| Since January, 2008, the Kothari team has implemented numerous processes to encourage collaborative problem solving, Kaizen, and innovation. Below is a case study of a recent success in this effort |
| Innovative Techniques in Problem Solving – A Case Study |
| Issue |
| Operation Team had observed a gradual deterioration of vacuum in "Vacuum Flash Column" (T-116). After many deliberations with the Operations and Maintenance team, our Tech Service Engineer Arumugam examined the situation to determine the cause. |
| Impact |
| Flash Point of the final product started seeing a downward trend. Vacuum level of the column was reported to be 15-20 mm hg as against 3-5 mm hg normal level. |
| Root cause |
| Stem Ejector Condenser (E-119) of this column was found out to be performing poorly due to fouling. |
| Immediate Proposal made by the Team |
| It was suggested that the Plant had to shutdown and go for mechanical cleaning of the condenser, which could have easily taken 2 days. We explored innovative ideas to clean the condenser online and hence, formed a team to study the opportunities. |
| Team formation |
| A team was put in place and A.R.Ashok Kumar, Arumugam and A.R.Sridhraran led from the front with others supporting them in their endeavours. |
| The team identified 'Online cleaning' using solvent as a solution and immediately utilised the services of Sical Logistics Ltd - a third party which provides cooling water treatment program. |
| Online cleaning commenced on 5th April 2008 |
| Sical Logistics provided the required chemicals and man power to support Kothari Team. Cleaning activity was carried out for 24 hours. |
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| Good news in the end |
| The team had successfully cleaned the condenser online and within 24 hours the process condition was re-established. With improved product quality, we are continuously exporting to Infinium. There has never been any stoppage for a minute considering the situations that were precarious. The vacuum level is maintained below 5mmHG. |
