fuelling frugal innovation in industry

7/29/2019 Fuelling Frugal Innovation in Industry

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by

GAGAN GOEL & SHOBHITAGARWAL

DEPUTY MANAGER

AONLA UNIT, BAREILLY

FUELLING

FRUGAL INNOVATIONIN INDUSTRY

Technical Seminar on

Engineers Day-2013Institute of Engineers, Bareilly Chapter


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Dr. R. A. Mashelkar

What is Frugal Innovation?

Frugal innovation or frugal engineering is theprocess of reducing the complexity and cost of a good

and its production.

Frugal innovation responds to limitations in resources,

whether financial, material or institutional, and turnsthese constraints into an advantage through

minimizing the use of resources in development,

production and delivery.

Frugal innovation results in dramatically lowercostproducts and services & a better way of doing a job.

Successful frugal innovations are not only lower in

cost, but outperform the alternative, and can be made

available at large scale.


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Value forMoney

Value forMany

Dr. R. A. Mashelkar,

President of Global Research Alliance,

(former Director General of the Council of

Scientific & Industrial Research (CSIR))

Frugal Innovation =


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Drive the

economicgrowth of

nations

Improve

people welfareSustain

Organizations

Why Frugal Innovation is

Important?


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FRUGAL Innovation in India ..

Jugaad is a colloquial Hindi wordthat roughly translates as aninnovative fix; an improvised solutionborn from ingenuity and cleverness.

Jugaad Innovation is about: Less,but better it concentrates on the

essential aspects and not burdenedwith non-essentials

back to purity,back to simplicity.

Jugaad applications include findingnew uses for everyday objectsIndian kitchens are replete withempty bottles reused as ad-hoc

containers for dried legumes orcondimentsor inventing newutilitarian tools using everydayobjects, like a makeshift truckcobbled together with a dieselengine slapped onto a cart(makeshift vehicles).


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FRUGAL INNOVATION - EASY COST

EFFECTIVE DAILY SOLUTION

MittiCool Fridge Jugaad Espresso Coffee MakerWashing Machine without Electricity


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Believe it or NOT Indian Jugaad is

MOST HAPPENING Thing for the world


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MANAGING INNOVATION A WESTERN

APPROACH

In the 20th century, as North American andEuropean economies expanded, Westerncorporations began to institutionalize theirinnovation capabilities, creating dedicated R&Ddepartments and standardizing the businessprocesses needed to take their ideas to market.

They focused on managing innovation, just asthey managed any other business activity. Thisindustrialization of the creative process led to astructured approach to innovation with thefollowing key characteristics: big budgets,standardized business processes, andcontrolled access to knowledge.

But this structured innovation approach, whichhelped Western firms become highly successful inthe second half of the twentieth century, has threeclear limitations in the fast pace and volatility ofthe twenty-first century:

1. The structured approach is too expensiveand resource consuming

2. The structured approach lacks flexibility3. The structured approach is elitist and


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Natural ResourcesCapital

LandSkilled Labor

Infrasctructure


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Diversity- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Geographic Cultural Social Economic Biological


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InterconnectivityCloud Computing Mobile Social Media


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Technological

Market

Competitive

Velocity- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -


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Emerging Markets

More ConsumersGreater Strain on Existing Resources

Frugal Innovation

Globalization- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -


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THE SIX PRINCIPLES

OF FRUGAL INNOVATION

Find more opportunity in adversity.

Do more with less.

Think and act flexibly. Keep it simple.

Include the margin.

Follow your heart.


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IFFCO Aonla

Producing 1.21 lacs Bags having 50 kg

Urea.

Plant is continuously running &

DOWNTIME is not desirable. 1 day DOWNTIME cost = Production Loss

of Rs.6 crore + Shutdown & Startup

Energy Loss of Rs.2 crore.

Shutdown Planning is a mega activity inthe continuous running plants so that all

activities can be completed within a

specified span of time.


