Rajshahi University of Engineering & Technology

NAME ID
Prosenjit Ghosh 135005
Md. Zahid Hasan 135021
Ruhul Amin Shatu 135056

Dept. of Industrial & Production Engineering

INTERNSHIP
REPORT
2018
ASIAN PAINTS BANGLADESH LIMITED
Tel: +880029204482
Website:
Plot#317 & 757, Bahadurpur, Gazipur
https://www.asianpaints.com.bd/
Website:
https://www.asianpaints.com.bd/
TABLE OF CONTENTS
Acknowledgement _______________________________________________ 3
Executive Summary ______________________________________________ 4
Overview of the organization _______________________________________ 5
Vision, Production Target,Objectives ________________________________ 6
Departments ___________________________________________________ 7
Organigram ____________________________________________________ 8
Internship Observations ___________________________________________ 9
Products of APBL ______________________________________________ 10
Description of Paints Ingredients ___________________________________ 12
Paint processing method _________________________________________ 15
Water based paints _____________________________________________ 17
Solvent based paints ____________________________________________ 21
Resin ________________________________________________________ 27
Quality Parameters _____________________________________________ 29
Importance of Paints ____________________________________________ 29
Equipment health card ___________________________________________ 31
Factory flow chart ______________________________________________ 32
Commissioning of New Pug Mill 4 __________________________________ 33
Volume Measurement of New Pug Mill 4 ____________________________ 34
Solution of Motor Belt not running __________________________________ 35
Database of Equipments _________________________________________ 37
Recommendations ______________________________________________ 41
Conclusion & Discussions ________________________________________ 42
References ___________________________________________________ 42

2|P a g e
ACKNOWLEDGEMENT
We would like our deep sense of gratitude & our profound regards to
Sanjib Sarker, MANAGER PLANT ENGINEERING of Asian Paints
Bangladesh LTD. Who suggested numerous improvements to the
report.

His experience and knowledge helped to give the complete form of

the report. We offer our appreciation and gratitude to the officers &
staffs who helped us with required info about the whole process.
Without their help we could not have completed the report. We
always tried to collect proper info from the respondents & analyzed
the report carefully. We are very grateful to the persons who raised
their hand to help us to complete our journey.

Although we tried to know the overall system regarding to production

and engineering properly, there may have some errors in to the report.
We will be grateful to the readers who have comments or suggestions
regarding content.

Thankfully,

Prosenjit Ghosh

Md. Zahid Hasan

Ruhul Amin Shatu

3|P a g e
EXECUTIVE SUMMARY
This is the internship report based on the 4 weeks long internship program
that we have successfully completed in Asian Paints Bangladesh Limited from
15-05-2018 to 11-06-2018 as a requirement of my Industrial & Production
Engineering Program under Faculty of Mechanical Engineering, Rajshahi
University of Engineering & Technolog y (RUET). We were new in practical
field of our studies & corporate world. The all sections of the Industry tried to
help us to learn about all the processes, equipment & systems they have.
These knowledge s will be very useful for our career.

There are mainly 4 production sections in that industry. We went to Water

based paints block, Solvent based Paints block , Resin Production block,
Distemper block & ETP & learned ins & outs of all sections. We were
introduced all the stuffs & top brass of all sections & they were very helpful &
cordial to us.

We have learnt all processes & procedures including the corresponding

machines in a particular product producti on system. We were taught how they
generates idea of the new products, research for the new products, prepares
Batch sheet, make plan for production, analyze market demand, determine
customers & consumers, set manpower & investments, maintain machines &
equipment, handle manpower, determine product’s cost, manage downtime,
supply to the market etc .

Asian Paints Bangladesh Limited has all modern equipment & systems &
highly skilled manpower. The behavior of all the employees were very
satisfying. They helpe d us with all kind of information. They described the
working principles of all machines, systems & processes. We were also taught
about how to keep pace with the competitive corporate career. We also
witnessed defects & wastage in all processes & tried to find solutions. We
have also learnt about the safety of manpower & machines.

We have achieved a complete idea of this industry. From this internship

program a full concept of an industrial system has been understood.

4|P a g e
1.1 OVERVIEW OF THE ORGANIZATION
Asian Paints Bangladesh Ltd. started its journey in the year 2002 as a joint venture with
Confidence Cement to produce top class range of paints for the discerning consumers of
Bangladesh. Now the company is manufacturing and distributing a wide range of high-
performing decorative, marine and industrial paint product with its expertise and cutting-
edge technology to satisfy all the painting needs of consumers in Bangladesh.
Beginning with selling imported paint, they quickly ramped up through our own plant in
Gazipur on the outskirts of Dhaka. Currently this plant manufactures over 25000 KL of paint
annually.
Today Asian Paints Bangladesh Limited has come a long way from its humble beginnings,
becoming the 2nd largest paint company in Bangladesh. With a presence across all 64
districts, a 1,400 plus supportive dealer network, they are well placed to meet the painting
demand of all category of consumers across Bangladesh. They serve (service) our
customers through a network of a strategically located depots in Demra, Tongi, Chittagong,
Sylhet, Comilla, Khulna, Bogra, Barishal and Mymensingh.
The Company aims to provide the best products to consumers in most prominent segments.
Apart from a wide range of decorative paints, there are a number of popular industrial
products which have strengthened their presence in the Bangladesh paint market. Asian
Paints have also brought excitement in the Bangladesh market through introduction of a
number of innovative concepts and initiatives, which have set benchmarks of progress in
the market today. Some of these would include work on a better retail ambience in paint
shops (Through attractive shop makeover in certain outlets with usage of interesting layouts
and tools to help consumers understand products and color more effectively), popularizing
the concept of signature walls (through a successful launch of Royale Play Special Effect
Paints) and consistent work on applicator education and skill enhancement. The world class
brands widely accepted in Bangladesh today includes Royale Play, Royale Luxury Silk
Emulsion, Apex Ultima, Apcolite and Decora. Today there are more than 850 Color Worlds
(outlets with automatic color dispensing machine for delivering a wide range of shades
within minutes) in the country which has ensured even better servicing of customer needs.
It is also a matter of pride that Asian Paints have been awarded "Super brand" status since
2009 in Bangladesh - and is seen as one of the most respected corporate entities in the
country.
Asian Paints Bangladesh Limited is an ISO 9001: 2015 and ISO 14001:2015 certified
company.

5|P a g e
1.2 VISION
Asian Paints aims to become one of the top five decorative coatings companies world-
wide by leveraging its expertise in the higher growth emerging markets. Simultaneously,
the company intends to build long term value in the industrial coatings business through
alliances with established global partners.

