Date(s) - 31/05/2017 - 02/06/2017
JK LAKSHMI CEMENT LIMITED
Small Group Activities (SGA) is now being widely recognized as an effective means for achieving continuous energy efficiency and effective energy management at plant level. SGA is a problem solving tool that provides the capacity to engineers at operational level to identify, assess, and implement appropriate solutions within their area of operation to achieve energy efficiency, higher productivity, zero defects, zero breakdown and zero waste. Because of the holistic approach of SGA in supporting ground level energy efficiency improvements on a continuous basis, KEP, which is a joint initiative of BEE & IIP, is supporting industry in organizing and implementing SGA at plant level. The support for SGA is being provided by KEP as a value added service under the SPARC model.
A three day SGA for JK Lakshmi Cement Limited, Sirohi was organized during 31st May to 2nd June, 2017. The SGA for JK Lakshmi Cement Limited, Sirohi was designed to ensure that employees from all levels of production participated and went through a series of guided/ facilitated process that included self-assessment, listing of options, and assessment of options on their relative economics and impact and prioritization of actions most suited to meet the energy efficiency requirement of their specific area of plant operation. These sessions were carefully facilitates so that the employees work as a team in coordinated fashion and there is a healthy competition within and across groups in different operational areas. The basic objectives of carrying out these activities were:
- To use the existing knowledge experience and wisdom of plant level operators to identify and analyze energy efficiency opportunities
- To build the capacity of the plant level operators to implement energy efficiency actions.
- To contribute to the improvement of productivity, profitability and development of the organization.
Small Group Activity for JK Lakshmi Cement Limited, Sirohi, started with an opening session by Shri K K Chakarvarti, Expert Consultant. Shri Chakarvarti provided a brief overview on SGA activities and its objectives along with an overview on electrical and thermal saving possibilities at the plant level. He mentioned that an energy saving target of 4.86% has been set under PAT-2 Cycle by Ministry of Power, Government of India. This amounts to 24,237 tonne of oil equivalent energy saving to be achieved by Sirohi Plant in the target year of 2018-19. Plant management has already implemented new and energy efficient technologies to improve its energy performance parameters. Further improvement to be achieved in energy performance indicators would require involvement of all employees. He mentioned that while SGA has tremendous potential in helping a plant realize its productivity and efficiency targets, the onus of its success was with the employees at the operational level. He emphasized that the SGA needs to work as a team and identify innovative approaches through change in practice, technology, approaches to enhance the efficiency of the plant in their area of operation, reduce energy use and minimize wastage. He clarified that in doing SGA, the burden of employees doesn’t increase but infact helps them in improving their productivity, boosting their knowledge and confidence, team building and communication.
At the end of this session, the following 7 small groups were constituted based on the scope of their existing roles and work area:
- Group 1: Grind Boosters
- Group 2: Lakshya
- Group 3: S.P.A.R.K ian
- Group 4: Urja Sanrakshak
- Group 5: Jeet
- Group 6: Search
- Group 7: Energy Warriors
Each group comprised of 4-6 engineers. The engineers working in various departments viz. Mechanical, Electrical, Instruments, Mining, Process, Environment and Power Plant were part of these groups.
Officials of JK Lakshmi Cement Limited, Sirohi during the SGA workshop
These small groups visited their respective departments and through an intense facilitated brain storming sessions identified issues in the existing operations/technology areas and identified options for improvement as well as their respective saving possibilities. The group then analyzed all the options and prioritizes the most viable option based on the following:
- The scale of the problem and its impact on existing operation
- Analysis of the problem through tools such as “Cause and effect” diagram and “Why-Why” analysis
- Existing options to solve the problem in hand
- Prioritization the option based on the cost benefit analysis and suitability to the overall plant operation.
- Assess the overall investment and energy saving potential of the option chosen by the SGA for implementation and making a case for investment by the management.
Once all groups had identified their projects for energy efficiency, they all re-convened and presented their projects. In these presentations, the groups pledged their commitment on energy efficiency in their operation before their peers and committed to certain energy saving targets based on the projects identified by them.
Groups making presentation on their identified projects
This session was attended by plant top management, including Shri P. L. Mehta, Plant Head; Shri Wadhawan, VP (Engineering); Shri Rajpal Singh Sekhawat, GM (Production) ; Shri NKJ Panchal, Deputy General Manager and various Plant Heads. Shri Chakarvarti informed the plant management that SGA has resulted in great enthusiasm among the group members and to find out the solutions and steps to achieve energy efficiency development. In total 650 kW and 3kcal/kg clinker energy saving target was planned by 7 Groups.Groups making presentation on their identified projects
Shri P. L. Mehta, Plant Head, was impressed by the efforts put in by the plant engineers and hoped that planed savings will be achieved within the stipulated time. He congratulated the SGA members and KEP for taking this initiative. Shri Wadhawan, VP (Engineering), advised the participants to review the progress achieved on weekly basis, which should be further reviewed on bi-weekly basis by two GMs. Shri Rajpal Singh Shekhawat, GM (Production), conveyed his thanks to Plant head, Vice President (Engineering), KEP faculties and members of SGA for making this program highly successful.
The SGA’s will now prepare a detailed action plan for implementing the projects identified by their groups, the progress of which will be reviewed by the Management of JK Lakshmi Cement and KEP at the end of 2 months. After this mid-term assessment, the final assessment will be carried out by the plant at the end of the implementation period to evaluate the relative performance of each group in terms of achieving their objects and energy saving targets proposed by them. To encourage the team members, JK Lakshmi Cement Limited may also institute a reward system to recognize the best achievers.
The workshop was concluded with a feedback session where the participants were requested to provide their inputs/suggestion for improving and enhancing the effectiveness of such small group activities organized at plant level. 91 % respondents mentioned that this program enhanced their critical thinking, oral communication, leadership skills, team and self- management along with an increase in understanding of diverse perspective while working as a team. 89% respondents felt that this training program helped in learn about one or more specific ideas that they will be able to implement in the area of energy efficiency and new approaches to energy management.
The SGAs can go along with in improving the technical and operational efficiency of the plant which in the long run can will not just help the plant meet its’ regulatory environment and standards but also increase the productivity and profitability of the organization.
Participants of JK Lakshmi Cement Limited, Sirohi with Shri P. L. Mehta, Plant Head; Shri Wadhawan, VP (Engineering); Shri Rajpal Singh Sekhawat, GM (Production) and Shri NKJ Panchal, Deputy General Manager .