficiency

Markets catering to

Storage space &

Packaging

Quality of raw material &

fuel.

Overheads &Maintenance

Production Capacity

Waste at all levels

Moulder’s skill

Moulder’s availability

Labour skills

Test lab /facilities

Quality control

Labour availability

Work culture.

Labour from nearby

villages

Coal mines- better pay,

labour would go back

Raw material from same

place

Connectivity of roads

Cooperation in sharing

facilities

Younger generation more

qualified-more open to

change

All the units needs to be

upgraded and so with kiln

Water and electricity

consumption huge

Fuel availability/policy for

natural gas

Rural trends /schemes

Excise duties

Labour policies at national

level /WB govt.

Migration from other

states

Illegal mining at nearby

areas

Transportation and

connectivity

Technical support e.g.

CGCRI etc.

Lack of better suited

younger generation to take

up responsibility

Loan policies and

subsidies.

RECOMMENDATION

The present scenario is that the cluster is not technically educated and has very little

design consciousness. Design intervention is required both at unit level and cluster level to

have efficient low cost unit along with their aspirations. There is lack of awareness, technical

education, organizational health consciousness and labour welfare. The clusters need a

system and a proper business model where each and every things are taken care by

responsible people or committee so that the organized format can work for the betterment of

the unit and workers both for production as well as process.

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CONCLUSION

This NAS /study of refractory cluster is good step towards understanding their full

potential and a footstep toward their betterment and utilization of the same for revenue generation

of government agencies. Mostly the cluster units are located in the village area and far away from

the local towns, but producing costly and useful products for various steel manufacturing units in

the state, outside the state and abroad (such as middle east countries, Saudi Arabia, Bangladesh

etc) too. Except a few units, quality products are not emphasized as they are getting direct orders

from the steel industries. In order to make and sell the product in lowest possible rates the

manufacturers do not make quality product. Branding is also not done in most of the units as the

standard or quality is not maintained. Also they do not have any sort of collaboration with

technical institutions to improve growth pattern. Also some of them are working in an organized

way following semi-automatic technology while others are in an unorganized way and running

somehow. Hence attention may be paid to built up technically sound processes, systems,

product and brand with fuel efficient techniques. Moreover training programmes may be

arranged for awareness of the owners /partners and skill upgradation of workers. This is

possible if we acutely understand the culture, the people and their aspirations. This holistic

view and understanding would provide authentic guidelines for changes that may be

beneficial for this Refractory cluster.

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1-1

Chapter 1

DESIGN AWARENESS PROGRAMME (Refractory Cluster) 

CHECKLIST  

Need Assessment Survey : June’2012

1.1 Cluster Information and Contact Details (Refractories) 

Sl. no. Name of Unit(s) Contact person Contact Details

1.  Burnpur Ceramics  Mr. B. P. Biyani  Vill.‐ Bartoria, P.O.‐ Mithani,    Burdwan – 713 371, W.B.  Mob. No. : +91 9434025307 [email protected] 

2.  Maa  Sharada Refractories & Ceramics 

Mr. Tushar Upadhaya  Vill.‐ Bansoradihi, Palsdihi Road, Asansol,    Burdwan – 713 302, W.B.  Mob. No. : +91 9233312037 [email protected] 

3.  Royson’s Refractory  Mr. Subhankar Roy  Vill.‐ Amdiha, P.O.‐ Lalgange,              PS‐Barabani,  Burdwan – 713 359, W.B. Mob. No. : +91 9832147585 [email protected] 

4.  Raimata Ceramics  Mr. Sanjiv Khemka  Vill.+ P.O.‐ Banra,                             Purulia – 713 312, W.B.  Mob. No. : +91 9679300574 [email protected] 

5.  Royal Refractories  Mr. H. L. Prasad.  Vill.+ P.O.‐  Bartoria,                        Purulia – 723121, W.B.  Mob. No. : +91 434115132 [email protected] 

6.  Maa Chinnamasta Ceramics 

Mr. Aniridhha Rakshit  Vill.‐ Pochara, P.O.‐ Digha,              Purulia – 723121, W.B.  Mob. No. : +91 9732006162 [email protected] 

7.  Apodicitc Ceramics  Mr. B. Jalan  Vill.‐ Manpura, P.O.‐ Digha,          Purulia – 723 121, W.B.  Mob. No. : +91 9431124482 [email protected] 

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Chapter - 1 Cluster Information 1-2

Need Assessment Survey /Refractory cluster /Asansol Division /W.B. /MSME 2012.