1.3 PRODUCTION TARGET

Product Name Daily Target (KL) Monthly Target (KL)

Emulsion 44 1059
Stiff 31 735
Solvent 22 519
AMC 1 24
NON-INVENTORY 0.8 20

AVERAGE DAILY PRODUCTION TARGET = 98 KL (MAY 2018)

AVERAGE MONTHLY PRODUCTION TARGET = 2357 KL (MAY 2018)
TOTAL SHIFT OF PRODUCTION = 2
TOTAL MANPOWER IN PRODUCTION = 130

1.4 OBJECTIVES
• To become No. 1 brand in Paints in Bangladesh.
• Become highly appreciated & accepted in urban markets & now trying to achieve
customer satisfaction & market in rural areas.
• Trying to increase market demand & minimize inventory cost.
• Uses very sophisticated machines in Production to get high quality output.
• Zero tolerance against Quality parameters.
• The International unit is relentlessly trying for rapid growth of sales.

6|P a g e
1.5 DEPARTMENTS OF ASIAN PAINTS
BANGLADESH LTD.
• PRODUCTION
• QUALITY CONTROL & RESEARCH & DEVELOPMENT
• ADMIN
• QEHS
• DISTRIBUTION
• INFORMATION TECHNOLOGY
• MAINTENANCE
• STORE
• VAT

7|P a g e
1.6 ORGANIGRAM
GENERAL MANAGER

HEAD OF SUPPLY CHAIN

& OPERATION

MANAGER OPERATIONS

MANAGER MANAGER ASST.

MANAGER MANAGER SR. OFFICER
ADMIN & PLANT MANAGER
PRODUCTION TECHNOLOGY QEHS
STORES ENGINEERING COMMERCIAL

SR . OFFICER
COMMERCIAL
SR.
ASST. ASST. ASST.
EXECUTIVE OFFICER
MANAGER MANAGER MANAGER
RPM EMPLOYEE
PRODUCTION R&D FG & VAT
RELATIONS

SR.
EXECUTIVE EXECUTIVE EXECUTIVE PERMANENT
OFFICER OPERATOR
PRODUCTION R&D VAT
RPM

SR.
EXECUTIVE
SR. OFFICER SR. OFFICER OFFICER PERMANENT CASUAL PERMANENT
OPERATOR PLANT OPERATOR
PRODUCTION R&D FG & OPERATOR
ENGINEERING
DISPATCH

OFFICER
OFFICER OFFICER CASUAL ASST. PLANT CASUAL
FG &
PRODUCTION R&D OPERATOR ENGINEERING OPERATOR
DISPATCH

PERMANENT PERMANENT PERMANENT PERMANENT

OPERATOR OPERATOR OPERATOR OPERATOR

CASUAL CASUAL CASUAL CASUAL

OPERATOR OPERATOR OPERATOR OPERATOR

8|P a g e
2 INTERNSHIP OBSERVATIONS
2.1 PAINTS
P → PIGMENT
A → ADDITIVES
I → INHIBITOR
N → NATURAL/BINDER
T → TINTER
S → SOLVENT
Paint is a solution or suspension (emulsion) of pigment, binder, and mineral solvent (or
water) that on drying forms an adhering film on the surface it is applied for protection and/or
decoration.
It is A homogeneous mixture.

2.2 CLASSIFICATION OF PAINTS PRODUCED in ASIAN PAINTS

BANGLADESH LTD.

PAINTS

DECORATIVE PROTECTIVE

SOLVENT BASED WATER BASED

WATER BASED SOLVENT BASED
(MAJOR) (MINOR)

FIGURE: Classification of paints in Asian Paints Bangladesh LTD.

9|P a g e
2.3 PRODUCTS of ASIAN PAINTS BANGLADESH LTD.

WATER BASED EXTERIOR PAINTS

• EXTERIOR WALL PUTTY
• EXTERIOR WALL PRIMER SEALER
• WEATHER PROOF EXTERIOR EMULSION
• APEX ULTIMA
• EXTERIOR SILICON COATING
• DECORA CEMENT PAINTS
• ROOFING COMPOUND PAINTS

WATER BASED INTERIOR PAINTS

• INTERIOR WALL PUTTY
• INTERIOR WALL PRIMER SEALER
• DECORA DISTEMPER
• ARCYLIC DISTEMPER
• ACRYLIC EMUSLION
• APCOLITE SILK EMULSION
• ROYALE SILK EMULSION
• ROYALE PLAY SPECIAL EFFECTS - NORMAL
• ROYALE PLAY SPECIAL EFFECTS – METALIC

ENAMEL PAINTS
• APCOLITE ACP RED OXIDE
• APCOLITE WALL PRIMER SEALER
• ASIAN PAINTS Z/P PRIMER
• DECORA SYNTHETIC ENAMEL
• ASIAN PAINTS PREMIUM GLOSS ENAMEL

INDUSTRIAL PAINTS
• METACARE RED LEAD PRIMER
• METACARE Z/C PRIMER
• METACARE Z/P PRIMER
• METACARE WASH PRIMER

10 | P a g e
 • METACARE EPOXY GRADE PAINTS
• METACARE INDUSTRIAL GRADE PAINTS
• ASIAN PAINTS TOWER PAINTS
• METACARE HIGH HEAT RESISTING PAINTS

FIGURE: SOME PRODUCTS of ASIAN PAINTS BANGLADESH LIMITED

11 | P a g e
2.4 DESCRIPTION of PAINTS INGREDIENTS

2.4.1 PIGMENTS
In the coloring of paints, a pigment is a dry colorant, usually an insoluble powder. Pigments
that are dispersed in paints, work by selectively absorbing some parts of the visible spectrum
whilst reflecting others. It's used both to provide color, and to make paint opaque, thus
protecting the substrate from the harmful effects of ultraviolet light while also increasing
paint's hiding power. Role: 1. Provide color & give opacity. 2. Responsible for hiding. 3.
Enhance film durability 4. Reduce moisture permeability & serves as a barrier 5. Protect the
film by reflecting the UV light.

Role of PIGMENTS
• Provide color & give opacity
• Responsible for hiding.
• Enhance film durability
• Reduce moisture permeability & serves as a barrier
• Protect the film by reflecting the UV light.

2.4.2 EXTENDER
Extender pigments are added in order to reduce the cost of a paint formulation. They are
also used to modify the flow (viscosity), sedimentation stability and film strength. Most
extender pigments appear white and possess a refractive index similar to commonly used
binders. Most of the extender pigments occur naturally and others can be produced
synthetically. Aluminum silicate, magnesium silicate (talc), silica, calcium carbonate
(synthetic and natural) and barium sulfate are some commonly used extender in paints and
coatings.

