Kaizen_ Electrical Unit saving fhgdgutfhfhgh

BALKRISHNA INDUSTRIES LIMITED,WALUJ,AURANGABAD.
1
TO
RESPECTED JURIES AT
23rd CCQC AURANGABAD-2022

CHOPANKI
BHIWADI
AURANGABAD
W-I & W-II
BHUJ
PLANT
AURANGABAD W-I & W-II
BHIWADI, RAJASTHAN
CHOPANKI, RAJASTHAN
BHUJ, GUJRAT
Tire size range from 09” to 58’’ bead diameter
Manufacturing of
Tires (off the road)
PLANT PRODUCTS & LOCATIONS
2

AWARDS & RECOGNITIONS
3
AWARDS WON BY BKT AURANGABAD PLANT
Sr. No Date Competition Prizes won total
13 14-Nov National convention -Pune 2 Excellence, 2 distinguish 4
14 15-Feb Mini Convention- QCFI, Nagpur. 1 best of best 1
15
15-Aug Chapter convention QCFI- A 'Bad
1 best of best runner up, 2
gold,
4
1 silver
16 15-Sep QPRO NAGPUR 1 Gold 1
17 15-Oct ICQCC-2015 SOUTH KOREA 1 Excellence (SILVER) 1
18
15-Dec National convention, Chennai
1 Par Excellence, 1
distinguish 2
19
16-Aug Chapter convention QCFI- A 'Bad
1 best of best ,2 silver, 1
distinguish 4
20 16-Aug ICQCC-2016 BANGKOK 1 Par Excellence (GOLD) 1
21 16-Sep QPRO NAGPUR 2 GOLD 2
22 Dec-2016 National Convention Raipur 2 Par Excellence 2
23 July-2017
17th Chapter Convention QCFI
A'bad
1 Best of Best Trophy, 2 Gold
Awards 3
24 Dec-2017 National Convention ,Mysore 1 Excellence & 1 Distinguish 2
25 Aug-2018
18th Chapter Convention QCFI
A'bad
1 Best of Best Trophy, 2 Gold
Awards 3
26 Dec-2018 National Convention ,Gwalior 1 Excellence 1
27 Aug-2019 20 TH CCQC AURANGABAD 1 Best of best and 1 silver 2

4
PROBLEM IDENTIFICATION
4

5
PRESENT PROBLEM & REASON FOR SELECTION
Sr. No. Reason
1
Electrical energy loss due to running of separate pump
which is suppling water for top up in plant air washers.
2
Normally soft/raw water supplying for any air washer, in
our system we are using raw water which having more
hardness against soft water.
5

6
6
Sl No Name Responsibility
1 Mr. Pankaj Patil Leading of project
2 Mr. Pravin Shinde Data collection & Follow up
3 Mr. Sitaram Sonne Implementation of job
4 Mr. Badrinath
Borade
Elect data collection

MILE STONE-ACTIVITY CHART 8
STEP ACTIVITY P/A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
1
PROBLEM
IDENTIFICATION
P
A
2
PRESENT PROBLEM
AND REASON FOR
SELECTION
P
A
3 DEFINE THE PROBLEM
P
A
4
ANALYSIS OF THE
PROBLEM
P
A
5
IDENTIFICATION OF THE
CAUSE
P
A
6
FINDING OUT THE ROOT
CAUSE
P
A
7 DATA ANALYSIS
P
A
8 DEVELOPING SOLUTION
P
A
9
FORESEEING PROBABLE
RESISTANCE
P
A
10
IMPLEMENTATION &
CHECKING THE
PERFORMANCE/RESULT
P
A
PLANNED ACTUAL DELAYED
MILESTONE ACTIVITY CHART (01.07.22 TO 15.07.22)
7

BRAIN STORMING
Can we use soft
water to air
washers?
Can we supply soft water
from existing running
pump for process to air
washers ?
Can we prolong life of
Air washers ?
Can we eliminate pump to
save energy ?
8
Can raw water harmful
For air washer’s system ?

