Brainstorming

1
Brainstorming
2
Flow Charts
3
Process Flow Diagram (PFD)
4
Plant Layout
5
Eco-maps
6
Eco-maps to identify problem areas
7
Concentration Diagrams
8
Checksheets
9
Checklists
10
Using Checklists as pointers to generate new GP
Options
11
Material Balance
12
Steps in Developing Material balance
13
Considerations in Developing Material balance
14
Material Balance- Illustration from a textile
dyeing mill
15
Energy Balance
16
Energy Balance- Illustration from a textile
dyeing mill
17
Material and Energy Balance Illustration from a
textile dyeing mill
18
Cause-Effect Analysis Ishikawa (Fishbone) Diagram
19
Ishikawa Diagram - Illustration for a Textile
Industry
20
Pareto Diagram
21
Control Chart
22
Spider Web Diagram
23
Failure Mode Effect Analysis
GP Option
Direct reuse of dyebath
Restrict reuse only for disperse dyebaths
Problems leading to failure

Shades not matching with standard
Shades not matching with standard
Detection
9
9
Likelihood of occurrence
8
3
Cost liability due to failure
8
8
Risk Priority Number
576
216

Corrective Measure
Restrict reuse only for disperse dyebaths
24
Cost Benefit Analysis

• Simple payback
• Net Present Value
• Internal Rate of Return

25
Example of CBA when there is no Capital Investment
Combined Scour-Bleach in a Cotton Textile Unit in
Egypt
26
Example of CBA when there is Capital Investment
White Water / Fiber Reuse in Pulp and Paper
Industry
Annual Savings 350,670 Financial
Indicators Simple Payback period 4.19 years Net
Present Value - Years 1-15
359,544 Internal Rate of Return - Years 1-15
21 Annual operating cash flow before
interest and taxes
Capital Costs Saveall Equipment
345,985 Saveall and White Water Pump Materials
374,822 Piping, Electrical, Instruments and
Structural Installation 397,148 Engineering
211,046 Contingency 140,403 Equipment Life
15 years Borrowing Rate of Interest
15 Total Capital Costs 1,469,404
27
Benchmarking
28
Comparison With Norms to Identify Problem Areas
29
Benchmarking of Energy Consumption
30
Decision Matrix