8.  Baba Baidnath Refractories 

Mr. Sudipta Chatterjee       Parbelia, Hijuli Road, P.O.‐ Saltore,    Purulia – 723121, W.B.  Mob. No. : +91 9732387637 [email protected] 

9.  Silicon Ceramics  Mr. Amit Gupta.  Biridangal, P.O.‐ Barakar,            Burdwan – 713 324, W.B.  Mob. No. : +91 9832195100 [email protected] 

10.  Shree Kishan Refractories  Mr. R. S. Bansal.  Hanuman Charai, P.O.‐ Barakar,    Burdwan – 713 324, W.B.  Mob. No. : +91 9749734444 [email protected] 

11.  Shiva Refractories  Mr. Pankaj Bansal.  Deepu Dangal, P.O.‐ Barakar,    Burdwan – 713 324, W.B.  Mob. No. : +91 9434744595 [email protected] 

12.  Jaya Ceramics  Mr. Dinabandhu Rooj.  Badradi, Siakulberia,  PS‐Salanpur, Burdwan – 713 335, W.B.  Mob. No. : +91 9474910009 [email protected] 

13.  Liberty Refractories Pvt. Ltd. 

Mr. R. S. Gandhi.  NH‐2 byepass, Salanpur,            Burdwan – 713 357, W.B.  Mob. No. : +91 9333719097 ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ 

14.  Shree Bhim Refractories  Mr. Bansi Bansal.  NH‐2 byepass, Sabanpur,          Burdwan , W.B.  Mob. No. : +91 9832195155 [email protected]

15.  Salanpur Ceramics  Mr. Akash Sharma.  Nimtala, PO‐ Salanpur,  Burdwan ,W.B. Mob. No. : +91 9547416227 [email protected] 

16.  Anant Ceramics.  Mr. Subhas Roy.  Vill.‐ Angaria, P.O.‐ Ethora,        Burdwan – 713 359, W.B.  Mob. No. : +91 9434009220 [email protected] 

17.  S. P. Refractories  Mr. Pradip Roy.  Vill‐Monohar Bahal, P.O.‐ Ethora,    Burdwan – 713 359, W.B.  Mob. No. : +91 9832194127 [email protected] 

18.  Madhusudan Refractories  Mr. Ashoke Kr. Das.  Vill‐Monohar Bahal, P.O.‐ Ethora,    Burdwan – 713 359, W.B.  Mob. No. : +91 9832132690 [email protected] 

19.  Keshri Industries  Mr. Vinod Keshri.  G.T. Road(NH2), P.O.‐ Searsole Rajbari,   Burdwan – 713 358, W.B.  Mob. No. : +91 9832164442 [email protected] 

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Chapter - 1 Cluster Information 1-3

Need Assessment Survey /Refractory cluster /Asansol Division /W.B. /MSME 2012.

20.       

21.       

22.       

23.       

24.       

25.       

1.2 Brief Resume :

NAME & ADDRESS OF MSME UNIT  : 

M/s Burnpur Ceramics Vill.‐ Bartoria, P.O.‐ Mithani, Burdwan – 713 371 

CONTACT PERSON WITH DESIGNATION & CONTACT DETAILS  : 

Name : Mr. B. P. Biyani.,  Qualification : B.Sc. Age : 67 Yrs. Mob. No. : +91 9434025307 Email    :    [email protected] 

PRODUCT RANGE :  Refractory /Fire clay bricks (Alumna 30% to 90%), Acid proof /Insulation bricks, Castables. 

TURN OVER :   Approx. 2 Crores   

PRODUCTION VOL. :  3000 MT p.a. (Capacity ‐ 7000 MT p.a.) 

MAJOR CLIET(S) :  Govt. Steel Plants (Durgapur, Bokaro, Bhillai, Rourkela) 

MAJOR MACHINARIES :  Jaw Crusher, Disintegrator, Muller mixer(3MT/hr., 1.5MT/hr.), Magnetic iron separator, Friction Screw Press(FSP 150MT‐2nos., 110MT‐2nos.), Chamber(18) Kiln. 

PLANT AREA :   Approx. 5 acres. 

ESTABLISHED IN :  1975 

REGISTRATION NO. :  1900 9120 0349 

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Chapter - 1 Cluster Information 1-4

Need Assessment Survey /Refractory cluster /Asansol Division /W.B. /MSME 2012.

Sl. no. 

Opportunity areas for Design Intervention 

Has it been covered  Remarks

1.  Product Design, Redesign,  Product Development 

Fair  Tailor made products, sometimes as per Client. 

2.  Technology, Modernisation,  Collaboration 

No   

3.  Research and development directions for future initiatives. 

Fair  Home made 

4.  Innovation in process and related areas for design intervention. 

Yes   

5.  Workstation & Tooling Design  yes   

6.  Market & competitive study for design advantage and distinction 

Yes   

7.  Training and skill upgradation  No   

8.  Ergonomic and environment factors  Fair   Pollution device installed, but not functioning properly. 

9.  Packaging, logistics and storage related design opportunities 

No   

10.  Infrastructure and capability enhancement from design perspective 

No   

11.  Exhibition /Display design opportunities  Not frequently  Only in NSIC /MSME 

12.  Visual identity and branding from communication design point of view 

No  Only embossing is done 

13.  Inter cluster communication  Excellent   

14.  To create a visible impact and effectively develop the capabilities of MSME 

Excellent  Raw Materials available easily. 

