Download - Fuelling Frugal Innovation in Industry
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by
GAGAN GOEL & SHOBHITAGARWAL
DEPUTY MANAGER
AONLA UNIT, BAREILLY
FUELLING
FRUGAL INNOVATIONIN INDUSTRY
Technical Seminar on
Engineers Day-2013Institute of Engineers, Bareilly Chapter
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Dr. R. A. Mashelkar
What is Frugal Innovation?
Frugal innovation or frugal engineering is theprocess of reducing the complexity and cost of a good
and its production.
Frugal innovation responds to limitations in resources,
whether financial, material or institutional, and turnsthese constraints into an advantage through
minimizing the use of resources in development,
production and delivery.
Frugal innovation results in dramatically lowercostproducts and services & a better way of doing a job.
Successful frugal innovations are not only lower in
cost, but outperform the alternative, and can be made
available at large scale.
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Value forMoney
Value forMany
Dr. R. A. Mashelkar,
President of Global Research Alliance,
(former Director General of the Council of
Scientific & Industrial Research (CSIR))
Frugal Innovation =
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Drive the
economicgrowth of
nations
Improve
people welfareSustain
Organizations
Why Frugal Innovation is
Important?
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FRUGAL Innovation in India ..
Jugaad is a colloquial Hindi wordthat roughly translates as aninnovative fix; an improvised solutionborn from ingenuity and cleverness.
Jugaad Innovation is about: Less,but better it concentrates on the
essential aspects and not burdenedwith non-essentials
back to purity,back to simplicity.
Jugaad applications include findingnew uses for everyday objectsIndian kitchens are replete withempty bottles reused as ad-hoc
containers for dried legumes orcondimentsor inventing newutilitarian tools using everydayobjects, like a makeshift truckcobbled together with a dieselengine slapped onto a cart(makeshift vehicles).
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FRUGAL INNOVATION - EASY COST
EFFECTIVE DAILY SOLUTION
MittiCool Fridge Jugaad Espresso Coffee MakerWashing Machine without Electricity
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Believe it or NOT Indian Jugaad is
MOST HAPPENING Thing for the world
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MANAGING INNOVATION A WESTERN
APPROACH
In the 20th century, as North American andEuropean economies expanded, Westerncorporations began to institutionalize theirinnovation capabilities, creating dedicated R&Ddepartments and standardizing the businessprocesses needed to take their ideas to market.
They focused on managing innovation, just asthey managed any other business activity. Thisindustrialization of the creative process led to astructured approach to innovation with thefollowing key characteristics: big budgets,standardized business processes, andcontrolled access to knowledge.
But this structured innovation approach, whichhelped Western firms become highly successful inthe second half of the twentieth century, has threeclear limitations in the fast pace and volatility ofthe twenty-first century:
1. The structured approach is too expensiveand resource consuming
2. The structured approach lacks flexibility3. The structured approach is elitist and
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Natural ResourcesCapital
LandSkilled Labor
Infrasctructure
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Diversity- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Geographic Cultural Social Economic Biological
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InterconnectivityCloud Computing Mobile Social Media
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Technological
Market
Competitive
Velocity- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
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Emerging Markets
More ConsumersGreater Strain on Existing Resources
Frugal Innovation
Globalization- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
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THE SIX PRINCIPLES
OF FRUGAL INNOVATION
Find more opportunity in adversity.
Do more with less.
Think and act flexibly. Keep it simple.
Include the margin.
Follow your heart.
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IFFCO Aonla
Producing 1.21 lacs Bags having 50 kg
Urea.
Plant is continuously running &
DOWNTIME is not desirable. 1 day DOWNTIME cost = Production Loss
of Rs.6 crore + Shutdown & Startup
Energy Loss of Rs.2 crore.
Shutdown Planning is a mega activity inthe continuous running plants so that all
activities can be completed within a
specified span of time.
