This document discusses lean manufacturing and its application to petrochemical plants. It defines lean manufacturing as focusing on eliminating waste, improving productivity, quality and optimizing resources. The document outlines various lean tools like 5S, kaizen, total productive maintenance and their use. It analyzes sources of waste in petrochemical plants and provides examples of applying lean thinking to maximize byproduct value, reduce conversion costs and implement business cases around market optimization, product development and opportunity realization. The overall objective is to translate lean philosophy for continual improvement in petrochemical operations.
Lean manufacturing is a production process based on an ideology of maximising productivity while simultaneously minimising waste within a manufacturing operation
A very simple way to understand Lean Manufacturing and its concepts, with lots of images that makes it more easy.
Lean manufacturing is the concept of the manufacturing which is more about saving time and best quality. Lean is the systematic way of manufacturing to utilize the source and get maximum out of it.
Lean manufacturing is a production process based on an ideology of maximising productivity while simultaneously minimising waste within a manufacturing operation
A very simple way to understand Lean Manufacturing and its concepts, with lots of images that makes it more easy.
Lean manufacturing is the concept of the manufacturing which is more about saving time and best quality. Lean is the systematic way of manufacturing to utilize the source and get maximum out of it.
Overview on the Toyota production system principles, techniques and theories.
The presentation include:
-Lean Manufacturing Principles
-Productivity Measurement, Analysis and Improvement
-Effect & Elimination of the Manufacturing 7-Wastes
-Lean Improvement Techniques
-Lean Management for Making Improvement & Gaining Sustainability
IMPROVEMENT OF MANUFACTURING OPERATIONS THROUGH A LEAN MANAGEMENT APPROACH A...sanobar77
The case study concerns the plant of a primary multinational company of the pharmaceutical industry. This plant produces pharmaceutical products in a solid form (pills, tablets, capsules, etc.). The company has about 400 employees and its annual production adds up to about 100 million packages sold in the European market and to more than 100 markets globally.
The pharmaceutical industry has been greatly affected by the 2008-2010 global economic crises. Revenues are decreasing because of competition from generic alternatives, while the costs of R&D are rising for and competition is increasing. All these features push pharmaceutical companies to apply methodologies for performance improvement
Applications of lean manufacturing toolsIshmam Ahmed
Lean Tools application with powerpoint animation. all processes are easily described with images & animation.
Uploaded by
Ishmam Ahmed
Industrial & Production Engineering (IPE)
Shahjalal university of science & Technology, Sylhet, Bangladesh
Webinar held on July 15, 2009
Lean Fundamentals Overview
Presented by: Michael E. Parker
Description:
Utilizing my one-on-one training by lean experts from Toyota Motor Corporation (TMC) in Japan's Toyota City, you'll receive an overview on the main fundamentals that drive the lean management philosophy and learn how you can begin implementing these philosophies in your business. Whether you are a small business owner, entrepreneur, mid-level to senior-level manager or director, you will gain valuable insight on the critical business issues you are facing today and how to utilize lean management principles to recognize areas to reduce costs, add value and change your processes for the better.
We will discuss these key fundamentals of lean management:
o Cost Reduction Principle
o Lead-Time Reduction
o 7 Forms of Waste
o Just-In-Time
o Built-in-Quality (Jidoka)
o Level Scheduling (Heijunka)
o Pull Systems (Kanban)
o Kaizen
Lean manufacturing is a systematic method for waste minimization ("Muda") within a manufacturing system without sacrificing productivity.http://www.vpresentationslides.com/lean-manufacturing-ppt/
Real-time Data, Site wide Digital Twin, and Proprietary Analytics Cuts into P...Yokogawa1
Energy is one of the largest costs for process facilities. While operators can save significant money with minimal impact to production, they often lack structured and automated digital technologies to identify and sustain performance improvements. The situation is further exacerbated by the lack of inconsistent data and inaccurate tools. This presentation will showcase how a process facility combines real-time data, site-wide digital twin, and proprietary analytics in a digital energy management solution to deliver up to 15% sustainable reduction in facility energy costs and carbon footprint. Performance gaps are automatically identified and broken down using a best technology benchmark to highlight improvement areas in real-time. Daily facility energy improvement opportunity lists are provided for operators to maximize value and track the efficacy of planned capital projects with accurate projections so operators can make faster informed decisions for capital allocation throughout the implementation cycle.
