Innoways 2015

Mission
To make the world

a more efficient, prosperous and safer place
by providing sustainable
Engineering & Construction Projects and Technology services
Vision 2025
Amongst the top 50 global
infrastructure commpanies.
On time always | Caring | Admired
Respected | Responsible
VALUES
Integrity
Excellence
Responsibility
Understanding & Unity
Cultural Pillars
A G I L E
ALWAYS AHEAD GENUINE INNOVATIVE LEARNING ENTREPRENEURSHIP
• Energetic • Honest • Challenging Status Quo • Observant • Ownership
• Initiative • Respectful • Thinking Creatively • Inquisitive • Risk Taking
• Leading • Caring • Doing Differently • Questioning • Resourceful
Table of Contents
Message
3
Executive Summary
13
Innoways Process
17
Evaluation Committee
18
SBU-Industrial Infrastructure
20
SBU-Urban Infrastructure
117
SBU-Quality Services
130
Support Services
135
New Business Growth
149
Page 1 of 152
Page 2 of 152
Message
“Opportunity is missed by most people because it is dressed in overalls and looks like work.”
- Albert Einstein
I believe that our mission of making the world a more efficient, prosperous and safer place by providing
sustainable Engineering & Construction Projects and Technology services, inspires every employee.
In today's competitive world, Continuous improvement and Innovations at the workplace have
become critical. I recognise there exits opportunities to unlock improvements and innovations at
each task we do. This is critical for us to sustain the competitive advantage over domestic and
global competitors.
Each one of us has enormous potential; our cultural pillars “AGILE” support us, to be innovative
in our work.
I am happy that Innoways report captures the improvement & innovation of Tata Projects. I urge all
employees to study this, adopt the relevant and improvise further.
I am sure each one of us will make difference in the way we improve our work practices. This will
inspire many more to continuously improve and innovate.
Best Wishes,
Vinayak K Deshpande
Managing Director
Page 3 of 152
Message
I am happy to see the enthusiasm, ownership and efforts put in by the teams in identifying and
implementing solution using innovative thinking. I believe that Innoways provides the platform
required to building culture of Improvements & Innovations at TPL. Our cultural pillars “AGILE”
challenges employees to be innovative and challenge the status quo of every activity we do to bring
improvements and innovations.
I personally believe “every dollar saved is a dollar earned”and wish many more participation in
coming years. I am sure that by doing simple, small improvements and innovations at our respective
area of work ,we can surely improve our processes and bottom-line. This will inspire many others to
participate in making Tata Projects an innovative company to meet our vision of “amongst top 50
infrastructure companies in the world”.
I am sure Innoways will enable innovative culture in the journey of excellence.
Arabinda Guha
COO – Industrial Infra
Page 5 of 152
Message
One of the important elements for business is creativity – continuing improvement and innovation to provide
increasing value to the customer. A vital strategy for addressing these elements is kaizen. Kaizen has two
definitions—the use of very small, incremental steps to improve quality and the use of very small moments to
inspire that the assigned tasks and milestones are accomplished. All improvements have one purpose in mind,
which is to serve the customer. We will explore the use of kaizen to increase quality, reduce costs, improve
employee health, reduce errors, and develop new construction methodology.
“Management is doing things right; leadership is doing the right things” - Peter F Druker. These words of
wisdom serves as a foundation for the complex projects that SBU – Urban Infrastructure is executing. The
teams have to apply Management and Leadership thinking to execute the project. Executing team coordinates
with multi agencies for accomplishment of the milestones as per the client requirements has opportunity to
apply frugal engineering and develop new construction methodologies for faster completion.
I believe that Innoways provides a platform for all the employees to feel proud of their ability in achieving
milestones through application of problem solving skills and creative thinking in accomplishing the projects on
time.
Let us stay committed in our journey of continuous improvement and excellence.
Vivek Singhal
Chief Operating Officer,
Urban Infrastructure
Page 7 of 152
Message
Organizations were facing ever-increasing challenges to escalate improvements and innovation for launching new
services to market faster than their competitors. Innoways provides a continuous improvement (CI) opportunity for all
employees at Tata Projects to identify the pain area and apply Quality Tools to overcome the pain area which can be
incremental or radical.
I view Innoways at Tata Projects as Green Hat of Six Hats associated with thinking creatively for resolving the problems /
concerns. In Business – Unit Quality Service, the war room concept is brainstorming for providing out of box ideas and
creative thinking for resolving the concerns.
I acknowledge that Innoways has provided a culture for improvement and innovations at Tata Projects and employees
show enthusiasm to participate. Innoways compendium provides a freewheeling way to replicate these improvements at
our project sites. The success depends on raising the bar consistently in doing the things that matter most by constant
reminder of the real reason why innovation and quality matter. This will enable many more Quality participation in building
the culture of Innovation & Improvement.

