PROJECT REPORT ON SUMMER INTERNSHIP PROGRAM

IN

SHALIMAR PAINTS LIMITED

DANESH SHAIKH LANE, HOWRAH

IN FULFILLMENT OF SIX WEEK INTERNSHIP, POST-GRADUATE DIPLOMA IN MANAGEMENT

SUBMITTED BY SANJAY RAY UDAI INSTITUTE OF MANAGEMENT STUDIES,JAIPUR PGDM 2011-13

CONTENTS
ACKNOWLEDGEMENT ............................................................................................................................ 3 ABOUT THE SHALIMAR PAINT LTD..................................................................................................... 4 VISSION & MISSION ................................................................................................................................. 5 ORGANIZATIONAL CHART ...................................................................................................................... MANUFACTURING PROCESS ................................................................................................................. 6 PAINT ........................................................................................................................................................... 7 RAW MATERIAL SECTION .................................................................................................................... 11 RESIN PLANT ........................................................................................................................................... 25 COLOUR HOUSE & PAINT MILL .......................................................... Error! Bookmark not defined. TEST ROOM .............................................................................................................................................. 48 PROJECT ON THE STRATEGY OF RFT (RIGHT FIRST TIME) CALCULATE IN WATER BASE PAINT & SOLVENT BASE PAINT............ 53 CONCLUSIONS......................................................................................................................................... 60

ACKNOWLEDGEMENT
A summer project is a golden opportunity for learning and self development. I consider myself very lucky and honored to have so many wonderful people lead me through in completion of this internship and report. My grateful thanks to all of the EXECUTIVES, CHEMISTS AND WORKERS who in spite of being extraordinary busy with their duties, took time out to bear, guide me and keep me on the correct path. I don`t know where would I have been without them. A humble Thank you to all of them. I would like to thanks to all co-coordinators Mr. Anup Ghosh, Mr. Dipankar Chatterjee, Mr. Manoranjan Banerjee, Mr. A. Mahato, Mr. Sital De and Mr. Chinmay Das. DR. S. K. PAL VICE PRESIDENT (OPERATION) monitored my progress and arranged all facilities to make my life easier. I choose this moment to acknowledge his contribution gratefully. I would like to thanks for his effort and help provided me to get such an excellent opportunity. I would like to thanks OFFICERS, MESS STAFF for such a delicious meal they provided. Last but not the least there were so many who shared valuable information that helped me in the successful completion of this internship project.

ABOUT THE SHALIMAR PAINTS LTD. Now for more than a century, Shalimar Paints established on 1902, It is in the business of protecting & enhancing effective service life of Plant & Machinery and National Infrastructure with its TUFFKOTE range of High Performance Coatings & Services, meeting the highest international standards, through a process of innovation & continued improvements, while meeting or exceeding the requisite legislation of business & environment. Our R&D capabilities, production infrastructure and country wide marketing network with dedicated, qualified & experienced team has enabled us to achieve the status of total solution providers to our valued clients, in terms of problem identification, development & supply of specific product to meet the specific needs & efficient after sales service. Shalimars well equipped state of the art R&D set up, supported by the efforts of a team of dedicated scientists working on the state of the art equipments, has indeed been instrumental in revolutionizing the protective coating industry. The association till few years back we had with U.K. based International paints Plc has also helped us to indigenize the latest paints technology. Shalimars R&D laboratory is approved by the Department of Science & Technology, Government of India. As on date we have three plants across the country, Howrah (West Bengal), Nasik (Maharashtra) and Sikandrabad (UP). The Tuffkote Range of products include Chlorinated Rubber, Epoxy, Polyurethane, In Organic Zinc Silicate, Glass Flake epoxy, High Temperature Silicon Aluminum, Acrylic Polysiloxane, Coal Tar Epoxy, Bituminous, Surface Tolerant & Rapid Cure coatings has been assiduously developed over the years with proven technology, to meet the specific needs of corrosion protection, both at the project stage as well as at the maintenance stage. Across the country, these products have met the stringent requirements of performance in almost all industries & environment categories ranging from general engineering to oil exploration and nuclear power projects. The name Shalimar symbolizes more than 100 years of experience & expertise in providing coating solutions to the Indian Industries.
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VISION & MISSION Vision: Shalimar's vision is to become one of the leading paint manufacturing companies of the country, a leader in product innovation and customer satisfaction. Shalimar intends to build long term value relationships with all its suppliers and customers Mission: The Company's mission is to maximize returns of each stakeholder in the Company be it customers, shareholders, suppliers or employees and become a socially responsible global Corporate Citizen.

The Company has more than 54 branches and depots who service more than 7000 dealers all across the country. With its wide distribution network the Company is able to reach not only the urban market but also the rural and up-country markets.

MANUFACTURING PROCESS
PRODUCTION PLANNING COLLECTION OF RAWMATERIALS FROM STORE & VARNISH PLANT WEIGHING OPERATION

CHARGING & MIXING OPERATION

DE-AGLOMARATE OR DISPERSING OPERATION

INSPECTION STATION DELAY -1

TINTING & ADJUSTMENT SECTION

INSPECTION STATION DELAY -2

LABELLING OPERATION

TRANSFER TO BONDED STOCK RECEIVE(BSR)

INSPECTION STATION - 3

PACKING OR FILLING OPERATION

PAINT
FROM A LAYMAN POINT OF VIEW IT IS SIMPLE A COATING MATERIAL

TECHNICALLY DEFINED AS
Paint is any liquid, liquefiable, or mastic composition which has continuous flow after application to a substrate in a thin layer is converted to an opaque solid film . It is a Heterogeneous solution.

COMPONENTS OF PAINTS:
PIGMENT BINDER SOLVENT ADDITIVE

Pigment
Pigments are granular solids incorporated into the paint to contribute color, toughness, texture or simply to reduce the cost of the paint. Alternatively, some paints contain dyes instead of or in combination with pigments. Pigments can be classified as either natural or synthetic types. Natural pigments include various clays, calcium carbonate, mica, silicas, and talcs. Synthetics would include engineered molecules, calcined clays, Blanc fix, precipitated calcium carbonate, and synthetic silicas. Hiding pigments, in making paint opaque, also protect the substrate from the harmful effects of ultraviolet light. Hiding pigments include titanium dioxide, phthalo blue, red iron oxide, and many others. Fillers are a special type of pigment that serve to thicken the film, support its structure and simply increase the volume of the paint. Fillers are usually made of cheap and inert materials, such as diatomaceous earth, talc, lime, baryte, clay, etc. Floor paints that will be subjected to abrasion may even contain fine quartz sand as a filler. Not all paints include fillers. On the other hand some paints contain very large proportions of pigment/filler and binder.
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 Binder or vehicle The binder, commonly referred to as the vehicle, is the actual film forming component of paint. It is the only component that must be present; other components listed below are included optionally, depending on the desired properties of the cured film. The binder imparts adhesion, binds the pigments together, and strongly influences such properties as gloss potential, exterior durability, flexibility, and toughness. Note that drying and curing are two different processes. Drying generally refers to evaporation of the solvent or thinner whereas curing refers to polymerization of the binder. The term "vehicle" is industrial jargon which is used inconsistently, sometimes to refer to the solvent and sometimes to refer to the binder. Depending on chemistry and composition, any particular paint may undergo either, or both processes. Thus, there are paints that dry only, those that dry then cure, and those that do not depend on drying for curing. Paints that cure by oxidative cross linking are generally single package coatings that when applied, the exposure to oxygen in the air starts a process that cross links and polymerizes the binder component. Classic alkyd enamels would fall into this category. Oxidative cure coatings are catalyzed by metal complex driers such as cobalt naphthenate. Paints that cure by catalyzed polymerization are generally two package coatings that polymerize by way of a chemical reaction initiated by mixing resin and hardener, and which cure by forming a hard plastic structure. Depending on composition they may need to dry first, by evaporation of solvent. Classic two package epoxies or polyurethanes would fall into this category.

