Proficient Plant Proficient Plant OperationOperation

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Senergy Consultants (P) LtdSenergy Consultants (P) Ltd

91-982127163091-9821271630senergy@vsnl.com senergy@vsnl.com

www.senergy-india.comwww.senergy-india.com

Proficient Plant OperationsProficient Plant Operations

• Product needs to be competitive in market. Product needs to be competitive in market.

• Saving is the simplest & the best way to Saving is the simplest & the best way to increase profits. increase profits.

• Rejection & Wastages have controlling Rejection & Wastages have controlling impact on product costimpact on product cost..

• Small steps lead to substantial Small steps lead to substantial improvements. improvements.

• Productivity improvement of over 10% is Productivity improvement of over 10% is possible in most of the industries. possible in most of the industries.

• Streamlining plant operations results in Streamlining plant operations results in substantial reduction in working capital. substantial reduction in working capital.

Senergy Senergy

Synergy Synergy

between between

Our expertise on conservation of energy Our expertise on conservation of energy

&&

Your experience & knowledge ofYour experience & knowledge of

process, operations, plant engineering, etc. process, operations, plant engineering, etc.

To To

Save EnergySave Energy

Senergy Senergy • Leading Energy Conservation Consultants in Leading Energy Conservation Consultants in

IndiaIndia

• Conducting Studies for past 20 years.Conducting Studies for past 20 years.

• One of the first auditor to receive ISO 9001-One of the first auditor to receive ISO 9001-2000 certification. 2000 certification.

• Team of experts headed by a technocrat from Team of experts headed by a technocrat from IITIIT

• Customer driven company with many repeat Customer driven company with many repeat orders & orders form group companiesorders & orders form group companies

Senergy Senergy

• Empanelled with Maharashtra & Gujarat Empanelled with Maharashtra & Gujarat Governments (MEDA & GEDA)Governments (MEDA & GEDA)

• BEE certified auditorsBEE certified auditors

• Customer base of over 450 industriesCustomer base of over 450 industries

• Contributing Rs 50 crores/year, towards Contributing Rs 50 crores/year, towards conservation of energyconservation of energy

Senergy Senergy • Interactive studies.Interactive studies.

• Practical & Realistic Suggestions.Practical & Realistic Suggestions.

• Turnkey Consultancy during Implementation.Turnkey Consultancy during Implementation.

• Long term services for Sustainable Savings Long term services for Sustainable Savings & Continuous Improvements.& Continuous Improvements.

• Basic & Advanced Training Programs. Basic & Advanced Training Programs.

Few of our clientsFew of our clients• Sterlite Industries LtdSterlite Industries Ltd

• South Seas DistillerySouth Seas Distillery

• Excel Industries Ltd Excel Industries Ltd

• Century Enka Ltd Century Enka Ltd

• Century RayonCentury Rayon

• Asian Heart Hospital Asian Heart Hospital

• Essel World Essel World

• EBG India Pvt LtdEBG India Pvt Ltd

• Aarti Drugs LtdAarti Drugs Ltd

• EEmco Ltdmco Ltd

• PPepsiCo India LtdepsiCo India Ltd

• ICI LtdICI Ltd

• USV LtdUSV Ltd

• Allana Industries LtdAllana Industries Ltd

• Tata Chemicals LtdTata Chemicals Ltd

• Schenectady Herdillia ltdSchenectady Herdillia ltd

• Hindustan Lever Ltd Hindustan Lever Ltd

• Nicolas Piramal India LtdNicolas Piramal India Ltd

• Wyeth Lederle Ltd Wyeth Lederle Ltd

• DGP Hinoday Ltd DGP Hinoday Ltd

• GTC Industries LtdGTC Industries Ltd

• M S E B M S E B

• WhirlWhirlpool of India Ltdpool of India Ltd

• PPidilite Industries Ltdidilite Industries Ltd

• Sachivalay – Gujarat Sachivalay – Gujarat

• Wochkhardt Ltd Wochkhardt Ltd

MethodologyMethodology

1.1. Team formationTeam formation

2.2. Identification of saving potential through Identification of saving potential through • Optimizing Wastages Optimizing Wastages • Minimizing RejectionsMinimizing Rejections• Conservation of energy Conservation of energy • Productivity Improvement Productivity Improvement • Control over Work in Progress InventoryControl over Work in Progress Inventory• Monitoring Throughput / Manufacturing Lead Time Monitoring Throughput / Manufacturing Lead Time