Tenny Cherian
COO – Quality Services
Page 9 of 152
Message
As the speed, uncertainty, and complexity of global markets intensify, organizations learn to
navigate this fast-moving landscape for keeping their businesses on track by embracing critical
problem solving skills, creative thinking and innovative approach.
Our Mission and Vision always challenge us to bring out our passion, dedication, and innovative
potential to execute the projects within time and cost. Each one of us has enormous potential;
our cultural pillars “AGILE” support us, to be innovative in our work. The journey of innovation
and continuous improvement is gaining momentum. In future, Innovation is key to growth.
In Tata Projects every employee, has an opportunity to take up improvements and innovate in their
area of work. Each one us must have the urge to do every task right first time and every time. This is the
way – delivering projects in line with the cost, quality, speed and service requirements – to delight the
customer.
Let us commit ourselves to achieve excellence through Continuous Improvement and Innovation.
N Sudhakara Moorthy
VP – Human Resources
Page 11 of 152
Executive Summary:
Innovation has become the buzz word today. The word Innovation has taken the world by storm. From
the moment a business begins, innovation & improvements forms an integral part of business
success. Innovation happens on what is already invented. Innovation is all about looking at things in
different way and bringing solutions and services as required. In construction and Infrastructure
sector, there exists opportunities for improvement and innovation across the project life cycle.
Innovation is a complex, company-wide endeavour, having a set of crosscutting practices and
processes.
Tata Projects launched its fourth annual month 800
long “Innoways - a festival of innovation” in the 600
month of November 2015. The objective of
400
Innoways is to create a culture that motivate,
200
engage and develop continued learning for
0
improvement & Innovation. The enthusiasm
and participation in fourth edition of Innoways Fig. 01
restored the belief that Improvement &
Innovation is the way of life in the journey of excellence at Tata Projects. Innoways provides the
platform for demonstrating the commitment and support the culture of improvement and innovation.
Innoways- 2015 had successfully accomplished with 488 entries across five categories i.e.,
Promising Innovation (PI), Dare To Try (DTT), Excellence in Design (EID), New Business Model
(NBM) and Challenges Worth Solving (CWS). The overall innovation & improvement projects trend is
shown in Fig. 01.
Innoways follows a defined process of
a. Invitation for participation,
b. Screening,
c. Evaluation and
d. Reward & recognition.
Fig.02 shows the trend on the percentage Fig. 02
innovation & improvement projects that were

