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Proficient Plant Operation

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 profits. Rejection & Wastages have controlling impact on product cost .

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Proficient Plant Operation

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  1. Proficient Plant Operation by Senergy Consultants (P) Ltd

  2. Proficient Plant Operations • Product needs to be competitive in market. • Saving is the simplest & the best way to increase 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.

  3. Senergy Synergy between Our expertise & Your experience & knowledge for Proficient Plant Operations

  4. Senergy • One of the leading Energy Conservation 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

  5. Senergy • 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

  6. For Energy Century Enka Ltd Century Rayon Nanavati Hospital Essel World EBG India Pvt Ltd Aarti Drugs Ltd Emco Ltd PepsiCo India Ltd ICI Ltd Tata Chemicals Ltd Conservation Studies Hindustan Lever Ltd Nicolas Piramal India Ltd Wyeth Lederle Ltd DGP Hinoday Ltd GTC Industries Ltd Advani Oerlikon Ltd M S E B Whirlpool of India Ltd Pidilite Industries Ltd SRF Industries Ltd Few of our clients

  7. Team formation Identification of saving potential through 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 Methodology

  8. TEAM You and only you can save TEAM ensures • Participation of all stake-holders • Platform for immediate & correct evaluation of all suggestions (including ours) • Quick & Effective Implementation • Savings on sustainable basis • Continual improvements • Development of knowledge bank

  9. Core Team Coordinator Production Manager Engineering Manager Industrial/ Mechanical Engineer Task Force (s) - Coordinator - Cross-functional Members TEAM: Basic Constituents

  10. 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

  11. 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

  12. 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

  13. PlantProductivity • 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

  14. 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

  15. 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

  16. 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

  17. Schedule • First month: Resources data collection / analysis • 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

  18. Thank You!

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