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To be a World-Class Chemical company

making great product for society


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Organization
Indorama Polyester Industries (IPI) was found in 1997 at Nakornpathom. IPI intend
to be the leader of synthetic fiber producer and polyester resin for selling in Thailand and
for export.
To be a World-Class Chemical company making great product for society

1. ISO 9001:2004 in 2005


2. ISO 14001:2008 in 2008
3. OHSAS 18001:2007 in 2009
4. CSR-DIW B.E. in 2010

1. Polyester staple 2. Polyester 3. Polyester resin 4. Flake


fiber Filament yarn

The Best Factory


in 2002
CSR-DIW B.E.
In 2011
GLP/DIW
in 2010
The Best safety Factory in 2009 Zero-Accident Smoke Free Factory
In 2010
QCCin 09Awards
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Organization

Mr. Anivesh Tewari


Management Committee

Mrs. Prapai Pala ka Wong Na Ayutthaya


Department of Human Resource
QCC Premotor

PERSONEL ENGINEERING FIBER SAFETY POLY QC. LAB YARN

INSTRUMENT HTM COAL FIRE


MECHANICAL UTILITY CIVIL
& ELECTRICAL

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QCC Team member

Mr. Wutti Kaewkhao


Leader Mr. Anan Chamket Payup Wongsri
Member Mr. Phudthidetch Pongchavee Advisor
Member
Registration date : Feb. 23, 2007
Registration No. : IP- 003/07
Section : UTILITY
Slogan : Energy source Stable supply
Mr. Pakin Tachatatijinda
Member Ms. Kritsana Lertwichitcharus No problem Develop Indo
Member Mr. Teerayut Vestprasit Education : Vocational Certificate
Member Bachelor degree
Experiences : 2-17 years
Group Symbol QCC Experiences : 8 Projects

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Responsibility of Team
Machine Supply Process

- 5 ton-steam/hour - Vacuum system


pressure 20 bar. - Heat exchange

- High pressure 15 Bar.


- Suction Gun
- Medium Pressure 7 Bar
- Air control system
- Air Instrument 7 Bar.
- Air in process
- Low Pressure 5.5 Bar

-Pure Liquid 99.99% -Polymer transfer to prevent


-N2 98% Oxygen come in the system

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Responsibility of Team
Machine Supply Process
- Heat exchange set of
-Chilled water temp
production process
is 6 8 o C.
- Air conditioning
system (AHU)

-Cooling water WCL - Cooler and


temp is 29-32 o C production process

- Air conditioning
system in production - Buildings /
line and all office- Machines, Process
building
Responsibility of Team
Machine Supply Process

- Offices
- Air conditioning
- MCC control
system
room

- General use water -General Use, dormitory,


- Adjusted water canteen
- Steam Boiler, Cooling
(Purified water, soft Tower
water) - Drinking water

- Water treatment by -Reduce


aeration (Aerated -Reuse
Lagoon) -Recycle
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Problem Selection by RPN
Effect on Machine
Problem occurrence
related units Running/Day
Total
Problems

> 2 Machine/Day

1-2 Machine/Day
Level

11 - 20 Day / M.

1 Machine/Day
21-30 Day / M.
1 - 10 Day / M.
Within Unit
Scores

2 4 Units
All Units
Scores 1 2 3 1 2 3 1 2 3

1. ACH is not based on performance KPI 2 3 3 18 2

2. AI is not based on performance KPI 3 3 3 27 1


3 . ACM is not based on performance
KPI
2 2 2 8 3

4. ACL is not based on performance KPI 3 2 1 6 4


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QCC Activity
Optimization of Air Instrument to meet the KPI.

Motivation
-To optimize compressed air systems to meet the KPI. 8.0 M3 / Kw.
- Reduce energy loss from a compressed air than necessary.
- To use energy efficiently.
-To meet the company's policy to save power 2,500 Kw / Day.
-Working together as a team Skills and creativity to fix it.

