indo gulf fertilisers (a unit of aditya birla nuvo … · 3 integrity commitment passion...

INDO GULF FERTILISERS (A Unit of Aditya Birla Nuvo Ltd.)

Confidential

2 Integrity Commitment Passion Seamlessness Speed INDO GULF FERTILISERS

ABG AT A GLANCE

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ABG GROUP AT A GLANCE – GLOBAL PRESENCE

Global

The largest aluminum rolling company

No.1 in viscose staple fiber

No. 1 in carbon black

The 4th largest producer of insulators

The 5th largest producer of acrylic fiber

Among the top 10 cement producers

Among the best energy efficient Fertilizer plants – INDO GULF

India

The top fashion (branded apparel) and lifestyle player

The 2nd largest producer of viscose filament yarn

The largest producer in the Chlor-alkali sector

A leading player in Life Insurance and Asset Management

Among the top 3 mobile telecom players

Among the top 2 Supermarket chains in the retail

business

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Product Portfolio From Sowing To Harvesting

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AWARDS & RECOGNITIONS YEAR

First Fertilizer unit to achieve ISO-9002 Certification 1994

Best Environment Protection Award - Fertiliser Association of India 1995, 2000 & 03

Production Performance Award - National Productivity Council 1995-96 & 98-99

First Fertiliser unit to achieve ISO-14001 : 1996 Certification 1998

Production Performance Award - Fertiliser Association of India 1999

TPM Excellence Award – 1st Category & Consistency Award - JIPM, Japan. 2000 & 2002

IMC-Ramkrishna Bajaj National Quality Award - Certificate of Merit 2000

IMC-Ramkrishna Bajaj National Quality Award - Trophy 2001

ISO-9001 : 2000 Certification for Investor Services 2001

ISO-9001 : 2000 Certification for Quality Management System 2001

OHSAS 18001 : 1999 Certification for Occupational Health & Safety Management System 2001

Good Corporate Citizenship Award – PHD Chamber of Commerce 2001

“Best Managed Company” - M/s Forbes Global, USA 2002 & 2003

Special Contribution in Industrial Development in U.P.State - INDIA 2002

International Asia Pacific Quality Award (First Indian company) by Asia Pacific Quality Organisation, Mexico

2003

Golden Peacock Environment Management Award by World Environment Foundation, New Delhi 2004

Greentech Safety Gold Award by Greentech Foundation 2004

Awards & Recognitions

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AWARDS & RECOGNITIONS YEAR

Most Energy Efficient Unit by CII 2004

Deming Application Prize 2004 by JUSE, Japan 2004

Chairman’s WCM Gold Award (Aditya Birla Group) 2004

Suraksha Pursakar by National Safety Council of India 2004

ISO 14001 : 2004 Re-Certification – Environment Management System 2005

Corporate Social Responsibility Award – Commendation Certificate by FICCI 2005

Corporate Environmental Award - Commendation Certificate by TERI 2007

ISO-9001 : 2008, ISO 14001:2004 & OHSAS 18001:2007 Re-Certification for Quality, Environment and Occupational Health & Safety Management System

2009

Runner-up Award for the best overall performance (Ammonia & Urea) for the year 2008-09 - Fertiliser Association of India

2009

Agriculture Leadership Award 2010 for its Innovative Extension Model and the outstanding contribution in agriculture extension and development.

2010

ISO/IEC 27001: 2005 /2013 Certification for Information Security Management System with New Version 2011 & 2015

India Manufacturing Excellence Award 2012 – Platinum Award in Process Sector by The Economic Times and Frost & Sullivan

2012

Chairman’s WCM Awards – Commendation Certificate in Business category 2013

World CSR Congress - Global CSR Excellence & Leadership Awards for “Best use of CSR practices in Manufacturing”.

2015

Chairman’s WCM Awards – Bronze Medal in Business category 2015

Asian CSR Leadership Award – 1st Prize for “Community Development” 2015

National Energy Conservation Award by BEE – First Prize in the Fertilizers Sector (Sub-sector :Urea) 2015

Awards & Recognitions

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Integrity Commitment Passion Seamlessness Speed INDO GULF FERTILISERS 8 Integrity Commitment Passion Seamlessness Speed INDO GULF FERTILISERS 8

National Energy Conservation Award-2015

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Integrity Commitment Passion Seamlessness Speed INDO GULF FERTILISERS 9 Integrity Commitment Passion Seamlessness Speed INDO GULF FERTILISERS 9

