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Good morning jury members and members of the audience. During this presentation we will present a process improvement project & share with you our learning's and experiences and how we have increased (i)Liquid Hydrocarbon Production of GAIL Gandhar, (ii) High Pressure Gas (HP) Gas quantity from ONGC Gandhar, (iii) Net Profit of GAIL Gandhar by suppling SRG to Gas Gathering Station-IV ONGC Gandhar Using Lean Gas Line of Reliance Industries Limited by using a structured DMAIC methodology. 1 We(GAIL) are in presence of these Business Vertices. 2 There are 5 subsidiary and 18 joint ventures of GAIL. 3 Process flow diagram of GAIL Gas Processing Unit Gandhar, Which is situated at Bharuch District of Gujarat. Which are associated with Oil and natural gas corporation (ONGC), Gujarat Narmada Valley Fertilizer Limited (GNFC), Gas Gathering Station No- 4 (GGS-IV M/s ONGC ), National Thermal Power Corporation Limited (NTPC), Reliance Industries Limited Dahej as upstream source and down stream consumers. 4 Steps followed in this project listed here 5 In Project background for identification, planning and prioritization of problems done in this step. 6 In This step GAIL shows our project planning and identification of opportunity area to increase our turnover. 7 These the mode of suggestions, ideas, problems identification are welcome either through online portal or offline portal are listed here. 8 Here we have shown how idea’s are generated or problem are listed through brainstorming and SAP for identification of problem. 9 In GAIL gandhar we have characterized our process area in A,B,C,D,E class for stratification of problem’s. Through this one can easily know the location of problem occurred. 10 Here we have taken top five problems of GAIL gandhar which are rated on the basis of Quality loss, production loss, downtime loss, cost loss, safety loss in scale of 01-10. Where 0 for least and 10 for highest. 11 Here these five problems P1,P2,P3,P4,P5:- How the team member’s individually rated on the scale of 1 to 10 for Quality loss, production loss, downtime loss, cost loss, safety loss for sample case. 12 Here these five problem ate stratified in the frequency of occurrences. Total occurrence frequency is 420. Than their individual percentage calculation done and cumulative calculation done. 13 Last Slide data is presented through Pareto Diagram, which clearly shows that LOW LHC production at GAIL Gandhar is Vital Problem. 14 On the basis of rating method and Pareto Chart our team has selected the problem of Low LHC Production as a Project. 15 Smart GOAL for this project is to increase LHC Production of GAIL Gandhar from 450 MT/Day to more than 490 MT/Day. Enhance of LHC Production of 40MT/Day as a project GOAL. 16 In this project success measures are also listed in the from of increase in HP Gas Quantity from GGS-IV, SRG Supply to GGS-IV, Net Profit of GAIL Gandhar. Increase efficiency of GAIL-ONGC-RIL. 17 Additional goal of this project is to increase turnover of GAIL more than 53.44 Crore/Year. Along with this associated goals are To Increase Plant load of GAIL Gandhar;-To Increase Rich Gas Quantity ,Minimize Natural Gas flaring at GAIL / ONGC ,Increases the process efficiency of GAIL and ONGC,Increase Reliability and availability of GAIL Gandhar, To Build up Strong Team Spirit 18 Step-2 of This Project Framework 19 Concise project statement of this project is To Enhance Liquid Hydrocarbon Production Through Semi Rich Gas Supply from GAIL Gandhar to GGS-IV (M/s ONGC) using Lean Gas Pipeline of M/s RIL Dahej. Enhance LHC PRODUCTION OF GAIL GANDHAR BY 40 MT/DAY and NET TURN OVER MORE THAN 53.4 Crore/Year 20 In This Project our team followed DMAIC six sigma process for This project is a process improvement and redesign effort. Process efficiency of GAIL Gandhar, GGS-IV ONGCL i.e. production (oil & gas recovery) of ONGCL & Pipeline usage efficiency of RIL Dahej will increased through this project. 21 Here we are showing the in scope and out of scope of this project which are listed here in the form of table like in scope 1) Change in design. 2) Change in Process. 3) Incorporation of additional features 4) Provision for addition of addition downstream consumer.5) Provision for HAZOP Study, Plant Load Increase.6) Change in SOP, P&ID 22 Before start of this project our team listed few assumptions which are used in this project and who will be responsible for that particular job and whether that particular responsible person had acknowledged their responsibility. 