INDUSTRIAL TRAINING REPORT

ALUMINIUM PRODUCTION, BALCO

Degree of Bachelor of Engineering in Mechanical Engineering

SUBMITTED TO:

DEPARTMENT OF MECHANICAL ENGINEERING

GOVERNMENT ENGINEERING COLLEGE JAGDALPUR
SUBMITTED BY:

SNO NAME OF STUDENT UNIVERSITY ROLL NO

01 Ayushi Jha 3083715004
02 Chandrika Baghel 3083715005
03 Karishma Dhruw 3083715012
04 Harshita Manjhi 3083715008
05 Tameshwari Dhiwar 3083715029
06 Gulshan Chandra 3083715007
07 Sudhir Thakur 3083715028
BHARAT ALUMINIUM COMPANY LIMITED

REPORT ON
VOCATIONAL TRAINING
 ACKNOWLEDGEMENT

It’s our privilege to acknowledgement all the technical and non-technical staffs
who helped us and gave their moral support to make us understand and complete
vocational training.
We express sincere gratitude to
KAPIL MALHOTRA
(Head of learning Dept.)

Ayushi Jha

Chandrika Baghel

Harshita Manjhi

Karishma Dhruw

Tameshwari Dhiwar

Gulshan Chandra

Sudhir Thakur
 CONTENTS
1. Introduction of BALCO, KORBA
 About BALCO, Korba
 History
2. Operations at BALCO
 Technology overview
 Mining
 Smelting
 Fabrication
 Aluminium production technology
 Power
3. Products & Sales
 Primary products
 Secondary products

4. Major roles:
5. Conclusion
6. Reference
 Introduction

BALCO
Bharat Aluminium Company Ltd. (BALCO) is an Indian aluminium company.
BALCO was incorporated in the year 1965 as a Public Sector Undertaking
(PSU) and it was the public sector until 2001, when it was taken over
by Vedanta Resources, a company listed on the London Stock Exchange. The
Company has been closely associated with the Indian Aluminium Industry, in a
pivotal role.

History
It was incorporated in 1965 as a Public Sector Undertaking.[1] It is the
first public sector enterprise in India which started producing aluminium in
1974. Till 2001, BALCO was a public sector enterprise owned 100%
by Government of India. In 2001, GoI divested 51% equity and management
control in favour of Sterlite Industries India Limited. There's a little history
behind the privatisation of the company that was not doing so well being a
public sector company. There were groups formed among people or rather
BALCO employees namely supporters of privatisation and the ones who
opposed it. Rallies and processions were carried out in the evenings to oppose
the privatisation and those who supported it were left in minority. Eventually,
things happened as they were planned and the company was listed under Sterlite
BALCO KORBA, CHHATTISHGARH
HIGHLIGHTS
 Government of India (GoI) divested 51% equity in the year 2001 in favour of Sterlite
Industries (I) Limited. Remaining 49% is with GoI.
 Superior Quality and Craftsmanship
 BALCO is playing a crucial role in introducing Aluminium as a potential alternative
to other metals like Steel in construction, and Copper in power transmission industry.
 Major operations of BALCO are in the town of Korba (Chhattisgarh), whereas its
mines supplying high grade Bauxite are situated at Kawardha and Mainpat.
 The smelter capacity (installed capacity 100 KTPA), based on Soderberg Process, is
being revamped to produce 345 KTPA through modern Prebake Technology.
 After disinvestment, a smelter of capacity 245 KTPA has been established in the year
2004.
 The smelter plants are being supported by uninterrupted power supply through
Captive Power Plants - 270 MW at Jamnipali, Korba and 540 MW at smelter site.
 New power plant with rated capacity of 1200 MW - Two units are in operation and
rest two units will commence production by the last quarter of FY15-16.
 Finishing lines are capable of producing high quality Ingots, Wire Rods, Billets,
Busbars and Rolled products.