ADHESION or BINDERS
A binder is a material used to bind together two or more other materials in mixtures. Its two
principal properties are adhesion and cohesion. The binder determines many of the
necessary film properties such as adhesion, gloss level, hardness, abasing resistance,
flexibility, drying & durability.

12 | P a g e
Role of ADHESION or BINDERS
• Hold pigment in dispersion
• Convert liquid coating to solid film
• Adherence to substrate/ undercoat
• Gloss
• Elasticity to film
• Water/ Chemical resistance
• Abrasion resistance
• Durability to paint film

2.4.3 ADITIVES
Impart specific properties.
• Used in small proportion.
• Available for all stages

Processing: Wetting, Dispersing agents

Application: Thixotropic Additives
Storage: Anti- skinning agents
Performance: Biocides

Some important types of additives are:

Fungicide Algaecide
Freeze-thaw Stabilizer Rheological additives
Thickener Scavengers
Coalescent Dispersing Agents
Wetting Agents Anti-settling
Anti-floatation Drier
Thixotropic Defoamers
Rust inhibitor Ph stabilizer
Bactericide

13 | P a g e
2.4.4 INHIBITOR
Critical Function - It Acts as a Catalyst.

Nature of Surface
Wood Metals
Masonry Others
Surface Preparation Before Painting
Following Subjects have to be followed Before Painting on the Surface:
• Identify the Type of Surface to select the Paints Product Selection.
• Surface Should be cleaned Properly with Biocidal or Fungicidal & Clean Water Wash.
• Filling of Cracks and Dents.
• To Remove all the Loosely Adhering Particles and lower down content of soluble
salts at surface level.
• To Ensure The surface is free from Rust, Dust & Oil material like as Grease, Oil.
• To Ensure the surface is Dry and free from damp. - Moisture and Salts. Moisture
content must below 17% for new painting.
• To Check Alkalinity Up to PH- 9 is Ok for Painting
• To Select Appropriate Paints Product for Appropriate Substrates and Follow the Use
instruction in Technical Guide Books or Container Body.
• During Painting Use PPE for Health & Safety.

2.4.5 SOLVENT or THINNER

In paint, the solvent serves to adjust the viscosity of the paint. It is volatile and do not become
part of the paint film. Solvents are also known as diluents and thinners. Dissolve / dilute film
forming agents to provide consistency suitable for application.

Properties:
• Should be colorless
• Should be completely miscible with the paint at room temperature.
• Should be evaporate from the dried paint film
• Should act only on binder, not with pigment.
• Should be free from any residue.

14 | P a g e
Function of Solvent:
• It controls flow and application properties, affects stability of paint while in liquid state.
• Its main function is as the carrier for non-volatile components.

2.5 PAINT PROCESSING METHOD

BATCH PROCESSING

WATER INTAKE INTO

TSD

PRINT BATCH PAPER

ISSUE RAW MATERIAL

WEIGHT CHECKING

BATCH COMPLETION

NO

IS ALL OK IN
QC CHECK?

YES

PACKAGING

FG STORAGE

Figure: FLOW CHART of PAINTS PROCESSING

15 | P a g e
2.6 PROCESS DESCRIPTION
All the Powders (Pigments, Extenders Etc.), Part of The Medium and Solvent along with
Dispersing Agents are added into A Premixing Vessel (TSD or HSM) and Mixed thoroughly.
The Purpose of this stage Is to achieve A Homogeneous mass, known as Premixed Mill
base. Twin Shaft Disperser (TSD)

Figure: Schematic view of a TSD

Critical Parameters:
• Batch charging to be done under slow speed only.
• Maintaining of addition sequence.
• Mixing &Dispersion at high speed / shear force.
• Control on mixing time.
• Control on mixing speed.
• Preventive maintenance
• Cleanliness of mixer.

16 | P a g e
Batch Completion
Tinting
Tinters, as specified in the formulation are added to the batch, step by step and the shade
of the batch is matched close to the standard shade panel. Final shade matching is done
visually or with the help of color computer.

Final Adjustment
The Batch is adjusted step by step, with addition of the ingredients, as specified in the
Formulation, to achieve the specified properties.

Packing Operations
• Packing consists of following operations
• Filling
• Lid Pressing
• Printing / Stamping / Labeling
• Secondary Packing (In case of small & retail packs)

2.7 WATER BASED PAINTS

The paint in which various water are used as thinner and emulsions are used as binder is
called as Water-based paint. Recently, water base paint become most popular because of
its low price and hazardousness quality water base paint is appropriate for protecting and
decorating of concrete surface. It contains more than 25% water.

Water based paints are two types:

1. INTERIOR PAINTS:
• Asian paint acrylic distemper (APAD)
• Apcolite acrylic emulsion(AAE)
• Asian paint premium emulsion(APPE) etc.
•

2. EXTERIOR PAINTS:
• Asian pain weather proof exterior (AWPEE)
• Apcolite exterior emulsion (AEE) etc.

17 | P a g e
Raw materials for Water based Paint:
• Solvent (H2O
• Binder(emulsion)
• Additives
• Stanier
• Filler

18 | P a g e
 PREPARATION OF BATCH
CARD

RAW MATERIAL ISSUED BY RM

FOLLOW MACHINE COLOR

SEQUENCE

CHARGING DISPERSING AGENT,

TITANIUM, FILLER, OTHER
POWDER, EMULSION, WATER
ETC.
NOT OK

GRINDING CHECK?

OK

DROP IN MIXING TANK

MIXING & COLOR MATCHING

NOT OK

SAMPLE SEND TO QUALITY CONTROL

FOR COLOR FOR COLOR MATCHING & OTHER
PARAMETERS

OK

RFF STATUS & FILLING AS PER

PACK SIZE

Figure: Flow chart of Water Based PAINTS Production

19 | P a g e
Preparation of Batch Card:
• First batch card prepared by Research and Development department of Asian
Paints Bangladesh Limited.
• Then the raw materials used for respective paint production is issued by Raw
Material department of Asian Paints Bangladesh Limited.

Charging of raw materials:

• Pigment manufacturers send bags of fine grain pigments to paint plants. First, Water
and dispersing agent is added to the Twin Shaft Disperser or High-Speed Disperser
depending upon the nature and quantity of the paints. To this mixture, dry pigment
and pigment extenders are added. Four additions of materials occur in this tank. First,
plasticizers are added to the mixture; second, a preservative and an antifoaming
agent are added; third, an emulsion is added; and fourth, water is added as a thinner.
There, the pigment is premixed with emulsion (a wetting agent that assists in
moistening the pigment), one or more solvents, and additives to form a paste.

