Planning the database for the business decision is governed by the use of the world class ERP -SAP system uniformly across PLASWARE for capturing the data at source, for availability of information online, realtime to the users for data security and for smooth data transfers interfaces. PLASWARE naphtha cracking process is supported by process control simulation soft system of ABB, Lummus.
Energy Management Set up
PLASWARE has three-tier energy management cell.
The Energy Management Apex Group (EMAG) comprises of primarily the top management at plant. The Plant-Head is heading this group, which comprises of all the HODs, General Managers, & Dy. General Managers. General Manager – Technology who is the Energy Manager of the organization is the administrator of this EMAG.
Each of the plants & engineering discipline has a designated Energy Representative. The Energy
Representative of individual plant & Engineering discipline along with the representatives of Technology forms the Energy Management Core Group (EMCG). Energy Manager is heading this group.
Energy Management Working Group (EMWG) is the initiative to involve shop floor people in the energy conservation. All the plants have nominated members for the EMWG and the training for the group was organized through PCRA. The groups have started regular meetings for brainstorming and developing ideas in their working area.
Activities of EMWG
- Create & update data base for the Base level of energy consumption & finalizing Target.
- Monitor efficiencies of major energy consuming equipments.
- In-house Audit.
- Conceive & review new schemes.
- Implement approved schemes.
Activities of EMCG
- Prioritize the new schemes.
- Review & add value to schemes.
- Guidelines to EMWG.
- Energy accounting and MIS reporting to.
- EMAG & Statutory bodies.
- Substitution of costly fuels.
- Continuously creating awareness.
- Planning for External Audit & Training.
Activities of EMAG
- Review Energy Cons. Trend.
- Approve & Review implementation status of schemes.
- Major decision making about Benchmarking.
- External Training, External Audit, Appointing of external agencies etc.
- Decision in implementation.
- Review effort for improvement.
- Guidelines to EMCG.
Energy Conservation Achievements: Major Energy Conservation Schemes implemented
- Using of nitrogen instead of fuel gas (FG) as sweeping gas for flare header.
- Butadiene dispatch through jetty pipeline.
- Cooling Tower fans.
- Butadiene Chiller.
- Part replacement of naphtha with excess fuel gas in captive power plant.
Problem encountered:
During the operation it has been noted that large quantity of liquid propylene getting accumulated in the Knock Out Drum (KOD) (being carried out from butadiene chiller) at full load of the compressor & even at the 50% loading of the compressor. Liquid level rapidly builds up in the KOD & the compressor got tripped at high level in KOD. To maintain the suction pressure, the pressure control valve got fully opened to put hot vapor in the KOD. Thus the full energy of the compressor is not utilized. To avoid liquid carry over from the chiller, minimum liquid level was maintained in the chiller. Thus most of the Butadiene tube bundles are not immersed in the liquid propylene. So chilling effect on Butadiene was nominal resulted continuous running of the compressor against the 16 hr running & 8 hrs recession philosophy. Temperature across the chiller in butadiene was only 3°c against the design of 5°c. The problem could not be solved even after communication with the designer for several times.
Note: Figures are in KTA
DATABASES
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Departments :- In the department menu, database regarding all department can be entered, modified or deleted.
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Operations:- This database concern with inventories and other operation activities.
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Suppliers:- This database contains contact and all information about suppliers.
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Material:- This database contains raw material used, inventories and ordered.
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Items:- This database contains items used , their stock and orders.
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Packaging:- This database contains information about goods used in packaging.
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Consumables:- This database contains data about consumables used in the company.
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Customers:- This database contains contact and all information about customers.
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Tools:- This database contains data about tools used, stock and future order.
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Operators:- This database contains all information about operators who have operated the machines with time spend on the machine.
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Plant:- This database contains all information about plant machineries, purchased etc.
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Product:- This database contains all information about products, id, type, amount of raw material etc.
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Bill of routes:- This database contains contact and all information about transporters, their recent bills etc.
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Bill of material:- This database contains information about all past bills.
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Manager plus:- This is a customised option where you can select different attribute from different report to prepare customised report.
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Currency:- This a database of transaction carried out in different foreign currencies.
CUSTOMER ORDER
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Order Processing Data:- This report gives information about order which is under processed, past order and also future palced orders.
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Pre-Production Reports:- This report is related with cost accounting, overhead absorption.
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Set Serial No. Detail:- This is used to set the serial number on the despatched production.
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Tranpotation Details:- This Report gives the transportation details.
PRODUCTION MANAGEMENT
As soon as production plan are formed Production management starts working.
The production unit first inspects the works that is already in process.
It maintains the product work list.
It then enters the production quantity fron work to list.
A proper production report is the made.
Graph of daliy rountine production is made.
PRODUCTION LABEL
When the production is complete ,products come to the labeling unit.
The first step is the external labeling
It is followed by production box labeling.
Pallets are then labeled.
Prints from window labeling is done.
Then product code are made in form of pictures.
PURCHASING AND STOCK MENU
As soon as stock department running out of minimum level of inventory purchasing and stock control management system starts working.
Purchasing department first inspect the inventory and work in progress material.
Then prepare a list to purchase.
QUALITY CONTROL
As soon as new batch produce quality control MIS start working.
First it enquires about batch number and match with database.
Calculate mixture components and send to production record.
ACCOUNTS MENU
Invoicing Details
This section displays the following basic details:
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To Party - This is the internal name of the customer you are invoicing.
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Status - This is the current status of the invoice (for example, "Pending" or "Paid").
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Paid Date - If the invoice payment has been received, the date and time will be displayed here.
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Orders - This is the reference number of any orders added to the invoice.
You may also update the following invoice details:
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Invoice Date - This is the date and time that the invoice is created. You may enter the date manually or by using the . Select the time by using the drop down menus.
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Due Date - Enter the date and time that the invoice is due.
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Billing Address - Select the correct billing address from the drop down menu. Please note that any addresses created for the invoiced party will be listed in the drop down menu.
VAT Details
This section displays basic details VAT
Type - Select the type of item that you are adding the VAT from the drop down menu.
Description - Enter a brief description of the term to distinguish it from other items that may be applied to this VAT.
Tax Authority - Indicate the appropriate tax authority by either selecting the relevant state from the first drop down menu, or by selecting the specific state tax authority name from the second drop down menu.
VAT registration number goes in the VAT Number field
VAT scheme operated
Last Month of VAT Quarters and the Next VAT period end date
Discount Details
This section displays basic detail of Discount
Type - Select the type of item that you are adding the discount from the drop down menu.
Description - Enter a brief description of the term to distinguish it from other items that may be applied to this Discount.
Discount scheme operated
Purchase Order Invoice Receipt
This section displays receipt of purchase order
End of Month Processing
This section deals with the month’s end processing that is rebating and adding of all the months expenses and income
Nominal Code Entry
This section contains all the methods and process of account entered in the tabular form.
Exit to Window
This will lead to the home page
SYSTEM PARAMETERS
This section will allow changing the different parameters of the system. For example: one can skip the discount box from invoicing also one can print packaging instruction to laser just by clicking the box behind that option and make it at tick mark position.
And after that click on the save option to save the changes made and then the system works accordingly. There are many parameters there which can be used to make the system work at owner requirement and choices.
CONCLUSION
MIS helps us to gather data and retrieve information from it. This information can be helpful in deciding the future decision of the company. It helps manager to evaluate option on hand. With tons of data and information available a manager can predict a future course of a industry.
MIS also helps in giving us a cost-benefit analysis of each process of our company. Through MIS we are able to analyze even a small related process.