SEVERAL FIRSTS TO ITS CREDIT IN INDIA

 First integrated Aluminium Industry

 First to have Captive Power Plant

 First to venture into + 300 kA Prebake pots

 First to produce Alloy Rods for conductors used in power transmission industry

 First to roll material for Aerospace in the Country

 First to produce largest Billet of diameter – 800 mm, length - 6 mt

 First to set up the widest Hot Rolling Mill

OPERATIONS AT BALCO

MINING

BALCO has two captive Bauxite mines in Chhattisgarh state - one at Mainpat with
capacity 7,50,000 TPA & another at Bodai Daldali(Kawardha) with capacity of 12,50,000
TPA and a Coal mine at Chotia with capacity of 1 MTPA.

Both the Bauxite mines are situated at an elevated plateau; the area is flat and covered
with soil/lateritic boulders. The Bauxite ore is available as pocket deposit with 1.5 metre
average thickness and is normally available below 3 - 5 metres from ground level.
Chotia Coal mine located in Hasdeo Arand coal field in the state of Chhattisgarh, was
originally allocated to M/s Prakash Industries Limited (PIL) in the year 2003. BALCO has
participated in the e-auction conducted by the Nominated Authority, Ministry of Coal and
on winning the bid, Chotia Coal mine has been vested with BALCO vide vesting order no.
104/11/2015/NA dated 23 rd March 2015.

Chotia Coal Mine consists of two sub-blocks namely Chotia I and Chotia II.

OPERATIONAL EXCELLENCE
 Mining Method - Mechanised Opencast Mining.

 Top Soil - Reused for backfilling and to retain fertility of land.

 Equipment Deployed - Drill, Excavator, Dumper, Dozer and Water Sprinkler.

 Coal Cutting - By Excavator.

 Reclamation - Mining and backfilling executed concurrently.

 Reclaimed area is afforested to cover the exposed land with greenery.

 Original topography is retained.

 Afforestation - Plantation of manifold local species has increased the green density in

the surrounding landscape.

 Environment Conservation – Pre-defined and systematic design of Garland Drains,

Check Dams, Parapet Walls, development of Green Belt etc.

 Wildlife Conservation in association with State Government.

 Zero accident record since the start of mine by Balco.

 All mining activities and pollution prevention mitigation measures undertaken as per the

stipulated guidelines of various governing agencies.

RESETTLEMENT & REHABILITATION OF MINES DISPLACED FAMILIES

SMELTING
BALCO has its operations at Korba in the state of Chhattisgarh with a smelter capacity of
570 ktpa with capabilities to produce ingots, Alloy ingots, wire-rods, busbars and rolled
products.
The Hall - Heroult process is the method by which Aluminium is produced industrially. The

steps involved in the process are-

 The process involves electrolytic reduction of Alumina (Al2O3) dissolved in electrolyte

(bath) mainly containing Cryolite (Na3AlF6).

 The mixture electrolysed causing the Oxygen ion of the dissolved Alumina to discharge

on positive electrode where it reacts with Carbon anode to form gases like CO2 and

CO.

 The Al3+ ion deposited at the negatively charged cathode converts into liquid metal

which sinks to the top of cathode from where it is periodically collected and sent to

casthouse or fabrication for further processing.

 Electrical resistance within the bath provides sufficient heat to keep the Cryolite molten.

 The pot is thermally insulated from side and bottom to maintain the optimum heat

balance and sufficient ledge (frozen electrolyte) on the side of the shell.

 A crust of bath and Alumina covers the anode to avoid anode oxidation.