 Solvent The main purposes of the solvent are to adjust the curing properties and viscosity of the paint. It is volatile and does not become part of the paint film. It also controls flow and application properties, and affects the stability of the paint while in liquid state. Its main function is as the carrier for the non volatile components. In order to spread heavier oils (i.e. linseed) as in oil-based interior house paint, a thinner oil is required. These volatile substances impart their properties temporarilyonce the solvent has evaporated or disintegrated, the remaining paint is fixed to the surface. Water is the main diluents for water-borne paints. Solvent-borne, also called oil-based, paints can have various combinations of solvents as the diluents, including aliphatic , aromatics ,alcohols, ketones and white spirit. These include organic solvents such as petroleum distillate, esters, glycol ethers, and the like. Sometimes volatile lowmolecular weight synthetic resins also serve as diluents. Such solvents are used when water resistance, grease resistance, or similar properties are desired. Additives Besides the three main categories of ingredients, paint can have a wide variety of miscellaneous additives, which are usually added in very small amounts and yet give a very significant effect on the product. Some examples include additives to modify surface tension, improve flow properties, improve the finished appearance, increase wet edge, improve pigment stability, impart antifreeze properties, control foaming, control skinning, etc. Other types of additives include catalysts, thickeners, stabilizers, emulsifiers, texturisers, adhesion promoters, UV stabilizers, flatteners (de-glossing agents), biocides to fight bacterial growth, and the like. Additives normally do not significantly alter the percentages of individual components in a formulation.

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RAW MATERIAL SECTION QUALITY ASPECT 1) Determination of Acid Value Acid value is the number of milligrams of Potassium Hydroxide required to neutralized the free acid contained in one gram of the material. Reagents Potassium Hydroxide Solution 0.1(N) Alcohol & Solvent mixture (1:1) by vol. Phenolphalein Indicator . Procedure 1) Dissolve 10 gm of the material accurately weighed in a 250 ml. conical flask. Add to it 75 ml. of neutralize alcohol Solvent mixture . Then titrate with std. Potassium Hydroxide solution approximately 0.1(N). Using Phenolphthalein as indicator. 2) Check the strength of the standard Potassium Hydroxide solution of intervals to provide against any deterioration in the strength of the alkali. Calculation Acid Value = (V*N)/W Where , V = Volume in ml. of slandered Potassium Hydroxide required W = Weight in grams of the material taken for the test. N = Normality of Potassium Hydroxide Solution Practical :Wt.(W) = 1.086 gm. V = 1.9 ml. Indicator = Phynolphothaline

Strength( N) = 0.253 (NaOH)

Acid Value = (56.1 * 1.9 *0.253)/1.086 = 24.83 Require Acid Value = 28

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2) Acid Value of Benzoic Acid Weight (W) = 0.337 gm. + Add Neutralized Alcoholic Solvent Strength (N) = 0.2530 (NaOH) Acid Value = (56.1 * 10.9 * 0.253)/ 0.337 = 459.07 2) Determination of Iron Content(Fe2O3) The Ferric Iron is reduced by Stannous Chloride (SnCl2) to ferrous and titrated against standard dichromate solution as the indicator. Reagents :1. Concentrate HCl. 2. Standard Potassium Dichromate Solution . 3. Stannous Chloride Solution . 4. Mercuric Chloride Solution . 5. H2SO4 H3PO4 acid mixture Add slowly 150 ml. of con.H2SO4 to 700 ml. of water with continuous stirring . Add to this 150 ml. Phosphoric Acid. 6. Sodium Diphenyl amine Sulphonate Indicator Solution Dissolve 0.2 to 0.3 gm. Of Sodium Diphenyl amine Sulphonate in 100 ml. hot water . cool and store in amber colored bottle. Procedure :1. Weigh accurately 0.25 to 4.40 gm of material, dried, thoroughly as per I.S. 33 and transfer to a 500 ml. conical flask. Add 25 ml. of HCl and warm gently until the solution is completed. The addition of a few drops of stannous chloride(SnCl2) solution after adding the acid greatly assists dissolving of iron. If the solution of the sample is different, digest, the solution on a hot plate and evaporate to dryness a reddish in HCl as above . Filter into long necked flask and dilute the solution to boil and keeping the solution hot, add SnCl2 solution in drops until the solution is colorless . If too much SnCl2 is added by mistake , add Potassium permanganate to the solution until a yellow color appears, then adding one or two drops in excess. Volume(V) = 10.9 ml.

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2. Cool the solution rapidly and dilute to 150 200 ml. with water add a slight excess of mercuric Chloride solution (5ml.) when a silky precipitated will be formed. 3. Add 15 ml. of Sulphuric acid phosphoric acid mixture and dilute to 100 ml. Add 5 Drops of Sodium Di-phenyl Standard di- chromate solution with constant stirring until the solution begins to darken. Complete the titration by adding the standard di Chromate solution in drops until a blank determination with the reagents using the same procedure . Calculation :Total Iron (as Fe2O3) = (V*N*7.984)/W V = Volume in ml. of Std. K2Cr2O7 solution require for Titrate solution W = Weight in gm. Of material taken for determination . 7.984 = (2*55.845 + 48)/2 = 79.84 = 79.84/10 = 7.984 Practical V= 35.2 W = 0.645gm. N = 0.1003

Total Iron = (7.894*35.2*0.1003)/0.645 = 43.70 Required 83-84 This is not match with required quantity. So, this order rejected on that day.

3) Determination of Distillation Range Apparatus :1. 2. 3. 4. 5. Distillation Flask. Receiver (100 ml.Measuring Cylinder ) Thermometer Specific range. Condenser Water condensing. Heating System (Bunsen Burner)

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Method :Measure 100 ml. of sample in receiver & transfer the whole amount into distillation flask .Place the distillation flask, Thermometer , & receiver in proper position & ensure that the condenser has a steady supply of water. Light the burner & regulate the flame. So the distillation is collected at the rate of 3 to 4 ml/min. Now read the temperature from thermometer at the instant the 1st drop falls from the end of the condenser and record as the initial Boiling point. Read temperature for each corresponding 10 ml. in receiver as distillation range. Practical :Solvent D/R Distillation Range First Drop(FD) = 144 0C 5 ml = 152 10 ml = 160 20 ml = 162 30 ml = 170 40 ml = 176 50 ml = 178 60 ml. = 180 80 ml = 192 90 ml = 200 95 ml = 210 Last Drop (LD) 224 (99 ml)

4) Measuring The Non Volatile Content Weigh about 1 1.5 gm. Of the material in a dry and previous weighed glass disk in the oven maintained at 120 +/- 5 at about 3 hrs. Remove the dish from the oven cool at room temperature and weigh again .

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Calculation : Non Volatile Content (% by wt) = (M1 M2)*100/ W M1 = Wt. in gm. Of the dish with material taken for the test . M2 = Wt. in gm. Of the dry dish W = Wt. in gm. Material taken Practical : - 1) Aluminium Paste Dish 1 Empty Weight Sample Taken Final Weight 8.430 gm. 1.803 gm. 9.598 gm Dish - 2 8.295 gm. 1.870 gm. 9.570 gm.