3.3. Formulate strategy for ImplementationFormulate strategy for Implementation

4.4. Provide assistance during Implementation Provide assistance during Implementation

5.5. Compute actual savingsCompute actual savings

6.6. Suggest monitoring system for further Suggest monitoring system for further improvementsimprovements

TEAMTEAM

You and only you can saveYou and only you can save

TEAM ensures TEAM ensures • Participation of all stake-holdersParticipation of all stake-holders

• Platform for immediate & correct evaluation Platform for immediate & correct evaluation of all suggestions (including ours)of all suggestions (including ours)

• Quick & Effective Implementation Quick & Effective Implementation

• Savings on sustainable basisSavings on sustainable basis

• Continual improvementsContinual improvements

• Development of knowledge bankDevelopment of knowledge bank

TEAM: Basic ConstituentsTEAM: Basic Constituents

Core Team Core Team – CoordinatorCoordinator– Production Manager Production Manager – Engineering Manager Engineering Manager – Industrial/ Mechanical Engineer Industrial/ Mechanical Engineer

Task Force (s) Task Force (s) - Coordinator- Coordinator

- Cross-functional - Cross-functional MembersMembers

RejectionsRejections

• Identifying major sources of rejection

• Quantifying contribution of the individual source

• Estimating losses due to rejections

• Analyzing reasons for individual rejections

• Suggesting remedial steps to eliminate the sources / minimizing their impact

Wastages Wastages

• Identifying major sources of wastages

• Quantifying losses at various stages of operation

• Analyzing reasons for wastages

• Suggesting remedial steps to eliminate the sources / minimize their impact

Machine Machine Productivity Productivity

• Computing minimum, average & maximum output from the individual machine / equipment

• Comparing the data with design data

• Analyzing reasons for the deviations, if any

• Estimating gains from productivity improvements

• Suggesting methods for improvements

PlantPlantProductivityProductivity

• Computing minimum, average and maximum output for the individual production section

• Comparing established & design data

• Identifying bottlenecks

• Suggesting methods for de-bottlenecking

• Estimating gains from bottleneck removal

Work-in-Progress Work-in-Progress

• Estimating contribution of Work in Progress to overall inventory for individual machine / Manual operation

• Establishing desired level of inventory for the respective machine / Manual activity

• Estimating gains from reduction in the inventory level

Throughput Time Throughput Time

• Estimating actual throughput time for all the key products

• Computing theoretical through put time and manufacturing cycle efficiency for the respective products

• Establishing optimal through put time / manufacturing lead time

• Estimating savings in working capital

Energy Energy Conservation Conservation

• Conduct Detailed Energy Audit covering Conduct Detailed Energy Audit covering – ElectricityElectricity– Fuel Fuel – Utilities like air compressors, refrigeration Utilities like air compressors, refrigeration

system, blowers, pumps, steam, etc.system, blowers, pumps, steam, etc.– Estimating performance of all major Estimating performance of all major

equipments equipments – Quantifying losses in the various distribution Quantifying losses in the various distribution

system like electrical cables, various piping system like electrical cables, various piping – Analyzing cost of energy & suggest use of Analyzing cost of energy & suggest use of

alternative source for the same alternative source for the same – Provide concrete suggestions for conservation Provide concrete suggestions for conservation

of energyof energy

Schedule Schedule

• First month: Resources data collection / analysisFirst month: Resources data collection / analysis• Wastages / RejectionWastages / Rejection• ProductivityProductivity• Work-in-ProgressWork-in-Progress• Energy ConservationEnergy Conservation

• Second month: Identification of suggestions & Second month: Identification of suggestions & finalization of strategies for implementation.finalization of strategies for implementation.

• Subsequent months: Implementation of Subsequent months: Implementation of suggestions & computation of actual saving.suggestions & computation of actual saving.

• Overall study duration of 6 months Overall study duration of 6 months

Thank You!Thank You!