SALIENT FEATURES OF BALCO POTLINE- 1

 BALCO, Potline -1 works on Prebaked technology

 A total of 288 electrolytic cells are installed with potline-1 current of 320 kA

 All 288 pots are connected in a series circuit

 The name plate capacity of potline-1 is 245 ktpa

SALIENT FEATURES OF BALCO POTLINE-2

 BALCO, Potline -2 works on Prebaked technology

 A total of 336 electrolytic cells are installed with potline-2 current of 340 kA

 All 336 pots are connected in a series circuit

 The name plate capacity of potline-2 is 325 ktpa

FABRICATION

To stay ahead of competition BALCO has always adopted state-of-the-art technology in its

processes. Catering to the needs of Defence and Space Research since 1980, the Company

has firmly established itself as a front-runner among the producers of Aluminium sheets and

plates.

The molten metal (Aluminium) is fabricated into saleable products by adapting different

processes. Fabrication SBU is broadly divided in three units operating as separate profit

centres – Cast House, Foundry and Sheet Rolling Shop. Each has been discussed in detail

below.

CAST HOUSE

In Cast House continuous Casting and Rolling process is adopted in which hot metal, after
being continuously cast as Cast Bars is rolled to Wire Rods. The different stages involved are
discussed as follows –

 In Cast House, hot metal is taken into holding furnaces, where it is degassed, fluxed,
alloyed & prepared.
 Subsequently, hot metal is solidified in the shape of bar in properzi casting machine,
which then is passed through multi stage stands rolling mill thus obtaining a 9.5 mm
diameter rod . BALCO also produces 12 mm Rod on demand.
 Coil of 2 – 2.5 m is dispatched to the downstream customers, and converted to
conductor/cables. These conductors are used for over-head electricity transmission.
Electrical Conductor (EC) grade Commercial Grade (CG) and Alloy Grade Wire Rods
are manufactured in the Cast House.
FOUNDRY SHOP

Foundry Shop is designed to handle 1, 45, 000 MT hot metal per year from Smelter Process.
Scrap generated in the plant is reprocessed at the Foundry.

 Hot metal received from smelter is alloyed as per the chemical composition of the alloy with
required alloying elements.
 Metal that is chemically ready, is treated in the melting and holding furnace and
subsequently slabs and caster coils are made with controlled cooling which gives it the
required shape.

Further, alloying elements are also added to produce dif ferent alloys as given below:

Alloy Series Composition

1XXX Pure Aluminium

2XXX Al-Cu

3XXX Al-Mn

4XXX Al-Si

5XXX Al- Mg

6XXX Al-Mg-Si

7XXX Al-Zn

8XXX All other Alloys

SHEET ROLLING SHOP

In Sheet Rolling Shop, slabs and caster coils are processed as semi -finished products for
further rolling into sheets, coils and plates. The steps involved are outlined below –

 In Sheet Rolling Shop, slabs are pre-heated and rolled in hot rolling mill to produce hot
rolled coils.
  These hot rolled coils are subsequently cold rolled and the coils are then slit /cut to the
required size.
 Caster coils are directly rolled into the cold rolled coils, that is again slit /cut through
slitting/cut-up lines.

ALUMINIUM PRODUCTION TECHNOLOGY

The Hall- Heroult process is an example of Aluminium smelting process and is used industrially.
Aluminium cannot be produced by an aqueous electrolytic process because hydrogen is
electrochemically much nobler than aluminium. Thus, liquid aluminium is produced by the electrolytic
reduction of alumina (Al2 O3) dissolved in an electrolyte (bath) mainly containing Cryolite (Na3AlF6).
The overall chemical reaction can be written as:

2 Al2O3 (dissolved) +3C (s) = 4 Al (l) +3 CO2 (g)

 Aluminium is formed at about 900°C, but once formed has a melting point of only 660°C. In some
smelters this spare heat is used to melt recycled metal, which is then blended with the new metal.
Recycled metal requires only 5 percent of the energy required to make new metal. Blending recycled
metal with new metal allows considerable energy savings, as well as the efficient use of the extra heat
available. When it comes to quality, there is no difference between primary metal and recycled metal.

