TPI Head – Direct Cost reduction (Water cost)

TDR Registration

Amber Pune Unit

Theme - Reduce Water cost by 30% in 16-17

TDR leader - Amrit Raj Jaiswal

COOPl. Head Dir. Oprn.

THEME

EXISTING PROBLEM INNOVATION IDEA TARGET TEAM MEMBERS

NECK POINT BenefitsIMPLEMENTATION PLAN

PROCESS MONTH

Oprn Head

usages & plant capacity Working

TARGET DATE

Name Sign.

Monetary Effect

Target

Before

After

LEADER

Qualitative

Quantitative

Amrit

PUNE Unit

Water Cost Reduction

April.16 31 Oct.16Jun.16 31 Aug.16

Innovation Plan

Implementation

Monitoring & Control

10 % improvement

TDR Registration sheet

Manoj .

Ujjwal

NavnathSudam

•Improve basic condition of R.O. & DM plant & utilize capacity• Increase capacity of R.O.• Process water reuse by cascading system•R.O. reject water use for general purpose .

Rs. 14.4 Lacks / Year ( Till date-4.57 Lack)

Brainstorming & Data Collection

Year 15-16 – 0.34 of Sale % (Q 1- 0.29 % ,Q 2 – 0.42 %) (Q 3 – 0.49 % , Q 4 – 0.32 %) Sweta

31 Dec.16

Year 16-17 – 0.10 % of Sale (Q 1- 0.20 % ,Q 2 – 0.26 % ) (Q 3 – 0.10 %)

Wakle

Dept. :

Date : 01.04.2016

31 Dec ’16

Guide Satyendra/ Rishi

• High water cost due to R.O. water purchase • Capacity constraints in peak time•Water Quality not as per std. in peak time

Water Consumption Details- 2015

2015

Water cost Other costTotal cost Paint in sqm Cost /

sqmCost if no

innovation SavingsMIDC bill RO

Purchase Raw water Sub-total Maint cost Mambrane cost

Investment cost

Jan-15 20,578 313,600 2,400

336,578 -

336,578

77,485 4.34

Feb-15 20,665 312,000 7,200

339,865 -

339,865

95,477 3.56

Mar-15 23,440 372,000 20,800 416,240

-

416,240

88,419 4.71

Apr-15 12,767 320,000 7,200

339,967 -

339,967

83,238 4.08

May-15 30,743

94,000 5,600

130,343 -

130,343

42,919 3.04

Jun-15 27,546

- -

27,546 - 27,546

18,329 1.50

Jul-15 25,600

- -

25,600 12,550 - 38,150

15,954 2.39

Aug-15 22,529

- -

22,529 66,000 - 88,529

11,271 7.85

Sep-15 19,462 5,500 -

24,962 - 24,962

9,058 2.76

Oct-15 23,882

-

-

23,882

- 23,882

7,586 3.15

Nov-15 46,307

- -

46,307 - 46,307

15,748 2.94

Dec-15 15,433 5,200 -

20,633 - 20,633

25,623 0.81

Total 288,952 1,422,300

43,200 1,754,452 12,550 66,000 -

1,833,002

491,106 3.73

Water Cost Trend- 2015

Jan-15 Feb-15 Mar-15 Apr-15 May-15 Jun-15 Jul-15 Aug-15 Sep-15 Oct-15 Nov-15 Dec-15 Total0.00

1.00

2.00

3.00

4.00

5.00

6.00

7.00

8.00

9.00

4.34

3.56

4.71

4.08

3.04

1.50

2.39

7.85

2.763.15 2.94

0.81

3.73

Water Cost / sqm

Basics• Capture database of purchase RO Water in Year

15-16• Enhance capacity planning if in-house mfg of RO

water

Actions

• Requisition of added new R.O. plant for capacity improve

• Cascading system implementation for process water re-use

• Preventive maint. & spares availability of R.O. & D.M. plant to enhance 100 % utilization

Monitoring

• Maintain RO plant with close monitoring of capacity enhancement

• Maintain equipment efficiency • Work on Greenco activity with water

conservation ideas

Activity Plan Sheet

Sr. No. Equipment Current Capacity Requirement Shortfall Remark

1 RO. Plant 1100 lit / hrs.Ok out put 1160 lit/ hrs max -60 lit/Hrs.

New R.O. plant to be install for

fulfill requirement

2. D.M. Plant 1000 lit/ Hrs. OK out put 600 lit /Hrs. + 400

lit/Hrs. No issue

3.Incoming Raw water capacity

from MIDC 75000 Lit / Day 70000 Lit/ Day +5000/Day No issue

RO plant capacity enhancement with availability

MIDC Inlet

70K

General Use

41.9K

E.T.P.

1.2K

R.O.

28.1K

For D.M.

13.6K

Direct R.O. Use

14.4K

D.M.