Chairman’s WCM Award (Bronze) in Business Category


ENERGY CONSUMPTION

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Integrity Commitment Passion Seamlessness Speed INDO GULF FERTILISERS 11 Integrity Commitment Passion Seamlessness Speed INDO GULF FERTILISERS

Summary of the implemented energy saving schemes are given here-in-below:

MAJOR ENERGY SAVING SCHEMES IMPLEMENTATION

S. No Year No. of

Schemes

implemented

Energy Saving

(MKCal/Te of Urea)

Capex

(Rs.Lacs)

Envisaged Achieved Budget Actual

Before - Total energy Consumption in 2000-01 was 5.950 MKCal/MT

1 2001-02 6 0.225 0.230 1335 976.38

2 2002-03 7 0.112 0.108 628.02 494.01

3 2003-04 4 0.152 0.157 568 451.73

4 2005-06 4 0.021 0.016 253.8 338.36

After - Total energy Consumption was 5.404 MKCal/MT


ESS (Energy Saving Schemes) Project Implemented in March - 2014

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Benchmarking / Mapping done for energy consumption in our existing plant and

energy consumption in latest generation technology plant.

Detailed mapping carried out for heat dumping in cooling water and in atmosphere

through flue gas.

This gave us an idea of areas where we have to focus for energy conservation for

achieving the world class specific energy consumption.

Approach

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SPECIFIC ENERGY CONSUMPTION (COMPARISION WITH IDEAL ENERGY, LATEST TECHNOLOGY & EXISTING)

Particular Unit Theoretical Existing IGF

Plant

Existing IGF

Plant After

ESS

Latest

Technology

Heat Loss to Cooling water MKCal/MT of Urea 0 2.350 2.260 1.934

% Heat of Total Energy

consumption % 0 44 43 41

Heat Loss to Atmosphere MKCal/MT of Urea 0 0.390 0.370 0.142

% Heat of Total Energy

consumption % 0 7 7 3

Radiation Losses 0 0.1 0.1 0.1

Ideal Energy consumption for

Urea MKCal/MT of Urea 2.524 2.524 2.524 2.524

Total Energy Consumption MKCal/MT of Urea 2.524 5.364 5.254 4. 700

Above table indicates that

In Existing Plant, about 51 % heat is lost in Cooling water (CW) and Flue gases.

Majority energy is lost in cooling water- In existing plant( current operation) about 44% energy is lost to

CW

Latest generation plants are able to reduce energy loss to CW from 44 % to only 41%

After ESS implementation energy loss to CW will reduce by about 1% .

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Major Equipments

Existing Plant New Plant (Expansion)

C.W flow

(M3/hr)

Heat duty

(Gcal/hr)

C.W flow

(M3/hr)

Heat duty

(Gcal/hr)

Turbine Condenser, Syn. Compr. 2094 32.0 1495 14.8

Inter-stage of Coolers of Syn. gas 2345 19.0 1423 14.1

CO2 Removal Condensers 2200 32 1350 10

Inter-stage Coolers of K-421/PAC GT 1100 8.5 1334 13.2

Turbine Condenser of Air Compr. 2240 33.0

Turbine Condenser, Amm. Compr. 850 8.1 1378 13.7

Final Gas Cooler 900 8.1 806 4.0

Water Cooler 1375 9.6 2894 14.4

Ammonia Condenser 2845 18.0 5187 25.7

Stripped Condensate cooler 300 5.5 674 6.7

Inter-stage Cooler of CO2 Compressor 970 13.5 1579 15.7

Turbine Condenser of CO2 705 12.5 965 9.6

Heat rejection in Syn gas / CO2 removal coolers is an area of improvement

ENENRGY MAPPING AT MICRO LEVEL (With Latest Generation Plant)

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M/s Haldor Topsoe (HTAS) carried out feasibility study for reducing specific energy

consumption of Ammonia plant. Based on the study following schemes were

identified:

Molecular sieve dryer unit at the suction of syn gas machine to remove water

and traces of CO2 from the synthesis gas.

Upgradation of CO2 Removal section to reduce steam consumption.

VAM unit for inter-stage chilling in Process Air compressor (PAC).

Fuel gas Expander to generate power.

Ammonia Expander to generate power.

Purge gas expander.

Installation of HTER to save feed & fuel energy on Primary Reformer.

Upgradation of Syn Gas Compressor to reduce steam consumption.

Replacement of steam turbine drive of Primary Reformer ID fan with motor.