15.  To improve the process of manufacturing and productivity 

Good   

16.  To increase the market share and profitability 

Good  Being handled by Association at present. 

17.  To reduce rejections, wastages in material, process, resources and the drudgery on labor 

Fair  Wastages are being recycled. 

18.  To improve product manufacturability, serviceability, manufacturing process, packaging, logistics operations etc. 

Unsatisfactory  

Not being done in a planned manner. 

19.  To add value to the products or services concerned and increase their competitiveness 

Excellent  Has own test lab and experts are being hired time to time. 

20.  To create positive difference to the MSME, either in absolute 

Fair  Opportunities open. 

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Chapter - 1 Cluster Information 1-5

Need Assessment Survey /Refractory cluster /Asansol Division /W.B. /MSME 2012.

revenues(indicating higher profits) or in percentage terms) 

Remedial Design Solution Suggested, if any 

1.  Common Support (technical know how /testing etc.) for the cluster is highly demanding. 

2.  NIT Durgapur may provide necessary support (Technical /management etc.) as and when needed by the respective unit in the form of Project(s) being funded by NID/MSME. 

3.  Different socioeconomic issues may be addressed /discussed in the workshop for feasible outcome. 

4.   

1.3 Site Snapshot(s) :

Raw Materials Storage Yard  Manual Batching 

Disintegrator of raw materials  Crusher /Pulveriser unit 

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Chapter - 1 Cluster Information 1-6

Need Assessment Survey /Refractory cluster /Asansol Division /W.B. /MSME 2012.

Collection of Dry Mix  Muller(for dry Mix) 

FSP Units  Green samples from Wet Mix 

 Wastages  Green Samples under preparation 

Green Samples under preparation  Chamber(18) Kiln 

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Chapter - 1 Cluster Information 1-7

Need Assessment Survey /Refractory cluster /Asansol Division /W.B. /MSME 2012.

Chamber Kiln /Chimney with Pollution Device  Samples inside Kiln after firing 

Samples from the Kiln  Tested, Inspected and Stamped Samples 

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

REPORT ON REFRACTORY CLUSTER

DEIGN CLINIC WORKSHOP

15th December to 19th December, 2012 Asansol, Burdwan District

West Bengal

Conducted by Dr. Amiya K. Samanta, Design Expert

Organised by

Refractory Manufactures’ Association, Asansol

In Association with National Institute of Design, Ahmehdabad.

Supported by

Design Clinic Scheme for MSMEs, Ministry of MSMEs

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TABLE OF CONTENTS

No. Description of Item Page No.

Cover Page

1. Workshop Schedule ........………………………………..............……..……….. 3

2. Activity Report during Five days ………………………..................…………... 5

3. Profile of Guest Speakers …………………………..………………………...… 10

4. Details /Topic covered …………………………………………….…………..… 14

5. Attendees list during Five days ………………………..................……..…….... 19

6. Sample Registration Forms ………………………..................……..………….. 37

7. Sample Feedback Forms ………………………..................……..……………... 42

8. Workshop Photograph …………..................……..…………………………...... 47

9. Opportunity Area, Remedial Design Solution & Future Direction ………….. 64

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

*

"REFRACTORY MANUFACTURERS' ASSOCIATION(RMA)"

REFRACTORY CLUSTER,

DESIGN CLINIC WORKSHOP SCHEDULE:

15/12/2012 to

19/12/2012

(5 Days)

Venue : Asansol Club, Near Asansol Court /BNR

(First Floor)Day-1 : 15th December (Saturday), 2012 {For Assoc iat ion/NGO & Unit Owners}

Venue : Asansol Club, near BNR.

* PRESENTATION / NATURE OF WORK TIME

Regis t rat ion 4:00 pm to 5:00 pm

Inaugural Sess ion

1 Lightening /Opening of the Workshop 5:00 PM

2 Felicitation of Guest(s) 5:05 PM

3 Welcome address by Mr. B.P. Biyani (President, RMA) 5:15 pm to 5:30 pm

4 Speech by Mrs.(Dr.) Mou Sen, Dy. Director, MSSE, Govt. of W.B. contd.

5 Speech by Mr. R.N. Yadav, Asansol Chamber of Commerce contd.

6Speech by Mr. Tapas Bandyopadhaya, Mayor-Asansol, MLA-Govt.

of W.B. ---------- Chief Guestcontd.

