Over the last 75 years, Bajaj Electricals Ltd, a pioneer in electrical home appliances, lighting and luminaires business, has progressively diversified into turnkey projects. Bajaj Illumination and High mast lighting system projects involve providing lighting solutions for a wide spectrum of utilities such as airports, shipyards, port trusts, sports stadiums, monuments etc., while the Power Distribution projects work on rural electrification. And TLT projects cater to connecting power transmission grids across India –i.e. connecting power generating plants or sub-stations.
Most of the EPC projects in India are executed in environments of high uncertainty and completion of these projects require coordination and cooperation between various stakeholders like state owned companies, individual landowners and the contractors. Therefore gross delays are very common. When Bajaj started TOC implementation, it too had large number of open projects with chronic delays and cost over runs but with the new paradigm of TOC based synchronized supply and execution management of projects, the company reaped both operational and financial benefits. The results include:
Completed a new manufacturing plant in a location ravaged by rains in 8 against the industry standard lead time of over 12-14 months.
One of the leading players in textile industry. Using CCPM, Abhishek Industries (Trident Group) erected a spinning plant of 30,000 spindles, a greenfield project, in a record time of 9 months as compared to the industry benchmark of 12 months. The ramp up to peak production was also achieved in 40 days as compared to the typical industry time of 3-4 months.
World’s largest producer of Pig Iron. Tata Metaliks sets an industry benchmark in executing Blast Furnace relining shut down using CCPM. Blast Furnace relining shut down completed in record 23 days with 25% extra scope and with expenses at 87% of the initial budget. Peak plant production reached in record 10 days. Usually the lead-time of such shutdowns and revamps is between 45-60 days, and reaching peak production takes about 3 months.The earlier similar project was completed in 30 days.
Engineering, Procurement, Manufacturing and Site Erection of structural steel forIndustrial Buildings.
With implementation of flow principles of CCPM, the lead-time of projects has reduced by 25%, with 15% more output from manufacturing facility and 30% more output from engineering resources.