Methodology Adopted

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M/s Haldor Topsoe (HTAS) carried out Basic Engineering and M/s EIL carried out Detailed

Engineering for the ESS project in Ammonia Plant.

While carrying out basic engineering / detailed engineering some of the schemes have

been dropped due to not techno-commercially viable, design issues, voluminous jobs

requiring high shutdown days, structural issues etc.

Final schemes for ESS project:

Upgradation of Synthesis gas compressor train in Ammonia Plant to reduce steam

consumption.

Upgradation of CO2 Removal section to reduce steam consumption.

Replacement of steam turbine drive of Primary Reformer ID fan with motor.

Modification in combustion air duct in Primary Reformer furnace for uniform

distribution of air in burners.

VAM for suction air chilling of gas turbine to increase power generation.

VAM for suction CO2 chilling of CO2 Compressor.

• Investment: Rs 150 Crs.

• Savings: 0.133 MKCal/MT Urea

Methodology Adopted

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Upgradation of Synthesis Gas Compressor Train

• Synthesis gas compressor is the extraction-cum-condensing High Pressure steam driven

turbine.

• Internals of Upgradation of Synthesis gas compressor train is of the year 1980 vintage

since inception of the plant and less efficient as compared to the latest design

machines.

• Installed efficient latest design rotors / internals of both Turbine and Compressor.

• This scheme led to improvement in overall efficiency of the compressor train and

consequential reduction in HP steam consumption by about 15 Te/hr. This scheme

reduced heat dumping in cooling water.

• Upgradation of internals with efficient latest design and replacement of corresponding

diaphragm of inner casing done for all three compressor bundles keeping same outer

casing for all three barrels of compressor train.

• This idea was vetted & developed by M/s. GE.

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ESS Project Before and After Implementation

Upgradation of Synthesis gas compressor train in Ammonia Plant:

Before Implementation (Old Rotor)

After Implementation (New Rotor)

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Revamping of CO2 Removal Section

• CO2 removal section in Ammonia Plant is based on GV (Giammarco Vetrocoke)

Technology where-in hot Potassium Carbonate (K2CO3) is used as solvent to absorb CO2

from process gas in Absorber.

• CO2 loaded solution is regenerated in HP regenerator and LP regenerator.

• The open stripping process is used in HP regenerator for CO2 stripping from the loaded

solution with the help of LP steam whereas in LP regenerator solution is flashed by

pressure reduction and consequential stripping of CO2.

• Over the period of time, load on HP Regenerator gradually increased with the increase

in Ammonia production capacity.

• In this revamping of CO2 Removal section, a new LP regenerator identical to existing one

installed in parallel to the existing one. A new overhead condenser, new CO2 booster

compressor and new overhead separator installed.

• Shifting of more quantity of regeneration load from HP regenerator to LP regenerator

leading to reduction in energy consumption by way of saving in LP steam consumption

which reduce from current about 22 Te/hr to 8.0 Te/hr. This scheme reduced heat

dumping in cooling water.

• This idea was vetted by M/s. GV.

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• As this was a revamp project to be implemented in the existing plant therefore space

availability for installing new equipment were thoroughly checked.

• Installation of new tower (LP Regenerator - weight 83 MT, length 45 meter etc) along

with other equipment was a big challenge.

• From process point of view, all new equipment are to be installed nearer to the existing

system so as to facilitate easy flow of fluid from one vessel to other & to have minimum

pressure drop.

• Available space in the plant was so limited, creating enough space for movement of the

440 Te heavy duty crane.

• Equipment maintainability post revamp etc. were a great challenge.

• Additional space required for new equipment was created in existing space of CO2

removal section by Innovative ideas like diversion of road, installation of exchangers

over existing exchangers, reconfiguration of booster compressor cooling water skid etc.

& the team prepared layout for installation of these equipment effectively in available

space 20 m x 10 m.

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Risk Mitigation Plan

Risk mitigation planning done at IGF helped in developing options & actions to reduce

threats to project objectives. Risks were identified based on experience of project team &

all the stakeholders, previous project experience and utilizing a risk identification checklist.

Some of the potential risks identified & their mitigation is explained below:

S.N Risk Cause Mitigation plan Remark / Examples 1 Plant

Reliability Modification is being done in all the critical sections of a 26 year old plant

Reinforcing and evolving a robust system. Take help of Licensor/Expert, competitors experience etc. wherever required.

The weak link in the CO2 removal scheme was addition of a new LP tower to operate in parallel with the existing one. Midterm corrections were made during engineering & erection based on inputs from Technology vendor & IGF’s own experience.

