production and operation management project (1)

8/17/2019 Production and Operation Management Project (1)

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BRICK INDUSTRY

PRODUCTION AND OPERATIONMANAGEMENT PROJECT


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INTRODUCTION

The fundamentals of !"#$ manufa#tu!"n% ha&enot

#han%ed o&e! t"me'

(o)e&e!* te#hnolo%"#al ad&an#ements ha&e

made

#ontem+o!a!, !"#$ +lants sustant"all, mo!eef-#"ent


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RA0 MATERIA1SFor brick manufacturing, clay must possess some Specific properties andcharacteristics. Such clays must have plasticity, which permits them to be

shaped or molded when mixed with water; they must have sufficient wet

and air-dried strength to maintain their shape after forming. Also, when

subected to Appropriate temperatures, the clay particles must fuse

together.


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MANU2ACTURING

Although the basic principles of manufacture are fairly

uniform, individual manufacturing plants tailor their

production to fit their particular raw materials and operation.

!ssentially, brick are produced by mixing ground clay withwater, forming the clay into the desired shape, and drying

and firing. "n ancient times, all molding was performed by

hand.

#owever, since the invention of brick-making machines

during the latter part of the $%th century, the maority of brick produced in the &nited States have been machine made.


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P(ASES MANU2ACTURING

'he manufacturing process has six general phases(

$)*ining and storage of raw materials,

+)reparing raw materials,

)Forming the brick,

/e-hackin and storin finished roducts


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DIAGRAMMATIC REPRESENTATION O2 MANU2ACTURINGPROCESS


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Clay or Shale Being Crushed

and Transported to Storage Area


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ay s oroug y xe w a er

in Pug Mill Before Extrusion


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After Mining, Clay is Extruded Through a Die andTrimmed to Specified Dimension Before Firing


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Brick Enter Tunnel iln for Firing


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Robotic Arm nloading Bric! After"iring


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P1ANT 1AYOUT


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Colo!'he color of fired clay depends upon its chemical composition, the firing

temperatures and the method of firing control.

0f all the oxides commonly found in clays, iron probably has the greatesteffect on color. 1egardless of its natural color, clay containing iron in

practically any form will exhibit a shade of red when exposed to an

oxidi2ing fire because of the formation of ferrous oxide.

3hen fired in a reducing atmosphere, the same clay will assume a dark 4or

black) hue. 5reating a reducing atmosphere in the kiln is known as flashing

or reduction firing.

6iven the same raw material and manufacturing method, darker colors are

associated with higher firing temperatures, lower absorption values and

higher compressive strength values.

#owever, for products made from different raw materials, there is no direct

relationship between strength and color or absorption and color.


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#uality control $ac!ing andstorage


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Si%e &ariation

Because clays shrink during both drying and firing, allowances are made in the forming process to achieve the desired size of the

finished brick. Both drying shrinkage and firing shrinkage vary for different clays, usually falling within the following ranges:

• Drying shrinkage: 2 to percent

• !iring shrinkage: 2." to percent

!iring shrinkage increases with higher temperatures, which produce darker shades. #hen a wide range of colors is desired, some

variation between the sizes of the dark and light units is inevitable. $o obtain products of uniform size, manufacturers control

factors contributing to shrinkage. Because of normal variations in raw materials and temperature variations within kilns, absolute

uniformity is impossible. %onse&uently, specifications for brick allow size variations.


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production and operation management project (1)

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