• 90 percent of the water-based latex paints designed for use by individual

homeowners are instead processed in a high-speed dispersion tank. There, the
premixed paste is subjected to high-speed agitation by a circular, toothed blade
attached to a rotating shaft. This process blends the pigment into the solvent.

• After a pre-determined time, the grinding is checked by Quality Control department.

If the grinding not fulfills the required condition the grinding operation is repeated
several times.

• If the grinding fulfills the required condition then the bulk mixture is dropped into the
mixing tank of the strainer zone, where the color is matched by Quality Control
department.

• If the required color is not matched, the required amounts of pigments are added into
the bulk mixture in the mixing tank. After completion the mixing the color is again
checked by Quality Control department.

20 | P a g e
Packaging of the paint:
Empty cans are first rolled horizontally onto labels, then set upright so that the paint can be
pumped into them. A machine places lids onto the filled cans, and a second machine
presses on the lids to seal them. A certain number of cans (usually one and two) are then
boxed and stacked before being sent to the warehouse.

2.8 SOLVENT BASE PAINTS

The paint in which various solvents are used as thinner and resins are used as binder is
called as Solvent-based paint or oil-based paints. It can have various combinations of
solvents as the diluents, including aliphatic, aromatics, alcohols, and ketones. Some
common thinners are used for solvent base are – Mineral turpentine oil (MTO), Xylene,
Mineral turpentine (MTT), Toluene, Butyl Acetate etc. Resins are used - Alkyd Resin, Epoxy
Resin etc. Solvent-based paint are widely used for industrial application.

Some important solvent-based paints of Asian Paints(BD) Ltd. Are:

• Apcolite gloss enamel (APGE)
• Decora synthetic enamel (DSE)
• Primer – ANTI corrosive primer (ACP)

Raw materials for Solvent based Paint:

• Resin
• Additives
• Pigments
• Filler
• Thinner

21 | P a g e
Preparation of Batch Card:
First batch card prepared by Research and Development department of Asian Paints
Bangladesh Limited. Then the raw materials used for respective paint production is issued
by Raw Material department of Asian Paints Bangladesh Limited.

Charging of raw materials:

• Pigment manufacturers send bags of fine grain pigments to paint plants. First, Resin
and dispersing agent is added to the Attritor machine or Batch Bead Mill or Ball mill
depending upon the nature of the paints. Then the machine is operated for several
hours. Then dry pigment and pigment extenders are added. Then there, the pigment
is premixed with resin (a wetting agent that assists in moistening the pigment), one
or more solvents, and additives to form a paste.

• After a pre-determined time, the grinding is checked with grind gauge machine by
Quality Control department. If the grinding not fulfills the required condition the
grinding operation is repeated several times.

• If the grinding fulfills the required condition then the bulk mixture is stabilized into the
machine for 15-20 minutes.

• Then the bulk mixture is dropped into the tank or pot or drum depending upon the
quantity of the paints of the slurry dropping zone, where the color and opacity is
matched by Quality Control department.

• If the required color and opacity is not matched, the required amounts of pigments
are added into the bulk mixture in the mixing tank. After completion the mixing the
color is again checked by Quality Control department.

22 | P a g e
 Figure: A typical Basket Mill Grinder

Figure: Mechanism of Grinding Operation in Basket Mill Grinder

23 | P a g e
 Figure: Grinding Mechanism with BEADS

Figure: Different Size Grinding Media

24 | P a g e
Thinning the paste:

If the required color and opacity is matched the bulk slurry must now be thinned to produce
the final product. The bulk paste is agitated with the proper amount of solvent for the type of
paint desired. The sample paste is send to the Quality Control department for testing the
viscosity and specific gravity. If it is matched the required level the paste is ready for filling.

Packaging of the paint:

Empty cans are first rolled horizontally onto labels, then set upright so that the paint can be
pumped into them. A machine places lids onto the filled cans, and a second machine
presses on the lids to seal them. A certain number of cans (usually one and two) are then
boxed and stacked before being sent to the warehouse.

25 | P a g e
 PREPARATION OF BATCH
CARD

RAW MATERIAL ISSUED BY RM

FOLLOW MACHINE COLOR

SEQUENCE

CHARGING DISPERSING AGENT,

TITANIUM, FILLER, OTHER
POWDER, EMULSION, WATER
ETC.

NOT OK

GRINDING CHECK WITH

GRIND GAUGE MACHINE?

OK
STABILIZATION FOR 15-20
MINUTE

DROP IN MIXING TANK/ POT/

DRUM WITH BALANCING PART

MIXING & COLOR MATCHING

NOT OK

SAMPLE SEND TO QUALITY CONTROL

FOR COLOR FOR COLOR MATCHING & OTHER
PARAMETERS

OK

RFF STATUS & FILLING AS PER

PACK SIZE

Figure: Flow Chart for Solvent Based Paints Production

26 | P a g e
2.10 RESIN:
Resins acts as binders in solvent base paints.
Following resin systems are used in solvent base paint:
• Alkyd Resin
• Epoxy Resin
• Polyurethane Resin
• Chlororubber Resin
• Phenolic Resin

DESCRIPTION

Alkyd resin Alkyd coatings are a class of polyester coatings derived from the reaction of an
alcohol (alcohol) and an acid or acid anhydride hence the term alk-yd from "alcohol and acid
or anhydride]" and are the dominant resin or "binder" in most "oil-based" coatings sold to
the consumer market. Alkyd coatings today are typically manufactured from acid anhydrides
such as phthalic anhydride or maleic anhydride and polyols such as glycerin or
pentaerythritol and are modified with unsaturated fatty acids (from plant and vegetable oils)
to give them air drying properties. The unsaturated oils react with oxygen from the air which
cause the oils to polymerize or crosslink with each other. The drying speed of the coatings
depends on the amount and type of drying oil employed (more unsaturated oil means faster
reaction with oxygen from the air) and use of organic metal salts or "driers" which catalyze
crosslinking between the unsaturated oils used to modify the base polyester resin.
Traditionally organic lead salts were employed but have been replaced with cobalt and other
alternative driers such as zirconium, zinc, calcium, and iron. Most driers are colorless but
cobalt is a deep blue purple color (iron driers are reddish orange) thus the colored driers are
typically employed only in paint colors where the blue color of cobalt or reddish orange color
of iron can be easily masked. Alkyd coatings are typically sold in three classes; Long,
Medium, and Short. These terms represent the relative fraction of drying oil component in
the resin. Long oil alkyds have a high percentage of drying oil content and are generally sold
as medium duty coatings for the consumer market. Medium oil alkyds have less drying oil
and have a higher percentage of large molecular weight polyester backbone. They dry
slower and are employed as high gloss coatings and wood finishes. At the bottom end are
short oil alkyds where the percentage of drying oil is very low in relation to the base polyester
polymer or backbone chain. These coatings will not air dry or harden unless heated. Short
oil alkyds are employed as baking as enamels for finished metal products.

