Proficient Plant Operation

1. Proficient Plant Operation by Senergy Consultants (P) Ltd 91-9821271630 senergy@vsnl.com www.senergy-india.com

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 on conservation of energy & Your experience & knowledge of process, operations, plant engineering, etc. To Save Energy

4. Senergy • Leading Energy Conservation Consultants in India • Conducting Studies for past 20 years. • One of the first auditor to receive ISO 9001-2000 certification. • Team of experts headed by a technocrat from IIT • Customer driven company with many repeat orders & orders form group companies

5. Senergy • Empanelled with Maharashtra & Gujarat Governments (MEDA & GEDA) • BEE certified auditors • Customer base of over 450 industries • Contributing Rs 50 crores/year, towards conservation of energy

6. Senergy • Interactive studies. • Practical & Realistic Suggestions. • Turnkey Consultancy during Implementation. • Long term services for Sustainable Savings & Continuous Improvements. • Basic & Advanced Training Programs.

7. Sterlite Industries Ltd South Seas Distillery Excel Industries Ltd Century Enka Ltd Century Rayon Asian Heart Hospital Essel World EBG India Pvt Ltd Aarti Drugs Ltd Emco Ltd PepsiCo India Ltd ICI Ltd USV Ltd Allana Industries Ltd Tata Chemicals Ltd Schenectady Herdillia ltd Hindustan Lever Ltd Nicolas Piramal India Ltd Wyeth Lederle Ltd DGP Hinoday Ltd GTC Industries Ltd M S E B Whirlpool of India Ltd Pidilite Industries Ltd Sachivalay – Gujarat Wochkhardt Ltd Few of our clients

8. 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

9. 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

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

11. 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

12. 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

13. 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

14. 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

15. 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

16. 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

17. 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

18. 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

19. Thank You!