Kaizen case study submitted by SRF Overseas Limited during 3rd Continual Improvement & Innovation Symposium organized by Dubai Quality Group's Continual Improvement Subgroup to celebrate World Quality Day 2011.

1. Quality Month: Kaizen Page
November 2011 No. No.:
KAIZEN REPORT
Company logo Company Name Department Section/Process
SRF Limited, Technical Textiles Business, Manali Electrical Electrical
Improvement Title: To reduce production loss due to Maximum demand (MD) controller acting
Category: [√ ] Quality improvement [ ] Health & Safety [ ] Environment [√ ] Productivity [ ] Office processes
Before Situation Root Cause Analysis Improvement After Situation
Measures
TNEB supply To avoid tripping of
Why 4 MCCs at a time,
one multi output 4
3.5
3.703 3.174
Kaizen
1
Kaizen
2
Production loss in MT
timer introduced 3 Befor
MD controller trip comment is connected 2.645 e 2.645
 If MD alarm
2.5
2.116 2.116
With LCSS 4 input 2
1.5
1.109
signal comes 1
0.255 0.255 0.255 0.255
immediately one 0.5
1.075
Why MCC will trip
0
0
0
0
0
10
10
0
1
10
1
11
10
r-1
-1
-1
-1
-1
y-1
h-1
ly -
y-
ri l-
ry-
st-
 If MD alarm still
ne
er
er
er
be
ar
Ma
rc
Ju
Ap
mb
mb
ua
tob
gu
Ju
nu
em
Ma
MD controller
br
Au
ve
ce
Oc
Ja
pt
Fe
No
De
Se
LCSS 4 distributions are faraway from MD controller continue, after 1
And no load shedding provision mint 2nd MCC will
Why trip
LCSS - 4  If still MD alarm
TRIP
continue, after 1.5
OEM Design mints 3rd MCC will
trip
 If still MD alarm
continue, after 2
How mints 4th MCC will
Critical Loads Non Critical Loads – 2 MW trip
We can utilize with available power SCADA If MD not reached
communication system to communicate MD to the set value,
only one MCC will
controller ALARM comment to the faraway be affected
LCSS 4

2. Why
 MD controller trip comment is connected with
LCSS - 4
Still the production loss High during
 Twisting machines – 58 Nos & ETP plant will
affect MD controller acting (1.092MT/Month)
 Twisting machines production capacity is 25.40
MT / day Why
 For every MD controller trip, plant stabilizing No proper load shedding provision in MD
period is 30 mints controller
 Avg. production loss / Month is 2.73 MT Why
OEM Design
(Only one output is available)
 Due to high fuel cost, we are purchasing 3rd party
power through TNEB grid
How
Now CPP is under stand by
Now there is no power adjustment during MD The MD controller ALARM
alarm acts signal to be converted into multi timer function
So MD controller should trip the non critical load
to avoid MD shoot up
Hence all twisters are affected
Considerable production loss
8
7
7
6
6
No of occurance
5
5
5
4
4 4
3
2
1
0
April-10 May-10 June-10 July-10 August-10 September-10

3. Benefits: Participation
Standardization Horizontal Deployment Opportunities (Replication):
Work Instruction Updated, Drawings revised, Training and communication to all the Electrical Team members
Not Applicable
Single Point Lesson: Remark / Management Comments:
Approved.
Shared.
Sign
Copy Distribution: Date of Starting: Date of Control No.
Electrical, TQM Cell 5th Oct’10 Completion: (by DQG)
15th Dec’10
Declaration: We are submitting this Kaizen case voluntarily to DQG for participation in Kaizen Blitz competition. We are glad to authorize DQG to share this information with the Business
community at large to promote Continual Improvement and good practices.
Signed by Authorised signatory: _______________________Name:___M.N.Rathnam___________________________Designation:____Cheif Manager – MT
_________________________________ Date: _07___/_10___/_2011_______