7 Speech by Mr. Malay Ghatak, H'onable Minister, Govt. of W.B. contd.

8 Refreshment (Tea/Snacks) Break 06:30 to 07:00 pm

Technical Sess ion

9 Design Clinic Scheme for MSME, Presentation by Mr. Ashok

Mondal, Coordinator, Eastern India, NID Ahmedabad7:00 pm to 7:30 pm

10 Presentation on Refractory Cluster : Need Assesment Survey by Dr.

Amiya K. Samanta, Design Expert7:30 pm to 8:00 pm

11 Interactive Discussion (Question & Answer) Session 8:00 pm to 8:25 pm

12 Vote of Thanks by Mr. Ashoke Chakraborty (Gen Sec., RMA) 8:25 pm to 8:30 pm

13 Dinner 8:30 to 9:30 pm

Day-2

Venue : Raghunath Niwas, Senraleigh Road, Asansol

Regis t rat ion 4:30 pm to 5:00 pm

1

Presentation "Testing and Evaluation Procedure for refractory raw

materials and products" by Dr. Swapan Kr. Das Scientist & Head-

Refractory Division CGCRI, Kolkata (Speaker-1)

5:00 to 5:45 pm

2 Refreshment (Tea/Snacks) Break 05:45 to 06:15 pm

3Presentation "Quality Control during manufacturing process of

refractories." by Dr. Swapan Kr. Das (Speaker-1)6:15 to 7:00 pm

4 One to One Interaction /Discussion /Q & A 7:00 to 8:25 pm

5 Concluding Remarks 8:25 to 8:30 pm

6 Dinner 8:30 to 9:30 pm

: 16th December (Sunday), 2012 {For Unit Owners : Group-I}

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

Day-3

Venue : Raghunath Niwas, Senraleigh Road, Asansol

Regis t rat ion 4:30 pm to 5:00 pm

1Presentation "Application of Refractories in Steel Industries." by Mr.

Prabir Dutta, DGM Durgapur Steel Plant, Durgapur (Speaker-2)5:00 to 5:45 pm

2 Refreshment (Tea/Snacks) Break 05:45 to 06:15 pm

3 Panel Discussion by Design Expert Dr. A..K. Samanta 6:15 to 7:00 pm

4 One to One Interaction /Discussion /Q & A 7:00 to 8:25 pm

5 Concluding Remarks 8:25 to 8:30 pm

6 Dinner 8:30 to 9:30 pm

Day-4

Venue : Raghunath Niwas, Senraleigh Road, Asansol

Regis t rat ion 4:30 pm to 5:00 pm

1Presentation "Refractory Industry : Effective Fuel & Firing." by Mr.

Aloke Sarkar, DGM IISCO Steel Plant, Burnpur. (Speaker-3)5:00 to 5:45 pm

2 Refreshment (Tea/Snacks) Break 05:45 to 06:15 pm

3Presentation "Refractory Industry : Effective Fuel & Firing." by Mr.

Aloke Sarkar. (Speker-3)6:15 to 7:00 pm

4 One to One Interaction /Discussion /Q & A 7:00 to 8:25 pm

5 Concluding Remarks 8:25 to 8:30 pm

6 Dinner 8:30 to 9:30 pm

Day-5 : 19th December (Wednesday), 2012 {For Assoc iat ion/NGO & Unit Owners}

Venue : Raghunath Niwas, Senraleigh Road, Asansol

Regis t rat ion 4:30 pm to 5:00 pm

1

Presentation "Growth of Refractory Sector in Asansol Area vs NIT

Durgapur" by Prof.(Dr.) Anup K. Saha. Professor and Chairman-

Industry Institute Interaction Cell, NIT Durgapur (Speaker-4)

5:00 to 5:45 pm

2 Refreshment (Tea/Snacks) Break 05:45 to 06:15 pm

3 Panel Discussion by Prof.(Dr.) Anup K. Saha. (Speaker-4) 6:15 to 7:00 pm

4Concluding Session, "Feedback, Suggestion and Future direction of

the Cluster" by Design Expert Dr. A. K. Samanta7:00 to 8:00 pm

5 Vote of Thanks by Mr. Ashoke Chakraborty (Gen Sec., RMA) Contd.

6 Dinner 8:30 to 9:30 pm

*********************

: 17th December (Monday), 2012 {For Unit Owners : Group-II}

: 18th December (Tuesday), 2012 {For Unit Owners : Group-III}

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

ACTIVITY REPORT

Design Clinic Workshop : Refractory Cluster

(15th Dec to 19th Dec 2012)

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

Date: 15th December 2012 : Asansol Club

Inaugural Session :

1. All the distinguished guests including Mayor & MLA Asansol, Dy Director

Small industries (ancillary) WB, Design Expert, NID representative etc.

were invited to the dais and then the workshop started.

2. At the outset Mr. B. P. Biyani, President, RMA welcomed the participants

and introduced Guest Speaker, Design Expert and other invited guests in

the opening ceremony of Design Clinic Workshop for Refractory cluster.

3. The flower bouquets were presented to Dr.(Mrs) Mou Sen, Deputy

Director, Micro & Small Scale Enterprises (Ancillary) Durgapur, Govt. of

West Bengal, Mr. Tapas Bandyopadhaya, Mayor-Asansol and MLA-Govt. of

W.B., Mr. Malay Ghatak, H'onable Minister, Govt. of W.B. Mr. Ashok Mondal,

Co-cordinator, Design Clinic Scheme: MSMEs, Eastern Regional Centre of

National Institute of Design”, Dr. Amiya Kumar Samanta Design Expert and

the other dignitaries.