27 | P a g e
Because the major components of an alkyd coating, i.e. fatty acids and triglyceride oils, are
derived from low cost renewable resources this has kept the cost of alkyd coatings very low
despite ever increasing cost of petroleum which is the predominant raw material source of
most other coatings such as vinyls, acrylics, epoxies, and polyurethanes. Typical sources
of drying oils for alkyd coatings are sunflower oil, safflower oil, soybean oil, fish oil, corn oil,
and tall oil (resinous oil by-product from pulp and paper manufacturing.

2.11 FUNCTION of PRODUCTION

EFFICIENCY of
PRODUCTION TARGET
OPERATIONS

PRODUCTION DEPT.

MANUFACTURING
INITIATIVE

PRODUCT & PROCESS

QUALITY

SAFETY &
ENVIRONMENT

28 | P a g e
2.12 QUALITY PARAMETERS
• Viscosity
• Weight Per Liter
• Finishing
• Drying Time
• Shade
• Contrast Ratio
• RS/TS
• Witness / Brightness
• Gloss
• Rubbing Test etc.

2.13 IMPORTANCE of PAINTS

Paint has four important uses:

Protection: Paint is used to protect all sorts of building and structures from the effects of
water and sun. Wooden buildings such as houses are usually painted because a coat of
paint prevents water seeping into the wood and making it rot. The paint also helps to prevent
the wood from drying out in the hot sun.
Metal structures and objects of all sorts are painted to stop them from rusting. A very large
steel structure such as a bridge must have a team of painters who keep the paint in good
condition all the time.

Decoration:
Paint is used to decorate all sorts of objects. Since pre-historic times, people have painted
the inside walls of their houses to make them look attractive. Painting and decorating the
exterior (outside) and interior (inside) of houses is an important industry in many countries.
There are many types and colors of paint to choose from. All sorts of other objects are
painted to make them attractive. This includes furniture, toys, tools and utensils, and street
fittings. Sometimes things made of wood such as furniture are painted in decorative
patterns. In some countries, many people enjoy decorating furniture and other small things
like trays and boxes. This is often called Folk art. In other countries such as Japan, painting
furniture is a very skilled profession and an antique piece of decorated furniture is very
valuable. Other people enjoy the hobby of painting small objects such as model planes or
soldiers.

29 | P a g e
Art:
Paintings are pictures that are done in paint. Many different types of paint are used for
paintings. They include tempera, oil paint, gouache, water colors and acrylic paints. The
paintings are usually done on board, canvas or paper. Many other famous paintings are
done on the walls and ceilings of buildings, such as the Sistine Chapel ceiling which was
painted by Michelangelo. Many artists are famous for their painted pictures. Old, beautiful
and famous paintings are very valuable and are sometimes sold for millions of dollars.
Famous painters include Giotto Leonardo da Vinci, Titian and Rembrandt.

Information:
Paint is a very good way to give important information to people, using painted signs.
Painted signs include lane markings on the road, street signs of all sorts, advertising signs
and warning signs.

30 | P a g e
3. EQUIPMENTS HEALTH CARD

HEALTH CARD

EQUIPMENT NAME:
TAG NO.:
USED
TYPE of DESCRIPTION of THE
DATE SPARE REMARKS
BREAKDOWN WORK
DETAILS

31 | P a g e
4. FACTORY FLOW CHART

MATERIAL RECEIVED

UNLOADING MATERIAL
AT UNLOAD AREA

STORE MATERIAL AT RM STORE

WATER SENT TO ETP

RECEIPT BATCH SHEET FROM
PRODUCTION

ISSUE MATERIAL TO PRODUCTION

TREATED
SLUDGE
WATER

PRODUCTION OF PAINT

NO

IS IT OK IN
QC CHECK?

YES

PACKAGING

PACKED GOODS SEND TO

FG
STORAGE

FACTORY PROCESS FLOW CHART OF ASIAN PAINTS

32 | P a g e
5. COMMISSIONING of NEW PUG MILL 4
Location: Distemper Block
Floor#2
Date: 2/06/2018
Product: ACRYLIC WHITE PUTTY MIX

5.1. TIME & ELECTRICITY FLOW RATE DATABASE

CONDITION TIME AMPERE AMPERE2 AMPERE3 AMPERE4 AMPERE5 AMPERE6
MOTOR 1 MOTOR 1 MOTOR 1 MOTOR 2 MOTOR 2 MOTOR 2
R Y B R Y B
START 11.53 AM 18.28 16.44 17.5 15.82 19.72 17.36
RUNNING 12.08 PM 18.07 16.03 17.54 15.94 19.47 17.36
STOP 12.17 PM 0 0 0 0 0 0
START 12.18 PM 6.048 5.28 5.976 5.184 6.744 5.556
STOP 12.24 PM 0 0 0 0 0 0
START 12.26 PM 17.91 16.08 18.09 15.87 19.23 17.82
STOP 12.33 PM 0 0 0 0 0 0
START 12.36 PM 16.84 14.89 17.07 14.8 18.12 16.93
RUNNING 12.51 PM 16.96 14.61 16.41 15.19 17.89 16.56
STOP 12.51 PM 0 0 0 0 0 0
START 12.52 PM 17.05 14.65 16.82 15.27 17.61 16.38
RUNNING 1.07 PM 16.84 14.65 16.74 14.89 17.82 16.52
STOP 1.09 PM 0 0 0 0 0 0
START 1.10 PM 17.18 14.11 16.65 15.24 17.32 16.58
STOP 1.14 PM 0 0 0 0 0 0
START 1.18 PM 16.81 14 16.69 14.76 17.17 16.56
RUNNING 1.33 PM 17.22 14.48 16.81 15.12 17.71 16.62
STOP 1.43 PM 0 0 0 0 0 0
START 1.47 PM 18.03 17.18 17.32 15.86 20.58 16.95
RUNNING 2.02 PM 18.62 17.02 17.73 16.33 20.35 17.42
RUNNING 2.17 PM 18.68 17.1 17.33 16.58 20.68 17.55
RUNNING 2.32 PM 18.32 17.25 17.76 16.12 20.6 17.44
RUNNING 2.47 PM 18.73 16.75 18.34 16.45 20.07 18.09
RUNNING 3.02 PM 20.08 17.78 19.26 17.72 21.78 19.35
RUNNING 3.17 PM 20.56 18.28 28.59 18.14 22.05 19.63
RUNNING 3.32 PM 23.89 22.89 22.82 19.72 25.57 22.17
RUNNING 3.47 PM 23.54 21.52 22.52 20.14 26.16 22.75
RUNNING 4.02 PM 23.19 21.04 22.02 19.52 24.93 21.93
RUNNING 4.17 PM 22.69 22.52 21.6 19.56 24.99 21.8
STOP 4.24 PM 0 0 0 0 0 0
START 4.25 PM 22.74 21.15 22.06 18.94 24.58 21.36
RUNNING 4.40 PM 21.08 20.49 20.96 18.16 24.31 20.77
STOP 4.46 PM 0 0 0 0 0 0
START 4.47 PM 23.88 28.03 21.98 19.47 23.54 21.33
STOP 4.53 PM 0 0 0 0 0 0
START 5.07 PM 23.28 21.12 21.93 19.75 25.33 21.85
STOP 5.08 PM 0 0 0 0 0 0
START 5.30 PM 20.41 18.48 19.35 17.71 21.85 18.94
STOP 5.39 PM 0 0 0 0 0 0
START 5.40 PM 20.73 19.23 19.84 18.22 22.86 19.88
STOP 5.46 PM 0 0 0 0 0 0

