08 October 2014 | 26th QualTech Prize
HV cable manufacturing by continuous catenary vulcanization process requires very long, failure free run. Zero breakdown & zero power failure is a must.
08 October 2014 | 26th QualTech Prize
Hindustan Unilever Limited (HUL) is India's largest FMCG Company; project on Sustainability is implemented at HUL, Sumerpur, UP, manufacturing capacity of 210,000 TPA. It is HUL’s second largest 25year old Home Care factory in South Asia. Common brands are Surf Excel , Vim, Wheel, Rin Bar & Wheel Powder.
08 October 2014 | 26th QualTech Prize
The project evolved out of brainstroming by the "managenment team" on ways and means to optimise "project execution" on a repeatable basis, as an offering to our customers and a key differentiator vis - a - vis our competitors.
08 October 2014 | 26th QualTech Prize
Frequent Electrolyser Cell Failure in Electro Chlorination Plant
08 October 2014 | 26th QualTech Prize
In coal handling plant C-31B belt sway on feeding above 600 TPH & Diverter gate change over problem in TT’s was the repeated issue.
08 October 2014 | 26th QualTech Prize
Based on F13 market predictions we had readiness for F14 volumes (without any major capital investment). However, marked demand surged, based on this, per day demand increased from 150/day to 160/day in F14 & 180/day to 20/day in F15.
08 October 2014 | 26th QualTech Prize
Control valve failure is the top contributor in field failure as well as internal rejections (3.2%) and are costing INR 2 lac per annum to the company. Target has been taken to reduce in house rejection by 50% & early hour field failures by 80% by June 14.
08 October 2014 | 26th QualTech Prize
Being an Innovative Titan Team, the Jewellery In-house manufacturing team had challenged the obvious and came out with the innovation which had provided break through for In house manufacturing, thereby we can able to achieve: Consistency in process, Customer complaint-Zero, Customer responsiveness-on time, Competitive cost amongst manufacturing
08 October 2014 | 26th QualTech Prize
The aluminium pots are need to cut out due to various reason i.e. completion of its life, non performing pots as per production target, leakages of pots, bus bar welding failure resulting no metal production during these period, so project was taken to reduce Turnaround time of pot.
08 October 2014 | 26th QualTech Prize
The plain gold manufacturing industry is a cottage industry, working with primitive technology, in dark dinghy poor ventilated work-spaces. Karigars work 16 hours/day, develop eye, lungs or back problems, retire at the age of 40 year and want alternate careers for their children, rendering a dying trade
08 October 2014 | 26th QualTech Prize
Aim of the Operation: Leaching of Raw Slime to produce de-copperiszed (leached) Slime containing less than 0.5% copper by oxidation process. 30% Cu (Raw slime) + Oxygen + Sulphuric Acid = CuSO4 (Leached electrolyte ) + 0.5%Cu( leached slime) Raw Slime: Slime generated during Copper electrorefining process having Copper 25-35%.
08 October 2014 | 26th QualTech Prize
Current Efficiency of electrowining cells is low [68%] compared to business requirement [82%] resulting in Rs 58.87lacs/year loss. Electrowinning process: The process of copper plating from electrolytic solution by applying DC current across the electrodes. Current efficiency: Ratio of ‘Actual Mass of copper plated’ and ‘theoretical Mass of copper deposited’ on cathode by Faraday’s law.
08 October 2014 | 26th QualTech Prize
This innovation is from Automatic assembly line of Watch assembly department. This is on reducing cycle time of the assembly station from 3.2 sec to less than 2.0 secs to improve productivity and optimise the resources (Machine and Man power).
08 October 2014 | 26th QualTech Prize
In Phosphoric acid plant, average raw water consumption is 3.57m3/ton of phosphoric acid against business target of 3.47m3/ton of phosphoric acid production which is greater than norms this leads to increased COP of Phosphoric acid and resulted in PAP Stoppage .
08 October 2014 | 26th QualTech Prize
In LLDPE plant, there is a grid (5mm diameter holes) inside the main polymerization reactor of Train-1. This grid, over a period of operation, gets choked with powder which requires a shutdown for cleaning. Presently the grid is cleaned twice a year, with downtime of 145hrs&slowdown of 96hrs each time.
08 October 2014 | 26th QualTech Prize
Polypropylene Plant of RIL Nagothane is producing Homo and Random Copolymer (RCP) grades. RCP grades are being imported to cater customer requirement as demand is increasing exponentially and there are few manufacturer in India. Product value of PP RCP grades are more than PP Homo grades.
08 October 2014 | 26th QualTech Prize
Several parts of Goa are parched in the dry season due to unavailability of fresh water sources like ground water for portable use. Coupled with mining this resulted in depletion of the water table, making it extremely difficult for the locals to have water for farming, irrigation, drinking and hygiene.
08 October 2014 | 26th QualTech Prize
In cable industry Stranding machines are used to make a bunch of wires, the particular machine that we selected for project can make a bunch of 54 wires (ie 12 wires cage + 18 Wires cage +24 Wires cage) individual cages are driven by separate motors.
26 September 2011 | 23rd QualTech Prize
we have started this initiative under the name of Think Fresh Be Green. Every year we are taking new initiatives related to Green. Think Fresh Be Green is being driven at Organizational level.
26 September 2011 | 23rd QualTech Prize
We were using Acidic Bleaching earth which was used traditionally for bleaching of Sunflower Oil for good colour reduction. Due to high price of Acidic Bleaching Earth the impact on Bleaching cost is not affordable.