4. Then the seminar were inaugurated by Mr. Tapas Bandyopadhaya (Invited

Guest Speaker), Dr.(Mrs) Mou Sen, Dr. Amiya Kumar Samanta (Invited

Design Consultant), Mr. Ashok Mondal through lighting the inaugural

candle.

5. At first, Mr. B. P. Biyani, President, RMA in his address delivered brief

information about workshop, schedule and activities for the five days. Also

he appealed the Refractory cluster units to take part with their full

presence in the deliberation of the various experts to make the

programme success. He also promoted the scheme enthusiastic for taking

it further as an initiative.

6. Dr.(Mrs) Mou Sen, Deputy Director, Micro & Small Scale Enterprises

(Ancillary) Durgapur, Govt. of West Bengal expressed her joy on receipt of

the NAS report for the cluster and was very happy with the sincere effort

provided by the Design expert Dr. Amiya K. Samanta to understand the

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

need of the cluster at the moment. She particularly emphasised the unit

owners to take part in the technical sessions on regular basis so that the

practical difficulties encountered by the units be properly highlighted

throughout the workshop.

7. On behalf of Asansol Chamber of Commerce, Sri R. N. Yadav thanked the

Refractory Manufactuers Association unit owner and briefly encouraged to

gain maximum benefit out of the workshop arranged by both NID

Ahmedabad as well as Government of West Bengal.

8. Mr. Tapas Bandyopadhaya, Mayor-Asansol and MLA-Govt. of W.B. Mr.

Maloy Ghatak, H'onable Minister, Govt. of W.B. addressed various key

issues /concerns for the growth of the refractory cluster in their respective

deliberations.

9. Finally the inaugural session was closed by Mr. B. P. Biyani, President, RMA

by vote of thanks to the dignitaries and the august gathering.

Technical Session :

10. Presentation and Discussion on Design Clinic Scheme for MSME by Mr.

Ashok Mondal, Co-cordinator, Eastern Region, NID Ahmedabad.

11. Presentation on the report of Refractory Cluster- Interactive Design &

Need Assessment Study cum Survey by design consultant & expert- Dr.

Amiya Kumar Samanta.

12. Mr. Ashoke Chraborty, Secretary RMA addresses a vote of thanks to all on

and off the dais.

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

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Date : 16th December 2012 : Raghunath Niwas, Asansol

1. Welcome address and felicitation to Dr. Swapan Kumar Das, Chief Scientist

& Head-Refractory Division CGCRI, Kolkata (Speaker-1) by Mr. Ashoke

Chraborty, Secretary RMA.

2. Dr. Amiya K. Samanta, Design Expert introduced Dr. S. K. Das to the

audience.

3. Presentation (Session-I) on ‘Testing And Evaluation Procedure For

Refractory Raw Materials And Products’ by Dr. Das.

4. Presentation (Session-II) on ‘Quality Control During Manufacturing

Process of Refractories.’ by Dr. Das.

5. One to one interaction along with Q & A on practical difficulties to run the

unit relevant to the talk delivered by the Speaker was coordinated by the

Design Expert Dr. Amiya K. Samanta

6. Mr. Ashoke Chraborty, Secretary RMA addressed a vote of thanks to one &

all

Date : 17th December 2012 : Raghunath Niwas, Asansol

1. Welcome address and felicitation to Mr. Prabir Kumar Dutta, Dy. Gen.

Manager, Durgapur Steel Plant, SAIL(Speaker-2) by Mr. Ashoke Chraborty,

Secretary RMA.

2. Dr. Amiya K. Samanta, Design Expert introduced Mr. P. K. Dutta to the

audience.

3. Presentation on ‘Application of Refractories in Steel Industries.’ by Mr. P.

K. Dutta.

4. Panel discussion along with Q & A on requirements set by Steel Industries

was coordinated by the Design Expert Dr. Amiya K. Samanta.

5. Mr. Ashoke Chraborty, Secretary RMA addressed a vote of thanks to one &

all.

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

Date: 18th December 2012 : Raghunath Niwas, Asansol

1. Welcome address and felicitation to Mr. Aloke Kumar Sarkar, Dy. General

Manager, Refractory Division, IISCO Steel Plant, SAIL, Burnpur (Speaker-3)

by Mr. Ashoke Chraborty, Secretary RMA.

2. Dr. Amiya K. Samanta, Design Expert introduced Mr. A. K. Sarkar to the

audience.

3. Presentation on ‘Refractory Industry And Effective Fuel & Firing’ by Mr. A.

K. Sarkar.

4. One to one interaction along with Q & A on Effective fuel and firing

/related issues was coordinated by the Design Expert Dr. Amiya K.

Samanta.

5. Mr. Ashoke Chraborty, Secretary RMA addressed a vote of thanks to one &

all.