TOTAL 4 H 59 Min 537.66 493.05 527.71 466.47 579.03 513.46

AVERAGE 13.11 12.03 12.87 11.38 14.12 12.52

33 | P a g e
5.2 POWER CONSUMPTION
TIME MAGNITUDE UNIT
11.53 AM 4996.9 KWH
5.50 PM 5119.5 KWH
TOTAL 122.6 KWH

TOTAL COST 122.6*8.2 TK

1005.32 TK

5.3 VOLUME MEASUREMENT of NEW PUG MILL 4

Figure: Schematic of Half of the PUG MILL 4 (Measurements are in cm)

34 | P a g e
We know,
Volume of a cylinder = π𝑟 2 ℎ
= 𝜋 ∗ (51.125)2 ∗ 204.5 𝑐𝑚3
= 1.679𝐸6 𝑐𝑚3
Convert cm3 into KL:
1 𝐾𝐿 = 1000000 𝑐𝑚3
1 𝑐𝑚3 = 1.0𝐸 − 6 𝐾𝐿
1.679𝐸 − 6 𝑐𝑚3 = 1.679 𝐾𝐿
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟 = 2
𝑇𝑜𝑡𝑎𝑙 𝑉𝑜𝑙𝑢𝑚𝑒 = 1.679 ∗ 2 𝐾𝐿
= 3.358 𝐾𝐿

5.4 SOLUTION of MOTOR BELT NOT RUNNING

Date: 03-06-2018
M/C name: New Hopper 5
Problem type: Belt not moving

Problem effect: Wall Putty Mix was not being Dispersed into Packaging tank via Hopper
because the motor was running but the power was not transmitting. The pulley was
rotating but the belt was not moving.

Solution:
Timing belt pulleys are very much suitable for machine tool drive system. It has very less
chance of slip. The gripping is very effective in this timing belt pulley arrangement. So, using
a Timing belt pulley drive system is a permanent & preventive solution. The mechanical
efficiency is very high (about 98%) & can absorb vibrations. There is no extra cost of
lubrication. It is also very economic.

35 | P a g e
 Figure: Timing Belt & Pulley

36 | P a g e
6. DATABASE of EQUIPMENTS
Equipment Name Capacity
Equipment Number Location/ Area
KL
Twin Shaft Disperser TSD-1 2 WB process floor
Twin Shaft Disperser TSD-2 2 WB process floor
Twin Shaft Disperser TSD-3 2 WB process floor
Twin Shaft Disperser TSD-4 2 WB process floor
Twin Shaft Disperser TSD-5 2 WB process floor
Twin Shaft Disperser TSD-6 2 WB process floor
Twin Shaft Disperser TSD-7 4 WB process floor
Twin Shaft Disperser TSD-8 4 WB process floor
Twin Shaft Disperser TSD-9 4 WB process floor
Twin Shaft Disperser TSD-10 4 WB process floor
Twin Shaft Disperser TSD-12 2 SB process floor
PUGMILL PGM-1 3.5 WB process floor
PUGMILL PGM-2 3.5 Distemper Block
PUGMILL PGM-3 3.5 Distemper Block
PUGMILL PGM-4 3.5 Distemper Block
High speed disperser HSD-1 0.36 SB process floor
High speed disperser HSD-2 0.36 SB process floor
High speed disperser HSD-3 0.4 WB process floor
High speed disperser HSD-4 0.413333333 SB process floor
High speed disperser HSD-5 0.433333333 SB process floor
High speed disperser HSD-6 0.453333333 WB process floor
High speed disperser HSD-7 0.473333333 SB process floor
High speed disperser HSD-8 0.493333333 SB process floor
High speed disperser HSD-9 0.513333333 WB process floor
High speed disperser HSD-10 0.533333333 SB process floor
High speed disperser HSD-11 0.553333333 SB process floor
High speed disperser HSD-12 0.573333333 WB process floor
High speed disperser HSD-13 0.593333333 SB process floor
High speed disperser HSD-14 0.613333333 SB process floor
High speed disperser HSD-15 0.633333333 WB process floor
High speed disperser HSD-16 0.653333333 SB process floor
High speed disperser HSD-17 0.673333333 SB process floor
High speed disperser HSD-18 0.693333333 WB process floor
High speed disperser HSD-19 0.713333333 SB process floor
High speed disperser HSD-20 0.733333333 SB process floor
High speed disperser HSD-21 0.753333333 WB process floor
High speed disperser HSD-22 0.773333333 SB process floor
High speed disperser HSD-23 0.793333333 SB process floor
High speed disperser HSD-24 0.813333333 WB process floor
High speed disperser HSD-25 0.833333333 SB process floor
High speed disperser HSD-26 0.853333333 SB process floor
High speed disperser HSD-27 0.873333333 WB process floor
High speed disperser HSD-28 0.893333333 SB process floor
High speed disperser HSD-29 0.913333333 SB process floor
High speed disperser HSD-30 0.933333333 WB process floor
High speed disperser HSD-31 0.953333333 SB process floor
High speed disperser HSD-32 0.973333333 SB process floor
High speed disperser HSD-33 0.993333333 WB process floor