23 Our team has planned to complete this project in 18 weeks and work progress will be discussed on every Monday as per the work progress activity schedule and may be re-planned the activity schedule which will be changed accordingly time to time. 24 Total budget required for implementation of this project is 5.21 Lac, which is capital budget in different heads. Our team has taken management approval for budget allocation for this modification job. 25 Risk management at GAIL, we are following proactive and preventive method of any kind of potential risk in advance. We having online risk management system for mitigation of risk, or register of risk will be associated with any new project or existing. GAIL is properly assessing any kind of future risk in advance and also giving proper training to their employee to overcome any kind or risk. We are also following behavior based safety BBS system at work place. 26 Step-3 of this project is project stakeholders and Project Team . 27 Identification of stakeholder’s for this project our team followed SIPOC- supply, input, process, output, customers & ARMI:- Approver, resource, member and interested party. For this project (i) HP Gas supplier if ONGC and we are using Lean gas line of RIL Dahej (ii) Input as HP rich gas from ONGC Gandhar (iii) GAIL Gandhar processing rich gas for production of liquid hydrocarbon :- LPG, Naphtha, Pentane (iv) Output of this project if increased quantity of Liquid hydrocarbon :- LPG, Naphtha, Pentane and semi rich gas (V) Customer of this project is for (a) LPG-IOCL, HPCL, BPCL (b) Naphtha- RIL (c) Pentane- some private player like Orcon etc (d) Semi Rich Gas to GGS-IV ONGC Gandhar. 28 For this project here we have showing the degree of power and interest of the stakeholders and how they are prioritized. 29 In this slide our team is showing the input, output, capacity, power, impact, degree of impact, support and strategy of different stakeholders. 30 Here we are giving introduction about our team’s champion. 31 For selection of team for execution of this project following test for Knowledge /Skill Set are required:-Domain Knowledge, Basic quality tool ,Leadership Skill, Communication ,Project Management, Decision making ,Conflict management ,Team building 32 For preparation of our team following training are given to team members for successfully implementation of this project. 33 Before the project started, what was done to prepare the team to work together as a team by using these Activities:-Set clear purpose and goals which related to the project , Empowering Team Member , Role clarification , Expected Reward & Recognition Scheme , Basic Team Building Training 34 These are the committee which are evaluating the project at different levels. 35 The Team Brainstormed and planned the project ahead 36 In this project teams routines of reporting type, meeting or communication plan are prepared. 37 In this project teams routines of reporting type, meeting or communication plan are prepared. 38 In this project teams routines of reporting type, meeting or communication plan are prepared. 39 Step-4 Project Overview 40 Our team followed DMAIC for implementation of this project and for different steps activities are listed below. 41 Here Phase wise milestone are planned for completion of this project. 42 In this slide we are discussing about the approach of this project. Our team followed DMAIC for completion of this project. 43 Our Project teams used following tools in different phase and phase with purpose is defined here. 44 Our Project teams used following tools in different phase and phase with output is defined here. 45 Our Project teams used following tools in different phase and phase with purpose is defined here. 46 Here we have discussed about the organizational training process and their certification types. 47 Here we have discussed about the organizational training process and their certification types. 48 Here we are dealing with associated risk with our project how we are overcoming these risk. 49 In this we are showing the screen shot of Risk management system which is existing in our organization for proactive measure of risk or mitigation of GAIL. 50 In this step our team is following DMAIC for this project and also showing the involvement of stakeholder’s. 51 Step-5 Project Walkthrough 52 DMAIC- define, measure, analysis, improve, control is followed in this project. 53 This is the process flow diagram GAIL Gandhar, which is showing the problem area of GAIL Gandhar which appeared after 31.10.2017. Which decreased the Liquid hydrocarbon Production of GAIL Gandhar. 54 Detailed flow diagram of this project which clearly showing the non availability of the pipeline to supply SRG from GAIL Gandhar to GGS-IV is main problem area of this project. 55 These Data are collected from -01.11.2017---to 31.07.2018, Source of Data:- Daily Progress Report, DCS Data & Trends, Field Log Book, Finance Department Month Cost & Benefit Analysis report. Which clearly shows the impact of Less LHC Production (MT),LG Supply to GGS-4 (in MMSCMD) ,Decreased In Plant Load, Decreased In Rich Gas (in MMSCMD),Decreased in NET Profit (in Crore).
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