PRESENTATION ON PROJECT FAB-1

SUMMER INTERNSHIP PROJECT

INTRODUCTION ABOUT JOURNEYPROJECTS UNDERTAKENABOUT FABAPPROACH FOR FABCHALLENGES DURING THE PROJECTFINDINGS LIMITATIONS DURING PROJECT

INDEX

Started on 15th January 2016.

Got selected and told to do the internship at Nagpur.

Connected with Mitra sir for further Guidelines.

Arrived at Nagpur on 1st May 2016.

Introductory session on 2nd May 2016.

Started working on projects from 3rd May 2016.

INTRODUCTION ABOUT JOURNEY

JCB-CTA,CSMM for JCB India-50 interviews.

Edge-Pureit Audit-5 shops.

Khushi-CSMM for John Deere-6 interviews.

JSW steel, customer feedback-6 interviews.

FAB-I-35 interviews.

SSI-India, dealer rating for JD power-12 interviews.

PROJECTS UNDERTAKEN

Started working on 20th of May 2016. The project has the main objective to understand the market

potential of Fly ash bricks and the expectation of manufacturers regarding the brick manufacturing machines.

There are 2 types of respondents1.Fly Ash brick manufacturers.2.End customers of Fly ash bricks.-builders, government

contractors,architects,CAThe region for the study was Nagpur cluster including

Nagpur,Wardha and chandrapur districts in perticular.

ABOUT FAB-I

The sample size for Nagpur was 15 for each type of respondent.

For Wardha it was 7 per type of respondents.

For Chandrapur it was 8 per type of respondents.

We have conducted interviews for both manufacturer and end user respondents.

ABOUT FAB-I

Fly ash brick is a building material mainly containing Fly ash which is a waste generated from various power plants

The brick is described as Self cementing brick.The manufacturing method saves energy,

reduces mercury pollution and costs 20% less than traditional clay bricks

These bricks are considered to be replacement for traditional bricks along with CLC(cellular lightweight concrete) blocks and ultra light AAC (autoclaved aerated concrete) blocks.

Fly Ash bricks

Material MassFly ash 45%

Sand/stone dust 30%Lime sludge 10%

Cement 10%Gypsum 5%

Total 100%

contents

Same number of bricks will cover more area than clay bricks.

High fire insulation.

No breakage during transport.

Uniform size-mortar reduction by 50 %.

Does not require soaking in water for 24 hours, only sprinkling is enough.

Best example of waste Management.

Advantages

Mechanical strength is low.

Limitations of size-only modular size can be produced. Large size have more breakage.

Can be manufactured only in those areas where fly ash is easily available as its the main material in the production.

Disadvantages

Diagrams

FAB manufacturing machines

Block diagram of process

To get information about the leading fly ash brick manufacturers in the cluster.

Take their response and get further respondent details from them-Snowball sampling.

To get the information about the customers of FAB from the manufacturers which comes under the end user segment of our project.

Approach for FAB-I

Initial thought 1. Since the industry is local we thought that we’ll get

the respondent information easily.2. Also we thought people will be really interested to

give their expectation for the client’s new machine.3. Builder and other end users will not be having any

issue in sharing information abut the client.4. Since the information is general getting references

from the respondents will not be an issue

Challenges during the project

Practical scenario1. Manufacturer were not ready to give any

information without knowing the client name.2. No any manufacturer was ready to share name of its

customers.3. The industry is on downward spree so many

manufacturers have stopped producing FAB.4. Due to slowdown real estate industry builders were

neither accessible to us nor they were interested to share any information.

Challenges during the project

Our final approach1. Managed to convince manufacturers by telling them

that the study is for government report.

2. Took the help of questions in the questionnaire.

3. Told them about getting their references from others and how others have contributed into the study.

4. Took more contacts from the DIC office .

Challenges during the project

For ManufacturersMany plants were established during the

period of 2008 to 2012 as the demand was high in those days.

FINDINGS

2004-2008 2008-2012 2012-201602468

10

3

9

6

no. Of new plants

no. Of new plants

FINDINGS

supporting red bricks business

increasing FAB demand

government encouragement

in line with education and

business

02468

101214

2

12

13

Reason for entering FAB business

FINDINGS

will improve

will remain same

will deplete

0 2 4 6 8 10 12 14

12

6

0

Availability of raw ma-terial

will improve

will remain same

will deplete

0 2 4 6 8 10 12 14

12

6

0

Availability of raw ma-terial in future

FINDINGS

2000-4000 4000-8000 8000 and above0

2

4

6

8

10

12

Average FAB production per day

Almost all plants have machines mainly purchased from companies in Coimbatore and Gujrat.

Machine manufacturers like engineering enterprise, Reva engineering holds great reputation here.

Few small scale manufacturers have self built machine.

Manufacturers from Butibori MIDC have customised machines which can be threat to big machine manufacturers and our client.

FINDINGS

But suddenly the demand has fallen leading to the halt of many FAB production units.

Only 1-2 manufacturers are getting subsidies an that too in the form of tax exemption of 10%.

No special subsidy as such.The manufacturers are facing challenges in selling FAB

due to bad perception of people towards FAB.Red brick is still considered better over FAB.Manufacturers are no more interested in the production

of FAB.

FINDINGS

For end users1. FAB has been mainly used by the builders as it is cheaper

than red clay bricks.2. Government contractors have been ordered to use only fly ash

bricks as they are environment friendly.3. AAC blocks and other ultra light concrete blocks are more

famous than FAB when it comes to replacement of red bricks.4. Household end users and normal people have extremely bad

perception about FAB like over heating , rigid-cannot make holes, doesn’t hold plaster.

FINDINGS

Name of the client was unknownUnable to fetch more information regarding machinesRespondents were not aware about market research

studiesNon co-operative and suspicious attitude of manufacturers

and buildersConversion ratio of contacts to respondents was poor 0.3.Snowball sampling failedRespondents didn’t give the factual information about

subsidies and the finance in the business.

LIMITATIONS DURING PROJECT

THANK YOU