37 | P a g e
 MIXER M28 4 WB process floor
MIXER M29 2 WB process floor
OPIGEAR OPR-1 0.2 SB process floor
OPIGEAR OPR-1 0.2 SB process floor
REACTOR RCT-1 3 Resin House
BLENDER BLD-1 6 Resin House
Thermopack TMP-1 2 Luc K.Kal Resin House
Therm oil Circulationr pump TOTP-01 10 m3/hr Resin House
Therm oil Circulationr pump TOTP-02 10 m3/hr Resin House
Resin transfer pump RTP-01 10 m3/hr Resin House
Resin transfer pump RTP-02 10 m3/hr Resin House
Resin transfer pump RTP-03 10 m3/hr Tank farm area
Resin transfer pump RTP-04 10 m3/hr Tank farm area
Resin transfer pump RTP-05 12 m3/hr SB process floor
Soya oil transfer pump SOTP-01 12 m3/hr Tank farm area
Soya oil transfer pump SOTP-02 12 m3/hr Tank farm area
MTT transfer pump MTP-01 12 m3/hr Tank farm area
MTT transfer pump MTP-02 12 m3/hr Tank farm area
Xylene transfer pump XTP-01 12 m3/hr Tank farm area
Deisel transfer pump DTP-02 12 m3/hr Tank farm area
Electrical weighmetric emulsion Packing Machine
EPM-1 3.64 WB packing floor
Pneumatic volumetric emulsion Packing Machine EPM-2 3.64 WB packing floor
Electrical weighmetric emulsion Packing Machine
EPM-3 18 WB packing floor
Electrical weighmetric emulsion Packing Machine
EPM-4 18 WB packing floor
Augor electrical weighmetric distemper Packing Machine
DPM-1 3.6 WB packing floor
Augor electrical weighmetric distemper Packing Machine
DPM-2 3.6 WB packing floor
Augor electrical weighmetric distemper Packing Machine
DPM-3 18 WB packing floor
Augor electrical weighmetric distemper Packing Machine
DPM-4 18 WB packing floor
Pneumatic volumetric Enamel/primer Packing Machine
SPM-1 3.64 SB packing floor
Pneumatic volumetric Enamel/primer Packing Machine
SPM-2 3.64 SB packing floor
Pneumatic volumetric Enamel/primer Packing Machine
SPM-3 3.64 SB packing floor
Manual enamel/ primer packing machine Unitech-1 18 SB packing floor
Pneumatic volumetric Enamel/primer Packing Machine
SPM-4 3.64 SB packing floor
Hand lifting plate truck PK-1 2300 PAKING FLOOR
Hand lifting plate truck PR-1 2300 PROCESS FLOOR
Hand lifting plate truck RM-1 2300 RMG FLOOR
Hand lifting plate truck FG-1 2300 FG FLOOR
Hand lifting plate truck PR-2 2300 RMG FLOOR
Hand lifting plate truck RM-2 2300 RMG FLOOR
Hand lifting plate truck FG-2 2300 FG FLOOR
Hand lifting plate truck PR-3 2300 RMG FLOOR
Hand lifting plate truck FG-3 2300 FG FLOOR
Hand lifting plate truck RM-3 2300 RMG FLOOR
Hand lifting plate truck PR-4 2300 PROCESS FLOOR
Hand lifting plate truck FG-4 2300 FG FLOOR
Hand lifting plate truck PR-5 2300 PROCESS FLOOR
Hand lifting plate truck RM-04 2300 RMG FLOOR
Hand lifting plate truck RM-05 2300 RMG FLOOR
Hand lifting plate truck PK-02 2300 PAKING FLOOR
Hand lifting stacker RM-01 1200 RMG FLOOR

38 | P a g e
 Hand lifting stacker RM-02 1500 RMG FLOOR
Hand lifting stacker PR-01 1500 PROCESS FLOOR
Hand lifting stacker SB-1 1200 SB FLOOR
Hand lifting stacker FG-2 1500 FG FLOOR
Battery lifting stacker BOPT-1 1600 FG FLOOR
Battery lifting stacker BOPT-2 1600 FG FLOOR
Primary Effluent Transfer Pump PETP-01 10 m3/hr ETP
Secondary Effluent Transfer Pump SETP-01 4 m3/hr ETP
Secondary Effluent Transfer Pump SETP-02 4 m3/hr ETP
Treated water transfer pump TWTP-01 ETP
Treated water transfer pump TWTP-02 ETP
Bio sludge transfer pump BSTP-01 4 m3/hr ETP
Bio sludge transfer pump BSTP-02 4 m3/hr ETP
Clarifier water transfer pump CWTP-01 ETP
Clarifier water transfer pump CWTP-02 ETP
Sludge transfer pump STP-1 ETP
Sludge transfer pump STP-2 ETP
Blower Pump BP-01 2m3/Min ETP
Blower Pump BP-02 2m3/Min ETP
Blower Pump BP-03 4m3/Min ETP
Sludge filter press Filter press ETP
Induced draft fan IDF Incinerator House
Ejector Fan EJF-01 Incinerator House
Ejector Fan EJF-02 Incinerator House
Venturi pump VP Incinerator House
Packed bed pump PBP Incinerator House
Combustion Air Fan CF Incinerator House
Contineous Environmental monitoring system CEMS Incinerator House
Air operated Diaphragm pump for SB paint transfer
DPP-1 2 SB packing floor
Air operated Diaphragm pump for WB paint transferDPP-2 2 WB packing floor
Air operated Diaphragm pump for WB paint transferDPP-3 2 WB packing floor
Air operated Diaphragm pump for WB paint transferDPP-4 2 WB packing floor
Air operated Diaphragm pump for WB paint transferDPP-5 3 WB packing floor
Air operated Diaphragm pump for WB paint transferDPP-6 3 WB packing floor
operated Diaphragm pump for Emulsion transfer fromDPP-7
FRP tank 1.5 ET1
operated Diaphragm pump for Emulsion transfer fromDPP-8
FRP tank 1.5 ET2
operated Diaphragm pump for Emulsion unloading inDPP-9FRP tank 2 Emulsion unloading Bay
operated Diaphragm pump for Emulsion unloading inDPP-10
FRP tank 2 Emulsion unloading Bay
operated Diaphragm pump for Emulsion transfer from DPP-11
FRP tank 1.5 ET5
Air operated diaphragm pump for filter press DPP-12 2 ETP
ELGI Screw air compessor AC-01 5.92 m3/min Compessor room in SB packing floor
ELGI Screw air compessor AC-02 4.2m3/min Compessor room in SB packing floor
Fire hydrant & jocky pump FHP-01 35m3/ Hr Pump House
Raw water pump RWP-01 10m3/ Hr Water Softening Unit
Raw water pump RWP-02 10m3/ Hr Water Softening Unit
Soft water pump SWP-01 10m3/ Hr Water Softening Unit
Soft water pump SWP-02 10m3/ Hr Water Softening Unit
Soft water pump SWP-03 10m3/ Hr Water Softening Unit
Soft water pump SWP-04 10m3/ Hr Water Softening Unit
Cooling tower pump for production CTPP-01 40m3/ Hr Cooling tower (West side of expansion paint house)