The smelting process required to produce aluminium from the alumina is continuous, the potline is
usually kept in production for 24 hours a day year around. A smelter cannot be easily stopped and
restarted. If production is interrupted by a power supply failure of more than four hours, the metal in
the pots will solidify, often requiring an expensive rebuilding process.

There are two basic technology- Prebaked Technology and Soderberg Technology. In prebaked
technology the anodes used are termed as prebaked anodes which are made from a mixture of petroleum
coke, aggregate and coal tar pitch binder moulded into blocks and baked in separate anode baking
furnace at about 1120 °C. An aluminium rod with iron studs is then cast or rammed into grooves in the
top of the anode block in order to support the anode and conduct the electric current to the anode when
it has been positioned in the cell.

Prebaked anodes have to be removed at regular intervals, when they have reacted down to one third or
one fourth of their original size. These remaining anodes are termed as butts and are usually cleaned
outside the cell in a separate cleaning station to be able to recirculate the adhering bath materials
removed from the cell. The cleaned butts are then crushed and used as a raw material in the
manufacturing of new anodes. A typical prebaked cell is shown below
 RAW MATERIAL FOR ALUMINIUM PRODUCTION
The major raw material required for aluminium production is alumina, carbon, power, aluminium fluoride and
cryolite.
GAMI Specification Raw Alumina Carbon Cryolite Aluminium Energy
Material Fluoride
Theoretical Consumption 1930 415 2 20 13460 KWH/t-Al
(Kg per Ton of Aluminium)
To produce 1 kg of aluminium the following amounts of raw materials are needed:

Process of aluminium reduction:

POWER
Aluminium is a power intensive industry. The electrolysis process used to produce Aluminium
requires large quantities of electrical power, cost of which is almost one-third of the total cost
involved in production of Aluminium. The Direct Current (DC) required depends on the total
number of cells or pots installed and the potline current involved. For meeting this huge power
requirement most Aluminium smelters are equipped with their own Captive Power Plants.

CAPTIVE POWER PLANT 1

 Capacity: 1200 MW (CPP -2 X 300MW & IPP - 2 X 300 MW)
 Location: Balco Plant, Korba
 Source of Coal: Gevra, Kusmunda & Manikpur Mines of South Eastern Coalfields Ltd.
(SECL) in Korba.
 Source of Water: Hasdeo River
 Operation & Maintenance: BALCO's own operation

SALIENT FEATURES
 Primary Fuel : Thermal Coal
 Startup Fuel : LDO, Burning Oil & HFO
 Pulverizing System : Primary air system medium speed mill
 Water Source - DM water
 Steam turbine : Subcritical pressure, single reheating type, single-shaft, two cylinders,
condensing steam turbine

CAPTIVE POWER PLANT 2

 Capacity: 540 MW (4 X 135 MW)
 Location: BALCO Plant, Korba
 Source of Coal: Gevra & Kusmunda mines of South Eastern Coalfields Ltd (SECL) in
Korba.
 Source of Water: Hasdeo River
 Operation & Maintenance: BALCO’s own operation

SALIENT FEATURES
 Primary Fuel - Thermal Coal
 Start-up Fuel - LDO / HFO
 Pulverising System - Primary Air System with Vertical Roller Mills.
 Steam Turbine - Double cylinder, Impulse, Condensing and Nozzle & Throttle-governed
turbine
 Turbo Generator - Air Cooled, Direct Coupled Generator, Static Excitation
CAPTIVE POWER PLANT III

1200 MW comprises of 4units of 300 MW each in which 2 Units are IPP and 2 Units are CPP.

 Capacity: 1200 MW (4 X 300 MW)

 Location: BALCO Plant, Korba
 Source of Coal: Gevra & Kusmunda mines of South Eastern Coalfields Ltd (SECL) in
Korba.
 Source of Water: Hasdeo River
 Operation & Maintenance: BALCO's own operation
 Installation / O & M: Balco’s own operation from 01.05.2016 onwards.

