Innovative Award - Barrel Cleaning Machine - KNPL final - 14.09.2012

Recovery and re –use of sticking material waste by using new method of cleaning through

INNOVATIVE BARREL CLEANING MACHINE

Presented By

R.Rameshbabu, Works Manager, Kansai Nerolac Paints Ltd, Chennai & Hosur

Date: 14.09.2012

Category Name for Award: Manufacturing Innovation & Design

My Name is R.Rameshbabu, 41 years, BE ( Mechanical), MBA ( Operation Mgt) professional with 22 years of rich experience in different verticals of manufacturing & support functions in following reputed industries1.Binny Ltd (Textile processing)2.Steel Tubes of India Ltd & Tube products of India Ltd (Steel processing)3.Comcraft group – Uganda Baati & Metecno India ( Steel & Chemical processing)4.Graphite India & currently with Kansai Nerolac Paints ( Chemical processing)

My strengths are highly task oriented, very strong in problem solving & team building, expertise knowledge in all kinds of machineries & equipments and also a good team leader.

My few significant achievements in the manufacturing functions are1.Developed cyclone separator to collect fly ash in coal fired boiler.2.Developed damper control mechanism for uniform raise in temperature throughout the furnace (fuel saving)3.Developed on line double end chamfering machine & abrasive wheel cut off mechanism (defect elimination)

About Me …

4. Designed and fabricated vertical rack storage system (loading / unloading through EOT cranes) for pre-painted steel coils

5. Manufactured World longest single PUF insulated Panels – length: 20 mts exported to Vietnam by way of modifying the machine & containers for shipment.

6. Developed / sourced low price fully automated mineral wool cutting & feeding machines and integration with PUF insulated panel machine – two category of products in one line (products – PU insulated panel and mineral / rook wool insulated panel )

•Kansai Nerolac Paints Ltd - A subsidiary of Kansai Paint Co., Japan

•Company Gross Sale: Rs. 30199 million ( Mar 2012 end )

•India’s second largest paint company.

•Market leader in the Industrial & Automotive Coatings business in India.

•Reputation for innovation, Superior Technology, Value Engineering , Quality and Service.

History:1920 Established as Gahagan Paint & Varnish

1933 Acquired by Lead Industries Group, UK

1946 Name changed to Goodlass Wall Pvt. Ltd

1957 Name changed to Goodlass Nerolac Paints Pvt. Ltd

1976 Forbes Gokak (Tata Group) acquired a part of the foreign shareholding

1986 Kansai Paint Co. Ltd, Japan bought out the share of the UK partner.

2000 Forbes Gokak divested its holding in favor of Kansai Paint

2006 The name of the Co. changed to “Kansai Nerolac Paints Ltd.”

About Company…

Awards Won

Plant Capacity & Certification Location Lote Jainpur Bawal Perungudi Hosur

State Maharashtra UP Haryana Tamil Nadu Tamil Nadu

ProductsDecorative IndustrialPowders

Decorative Industrial

IndustrialPowders

Decorative Industrial

Decorative + Industrial (Phase2)

AnnualCapacity

50,920MT

78,400MT

30,400MT

30,700MT

18.000 + 44,000(Phase2)

MT

Certification

ISO 14001OHSAS 18001

TS 16949 & BSC Safety

ISO 14001OHSAS 18001

TS 16949

ISO 14001OHSAS 18001

TS 16949BSC Safety

ISO 9001ISO 14001

ISO 9001ISO 14001

OHSAS 18001

Our Customers

Paint Manufacturing Process

POWDERS RESINS RESINS SOLVENTS SOLVENTS

DRIERSSTAINERS

SLURRY

THINNING MIXER

HIGH SPEEDDISPERSER(PRE-MIXING)

FILTRATION

SAND MILL (DISPERSION)

FILLING MACHINE CONVEYOR

Lot of barrel generation

PROJECT BACKGROUND

Recovery and reuse of Sticking Material Waste of the incoming High Viscous hazardous Chemicals into the Prime Products by way of using new method of cleaning thro’ Innovative Barrel cleaning Machine in KNPL unit.