OUTCOME OF BRAIN STORMING
9

Area Application
Energy
consumption
avg. Kwh/day
Water treatment
plant (Utility)
Water supply pump with
motor of 7.5 kw @ 24 hrs
running
145
DATA COLLECTION BEFORE IMPLEMENTATION
10
Team installed energy meter at electrical panel of
water supply pump’s motor and collected energy data
for 3 to 4 days

15
IMPLEMENTATION OF PROJECT
 In water treatment plant, team fabricated the pipe line
and connected with soft water line which is supplying soft
water to process. This pump is continue running as per
process requirement.
 Now soft water is supplying to air washers also in place of
raw water.
 Resulted one separate pump made stopped permanently,
hence saved electrical power.
11

12
DEVELOPING SOLUTION
Soft water
Supply to plant
Existing water supply line for air
Washers connected to soft water line
Soft water supply line from pump
Now soft water
Supply to air washer

TOOLS & TECHNIQUES USED
 DATA COLLECTION
 BRAIN STORMING
13

Electrical unit saved = 145 kwh/day
14
Area Application
Energy
consumption
avg. Kwh/day
Water treatment
plant (Utility)
Water supply pump with
motor of 7.5 kw @ 24 hrs
running for A/W supply
00
DATA COLLECTION AFTER IMPLEMENTATION

FOLLOW-UP & REVIEW
15

STEP ACTIVITY P/A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
1 PROBLEM IDENTIFICATION
P
A
2
PRESENT PROBLEM AND
REASON FOR SELECTION
P
A
3 DEFINE THE PROBLEM
P
A
4
ANALYSIS OF THE
PROBLEM
P
A
5
IDENTIFICATION OF THE
CAUSE
P
A
6
FINDING OUT THE ROOT
CAUSE
P
A
7 DATA ANALYSIS
P
A
8 DEVELOPING SOLUTION
P
A
9
FORESEEING PROBABLE
RESISTANCE
P
A
10
IMPLEMENTATION &
CHECKING THE
PERFORMANCE/RESULT
P
A
PLANNED ACTUAL DELAYED
MILESTONE ACTIVITY CHART-COMPLETED(01.07.22 TO 15.07.22)
16

 Reduced electrical power consumption @ 145 kwh/day.
 Reduced maintenance / spare cost @ rs 25 thousand/ annum
 Air washer’s cell pads life increased & saved @ avg 2 lac rs /annum
17
BENEFITS
Tangible :
Intangible :
 Conserved natural resources.
 Reduced carbon foot print.
 Air washer inside water spray system made healthy.

CONSERVED ELECTRICAL UNITS
18
 Per day electricity saved = 145 kwh
 Annual electricity saved ( considered 220 days) = 31900 kwh
Annual saving in lac Rs= 3.20

KAIZEN IDEA SHEET
19
@
Dept: Engineering
Improvements Waluj-II
Plant
Aurangabad
Section: Utility
Loss: Electrical Energy
Kaizen
Theme -
Energy conservation by
eliminating air washer supply
with additional pump by the
soft water pump
Idea Energy conservation by eliminating air
washer supply with additional pump by
the soft water pump
Separate HVAC pumps used for Water in Air washers
Soft water line connected to Air washer water
supply line
Problem / Present status Counter measure Bench mark
Following problems were faced ;
1. Energy loss, separate HVAC pumps are run for air
washers water supply.
2. Air washers' life is prolonged as usage of soft water
in it.
After the SW line connection to air washers' water
supply line,
1. The energy conservation is achieved.
2. Pump maintenance cost is saved.
3. Prolonged the life of air washers
Target 15.07.2022
Kaizan started on 01.07.2022
Kaizen finished on 15.07.2022
Team members
1. Pankaj Patil
2. Sitaram Sonne
3. Pravin Shinde
4. Badrinath
BENEFITS :-( Mention in PQCDSM as Applicable )
Quality
Cost
Analysis. Result
Air washer needs soft water for spraying which was
supplied by HVAC pumps which were running only for
air washer water supply.
we saved Electrical power @ 7.5 KW X 24 hrs.X
200 days as well as save cost of maintenance of
pump & motor. Annual saving= 03.6 Lac Rs Scope & Plan for Horizontal Deployment
Sr.no. Location Resp. Target Dt Status
Energy loss due to running of separate pumps of
HVAC 1 WTP Ritesh Gupta 15.07.2022 Closed
we already run the soft water pump for soft water
supply in the plant.Tapping can be provided from it to
air washers.
raw water
supply to
Air Washers
through
pump
Soft Water
supply
through
existing
soft water
supply

20
20
This was an in-house activity initiated by plant engineering team
who took the challenge to develop this energy saving solution by
permanently stopped one water supply pump which has also
helped us to recused running cost of plant !
CONSISTENT EFFORTS IN RIGHT
DIRECTION PAY BACK IN LONG
RUN………….
ENERGY SAVED IS ENERGY PRODUCED

21
21

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