Proficient Plant Operation by Senergy Consultants (P) Ltd

Proficient Plant Operations Product needs to be competitive in market. Product needs to be competitive in market. Saving is the simplest & the best way to increase profits. Saving is the simplest & the best way to increase profits. Rejection & Wastages have controlling impact on product cost. Rejection & Wastages have controlling impact on product cost. Small steps lead to substantial improvements. Small steps lead to substantial improvements. Productivity improvement of over 10% is possible in most of the industries. Productivity improvement of over 10% is possible in most of the industries. Streamlining plant operations results in substantial reduction in working capital. Streamlining plant operations results in substantial reduction in working capital.

Senergy Synergybetween Our expertise & Your experience & knowledge for Proficient Plant Operations

Senergy One of the leading Energy Conservation Consultants in India One of the leading Energy Conservation Consultants in India Conducting Energy Conservation Studies for past 15 years Conducting Energy Conservation Studies for past 15 years An ISO company An ISO company Team of experts headed by a technocrat from IIT Team of experts headed by a technocrat from IIT Company with customer base of over 300 industries Company with customer base of over 300 industries Customer driven company with many repeat orders & orders from group companies Customer driven company with many repeat orders & orders from group companies

Senergy Provides Personalised and Total solutions Provides Personalised and Total solutions Conducts interactive studies Conducts interactive studies Gives practical & realistic recommendations Gives practical & realistic recommendations Conducts basic training programmes Conducts basic training programmes Undertakes comprehensive monitoring services Undertakes comprehensive monitoring services Provides support during implementation of all the recommendations Provides support during implementation of all the recommendations Demonstrate the actual savings – on sustainable basis Demonstrate the actual savings – on sustainable basis

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

Methodology 1. Team formation 2. Identification of saving potential through Optimizing WastagesOptimizing Wastages Minimizing RejectionsMinimizing Rejections Conservation of energyConservation of energy Productivity ImprovementProductivity Improvement Control over Work in Progress InventoryControl over Work in Progress Inventory Monitoring Throughput / Manufacturing Lead TimeMonitoring Throughput / Manufacturing Lead Time 3. Formulate strategy for Implementation 4. Provide assistance during Implementation 5. Compute actual savings 6. Suggest monitoring system for further improvements

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

TEAM: Basic Constituents Core Team –Coordinator –Production Manager –Engineering Manager –Industrial/ Mechanical Engineer Task Force (s) - Coordinator - Coordinator - Cross-functional Members - 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 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 First month: Resources data collection / analysis Wastages / RejectionWastages / Rejection ProductivityProductivity Work-in-ProgressWork-in-Progress Energy ConservationEnergy Conservation Second month: Identification of suggestions & finalization of strategies for implementation. Second month: Identification of suggestions & finalization of strategies for implementation. Subsequent months: Implementation of suggestions & computation of actual saving. Subsequent months: Implementation of suggestions & computation of actual saving. Overall study duration of 6 months Overall study duration of 6 months

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