CSFS AND KPIS

Santosh Mahadeshwar Sagar Baligeri Nilesh Gham

MANUFACTURING IN THE CHEMICAL INDUSTRY

Manufacturing in the chemical Industry is highly specific. Much of the processes are automated generating real time data. However, there are still plants which run on manual configuration.

BUSINESS OBJECTIVES AND PROCESSES

CRITICAL SUCCESS FACTORS

Efficient working of utilities to ensure smooth functioning of process plant Efficient and timely functioning of QC laboratoryKPIs Smooth functioning of EHS and allied departments.

1. EFFICIENT WORKING OF UTILITIES TO ENSURE

SMOOTH FUNCTIONING OF PROCESS PLANT

KPIS

Performance Parameters (KPIs)

5% reduction in the ratio of water consumed per unit product produced. 9-11% reduction in the ratio of aqueous waste generated to unit water consumed. 5% reduction in ratio of electricity consumed to unit product produced. 2% reduction in the ratio of fuel required to unit utility produced.

EFFICIENT WORKING OF UTILITIES TO ENSURE SMOOTH FUNCTIONING OF PROCESS PLANT- CONSTRAINS

Manual boiler efficiency calculations. Manual recording of log. Visual indication of measuring devices/ not automated logging. No system for the management of data related to WAGES(water, air, gas, electricity & steam).

CHANGES AND IMPACT ON KPIS

Changing existing meters (like gas flow meters, steam flow meters, electricity, etc.) to ones which can communicate with the data network. Recording and trending of data. Easy reporting and analysis at click of button. On line acquisition of the key process variables for utility consumption and production. Material balance reconciliation of all the utility networks, including fuel oil storage and refinery fuel gas network. Comparison of actual and target values for each utility consumption and production.

INPUTS
Utilities and Engineering Department. Production Department. Quality Control Laboratory.

Validation
Input raw materials check. Regeneration checks. Regular demanded supply checks.

REPORTS
Monthly water consumption report. Report of electricity required per unit product produced.

MONTHLY WATER CONSUMPTION REPORT.

Frequency: Monthly/ half yearly. Purpose: To provide comparison statistics of water consumed. Water required per product. Format: Table/ Pie Chart Content: Daily input and output figures, disposables, etc. Distribution: Middle and Senior Management. Meant for: TPS/MIS/DSS Access Rights: Area Managers and GM

REPORT OF ELECTRICITY REQUIRED PER UNIT PRODUCT PRODUCED.

Frequency: Monthly. Purpose: electricity requirements per unit product produced, for various products. Format: Table/ pie chart. Content: Monthly calculated Performance values. Distribution: Middle and Senior Management. Meant for:TPS/MIS/DSS Access Rights: Area Managers and GM

2. EFFICIENT AND TIMELY FUNCTIONING OF

QC LABORATORY-KPIS
12 % reduction in sampling time. 8% reduction in production delay times owing to sampling. 10% Reduction in the time between sample receipt in the laboratory to actual sample testing. Performed by system notification of arrival of sample from production to laboratory. 7% increase in business process by increased data flow between lab and production. 6% decrease in time for preparation of final report (post production) and quality disposition of finished product. 18% increase in laboratory productivity.

SMOOTH, EFFICIENT AND TIMELY FUNCTIONING OF QC LABORATORYCONSTRAINS.

Paper based procedures (SOPs/ test methods/ specifications) No information/ alerts with regards to the arrival of sample to the laboratory (causing delays). Non-uniform reporting system/ format. No specific system for issue notification. No in-built diagnosis procedure.

CHANGES AND IMPACT ON KPIS

Standardize laboratory practices by storing SOPs, test methods, specification, etc. in a single system which facilitates the compliance with industry regulations and ensures that unified processes are followed across the enterprise. Search, edit and export of data (belonging to different analysis / instruments), all from one interface. When an issue arises, notification can be made instantaneous. System investigation tools can be used to diagnose and resolve incidents in a timely manner. Easily move samples from the receiving area to appropriate chemical testing.

REPORTS
Sample Time Reports. Laboratory Issues Monthly Report.

SAMPLE TIME REPORTS

Frequency: Monthly/ Once In Two Months Purpose: to provide report summary of time difference between sample arrival and actual testing. Format: Table and scatter plot indicating graph. Content: Every Sample arrival and injection time. Distribution: Middle and Senior Management. Meant for: TPS/MIS Access: QC/QA and Works Manager.

Indicates time reduction further steadying of between sample receipt actual injection in instrument.

and time and the

LABORATORY ISSUES MONTHLY REPORT

Frequency: Monthly Purpose: To provide list of issues with regards to instrumentation in a tabular format. Format: Paragraph and Table Content: Issues, with Corrective Action taken Distribution: Senior Management. Meant for: TPS/MIS/DSS Access: Laboratory and Works Manager.

3. SMOOTH FUNCTIONING OF EHS AND ALLIED DEPARTMENTS.

Performance Parameters (KPIs)

10% reduction in the ratio of waste generated to unit of product produced. 12% reduction in treatment cost per unit of waste. 8% reduction in storage and disposal cost per unit waste. 5% reduction in noise levels.

TIMELY DISPOSAL OF WASTES TO AVOID ACCUMULATION (OF WASTES) AND FURTHER, HALTING PRODUCTION-CONSTRAINS

No regular noting/ monitoring of noise levels. No database of MPCB Approved transporters for Hazardous waste disposal-difficult and expensive. No recording system of product specific waste streams. No quantities and stock of waste treatment chemicals. Manual filing of MSDSs

CHANGES AND IMPACT ON KPIS

Database of specific, product related waste streams-useful since multipurpose plant. Access to all concerned employees. Database of retrievable MSDSs. Database of MPCB approved transporters (for Haz Wastes). Noise monitoring devices linked with real time recording. Integrated MSDS system.

INPUTS
ETP and EHS Department. Production Department. ETP Laboratory.

Validation
ETP/ EHS Statistics Emissions Track checks Hazardous Wastes Disposal checks

REPORTS
Weekly report of noise levels monitored. Monthly report of Hazardous Waste Transportation to Hazardous Waste Disposal site.

WEEKLY REPORT OF NOISE LEVELS MONITORED.

Frequency: Weekly. Purpose: Monitor and Chart noise levels. Format: Scatter plot (against and upper limit)/ table. Content: Weekly monitored results of noise levels in different zones in the plant. Distribution: Middle and Senior Management. Meant for: TPS/MIS/DSS Access Rights: Area Managers , GM, VP.

REPORTS ON REGULAR TRANSFER OF HAZARDOUS WASTES.

Frequency: Quaterly. Purpose: Disposal Quantities and records of hazardous wastes disposal. Format: Table containing waste trasported/ transporter name, details, etc. Content: Haz Wastes Disposal Quantities and transporter details. Distribution: Middle and Senior Management. Meant for:TPS/MIS/DSS Access Rights: Area Managers and GM.

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