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A Brief of IFFCO Aonla
Certified for following Management System
ISO-9001 Quality
ISO-14001 Env ironm ent
OHSAS-18001 Helath & SafetyISO-16001 Energy
ISO-26001 CSR
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" IFFCO Employees Suggest ion
Scheme"
IFFCO has always encouraged frugal innovation, novel ideasand creative thinking on the part of employees.
"IFFCO Employees Suggestion Scheme" is yet another step
towards utilizing employees creativity and potential for improved
organizational performance.
The Scheme is aimed towards an objective of providing a well-structured and formal platform for nurturing, supporting and
rewarding creative ideas of employees.
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Computerization
http://localhost/var/www/apps/conversion/tmp/scratch_1/SuggScheme_Eng.pdf -
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Growth of IFFCO Suggestion Scheme
969924 897
156
802
1133
28
15750
0
200
400
600
800
1000
1200
2010-2011 2011-2012 2012-2013
Number of Employees
Number of Suggestions
Received
No. of Suggestions
Impleented
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THE JOB: Inspection of inside wall of Ammonia Convertor which involved
NDT (DP/UT/Hardness/etc) of 6 nos. of C-Seam weld joints and 5 nos. of
L-Seam joints.
To reach different levels of C-seam and L-seam joints, it is necessary to have
scaffoldings inside the vessel of about 26 meters height and 3.0 metersdia.
It involves 150M3 ofscaffolding which takes 02 days to erect and 01 days to
dismantle. Additionally 01 day required for Inspection .
Reduction in inspection time of Ammonia
Converter (S-200 ) by providingprefabricated multi-storied inspection cage.
FRUGAL INNOVATION-1
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Conventional
Scaffolding
Basket support
ring
FRUGAL INNOVATION-1
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In nut shell Reduction in scaffolding activity and
inspection activity can reduce the Shutdown
time by 3days to match production targets.
Something very different and innovative idea
can only help in this situation.
FRUGAL INNOVATION-1
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The Idea struck was :
Why not to Fabricate and use amulti-storied platform to help the
Inspection activities inside the
Ammonia Synthesis Convertor
Pressure Vessel.
This will allow inspection of all C-
seam joints of all 6-levels at a time
i.e. Inspection time is reduced.
More safe
Installation and removal is one
houreach only.
FRUGAL INNOVATION-1
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FRUGAL INNOVATION-1
This scaffolding structure was actually
erectedinto vessel in 1 hour instead of2days.
Inspection was carried out through out
the vessel in a time in 12 Hrs instead
24hrs due to easy access.
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FRUGAL INNOVATION-1
The scaffolding was de erectedfrom
the vessel in 1 hour instead of 1 day The whole inspection activity
completed with in 16 hrs instead of 4
days
Net saving of 3 days
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This innovative idea Reduced shut down time by 3days
9,090 MT More Urea Production (@ 3030 MT Per day)
More profit on the production approx.Rs. 1.5 Crore.Other Benfits :
The fabricated structure can be utilised for such
applications with slight modification
The used material can be reclaimed and re-utilised.
FRUGAL INNOVATION-1
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REDUCTION IN REPAIR TIME OF
Syn-loop boiler (E-1501) Ammonia-1
IMPORTANCE:Use waste heat of syn gas coming from
converter (Exothermic Reaction).
Produce HP steam
OBSERVATION:Tube leakage.
EFFECT:Boiler steam conductivity running higher
than normal and Loss of syn gas.
FRUGAL INNOVATION-2
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Repair Procedure with
Hydro Testing
Shell has to be Hydro tested at max at 80
kg/cm2 to find out leaks and than carried out
repair. If repair having some defect repeat
hydro test in iterations till all leak points
repaired.
Tubes were plugged with Inconel plugs and
welding was done with TIG process using ErNi Cr3 filler wire of 1.6 &2.4 mm size. Tube to
tube sheet leakage was also repaired by
welding overlaying process.
FRUGAL INNOVATION-2
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Difficulty in hydro testing Procedure:
In hydro test DM water was being used and after leak detection this
water required to be drained from shell for leakage repairing.