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Explore current problems System Air Instrument.
The following table shows the efficiency of compressed air systems Air Instrument
UTILITY Department ( January - May 2015 ) .

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8
8.45
7.34 6.98
Target KPI.
6 6.50 6.25
4

-
January February March April May
Month
Performance Air Instrument Jan - May 2015 averaged 7.10 M3 / KW (KPI = 8 M3 / Kw)
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Introducing the principle of compressed air.
Minimum Check valve Oil Cooler
Air Inlet valve

Oil Filter
After Cooler

Screw
Oil Separator
Air Filter

Check Valve

Oil Return

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Target
Optimize Air Instrument of 7.1 M3 / Kw. A 8.0 M3 / Kw. According to KPI.
The front of the UT 2015, within a period of six months
( June 1 -30 Nov 2015 ) .
M3/Kw-Hr

8.2

7.8

7.6
8.0 Increase
7.4 M3/Kw-Hr 11.25% Target Derivation
KPI of Utility Department Year 2015
7.2

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7.1
Target KPI of Air Instrument at 8.0 M3/kw
6.8
M3/Kw-Hr
6.6

Target
Actual
now

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Work Plan June November 2015
WHEN
WHAT HOW WHY WHO WHERE
Jun July Aug Sep Oct Nov

Division meeting
Problem selection Pareto graph Problem selection All members
room

Current problem survey Work place survey Study problem


All members On work place
and target setting FLOW CHAT factors
P Set step of works,
Set work plan of QCC Wutti, Division meeting
5W1H time periods and
activities responsibility Anan room
Division meeting
Proem analysis and WHY-WHY,
Root cause analysis Phudtidetch room and on work
countermeasure setting MATRIX place
5W1H, Problem solving
D Problem solving
HOW HOW
according to root All Member On work place
causes
Follow up and result
C evaluation
Graph
Compare results Weerasak, Division meeting
with the target Pakin room
5W1H, Khunchit, Division meeting
Set Standards Set Standards room and on work
A Check Sheet, PM Weerasak place
Wutti, Division meeting
Conclusion Graph Results conclusion
Anan room 14
Why Why Chart
Problem Main causes Minor causes Sub-minor causes 1 Sub-minor causes 2

The wind has not been Flow Measuring the


Flow was measured
measured Flow. wind does all the work . 1
incorrectly .
Air is leaking out of the Drain the wind has
system . dropped 2
Air Flow

Flow sensor Flow meter readings are Dirt The catch is that the
3
AI is not malfunction inaccurate . probe Flow.
based on
performance
KPI Machine running The wind farm produces Used effectively
not Unload enough decreased the lifespan . 4

KW More Air Filter air through


Air Filter Block Part of the plan is not 5
consumption poorly.
changed PM

Adjust air pressure at 6


higher process Defensive pressure drop
equipment needs.

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Cause proof 1
Flow Measuring the wind does all the work
Proving cause
Surveyed the AI Main air supply and installation of the wind measurement Flow Power division .
The results Prove the cause Found a pipe that delivers air to the nitrogen, 98 % without Flow Measuring wind , but Flow Measuring
wind from the production of nitrogen, 98 % only , and measurement results were calculated for Flow wind really so . inaccurate data

Flow Main AI supply (m3/Day)


50000 46,028
41,603 41,058 37233
40000
30000
20000
AVG Flow Main AI
10000 11,069
= 35,398 M3/Month
Responsibility : Mr. Khunchit , Mr. Pakin 0
January February March April May

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Cause proof 2
Drain the wind has dropped
Proving cause Check the condition and operation of the Auto-drain systems, air tanks AI.
The results Auto-drain the air tank is the system Timer Drain every 5 minutes, 10 seconds that it takes
too long , the wind Drain off the excess .
Air Compressor Timer Drain
Air Dryer