2 Erection/ Prefabrication in running plant.

Plant handles highly hazardous and explosive gases

A task force was entrusted responsibility for execution. Conducted Hazop study etc.

Complied all safety measures during fabrication and erection through continuous monitoring which resulted in completing the project with Zero accident / incidence.

3 Over run of Budget.

Increase in eqpt cost and any additional requirement arising during engineering.

Adopted Zero Based Costing to arrive at best price & close monitoring of Capex

This helped in saving project cost by 16%

4 Delay in time Schedule

Any unforeseen hurdle affecting the schedule during the project

Incorporated LD clause in all Purchase orders. Obtained manufacturing schedules & expediting with vendors.

Team made periodic visits to vendor’s works for inspection / expediting /quality checks etc.

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Teams and Responsibilities

Team Name Members Name (S/Shri)

Responsibility Review by Review Frequency

Core Team CKD, RKL, AKG, RJ, DKS, MJ

Provide required resources, Monitor entire process & review the progress.

CEO Monthly

Project Team AKG, RJ, DKS, NS, MPY, SKP, KKS, BG

Ideation / finalization of the scheme, interaction with the technology suppliers, Communication with Core Team

Core Team Fortnightly

Engineering Team

RJ, DKS, SD, TKB, VK, AKS, FLP, MKH, NL

Review, Finalization & approval of engineering documents like enquiry documents, plot plan, piping layout, etc. provided by manufacturers

Core Team/ Project Manager

Monthly Fortnightly

Procurement & Expediting

BP,DKS,BG,RS,AJ, SWAPNIL

Vendor selection, floating enquiry, review of offers, technical recommendations and finalization of orders. Expediting and quality checking at vendors shop. Taking care of transportation issues.

Core Team/ Project Manager

Monthly Fortnightly

Shop Floor Team Team 1 SD, SS, OPV, PK Assist project team in identifying issues in the

scheme. Assist engineering team in reviewing the engineering

documents. Check layout and fouling issues Check safety and environment issues Supervise daily job progress during erection and

prefabrication. Monitor contractor progress commissioning.

Navin Weekly Team 2 NS, DKS, MPY, AKS, PT,

VKP, PK, KD, NL, FLP MP Yadav

Team 3 AS, AK, MKA KK Singh Team 4 MKA, AKM, AS Rakesh Jain

Team 5 Vikas Kumar, Kunal Das SK Pandey

Team 6 SKG, BG, AS, AKS SS SK Gupta

Team 7 TKB,SKG,RC,SPS Tapas Bag

Team 8 TNM, MSK,BG,RBS KK Singh

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Project Activity Chart

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Project Monitoring Matrix

Control & Monitoring

Purpose Description Responsibility Frequency Deliverable

Integrated change control

To control changes across the project, cost, quality, schedule and scope.

Approval / rejection of request for change to ensure that requests are addressed at the appropriate level, track changes.

Project Manager

As & when required

Feedback to originator. Up-dation of documents

Procurement To ensure vendors performance is in line with the requirement.

Monitor contractual obligations & Progress monitoring as per schedule

Head (Comml.) Fort nightly Timely procurement of all items

Project Schedule

To maintain the project progress as per schedule

Monitoring the project progress and change management to the schedule.

Project Manager

Weekly Timely action to maintain schedule,

Cost To maintain the cost of project within budget

Monitoring the project cost and managing changes to the cost baseline

PM/ HOD (Fin) Monthly Timely action to maintain cost

Quality control

To maintain quality as per standards

Monitoring and recording of results of executing the quality plan

Project Manager (Insp.)

Monthly Ensure quality standards are maintained.

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Key Learning

The major learning were:

• If an unwarranted situation is faced by the organization due to any reason, then no one

else but we ourselves can make things happen by banking upon the strength of our

employees.

• Success of any initiative lies in kind of team handling the task. If team is highly motivated,

seamless, passionate & have role clarity, then something breakthrough is surely to happen.

• Never treat failure as a final conclusion. IGF developed culture of not surrendering to

situations and has learnt to convert weaknesses into strength.

• During transportation of LP Tower the Trailer carrying the lower part of Tower failed on

the highway and IGF had to carry out shifting of ODC from one trailer to other trailer. IGF

learned that keeping transportation in vendor scope does not absolve IGF responsibility for

smooth transportation & doubly ensure the credentials of all sub venders of suppliers.

