ULTRATECH CEMENT LIMITED,RATNAGIRI

Presented by

Guided by:

Prof H. V. Shete sir

H.O.D mechanical

Vision And mission UltraTech Cement

Introduction Narmada Cement , Ratnagiri

Product

Kaizen 5 S Techniques SCAMPER

Process LayoutMechanical Department

Machines Used

Horizontal Ball Mill Production Department

Packaging Department

Jetty Conclusion

INTRODUCTION

Fig 1.1 Front View of Narmada Cement Ratnagiri

•M

O I

U SS

R I

ON

V

O I

U S

R I

O

N

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

• To Achieve lowest manufacturing cost among the grinding units

• To achieve 15 Kaizen per employee per year

• To provide premium quality with service excellence

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

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

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

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.

1. GRINDING

2. STORAGE, PACKING, DISPATCH

2. STORAGE, PACKING, DISPATCH :The cement is stored in silos before being dispatched either in

bulk or in bags to its final destination.

clinker

storage

Gypsum and the secondary additives are added

to the clinker.

silos

dispatch

bags

Finish grinding

• 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

4. Hopper

5. Bucket elevator

6. Dust Collector

7. Vibrating screen

8. Silos

Hopper

Bucket Elevator

Structure Of Silo

Ball Mill LRS StarterInside of Ball Mill

Schematic diagram of Ball Mill

QUALITY PARAMETERS OF CEMENT:

1) Chemical Parameters:• Loss of Ignition • Insoluble Residue• Lime saturation factor• Alumina modulus

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

Chemical Laboratory

Packing

60% in Ratnagiri And Sindhudurg

40% in Kolhapur ,

Satara & Sangli

Silos

Bucket Elevator

Hopper (PPC or OPC ) Thought Air Slides

Sieves (Screens)

Roto Packer

Conveyor Belt

Bags For Transit Rotary Packer

Sales Distribution Of the plant

Packaging Process

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