SALIENT FEATURES
 Primary Fuel : Thermal Coal
 Startup Fuel : LDO, Burning Oil & HFO
 Pulverizing System : 5 Mills, ZGM133G Bowl Mill (4 Working + 1 Stand By)
 Water Source - DM water
 Steam turbine : Subcritical pressure, single reheating type, single-shaft, two cylinders,
condensing steam turbine.
 CAPACITY : 1200 MW
 RAW MATERIAL : Coal, Water, Oil
 TECHNOLOGY : Thermal Power Plant with Pulverized coal fired boiler.
 BOILER :
o Manufacturer - HARBIN BOILER CO. LTD.
o Type - Natural Circulation, Sub critical, Reheat, Drum type & Corner firing.
o Capacity - 1025 TPH (BMCR),Operating SH Pr. 17.39 Mpa.

 TURBINE :
o
o Manufacturer - DONG FANG TURBINE FACTORY LTD.
o Type - Sub Critical, Reheat, Single Shaft. Double cylinder & Condensing Steam
Turbine
o Capacity - 300 MW (normal); 3000 RPM

 GENERATOR :
o
o Manufacturer - DONG FANG ELECTRICAL MANUFACTURING CO. LTD
o Type - 2 Pole, synchronous generator at 20 KV and 10189 amps rated current with
hydrogen cooled rotor and water cooled stator.
o Capacity - 300 MW (normal)
PRODUCTS & SALES

INGOTS

Type
P1020 (LME Registered), EC Grade, CG Grade
Size of Ingots
740 mm x 170 mm x 114 mm
Weight of Ingots
22.7 ± 1.5 kgs each on an average
Size of Ingot stack
740 mm x 740 mm x 1026 mm
Weight of Ingot stack
Approx. 1000 kgs
LME Brands
‘ Bharatal ’
WIRE RODS-UTS & CONDUCTIVITY

EC Grade
Temper UTS (MPa) Conductivity (%)

O 59 - 97 61.8

H12 83 - 117 61.5

H14 103 - 138 61.4

H16 117 - 152 61.3

Alloy Grade
Temper UTS (MPa) Conductivity (%)

O 90 – 159 55.0

M 147 – 227 53.0

BILLETS

Diameter:16”,20”,24”,32”
Length range:1000mm-6000mm
Alloy:1xxx,2xxx,3xxx,4xxx,5xxx,6xxx,8xxx

HOT ROLLED COILS

Width in as rolled condition
Untrimmed
Range -
885 mm -1620 mm
Standard
890, 965, 1240, 1270, 1540, 1620 mm

Alloy
1xxx, 2xxx, 3xxx, 4xxx, 5xxx, 6xxx, 8xxx
Thickness
4.50 - 12 mm for alloys of AI, AI-Mn, AI-Si
6 - 8 mm for alloys of AI-Mg, AI-Mg-Si, AI-Cu-Mg
Arbour Diameter
750 mm without spool
Coil Density
2000 - 4500 kgs
Temper
M, F
Finish
Mill Finish

HOT ROLLED PLATES

Thickness
6-200 mm for 1xxx
10-200 mm for 3xxx, 4xxx
25-200 mm for 5xxx
8-20 mm for 2xxx, 6xxx (stretched)

Alloy
1xxx, 2xxx, 3xxx, 4xxx, 5xxx, 6xxx
Width Range
800-1540 mm
Standard (Trimmed)
915, 1220, 1400 and 1500 mm
Standard (Untrimmed)
1270, 1540 mm
Weight
Depends on dimensions
Temper
F / M, O, H1, H111, H112, T4, T6
Finish
Mill Finish
COLD ROLLED COILS & STRIPS

