ENERGY OPTIMIZATION STUDY - Energy Audit_ Energy Conservation_1_

							Proficient Plant
  Operation



            by

Senergy Consultants (P) Ltd

                         91-9821271630
                      senergy@vsnl.com
                   www.senergy-india.com
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.
Senergy

                    Synergy
                   between
    Our expertise on conservation of energy

                        &

        Your experience & knowledge of
   process, operations, plant engineering, etc.
                       To
                  Save Energy
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
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
Senergy
 • Interactive studies.

 • Practical & Realistic Suggestions.

 • Turnkey Consultancy during Implementation.

 • Long term services for Sustainable Savings &
   Continuous Improvements.

 • Basic & Advanced Training Programs.
Few of our clients
•    Sterlite Industries Ltd   •   Allana Industries Ltd
•   South Seas Distillery      •   Tata Chemicals Ltd
•   Excel Industries Ltd       •   Schenectady Herdillia ltd
•   Century Enka Ltd           •   Hindustan Lever Ltd
•   Century Rayon              •   Nicolas Piramal India Ltd
•   Asian Heart Hospital       •   Wyeth Lederle Ltd
•   Essel World                •   DGP Hinoday Ltd
•   EBG India Pvt Ltd          •   GTC Industries Ltd
•   Aarti Drugs Ltd            •   MSEB
•   Emco Ltd                   •   Whirlpool of India Ltd
•   PepsiCo India Ltd          •   Pidilite Industries Ltd
•   ICI Ltd                    •   Sachivalay – Gujarat
•   USV Ltd                    •   Wochkhardt Ltd
Methodology
 1. Team formation
 2. 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
 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
 • Platform for immediate & correct evaluation of
     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
    •   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!