Material Apr-10 May-10 Jun-10 Jul-10 Aug-10 Sep-10 Oct-10 Nov-10 Dec-10 Jan-11 Feb-11 Mar-11 total2300017 58828 64783 77100 70488 52961 63216 70454 79693 72157 72683 73120 66868 8223522300021 65688 57216 70001 62059 62952 68763 61578 65134 50349 43147 50445 36048 6933802300140 39578 36240 55432 44396 40833 44661 51742 59143 45281 49759 39548 46715 5533292300150 7043 11453 15258 12758 6415 9376 10213 9342 7069 8072 10253 5278 112529

2181590

2300017 294 324 386 352 265 316 352 398 361 363 366 334 41122300021 328 286 350 310 315 344 308 326 252 216 252 180 34672300140 396 362 554 444 204 447 517 591 453 498 395 467 53292300150 70 115 153 128 32 94 102 93 71 81 103 53 1093

14001

2300017 45298 49883 59367 54276 40780 48676 54249 61364 55561 55966 56303 51488 6332112300021 89993 78386 95901 85021 48473 94205 84362 89234 68977 59111 69110 49386 9121592300140 55014 50374 77051 61711 31441 62079 71922 82209 62940 69165 54971 64934 7438102300150 11409 18554 24718 20668 4940 15189 16546 15134 11451 13076 16610 8550 176845

2466026

All Plant - Material in consumption ( in Kg)

All Plant -Stick loss in qty ( in Kg)

All Plant Stick loss in value ( Rs.)

As is data ( all plants)

1. Total consumption of barrel item: 2181 ton per annum & approx. 11000 barrels per annum.

2. Total sticking loss: 14 ton per annum & 24.66 lacks per annum

2300017 POLYHYDROXY ACRYLIC RESIN -HV

2300021 POLYHYDROXY ACRYLIC RESIN HIGH GLOSS

2300140 75% SOLUTION OF ARALDITE 6071

2300150 ARALDITE G Y 250 / Epoxy Resin EPG 180

Material Apr-10 May-10 Jun-10 Jul-10 Aug-10 Sep-10 Oct-10 Nov-10 Dec-10 Jan-11 Feb-11 Mar-11 total2300017 42 1218 931 1481.1 548 379 412 460.9 1060 348.2 462.4 62.5 7405.12300021 2789 5389 4892 4733.8 2013.3 825 3343 5308 9444 4386 6259 5124.01 54506.112300140 11725 10559 15226 12935.9 11525 10070 12809 16990 14266 13075 12237 16375.001 157792.9012300150 1292 4688 2677 1137.3 1394 1868 3625 2977 2311 1035 2297.14 991 26292.441

245996.552

2300017 0.21 6.09 4.655 7.4055 2.74 1.895 2.06 2.3045 5.3 1.741 2.312 0.3125 37.02552300021 13.945 26.945 24.46 23.669 10.0665 4.125 16.715 26.54 47.22 21.93 31.295 25.62005 272.530552300140 117.25 105.59 152.26 129.359 57.625 100.7 128.09 169.9 142.66 130.75 122.37 163.75001 1520.304012300150 12.92 46.88 26.77 11.373 6.97 18.68 36.25 29.77 23.11 10.35 22.9714 9.91 255.95441

2085.81447

2300017 32.34 937.86 716.87 1140.45 421.96 291.83 317.24 354.893 816.2 268.114 356.048 48.125 5701.9272300021 3820.9 7382.93 6702.04 6485.31 1550.241 1130.3 4579.9 7271.96 12938 6008.82 8574.83 7019.8937 73465.39072300140 16298 14677 21164.1 17980.9 8874.25 13997 17805 23616.1 19830 18174.3 17009.4 22761.251 212186.6322300150 2093 7594.56 4336.74 1842.43 1073.38 3026.2 5872.5 4822.74 3743.8 1676.7 3721.37 1605.42 41408.8544

332762.805

Chennai Plant - Material in consumption ( in Kg)

Chennai plant -Stick loss in qty ( in Kg)

Chennai plant - Stick loss in value ( in Rs.)

