Q.6 The following graph represents the installed capacity for cement production (in tonnes) and the
actual production (in tonnes) of nine cement plants of a cement company. Capacity utilization of a
plant is defined as ratio of actual production of cement to installed capacity. A plant with installed
capacity of at least 200 tonnes is called a large plant and a plant with lesser capacity is called a
small plant. The difference between total production of large plants and small plants, in tonnes is
____.

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In the cement industry, optimizing production efficiency is crucial for profitability and sustainability. A common data interpretation question compares installed capacity (potential output) versus actual production across nine plants. Plants with installed capacity of at least 200 tonnes are classified as large, while those below are small. This analysis reveals the difference between total production of large and small plants, highlighting operational gaps.

The bar graph shows data in tonnes:

• Green bars: Installed capacity.

• Orange bars: Actual production.

• X-axis: Plant numbers 1 to 9.

• Large plants: 1, 2, 5, 8, 9 (≥200 tonnes capacity).

• Small plants: 3, 4, 6, 7 (below 200 tonnes).

Quick Data Extraction from the Graph

Here’s a tabulated summary for clarity:

*Note: Plant 4’s 200 tonnes exactly meets the “at least 200” threshold for large.

Total actual production of large plants (1,2,4,5,8,9): 180 + 150 + 160 + 160 + 200 + 190 = 1,040 tonnes.
Total actual production of small plants (3,6,7): 160 + 100 + 140 = 400 tonnes.
Difference: 1,040 – 400 = 640 tonnes.

Large plants contribute over 70% of total output despite capacity utilization challenges (e.g., Plant 1 at ~72%).

MCQ Explanation: All Options Analyzed

This graph often appears in competitive exams like SSC, banking, or engineering entrances testing data interpretation. Assume the question: The difference between total production of large and small plants, in tonnes, is:

Correct Answer: 640

Explanation: Large plants (1,2,4,5,8,9) total 1,040 tonnes actual production. Small plants (3,6,7) total 400 tonnes. Subtract: 1,040 – 400 = 640. This matches the query’s focus on total production (actual output), not capacity.

Why Other Options Are Incorrect

• Option A: 500 – Underestimates large plant output (ignores Plant 4’s 160 or misadds totals).

• Option B: 540 – Close but wrong; possibly excludes Plant 9 (190) or misreads Plant 5 as 150.

• Option C: 640 – Correct, as calculated precisely from graph bars.

• Option D: 700 – Overestimates; might add capacities instead of production or include Plant 3 as large.

Common pitfalls: Confusing installed capacity with production, misclassifying Plant 4, or averaging instead of totaling.

Key Insights for Cement Industry & Exam Prep

Large plants show higher absolute production but lower utilization rates (e.g., Plant 5: 160/250 = 64%). Small plants like Plant 3 overperform (160/180 ≈ 89%). Factors include maintenance, demand, or efficiency.

For students: Practice by summing bars visually—large plants dominate output, emphasizing scale advantages in manufacturing.

This difference between total production of large and small plants underscores why cement firms invest in capacity expansion.