Thickness
Untrimmed -
0.25-6.0 mm

Trimmed -
0.12-2.0 mm

Arbour Diameter
Untrimmed -
750 mm with full weight coils
Trimmed -
200 mm (for all thickness)
500 mm (for thickness 0.4 mm & above)
Alloy
1xxx, 2xxx, 3xxx, 4xxx, 5xxx, 6xxx, 8xxx
Width in as rolled condition
Untrimmed -
Range :
800-1620 mm
Standard :
890, 965, 1000, 1015, 1270, 1460, 1540, 1620 mm
Trimmed -
Range :
100-1500 mm
Standard :
305, 610, 762, 915, 1000, 1009, 1220, 1321, 1500 mm
Coil Density
1.0-4.0 kgs / mm width
Coil Weight
Untrimmed -
1000-3000 kgs
Trimmed -
1000-2500 kgs
Part Coil -
250-350 kgs
Temper
M, O, H1, H2, H3, H4
(For coils of thickness 0.12 mm-2.0 mm in trimmed
condition with coil density of 1.0-2.0 kgs / mm width)
O, M
(for coil with untrimmed edges in heat-treatable alloys)
Finish
Mill Finish

COLD ROLLED SHEETS

Thickness
0.56-4.00 mm
(length & width for sheets having thickness of over 4.00 mm is subject to confirmation)

Alloy
1xxx, 2xxx, 3xxx, 4xxx, 5xxx, 6xxx, 8xxx
Width Range
800-1500 mm
Standard
915, 1000, 1159, 1220, 1300, 1321, 1500 mm
Length Range
1830-4350 mm
Standard
2440, 2540, 2745, 3000, 3050 mm
Weight
Depends on dimensions
Temper
O, H1, H2, H3, H4, T4, T6
Finish
Mill Finish
CHEQUERED SHEETS
Balcheq
Width Standard - 813, 915, 1220, 1500 mm
Length Range - 1830-4350 mm
Thickness 0.7-5 mm
Alloy Special, 3105
Temper M

Chequered 6061 Heat Treated

Width
Range - 800-1500 mm
Standard - 813, 880, 1500 mm
Length
Range - 1830-4000 mm
Standard - 2440, 3660 mm
Thickness
1.5-3.25 mm
Alloy
6061
Temper
W, WP, M
Finish
Mill Finish
Patterns
Star, Diamond
Baltread
Width
Standard - 813, 880, 915, 1220, 1550 mm
Length
Range - 2000-4000 mm
Alloy
Special, 3105
Temper
M
Thickness
1.0-3.25 mm
(More thickness can be supplied in coil form)
MAJOR ROLES:-
The major functions of the Quality Assurance, R&D and Technology Departments are:

1. Bauxite and Alumina process control

 >Control of Bauxite quality w.r.t. Tri-Hydrate Alumina (THA) and Reactive Silica
(RSiO2)
o In Process Control of Alumina production

 2. Process Control of Hot Metal Area -The Smelter

o Control on Bath and metal sampling

o Measurement of pot parameters like CVD, ACD, bath level, metal level, etc.
o Process Audit - Hood covering, flames in pot, Anode covering, variations in
process
 Parameters etc.
o Examination and analysis of failed pots
 >Control on pot relining

 3. Process Control of Finished Products in Finishing lines

o Control of Furnace and casting parameters in Cast House and Foundry

 >Inspection and clearance of intermediate / final product
o Process Audit

 Quality Assurance Laboratory

o Quality Control of incoming raw materials

o Analysis of in-process samples
 >Analysis and gradation of intermediate / final products

 Research and Development Department

o Recognised R&D Centre by Department of Scientific and Industrial research,

Govt. of India.
o Involved in process development, process improvement, product
development and product
 Improvements.

 Vendor development for raw materials

 Customer complaint handling and resolution of complaints by incorporation of

corrective
 And preventive actions.

