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COST REDUCTION STRATEGIES FOR MANUFACTURING INDUSTRIES

COST REDUCTION STRATEGIES FOR MANUFACTURING INDUSTRIES

INTRODUCTION

Technology advancement in industry today tends to have serious effects in the growth of many industries. Automation multiplies the problem of parts and equipment failure by increasing the cost of downtime, the value of output per hour for machines in industries is enormous. An hour of downtime in some industries can cost thousands of ringgits. By attending this course the participants can benefit in reduction of cost involving downtime

OBJECTIVES

To provide knowledge and solution and to update personnel on the latest technology to ensure plant and machinery would be maintained in good operating condition and at low maintenance cost

WHO SHOULD ATTEND

Maintenance & Equipment Managers. Supervisors and Senior Technicians / Technicians

FACILITATOR

1. Mr. S.P. NARAYANAN whom is qualified in Mechanical Engineering and Steam Certificate Engineer has 30 years of experience in operation & maintenance of palm oil mill.

He has undergone various training in United Kingdom, Germany and Italy in controls & automation systems and cable manufacturing.

2. MR. MURU is a qualified Electrical and Electronic Engineer and he has over 35 years of experience in Electrical application in the industries. He is also a Certified Energy Manager, 33KV High Voltage Competency Certificate & Competency Electrical Supervision from Energy Commission

DURATION

2 Days / 14 Hours

100 % HRDF CLAIMABLE

 

 

PROGRAMME OUTLINE

Day -1

1.Incredible Cost & Consequences of Wear

  • Mean life Before Failure (MLBF)
  • Life Extension Policy (LEP)
  • Why Should We Look Into Cost Saving
  • Rise in Cost and Material
  • Competition Between Industry
  • International Requirement ISO 14000
  • ‘3R’ – Repair, Reuse and Recycle

2.Factors Contributing To Equipment Failure

  • Friction During Operation
  • Abrasion of Moving Parts
  • Wrong Selection of Materials
  • Inferior Quality Parts
  • Rapid Change in Operation Condition
  • Wrong Design/Under Design
  • Effective Use of Predictive Maintenance Will Eliminate Approx 30% Maintenance Expenditures
  • Understanding the meaning of TPM

3.Life Cycle Cost Calculation

  • Cost Saving Engineering Formula
  • Optimizing Life & Efficiency of Equipment with Innovative Technology
  • Case Studies & Discussions

 Day-2

4. Optimization of Electrical Energy

  • Energy saving in Electric Motor
  • How Loads Effect Motor Efficiency
  • How to Measure Motor Efficiency
  • Energy Saving with Variable Speed

5. Optimization of Boiler Efficiency

  • Methods of Decreasing Boiler Losses
  • Optimization of Heat Losses in Insulation

6. What is Energy Management

  • Financial Incentives for Adopting Energy
  • What is Energy Audit
  • Importance of Managerial Approach to Energy Saving

7. Energy Management Strategies

  • Energy savings in Air Compressor
  • Energy savings in Air Dryers
  • Energy savings in Chillers

8.Case Studies & Assignment

 

Hostel can be arranged for outstation participants

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