% of Non Volatile Content = (9.598 8.430)*100/1.803 = 64.78% Required = 70-72 % 2) UF (Urea Formaldehyde) Resin Dish 1 Empty Weight Sample Taken Final Weight 8.340 gm. 1.663 gm. 9.439 gm

= (9.570-8.295)*100/1.870 = 68.18 %

Dish - 2 6.664 gm. 1.730gm. 7.817 gm.

% of Non Volatile Content = (9.439 8.340)*100/1.663 = 66.08% Required = 62 - 63 %

= (7.817 -6.664)*100/1.730 = 66.64 %

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3) Antifoam Dish 1 Empty Weight Sample Taken Final Weight 8.525 gm. 1.548 gm. 8.723 gm

% of Non Volatile Content = (8.723 8.525)*100/1.548 = 12.79%

Required = (12 14) %

5) Determination Of Leafing Value Leafed area is completely covered surface free from cracks or breaks when tested as per the procedure prescribed below : Apparatus :-\ Spatula, Test Tube, Glass Cylinder . Reagents : Leaf Testing Vehicle. Procedure :Enough of the mixture to the test tube .Remove any bubble on the surface of the liquid by dipping and withdrawing the end of the spatula . Dip the spatula to the end of the mixture and rotate it gently by reversing the direction of rotation once a second .Avoid the formation of bubble and excessive splicing . Withdraw the spatula at a uniformly rotate in total time of 6 +/- 1 without touching the sides of the test tube and suspend it vertically in a closed glass cylinder containing 5 ml. of the leafing liquid. At the end of the six minutes, after which time the leafing
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comes to rest, measure the length of the leafed area on both sides of the spatula. Stir the mixture in the test tube and repeat it. Calculation :Calculate the leafing value from the average of at least five determination according to the following formula. Leafing Value = (100*A)/L A The avg. length of the completely leafed area . L The total immersed length of the spatula.

Practical :Aluminum Paste Total Length = 13.9 c.m The completely leafed area = 9.4 c.m. Actual Leafing Value = 9.4*100/13.9 = 67.63 % Require Leafing Value = 70-72 % 6) Determination of Formaldehyde Content Reagents a) Sodium Sulphite solution dissolve 126 gm. of Anhydrous Sodium Sulphite in water & dilute to 1000c.c. b) 0.1(N) and 1.0 (N) standard HCl solution . c) Thymolphalein Indicator Solution dissolve 0.1 gm. thymolphalein in 100 ml. rectified spirit. Procedure Weigh accurately about 3.5 gm. of material in a glass stopperded conical flask containing 10 ml. of distilled water. Add two drops of thymolphthalein indicator solution followed by 0.1(N) NaOH Solution drop by drop a blue colour is just perceptible.

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Measure 75 ml. of freshly prepared Sodium sulphite Solution in another 250 ml. Conical flask. Add two drops of the thymolphthalein indicator solution followed by 0.1 (N) HCl drop by drop until the blue colour just disappears. Add this solution to the neutralized formaldehyde solution . Mix the two solution by swirly for two minutes and then titrate with 1.0 (N) HCl until the blue Colour just disappears. Calculation :Aldehyde content = 3.003 *NV/W Where V = Volume Of the Std. HCl used for titration . N = Normality of Std. HCl. W = Weight of the material taken for test. Practical :Conical Flask 1 Require = (1 1.5 gm.) Conical Flask - 2

Weight taken 9.45 gm. Na2SO3 + Taken = 1.310 gm. + 10 ml. H2O 75 ml. H2O + + Indicator use Thymolphthalein and solution Indicator use Thymolphthalein and solution color found Blue & Take a Biker and mixed color found Blue & Take a Biker and mixed with (NaOH + 20 ml. H2O) Drop by drop add with (HCl + 20 ml. H2O) Drop by drop add until color less found . After founding colorless until color less found . After founding colorless solution kept in separate. solution kept in separate. Then Conical Flask 1 Solution Mixed in Conical Flask - 1 Then Titrate by HCl 0.4362 (N) strength Color change Blue to color Less. Volume found = 37.5 ml. So, Weight (W) = 1.310 gm. Volume = 37.5 ml. N = 0.4362 Factor = 3.003

Actual % of Formaldehyde = 3.003*0.4362*37.5/1.310 = 37.50 %

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Required Range = 37%- 38 %

Also pH check by pH meter : 1st Buffer Solution Base 4.01 (Calibration Part) Formaldehyde Reading - 2.56 2nd Buffer Solution Base 9.18 (Calibration Part) Formaldehyde Reading - 2.10 1st reading accepted.

7) Determination of CrO3 and ZnO Content Chromic Anhydride is determined by Titrating the iodine liberated from Potassium Iodide with Std. Sodium Thiosulphate Solution Zinc. Oxide is determined by titrating the iodine subsequently liberated on addition of Potassium ferricyanide with Std. Sodium Thyosulphate` Solution . Reagents:1. 2. 3. 4. 5. 6. Dilute H2SO4 7(N) Potassium Iodine Solution = 1: 1 Std. Sodium Thyosulphate Solution 0.1 (N) Starch Solution = 1: 1 Potassium Ferricyanide Solution (M/10) Ammonium Bifluride Solid

Procedure : 1 . Weigh accurately about 0.5 gm. of material in 500 ml. conical flask. Add 70 ml. of water and 30 ml. of dilute Sulfuric Acid. Boil slowly for 2-3 min. and cool. 2. Transfer the solution to a 500 ml. iodine flask containing 100 ml. of water and 20 ml. of dilute H2SO4. Add 30 ml. Potassium Iodine solution and allow to std. for 5 minutes. Titrate the liberated iodine with std, sodium Thio sulphate Solution after adding 5 ml. Starch Solution Thiosulphate solution solution used in the titrate as (V1)

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3. After the titration for chromic anhydride, add ammonia solution drop wise until the litmus test paper first turn blue cool add 2 to 3 gm ammonium bifluride and water to make up the volume to 250 ml. Add (V/3) ml. of Potassium ferricyanide solution . Stir and allow to stand for 2 minutes. Titrate liberated iodine with std. Sodium thiosulphate solution . After the End point the color of the test solution will be greenish yellow. Note the volume of Sodium thiosulphate solution used in this second titration (V2) CrO3 ( % by Mass) = (3.334 * V1 *N) /W ZnO = (12.45 * V2 * N)/W Where , V1 = Vol. in ml. of Sodium Thiosulphate solution used for first Titration . V2 = Second Titration N = Normality of Sodium Thiosulphate solution used. W = Mass in gm. of the material taken for Titration.

