ULTRATECH CEMENT LIMITED,

RATNAGIRI

Presented by

Guided by:
Prof H. V. Shete sir
H.O.D mechanical
Vision And mission Introduction Narmada
Product
UltraTech Cement Cement , Ratnagiri

Kaizen 5 S Techniques SCAMPER

Mechanical
Process Layout Machines Used
Department

Production
Horizontal Ball Mill Packaging Department
Department

Jetty Conclusion
INTRODUCTION

Fig 1.1 Front View of Narmada Cement Ratnagiri

 V
O I
U S
• “To be the most economical And Totally Eco-friendly Cement
R I producer and to Achieve 85% of the market Share in the cluster,
through innovative ways with clear focus on customer delight
O by 2016”
N

M • To produce 100% Eco-friendly Cement ( Blended Cement )

O I • To Achieve lowest manufacturing cost among the grinding units

U SS • To achieve 15 Kaizen per employee per year

R I • To provide premium quality with service excellence

ON • To Continue to be the model grinding unit among the group in safety

 PRODUCTS

Fig 1.2 PPC Cement Fig 1.3 OPC Cement

1. Always wear PPE (Personal protective
equipment’s)

2. LOTO (Lock out and Tag out)

3. Precaution must be taken before working in

confined space

4. While working at a height standard

procedure must be followed

5. During the process of welding and cutting,

standard procedure must be followed .

6. Near miss and accidents must be avoided

and if any it must be informed.
“ Continuous improvement is the result of continuous involvement “
 5 ‘S’ in TECHNIQUE

• 5S is a method for organizing a

workplace
• Seiri (Sort)

• Seiton (Set in order)

• Seiso (Shine)

• Seiketsu (Standardization)

• Shitsuke (Sustain)
• S – S stands for Substitute
• C – C Stands For Combine / Combination
• A – A Stands For Adapt / Adaptation
• M –M Stands For Modify
• P – P Stands For Put to other Use
• E – E stands For Eliminate
• R – R stands for Reverse
 Gypsum and the secondary additives are added
to the clinker.
clinker
storage Finish grinding

1. GRINDING
silos

dispatch

bags

2. STORAGE, PACKING, DISPATCH

1.GRINDING : The clinker and the gypsum are very finely ground giving a “pure cement”. Other secondary
additives and cementitious materials can also be added to make a blended cement.

2. STORAGE, PACKING, DISPATCH :The cement is stored in silos before being dispatched either in
bulk or in bags to its final destination.
• Chiefly responsible for the smooth running.

• Maintenance of the machine

• For scrutinizing the work which are taking place

inside the mill.

• Ensure Safety of the environment

1. Centrifugal blower

2. Cement Mill

3. Air compressor
Hopper
4. Hopper

5. Bucket elevator

6. Dust Collector

7. Vibrating screen

8. Silos Bucket Elevator

Structure Of Silo
 Schematic diagram of Ball Mill

Inside of Ball Mill

Ball Mill LRS Starter
QUALITY PARAMETERS OF CEMENT:

1) Chemical Parameters:
• Loss of Ignition
• Insoluble Residue
• Lime saturation factor
• Alumina modulus
Chemical Laboratory
2) Physical Parameters
• Fineness
• Consistency
• Setting time – Initial and Final
• Soundness
• Compressive Strength – 3days, 7
days, 28 days
• Heat of Hydration
• Drying Shrinkage
Curing Tank
 Silos
Packing
Bucket Elevator

60% in 40% in
Ratnagiri And Kolhapur ,
Sindhudurg Satara & Sangli Hopper (PPC or OPC )
Thought Air Slides

Sales Distribution Of the plant

Sieves (Screens)

Roto Packer

Conveyor Belt
Packaging Process

Bags For Transit Rotary Packer

 Ships
2700 MT

Unloaders

Conveyor
Belt

Silo

Trucks

Plant

Jetty Process Algorithm

• Familiarized with various materials, processes, products and their application

• Broadening my knowledge base.

• It helps me to understand the scope and job responsibilities

• Helped me understand the importance of safety