Overview on the Toyota production system principles, techniques and theories.
The presentation include:
-Lean Manufacturing Principles
-Productivity Measurement, Analysis and Improvement
-Effect & Elimination of the Manufacturing 7-Wastes
-Lean Improvement Techniques
-Lean Management for Making Improvement & Gaining Sustainability
IMPROVEMENT OF MANUFACTURING OPERATIONS THROUGH A LEAN MANAGEMENT APPROACH A...sanobar77
The case study concerns the plant of a primary multinational company of the pharmaceutical industry. This plant produces pharmaceutical products in a solid form (pills, tablets, capsules, etc.). The company has about 400 employees and its annual production adds up to about 100 million packages sold in the European market and to more than 100 markets globally.
The pharmaceutical industry has been greatly affected by the 2008-2010 global economic crises. Revenues are decreasing because of competition from generic alternatives, while the costs of R&D are rising for and competition is increasing. All these features push pharmaceutical companies to apply methodologies for performance improvement
Applications of lean manufacturing toolsIshmam Ahmed
Lean Tools application with powerpoint animation. all processes are easily described with images & animation.
Uploaded by
Ishmam Ahmed
Industrial & Production Engineering (IPE)
Shahjalal university of science & Technology, Sylhet, Bangladesh
Webinar held on July 15, 2009
Lean Fundamentals Overview
Presented by: Michael E. Parker
Description:
Utilizing my one-on-one training by lean experts from Toyota Motor Corporation (TMC) in Japan's Toyota City, you'll receive an overview on the main fundamentals that drive the lean management philosophy and learn how you can begin implementing these philosophies in your business. Whether you are a small business owner, entrepreneur, mid-level to senior-level manager or director, you will gain valuable insight on the critical business issues you are facing today and how to utilize lean management principles to recognize areas to reduce costs, add value and change your processes for the better.
We will discuss these key fundamentals of lean management:
o Cost Reduction Principle
o Lead-Time Reduction
o 7 Forms of Waste
o Just-In-Time
o Built-in-Quality (Jidoka)
o Level Scheduling (Heijunka)
o Pull Systems (Kanban)
o Kaizen
Lean manufacturing is a systematic method for waste minimization ("Muda") within a manufacturing system without sacrificing productivity.http://www.vpresentationslides.com/lean-manufacturing-ppt/
Real-time Data, Site wide Digital Twin, and Proprietary Analytics Cuts into P...Yokogawa1
Energy is one of the largest costs for process facilities. While operators can save significant money with minimal impact to production, they often lack structured and automated digital technologies to identify and sustain performance improvements. The situation is further exacerbated by the lack of inconsistent data and inaccurate tools. This presentation will showcase how a process facility combines real-time data, site-wide digital twin, and proprietary analytics in a digital energy management solution to deliver up to 15% sustainable reduction in facility energy costs and carbon footprint. Performance gaps are automatically identified and broken down using a best technology benchmark to highlight improvement areas in real-time. Daily facility energy improvement opportunity lists are provided for operators to maximize value and track the efficacy of planned capital projects with accurate projections so operators can make faster informed decisions for capital allocation throughout the implementation cycle.
The BPMA Annual Report, Directory and Buyers Guide 2016/17 aims to promote the British pump industry and the members of the BPMA. It is acknowledged as an authoritative, high-quality publication which ensures maximum awareness of the association, its members, their products and capabilities, throughout the world. It contains information about BPMA activities, useful articles, UK pump market data and details of the products and services offered by members.
Integrated asset model can provide a single source of the truth across the full stream for how molecules and operating conditions behave at the unit- and asset-wide level;
Thereby providing actionable insights into production activities that can drive convergence in decision-making and action across organizational silos.
ESTIEM Lean Six Sigma Green Belt Project at Continental - Scrap ReductionESTIEM
The project was conducted during an internship by a student who had attended ESTIEM Lean Six Sigma Green Belt Course.
Analytics presented in the case is directional to original. The case is used when students are selected for Lean Six Sigma Green Belt Intership at Continental. In the selection process candidates need to suggest a better way to use data and analytics.
More information about about the course and opportunities can be found here: https://www.estiem.org/default.aspx?PageId=3824
Achieving Manufacturing Excellence in Spinning mills through Productivity benchmarking is explained through reference standards and case studies by WINSYS SMC.