Practical :Taken two Conical Flask 1) 53/40 (0.3 to 0.5 gm.) 2) 53/50 (0.2 to 0.3 gm.) Both sample have take same test Firstly Add 70 ml. H2O + Add 30 ml. of 7(N) H2SO4 Then, 2 to 3 minutes boil and cool Then in a Biker take 3 to 4 gm. Potassium Iodide + 15- 20 ml. H2O After cooling in conical flask sample add (100 ml. H2O + 20 ml. 7 (N) H2SO4) and also add Upper Biker solution. Red color found after mixing. Stay 5 min. Then Titrate by Std. Sodium ThioSulphate up to yellow- reddish colour. Then add Starch Indicator and Blue Color found and again start Titration up to colorless

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Take the Volume in Two Sample 1) 53/40 (Zinc Tetra Oxichromate) Take 0.400 gm.(W) Volume 22.9 ml.(V) Strength 0.1063(N) Actual CrO3 % = (3.334 * 21.5 * 0.1063)/0.400 = 19.04 % Required Required = 19 % Minimum = 43 to 45 % 2) 53/50 ((Zinc Chromate)) Take 0.220 gm.(W) Volume 28.0 ml.(V) Strength 0.1063(N) Actual CrO3 % = (3.334 * 28.0 * 0.1063)/0.220 = 45.11 %

8) Flow on Glass Panel : Take 50 ml. of the solution (Under Test) in a glass Beaker, then pour this material on a clean Glass panel after filtering it through muslin cloth. After 2hrs. check the film and observe whether it bitty or not. 9) Test for Determination of Residue on Sieve on Pigment & other Solids :Outline :Residue on sieve can be determined by measuring the percentage of course particles remain on the sieve after washing the residue with the solvent . Apparatus :1) Sieve
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2) Brush Camel Hair 3) Oven 4) Analytical Balance. 5) Desicator. Procedure :1 ) Weigh accurately about 10 gm. of the material and transfer this material on the sieve. Wash the material using a wash with camel hair brush until a solvent passing through the sieve is clear and free from solid particles. 2 ) After washing, dry the sieve for one hour at 105 +/- 2 deg. C. Cool and transfer the residue with the help of a Camel Hair brush to a weighed watch glass and determine the weight of the residue. Calculation:Calculate the residue on sieve by the equation : R = (100 * M1)/ M R = Residue on sieve, percent by mass M1 = Mass in gm, of the Residue M = Mass , in gm, of the Sample 10) Cobalt Sample Test It use for drier . To check Pb contamination . Mix. Conc.H2SO4 with Cobalt Solution if Pb contamination present produce PbS and precipitate white . 11) Determination Of Metal Content by EDTA Method for Driers :Reagents :1) 0.01 (M) EDTA Solution :- Dissolve 3.7225 gm.of EDTA to make up one it with water. 2) 0.01(M) EDTA Solution :- Dissolve 2.99 gm. ZnSO4, 7 H2O to make up one it with water. Zn (Molarity of Zinc Solution) = (Wt. of Zinc. Salt taken) / 287.56 3) Buffer solution :- Add 350 ml. NH4OH to 54 gm. NH4Cl and dil to 1 lit. with water.
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4) Indicator :- Grind 0.2 gm. of Erichrome Black T and 100 gm. NaCl store. Procedure :1. Wt. 0.2 gm. material in a 250 ml. Conical flask, add 2 ml. Benzene and 50 ml. Iso Propyl alcohol. 2. 50 ml. EDTA , 15 ml. Buffer solution and add indicator. 3. Titrate with Zinc Solution and note the volume A in c.c of Zinc Solution. 4. End point blue to wine Red. Calculation : -

Metal % = {(B-A) * Zm * k}/ 10 * W

A B

Vol. in c.c. of Zinc Solution required for the Titration with metal Volume in c.c. of Zinc. Solution for blank

Zm Molarity of Zinc. Solution used in Titration K = 65.38 (Zn) = 207.234 (Pb)

Practical : Take 3 Conical flask 1. For Zn. 2.For Pb. 3.For Blank

After Weight (0.15 to 0.25 gm.) Add in Three conical flask 5 ml. Bezene + Add 50 ml. in every bottle Iso Propyl Alcohol( neutralised by drop by drop NaOH with Phynopthalin Indicator ) + Add in every Bottle 25 ml.EDTA Solution by Pipate + Add & Stir Eriochrome Black T. colour found Red +
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Add (10 15) ml. Ammonia Buffer Solution. Colour found Blue + Titration by ZnSO4 Solution.colour change light Reddish Blue

Zn Weight (w) = 0.183 gm. Volume (A1) = 7.3 ml. K = 65.38

Blank

Volume (B) = 22.6 ml.

Metal % = {(22.6 7.3) * .0105 * 65.38}/ 10 * 0.183 = 5.74 Req. 6 +/- 0.1

Pb Weight (w) = 0.197 gm. Volume (A1) = 4.7 ml. K = 207.24

Blank

Volume (B) = 22.6 ml.

Metal % = {(22.6 4.7) * .0105 * 207.24}/ 10 * 0.197 = 19.77 Req. 20 +/- 0.1

12) Melting Point Check : Melting Point of Benzoic Acid check & found 121 0C through Capillary Tube and Solution used Glycerin in a Biker. It used for Catalyst to prepare Alkyd Resin or Paint . Rest of checking part normally Specific Gravity, pH check by pH meter, Q-UV Test etc. I have seen & done. 12) Pigment : Checking Mass Tone, Under Tone by glass sheet, Residue check by 300 to 400 Mesh.

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RESINS Resin is a natural or synthetic compound which begins in a highly viscous state and hardens with treatment. Typically, resin is soluble in alcohol, but not in water. There are a number of different classes of resin, depending on exact chemical composition and potential uses. There are numerous applications for resins, ranging from art to polymer production, and many consumers interact with products which contain resin on a daily basis.

Natural resin comes from plants. A classic example is pine sap, which has the characteristic sharp odor of terpene compounds. As anyone who has interacted with pine sap knows, the substance is very viscous, but it hardens over time. A number of other plants produce resins, and plant resins have been used by humans for thousands of years. Some plants exude a similar substance called gum or gum resin which does interact with water. Gum tends to be softer and more malleable than resin. Plant resin can be clear to dark brown in color, and it varies in opacity and hardness. Some plant resin is also extremely volatile, since it contains unstable compounds. Misidentification of resinous trees can sometimes lead to unfortunate accidents, since some resins contain heptanes, flammable and potentially explosive hydrocarbons. The popular decorative material amber is fossilized plant resin. The rich golden color of amber is a common shade for plant resins, but amber can also be found in more rare colors, like blue.

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CURING AGENT AIR DRYING STOVING ALKYD RESIN QUICK DRYING

BASIC CHEMISTRY

CONDENSATION POLYMERISATION

OIL BASED (ALKYD RESIN)

ADDITION POLYMERISATION CO-POLYMERISATION

WATER BASED

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VARNISH DEPARTMENT

NEW ALKYD PLANT SOLVENT PROCESS 1) Short oil Alkyd 2) Medium Oil alkyd 3) Long Oil Alkyd

VARNISH KITCHEN PLANT FUSION PROCESS 1) Melting Bituminous 2) Alkyd Preparation by Fatty acid Process

AMINO PHENOLIC RESIN PLANT STEAM PROCESS 1) Nitrogenous Resin ( UF Lacker, MF etc.) 2) Phenolic Resin ( Novolack, Resol )

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NEW ALKYD PLANT In this Plant basically Alkyd or Resin prepare by Solvent process mean use by Solvent Azyotropic Distillation with Naphtha or Xylein.