Filter

AI Process Actuator Drain


Timer Drain
Tank

Timer Drain

Drain
Responsibility : Mr.Weerasak, Mr.Pakin
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Cause proof 3
Dirt caught in the probe Flow Meter.
Proving cause Condition monitoring of air measurement equipment Flow dirty that clog up
the sensor or not . Calibrate the probe flow and compare with others .
The results There was no dirty when comparing the values obtained from the sensor Flow
is measured , it is similar
Flow Meter

Flow Meter

Responsibility : Mr.Khunchit, Mr.Weerasak, 18


Cause proof 4
Adjust air pressure at higher process equipment needs.
Proving cause Explore the use of the process and pressure supply Utility department.
The results Pressure supply that exceeds the requirements of the process.
The compressors aerial work consume excessive power.

8.1 7.8

Pressure AI (Bar)

Responsibility : Mr.Wutti, Mr.Pakin


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HOW- HOW Analysis
Main
Target Countermeasures Methods
cause

Flow Measuring the wind Measurement equipment


Fitting Flow Measurement and analysis
does all the work . supply more Flow

Increase
Efficiency of Adjustable Timer Drain and analyzed at
Air Drain the wind has dropped Adjust Timer Drain
the on - off right .
Instrument

Adjust air pressure at Set pressure compressors. Using air pressure adjustments.
higher process equipment Proper air Used to fit With applications
needs.

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Problem solving of cause 1
WHAT HOW WHERE WHY WHEN WHO
Fitting Flow Flow meter installed at nitrogen 98% . Flow of
Main Nitrogen In order to know Mr.
measurement and information that has already passed . 15-30
the precise wind Khunchit,
measurement Measurement differences with the calculation 98% Jul 15 Mr. Pakin
makes the KPI. increase data.
analysis .
Program Kalki Flow chart showing the measurement results after installing
measuring devices Flow.

Install Flow Meter

Trend graph AI after install Flow Meter Daily report AI after install Flow Meter
Efficiency AI
9.39.39.39.3
10.0
7.4 7.5
7.17.17.36.86.96.97.17.17.27.1 7.37.47.37.3 7.5
7.5 7.6
7.5 7.4
8.0 6.96.7 6.56.4
5.9
6.0
4.0
2.0
0.0
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 21
Problem solving of cause 1
The installed measuring devices Flow has already started removing the probe Flow check out will be very
difficult. Because the air pressure 7 Bar can not stop the Air pressure will affect the Process. The wind and the sound of the
wind, the wind is gushing out of the pipe all the time. To assemble the pipe and back to a long and windy which makes rubber
Flow meter is defective lacking. Air leakage and subsequent The measurement may be inaccurate Making it very difficult to
operate. And may have an impact on the Process.
We produce special equipment "EASY FIT" Support to make it easy to disassemble and reassemble Flow meter
, reducing time and risk. To remove - Flow Meter and assembly works completed at this point . Can also be applied to the
Flow Sensor and the other as well.
Using
Equipment EASY FIT
EASY FIT

Creating EASY FIT Testing EASY


FIT
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Before Use Equipment Easy Fit

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Use of the "Easy Fit"

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Problem solving of cause 2
WHAT HOW WHERE WHY WHEN WHO

Adjustable Timer Adjustable Timer Drain every 5 minutes, 20-30 Mr.Weerasak,


Drain and analyzed 10 seconds Drain, decreased to 7 per Auto Drain To minimize air loss June 15 Mr.Pakin
at the on - off right second (down 3 seconds / times)
Air Dryer