selected for evaluation under each of the five categories of Innoways. The screened Innoways
projects were evaluated by Evaluation Committee of diversified management function, based on the
set criteria. The summary on each category of
Innoways is as follows;
Promising Innovation : These are the
innovations & improvements that are
implemented successfully and have
achieved significant results at Tata Projects.
The overall % entries selected for
evaluation is shown in Fig. 03. Fig. 03
Page 13 of 152
Dare To Try : These are attempts made to
improve or innovate, however could not
achieve the desired result or success. This
award is to appreciate the team for displaying
strong determination to succeed but could not
achieve the desired results due to various
Fig. 04 other factors. The attempts are on
improvements on Productivity, Delivery,
Quality, Cost, Safety and Motivation either individually or through team efforts during the
execution of the projects. Fig 04. shows the overall trend on the percentage projects selected
for evaluation under Dare to Try category of innovation.
Design Excellence : is an important
parameter for improving the bottom line and
providing the value proposition internally and
externally. These are the innovations &
improvements that are implemented
successfully and have achieved significant
results through Value Engineering or creative
Fig. 05
thinking in Design and Engineering. Fig 05.
shows the overall trend on the percentage entries selected for evaluation Excellence in Design
category.
New business model : provides opportunity
for the employees to showcase their business
acumen by providing business ideas &
business models for organization’s growth.
These ideas are either on the current business
lines that Tata Projects operates or in the New
Fig. 06
Business Lines, which are adjacent to Tata
Projects line of operations. The overall
percentage of entries selected for evaluation over the years is shown in Fig 06. The selected
Business Model gets discussed in the Corporate Leadership Council for decision making.
Challenges worth Solving : is an open
platform for the employees to provide
suggestions on the specific themes that
Management of TPL wants to resolve
Suggestions were invited from the employees
on the theme “Productivity Improvement in
Construction”. Delivering projects on time will
Fig. 07
not only beneficial to the customer, but also
Page 14 of 152
will help Tata Projects in building brand and reputation. On due diligence, the evaluation committee
could not find any suggestion that is worth implementation or conducting feasibility and hence no
suggestion was rewarded. The Management appreciates the efforts of employees for providing
suggestions.
Innovation is applied creativity of thinking;
three types of thinking are really required to
deliver a unique customer experience, i.e.s,
Process thinking, Statistical thinking and
Innovative thinking. Studies have shown that
innovation is built on past knowledge and
continuous experimentation. The engagement
and enthusiasm shown by the employees in
participating in Innoways is encouraging. The
trend on the employee segment wise
Fig. 08
participation is shown in Fig. 07. Tata Projects
strongly believes that the improvement and innovations will help in sustaining / improving the bottom-
line. The participation from respective Business Unit and Department is shown in Fig. 08.
Innoways covers Improvement & Innovation
projects identified during SDM, Take-Up
Improvement Project in the fields of
Productivity, Quality, Cost, Delivery, Safety and
Motivation. This includes improvement
initiatives identified and completed using both
Top-down approach and Bottom-up approach.
Fig.09 shows the trend of overall reward on Fig. 09
Innoways projects.
The Success Story:Innoways provides a
Innovation Category 2015-16
platform for Knowledge Management for
improvements and innovations successful Excellence in Design 5
and attempted across the organisation. The Promising Innovations 15
success dimension of Innoways is replication of Total 20
Fig. 10
improvements at other project sites. Innoways
reports – a compendium of all improvement and
14
innovation projects is published and circulated 12
10
to all the employees in both hard and soft form
Rs. in Cr.
as knowledge sharing. These improvement

ideas also help in hitch hiking for further
improvements & Innovations. This year we
have witnessed around 20 projects that were Fig. 11
Page 15 of 152
replicated at the project sites. These improvement projects were previously participated in Innoways
and published in respective Innoways Report.. Fig 10 shows the Innoways category where the
Innoways projects are replicated. Fig.11 shows the trend on the savings achieved on the projects that
are evaluated and rewarded under all category of Innoways.
Tata Projects Vision of “Amongst the top 50 infrastructure companies around the world” could
be achieved by adopting better construction methodologies and using new technologies &
innovation. Tata Projects has reconstituted a “Technology and Innovation Forum”, under the
mentorship of Mr. Arabinda Guha –COO – Industrial Infrastructure. The objective of Technology and
Innovation Forum is to identify and adopt new technology and innovation for Tata Projects that will
bring competitive advantage over competitors.
Page 16 of 152
Process for Innoways Awareness:
• Teasers
• Communication
Entries can be;
Invite Entries o SDM Projects
November
o Take-Up projects
o Self-initiated Projects
Gate-1
Screening:
• Categories of Innoways
No • Screening as per criteria
Screening
• Screening will be done
End
by BE Team
Yes
Database Gate-2
December
No
Evaluate Evaluation:
• Criteria for each Category
Yes Gate-3
Others Reward:
No • Innoways Reward
Feasibility Study for Scheme
Select for R&B New Business Model • Recognize for all
6 category
Yes
Gate-4
Presentation
Alignment:
January
to TPLTIF Evaluate
• Integrate to innovation
entry in to EPM process
Award EPM Process • Knowledge sharing
through CoP
STRAP • Study in detail New
No Business Model
End Replicate • Evaluate the findings
in BLC & CLC
End • Pilot Project &
Yes
Implement.
CoP Implement End
Page 17 of 152
Sanjeev Kumar Sanjay Kamat K Sunder Rao

VP-Business Development AVP- Corporate Initiatives AVP-Supply Chain Management
Subrata Roy Bellamkonda Srinivasa Rao Pratosh Saxena

GM-Projects (BU-PG) GM-Engineering GM-Engineering
Srinivas C Sesha Anil Y Ramesh P

