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

2. 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.

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

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

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

7. Few of our clients Sterlite Industries Ltd Sterlite Industries Ltd South Seas Distillery South Seas Distillery Excel Industries Ltd Excel Industries Ltd Century Enka Ltd Century Enka Ltd Century Rayon Century Rayon Asian Heart Hospital Asian Heart 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 USV Ltd USV Ltd Allana Industries Ltd Allana Industries Ltd Tata Chemicals Ltd Tata Chemicals Ltd Schenectady Herdillia ltd Schenectady Herdillia ltd 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 M S E B M S E B Whirlpool of India Ltd Whirlpool of India Ltd Pidilite Industries Ltd Pidilite Industries Ltd Sachivalay – Gujarat Sachivalay – Gujarat Wochkhardt Ltd Wochkhardt Ltd

8. 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

9. 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

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

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. 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

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 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 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

19. Thank You!