 Customer development for the new products developed and product development as
per
 Customer need.
2.7 QUALITY ASSURANCE LABORATORY:-

Quality Assurance Laboratory being an ancillary of Pot Room, Carbon and Cast House, it gives
technically valid analytical results by following Good Laboratory Practices (GLP), proper
maintenance and housekeeping of laboratory infrastructure and adherence to safety standards to
ensure smooth process flow of the whole plant

Fig no.14 laboratory

Though the responsibilities of the department are widely spread, the routine responsibilities are as
follows:

1. Raw Material Control

Raw material pertaining to smelter, carbon and cast house is monitored and controlled through state-
of-art instruments like X-Ray Fluorescence Spectrometer, Atomic Absorption Spectrometer & UV
visible spectrometers.

2. Ensuring the Quality of the Finished Product

Primary Aluminium products (Ingot and Wire rods) and Rolled products are tested using modern
analytical equipment like Optical Emission Spectrometer, Tensile Testing Machine and Resistance
Measurement devices.
The QA is committed to get Lab Accreditation by complying ISO 17025:2005 requirements for
finished products in the field of Chemical, Electrical and mechanical testing from National
Accreditation Board for Testing & Calibration Laboratories, India
.
3. Finalising the Specification of Raw Material and Finished Products
QA Lab plays major role in finalising the specification of various raw materials used in Aluminium
industry based on the available resources, without affecting the product quality, which in turn reduces
the cost of production.
QA Lab develops the specification of various products, which meets the requirements of customers
based on their application and also as per the national and international standards.
4. Vendor Development and Evaluation of Vendor

QA lab plays a major role in developing alternate vendor for various raw materials as per the plant
requirements with lower cost. Evaluation and re-evaluation of vendors is also carried out to reduce the
variations within the suppliers for better optimisation of process and product.

5. Evolve and Implement QA Plan for all Incoming Materials

QA lab evolves appropriate QAP (Quality Assurance Plans) for all raw materials based on the
suppliers manufacturing process, batch size, sample size, testing facilities and test methods etc. to
ensure the test results represent whole lots intended to supply.

6. Calibration of Analytical Equipment

Calibration is being done for all instruments and equipment at defined frequency using both internal
facilities as well as by authorised personnel from OEM service providers.

7. Asset Optimisation – Man, Machine and Methods

QA Lab does asset optimisation continuously to improve the productivity of Manpower and Machines
(Upkeep of Instruments & Equipment) and also updates Methods periodically as per the national and
international standards
.
8. Internal and External Customer Orientation - Customer Focus

a) Internal Customer Satisfaction:

Supporting the production and maintenance team in optimising the process parameters, process
improvement initiatives, trouble shooting, providing the failure analysis of equipment / spares for the
development of indigenous spares. Survey is conducted once in three months for enhancing customer
satisfaction.
b) External Customer Satisfaction:
Attending customer complaints and resolving the complaint with appropriate corrective action,
understanding the customer processes, sharing knowledge on BALCO’s products usage and guiding
on the same to obtain desired output etc.

9. Implementation of Lean Tools like TQM, Six Sigma etc.

QA team takes lead role in effective functioning of cross-functional Teams to implement TQM & Six
Sigma lean tools throughout processes to reduce process variation and maximise productivity.

10. Implementation of Integrated Management Systems

QA team is responsible for establishing, developing, implementing and maintaining the Integrated
Management System as per ISO 9001: 2008 requirements of Quality Management System, ISO
14001:2004 requirements of Environmental Management System and OHSAS 18001: 2007
requirements of Occupational Health and Safety Assessment Series.
CONCLUSIONS
The four week training was very helpful and beautiful for us. I would like to thank entire
faculty
for helping me browse throughout the plant. it gave me insight knowledge of a Aluminium
plant. In this report the entire overview of the plant has been given .

REFERENCE
The project is not possible without the help of all the faculties of BHARAT ALUMINIUM
COMPANY LIMITED and the engineers in BALCO. I hope that this project will be of great
Benefit in my career and in my life.
WWW.BALCOINDIA.COM