OCTOBER 19-20, 2012 - YMCA University of Science & Technology

Proceedings of the National Conference on
Trends and Advances in Mechanical Engineering,
YMCA University of Science & Technology, Faridabad, Haryana, Oct 19-20, 2012
1.4 Assumptions of the Work
1. The data provided by the industry are precise.
2. The data collection process adopted by the industry is reliable.
2.0 case study
Although the basic principles of manufacturing are fairly uniform, individual manufacturing plants tailor their
production to fit their particular raw materials and operation. Essentially, brick are produced by mixing ground clay
with water, forming the clay into the desired shape, and drying and firing. In developed countries, all molding is
performed by brick-making machines. However in India half of the Brick kilns still use the conventional method of
molding. Even in this brick kiln manual method (using cope and drag) is used for molding bricks.
Figure 2. Systematic Representation of Brick Manufacturing Process
Table 1 proposes the specifications of the process.
Material Used
Operating Temperature
Production Rate/hr
Manufacturing time
Fuel Materials Used
Table 1. Process Specifications
Brick Cakes from the mixture of Clay, Soil and Water
204 o C(final drying)
3200-3500 Units per hour
10hrs (with a break of 1 hr)
Coal + Coaltar + Wood
2.0 Application of six sigma DMAIC methodology
3.1 Define phase
In this stage, with the help of supplies, input, process and output various stages in the rings process were identified.
The results of the Define stage are as follows:
1. Customer – Workers who are involved in the process of De-Hacking.
2. Team – Project Team involves all those who are involved in the process of Preparation, Forming,
Drying, Hacking and finally firing.
3. Process Boundaries – All Process Steps from putting the raw materials till the final Bricks are obtained
All set-ups have preventive maintenance schedules in addition to random breakdowns.All work is inspected before
moving to the next operation in order to eliminate additional rework steps.Setups are required at each step in the
process whenever the previous and current product types differ.
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