Three Type of Alkyd Prepare :-

Processing Temp.(0C) Long Oil Alkyd Medium Oil Alkyd Short Oil Alkyd 230 - 235 220 225 205 - 210

% of oil 60 65 % 45 55 % Less than 35 %

Use For Decorative Paints For Decorative Paints For Industrial Paint

Instrument : 1) Three Kettle K1 , K2 , K3 where raw material take and processing or reaction . Volume Wise K1 < K2 < K3

2) Boiler for Heating Purpose a) Horizontal Boiler (Capacity 10,000,00 Kcal./hr) b) Thermopaq Boiler (Capacity 6, 000,00 Kcal/hr) Both boiler use Thermic Fluid for maintain Kettle Temperature and use Light Disel Oil (L.D.O) and Furnace oil for heating Purpose. 3) Three Blinder where dropping or kept output from Kettle & mixing by Thinner or M.T.O (Mineral Tarpentile Oil) or Xylin

Total 25 35 hr. take in Whole Process

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Process :Input Raw material take Sayabin or Linseed Oil in Kettle (K1,K2 & K3)

RAWMATERIAL
BOILER

RAWMATERIAL

RAWMATERIAL

K3
Heating (2500C)

K2

K1

M.T.O or Xylen M.T.O or Xylen

DROPPING

DROPPING
M.T.O or Xylen

DROPPING

BLENDER 2 BLENDER 3

BLENDER 1

INLET INLET OUTLET OUTLET (PAINT MILL TANK) FILTER PRESS

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Take Soyabine Oil or Linseed Oil or Dehydrated Castrol Oil in Kettle

Increase temp. 1500C via through jacket Thermoic oil

Add as a catalyst NaOH (0.1%)

At 1700C temp Add Glycerin or Penta Erithretol as a Polyol

At 2550C 1 hr. hold for Mono Glycerid

Sample collect for solubility check with Methanol (CH3OH) (1 : 2.5-3) Phthalic Anhydride test

If Ok, Cool Down upto 2000C

Add Phthalic Penta + Benzoic Acid + Azyotropic Distillation (Naphtha or Xylein) Esterification Reaction (condensation Polymerization)

Sample Testing (Take 50% sample + Thinner) Check Acid Value(10 to 15) & Viscosity for Long Oil 280S in For cup Method

If Ok, Then Dropping in Blinder and add Thinner or Xylein and blending by stirrer

Impurity Sieving by Filter Press

Filtrate Oil kept in Paint Mill Tank by through pipe

31

VARNISH KITCHEN PLANT In this Plant basically resin prepare by Fatty Acid Process. In this Process Kettle heating by Naked heat ,direct burner flame increase the Kettle Temperature. Also prepare of Bituminous paint. Simply heating the movable Pot and Melting the Bituminous.

Resin Process (Ester gum) Firstly Melt Rosin in open Pot

Then charging in Kettle & add Glycerin

Heating Temp. increase 2500C

4 hrs hold and again add 2nd lot Glycerin ,again increase the temp. upto 2700C

Check the Acid Value, Requirement Less Than 7

If, Ok then Add Solvent M.T.O & Stand Oil to increase Flexibility

Purify by Filter Press

Paint Mill Bituminous Paint Process:- Take Bituminous and Heating in 250 to 3500C in 3 to 3.5 hrs melt the material and Mixing Aromatic solvent Xylene or M.T.O . Then go to the packing section.

32

AMINO PHENOLIC RESIN PLANT In this Plant basically Alkyd or Resin prepare by Solvent process use by Steam for increasing temperature. Kettle should be must prepare by Stainless Steel (SS).Without SS kettle can not produce Phenolic Resin. Because Phenolic is high reactive with Iron. Temperature should maintain 100-1050C by steam jacket because those solvents are use in this process, they evaporate if increase the temperature after 1050C.

The Type of Resin Prepare :1) Melamine Formaldehyde (MF) : - For use of Lacker. 2) Urea Formaldehyde (UF) : - In Food Packaging Industry to Coating Can.

3) Phenolic Resin

Novolack (Acid catalyze) Use for Coating Meat Can

Resol (Base catalyze) Use hardness film, to use raw material of Chemical Coating etc.

Phenolic stobic Solution (High Reactive)

Pure Phenolic Resin (Low Reactive)

33

PROCESS
Steam BOILER

Raw material

Raw material

STEAM KETLER - 1

STEAM KETLER - 2

Heat Max 100 105 0C

Dropping Dropping
Xylean or M.T.O Xylean or M.T.O

Movable Pot

Movable Pot

INLET

OUTLET

Filter Press

(PAINT MILL TANK OR PACKING)

34

1)MF(Melamine Formaldehyde) RESIN PROCEDURE : Input Raw material take Melamine + Butanol + Formaldehyde Solution

Temperature Increase Gradually Upto 1000C

Add Hexamine for Maintain from pH (6-7)

Sample Take to Check Viscosity 4 to 5 min. in Forcup

Add M.T.O or Xylene in 1 : 2.8 Ratio

Final pH will within 3 to 5

Packing

2)UF(Urea Formaldehyde) RESIN PCEDURE : Input Raw material take Butanol + Para Formaldehyde Solution

Temperature Increase Gradually Upto 1000C

Add Phormic Acid for Maintain from pH (6-7)

When pH come (3 - 4) + Add Urea

Viscosity kept 3 4 min.

Add M.T.O or Xylene in 1 : 2 Ratio

Packing
35

3) PHENOLIC RESIN A)Resol or Phenolic Stobic Solution Procedure Input Material Take Pure Phenol (Solid)

Gradually Heat & Add 92% Para Formaldehyde

Initial Steam 50 to 55 0C Add Base Catalyst Ammonia(NH3)

Temperature Reach Step by Step Upto 800C

Viscosity Check in F-Cap in 250C

Add Butanol

Add Phosphoric Acid for Neutralized

After One Day , 50% drop the material

By Pump Butanol in 50 % material in 2 Step in 20 -22 lb/inch.2

Resol

B) Novolack :- Same Process Apply according to Previous Method. Only change in use 96% Para form from replace of 92% Para form and use of Acid catalyst Formic Acid from replace base catalyst NaOH.

36

C) Low Reactive Phenolic resin :Input Material take Formaline + Para Tertiary Phenol(PTP) in 2:1 ratio

Add NaOH (for catalyst)

On that time pH come 8 to 9

Acidification by HCl & Reduce pH 2 to 3

4 Times Washing Final pH come 5 to 6

Vacuum Distillation

Add Solvent Xylene and Acetol Alcohol

Final Product

37

38

Process
Add Pigment + Extender + Additives + Medium(60 -70%) + Thinner(15%) in Ball Mill / Attritor Overnight run Check the Grinding Material (Particle Size 10)

If ok, Stabilize (Add Medium, Thinner)

Drop Out in Pot

Pump the material in Lang & Then Thinning

Add Drier & Stainer (for Shade Matching)

Take Sample for Q.C check ,

Filling if Ok from Q.C Report

Despatch

39

Paint Mill SOP(Stander Operation Process)

1. 2. 3. 4. Follow the Plainning register Collect the batch card from production office . Fill up the batch card as per formulation sheet. Prepare the issue sheet for materials. Then collect the Raw materials, Varnish (from store section / Varnish section/Varnish tank) and keep the above mentioned materials near the charging mouth of the Mill to be charged. 5. Check the water flow of the steel Mill/ Bead Mill before loading. 6. Check the Mill before loading wheather the Mill is clean or not. If not then clean the Mill with require solvent. 7. Load varnish, then Additives, Pigments and then Solvents according to the batch card. 8. Ensure Charging mouth/ side plugs are properly closed. 9. Run the Ball Mill and continue it for overnight till morning 7.00 A.M. & Check H.G.R(Hegmen Gauge Reading). In case of Bead Mill run the Mill and check the H.G.R after One an an hour(approx) 10. If the H.G.R is not Ok then run the Mill as per advice of the Executive. 11. If the H.G.R is Ok then stabilize the Mill as mention in the formulation Sheet. 12. Before Dropping follow the Daily Position of Lang Mixed, wheather the Lang is empty or not and see the previous colour of Lang before Dropping. 13. Open the side plug of the Mill before Dropping. 14. Fit the Dropping Plug and Drop through pump or by gravity as suitable for that Mill into the Barrel /Pot/Lang. 15. After completion of dropping, Wash the Mill as mentioned in the Batch Card. 16. Send the Batch card to the tinting and the adjustment section.