How Productive Are Your Manufacturing Competitors?Sanderson Group
Why low manufacturing productivity rates could be crippling your operations – and how technology and upgraded ERP platforms are helping your competitors to boost theirs.
ARC's Greg Gorbach CPM & Operations Mgmt Presentation @ ARC Industry Forum 2010ARC Advisory Group
CPM and Operations Management “Manufacturers Plant Software – Need Now More Than Ever”
ARC's Greg Gorbach CPM & Operations Mgmt Presentation @ ARC Industry Forum 2010 in Orlando, FL.
Operations Management/MES Trends
1. Deals Driven Top-Down
• Governance
• Process Improvements
• Manufacturing Excellence
• Visibility, End-to-End Performance
2. Business Decision to Invest in Plant IT
• Ops Platform
• Legacy replacement
• Needed for responsiveness, flexibility, quality, etc.
3. Integration with PLM Needed
• Customer-driven, not industry hype
• No standards means implementation cost
4. Sustainable Manufacturing Dawning
• Energy Management
• Carbon tracking, accountability, compliance
• Integrated, Flexible Packaging Management
5. Cloud Computing/Services/SaaS on horizon
BQR’s apmOptimizer™ optimizing the maintenance plans based on 25 years filed experience and patent pending SW based on intelligent analytic tools algorithms. BQR can predict the outcome of different maintenance scenarios using analytic simulation tools, saving precious time and expenditures.
Just-in-time means, for example, that in the process of assembling the parts to build a car, the necessary kind of sub-assemblies of the preceding processes should arrive at the product line at the time needed in the necessary quantities. It is a management philosophy that strives to eliminate sources of manufacturing waste by producing the right part in the right place at the right time.
This is Profile Presentation for Operational Excellence / Lean Consultant / Leader , Industrial Engineering Lead .
11 Years Extensive knowledge and experience of Mfg. / corporate Functions
in Manufacturing & Operational Excellence.
Exposure of diff. Industries (Automobile , Air Conditing Mfg, Electronics , Oil
and Gas , Aerospace
Demonstrated ability to lead large scale Cost Saving projects with multifunctional and technical capabilities (i.e Kaizen Drive , Zero Defect Strategy Implementation , World Class
Manufacturing Best Practices Implemenation , DOJO Training center Installation
, OEE Improvements , Productivity Improvement , Consumable cost Reduction ,
WIP Reduction , Rejection Reduction , 5-S Improvement , Mfg. excellence , Low
cost Automation & Technology Upgradtion etc.)
Ability to pick up knowledge of the clients business, new technology areas,
new processes/methodologies and apply these changes in the day-to-day
working of the systems organisation
Techno-Managerial Scope :- Responsible for planning, organizing,
managing and executing projects from beginning to end with Team
Initiate and Planning for Plant Budget and compile Group Company Budget
along with Finance Team technically
Worked with Indian, Japanese , German , US , Norway team on diff. projects
Won 15+ Awards in SGA & QCC Convention (Internal and External) i.e ACMA/CII/QCFI/STQM/SCGA
Having Extensive knowledge and experience of 3 Company New Plant
Installation , 13 Manufacturing Section Installation , 180+ New Product Development in Diff. Industry
Asia NOC Bridges Business-wide Performance Objectives and KPIs through an Adv...Yokogawa1
Misalignment and conflicting performance objectives between management and front line operators is the root cause of a lot of profit erosion. Businesses need systematic ways to align senior management objectives and operating KPIs. This presentation will demonstrate how a National Oil Company in Asia utilized data analytics and KPI trees with drill-down capabilities to systematically align performance objectives and KPIs in its gas processing division to achieve profit driven operations. The presentation will also highlight how first principles digital twins can be incorporated to serve as a soft sensor to deliver further accuracy and rigour.
Immunizing Image Classifiers Against Localized Adversary Attacksgerogepatton
This paper addresses the vulnerability of deep learning models, particularly convolutional neural networks
(CNN)s, to adversarial attacks and presents a proactive training technique designed to counter them. We
introduce a novel volumization algorithm, which transforms 2D images into 3D volumetric representations.
