Kaizen Idea Sheet

Put Green colour in the block to Mark Activity and Results Area

Category : A / B (Tick Mark) Activity KK JH QM PM SHE OTPM DM ET 5S QCC

KAIZEN NO : Loss No./
Step
Department/Section : Engineering Result Area P Q C D S M E

Plant : Emami Masat Machine/Area :Boiler/utility

Kaizen Theme: To Reduce energy cost at masat unit Idea: Use of Furnace oil instead of L.D.O. which is cost effective & install automatic power factor controller

Problem/Background:At masat unit as boiler fuel
consumption is high due to vapour absorption
chiller,operting cost of boiler is very high.
Countermeasure: For switching over fuel necessory Benchmark 1)operating cost of boiler @L.D.O. cost @ 37/kg
modification required done.1)Electric heater provided in 2)Power factor - 0.85
stoarage tank & Day tank 2)insulation to be provided 3)Heat
tracing to be done on transfer line from storage tank to day Target 1)operating cost of boiler @F.O. cost @ 28/kg
tank 2)Power factor - 0.99
Kaizen Start Jan-10

Kaizen Finish Mar-10

Team Members: Kaushal desai,manhar lad,keyur bhatt

Benefits: Reccuring saving every year @ 9 Rs /kg for

approx 2,00,000 kg consumption & Saving of 11% in
electricity bill

WhyWhy Analysis/Analytical Tool used: Results: Saving in Boiler operating cost & Saving in
1)Why why analysis 2)cause & effects electricity bills

Horizontal Deployment plan

S.No. area Target Responsib
Date ility Status