Proficient Plant Proficient Plant OperationOperation

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Senergy Consultants (P) LtdSenergy Consultants (P) Ltd

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 Our expertise

&&

Your experience & knowledge Your experience & knowledge

for for

Proficient Plant Operations Proficient Plant Operations

Senergy Senergy

• One of the leading Energy Conservation One of the leading Energy Conservation Consultants in IndiaConsultants in India

• Conducting Energy Conservation Studies Conducting Energy Conservation Studies for past 15 yearsfor past 15 years

• An ISO 9001-2000 companyAn ISO 9001-2000 company• Team of experts headed by a technocrat Team of experts headed by a technocrat

from IITfrom IIT• Company with customer base of over Company with customer base of over

300 industries300 industries• Customer driven company with many Customer driven company with many

repeat orders & orders from group repeat orders & orders from group companiescompanies

Senergy Senergy

• Provides Personalised and Total solutionsProvides Personalised and Total solutions

• Conducts interactive studiesConducts interactive studies

• Gives practical & realistic recommendationsGives practical & realistic recommendations

• Conducts basic training programmes Conducts basic training programmes

• Undertakes comprehensive monitoring Undertakes comprehensive monitoring servicesservices

• Provides support during implementation of Provides support during implementation of all the recommendationsall the recommendations

• Demonstrate the actual savings – on Demonstrate the actual savings – on sustainable basissustainable basis

Few of our clientsFew of our clients

For Energy For Energy • Century Enka Ltd Century Enka Ltd • Century RayonCentury Rayon• Nanavati Hospital Nanavati 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• Tata Chemicals LtdTata Chemicals Ltd

Conservation Studies Conservation Studies • 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• Advani Oerlikon LtdAdvani Oerlikon Ltd• M S E B M S E B • WhirlWhirlpool of India Ltdpool of India Ltd• PPidilite Industries Ltdidilite Industries Ltd• SRF Industries LtdSRF Industries 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!