THE PROCESS OF PRODUCTION

Assignment 1
Production & total quality management
Sairaj D Mhatre / roll no 41/ SYBMS A [Finance]
 INTRODUCTION

 Ambuja Cements Limited, formerly known as Gujarat Ambuja Cement Limited, is a major Indian cement
producing company. The Group markets cement and clinker for both domestic and export markets.
 Ambuja Cement was founded in 1983 by Narotam Sekhsaria and Suresh Neotia, two traders with very little
knowledge of cement or manufacturing. What made up for this lack was their farsightedness: Anticipating
that cement would be a critical resource for a developing economy like India, they invested in a state-of-the-
art cement plant in Gujarat and went on to build a trusted cement brand that has become synonymous with
quality and strength.
CEMENT

A cement is a binder, a substance that sets and hardens and can bind other materials together.
The word “cement” can be traced back to the Roman term opus caementicium, used to
describe masonry resembling modern concrete that was made from crushed rock with burnt
lime as binder. The volcanic ash and pulverized brick supplements that were added to the
burnt lime, to obtain a hydraulic binder, were later referred to as cementum, cimentum,
cäment, and cement.
Cements used in construction can be characterized as being either hydraulic or non-hydraulic,
depending upon the ability of the cement to set in the presence of water.
PROCESS OF PRODUCTION

Step 1: extraction of raw materials

The raw materials needed to produce cement (calcium carbonate, silica, alumina and iron ore)
are generally extracted from limestone rock, chalk, clayey schist or clay. Suitable reserves can
be found in most countries.

These raw materials are extracted from the quarry by blasting. They are then crushed and
transported to the plant where they are stored and homogenized.
PROCESS OF PRODUCTION

Step 2: raw grinding and burning

Very fine grinding produces a fine powder, known as raw meal, which is preheated and then sent to the kiln.
The material is heated to 1,500°C before being suddenly and dramatically cooled by bursts of air.
This produces clinker, the basic material required for the production of all cements.
Cement manufacturing is the source of 5% of global CO2 emissions. The cement industry is a natural producer
of CO2: 60% of emissions are due to the transformation of raw materials at high temperatures (the
“decarbonation” of limestone), 40% result from the combustion required to heat the cement kilns to 1500°C.
PROCESS OF PRODUCTION

Step 3: cement grinding and shipping

A small amount of gypsum (3-5%) is added to the clinker to regulate how the cement will set.
The mixture is then very finely ground to obtain “pure cement”. During this phase, different
mineral materials, called “cement additives”, may be added alongside the gypsum. Used in
varying proportions, these additives, which are of natural or industrial origin, give the cement
specific properties such as reduced permeability, greater resistance to sulfates and aggressive
environments, improved workability, or higher-quality finishes.
Finally, the cement is stored in silos before being shipped in bulk or in bags to the sites where
it will be used.
PROCESS DIAGRAM
THE PROCESS OF PRODUCTION
 INTRODUCTION

A pencil is a writing or drawing implement with a solid pigment core in a protective casing that reduces the risk of core
breakage, and keeps it from marking the user's hand.
Pencils create marks by physical abrasion, leaving a trail of solid core material that adheres to a sheet of paper or other
surface. They are distinct from pens, which dispense liquid or gel ink onto the marked surface.

Hindustan Pencils Pvt. Ltd. is an Indian manufacturer of pencils, writing materials and other stationery items,
established in 1958 in Bombay (present-day Mumbai). The company makes writing implements under the brand
Apsara, and claims to be the largest pencil manufacturer in India. The wood-cased pencil has a distinctive silver-and-
black stripe design.
 PROCESS OF PRODUCTION

• STEP 1 Chunks of graphite (a soft, dark mineral) and clay are placed inside a huge rotating drum. Large rocks
inside the drum crush the graphite and clay into a fine powder. Then water is added, and the mixture is blended in
the drum for up to three days

• STEP 2 A machine squeezes all the water out of the mixture leaving behind a grey sludge. Here, a worker puts the
sludge in a cabinet where it air dries and hardens for four days.

• STEP 3 Huge wheels grind the dried sludge into another fine powder, and water is blended in again to make a soft
paste.
 PROCESS OF PRODUCTION

• STEP 4 The paste is pushed through a metal tube and comes out in the shape of thin rods. The rods are cut into
pencil-length called leads, and sent along a conveyor belt to dry.

• STEP 5 After drying, the pencil leads are put into an oven heated to 1,800 degrees F. The intense heat makes
the leads smooth and hard, which makes for good writing points.

• STEP 6 In another part of the factory, the wood is prepared. Machines cut blocks of Incense Cedar Wood, a
renewable resource, into wide slats. Eight shallow grooves are sawed lengthwise into each slat.

• Step 7A thin coat of glue is applied to the slats, and one pencil lead is placed into each of the eight grooves.
Within seconds, another wide grooved slat is glued on top, sandwiching the leads.
 PROCESS OF PRODUCTION

• Step 8 When the glue dries, the slats are fed through a cutting machine. Fast revolving steel blades trim the
wood into round or hexagonal shapes, one side at a time.

• STEP 9The same machine cuts apart each slat into eight separate pencils.

• STEP 10 The pencils are sanded, and each one receives from five to eight coates of paint.
 PROCESS OF PRODUCTION

• STEP 11A heated metal stamp presses the name of the company and a number - such as the number 2 - on the
pencil in foil or paint. The number indicates how hard the pencil lead is.

• STEP 12 A metal band, called a ferrule, is wrapped tightly around one end of the pencil. It holds the eraser, which
is being added here. The pencils are then ready to be sharpened, packaged, and used.
PROCESS DIAGRAM
THANK YOU