GM-Engineering GM-Engineering GM-Projects (BU-C&E)
A V S Prakash Rao Eswara Prasad C R Rahul Paliwal

GM-Facility Management DGM-Engineering DGM-Engineering
Page 18 of 152
Manohar Sundaresan Venkatesh M P Senthil Kumar

DGM-Supply Chain Mgt. DGM-Projects (BU-PG) DGM-Business Excellence
Harsh Wardhan Pathak Rajmohan Awadhiya Jaikishan Hemant Chourasia

AGM-Quality Mgt. Dept. AGM- BU-C&E AGM-EHS
Vishvesh Tyagi Vasudeva Rao B S N Sree Ram Prasanna K

AGM-Projects (BU-PG) AGM-Projects (BU-PG) Sr.Mgr-Projects (BU-C&E)
Cyril Danthi Manikyala Rao G S

Sr.Mgr-Business Excellence Consultant-QMD
Page 19 of 152
Strategic Business Unit - Industrial Infrastructure offers end to
end integrated solutions for industrial infrastructure projects.
The Business Units caters to customer requirements as
solution providers. There are six Business Units under SBU-
Industrial Infra.
The following Business Units form the part of overall
industrial Infrastructure.
l BU-Power Generation
l BU-Metals and Minerals
l BU-Oil, Gas & Hydrocarbons
l BU-Transmission & Distribution
l BU-Transportation
l BU-Construction & Environment
SBU-INDUSTRIAL INFRASTRUCTURE
Without continuous growth and progress, such words as

improvement, achievement, and success have no meaning
-Benjamin Franklin
Page 20 of 152
B V Ramesh Krishna
BU Head
Business Unit - Power Generation, offers customized turnkey solutions

for power plants. It has expertise in coal and gas based super and
subcritical technologies. Power Generation has extensive experience in
Total EPC, BoP of coal based power plants and Gas-based Combined
Cycle Power Plants. It has executed several large and complex projects.
BU-POWER GENERATION
We cannot solve our problems with the same thinking we used

when we created them
– Albert Einstein
Page 21 of 152
PG-100030-APPDCL-KRISHNAPATNAM
Everything can be improved.