40

Flow Chart For Paint Mill

Monthly Plan from H.O. Logistics

Daily Plan Prepared by Dy.Manager(P)

Requisition of Batch Card as per Quality & Quantity by Office Staff

Formulation in Batch Card as per Quality & Quantity by Office Staff

Collection of Raws from Stores BALL MILL(D-Bay) SECTION MAN POWER ALLOCATION 2 Executive (8) Permanent Worker for 2 Shift(4 +4) Mill Charging Mill Wash Mill Drop Binder & Additives Solvent (3) Contractor Worker Only Powder Fetching Stores Intermediates from VSH dept. or Mill Tanks

Dry Powder

Thinner & Additives

Input in Ball Mill / TSD/ Attritor Consistency Check & Adjustment

Dispersion

Machines Ball Mill(10) 1000 Galon -5 400 Galon -1 200 Galon 4 Attritor 1 TSD - 2

Check H.G.R

Stabilization

Lang/ Pot

Dropping of Mill Base

C 41

BEAD MILL(A - Bay) SECTION

Collection of Raws from Stores BEAD MILL(A - Bay) SECTION MAN POWER ALLOCATION 1 Clark (4) Permanent Worker for 2-> Ball Mill 1- For Bulk Batch & 1 for Stainer 2-> Bead Mill & Attritor (4) Contractor Workers Stores Intermediates from VSH dept. or Mill Tanks

Dry Powder

Thinner & Additives

Input in Bead Mill / Ball Mill/ Attritor

Machines Ball Mill(12) 160 Gallon 5 60 Gallon 6 40 Gallon 1 Bead Mill 3 Attritor - 1

Consistency Check & Adjustment

Dispersion

Check H.G.R

Stabilization

Dropping of Mill Base

Lang/Pot

42

High Speed Disperser(HSD)

1. 2. 3. 4. Collect the batch card from production office. Fill up the batch Card. Follow the H.S.D Mixing. Select the Pot as per batch size written on batch card (e.g. for 700 liters. Paint take 800 liters. Capacity pot). 5. Prepare the issue cheat for Raw material Varnish & Solvent, collect the Material from store department. 6. Fit the Pot under the Machine . 7. Add Require Binder, Additives & Solvent. 8. Run the machine and go on adding powder slowly & complete addition of Powder. 9. Run the machine(approx 3hrs) until the recommended Dispersion comes as mentioned in the batch card. 10. If the dispersion is Ok then adjust the Shade against mentioned Shade reference(ISC) in the Batch Card. If the dispersion is not Ok then run the machine until the dispersion is O.K. 11. Send the sample of the batch to Q.A. along with batch card & Laboratory Analysis slip. 12. Collect the Report of the batch & adjust the batch as per lab/ Test report mentioned in the batch card. 13. After adjustment of the batch send the batch sample to Q.A. for final testing. 14. Once the batch is Passed by Q.A passed batch card collect by the Filling section of the Mill.

43

Flow Chart of HSD SECTION Collection of Raws from Stores LENERT & HSD SECTION MAN POWER ALLOCATION 1 Executive (4) Permanent Worker (5) Contractor Worker Stores Intermediates from VSH dept. or Mill Tanks

Dry Powder

Thinner & Additives

Input in HSD Machine(2)

Consistency Check & Adjustment

Dispersion

Stabilization

Recycle No Tested Ok Yes Filling Section Final check Final Product testing at Q.A

Dropping of Mill Base

Addition of Further Resin, Solvents, Additives,Stainer or Shade Matching

44

Tinting and Adjustment

1. After dropping the grinded material from Ball Mill or Bead Mill into Barrel/Pot/Lang charging section hand over the batch card to the tinting and adjustment section. 2. Follow the daily position Lang Mixer of whether the Lang is Empty or not and see the previous colour of the Lang before pumping. 3. Prepare the issue chit for Varnish, Drier and Solvent. Then collect the material. 4. Make up the batches with remaining portion of Medium drier & part of the thinner(Hold back a portion of Thinner for Final Adjustment of Viscosity) as listed in batch card. 5. Stir the material for one hour if the material is in Lang. If the material is in Pot, Then feed the Pot under stirrer & stir the material for one hour. 6. Adjust the shade of every batch by using Stainer against Specified colour reference mention in the batch card and adjust Viscosity. 7. Then send the batch sample to Q.A. department along with the Batch Card & Laboratory analysis Slip. 8. Collect the report of the batches(send for test) and adjust the batches if necessary as per Lab test Report mentioned in the tested batch card. 9. After adjustment of the batch again send the adjusted batch Sample to Q.A. for final testing. 10. Once the batch is Passed by Q.A passed batch card collect by the Filling section of the Mill.

45

Colour Combination

Yellow

Light

Green

Red

Dark

Blue

Colour Deference = dE dE = dl2 + da2 + db2 If, dl = (+ Ve) = Lighter = (- Ve) = Darker da = (+ Ve) = Reddish = (- Ve) = Greenish db = (+ Ve) = Yellower = (- Ve) = Blue TiO2 = White, Prussian = Blue Thalo, Phtalo Green = Green, Red = Red Oxide Dirty(Bluish Yellow)

46

Flow Chart of Tinting & Adjustment and Filling Section

C TINTING & ADJUSTMENT JONE 3 Executive 1 Clark 7 Permanent Worker 1 Trainee Worker Recycle No Tested Ok Yes Machines Lang(39) 1.5 Kl 1 3 Kl - 9 3.5 Kl 2 4 Kl - 2 5 Kl 14 5.5 Kl 4 8 Kl - 2 FILLING SECTION 2 Executive 3 Contractor 2 for Packaging Material Services 1 for Miscellenious Job Final check Final Product testing at Q.A Addition of Further resin, Solvents, Additives,Stainer

24 Permanent Worker 1 for Bradma Printing( M.S.) 2 for Stenciling & D.M (G.S) 1 for Cartoon Marking 20 for Filling(5-> M.S & 15 -> E.S)

Check Point Filling Section Wt, Lidding to Stenciling to check

Bonded Stock Received(BSR)

47

48

Standard Operation Process to Step by Step Operation Check to Finished Product

Sample (In Two Can)

For Physical Content (SG, Viscosity, NV etc.)

For Film Property (Shade, Drying, Pot Life etc.)

