CII Competition at Forbes Marshall

FORBES MARSHALL PVT.
LTD
2nd Edition: CII National Electrical Safety, Power Quality & Reliability Circle Competition 2022 1
FORBES MARSHALL PVT.LTD
Manufacturing Footprints
OUR PRODUCTS
Steam Engineering and
Control Instrumentation Solutions
Edible Oil
Chemicals Pharmaceuticals
Textile
Power
Dairy
Oil and GasRubber and Tyre
Oil and Gas
Water
We help customers build and sustain highly

efficient plants by reducing waste, optimising
process and energy efficiency, and complying
Hospitality Paper and Pulp Food and Beverage
with regulatory requirements. Steel Textile Food and Beverage
Pharmaceuticals Fertilizers Steel Sugar Power

Sugar Paper Fertilisers Rubber and Tyre Hospitality
Energising Businesses
We build long-term, collaborative partnerships with customers
1955: Amul Dairy Company 2015: Amul Dairy Company

Coal Boiler Inauguration by the Prime Minister. Biomass Boiler Inauguration by the President.
Best Organization For Electrical
Safety, Power Quality & Reliability
Forbes Marshall Pvt. Ltd
Team Details
Name and Designation Contact Number E-Mail ID
Ajay Pachpande 8308824525 apachpande@forbesmarshall.com
Sanjay Mahanty 7058453489 smahanty@forbesmarshall.com
Ajinkya Gaikwad 9096216321 FMS.Forbesmarshall@in.knightfra
nk.com
Overview on Electrical
Distribution System/ SLD
Adobe Acrobat
Document
2nd Edition: CII National Electrical Safety, Power Quality & Reliability Circle Competition 2022
Safety Enhancement No.1
1.0 Problem Definition:-
Industrial Distribution Box
“The Industrial distribution box throughout the
factory & shop floor have RCCB of Rated current
63A and residual/ trip current 100mA as per old
electrical safety regulations ”
As per the new study 50 to 100 Milliamps of current
is capable of producing painful to severe shock,
respiratory arrest, severe muscle reactions and
current between 100 to 200 mA are considered
lethal.
BEFORE – RCCB with

Tool / Technique Used To Solve The 100mA residual/ trip
Problem:- PDCA / Deming Cycle. current to Industrial DB.
1.0 Solution to the Problem:-
Industrial Distribution Box
Created an action plan to replace “RCCB
PLAN with residual / Trip current 100mA” with
“RCCB with residual /Trip current 30mA”
from Industrial Distribution Box.
DO Execute the action plan of the task.
Take a trial to confirm the RCCB with
CHECK residual /Trip current 100mA is working as
per its objective.
After successful trial and achieving desired NOW- RCCB with 30mA
ACT results, replaced RCCB 100mA total 65 Nos residual/ trip current to
at various location throughout the factory. Industrial DB.
2.0 Problem Definition:- DG Control Panel
Diesel Generators did not have “Emergency
stop button with key” which may lead to
unexpected incident while DG maintenance
and cleaning activity and sudden MSEDCL
power failure as DG’s starts in auto mode when
power fails, also continuous supervision is
required to safeguard person during
maintenance work.
BEFORE - Without
Tool / Technique Used To Solve The Problem:- Emergency Stop Button
PDCA / Deming Cycle.
1.0 Solution to the Problem:-
DG Control Panel
Created an action plan to install the
“Emergency Stop Button” i.e. defined a
PLAN schedule & people responsible to
perform the task.
DO Execute the action plan of the task.
CHECK Take a trial to confirm the installation is
working as per its objective.
After successful trial replicate the same
ACT safety improvement to rest of the DG NOW- Emergency Stop
sets. Button with key.
Results Achieved
• The effectiveness or successfulness of any kaizen done to enhance
safety can measured on account of the number of users and the ease
to restrict hazard to their working environment.
• Thus below are the of number users whose working environment
hazard ease off by the following improvements
1) Emergency Stop Button With 50+

Risk Level Reduced 50%
10
Key installed to DG sets. Users 0
DG Sets
BEFORE NOW
No. Of Users
2) Installation of low residual
Risk Level Reduced 50%
current of RCCB as replacement 500+ 20
of old high residual current i.e. Users 0
Industrial DB RCCB
100mA RCCB. No. Of Users BEFORE NOW
Environmental Protection Enhancement No.3
Roof top solar power plant installation

at Forbes Marshall Chakan unit with
M/s Amplus Energy Solution on
Operating Expenses Model.
Operational Date 15 Aug 2021
Plant Capacity – 1050Kwp (800 KW A/C)
Total Panels – 2500 Nos
Total Inverters – 8 nos.
CO2 emissions due to electricity
generation 0.23314 kg CO2e per kWh
Therefore reduction of 1873 metric
tones of CO2 emission in 16 months
Training Vendors to Enhance Electrical
Safety Practices
12 Feb 2022 Briefing on Electrical- PPE’s use, LOTO, Unsafe condition

Online Electrical in Morning Toolbox Talk on every Sunday before
Safety Training starting maintenance activities
Uniqueness of the project and take away
for audience/company from the project
Thank you !

CII Competition at Forbes Marshall

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CII Competition at Forbes Marshall

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FORBES MARSHALL PVT.

We help customers build and sustain highly

Pharmaceuticals Fertilizers Steel Sugar Power

1955: Amul Dairy Company 2015: Amul Dairy Company

Forbes Marshall Pvt. Ltd

BEFORE – RCCB with

1) Emergency Stop Button With 50+

Roof top solar power plant installation

12 Feb 2022 Briefing on Electrical- PPE’s use, LOTO, Unsafe condition

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