This paper presents a case study conducted in a chemical plant with a cogeneration facility, focusing on optimizing boiler shutdown timing to enhance availability and reliability and minimize downtime during annual inspections. The study addresses two key problems faced by the plant, namely scaling in the furnace and prolonged annual shutdown periods required for repairs, replacements, cleaning, and inspections. The assigned  BiC promoter from a consulting firm took charge of implementing improvements and demonstrated effective leadership throughout the process. This paper outlines the approach adopted for each problem, the action points undertaken, and the corresponding results achieved.

This case study focuses on a mechanical brickett manufacturing plant in chemical plant, known as the Densh Ash Plant, which faced significant challenges resulting in the accumulation of rejected finished products. Despite various attempts by experts, the problem persisted, hampering production. The objective of this case study is to present a systematic and professional approach to resolving the issues at the plant.

Necessity is the mother of invention, and this holds true for a large multinational chemical company that faced a significant dip in profitability due to various reasons, including the high cost of imported energy, leading to declining margins. If swift action had not been taken, the company would have faced substantial losses. In fact, the organization experienced its first loss in the first quarter of that year after 20 years of continuous profit.