• While carrying any activity, its impact on other associated equipment must be

ascertained e.g. while carrying out welding in GT structure, its control system cards got

affected. SOP revisited & modified.

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Energy Consumption Scenario

5.40

5.23

4.80

4.90

5.00

5.10

5.20

5.30

5.40

5.50

Pre-ESS(IMPLEMENTED MAR'14)

PRESENT LEVEL

Specific Energy Consumption (MKCal/Te of Urea)

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Year Wise Energy Consumption and Production Scenario

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IGF energy Consumption is lowest amongst same vintage plants in India

Energy Consumption Benchmarking INDIAN FERTILIZER PLANTS (2014-15)

Same Vintage

Plant (Pre 1992)

Latest Generation

Plant (Post 1992)

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BENCHMARKING STUDY INDIAN PLANTS

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IGF’s track-record as a leading Urea Manufacturer

Benchmarking Energy Efficiency

Avg. Specific Energy Consumption of leading Gas-based Urea Manufacturers FY 08 to FY11

Source: Report of the Working Group on Fertilizer Industry for the Twelfth Plan (2012-13 to 2016-17)

(G-cal/MT of Urea)

IGF

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WORLDWIDE AMMONIA PLANT BENCHMARKING STUDY

Source: Plant Surveys Int’l Inc. (USA) 2008-09 Ammonia Plant Benchmarking Study Report

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126

120

122

117

112

99

110 109

112

114

103 103

98 96

99 97

134

128

120 118

117

113

110 107

104 104 103 102

101 101 99

83

127

119

124

119

111

103

110

99

106 104

108 109

97

106 104

106

80

90

100

110

120

130

140 Capacity Utilization (%) 2012-13

Capacity Utilization (%) 2011-12

Capacity Utilization (%) 2010-11

CAPACITY UTILIZATION OF EXISTING PLANT (FY 2010-11 TO 2012-13)

Source: FAI statistics

IGF Existing Plant – No. 1 in Capacity

Utilization amongst Indian Fertilizer

plant


STEPS TOWARDS GREEN ENERGY

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Promote Green Energy

Identified and implemented several energy saving schemes to reduce energy consumption and

promote green energy:

• Installation of energy efficient fans in Cooling Tower (total 10 nos.)

• Installation of Solar Power Plant in Township and Aditya Birla Public School

• Replacement of street lights with LED lights in Plant area and Township

• Replacement of lights in building with LED lights like Administrative building, Guest House,

Control rooms, Office buildings in Plant area, Workshop etc.

• We are exploring further capacity enhancement and reduction of energy consumption to

achieve world best energy consumption level.

• We are also monitoring GHG emission under Scope-III i.e. GHG emission due to fuel

consumption for transportation of raw materials, products and employee movement.

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CO2 Emission Reduction – Contributing To Global Cause

Year Cumulative CO2 Emission Reduction (Tones)

Since year 2003 to FY 13-14 7.0 Lacs

Post ESS ( Year 2014-15) 8.1 Lacs

• Implemented several energy saving schemes resulting in reduction in CO2 emission. • During manufacturing of Ammonia / Urea about 45% of the Natural gas is used as fuel. • Reduction in Specific energy consumption leads to reduction in fuel consumption and

consequential CO2 emission reduction • First in the Aditya Birla Group as well as first fertilizer company globally to register CO2 emission

reduction project with UNFCCC in the year 2003. Since then, IGF has registered six projects leading to about 80,000 Te of CO2 emission reduction per annum.

• Total CO2 emission reduction is as follows.

PAT ( Perform, Achieve and Trade) status:

• PAT Target for IGF: 5.440 MKCal/Te of Urea (FY 2014-15)

• Achieved Sp. Energy consumption in FY 2014-15 : 5.344 MKCal/Te of Urea

• Reduction in Energy Consumption: (5.44 - 5.34) * 10,16,129 = 10,1613 Gcal = 10,161 MTOE

• 10 MKcal = 1 MTOE (Metric Tonne of Oil Equivalent) = 1 ESCert

• Expected no. of ESCert to be issued: 10,161

• M&V Audit completed on 10th June’15 by Empanelled Accredited Energy Auditors and the report submitted to BEE.

