COST SAVING INITIATIVES OF THE EMPLOYEES OF ERWPP

1. BADAL KUMAR KAR

Took up the initiative to switch off all the roof lights and idle running equipment on the shop
floor when not required especially during shift changes and break period when production is not
taking place. He also took up the initiative to sensitize all the people about the need for power
conservation.

2. NIRANJAN PATEL & SUKANT KUMAR DAS

They together have developed method of re-using the damaged tool holders (SMOW model) of
OD bead trimmer. The damaged tool holders in which the fixing bolts have been broken and got
stuck inside have been restored by drilling a through hole. A longer bolt and nut is used to fix
the tool in the holder which makes it easy for tool changing. This has proved very effective and
has saved cost.

3. SUKANT KUMAR DAS

He took up the initiative for the fabrication of various in-house hand-made spanners to suite
specific jobs like adjustment of guides, side rolls and pinions etc, required quite frequently in
ERWPP. Here ratchets were used earlier which were getting repeatedly damaged due to
jamming. Replacement of ratchets with torque wrenches was being explored but it was a very
costly affair. The new in-house hand-made spanners are made in a special design so as to
perform the job quickly and at the same time with stand the excess load put on them while
adjusting jammed guides. This initiative has saved a lot of cost as the ratchets/torque wrenches
are very expensive to procure.

4. SUJIT MISHRA

He took up the initiative to modify the design of the cover of fly cutter machine to ensure
reduction of production delay due to knife inspection/changing and other maintenance
activities. Earlier the cover had to be removed by EOT crane before commencing the
repair/inspection job. Now, the cover has been provided with small hatches so that jobs like
knife changing need not get delayed due to crane availability. This has really helped in reducing
the delay time and saved cost.

5. R.N.MAHANTO

He took up the initiative to modify the mounting arrangement of the high intensity bay lights so
as to facilitate the replacement of the high wattage SV lamps with highly power efficient high
intensity LED lamps. The problem is that the LED lamps come with a standard fitting bracket
which was not readily fitting the existing lamp bracket[