When combined with 3D convolution and deep curriculum learning optimization (CLO), itsignificantly improves
the immunity of models against localized universal attacks by up to 40%. We evaluate our proposed approach
using contemporary CNN architectures and the modified Canadian Institute for Advanced Research (CIFAR-10
and CIFAR-100) and ImageNet Large Scale Visual Recognition Challenge (ILSVRC12) datasets, showcasing
accuracy improvements over previous techniques. The results indicate that the combination of the volumetric
input and curriculum learning holds significant promise for mitigating adversarial attacks without necessitating
adversary training.
Hierarchical Digital Twin of a Naval Power SystemKerry Sado
A hierarchical digital twin of a Naval DC power system has been developed and experimentally verified. Similar to other state-of-the-art digital twins, this technology creates a digital replica of the physical system executed in real-time or faster, which can modify hardware controls. However, its advantage stems from distributing computational efforts by utilizing a hierarchical structure composed of lower-level digital twin blocks and a higher-level system digital twin. Each digital twin block is associated with a physical subsystem of the hardware and communicates with a singular system digital twin, which creates a system-level response. By extracting information from each level of the hierarchy, power system controls of the hardware were reconfigured autonomously. This hierarchical digital twin development offers several advantages over other digital twins, particularly in the field of naval power systems. The hierarchical structure allows for greater computational efficiency and scalability while the ability to autonomously reconfigure hardware controls offers increased flexibility and responsiveness. The hierarchical decomposition and models utilized were well aligned with the physical twin, as indicated by the maximum deviations between the developed digital twin hierarchy and the hardware.
Sachpazis:Terzaghi Bearing Capacity Estimation in simple terms with Calculati...Dr.Costas Sachpazis
Terzaghi's soil bearing capacity theory, developed by Karl Terzaghi, is a fundamental principle in geotechnical engineering used to determine the bearing capacity of shallow foundations. This theory provides a method to calculate the ultimate bearing capacity of soil, which is the maximum load per unit area that the soil can support without undergoing shear failure. The Calculation HTML Code included.
Cosmetic shop management system project report.pdfKamal Acharya
Buying new cosmetic products is difficult. It can even be scary for those who have sensitive skin and are prone to skin trouble. The information needed to alleviate this problem is on the back of each product, but it's thought to interpret those ingredient lists unless you have a background in chemistry.
Instead of buying and hoping for the best, we can use data science to help us predict which products may be good fits for us. It includes various function programs to do the above mentioned tasks.
Data file handling has been effectively used in the program.
The automated cosmetic shop management system should deal with the automation of general workflow and administration process of the shop. The main processes of the system focus on customer's request where the system is able to search the most appropriate products and deliver it to the customers. It should help the employees to quickly identify the list of cosmetic product that have reached the minimum quantity and also keep a track of expired date for each cosmetic product. It should help the employees to find the rack number in which the product is placed.It is also Faster and more efficient way.
Saudi Arabia stands as a titan in the global energy landscape, renowned for its abundant oil and gas resources. It's the largest exporter of petroleum and holds some of the world's most significant reserves. Let's delve into the top 10 oil and gas projects shaping Saudi Arabia's energy future in 2024.
Hybrid optimization of pumped hydro system and solar- Engr. Abdul-Azeez.pdffxintegritypublishin
Advancements in technology unveil a myriad of electrical and electronic breakthroughs geared towards efficiently harnessing limited resources to meet human energy demands. The optimization of hybrid solar PV panels and pumped hydro energy supply systems plays a pivotal role in utilizing natural resources effectively. This initiative not only benefits humanity but also fosters environmental sustainability. The study investigated the design optimization of these hybrid systems, focusing on understanding solar radiation patterns, identifying geographical influences on solar radiation, formulating a mathematical model for system optimization, and determining the optimal configuration of PV panels and pumped hydro storage. Through a comparative analysis approach and eight weeks of data collection, the study addressed key research questions related to solar radiation patterns and optimal system design. The findings highlighted regions with heightened solar radiation levels, showcasing substantial potential for power generation and emphasizing the system's efficiency. Optimizing system design significantly boosted power generation, promoted renewable energy utilization, and enhanced energy storage capacity. The study underscored the benefits of optimizing hybrid solar PV panels and pumped hydro energy supply systems for sustainable energy usage. Optimizing the design of solar PV panels and pumped hydro energy supply systems as examined across diverse climatic conditions in a developing country, not only enhances power generation but also improves the integration of renewable energy sources and boosts energy storage capacities, particularly beneficial for less economically prosperous regions. Additionally, the study provides valuable insights for advancing energy research in economically viable areas. Recommendations included conducting site-specific assessments, utilizing advanced modeling tools, implementing regular maintenance protocols, and enhancing communication among system components.