In first Stage if any Parameter does not matches, then in 2nd Stage sample is collected to match that parameter only. This Operation is repeated only. This operation is repeated until every parameter in specified and finally the batch released for packing. Procedure to keep Document of Passed batches and operation in Q.C. In case of Passed batch cards Three type of Indexing is used. First type of Indexing is maintained according to the batch no. of a certain batch . The corresponding Register is called R/S(Retain/ Sample ) Copy. Information can be found from this Copies are name of the Passing Chemist. Date of Passing and amount of retain sample kept (200ml/500ml.) 2nd type of indexing is maintained according to the quality no. Here one can found all the necessary details of a certain batch . The corresponding Cards are called Test Card. 3rd type of indexing maintained according to a curtained according to a certain date. The corresponding Copy detail daily Pass Book. From this Copy one can obtain the various batches of various qualities passed in a certain date. To keep document about the operation a separate Copy is used and The name of the Copy is Daily Report Copy. At the end of Working Day , Q.C. chemist first arrange the batch cards in the increasing order of their batch no. In the daily Report Copy . To keep documents about the analytical works (for example of analysis Zinc- Chrome, RedOxide, Purity of H3PO4) Another Copy called Analytical Copy is used. To keep document about the passed consignment of Passing material another register is used. Passing of consignment in SAP of packaging item is conducted with the help of this Copy.

49

INSTRUMENT
1. B4 Ford Cup. 2. Specific Gravity Cup. 3. Hegmen Gauge. 4. I.R.Oven. 5. Oven at 1200C 6. Oven at 3000C 7. Oven at 1400C 8. Incubator(600C) 9. FM Automotive Machine. 10. Sheen Rotothiner(Disk Type) 11. Bar coater 100 WFT(Weight Film Thickness). 12. Impression Bed. 13. Digital Balance(0.001 to 300 gm.) 14. Spray Booth. 15. Gyroshaker Machine. 16. Sheen Roto Thinner (Ball Type). 17. Digital Balance(0.1 to 3 Kg). 18. Square Applicator (100 & 200). 19. Thermometer (1100C to 3000C). 20. BYK Glossometer. 21. DFT Gauge (Electro Physik) 22. Gretag Macbeth color Matching system. 23. Bursting, Strength Apparatus. 24. Sheen Scratch Hardness Apparatus. 25. Oven at 2000C. 26. Centrifuge machine. 27. Flexibility Apparatus . 28. Bar Coater. 29. Digital Balance (0.001 gm. 300 gm.) 30. Sheen Cross cut adhesion tester. 31. Hot Plate.

50

TESTING IN LACKER PART Epoxy Phenolic Base (Internal) 1) Epoxy Food Lacker Epoxy(High Molecular weight) + Moitol Solution(Flexibility & Addition) + Mobitol (Resin where use in Aluminum surface) + Di- Acetone Alcohol + Phenolic Resin + Poly Tetra Fluro Chlorine Wax (For slippery). 2) Epoxy DD Lacker. 3) Epoxy Plate Gold Varnish For Pesticide Container. Alkyde(Long Oil) Base Lacker (External) 1) Silver Stoving Varnish. 2) Shalislip Trance Coating Epoxy Ester For Top Coat Vinyl Resin Metal Box SS coating (Two Pack System) Base : Accelator 3:1 Special Hard Water White Varnish(Castor Short Oil alkyde + MF Resin + UF Resin) For Battery Jacket Coating Testing :1) Viscosity 90+/- 5 (F4 Cup) 2) Non Volatile (NV) 39 +/- 2 % 3) Addition Check In 18 no. Bar coater. Draw down with R/S After First Code kept in 1700C & then Again after 2nd Code Apply 200 2050C in 12 min. Stove. 4) Acetone Rub Test (24 no. bar coater) with 200 2050C in 12 mins stove after curing soap by Acetone with 30 times Rup. If Metal part have seen this sample fail. 5) Dry Film Weight(DFW). 6) Wage Bend Value(WBV) For flexibility . NF(Non Fraction part)

51

TESTING IN SOLVENT BASE & WATER BASE PAINT

1) Drying Check :- By Metal Panel. 2) Shade Check :- By Draw down with Bar coater in Paper or Colour Spectrometer. 3) Gloss Check :- On Shade Checking time. 4) Viscosity Check : - By B4 Cup with Second or by Sheen Roto Thinner with Poise. 5) HGR : - Hegmen Gauge Reading for Particle Size in Micron(). 6) Settling Check :- Stay in a Biker after checking in a certain time. 7) NV Check :- Non Volatile check by I.R Oven in Percentage. 8) SG Check : - Specific Gravity check by Specific Gravity Cup. 9) Pigment % Check :- Check by Centrifuge machine. 10) DFT check :- Dry Film Thickness check by Electro Physik. 11) Jell Point Check :- For Zilcate Material.

52

PROJECT ON THE STRATEGY OF RFT (RIGHT FIRST TIME) CALCULATE IN WATER BASE PAINT & SOLVENT BASE PAINT

53

SYNOPSIS RFT (Right First Time) When Q.C Check on Finished Material of Paint with require many Parameter like as Drying, Shade, Viscosity, NV,Settling,HGR, SG etc. On that time those batch clearly Pass in First Time without adjustment by Production , These are called RFT. It measure by Percentage.

Objectives: - To reduce waiting time after producing the Finished Material. Data Collection Process : - From The Pass Batch Card from Filling Section in Q.C. Report. Sampling Unit :- Mainly I have focused in Paint Mill Sections RFT. Sample Size : - The sample size have restricted with in 110 in 15 days observation in time Period. Tools have used :1) Bar Graph. 2) Pareto Analysis. 3) Cause & Effect Diagram(Fish Bone Diagram).

54

DATA COLLECT OF WATER BASE PAINT Material Number 12081744 22202719 22212745 22571765 12101742 12103701 12081744 12081442 12081442 22212745 22212745 22571765 22571765 22212745 22571765 22212745 22212745 12081744 12081744 12081745 12082502 12082501 12101742 12101745 22212745 22212745 12081742 22571765 12083711 12081742 12081742 12081742 22212745 11061742 11061742 No. of Shot 2 2 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 2 2 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 2

Date 11.05.12 10.05.12 12.05.12 13.05.12 13.05.12 10.05.12 11.05.12 12.05.12 18.05.12 05.05.12 05.05.12 07.05.12 08.05.12 09.05.12 12.05.12 10.05.12 10.05.12 11.05.12 15.05.12 15.05.12 16.05.12 12.05.12 13.05.12 17.05.12 21.05.12 21.05.12 23.05.12 19.05.12 26.05.12 24.05.12 24.05.12 25.05.12 28.05.12 27.05.12 31.05.12

Pdt. Description Shaktiman Deep Base (Water) Universal White Primer W.T. Cement Primer Shalimar Exterior Wall Primer Shalimar XTRA Pastel Base XTRA White Shaktiman Deep Base (Water) Shaktiman Brown Base Shaktiman Brown Base W.T. Cement Primer W.T. Cement Primer Shalimar Exterior Wall Primer Shalimar Exterior Wall Primer W.T. Cement Primer Shalimar Exterior Wall Primer W.T. Cement Primer W.T. Cement Primer Shaktiman Deep Base (Water) Shaktiman Deep Base (Water) Shaktiman Accent Base Shaktiman Ext. Acr.Eml Terracotta Shaktiman Ext. Acr.Eml Mino Red Shalimar Extra Panel Base Shalimar Extra Panel Base W.T. Cement Primer W.T. Cement Primer Shaktiman Pastel Base Shalimar exterior Wall Primer Shaktiman Sparkling White Shaktiman Pastel Base Shaktiman Pastel Base Shaktiman Pastel Base W.T. Cement Primer No.1 Silk Emulsion Pastel base No.1 Silk Emulsion Pastel base

