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Kaizen

1) Several documents describe solutions implemented at an ETP plant to address recurring problems and reduce costs. 2) Solutions included creating checklists, fabricating covers, dampers, and hand trolleys, installing sheets and ventilators, and reusing materials. 3) Benefits included decreased downtime, improved performance, reduced costs, decreased cleaning time, and promoting reuse.

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sai murali
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236 views22 pages

Kaizen

1) Several documents describe solutions implemented at an ETP plant to address recurring problems and reduce costs. 2) Solutions included creating checklists, fabricating covers, dampers, and hand trolleys, installing sheets and ventilators, and reusing materials. 3) Benefits included decreased downtime, improved performance, reduced costs, decreased cleaning time, and promoting reuse.

Uploaded by

sai murali
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Prepared By :

5S CONCLAVE Het Patel


Prashant Patil
BEIL Infrastructure Ltd. Dahej Sai Murali
1
ETP Plant
Problems :
 Increased Down Time Because of Repeated Malfunction Of Equipment’s
 Equipment Servicing Frequency Increased And Doesn’t Meet Its Expected Performance

Solution :
 Prepared a Daily Equipment Checklist

Implementation
BENEFITS 2

1) Break Down Time Decreased. 2) Equipment Performance & Life Increased.


3
Trolley Cover Fabrication
Problems :
 Excess of dusting of salt in SPD plant and during transportation from plant to landfill in open
trolleys.
 Increased Land Contamination and Air Pollution
Solution :
 In-house Fabrication of Trolley Cover.

Implementation
BENEFITS 4

1) Dusting of salt reduced to a 2) Cost Saving


greater extend.
One time repairing cost of staircase edges : Rs
2) Cleaning Time reduced
Market cost of staircase edge protector : Rs
3) Required manpower for
cleaning reduced. Cost of reusing the trays : Rs
Money Saved : Rs
5
DFDV at SPD Chamber & Cyclone
Problems :
 Excess of Dusting of Salt in SPD Plant salt loading area.
 Repeatedly chocking of chamber and cyclone.

Solution :
 In-house fabrication of Double Flapper Damper Valve for both cyclone and chamber.

Implementation
BENEFITS 6

1) Time Required for Cleaning & 2) Cost Saving


de-chocking reduced.
Market cost of DFDV : Rs
2) Required manpower for
cleaning reduced. Which In-House fabrication cost of DFDV : Rs
saves labour cost. Money Saved : Rs
7
FRP Sheets on Roof Top
Problems :
 Too much darkness in shed during day time also, needed Halogens to work in shed
 Not sufficient ventilation in shed

Solution :
 Used Transparent FRP Sheets at equal distance on roof top.
 Installed Roof Ventilators
Before Implementation
BENEFITS 8

1) Proper and Sufficient 2) Cost Saving


Ventilation in shed.
Halogens Running Time : 24x7 / 365
2) More Natural light available in
shed. Electricity Cost for Running Halogens 24x7 : Rs
Reduction in Halogen Running Time : Rs
Electricity Cost after FRP sheet installation : Rs
Money Saved : 180 Rs
9
Waste Collection Hand Trolley
Problems :
 Collection of Waste on Main road was difficult.

Solution :
 In-house fabrication of hand trolly from scrap material to collect the waste

Implementation
BENEFITS 10

1) Reduce time of cleaning 1) Cost Saving


activity.  Market Cost of Trolly : 4800 Rs
2) Less manpower which saves  In-house Fabrication Cost : 2500 Rs
labour cost.

3) More quantity of waste can
be collected at the same time.
4) Ergonomically more effective
than before.
11
Gum Shoes Plantation
Problems :
 Discarded PPE’s difficult to dispose especially gum boots.

Solution :
 Used discarded gum boots as small pots for tree plantation.

Implementation
BENEFITS 12

1) Aesthetics Increased 2) Cost Saving


2) Promoted the concept of 3R Market Cost of POT : 200 Rs
Refurbishing Cost : 50 Rs
Money Saved : 150
13
FRP Cable Tray as Stair Case Edge Protector

Problems :
 Stair Case Edges used to be damaged and break repeatedly.

Solution :
 Used Discarded FRP cable trays as stair case edge protector.

Before Implementation
BENEFITS 14

1) Staircase repairing cost 2) Cost Saving


eliminated.
One time repairing cost of staircase edges : Rs
2) Promoted the concept of 3R
Market cost of staircase edge protector : Rs
Cost of reusing the trays : Rs
Money Saved : Rs
15
Routine Inspection Checklist
Problems :
 Increased Down Time Because of Repeated Malfunction Of Equipment’s
 Equipment Servicing Frequency Increased And Doesn’t Meet Its Expected Performance

Solution :
 Prepared a Daily Equipment Checklist

Implementation
BENEFITS 16

1) Break Down Time Decreased. 2) Equipment Performance & Life Increased.


17
File Stand Inside Cupboard
Problems :
 File and Inside papers use to bend.
 Difficult to see tags at a glance.

Solution :
 Used waste acrylic sheet to make a file stand inside cupboard .

Implementation
BENEFITS 18

1) Easy and fast retraction of 2) Cost Saving


files from cupboard.
Market Cost of Stand : 200 Rs
In-house making Cost : 20 Rs
Money Saved : 180 Rs
Atomizer Assembling & Dismantling 19
Procedure
Problems :
 Increased time for maintenance

Solution :
 Created a procedure of Assembling & Dismantling with time included for each step.

Implementation
BENEFITS 20

1) Decrease in plant down time 2)


and maintenance time of
atomizer.
 Time Reduced : 8hrs to 4hrs
Our Aim is……
CLEAN INDIA
GREEN INDIA &
MAKE IN INDIA.

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