As is data ( Chennai Plant)

1. Total consumption of barrel item: 245 ton per annum & approx. 1229 barrels per annum.2. Total sticking loss: 2.1 ton per annum & 3.32 lacks per annum3. Expecting increase of Production and Hosur new operation – Barrel consumption will be very high.

PROJECT OBJECTIVERecovery and reuse of Sticking Material Waste of the incoming High Viscous hazardous Chemicals into the Prime Products by way of using new method of cleaning thro’ Innovative Barrel cleaning Machine in Chennai KNPL unit.

BUSINESS OBJECTIVEEffective usage of Raw Materials by way of reducing sticking loss / recovery & reuse into the final Paint products to gain the value and to save the environment by the way of reducing the waste materials .

Rs. 24.66 lacks per annum material loss under sticking category in KNPL Factory

TECHNICAL OBJECTIVETo obtain Innovative method & machines for the recovery & reuse of the sticking materials close to 14 tons Per annum and also to avoid manual painful activity of cleaning.

Target : 85% Reduction of sticking loss

Chennai plant Considered for this Project & based on the success same will be horizontally deployed to all other units of KNPL.

Study of Existing Practice of Recovery in KNPL:

Problem???

Study of Existing Practice of Recovery in KNPL:

PFMEA – existing Test Procedures..

Finalised RCA –for less recovery of Materials based on Pareto & FMEA

Improper Wiping ( Positioning of Chain)

No Cyclic Rotation ( Top & Bottom surface contact with chain)

Team Formation for the project

Brainstorming Session Output

1. Check the feasibility of existing method fine tuning

Team expressed fine-tuning existing method will not support RCA

2. Go with Market available Barrel cleaning Machine

Market available Barrel cleaning machine is not suitable for sticky material recovery. Will be suitable for washing fresh barrels & non sticky materials.

3. Go with new Innovative Barrel Cleaning Machine with lesser cost

Best Idea

New Design Sketch..

Innovative Barrel Cleaning Machine

Specification of New Design

Diameter of drum used: 58cm# Length of drum used: 87.5 cm# Angle of tilt for cyclic motion: 30 deg# Revolution of drum: 10 rpm# Weight of the machine: 500 kg# Cleaning chain: 1/4 inch link & 3 mts# 1HP Motor with speed reduction Gear box.

Innovations:Horizontal revolving motions of the drum through the plain rollers are converted into cyclic ( upside down, downside up & horizontal) to have better abrasion of metal chain link inside the barrel and the chain link hinge position in the barrel to have effective cleaning of sticky material

Metallic chain

Barrel Cleaning

Machin chain

Fabrication Cost of Machine :Fabrication Cost of Machine :

Machine Utilisation & Cleaning Capacity :Machine Utilisation & Cleaning Capacity :

Activity Minutes M/C Man Time required for one barrel 8 minutesWeigh the empty barrel 0 Available time / shift 450 minutesAdd Solvent 0 Total barrels cleaned / shift 56 nosClose the barrel 0Load the barrel in M/c 0Lock the M/c 0Switch-on the M/c 0Run in Horizontal Position 3Run in Backward tilted Position 3Run in Front Side tilted Position 2Switch-off the M/c 0Take-out the barrel 0Remove the lid 0Discharge material 1 0Weigh the empty barrel 0Calculate the recovery 0Identify as Cleaned 0

14 8 2Net cycle time = Total time - load/unload time 8

2

28

1

2

Operational Cost Per Barrel:Operational Cost Per Barrel:

Trial Run / Demo of Innovative Barrel cleaning Machine..