Date: 19th December 2012 : Raghunath Niwas, Asansol

1. Welcome address and felicitation to Prof.(Dr.) A K. Saha. Professor-

Mechanical Engineering and Chairman-Industry Institute Interaction Cell,

NIT Durgapur (Speaker-4) by Mr. Ashoke Chraborty, Secretary RMA.

2. Dr. Amiya K. Samanta, Design Expert introduced Prof. A. K. Saha to the

audience.

3. Presentation on ‘Growth of Refractory Sector in Asansol Area vs NIT

Durgapur’ by Prof. A. K. Saha.

4. One to one interaction along with Q & A on Effective support and

cooperation available with NIT Durgapur /Project /related issues was

coordinated by the Design Expert Dr. Amiya K. Samanta. Also Feedback,

Suggestion and Future direction of the Cluster was discussed.

5. Mr. Ashoke Chraborty, Secretary RMA addressed a vote of thanks to one &

all.

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

2012

PROFILE

of

GUEST SPEAKERS

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NEEDS ASSESMENT SURVEY/REFRACTORY CLUSTER/ASANSOL DIVISION/WEST BENGAL/MSME 2012

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1. Dr. Swapan Kumar Das, Chief Scientist & Head-Refractory Division

CGCRI, Kolkata (Speaker-1)

Dr. Swapan Kumar Das, Chief Scientist and Head, Refractories Division,

CSIR-Central Glass & Ceramic Research Institute, Kolkata obtained his Ph D

degree in Ceramic Engineering in 1994 after completing his M. Tech Degree from

Calcutta University. He served industries namely Graphite India, BHEL,

Murdeshwar Ceramics in the R&D and Technology Department quite for a long

time. Then he moved to CSIR -NML, Jamshedpur & CGCRI. He is engaged in R&D

of Advanced Refractories, Wear Resistant Ceramics, Solid State utilization

programme and Traditional Ceramics. He has developed several technologies

and transferred many of them to industries in the area of monolithic castables,

rice husk ash nodules for ladle insulation and wear resistant ceramics sintered at

low temperature. He involved in many projects with industries like Vizag Steel

Plant, ESSER Steel, Tata Steel, TRL Krosaki,DVP Ltd. He has in his credit more

than 100 published papers and 25 patents. He received several awards such as

Ganpule, Deokaran, VA Altekar, Best Project Award and most recently in this

year(2012) he received Refractory Technologist Award,4th CIDC Viswakarma

Award and IRMA award for his contribution in Refractory Science& Technology

for Industries. He visited several countries as Session Chairman, invited speaker

in the international conferences and also as International Advisory Board

Member. He has represented BIS as Indian team leader for ISO TC33/Refractory

meeting held at Kyoto, Japan in 2011. He is serving IITs, Universities as Ph D

supervisor, M. Tech Thesis guide, conducting examinations. He is an Expert

Member of many committees such as DST, Vizag Steel Plant campus interview,

Calcutta University Ph D committee and Chairman of many selection committees

at CSIR-CGCRI and NML.

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2. Mr. Prabir Kumar Dutta, Dy. Gen. Manager, Durgapur Steel Plant, SAIL (Speaker-2)

P. K. Datta, graduated in Ceramic Technology from College of Ceramic

Technology, Kolkata in the year 1981. He joined in Durgapur Steel Plant in 1982

as Management Trainee (Tech). At present he is working in the field of

Refractories maintenance & development of alternative materials for different

metallurgical vessels & furnaces. He has received Metalurgical award twice from

Indian Institute of Metals (IIM : Durgapur Chapter) for ‘Renovation of metallic

recuperator of Soaking pit’ in 1990 & ‘in-house development of refractory tube

for LECO hydrogen analyser of BOF laboratory’ in 2002 as an import substitute.

He is closely associated with HRD activities for training & development of people

working in the field of Refractories maintenance.

3. Mr. Aloke Kumar Sarkar, Dy. General Manager, Refractory Division, IISCO Steel Plant, SAIL, Burnpur (Speaker-3)

Sri Alok Kumar Sarkar did B.Tech. in Ceramic Technology from Calcutta

University in 1975. Throughout his career, he has worked in Refractory

Manufacturing units in different position. Besides manufacturing, he has also

worked in R & D projects and in other areas. He has developed different products

as per the requirement of changing steel making technology. Some of the

products are

a. Mullite bricks for tap hole of modern blast furnace, which is an import

substitute,

b. Special castable for discharging end of Rotary kiln, 3) Alumina Magnesia

Spinel Castable for Steel Ladle,

c. Sintered Alumina slide gate plate,

d. Logistic Substitution of costly raw materials by cheaper raw materials,

etc.

He was instrumental in implementing different projects for cost control and

survival of plants. Some of the projects are

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a. Conversion of coke based producer gas plant to coal based to reduce

fuel cost,

b. Integarted computerised networking system of total plant to improve

efficiency with reduced manpower,

c. ISO 9000 as Management representation.

He is also instrumental for survival of a plant with negative worth to

positive as unit head, through different cost effective measures and systematic

control. He has presented more than 30 technical papers in different national and

international seminars.