Air Compressor
Filter

Process
AI
Tank Can save energy
= Reduce 3 seconds / times ( 288 times / day) .
Timer Drain Table losing air hose 1/2 " to 8 Bar lose air pressure = 28.52 L / Sec.
= 28.52 x 3 = 85.56 L / Time x 288 Time / Day x 360 Day = 766,434.5 M3 / Year)
Drain
= 766,434 / 8 M3 / Kw = 95,804 Kw / Year.
= 95,804 x 3 Baht = 287,412 baht / year . (U$ 8,211) 25
Problem solving of cause 4
WHAT HOW WHERE WHY WHEN WHO
Adjust Using
To reduce the
air pressure Try adjusting the pressure Air Compressor load of the
The machinery 1-15 July Mr.Wutti,
Supply , down from 7.2 Bar at Utility compressor
to make 2015 Mr.Pakin
Suitable for to 7.0 Bar. Department into line with
usage
work

8.1 7.8
Can save energy from setting pressure
Energy consumption 11.10 kw./hr x 24 hr./day
= 266.40 Kw./day
Cost saving as 266.40 x 3 Baht
= 799.20 Baht/day
or = 287,712 Baht/year (U$ 8,210)
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Engineering Value
* Running Air compressor No.2 Pressure supply 2,640 m3/hr. @ 7.2 bar
To reduce power consumption by reduce pressure supply to 7.0 bar.

From P1V1 = P2V2


P1 = 7.2 Bar, V1 = ?
P2 = 8 Bar, V2 = 2,640 M3/Hr
1. 7.2 x V1 = 8 x 2,640
V1 = 8 x 2,640 / 7.2
= 2,933.3 M3/Hr.

2. From P3V3 = P2V2


7 x V = 7.2 x 2,933.33
V3 = 7.2 x 2,933.33
= 3,017.14 M3/Hr
cost saving = 3017.14 2,933.33
= 88.80 m3/hr = 777,888 M3/Year
= 88.80 / 8 M3/Kw
Power saving = 11.10 Kw/Hr = 97,236 Kw/Year.
Total Saving = 287,712 Baht/Year.

Energy consumption 11.10 kw./hr x 24 hr./day = 266.40 Kw./day


Cost saving as 266.40 x 3 Baht = 799.20 Baht/day or 287,712 Baht/year (U$ 8,210) 27
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Direct results
The graph shows the performance of air compressors Air Instrument.
June - October 2015
8.89
8.6 8.7 8.7 8.6
8.6
AVG. M3/Kw

8.4
8.5
8.2
8.3
8.3
8 8
7.88 8.0 7.8
7.7 7.7
7.6
7.5
7.4 0
7.2
7 June July August September October
June-15 July-15 August-15 September-15 October-15 November-15 Month

VAG. M3/Kw The graph compares the results before and after activities QCC.
8.4 Increase 15.21%
8.2
8
7.8
7.6 The activities.
8.18
7.4
8.0
7.2

M3/Kw
Performance increased to 8.18 M3 / kw ,
6.8
7
7.1 M3/Kw
6.6
6.4 M3/Kw or 15.18 % . Target is 8.0 M3 / kw
Before Target After

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Indirect results (QCDSMEE)
Optimization of manufacturing wind Air Instrument.
Reduce energy and wind power totaling = 575,124 Baht / Year.
(U$ 16,432)

Wind can make the process has continued without problems .


Special equipment (EASY FIT) to help reduce the operation time . The
risk of making less work.
Employees are increasingly standard in performance .
Wind energy = 1,544,322 M3 / Year. Lower power consumption =
193,040 Kw / Year.

All stakeholders have to work together as a team UT/INS/Process

Total Saving 575,124 Baht / Year (U$ 16,432)


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Follow UP
The graph shows data from follow-up activities after the QCC.
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Before During QCC After and follow up QCC activity
9 8.5 activity
8.7 8.6 8.7
8.3
8.0 7.8 8.0
8 7.7
7.3 7.3
7.0 7.1
7 6.5
6.3
6 Target
5 7.1 M3/ Kw. 8.0 M3/Kw.
/

3
8.12 M3/ Kw.
2

AVG. Jan May 2016 Jun. Aug 2016 Sep 2016 Mar 2016 30
Air is Free
But. !! Compressed Air is not..

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