About
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
Technical Specifications
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
Key Features
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface
• Compatible with MAFI CCR system
• Copatiable with IDM8000 CCR
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
Application
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
2. Page 2 of 21Presented by: Sh VRM
OBJECTIVE
To understand the concept of Lean
Manufacturing and translate its philosophy to
Petrochemical plants.
LEAN MANUFACTURING
3. Page 3 of 21Presented by: Sh VRM
Elimination/Reduction of Waste within the system
WHAT IS LEAN MANUFACTURING ?
Identify
Eliminate/Reduce
Input OutputSystem
Waste
4. Page 4 of 21Presented by: Sh VRM
LEAN MANUFACTURING OVERVIEW
“Lean Manufacturing” incorporates tools and techniques to
Optimize time, human resources and assets
Improve productivity
Improve quality of products and services
5. Page 5 of 21Presented by: Sh VRM
Lean production focuses on
- Eliminating waste in processes
- Expanding capacity by reducing costs and shortening
cycle time
- Understanding what is important to the customer
Analyze the flow of information and materials for
continual improvement of the process
LEAN MANUFACTURING OVERVIEW
6. Page 6 of 21Presented by: Sh VRM
There are three types of operations in any process
Non-Value-Adding (NVA)
Necessary but Non-Value-Adding (NNVA)
Value-Adding (VA)
Focus on Value-Adding (VA) operations
WASTE REMOVAL
LEAN MANUFACTURING
7. Page 7 of 21Presented by: Sh VRM
Kaizen
Focus on eliminating waste, improving productivity and
achieving sustained continual improvement
• Six Sigma
A statistical process control and analytical tool to improve
productivity and quality.
Total Productive Maintenance (TPM)
Basket of Maintenance of Practices which helps in focusing
on elimination losses such as breakdowns, idling and minor
stoppages, reduced defects & rework, spills and process-upset
conditions
LEAN MANUFACTURING
TOOLS
8. Page 8 of 21Presented by: Sh VRM
Cellular Manufacturing/One-Piece Flow system
Process for connecting the manual and machine processes of
similar operations in order to eliminate non-value adding
activities.
Just-in-time (JIT) Production Systems / Kanban
Inventory strategy to reduce process inventory and it’s
associated costs.
Value Stream Mapping
Created a visual representation of all product and information
flows from raw material to shipping
LEAN MANUFACTURING
TOOLS
9. Page 9 of 21Presented by: Sh VRM
5S
Reduces waste and optimizes productivity through
maintaining an orderly workplace. Elements of 5S are
Seiri – Sort
Seiton – Set in Order
Seiso – Shine
Seiketsu – Standardize
Shitsuke – Sustain
Place for everything and everything in it’s place.
LEAN MANUFACTURING
TOOLS
10. Page 10 of 21Presented by: Sh VRM
2nd
Tier
1st
Tier
Toyota
Customer
Demand
Flow of
Information
Flow of
Production
2nd
Tier
1st
Tier
Assembler
Customer
Demand
Flow of
Information
Flow of
Production
Traditional “Buffered”
Supply Chain
Just-In-Time
Supply Chain
TOYOTA PRODUCTION SYSTEM
11. Page 11 of 21Presented by: Sh VRM
1. Faster Inventory updates
2. Shortening time for generating production forecast
3. Online reporting, cutting down paper
4. ERP
156% ROI
LEAN MANUFACTURING
APPLICATION IN CPC
12. Page 12 of 21Presented by: Sh VRM
Waste within the Toyota Production
System
Waste within the Petrochemical Plant
Overproduction
Waiting
Transportation
Inappropriate Processing
Unnecessary Inventory
Unnecessary Motion
Defects
Inappropriate feed stock
Lost by-product credit
Quality give away
Off spec generation/reprocessing
Equipment idling
High energy cost
LEAN MANUFACTURING
APPLICATION TO PETROCHEMICAL PLANT
13. Page 13 of 21Presented by: Sh VRM
1. Understanding waste in the form of loss of contribution at
every stage of operation.
