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
3.4 Improve Phase
After the analysis and brainstorming in the previous step, now comes the Improvement stage. For this purpose a visit
was taken up in another brick kiln located in the vicinity. Then the processes used in the kilns were compared. On the
basis of this comparison, knowledge and understanding some improvements were proposed. Then these
improvements were consulted with various expertise and the kiln owners. Here is the list of all the improvements that
were made:-
3.4.1 Improvement List- 1
a) Improve Brick Drying Before Firing:-Extended drying time reduces fuel requirements, even drying
throughout brick stacks reduces defective firing of bricks.
b) Improve Air Circulation For Drying Purpose:-This can be done by using high speed fans. This will improve
the quality of raw brick.
c) Improve Air Flow Control In The Kiln:-Controlling the kiln opening size allows better control of air flow
speed and direction to improve combustion.
d) Stack Fuel Around Bricks To Facilitate Preheating:-Solid fuel is mixed with the bricks throughout the kiln,
either as sawdust mixed into the brick mass or as fuel channels in different levels of the kiln. By doing this,
a combustion zone can be generated in the kiln that gradually moves upwards, using the residual heat in the
lower, already burnt bricks for preheating of combustion air. The residual heat in the flue gasses is used for
drying and preheating of the higher levels of crude bricks.
e) Switch To Propane Or Natural Gas Fuel:-If available and competitively priced, these fuels have
significantly less emissions and can increase production quality and speed.
f) Proper Placement Of Raw Bricks In The Furnace:-The setting pattern of the bricks has considerable
influence on the defect level. The bricks should not be placed face to face or face to back instead they
should be placed with some spacing in between. This will increase the brick area that is open to fire.
3.4.2 Improvement List- 2:-
This is a list of those improvements which the kiln owners have considered infeasible and denied to apply due to
financial constraints and lack of time. Here they are in brief:-
a) New and Improved Kiln Design instead of using conventional kilns
b) Stopping air leakages help in better control of air flow and also improve combustion
c) Use of Robotic Arms in case of loading and unloading the bricks in Hacking and De- hacking processes
reduces the manual effort and time. It can also reduce the defects that are caused in these stages.
d) Transportation Losses if reduced will also contribute in reducing the total no. of defects.
e) Use of Automatic Brick Molding Machine instead of using conventional manual molding methods using
Drag and Cope will reduce the time taken considerably. Use of this machine can reduce all the defects that
were produced in the Forming Stage.
f) Improve the method of Firing will not only reduce the pollution caused by the kiln but also help in
controlled Firing thereby reducing the defects.
g) The proportion with which the raw materials specially water and clay are mixed.
With the help of the Brick kiln Owner we finally these improvements were applied. The Defect level has came down.
Reading was taken of the three furnace chambers.
3.4.1 Calculations
Defects/unit (DPU) = = 0.01099
S.No. No. of Defects Total no. of parts produced
1 37 3200
2 35 3100
3 39 3800
Total 111 10100
Defects per million opportunities (DPMO) [3]
921