COST SAVING PROJECTS MAINTENANCE

OMAX AUTOS LTD. MANESAR

AIR CONSERVATIONS
Action taken for Air Conservation 1. Complete layout of Air Compressors changed , made common header with minimum Bands . 2. Steel layered flexible used in weld shop in place of PU pipes to control the wastages Of air . 3. Switching Off the air compressors in lunch / dinner break. 4. Separate air line provided in paint kitchen. 5. Educated operators for air conservations
Units

Units cons. in Air Compressors

90000
80000 70000 60000 50000

83637 65004

60475 51291 50012

40000
30000 20000 10000 0

May

June

July

August September

Month

Net saving of 33625 units ( Rs 184937.00 / Month) , compare from May to Sept11

SAVING IN M/C BREAKDOWN

Action taken to reduce the Machine breakdown % Monthly trend of Machine Breakdowns %
1.70%
1.65% 1.60% 1.55% 1.50% 1.45% 1.40% 1.35% 1.30% 1.25% May'11 June'11 July'11 Aug'11 Sep'11 1.65% 1.58% 1.50% 1.48% 1.40%

1.Mig Welding M/C- Card & Wire feeder B/D : Critical spares inventory and stand by MiG m/cs maintained. Also earthing improved for protection of circuit cards. 2.Old drilling and boring m/cs with contactor based control : Technology upgraded by PLC provision. 3.Line captains scheme implemented in deptt. 4.Strongly Preventive Maint. Implemented. 5.Keeping Min / Max level of Critical spares in Maint stores. 6.Training given to Maint technicians. 7.Motivated the team.

Total Available Hrs. in month of May11 Plant Run @ 25 days Total Break down in month Actual Production Hrs. Total Sale in month Per Hrs. Loss Loss Due to Breakdown Man hours Loss Actual Total Loss Total B/D hrs in Sept Net saving ( May Spt11)

36180 Hrs. 30150 Hrs. 363.52 Hrs. 29695 Hrs. 220000000 Aprx. 7296.8 2652550.6 185200 2837750.6 301 Hrs 62.52 Hrs

Saving in Rs ( 7296.8 X 62.52)

4561959 Rs

Net saving of Rs 4561959.00 in machine Breakdown

POWER & FUEL COST IN % ON SALE

Action taken for Energy Conservation
3.00%

POWER / FUEL COST % ON SALE

1.Power distribution system improved. 2.Compressor shifted to save wastage ,55 KW air compressor has been spared. 3. Plant running in two shifts instead of three shifts. 4.Electricity wastage reduced by switching off lights / fans / ACs / machines during lunch & dinner time. 5.Power saving LED lights to be introduced in place of conventional tube lights

2.50% 2.00% 1.50% 1.00% 0.50% 0.00%

Power & Fuel cost May11 Rs 4153930.00

Sep11 - Rs 3384402

Net saving Rs 769528.00 / month

WATER CONSERVATIONS
Action taken for Water Conservation 1.Wastage of water due to over flow of over head tanks, water leakage in canteen, paint shop. 2. Automatic water level sensor provided in overhead tanks.
400 350 300 250 200 150 100 50 0 May'11 June'11 July'11 Aug'11 Sep'11

WATER CONS. / DAY ( KL)

375 315

307
263 251

3. Reuse of ETP treated water in Air Washers and toilet flushing.

4.Leakage control shop floor and toilets Next steps 1. Automated water sensor to be provided in paint shop water tanks. 2. Urinal sensors to be provided to save water.

Water consumption reduced to 251 KL/Day about 30% saving approx Rs 33480 .00 /month.

IMPROVING THE POWER FACTOR

Saving in Power factor
1.Power factor was 0.8 upto month of May11. Now it is 0.98. 2.Every month penalty was paying to Haryana State Electricity Board . 3.Now we are taking rebate in electricity bill.
1.2 1 0.94 0.8 0.8

Power Factor

0.98

0.99

0.98

Following actions taken

0.6

1.We have added capacitor banks 2. Replace the weak / dead capacitors
0.4 0.2 0

3. Power Factor correction replay was not working in Auto mode , it was corrected Net saving = Rs 40000.00 per month in electricity bill & image of Omax Auto will improve

May'11

June'11

July'11

Aug'11

Sep'11

COST SAVING IN MOTOR REWINDINGS

Saving in Motor Winding cost
100000

Monthly Motor burning trend ( Rs)

90000 80000 88452 78980 81200 76800

Following actions taken

1. Daily monitoring ( Check current , Voltage , vibration & temp) of motors started in critical & High rating motors MPCBs ( Motor protection circuit breaker) initiated in paint shop motors. ONE MOTOR WINDER APPOINTED & INHOUSE MOTOR REWINDING STARTED. Earlier motor winders were using poor quality of motors , now best quality of materials are being used.

70000 60000 50000 40000 30000 20000 10000 0 2900 May'11 June'11 July'11 Aug'11 Sep'11

2.

3.

4.

Net saving = Rs 70000.00 Approx / month

MAINT. CONSUMABLES TREND

Saving in Maintenance Stores ( Consumables )1. Stopped the supply of spurious quality of products . Only Standard quality of products are being used. Only machine manufacturers recommended lubrication oil are being used . No compromise with quality . Net saving = Rs 400000.00 Approx / month

MONTHLY MAINT. CONSUMABLES TREND

30.00 25.00 20.00 15.00 25.17 28.45 23.87 22.88

21.2

2.

10.00 5.00 0.00

3. 4.

MAY 11

JUNE 11

JULY 11

AUG 11

SEP 11

MAJOR COST SAVING PROJECTS

1. CNC 3 axis m/c repaired in house @Rs 250000.00 . Even Electro Pneumatics P ltd quoted for Rs 12 lacks . m/c was required at Banglore for overhauling and time 3 months . Net saving Rs 105000.00 Ching Fong press sent for Overhauling at M/S Kirti Intertrade in the month of April 11@ Rs 14.00 lacks . Now m/c sent for other party @ Rs 4.5 lacks for overhauling . Net saving of Rs 9.5 lacks Press master press of R & D deptt was idle since last 4 years & it was decided by R & D team for scrap . Maint team took a challenge and called party for repairing ( Quotation was Rs 1.2 lacks) . then it was repaired in house by team with zero investment . Net saving of Rs 1.2 lacks AMC of Forklifts & DG sets was almost double earlier . Same parties called & negotiated at less rates . Net saving Rs 1.2 lacks Earlier Total make Hydraulic oil was using in presses / CNC m/cs. Breakdown was very high for high temp / DC valves malfunctioning . Now Castrol make oil is being used . Zero breakdown of presses for above said problems.

2.

3.

4.

5.

ONTIME SAVING RS 2240000.00

THANKS