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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 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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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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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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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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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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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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CHAPTER-1
I N T R O D U C T I O N
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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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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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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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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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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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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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CHAPTER-2
CLUSTER LEVEL INFORMATION
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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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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
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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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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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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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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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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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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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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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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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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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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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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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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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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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CHAPTER-3
DESIGN AUDIT unitwise
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Description of the
Units visited
(in brief) :
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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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[2]
Identifying Design Opportunity
in
Workstation and Tooling design
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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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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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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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[3] Identifying Scope
for
Training, Skill Upgradation and
Ergonomic factors.
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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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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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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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[4] Study of Infrastructure Setup
from
Design Perspective
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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.
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]
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]
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
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.
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
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
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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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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*
"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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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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ACTIVITY REPORT
Design Clinic Workshop : Refractory Cluster
(15th Dec to 19th Dec 2012)
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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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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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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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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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PROFILE
of
GUEST SPEAKERS
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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