4. Prof.(Dr.) A K. Saha. Professor, Mechanical Engineering and Chairman-Industry Institute Interaction Cell, NIT Durgapur (Speaker-4)

Prof A. K. Saha graduated in the year 1976 from National Institute of

Technology Durgapur (Erstwhile Regional Engineering College Durgapur) and

obtained M.Tech. degree in Machine Dynamics in 1979 from IIT Kharagpur. He

has served industry (coal /Fertilizer /Power /Oil & Gas) for around 20 years. To

name a few in India such as A) Cement Research Institute of India Ltd. New Delhi,

B) RECL New Delhi on material handling/Turnkey projects, EPC, C) Punj Lloyd

Ltd. on cross country pipeline, D) Huwood UK, E) FCB France and F) Ansaldo

Italy.

On obtaining vast experience in the industry, he decided to join research in

machine dynamics and joined IIT Kharagpur in 1999 and obtained Ph.D. degree

in 2005. Then he joined teaching at Gujrat University and finally at NIT Durgapuir

in 2007 as Professor Mechanical Engineering. He is also holding a few key

positions in the institute such as chairman of Industry-Institute Cell of the

Institute etc. His field of specialisation is Fault diagnosis, Mechanical vibration,

technical collaboration etc.

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DETAILS/ TOPICS COVERED:

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1. Dr. Swapan Kumar Das, Chief Scientist & Head-Refractory Division CGCRI, Kolkata (Speaker-1)

Testing and evaluation procedure be done as per national standard

Emphasis be given on systematic sampling as per relevant IS code of

practice before testing is taken up

Grouping of testing procedures (physical, chemical and high

temperature) was discussed in length

Need of good test lab and instruments /facilities was discussed in

particular for carrying out chemical composition properly

Quick analysis /test was elaborated using sophisticated instruments

such as atomic absorption spectrophotometer etc. available with

various test houses

Speciality of temperature tests and other significant tests (such as XRD

study, microstructure study, creep) were brought to the knowledge of

the audience

Tests required for monolitics were discussed separately

Audience was made aware of Knowledge and awareness of refractory

testing in the light of manufacturing quality products.

Management /owner /partner awareness is the ultimate answer to

appreciate the necessity of regular refractory testing to improve

productivity and quality.

Various Control parameters (raw materials, sizing & screening,

batching mixing, drying, pressing, fuel, firing techniques, temperature)

were discussed to maintain quality of the end products which will be

accepted by the clients

Introduction of Quality control chart and process of documentation at

each shop with strict instruction may help to improve quality. If a

product fails during use, the documents on quality control parameters

will help to investigate the causes of failure.

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2. Mr. Prabir Kumar Dutta, Dy. Gen. Manager, Durgapur Steel Plant, SAIL (Speaker-2) Present Senario of consumption of refractories in particular to the steel

industries were discussed

He mentioned that increase in Steel production will phase out of the old

technology of refractory manufacturing.

Consumption of ratio of Shaped & granular refractories is about 70:30 in

steel industries.

Lower Consumption refractories with higher Specific Cost in modern steel

plants.

Availability of new variety of Refractories at a reasonable price and

performance guarantee.

Area of use in an integrated steel industry is mainly in Coke Oven, Sinter

Plant, Blast Furnace, Steel Melting Shop, Foundry and Reheating & heat

treatment Furnaces

Alumina content, silica content, Aliminium silicate content in different

units including bottom pouring sets, castables were discussed and their

reason behind it.

He mentioned about the recent trend in steel making houses on Use of

performance based materials 1) on management basis(Supply, apply &

performance) and 2)Total management (Supply, apply & performance of

all components)

Demand in steel industry particularly in 1) Refractories for reduction in

consumption & cost 2) Refractories for cleaner steel and Improved

quality granular refractory

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3. Mr. Aloke Kumar Sarkar, Dy. General Manager, Refractory Division, IISCO Steel Plant, SAIL, Burnpur (Speaker-3)

Mentioned Challenges before Refractory Industry are in 1) Availability of

raw materials, 2) High Fuel & Energy cost, 3) Reducing demand, 4)

Inadequate R & D activity and 5)Competitive market

Mentioned specific consumption refractories in various steel

industries like DSP, RSP, BSP, ISP, RINL, JSW, Tata Steel and their

priorities regarding Safety, Control of pollution, Energy Saving, Waste

Management and Cost Control & Profit Making.

Safety is maintained by providing suitable tools & tackles, suitable

safety appliances, healthy machine condition whereas Control of

Pollution related to Dust c, Heat, Noise and Effluent.

Waste control related to Control of rejection, electricity consumption,

fuel consumption, Utilization of waste heat, Plugging the loss of heat

and Control of processing loss and discussed on it.

