20 October 2016 | 28th QualTech Prize
Machine developed on innovative idea of replacing 1 wire from outer most layer instead scrapping all wires in the whole layer. This machine replaces any wire with joint in length identified & marked during manufacturing. Replacement means taking out & layering in one go with no disturbance on construction of conductor.
20 October 2016 | 28th QualTech Prize
We made new lubrication system design to make oil free ACCC conductor surface which hepled to resist slipage and bird caging during stringing and also it reduces manufacturing cost with 30% increment in productivity.
20 October 2016 | 28th QualTech Prize
In a ACSR conductors the steel reinforced core is the strength member which bears the entire load of the power conductors along the span length. Use of X-ray Scanner machine for determining cracks or broken core of ACSR Power conductor due to corrosion thus becomes critical to project success.
20 October 2016 | 28th QualTech Prize
Generics Business contributes to 60-70% of the overall Ennore site revenue. Customer demand in key products increased leads to OTIF issue. This Project “Thiruppam” has helped us to achieve the required capacities thereby resulting in meeting 100% customer OTIF.
20 October 2016 | 28th QualTech Prize
The project is all about improving customer satisfaction through fulfill 100% demand of Ophthalmic products from plant without capital investment. Project is done through multi-dimensional approach to achieve required OTIF%.
20 October 2016 | 28th QualTech Prize
At Renukut Aluminum Smelter, profit margin has been decreasing from 35% to 17% in last five years due to increase in power cost. To reduce power consumption it is imperative to reduce pot voltage. This project was taken to reduce pot voltage from 4.523 V/pot (June’15) to 4.440 V/pot.
20 October 2016 | 28th QualTech Prize
In overall paint processing cost manpower cost contributes around 33% which is measured in cost / lts.To reduce the processing cost this project is scoped to increase the production Volume (liters)with effective utilization of Manpower and simultaneously improvement being measures in terms of productivity (Lts / manday), Targeted for 12% Improvement.
20 October 2016 | 28th QualTech Prize
Water Base segment for KNPL is an extremely challenging market which is growing at a good potential YOY. We are aggressively looking to gain higher market share and make this retail segment even more competitive. Our Project is on Productivity Improvement of WaterBase Paints by 9% before Q4-FY:2015-16.
20 October 2016 | 28th QualTech Prize
The project was selected under Quality domain to improve customer satisfaction. Many customer complaints were received related to packaging defects. There is immediate need to address the issues faced by customer to save sale loss due to customer dissatisfaction. Management had decided to take up the project "critical projects" category & form a team, lead by project leader, Mr. Gaurav Sinha.
20 October 2016 | 28th QualTech Prize
This innovation is to generate heavy naphtha (110 – 140) as feed to CCR unit, for maximizing intake and MS production. With 5000 Tons/day of stabilized naphtha (45-140), lower naphtha splitting capacity of 3600 Tons/day limited CCR feed. Idea was to use the Reformate Splitter in CRU to split stabilized naphtha.
20 October 2016 | 28th QualTech Prize
Lenovo Manufacturing planned to improve Rolled Throughput Yield (RTY) metric in FY1516 as a part of continual improvement in Process Quality. FPY is already sustained >99.60% as yield rate at the end of process & objective of selecting RTY is to improve pass yield rate at each individual stage.
20 October 2016 | 28th QualTech Prize
We are manufacturing an Intermediate product at Lupin Ankleshwar unit since last 22 years as a Market Leader. The contributing of this product in the revenue of Lupin Ankleshwar unit is close to 40 %. The project is taken to improve the Yield of the product & standard deviation reduction.
04 December 2015 | 27th QualTech Prize
Fluorides, in form of AlF3, Enriched alumina are required in Potline to control the bath temperature. AlF3 sp. consumption in Potline was higher (20 kg/MT of Al) than the target value (18 kg/MT of Al) due to high fugitive emissions which is harmful for environment & lead to higher COP
04 December 2015 | 27th QualTech Prize
In last 8 years we have improved energy efficiency by 52%. Up till now we were identifying projects internally by brainstorming or by conducting external energy audits. Since we observed downward trend in improvement so we decided to adopt some different approach- Benchmarking to get quantum improvement.
04 DEcember 2015 | 27th QualTech Prize
In this project we have worked on improving various parameters contributing to loss in energy efficiency.
04 December 2015 | 27th QualTech Prize
In PTA plant, Acetic acid is used as a solvent in Oxidation section. This solvent incurs burning losses in oxidation reactor and physical losses through various plant streams.
04 December 2015 | 27th QualTech Prize
Weight variation in anodes produced in ACP (Anode Casting Plant) was high(34%) compared to our business requirement of less than 10% resulting in high recycling cost (Rs45lacs/annum).
04 December 2015 | 27th QualTech Prize
In S9X ILV1 version of 2.1MW wind turbines rotor hubs are having 3 doors which are used to enter in rotor for maintenance. These doors were getting opened in running and falling from top. In other case winch shutter door is getting damaged due to continuous striking of winch which moves on traverse beam.
04 December 2015 | 27th QualTech Prize
Yaw motor is a component in windturbines which is aligning the nacelle wrt the wind direction. There are 3 yaw drives/motors per turbine.
04 December 20015 | 27th QualTech Prize
Main-bearing is a critical component in wind turbines which supports the static and dynamic loads of the hub-Blade assembly in our wind turbines.