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A Brief of IFFCO Aonla

Certified for following Management System

ISO-9001 Quality

ISO-14001 Env ironm ent

OHSAS-18001 Helath & SafetyISO-16001 Energy

ISO-26001 CSR


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" IFFCO Employees Suggest ion

Scheme"

IFFCO has always encouraged frugal innovation, novel ideasand creative thinking on the part of employees.

"IFFCO Employees Suggestion Scheme" is yet another step

towards utilizing employees creativity and potential for improved

organizational performance.

The Scheme is aimed towards an objective of providing a well-structured and formal platform for nurturing, supporting and

rewarding creative ideas of employees.


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Computerization
http://localhost/var/www/apps/conversion/tmp/scratch_1/SuggScheme_Eng.pdf


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Growth of IFFCO Suggestion Scheme

969924 897

156

802

1133

28

15750

0

200

400

600

800

1000

1200

2010-2011 2011-2012 2012-2013

Number of Employees

Number of Suggestions

Received

No. of Suggestions

Impleented


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THE JOB: Inspection of inside wall of Ammonia Convertor which involved

NDT (DP/UT/Hardness/etc) of 6 nos. of C-Seam weld joints and 5 nos. of

L-Seam joints.

To reach different levels of C-seam and L-seam joints, it is necessary to have

scaffoldings inside the vessel of about 26 meters height and 3.0 metersdia.

It involves 150M3 ofscaffolding which takes 02 days to erect and 01 days to

dismantle. Additionally 01 day required for Inspection .

Reduction in inspection time of Ammonia

Converter (S-200 ) by providingprefabricated multi-storied inspection cage.

FRUGAL INNOVATION-1


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Conventional

Scaffolding

Basket support

ring

FRUGAL INNOVATION-1


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In nut shell Reduction in scaffolding activity and

inspection activity can reduce the Shutdown

time by 3days to match production targets.

Something very different and innovative idea

can only help in this situation.

FRUGAL INNOVATION-1


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The Idea struck was :

Why not to Fabricate and use amulti-storied platform to help the

Inspection activities inside the

Ammonia Synthesis Convertor

Pressure Vessel.

This will allow inspection of all C-

seam joints of all 6-levels at a time

i.e. Inspection time is reduced.

More safe

Installation and removal is one

houreach only.

FRUGAL INNOVATION-1


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FRUGAL INNOVATION-1

This scaffolding structure was actually

erectedinto vessel in 1 hour instead of2days.

Inspection was carried out through out

the vessel in a time in 12 Hrs instead

24hrs due to easy access.


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FRUGAL INNOVATION-1

The scaffolding was de erectedfrom

the vessel in 1 hour instead of 1 day The whole inspection activity

completed with in 16 hrs instead of 4

days

Net saving of 3 days


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This innovative idea Reduced shut down time by 3days

9,090 MT More Urea Production (@ 3030 MT Per day)

More profit on the production approx.Rs. 1.5 Crore.Other Benfits :

The fabricated structure can be utilised for such

applications with slight modification

The used material can be reclaimed and re-utilised.

FRUGAL INNOVATION-1


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REDUCTION IN REPAIR TIME OF

Syn-loop boiler (E-1501) Ammonia-1

IMPORTANCE:Use waste heat of syn gas coming from

converter (Exothermic Reaction).

Produce HP steam

OBSERVATION:Tube leakage.

EFFECT:Boiler steam conductivity running higher

than normal and Loss of syn gas.

FRUGAL INNOVATION-2


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Repair Procedure with

Hydro Testing

Shell has to be Hydro tested at max at 80

kg/cm2 to find out leaks and than carried out

repair. If repair having some defect repeat

hydro test in iterations till all leak points

repaired.

Tubes were plugged with Inconel plugs and

welding was done with TIG process using ErNi Cr3 filler wire of 1.6 &2.4 mm size. Tube to

tube sheet leakage was also repaired by

welding overlaying process.

FRUGAL INNOVATION-2


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Difficulty in hydro testing Procedure:

In hydro test DM water was being used and after leak detection this

water required to be drained from shell for leakage repairing.