Evaluation of heat requirement to be calculated based on

Composition of Aggregate, Thermal Analysis of aggregate (DTA,

DTGA), Preparation of firing schedule and Theoretical calculation of

heat requirement exclusive of different losses

Area of heat losses are Spillage & handling loss of fuel, Incomplete

combustion of fuel, Improper stacking of bricks, Improper firing

zone, Insufficient combustion air, Heat loss through roof, walls, flue

channel etc. and mainly Non adhering to firing schedule.

Factors for checking of firing efficiency are Flue gas analysis,

Chimney Temperature, Analysis of ash, Ratio of theoretical

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requirement and actual consumption and Combustion air

temperature (Preheated) along with calorific values of different type

of fuels available such as Furnace oil, Coal (Indigenous), Coke,

Producer gas, Natural gas.

Heat recovery process was discussed through 1) Recuperators for

preheating combustion air, 2)Pre-heating through hot air and Proper

insulation of roof, walls & flue channel

Control of firing through 1)Preparation of firing schedule, 2)

Standardization of different parameters and 3) Strict control of

parameter through manual or PLC

4. Prof.(Dr.) A K. Saha. Professor, Mechanical Engineering and Chairman-

Industry Institute Interaction Cell, NIT Durgapur (Speaker-4)

The strengths of the Indian Refractory Industry was discussed and a

light of bright hope was highlighted due to vailability of many raw

materials in the country itself, both skilled & qualified manpower at a

cheaper rate and the presence of a continuously increasing, market.

Discussion made on Design and its evolution, Design

conceptualization, Product lifecycle and sustainability, Business

strategy, Some design project discussion - product and branding

projects, Design research - user, market and technology.

Discussion has also been made so as to encourage the unit holders

/owners to utilize the resources /labs /equipment facilities available

with NIT Durgapur and to involve students towards realization of

their dreams, design concepts and its viability through Industry-

Institute Interaction.

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ATTENDEES LIST

during

WORKSHOP

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SAMPLE REGISTRATION

FORMS

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SAMPLE FEEDBACK

FORMS

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WORKSHOP

PHOTOGRAPH

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Day 1 December 15, 2012

Inauguration, NAS Report Presentation

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Felicitation of Officials and Guests

Officials and Guests lighting the Lamp

(Inauguration ceremony)

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President, RMA welcomes Delegates, officials and Guests

NID Official welcomes Unit Owners /Partners

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Mayor, Asansol addresses the gathering

Dy. Director, MSSE, Govt. of W.B. Introduces the scheme

to gathering

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H’nable Minister Govt. WB addresses the gathering

A view of august MSME in Inaugural Session

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NID Official Introduces the scheme to gathering

Design Expert presenting the NAS report

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Day 2 December 16, 2012

Awareness on Testing Procedures & Quality Control

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Day 3 December 17, 2012

Refractory use in Steel Plants & its requirement

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Day 4 December 18, 2012

Effective fuel & Fire in Refractory Manufacturing

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Day 5 December 18, 2012

Technical Support, Questionnaire, Feedback, Future Direction

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Vote of thanks by the Secretary, RMA

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Opportunity areas, remedial design

solutions & Future direction:

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The existing refractory products of the units are currently serves as a

supplier of running low cost items which only fulfill the domestic

demand, mainly in steel making industries. They are also exporting,

but mainly and only through traders. Also they are unable to compete

strongly due lack of quality consciousness and associated compliance

norms due to unavailability of adequate facilities locally.

The proposed design intervention will provide and encourage the

relevant inputs to transform it into a cost effective and popular

product both in domestic and international market. The design

intervention will specifically address the technical, functional,

ergonomic & quality aspects of the product and upgrade the current /

standard production process.

Design consultant & the entire team shall wait to get involved with

the stakeholders in terms of research /collaborative projects in new

product line, competing products, context of use, ergonomic issues,

environmental issues etc. with an attempt to understand the growth

of the sector /cluster as lot of resources are still available with the

area.

Design consultant shall perform the necessary layout, detailing and

test on the product, process detailing and move into the technical

phase. The task at this stage would be to complete the technicalities,

do the component and material selection, organize the final layout of

components, do the technical reviews and finalize the product. To

make mass production friendly for the new product, the design

consultant should work closely with the unit holders /partners so as

to define the process.

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The above observations and recommendations are related to aspects

that requires design intervention of the consultant mainly in the

technical phase. However, there are other problem areas which may

not in the scope of this project. It may also be mentioned that a few

more areas where the refractory industry is also facing difficulties in

general, such as the policy of State Government /ECL towards the

cluster regarding supply of coal at economic prices, getting the raw

material. fuel efficiency in the oldest firing system of DD kiln, the

performance of installed pollution device in the flue gas extraction

system. After an extensive / interactive session and study in the

cluster it is found that most of the units are manufacturing the same

variety of products, by applying the same techniques and few are also

exporting their products abroad mostly through trading.

Development of various community schemes could be the only way

to uplift the growth of the refractory cluster. Apart from these, the

cluster needs to be aware and educated regarding common technical

expertise, government scopes /policies for better /improved product.

These are necessary for motivating new design and enhancing

product development.

Thank You