RFT %

74.29%

55

DATA COLLECT OF SOLVENT BASE PAINT PAINT

Material Number 10242696 10243701 51002750 53801826 53311664 53311664 53311664 53311664 53311664 53311664 53311664 53311664 53311664 21232324 22202719 73101631 72102720 53309596 51321619 53302673 71102418 71102418 21192459 10242631 12101744 10242537 10242538 10243701 51321419 21192459 74101349 10012692 11061742 12083711 12083711 10242692

Date 05.05.12 04.05.12 04.05.12 09.05.12 09.05.12 09.05.12 10.05.12 10.05.12 11.05.12 12.05.12 13.05.12 14.05.12 14.05.12 10.05.12 06.05.12 06.05.12 06.05.12 06.05.12 09.05.12 05.05.12 10.05.12 10.05.12 7.05.12 12.05.12 09.05.12 10.05.12 11.05.12 11.05.12 11.05.12 06.05.12 14.05.12 20.05.12 06.05.12 08.05.12 09.05.12 08.05.12

Pdt. Description Shalimar G.P Enamel. Smoke Grey Shalimar O.P. Enamel White Binder for Tuffkote Zilicate Shalitol HB Black Coating For - DI Pipe Epicard TL 543 HS LT. Grey Base Epicard TL 543 HS LT. Grey Base Epicard TL 543 HS LT. Grey Base Epicard TL 543 HS LT. Grey Base Epicard TL 543 HS LT. Grey Base Epicard TL 543 HS LT. Grey Base Epicard TL 543 HS LT. Grey Base Epicard TL 543 HS LT. Grey Base Epicard TL 543 HS LT. Grey Base Zinc Chromate Prime Yellow Universal White Primer Q.D Enamel light Grey to ISO.631 A/D Stoving Enamel White Epicard XL HB Smoke Grey Base Epicard 5 HB Zinc. Phosphate Primer Grey Epicard Finish Smoke Grey O.D/R.O Zinc Chromate Primer O.D/R.O Zinc Chromate Primer Spl.Red Oxide Zinc. Chromate Primer G.P Enamel Light Grey Shalimer Extra Deep Base Shalimer G.P Enml. Signal Red Shalimar G.P Enml. P.O Red Shalimar G.P Enml. White Epigard 5 HB Zinc. Phosphate Primer Red Spl.Red Oxide Zinc. Chromate Primer Stove. Barrel ENL. Coldmen Yellow SHE Smoke Grey No.-1 Silk Emulsion Pastel Basement Shaktiman Sparkling White Shaktiman Sparkling White Shalimar C.P Enml.Smoke Grey

No. of Shot 3 4 2 1 2 1 1 1 2 2 2 2 2 1 2 3 2 3 2 2 2 2 3 2 1 1 2 4 1 1 3 2 2 1 2 2

RFT %

38.66%

56

53508705 53502673 71102418 71102418 53502674 53302671 53311664 53311664 52502644 53801826 53402309 21192459 10242356 10242356 21192459 21192459 21192459 21192459 21582445 21582445 53311664 53311664 53311664 53311664 53311664 53311664 53311664 53311664 53311664 55126757 74101853 73101655 10243701 21192459 21192459 21192459 21192406 21192406 21612463

13.05.12 13.05.12 15.05.12 15.05.12 14.05.12 19.05.12 14.05.12 14.05.12 24.05.12 23.05.12 24.05.12 15.05.12 18.05.12 26.05.12 18.05.12 23.05.12 23.05.12 19.05.12 21.05.12 18.05.12 21.05.12 23.05.12 23.05.12 23.05.12 24.05.12 24.05.12 25.05.12 26.05.12 23.05.12 19.05.12 22.05.12 28.05.12 26.05.12 26.05.12 28.05.12 29.05.12 26.05.12 27.05.12 28.05.12

Chlorokote Road Making Paint White Chlorokote HB Finish Smoke Grey O.D/R.O Zinc Chromate Primer O.D/R.O Zinc Chromate Primer Chlorokote HB Finish Dark Grey Epigard Finish light Grey Base Epigard Tl 543 HS LT. Grey Base Epigard Tl 543 HS LT. Grey Base Chlorlokate HB MIO Dark Grey Shalitol HB Black Coating For - DI Pipe Shalithane HB- Finish Canary Yellow ISC-30 Spl.Red Oxide Zinc. Chromate Primer Shalimar G.P Enml. Golden Yellow Shalimar G.P Enml. Golden Yellow Spl.Red Oxide Zinc. Chromate Primer Spl.Red Oxide Zinc. Chromate Primer Spl.Red Oxide Zinc. Chromate Primer Spl.Red Oxide Zinc. Chromate Primer Pink Primer for Wood Pink Primer for Wood Epigard Tl 543 HS LT. Grey Base Epigard Tl 543 HS LT. Grey Base Epigard Tl 543 HS LT. Grey Base Epigard Tl 543 HS LT. Grey Base Epigard Tl 543 HS LT. Grey Base Epigard Tl 543 HS LT. Grey Base Epigard Tl 543 HS LT. Grey Base Epigard Tl 543 HS LT. Grey Base Epigard Tl 543 HS LT. Grey Base Tuffkote HB Zilliplate Grey Comp -II Stoving Dipping S/G Black Q.D Enamel Dark Grey to ISO.632 Shalimar G.P. Enamel White Spl.Red Oxide Zinc. Chromate Primer Spl.Red Oxide Zinc. Chromate Primer Spl.Red Oxide Zinc. Chromate Primer Red Oxide Zinc. Chromate Primer Red Oxide Zinc. Chromate Primer Spl. Red Oxide Primer

1 2 1 1 3 2 2 2 1 1 2 1 2 1 2 1 2 2 2 2 1 1 1 2 1 2 1 2 1 1 1 3 2 1 1 1 2 2 2

57

% RFT Evaluation in Bar Graph :-

RFT
80.00% 70.00% 60.00% 50.00% 40.00% 30.00% 20.00% 10.00% 0.00% Water Base Paint Solvent Base Paint 38.66% RFT 74.29%

Pareto Analysis Causes of Reduce RFT

% of Causes
50.00% 45.00% 40.00% 35.00% 30.00% 25.00% 20.00% 15.00% 10.00% 5.00% 0.00% Drying Shade Gloss Viscosity HGR NV SG 1.33% 6.67% 17.33% 24% 24% 21.33% % of Causes 46.67%

58

Cause & Effect Diagram:-

Man

Materials Other Raw material Alkyde Resin Quality Solvent Quality Viscosity Problem Improper Mixing C Repair Stirrer R.P.M

Worker Negligence Training Accuracy Measurement

Methods

Machinery

Conclusion of the Project :I have seen 46.67 % problem are coming from Viscosity. So, Firstly Should be focus to reduce the Viscosity adjustment problem. Also I have observed from Cause & Effect Diagram some reason may be possible to sort out the problem. Which will also increase the RFT %.

59

CONCLUSIONS It was a good experience spending 45 days in Shalimar Paint Ltd. Being a being a Management Trainee, its a new tactic to stay in a process where batch process is carried out. As far as improvement is concerned , YES there is always a need of improvement, some of which are explain :-

Scope from Improve to Increase Productivity

Commitment should be require by senior management and all employees. Reducing development cycle times. Just In Time/Demand Flow Manufacturing Activity. Make Improvement teams. To Be Reduce product and service costs. Systems should be require to facilitate improvement. Line Management ownership should be Require. Employee involvement and empowerment should be require. Recognition and celebration should be require. Challenging quantified goals and benchmarking should be require. Focus on processes / improvement plans

60