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Integrity Commitment Passion Seamlessness Speed INDO GULF FERTILISERS 37

Parameter FY 2013-14 FY 2014-15

Road 13819 12836

Rail 608 515

Total 14427 13351

GHG Emission Under Scope – III

CO2 Emission due to Employee movement (Te CO2):

CO2 Emission from Logistic of Urea product (Te CO2):

Parameter FY 2013-14 FY 2014-15

CO2 Emission (Te CO2) from petrol vehicles (Cars/Motor Cycle etc.)

for movement of all employees in local area (outside and inside the

plant) 272.6 299.9

CO2 Emission (Te CO2) from diesel vehicles (Taxi/Cars etc.) for

movement of employees outside the plant 89.9 93.6

CO2 Emission (Te CO2) from Diesel consumed in company vehicles

inside the plant (Loco/Cranes/Forklift/Fire tenders/Tractor

trolley/cars etc) 165.5 135.3

Total CO2 Emission (Te CO2) from vehicles (inside and outside the

plant) 528.1 528.8

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Planned to implement several energy saving schemes in FY 2016-17 to reduce CO2 emission:

CO2 Emission Reduction – Contributing To Global Cause

Sr. No

Item Description Investment

(Lacs)

Annual Saving (Kwh)

Annual Saving (Lacs)

Pay Back period

months

1

Energy efficient cooling tower fan (complete assembly) in Ammonia Cooling Tower

Replacement of existing cooling water fans (6 nos. + 1 spare) in Ammonia Cooling Tower with energy efficient fans will reduce power consumption in fan. Expected guaranteed saving of 20% from existing fan power consumption. We have already considered 4 nos. fans for Urea cooling Tower in FY 15-16 CAPEX. Implementation is in progress. Total power saving 6 nos. Ammonia cooling Tower fans will be 891648 KWh for On-Stream Days of 344 days. The financial saving has been worked out considering GT power cost of Rs 3.94 / KWh (@Rs. 2190 / MKcal based on Pooled gas price on Nov'15).

40 891648 35.13 14

2

Solar power plant in Township (for house no. KA 1, KA2, KB1, KB2, KB3 & KB4)

Power load in township for the selected house nos. is 25 KW. By installing Solar Power Plant, there will be annual power saving of 45000 KWh considering power saving of 25 kw for 6 hrs./day and 300 days. In addition to power saving, we shall get a tax benefit for one year on 80 % of total investment. The financial saving has been worked out considering Purchase power cost of Rs 7.19 / KWh.

25 45000 3.24 93

3

Solar Power Plant at ABPS

Power load in ABPS. is 70 KW. By installing Solar Power Plant, there will be annual power saving of 168000 KWh considering power saving of 70 kw for 8 hrs./day and 300 days. In addition to power saving, we shall get a tax benefit for one year on 80 % of total investment. The financial saving has been worked out considering Purchase power cost of Rs 7.19 / KWh.

70 168000 12.08 70

4

Replacemet of bulk head fitting in township common areas

Replacement of 400 Nos. 60 watt Bulk head lights with 20 Watt LED tube Light fittings in Township for common area of buildings. There will be power saving of 40 watt per lamp and considering 365 on-stream days with 12 hrs./day, annual power saving comes out to be 70080 KWh. The financial saving has been worked out considering Purchase power cost of Rs 7.19 / KWh.

8 70080 5.04 19

5

Replacement of 150 Nos. 250 watt HPSV lights with 90 Watt LED Light fittings in Plant area, Boundary Wall area & Sathin Plant

Replacement of 150 Nos. 250 watt HPSV lights with 90 Watt LED Light fittings in Plant area, Boundary Wall are & Sathin plant. There will be power saving of 210 watt per lamp including 50 watt loss in choke and considering 365 on-stream days with 12 hrs a day, annual power saving comes out to be 137970 KWh. The financial saving has been worked out considering GT power cost of Rs 3.94 / KWh (@Rs. 2190 / MKcal based on Pooled gas price on Nov'15).

15 137970 5.44 33

Total 158 1312698 60.93 4.6

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World Class Manufacturing (WCM)

Market & Customer

Orientation

Sustainability

IGF practices Aditya Birla Business Excellence Framework under World Class

Manufacturing (WCM) best practices in the following Key Manufacturing Focused

Areas.

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Best Practices Adopted at IGF

Market visit by CFT

Daily Morning

Meetings

Analysis of

Near miss

Cases

Think Tank

Customer Satisfaction

Measurement

Communication Meet

Extension Services

To Customers

Internal

Customer satisfaction

Meet

On-line

Suggestion &

Kaizens BCE

Visit 5S & Visuals

Team Performance

Index

indo gulf fertilisers (a unit of aditya birla nuvo … · 3 integrity commitment passion...

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