12.4K

MIDC water distribution chart

Water Consumption Reduction Action Plan

Sr.No. Type of water Dept. Present Source Action To Reduce

1 DM water

Paint shop

In-house DM plant used RO water to convert in DM

1.Casceding to be start with auto filling system 2.Rinse 5 water use for top up in Phospeting 3.Phospeting de-sludging pump to be start & increase bath de slugging frequency from one monthly to two monthly. 4. Repair all pipe line and valves to avoid leakages & wastages of water. 5. Change seals of pumps to avoid leakages

In-house R.O. plant used to make R.O. from MIDC water

1.Casceding to be start with auto filling system 2.Rinse 2 water use for top up in KOD & degreasing 3.Additional raw water tank for increase storage capacity. Up to 15K4.New R.O plant to be installed to avoid short falls.5.Primary filter increase from 1no to 4 nos. to increase membrane life6. Membrane change to increase out put.7. DM reject water collect & circulate through again RO plant.8. Change seals of pumps to avoid leakages

2 RO water

3 RawGeneral Use R.O. Plant reject flow water to

general purpose

Raw water can be use at canteen at hand wash basin with separate tank & one separate hand wash station for ladies with raw water connection

RO reject low (1800 ltr/hrs) use for toilet & fire fighting system (Daily appro. Generated 25K lit if all R.O. we made in house

Weld shop 1.Leakages from cooling towers arrest.2. Cooling tower PM to be carried out to improve performance

Action Plan

Best practices : Water cascading system in Pre-treatment lineImplementation of water cascading system for conservation

Issue Improvement Result

Before After

250100%

0

Paint peel off in PPM

Excess water uses in paint shop

1. Water filling in tank individually ,

wastage is higher

Water cascading system

1. Water Inlet pipeline in series to reduce

water drainage frequency

Quality improvement Water Reduction 3K / Day

Water Consumption / day

Before After

23KL 15%

20KL

Best practices : RO plant capacity enhancement activity

storage capacity increase from 5 k to 15 k

Issue Improvement Result

Leadership Through Innovation

Raw water capacity increase from 5K to 15K Eliminate raw water shortage for RO making

Raw water ( MIDC) storage capacity increase

from 5 k to 15 k , to use 100 % capacity of RO

working during shortage from MIDC supply

Storage capacity 5K only

1. Shortage water of water for RO

making

2. R.O. purchase from outside party

Water Consumption Details- 2016

Last year cost/Sqm. 3.73Water cost reduction - yearly ROI achievement sheet

2016Water cost Other cost

Total cost Paint in sqm Cost / sqm

Cost if no innovation Savings

MIDC bill RO purch. Raw water Sub-total Maint cost Mambrane cost

Investment cost

Jan-16 32,755

40,000

-

72,755 -

72,755

62,920 1.16

234,842

162,087

Feb-16 58,462

64,000

-

122,462 -

122,462

78,823 1.55

294,199

171,737

Mar-16 54,010

133,000

-

187,010 -

78,375

28,000

293,385

96,283 3.05

359,366

65,981

Apr-16 63,812

-

-

63,812 -

63,812

92,253 0.69

344,325

280,513

May-16

56,870 -

-

56,870 - 56,870

71,143 0.80

265,534

208,664

Jun-16

32,365 -

-

32,365 32,365

41,017 0.79

153,092

120,727

Jul-16

33,925

33,925 33,925

395340.86

147,556

113,631

Aug-16

43,000

43,000 43,000

17,793 2.42

66,411

23,411

Sep-16 -

- #DIV/0!

-

-

Oct-16 -

- #DIV/0!

-

-

Nov-16 -

- #DIV/0!

-

-

Dec-16 -

- #DIV/0!

-

-

Total

375,199

237,000 -

612,199 -

78,375

28,000

718,574 499,766 1.44

1,865,324

1,146,750

Water Cost Comparison- 2015 V/S 2016

2015 Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Total

Total cost

336,578

339,865

416,240

339,967

130,343

27,546

38,150

88,529

24,962

23,882

46,307

20,633 1,833,002

Painting in sqm

77,485

95,477

88,419

83,238

42,919

18,329

15,954

11,271 9,058

7,586

15,748

25,623

491,106

Cost / sqm painting 4.34 3.56 4.71 4.08 3.04 1.50 2.39 7.85 2.76 3.15 2.94 0.81 3.73

2016 Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Total

Total cost

72,755

122,462

293,385

63,812

56,870

32,365

33,925

43,000 718,574

Painting in sqm

62,920

78,823

96,283

92,253

71,143

41,027 39,534 17,793 499,776

Cost / sqm painting 1.16 1.55 3.05 0.69 0.80 0.79 0.86 2.42 #DIV/0! #DIV/0! #DIV/0! #DIV/0! 1.44

Saving value 263,823

217,403

122,855

276,155

73,473

(4,819)

4,225

45,529

998,644

Water Cost Trend- 2015 V/S 2016

Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Total0.00

1.00

2.00

3.00

4.00

5.00

6.00

7.00

8.00

9.00

1.161.55

3.05

0.69 0.80 0.79 0.86

2.42

1.44

4.34

3.56

4.71

4.08

3.04

1.50

2.39

7.85

2.763.15 2.94

0.81

3.73

2016 2015