39 | P a g e
 Cooling tower pump for production CTPP-02 40m3/ Hr Cooling tower (West side of expansion paint house)
Cooling tower pump for resin plant CTPR-01 50m3/ Hr Cooling tower (South side of resin house)
Cooling tower pump for resin plant CTPR-02 50m3/ Hr Cooling tower (South side of resin house)
Disel generator for paint house DG-01 560 KW Sub station
Disel generator for paint house DG-02 500 KW Sub station
Disel generator for resin house DG-03 160 KW South side of resin house
Disel generator for emergency lighting DG-04 15 KW West side of worker wash room.
Cargo lift for goods Lift-01 2.5 MT (Ground to 2nd Floor) Expansion Paint block
Cargo lift for goods Lift-02 2.5 MT (Ground to 1st Floor) Expansion RMG
Disel operated froklift FRL-01 2 MT Factory outside
Pressure Booster Pump BP-1 25m3/Hr Roof or worker amenity
Pressure Booster Pump BP-2 25m3/Hr Roof or worker amenity
Pressure Booster Pump BP-3 25m3/Hr Roof or worker amenity
Process water purifiers in Ultra violet ray treatment
UVT-01 Paint house ground floor
Process water purifiers in Ultra violet ray treatment
UVT-02 Paint house ground floor
Process water purifiers in Ultra violet ray treatment
UVT-03 Paint house 1st floor
Chiller for busket ball mill Chiller-01 10 TR Expansion paint block 2nd floor
Chiller for Producton ball mill Chiller-02 11 TR Expansion paint block 2nd floor
Chiller for Producton ball mill Chiller-03 12 TR Expansion paint block 2nd floor
Submersible pump for factory SP-01 30m3/Hr Pump house area
Submersible pump for factory SP-02 30m3/Hr Resin house area
Submersible pump for factory SP-03 30m3/Hr ETP area
Transformer TRF1 1250 KVA Substation area (Gate-02)
Solar Unit-1 Solar-01 3.2 KWP Roof of administration Building
Solar Unit-2 Solar-02 3.2 KWP Roof of administration Building
Power Control centre-1 PCC-1 MCC room in Paint house
Power Control centre-2 PCC-22 MCC room in Paint house
Power Factor Controll-2 APFC-1 MCC room in Paint house
Motor Control centre MCC-1 MCC room in Paint house-SB
Motor Control centre MCC-2 MCC room in Paint house-SB
Motor Control centre MCC-1 MCC room in Paint house-SB
Motor Control centre MCC-2 MCC room in resin house
Motor Control centre MCC-3 MCC room in resin house
Dust Collector DC1 WB process floor
Dust Collector DC2 WB process floor
Dust Collector DC3 WB process floor
Jet pump JP1 WB process floor
Jet pump JP2 WB process floor
FRP Emulsion tank ET-1 50 Out side(west) of paint house
FRP Emulsion tank ET-2 50 Out side(west) of paint house
FRP Emulsion tank ET-3 50 Out side(west) of paint house
FRP Emulsion tank ET-4 50 Out side(west) of paint house
FRP Emulsion tank ET-5 30 Out side(South) of paint house
FRP Emulsion tank ET-6 30 Out side(South) of paint house
FRP Emulsion tank ET-7 30 Out side(South) of paint house
FRP Emulsion tank ET-8 30 Out side(South) of paint house
Batching Vessel BV-1 0.5 Expansion paint house 2nd floor
Batching Vessel BV-2 0.5 Expansion paint house 2nd floor
Batching Vessel BV-3 2 Expansion paint house 2nd floor
Mechanical balance WMB-01 500 WB process floor

40 | P a g e
 Mechanical balance SMB-02 500 SB process floor
Digital Electric Balance RDB-03 60 RMG first floor
Digital Electric Balance RDB-04 30 RMG first floor
Digital Electric Balance WDB-05 60 WB packing floor
Digital Electric Balance WDB-06 30 WB packing floor
Digital Electric Balance SDB-07 25 SB packing floor
Digital Electric Balance DDB-08 150 DCP house
Digital Electric Balance RPDB-09 200 Resin plant
Digital Electrical Flow meter RFM-01 Resin Plant
Digital Electrical Flow meter SBFM-02 SB process floor
Digital Electrical Flow meter WBFM-03 WB process floor
Digital Electrical Flow meter WBFM-04 WB process floor
Digital Electrical Flow meter WBFM-05 WB process floor
Digital Electrical Flow meter ETPFM-06 ETP
Digital Electric Load cell LC-19 13 WB process floor
Digital Electric Load cell LC-20 13 WB process floor
Digital Electric Load cell LC-21 13 WB process floor
Digital Electric Load cell LC-22 13 WB process floor
Digital Electric Load cell LC-23 13 WB process floor
Digital Electric Load cell LC-24 13 WB process floor
Digital Electric Load cell LC-25 8.5 WB process floor
Digital Electric Load cell LC-26 8.5 WB process floor
Digital Electric Load cell LC-27 8.5 WB process floor
Digital Electric Load cell LC-28 8.5 WB process floor
Digital Electric Load cell LC-29 4 WB process floor

7. RECOMMENDATIONS
➢ Vacuum cleaner can be used to keep the inventory are & production floor dust free.
➢ A notable amount of waste is occurred during charging the raw materials into the
TSD. The sacks of raw materials should be charged vertically not horizontally.
➢ Safety goggles should be used in the production floor because the volatile
chemicals may affect the eyes of the employees.
➢ The operators required more training especially the maintenance.
➢ The proper method of demand forecasting can reduce a notable inventory cost as
well as scrap.

41 | P a g e
8. CONCLUSION & DISCUSSIONS
Asian Paints Bangladesh Ltd. has helped a lot to achieve a depth practical knowledge about
Paints production system, Machineries, Maintenance, Factory layout, Organizational rules,
Management system, Water treatment etc.
Asian Paints Bangladesh Ltd. has:
▪ Excellent Operations Management
▪ High technology in Paints manufacturing
▪ Skilled Chemists
▪ Effective Managers
▪ Proper discipline
▪ Concentration towards Employee satisfaction
▪ Sufficient Vendors & Dealers
▪ Extra facilities
▪ Reasonable working hour
▪ Sophisticated Machineries
▪ Zero tolerance at Quality Control

The learning & observation are beyond satisfaction.

9. REFERENCES
[1] https://www.asianpaints.com.bd/
[2] All Officers & Managers in Asian Paints Bangladesh Ltd.

42 | P a g e