2. Understanding the impact of HSE incidence on
contribution.
3. Understanding all components of cost of production.
4. Understanding of value added activities and non-value
added activities.
5. Understanding Process intensification.
6. Understanding EPS and Marketing functions.
LEAN MANUFACTURING
APPLICATION TO PETROCHEMICAL PLANT
14. Page 14 of 21Presented by: Sh VRM
Best Lean Manufacturing Practices:
Kaizan
Epsilon/Depsilon reports
Daily contribution reports
Daily feed stock & by-product analysis
Daily energy consumption report
Daily stream analysis for quality give away
E-mfg Practices
Structural Capital
5S for Safe work place
LEAN MANUFACTURING
Aromatics Plant
15. Page 15 of 21Presented by: Sh VRM
5°C increase in Platformer feed EP – loss 16.5 MUSD/yr
1% lowering of PX/C8A – loss is 12 MUSD/yr
High RVP of ED Raffinate – 10 MUSD/yr
200MTD C8A blending in Gasoline – Loss is 5.6 MUSD/yr
2% loss in heater efficiency – loss is 3.2 MUSD/yr
C10A conversion in Tatoray vs blend in Diesel/Gasoline – 2.1 MUSD/yr
1% reduction in PX recovery – Loss is 7 MUSD/yr
LEAN MANUFACTURING
Aromatics Plant - Opportunities
16. Page 16 of 21Presented by: Sh VRM
71.0
27.2
0.2 1.4
0.2
Net RM Cat Chem Utilities Manpower Maint
LEAN MANUFACTURING
PARAXYLENE COST STRUCTURE
•By product credit is 60% of Raw Material cost
•Conversion cost is 27% of operating cost
17. Page 17 of 21Presented by: Sh VRM
By Product Value
Maximization
Maximize production of OX, BZ, Hydrogen
Recovery of Hydrogen from gases to Sat/Unsat header
Recovery of BZ from low value streams
Up-gradation of low value streams to high value streams (ED raffinate)
BYPRODUCT
Yield
(wt% Plat feed)
Price
HIGH VALUE
H2 2.17 44259
OX 10.36 26818
BZ 11.12 29351
HAR 2.29 22109
LPG 4.24 17075
LOW VALUE
ED Raffinate 9.68 15573
Fuel Gas 14.05 10050
AHE 1.16 9137
FEED STOCK ANALYSIS
LEAN MANUFACTURING
18. Page 18 of 21Presented by: Sh VRM
• Conversion cost for Aromatic plant at Jamnagar is 27% of the
operating cost.
• 60% of conversion cost is fuel cost.
• Optimize Heater and Columns operation
28.9
12.3
58.8
Power Fuel Net Steam
LEAN MANUFACTURING
CONVERSION COST
19. Page 19 of 21Presented by: Sh VRM
• Business Case: 1
Market Interface: Based on Market scenario HASC production is
optimized
• Business Case: 2
Product Development: Renine was introduced in market which won
Golden Peacock Award for Techno-commercial innovation
• Business Case: 3
Byproduct Optimization: C10A conversion across Tatoray
• Business Case: 4
Opportunity in Adversity: Blending of C7A, Mix Xylene, C10A in
Gasoline
LEAN MANUFACTURING
EXAMPLES OF BUSINESS CASES
20. Page 20 of 21Presented by: Sh VRM
• Business Case: 5
Waste Elimination: Recovering Hydrogen going to Sat/Unsat
• Business Case: 6
Waste Elimination/Change in mindset: Reduction of BZ drag
• Business Case: 7
Quality giveaway: C2 loading in LPG product
• Business Case: 8
Human Resource : Enhancing Human Skill – Prepare for
tomorrow. Eliminate positions.
LEAN MANUFACTURING
EXAMPLES OF BUSINESS CASES
21. Page 21 of 21Presented by: Sh VRM
We are what we repeatedly do,
Excellence then is not an Act but
A Habit
THANKING YOU
22. Page 22 of 21Presented by: Sh VRM
Innovation
Knowledge
Known Things -
Productivity
Unknown Things -
23. Page 23 of 21Presented by: Sh VRM
KAIZEN
Plant Manager
Production mgr
Worker
Normal operation
Innovation
Supervisor