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Layout Improvement - Praj Industries
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Layout Improvement - Praj Industries



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  • 1. Lean Kaizen Mela 2013PRAJ INDUSTRIES LTD.Layout Improvements
  • 2. Lean Kaizen Mela 2013PRAJ Industries Ltd – A BriefAcross 5 Continents…In more than 50 Countries…Over 500 References…From Australia to Peru…Established in 1984 by first generation techno-preneur : Pramod ChaudhariPraj has been creating innovative technology platforms to make bio fuels asustainable and attractive choice for all stakeholders for the past 25 years !
  • 3. Lean Kaizen Mela 2013Over 28 years of experience in process engineering based solutions.AgriServicesAlcohol /Fuel EthanolPlants BreweryPlantsWater andWastewaterTreatmentBionutrientsCritical ProcessEquipment &SystemsLSTK Process/Chemical PlantsWhat Do We Do?
  • 4. Lean Kaizen Mela 2013Problem Statement - Summary1. Excessive distance of storagelocation from POU & time wastagedue to movement for machining2. Preparatory Shop as a bottleneck !
  • 5. Lean Kaizen Mela 2013Understanding the Problem : Praj LayoutUnit 01Unit 02Preparatory Shop&Unit 3
  • 6. Lean Kaizen Mela 2013Decentralizing themachine shopsActions : 1CreatingPoint of Use Storage&Point of Use MachiningHold/ Finished Goodsat a centralizedlocationCreating new spacefor storing materials
  • 7. Lean Kaizen Mela 2013Activity SequenceCurrent LayoutData CollectionCurrent Spaghetti DiagramsNew Spaghetti diagrams New LocationIdentificationBenefits Calculation Execution PlanExecution
  • 8. Lean Kaizen Mela 2013Layout Preparation
  • 9. Lean Kaizen Mela 2013Reduction in distance fromPOU - 30 MetersSpace Generated : 4500 Sq Ft.SS CoilsAfterBeforeSpaghetti Diagram
  • 10. Lean Kaizen Mela 2013BeforeAfterPhotographsSS Coils
  • 11. Lean Kaizen Mela 2013BeforeAfterPhotographsSS Coils
  • 12. Lean Kaizen Mela 2013Reduction indistance fromPOU– 45 metersNozzle Flanges, Body Flanges & Profile materialsBeforeAfterSpaghetti Diagram
  • 13. Lean Kaizen Mela 2013BeforeAfterPhotographs
  • 14. Lean Kaizen Mela 2013BeforeAfterPhotographsNozzle Flanges, Body Flanges & Profile materials
  • 15. Lean Kaizen Mela 2013BeforeAfterPhotographsNozzle Flanges, Body Flanges & Profile materials
  • 16. Lean Kaizen Mela 2013Reduction in distancefrom POU– 120 MetersBeforeAfterHE TubesSpaghetti Diagram
  • 17. Lean Kaizen Mela 2013BeforeAfterPhotographsHE Tubes
  • 18. Lean Kaizen Mela 2013BeforeAfterPhotographsHE Tubes
  • 19. Lean Kaizen Mela 2013Reduction inDistance fromPOU – 210 MetersBeforeAfterStiffener Channel, Flats andJacketsSpaghetti Diagram
  • 20. Lean Kaizen Mela 2013BeforeAfterPhotographsStiffener Channel, Flats andJackets
  • 21. Lean Kaizen Mela 2013Reduction in distance fromPOU - 880 MetersAdditional Space freed : 1076 S Ft.Machine shopAfterBeforeSpaghetti Diagram
  • 22. Lean Kaizen Mela 2013PhotographsMachine Shop shifted to Point of use
  • 23. Lean Kaizen Mela 2013Results- Reduction in Distance from POU StorageTotal Distance Reduced - 405 Meters
  • 24. Lean Kaizen Mela 2013Total Distance Reduced - 880 MetersResults- Reduction in Distance due to POU Machine Shop
  • 25. Lean Kaizen Mela 2013Understanding the Problem : Preparatory ShopPreparatoryShopFabricationShop 1FabricationShop 2FabricationShop 3Delivery TimeOff-cutUtilizationCNC MachineUtilizationGas Cylinder Storagefor CNC Plasma CuttingMachine
  • 26. Lean Kaizen Mela 2013Actions -2Preparatory ShopImprovementsShop LayoutImprovementOff-cut Area layoutto be rearrangedGas Bank
  • 27. Lean Kaizen Mela 2013Activity SequenceCurrent Layout Data CollectionPreparatory Shop newlayoutExecution Plan Off-cut Area, Sop Layout Change , Off-cut AreaRearrangement and Gantry Crane FabricationExecutionOff-cut Area newlayoutGas Bank AreaDrawing
  • 28. Lean Kaizen Mela 2013Layout PreparationOld LayoutNew Layout
  • 29. Lean Kaizen Mela 2013Layout PreparationLayout Changes
  • 30. Lean Kaizen Mela 2013Gas Bank FabricationProper shade to store gases for CNC Plasma M/c.Reduced gas changeover time.Two banks maintained now ( In Queue and In Process )
  • 31. Lean Kaizen Mela 2013PhotographsBeforeAfterGas Bank
  • 32. Lean Kaizen Mela 2013CNC Cutting Machine UtilizationIncreased CNC Machine UtilizationIncreased Bed length of Plasma Cutting MachineDedicated Overhead crane for CNC Cutting and CNC Drilling MachinesDesigned and Fabricated the Goliath Crane In-house
  • 33. Lean Kaizen Mela 2013Off-cut Area Re-arrangedArranged Off-cut Area Thickness and Material wise.Increased Utilization of off-cuts for cutting.Reduced preparation time for periodical stock take.Reduced WIP materialIncreased traceability by creating database as per layout
  • 34. Lean Kaizen Mela 2013Benefit Summary500 Km/Yr - Travel reduced350 min/day – Travel time reduction6500 Sq Ft - Space generated200 % Increase in Off-cut Utilization (Rs 40 Lac worth Off-cut utilized in 2 months)50 % - WIP reduced @ Prep Shop90% reduction – Man-Days for Stock taking operation2000 Sq Ft under crane space generated @ Prep Shop200 mins. per day (Rs 10 Lac. Per year ) –increased CNC Utilization2000 T overall yearly Production Capacity Increased !
  • 35. Lean Kaizen Mela 2013Thank You !!For Praj Industries Ltd:Milind PrabhuneS V DarekarMohit Malani