Complete cycle of one hydro test (Filling, pressurization and
draining) takes min. 10 hrs
Leakage repairing was done by TIG welding, which require clean
and dry surface. This condition was not achieved in presence of
water, which results difficulty in welding.
Note : Through this procedure more time required and also
difficulty in welding.
FRUGAL INNOVATION-2
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PNEUMATICALLY LEAK DETECTION
INSTEAD OF HYDROTEST,WAS
CONCEPTUALISED TO
SAVE TIME & WATER FREE WELD
REPAIR
FRUGAL INNOVATION-2
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New SYN LOOP BOILER TESTING ARRANGEMENTSynthesis Loop Boiler Pneumatic Testing Scheme
AMMONIA PLANT
UREA PLANT
MOTOR
COMP
K-3
Passivation Air Comp.
for Bimetallic Stripper
E-1501Synthesis loop
Air (80 kg/cm )
To Bimetallic
Stripper
Pr. Gauge
FRUGAL INNOVATION-2
FRUGAL INNOVATION 2
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Repair Procedure
with Pneumatic Testing: Shell was PNEUMATICALLY tested at 3kg/cm2, 7.0 Kg/cm2,
25 kg/cm2 and max at 62 kg/cm2 and repair was carried out in
each iterations.
Tubes were plugged with new modified Inconel plugs and welding
was done with TIG process using Er Ni Cr3 filler wire of 1.6 &2.4 mm
size. Tube to tube sheet leakage was also repaired by welding
overlaying process.
During last S/D -2012, 04 nos. leaky plugs were removed by grinding
and new plugs provided and welded. Tubes to tube sheet weld joint
were repaired by welding.
FRUGAL INNOVATION-2
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BENEFITS
1.Time saving
2. Defect free welding
The above suggestion has given a
Tangible Benefit of 3,00,00,000/- (one time)and other benefit like reduction in overall
plant shut down period.
FRUGAL INNOVATION-2
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Primary Reformer - Ammonia Plant
FRUGAL
INNOVATION - 3
Use of Special Jig for
handling more than one
catalyst Tube
AB Cell
CD Cell
View
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Earlier approach
Single catalyst Tube removal& insertion time was approx.
30 min. (One crane operation)
Total 288 Crane operations
would be required by
conventional method.CatalystTube removal & insertion was
done on single tube basis
(conventional method).
Total time taken for tube
removal & insertion comes
out
= 6days
= 288x30 min= 8640 min
FRUGAL INNOVATION-3
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The Idea struck was :
Why not to Fabricate and use
fixtures/clamps for removal &
insertion of two or more Catalyst
tubes.
This will reduce the total no of crane
operation and would reduce total
time taken for removal & insertion of
catalyst tube.
More safe.
Optimum utilization of Crane
capacity.
Conventional Fixture for singletube Removal/insertion
New Fixture for twotubes Removal/insertion
New Fixture for threetubes Removal/insertion
FRUGAL INNOVATION-3
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IMPLEMENTED APPROACH The Suggestion was
implemented by
fabricating new Jigs
& Fixtures in house
using the scrapstructural & piping
material.
FRUGAL INNOVATION-3
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Sr
no
Activity Conventional
Fixture for Single
catalyst tube
New Fixtures for two or
three catalyst tubes
%
Reduction
1 Total crane
operation
(Usage of
Crane)
288 50-AB Cell
74-CDCell
60%
2 Total time
taken
=288x30min
=6 days
=124x50* min
=4.3 days
28.3%
(1.7 Days
saved)
3 Safety Groove for Two part
ring But no Bolting
Stopper cleats for two
part ring and fixtures wereBolted
More safe
Note: *Extra time for single crane operation with new fixtures wasdue to Bolting & dismantling of clamps, difficulties in alignment &removal of old catalyst tubes.
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can only help in such situations
Out of box thinking
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CONVERT YOUR IDEAS
INTO ACTION THROUGH
FRUGAL INNOVATION