efficient plant management · 2016-04-11 · wan-ifra workshp : april 2016 • iso 9000 quality...

Efficient Plant Management

AUTOMATION

COST REDUCTION PRODUCTIVITY

Key Concerns & Challenges

Snehasis C Roy

WAN-IFRA WORKSHP : APRIL 2016

•Men

•Materials

•Machines

Management Sans Excitement


•Teams

•Services

•New Infrastructure

Management with Excitement


•AutomationReduced team size & HR Bill

•Cost ReductionBottom-line improvement

•ProductivityMore at a less, linked to Automation..Optimization and much more

Plant Management today


Automation : First lesson


Automation : Dream Machine


Automation : Optimal


• Reduction of Bottlenecks

• Gain Time advantage vs. Competition

• Capacity Maximization

• Wastage reduction

• Productivity improvement

• Consistent output - Quality improvement

• Creation of Sustainable Excellence….

Why Automate?


• Centralization vs Decentralization

– High volume High Risk

• Need Reliability

• Speed

• Online monitoring

• Online Communication

• Closed loop controls

• Simply put, you need “Automation”

Critical Centralized operations


Type 1 : Process automation

•• Direct & Immediate ROIDirect & Immediate ROI

•• Ink optimizationInk optimization

•• Soft ProofingSoft Proofing

•• Indirect but Life enhancement ROIIndirect but Life enhancement ROI

•• Workflow automationWorkflow automation

•• Digital Asset ManagementDigital Asset Management


Type 2 : Retrofit


•• Auto Blanket washAuto Blanket wash

•• Closed loop Density controlClosed loop Density control

•• Image based CutImage based Cut--off controloff control

•• Indirect but Life enhancement ROIIndirect but Life enhancement ROI

•• High speed Variable Data ImagingHigh speed Variable Data Imaging

•• Mailroom InsertersMailroom Inserters


Type 3 : Services


•• Dynamic UPS systemDynamic UPS system

•• FluidbagFluidbag Ink handling systemInk handling system

•• HygrostaticHygrostatic Climate controlClimate control


Soft Proof


Workflow Automation


Digital Asset Management


• Less waste and lower ink consumption

• Reduction in production time

• Operational efficiency

• Genuine CMYK measuring

• Dampening control

• Web inspection

Closed Loop Color Control


Dynamic UPS system

• Power Generators used as Insurance against poor SEB supply.

• Once power is lost, Generators run for the rest of the night.

• Power generation cost DG vs. SEB.

• Substantial Savings

• ROI in two years

• Major savings in Critical time, Drives, and communication reboot.


Need more than a few brave captains

• Key pre-requisites

– Qualification

– Professional experience

– Self Confidence

Team Management


Team Management

Figure Copyright : The Economic Times


Team Management

• Team must take ownership for the entire life of the plant


• Plant & Machinery layout• Storage and movement of Consumables• Utility Services layout• Manpower Access around the plant• Movement of finished product• Open area management : Landscaping & Water harvesting

Plant Design factors…we all know


•Maintenance Management•Process workflow design•Process Control measures•Wastage management•Effluent treatment•Inspection and Testing of Materials

•Control of Documents and Records•Audits and improvement

Operations factors…we all know


Productivity

• The trend must be positive.

• Incremental productivity gain may get offset by idle time.

• Economy of Scale

• Flight Takeoff & Landing


Zero measurement in-process…

• No solid color tabs to measure

• No grey bar, tablet, capsule

Just clean & clear evenly inked copy every time


• ISO 9000 Quality Management System

• ISO 14000 Environmental Management System

• 5S Work place Organization method

• ISO 12647-2: Newspaper Cold-set product Standard

• ISI Mark : BIS Product Standard

How Management systems can Help


Flip Chart Time…

5S Implementation at Barasat Plant


Over View of 5S MethodThe following table provides an overview of the 5 pillars of Visual Workplace, with a brief definition of what the step means in a manufacturing context, why it’s important, and the list of problems it avoids if implemented

Pillar What does it mean? Why is it important? What problems are avoided?

Sort“seiri”

Remove all items not needed for current production operations.

Space, time, money, energy, and other resources can be managed and used most effectively.

The factory becomes increasingly crowded and hard to work in.

Leave only the bare essentials: When in doubt, throw it out.

Reduces problems and annoyances in the work flow.

Storage of unneeded items gets in the way of communication.

Improves communication between workers.

Time wasted searching for parts/tools.

Increases product quality. Unneeded inventory and machinery are costly to maintain.

Enhances productivity. Excess stock hides production problems.

Unneeded items and equipment make it harder to improve the process flow


Pillar What does it mean?

Why is it important?

What problems are avoided?

Set-in-order“seiton”

Arrange needed items so that they are easy to use.

Eliminates many kinds of waste, including:

Motion waste.

Label items so that anyone can find them or put them away.

Searching waste.

Waste due to difficulty in using items.

Waste due to difficulty in returning items.

Searching waste.

Waste of human energy.Waste of excess inventory.Waste of defective products.Waste of unsafe conditions.





Shine“seiso”

Keep everything, every day, swept and clean.

Turn the workplace into a clean, bright place where everyone will enjoy working.

Lack of sunlight can lead to poor morale and inefficient work.

Keep things in a condition so it is ready to be used when needed.

Defects are less obvious.

Puddles of oil and water cause slipping and injuries.

Machines that do not receive sufficient maintenance tend to break down and cause defects.





Standardize“seiketsu”

Integrates Sort, Set in Order, and Shine into a unified whole.

By ensuring conditions do not deteriorate to former state, facilitates implementatio

n of the first three pillars.

Conditions go back to their old undesirable levels.

Work areas are dirty and cluttered.

Tool storage sites become disorganized and time wasted searching for tools.

Clutter starts to accumulate over time.

Backsliding occurs.


Pillar What does it mean? Why is it important? What problems are avoided?

Sustain“shitsuke

”

Making a habit of properly maintaining correct procedures.

Consequences of not keeping to the course of action greater than consequences of keeping to it.

Unneeded items begin piling up.

Instill discipline necessary to avoid backsliding.

Tools and jigs do not get returned to their designated places.

No matter how dirty equipment becomes, nothing is done to clean it.

Items are left in a hazardous orientation.

Dark, dirty, disorganized workplace results in lower morale.

The Mantra of 5S The Mantra of 5S MethodMethod

"A place for every thing,and every thing in its place"

Thank You !!