Trial run carried out with innovative barrel cleaning machine and achieved 95 % chain and barrel contact area. Recovery of the sticky material is 90 %, which is more than the target of 85% recovery

Video Shoot

Horizontal cleaning Bottom cleaning Top cleaning

Design Validation:Design Validation:

By way of Barrel sticking loss reduction data – 93% recovery observed.

Design Validation: Design Validation:

Horizontal Deployment:Horizontal Deployment:

Same machine had been implemented in all other units of KNPL Lote, Jainpur & Bawal unit

Benefits (all over plant): Benefits (all over plant):

1. Total sticking loss reduction from 5.8 ton to 0.42 ton for 5 month &2. Cost saving approx. 9 lacks for 5 month

Standardization

New Barrel Cleaning Procedure Ref No: KNPL /WI/EMS/35Step 1: Weigh the Wt of the Individual barrel

Step 2: Add the respective solvent in to the drum.

Step 3: Close the mouth with barrel using iron chain lid.

Step 4: Place the barrel in to cleaning machine.

Step 5:Close the barrel with barrel locking key.

Step 6: Switch on the machine.

Step 7: Run the machine 3min in Horizontal position.

Step 8: Run 3min in backward tilting position.

Step 9: Add the respective solvent in to the drum.lid.

New Barrel Cleaning Procedure Ref No: KNPL /WI/EMS/35Step 10: Switch off the machine in horizontal position.

Step 11: Remove the barrel from locking cover.

Step 12: Take the chain lid out.

Step 13: Place it in a respective collection vessel & Allow the material to flow.

Step 14: Weigh the Empty cleaned barrel and calculate the recovered material.

Step 15: Mark the green Dot in center of barrels.

On the environmental part, all the scrap barrels are taken up for cleaning & to realize higher price on scrap selling.

Cost of cleaning Rs. 9.50 per barrel and the price realised Rs. 25 per barrel more .

Other Benefits: ( Eco Friendly )Other Benefits: ( Eco Friendly )

Other Benefits: KNPL new plant (Hosur)ProposalOther Benefits: KNPL new plant (Hosur)Proposal

Apart from the material waste reduction, this machine will used for cleaning of used barrels to recycle / reuse for the sticky resins like acrylic, alkyd, MF, Polyester etc., to the extent of 6 times in the process

KNPL new plant (Hosur) machine layout proposalKNPL new plant (Hosur) machine layout proposal

Barrel washing Machine – Jet cleaning

Barrel cleaning Machine 1

Stage -1 : Preliminary Cleaning - Line 1Activity Minutes M/C Man

Weigh the empty barrel

2

0

2

Add Solvent 0Close the barrel 0Load the barrel in M/c 0Lock the M/c 0Switch-on the M/c 0Run in Horizontal Position 3

8Run in Backward tilted Position 3

Run in Front Side tilted Position 2Switch-off the M/c

10

Take-out the barrel 0Remove the lid 0Discharge material 1 0Weigh the empty barrel

20

Calculate the recovery 0Identify as Cleaned 0 14 8 2Net cycle time = Total time - load/unload time 8

Stage -1 : Preliminary Cleaning - Line 2Activity Minutes M/C Man

Weigh the empty barrel

2

0

2

Add Solvent 0Close the barrel 0Load the barrel in M/c 0Lock the M/c 0Switch-on the M/c 0Run in Horizontal Position 3

8Run in Backward tilted Position 3

Run in Front Side tilted Position 2Switch-off the M/c

10

Take-out the barrel 0Remove the lid 0Discharge material 1 0Weigh the empty barrel

20

Calculate the recovery 0Identify as Cleaned 0 14 8 2Net cycle time = Total time - load/unload time 8

Barrel cleaning Machine 2

Stage -2 : Solvent Flushing / barrel washing ( for line 1 & 2 )Fixing the barrel in spray M/c 1

2Solvent Spray 2 2Remove & identify as cleaned 1 Total ( Stage 2) 4 2 2