Efficient Plant Management

Transcription

1 Efficient Plant Management AUTOMATION COST REDUCTION PRODUCTIVITY Key Concerns & Challenges Snehasis C Roy

2 Management Sans Excitement Men Materials Machines

3 Management with Excitement Teams Services New Infrastructure

4 Plant Management today Automation Reduced team size & HR Bill Cost Reduction Bottom-line improvement Productivity More at a less, linked to Automation..Optimization and much more

5 Automation : First lesson WAN-IFRA WORKSHP : APRIL 2016

6 Automation : Dream Machine WAN-IFRA WORKSHP : APRIL 2016

7 Automation : Optimal WAN-IFRA WORKSHP : APRIL 2016

8 Why Automate? Reduction of Bottlenecks Gain Time advantage vs. Competition Capacity Maximization Wastage reduction Productivity improvement Consistent output - Quality improvement Creation of Sustainable Excellence.

9 Critical Centralized operations Centralization vs Decentralization High volume High Risk Need Reliability Speed Online monitoring Online Communication Closed loop controls Simply put, you need Automation

10 Type 1 : Process automation Direct & Immediate ROI Ink optimization Soft Proofing Indirect but Life enhancement ROI Workflow automation Digital Asset Management

11 Type 2 : Retrofit Direct & Immediate ROI Auto Blanket wash Closed loop Density control Image based Cut-off control Indirect but Life enhancement ROI High speed Variable Data Imaging Mailroom Inserters

12 Type 3 : Services Direct & Immediate ROI Dynamic UPS system Fluidbag Ink handling system Hygrostatic Climate control

13 Soft Proof WAN-IFRA WORKSHP : APRIL 2016

14 Workflow Automation WAN-IFRA WORKSHP : APRIL 2016

15 Digital Asset Management WAN-IFRA WORKSHP : APRIL 2016

16 Closed Loop Color Control Less waste and lower ink consumption Reduction in production time Operational efficiency Genuine CMYK measuring Dampening control Web inspection

17 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.

18 Team Management Need more than a few brave captains Key pre-requisites Qualification Professional experience Self Confidence

19 Team Management Figure Copyright : The Economic Times

20 Team Management Team must take ownership for the entire life of the plant

21 Plant Design factors we all know 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 WAN-IFRA WORKSHP : APRIL 2016

22 Operations 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 WAN-IFRA WORKSHP : APRIL 2016

23 Productivity The trend must be positive. Incremental productivity gain may get offset by idle time. Economy of Scale Flight Takeoff & Landing

24 Zero measurement in-process No solid color tabs to measure No grey bar, tablet, capsule Just clean & clear evenly inked copy every time

25 How Management systems can Help ISO 9000 Quality Management System ISO Environmental Management System 5S Work place Organization method ISO : Newspaper Cold-set product Standard ISI Mark : BIS Product Standard

26 Flip Chart Time WAN-IFRA WORKSHP : APRIL 2016

27 5S Implementation at Barasat Plant

28 Over View of 5S Method The 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? Remove all items not needed for current production operations. Leave only the bare essentials: When in doubt, throw it out. Space, time, money, energy, and other resources can be managed and used most effectively. Reduces problems and annoyances in the work flow. The factory becomes increasingly crowded and hard to work in. Storage of unneeded items gets in the way of communication. Sort seiri Improves communication between workers. Increases product quality. Enhances productivity. Time wasted searching for parts/tools. Unneeded inventory and machinery are costly to maintain. Excess stock hides production problems. Unneeded items and equipment make it harder to improve the process flow

29 Pillar What does it mean? Why is it important? What problems are avoided? Arrange needed items so that they are easy to use. Eliminates many kinds of waste, including: Motion waste. Set-in-order seiton Label items so that anyone can find them or put them away. Searching waste. Waste due to difficulty in using items. Searching waste. Waste of human energy. Waste of excess inventory. Waste due to difficulty in returning items. Waste of defective products. Waste of unsafe conditions.

30 Pillar WAN-IFRA WORKSHP : APRIL 2016 What does it mean? Why is it important? What problems are avoided? 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. Shine seiso 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.

31 Pillar Standardize seiketsu What does it mean? Integrates Sort, Set in Order, and Shine into a unified whole. Why is it important? By ensuring conditions do not deteriorate to former state, facilitates implementatio n of the first three pillars. What problems are avoided? 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.

32 Pillar What does it mean? Why is it important? What problems are avoided? 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. Sustain shitsuke 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.

33 The Mantra of 5S Method "A place for every thing, and every thing in its place"

34 Thank You!!