Transcript ENERGY OPTIMIZATION STUDY

Proficient Plant
Operation
by
Senergy Consultants (P) Ltd
Proficient Plant Operations
• Product needs to be competitive in market.
• Saving is the simplest & the best way to increase
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profits.
Rejection & Wastages have controlling impact on
product cost.
Small steps lead to substantial improvements.
Productivity improvement of over 10% is possible
in most of the industries.
Streamlining plant operations results in
substantial reduction in working capital.
Senergy
Synergy
between
Our expertise
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Your experience & knowledge
for
Proficient Plant Operations
Senergy
• One of the leading Energy Conservation
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Consultants in India
Conducting Energy Conservation Studies for
past 15 years
An ISO 9001-2000 company
Team of experts headed by a technocrat
from IIT
Company with customer base of over 300
industries
Customer driven company with many repeat
orders & orders from group companies
Senergy
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Provides Personalised and Total solutions
Conducts interactive studies
Gives practical & realistic recommendations
Conducts basic training programmes
Undertakes comprehensive monitoring services
Provides support during implementation of all
the recommendations
Demonstrate the actual savings – on sustainable
basis
Few of our clients
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For Energy Conservation Studies
Century Enka Ltd
• Hindustan Lever Ltd
Century Rayon
• Nicolas Piramal India Ltd
Nanavati Hospital
• Wyeth Lederle Ltd
Essel World
• DGP Hinoday Ltd
EBG India Pvt Ltd • GTC Industries Ltd
Aarti Drugs Ltd
• Advani Oerlikon Ltd
Emco Ltd
• MSEB
PepsiCo India Ltd
• Whirlpool of India Ltd
ICI Ltd
• Pidilite Industries Ltd
Tata Chemicals Ltd • SRF Industries Ltd
Methodology
1. Team formation
2. Identification of saving potential through
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Optimizing Wastages
Minimizing Rejections
Conservation of energy
Productivity Improvement
Control over Work in Progress Inventory
Monitoring Throughput / Manufacturing Lead Time
Formulate strategy for Implementation
Provide assistance during Implementation
Compute actual savings
Suggest monitoring system for further improvements
TEAM
You and only you can save
TEAM ensures
• Participation of all stake-holders
• Platform for immediate & correct evaluation of
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all suggestions (including ours)
Quick & Effective Implementation
Savings on sustainable basis
Continual improvements
Development of knowledge bank
TEAM: Basic Constituents
Core Team
– Coordinator
– Production Manager
– Engineering Manager
– Industrial/ Mechanical Engineer
Task Force (s)
- Coordinator
- Cross-functional Members
Rejections
• 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
• 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
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
Plant
Productivity
• 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
• 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
• 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
Conservation
• Conduct Detailed Energy Audit covering
– Electricity
– Fuel
– Utilities like air compressors, refrigeration system,
blowers, pumps, steam, etc.
– Estimating performance of all major equipments
– Quantifying losses in the various distribution system
like electrical cables, various piping
– Analyzing cost of energy & suggest use of alternative
source for the same
– Provide concrete suggestions for conservation of
energy
Schedule
• First month: Resources data collection / analysis
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Wastages / Rejection
Productivity
Work-in-Progress
Energy Conservation
• Second month: Identification of suggestions &
finalization of strategies for implementation.
• Subsequent months: Implementation of suggestions &
computation of actual saving.
• Overall study duration of 6 months
Thank You!