WEEK 6 in HLL Orai
It is week 6 in HLL Orai factory. The first three days of the week were spent in collecting the data about packing hall and its relation with the soap manufacturing at the back end, because that would be the crux of my report which I have been told to prepare, i.e. how to reduce the mismatching of timings and production between packing hall and backend production. I found out that while packing hall which in ideal conditions should produce 60 tons of soap, corresponding to about 7.5 tons per hour of neat soap, corresponding to 100 % efficiency, but the efficiency of the system is around 85%, so we get 7.5/0.85= 8.82 tons per hour of neat soap, or 8.82*72/77= 8.25 TPH of soap noodles. But the current soap noodle manufactured by the two Mazzonis= 7.4 TPH of soap noodles. Therefore, there is very less weathering time for the soap noodles which affects the quality of the soap.
Another glitch in the current system is the small size of the current bins, so if for any maintenance or breakdown, the packing hall has to shut down for a while, the mazzonis have to be shut down too, because the bins become full in about two hours, thus reducing the efficiency of backend systems.
To counter both of these problems (that is, of small weathering time, and less efficiency in case of packing hall breakdowns), we can have a sperate storage bin, of 40-50 tons capacity, which would be used to store the noodles produced by the mazzonis, and from there, the noodles will be transported to the cascade bins at the top, which will increase the weathering time for the noodles, and will allow the mazzonis to work at full capacity 24hrs a day, 7 days a week.
The next major problem is to increase the neat soap producing capacity, which is being restricted by the BLS pump, as there the DFA being used is already in full capacity, i.e. DFA usage cannot be increased. To counter this problem, either a new BLS pump can be installed, or to increase the flow of DFA, flow meter can be used instead of using BLS, which will increase the quantity of DFA being used for producing noodles and as DFA being used increases, the noodle production increases and the plant would be more equipped to meet packing hall requirements of 6-0 tons per shift.
Another major issue to be addressed was that of temperature in the air, for that the heat exchanger being used was first descaled, as I have written in my previous post, and then the chiller water pipeline was installed in the heat exchanger to get more heat transfer, but it had not made much of an impact, the temperature came down a lot, but not to the point till where it was required to do so.
Another thing that happened during the week was the summer summit at Mumbai training centre where we were given more sessions of interaction with senior managers and R & D people, who gave us insights on how innovations are done, with what purpose and how much of a balance is required between technology and innovations. The day started with a session by Mr Anurag Mehrotra who gave us a case study on pears and its growth through the ages along with the innovations done on it. The second session was with Mr Vivek Sirohi, who told us about the innovations and the balance to be taken between technology and impact on consumers, giving us the mantra of consumer is what matters in today’s day and age.
Ms Anuradha Razdan took the third session on careers in HLL that was an introduction to growth and opportunities in HLL, and the 4th session was taken Mr Bala Agarmurthy, who told us about the packing techniques being used in HLL, with some examples. Finally we had an open session with Mr Dhaval Buch, the ED Supply Chain of HLL, discussing the pros and cons of our internships, our experiences, problems faced etc.
I also met my mentor Mr Sirohi during the summit, who discussed my projects with me and also gave his contribution on how things work in HLL, and how I should proceed in my projects along with giving me a broader picture of things in HLL.
When I came back from the summit, I started work on the glycerine plant and revised the concepts of control engineering. The project is about studying the glycerine plant and making control analysis of the three effects and the type of controllers to be used which would make the plant stable.
Thus came to an end another learning week at HLL Orai.
Another glitch in the current system is the small size of the current bins, so if for any maintenance or breakdown, the packing hall has to shut down for a while, the mazzonis have to be shut down too, because the bins become full in about two hours, thus reducing the efficiency of backend systems.
To counter both of these problems (that is, of small weathering time, and less efficiency in case of packing hall breakdowns), we can have a sperate storage bin, of 40-50 tons capacity, which would be used to store the noodles produced by the mazzonis, and from there, the noodles will be transported to the cascade bins at the top, which will increase the weathering time for the noodles, and will allow the mazzonis to work at full capacity 24hrs a day, 7 days a week.
The next major problem is to increase the neat soap producing capacity, which is being restricted by the BLS pump, as there the DFA being used is already in full capacity, i.e. DFA usage cannot be increased. To counter this problem, either a new BLS pump can be installed, or to increase the flow of DFA, flow meter can be used instead of using BLS, which will increase the quantity of DFA being used for producing noodles and as DFA being used increases, the noodle production increases and the plant would be more equipped to meet packing hall requirements of 6-0 tons per shift.
Another major issue to be addressed was that of temperature in the air, for that the heat exchanger being used was first descaled, as I have written in my previous post, and then the chiller water pipeline was installed in the heat exchanger to get more heat transfer, but it had not made much of an impact, the temperature came down a lot, but not to the point till where it was required to do so.
Another thing that happened during the week was the summer summit at Mumbai training centre where we were given more sessions of interaction with senior managers and R & D people, who gave us insights on how innovations are done, with what purpose and how much of a balance is required between technology and innovations. The day started with a session by Mr Anurag Mehrotra who gave us a case study on pears and its growth through the ages along with the innovations done on it. The second session was with Mr Vivek Sirohi, who told us about the innovations and the balance to be taken between technology and impact on consumers, giving us the mantra of consumer is what matters in today’s day and age.
Ms Anuradha Razdan took the third session on careers in HLL that was an introduction to growth and opportunities in HLL, and the 4th session was taken Mr Bala Agarmurthy, who told us about the packing techniques being used in HLL, with some examples. Finally we had an open session with Mr Dhaval Buch, the ED Supply Chain of HLL, discussing the pros and cons of our internships, our experiences, problems faced etc.
I also met my mentor Mr Sirohi during the summit, who discussed my projects with me and also gave his contribution on how things work in HLL, and how I should proceed in my projects along with giving me a broader picture of things in HLL.
When I came back from the summit, I started work on the glycerine plant and revised the concepts of control engineering. The project is about studying the glycerine plant and making control analysis of the three effects and the type of controllers to be used which would make the plant stable.
Thus came to an end another learning week at HLL Orai.
posted by Abhinav Sharma at 9:45 AM
0 Comments:
Post a Comment
<< Home