Industrial Visit
After writing the Manufacturing Technology-2 Unit Test and
attending Math class. We went for a small break before we board our bus. It was
about 40 students from 2nd year Mechanical Dept and 10 students from
2nd Aeronautical Dept, with us Mr. Magaesh and Mr.Sekar professors
accompanied us. We are planned for a Industrial Visit to Murugappa Morgan
Thermal Ceramics Ltd at Rainpet,Vellore.
We got ready and the attendance was taken and we boarded the
bus around 11.30a.m and our travel started it was about a 2 hour travelling
distance crossing two toll booths on our way. We stopped at a Highway
Restaurant for our lunch for about 45 minutes. Then we reached about 1.45pm at
Murugappa Morgan Company.
We were waiting in their emergency exit area and parking
area. So, as in group of 20 we entered to the reception room to watch the
safety precautions video. After everyone watched it they provide as with masks.
They didn’t provide as florescent jackets and helmets as it was not totally
necessary for the trip and they didn’t take us to the place where those kind of
precautions need. But it is important to wear masks as it has toxic likable
gases may come out. Then they introduced themselves Mr. Ajay Joshi, Safety
manager recruited in 2015 and Lingeshwaran.
They explained about how Murugappa group divided and were there company
is placed in it.
Murugappa Morgan Thermal Ceramics Ltd. Is the JV between
Morgan Thermal Ceramics division of Morgan Crucible Plc. UK and Carborundum
Universal (CUMI) of Murugappa. The Murugappa takes the responsibility of
management and the Morgan industry provides the technology and machines. Safety
is their priority. They have a separate program called ‘Think Safe’. They also
installed a desktop in their canteen where they have uploaded their own
animated videos of accident which has happened in other industries around the
world. They said our employers learn from other mistakes instead of making
mistakes while as an employer inside the factory.
As soon as we got
down from the bus we regrouped into batch of 10 members and went into the
security reception to watch a video about Safety measures should be maintained
when we are inside the Plant. It was a great video about safety during the
visit. We were all regrouped into two batches of 25 members and Mr. Ajay Joshi took
a batch and Lingeshwaran took the rest and we were provided with masks. While
we were walking towards the Engineering Fiber manufacturing plant I observed
that the company spent a lot of money in making the employers and visitors
safe. As we entered the plant the employer asked the Chief to stop the process
in order to explain us what’s going on due to the heavy sound. So, it was a
fiber which is made up of main components like Alumina, Silica and Limestone
etc. There are putting that fiber into a machine which drags and moves to the
top position and through pneumatic process only the pure fiber gets down to the
delivery package and the non-pure or slots which is collected separately and
taken into a another process where it is placed in a process where a number of
small size steels balls are rolled through that slots to get the remaining pure
fiber out of it. After, that the pure fiber gets converted and the un-usable
fiber slots are packed separately for recycling. Those fibers are used in the
diesel engine where the used fuel comes out of the engine and this fiber with
other components extracts some of the harmful chemical substances and releases
the exhaust gas into the atmosphere.
Then we moved into the main plant where the fiber is
manufactured and different products manufactured and the lab area is located.
As I said before the fiber is made of number of components like Alumina, Silica
and Limestone etc, at first these chemicals arrive at a storage area where
those chemicals are added into a mixer and mixed in there and taken into the
furnaces, boilers and silos. At first, those chemicals are taken into the silo
and boiled when it is brought into the furnaces which is at 1008*C this furnace
rotates cylindrical and heats the fiber through electrical process and those
fiber filled and gets down into a chamber where a wheels rotates at 2000 rpm
the fiber drops through a hole and this air blows the impurities away and the
pure fiber gets down to packaging and the impurities are taken away through a
another tube. Then this fiber is
collected as a hole and transferred to manufacture engineering fiber and also
the new prepared fibers is introduced into Annealing process of sudden heating
and slow cooling to make Fiber blankets, Fiber paper and Fire protectors. This
fiber is taken to another machine to do knitting process. Then it is taken to a
machine where the blankets and paper is manufactured. The fire is dipped in
water and through vacuum they are made into thick and thin un-dimensional
rectangle. Then it is taken into
verification and packing where the paper fiber and protective fire are checked
form measurements and the un-even rectangle shape is cut into a correct
rectangle shape and sent for packing.
These fiber are
taken into testing in their own labs to find out the hardness, elasticity,
breaking point, composition, size and weight. The chemistry of the fiber is
checked through an X-ray machine. They also have two to three machines which
does 4000 clicks contains a small amount of fiber it is used to check their
volume and their consistency. They also have Universal Time Machine to check
their tensile force.
After, the entire visit we regrouped in the canteen where
the Vice-president of Murugappa Morgan Chennai Division came to see us. He
spoke a few words about Murugappa Groups and their joint venture with Morgan
Industry. Then he explained about why this much safety is given importance and
also clarified some of our students doubts. He was very sociable man, we
interacted with him well. He also explained that the company uses a huge amount
of water and the company is allowed to discharge some amount of water out into
the nearby location. But, the company has taken initiative to prevent the water
pollution and to recycle the used water they installed a new machine last month
we didn’t have opportunity to see that. But, it’s running cost around 80 lakhs
but after installing that they haven’t let any water outside their Plant. It
was amazing and very welcoming step by the company.
We have so far visited about 8 to 10 industries but we all
felt that this industrial visit very useful and educative to us. We thanked the
people who gave us permission to visit their plant and left to our buses .The
bus after a head count started around 4.10pm from Ranipet and we reached
college around 5.45pm. It was very fast travel and we all enjoyed the way it
all went for the day.
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