Complete cycle of one hydro test (Filling, pressurization and

draining) takes min. 10 hrs

Leakage repairing was done by TIG welding, which require clean

and dry surface. This condition was not achieved in presence of

water, which results difficulty in welding.

Note : Through this procedure more time required and also

difficulty in welding.

FRUGAL INNOVATION-2


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PNEUMATICALLY LEAK DETECTION

INSTEAD OF HYDROTEST,WAS

CONCEPTUALISED TO

SAVE TIME & WATER FREE WELD

REPAIR

FRUGAL INNOVATION-2


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New SYN LOOP BOILER TESTING ARRANGEMENTSynthesis Loop Boiler Pneumatic Testing Scheme

AMMONIA PLANT

UREA PLANT

MOTOR

COMP

K-3

Passivation Air Comp.

for Bimetallic Stripper

E-1501Synthesis loop

Air (80 kg/cm )

To Bimetallic

Stripper

Pr. Gauge

FRUGAL INNOVATION-2

FRUGAL INNOVATION 2


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Repair Procedure

with Pneumatic Testing: Shell was PNEUMATICALLY tested at 3kg/cm2, 7.0 Kg/cm2,

25 kg/cm2 and max at 62 kg/cm2 and repair was carried out in

each iterations.

Tubes were plugged with new modified Inconel plugs and welding

was done with TIG process using Er Ni Cr3 filler wire of 1.6 &2.4 mm

size. Tube to tube sheet leakage was also repaired by welding

overlaying process.

During last S/D -2012, 04 nos. leaky plugs were removed by grinding

and new plugs provided and welded. Tubes to tube sheet weld joint

were repaired by welding.

FRUGAL INNOVATION-2


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BENEFITS

1.Time saving

2. Defect free welding

The above suggestion has given a

Tangible Benefit of 3,00,00,000/- (one time)and other benefit like reduction in overall

plant shut down period.

FRUGAL INNOVATION-2


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Primary Reformer - Ammonia Plant

FRUGAL

INNOVATION - 3

Use of Special Jig for

handling more than one

catalyst Tube

AB Cell

CD Cell

View


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Earlier approach

Single catalyst Tube removal& insertion time was approx.

30 min. (One crane operation)

Total 288 Crane operations

would be required by

conventional method.CatalystTube removal & insertion was

done on single tube basis

(conventional method).

Total time taken for tube

removal & insertion comes

out

= 6days

= 288x30 min= 8640 min

FRUGAL INNOVATION-3


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The Idea struck was :

Why not to Fabricate and use

fixtures/clamps for removal &

insertion of two or more Catalyst

tubes.

This will reduce the total no of crane

operation and would reduce total

time taken for removal & insertion of

catalyst tube.

More safe.

Optimum utilization of Crane

capacity.

Conventional Fixture for singletube Removal/insertion

New Fixture for twotubes Removal/insertion

New Fixture for threetubes Removal/insertion

FRUGAL INNOVATION-3


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IMPLEMENTED APPROACH The Suggestion was

implemented by

fabricating new Jigs

& Fixtures in house

using the scrapstructural & piping

material.

FRUGAL INNOVATION-3


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Sr

no

Activity Conventional

Fixture for Single

catalyst tube

New Fixtures for two or

three catalyst tubes

%

Reduction

1 Total crane

operation

(Usage of

Crane)

288 50-AB Cell

74-CDCell

60%

2 Total time

taken

=288x30min

=6 days

=124x50* min

=4.3 days

28.3%

(1.7 Days

saved)

3 Safety Groove for Two part

ring But no Bolting

Stopper cleats for two

part ring and fixtures wereBolted

More safe

Note: *Extra time for single crane operation with new fixtures wasdue to Bolting & dismantling of clamps, difficulties in alignment &removal of old catalyst tubes.


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can only help in such situations

Out of box thinking


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CONVERT YOUR IDEAS

INTO ACTION THROUGH

FRUGAL INNOVATION

fuelling frugal innovation in industry

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