-Clarence W. Barron
Page 22 of 152
Innoways Celebrations @ APPDCL-KRISHNAPATNAM
Page 23 of 152
1. Breakdown reduction in Bottom Ash System
Team Details
Anil Kumar | Perumal E | Ganesh Dhole
Challenge:
We need to run the clinker grinder continuously for crushing of un-burnt coal lumps and sending
them out from boiler. For smooth running of the process, it is very important to remove the un-burnt
coal before feeding it to the Boiler. This process is known as bottom ashing. During this process in the
boiler, un-burnt coal particles get stuck in the clinker grinder resulting in tripping of the system. The
challenge was to operate the system without breakdowns.
Improvement:
We decided to shift the clinker grinders towards motor drive by shortening the distance by 1mts
and increase the height by around 600mm to clinker grinder. This resulted in smooth running of
clinker grinder without any breakdowns.
Benefits:
• Reduction in breakdowns
• Customer Satisfaction
Page 24 of 152
2. Bottom Ash overflow system modifications in AHP
Team Details
Vikrant Powar | Ganesh Dhole | Ravindra Kirange | Saikishore Turaga | Amit Ratre
Challenge:
As per drawing and client specification, the BAOF sump
was constructed underground. For disposal of BA
Overflow water, 2 nos of vertical turbine pumps
(1W+1S) were provided. It was observed that due to the
overflow water in the Bottom ash hopper, the % of ash
and temperature was high. This resulted in
continuously breakdown of pumps affecting heavy
flooding near bottom ash area below boiler. The
condition was not suitable for repair and maintenance
work of these pumps due to flooding of sea water
(300CubM/Hr) resulting in water contamination as it
flow through plant storm water drains. The challenge
was to reduce the breakdowns.
Improvement:
In order to overcome the situation, we have done the
following:
• Above ground Bottom Ash Overflow tank we
constructed from spare CW Pipe with inside PU
coating to cater the requirement of sea water and
the Bottom ash overflow diverted to this tank
modifying the piping.
• Installed belt driven horizontal centrifugal pumps
for ash slurry with sea water application having
capacity 300CubM/Hr for disposing the Bottom
Ash Overflow water from above ground tank to
the ash slurry sump/clarifier.
Benefits:
• Smooth Operation of System
• Reduction in maintenance cost
Page 25 of 152
3. Vacuum Pumps in AHP
Team Details
Vikrant Powar | Ganesh Dhole | Sachin Patil | Ravindra Kirange | Amit Ratre
Challenge:
As per the specifications and approved drawings
the Pumps were supplied with Cast Iron body.
These pumps were installed for pumping the
complete fly ash evacuations in Ash Handling
System were found to be damaged. Failure of the
ash evacuation pump created critical situation and
client has to spend huge money for manual
disposal of fly ash. The Performance Guarantee of
system as per contract could not be established
without availability of these pumps. The challenge
was to reduce the pump failures and complete the
Performance Guarantee Test for smooth handling
over.
Improvement:
Casing of all vacuum pumps found highly eroded
and leakages observed in pumps within a month.
These leakages resulted in breakage of vacuum
and the pump performance drastically reduced.
The fly ash evacuation system affected and client
had to ground load the fly ash and transport by
tractors with extra cost. In order to overcome the
situation, following analysis/ modifications have
been done.
• Analysis of input and outlet water used for sealing of vacuum pumps were carried out and it
was observed that the water is becoming acidic after in contact with the air containing sulphur of
flue gas.
• To avoid the heavy erosion/corrosion of vacuum pump bodies, it was decided to replace the
bodies from Cast Iron to SS316 lined cast Iron.
• Replacement of castings done in vacuum pump and pumps restored.
Benefits:
• Improved fly ash evacuation rate
• Reduction in repair and maintenance cost
• Employee Satisfaction
Page 26 of 152
4. Smart Re-engineering in Sludge Transfer Pumps
Team Details
S Praveen Kumar | Imran Sarfaraz Khan
Challenge:
The vertical sludge transfer pump installed had
frequent failures. The customer was dissatisfied as
frequent failures impacted operations and
increased the operational costs.
Improvement:
After exhaustive analysis and detailed study, we
enquired various pump manufacturers & technical
aspects like as Groundfos, ROTO Pumps, CRI
Pumps, Flow Serve and Harison Pumps and
concluded for providing vertical glandless pumps,
make of Process Pumps Pvt Ltd, Bangalore which
is glandless, mounting on above ground structures
and especially required flow of capacity 40 m3/hr&
suited in existing 15 KW rated motor capacity.
These pumps not only proved to be very efficient
but also nullified requirement of sea water as no
bearings, gland pack existed. Moreover this total
pump installing arrangement is above ground
which provided for ease in maintenance, only
having suction piping and overflow piping.
Benefits:
• Cost Saving
• Reduction in Maintenance
Page 27 of 152
5. Rathole belled in CHP Emergency Reclaim Hopper
Team Details
G Srinivas Kumar | B Ramanjineayulu | G Tirupati Rao | Ch Sivaprasad | Saikishore Turaga
Challenge:
It was observed that during the operation of reclaim
hopper, the coal flow rate was not meeting the design
requirements. The inadequate coal flow resulted in
frequent disruption of plant operation. It was observed
that stacking of coal from hopper bottom to top, creating
rat-holes type shape, obstruction to free flow of coal and
thereby reducing coal feed quantity. This was also major
hurdle in conductance of Performance Guarantee Test of
Coal Handling Plant. The challenge was to meet the
designed coal flow rate and clear the PG test.
Improvement:
Casing of all vacuum pumps found highly eroded and
leakages observed in pumps within a month.
1) Bottom rectangular flat portion was made into
conical portion by pouring the concrete on all
bottom sides to improve coal flow rate at the
feeding point to vibro-feeders.
2) Liner plates have been extended upwards from
existing level (from intersection points of hopper) to
make desired inclination for easy flow of coal
Benefits:
• Reduction in breakdown maintenance
Page 28 of 152
6.Reengineering in PLC panel for remote and Local mode operations
Team Details
Chalapathi Rao L
Challenge:
All the drives required to be operated from PLC in auto / remote mode for the plant operation. During
the PLC commissioning & site acceptance test, we observed that all drives are not running in local
mode irrupting of Plant operation. This resulted in effluent treated water tanks overflowing leading to
extra dewatering system and additional manpower for cleaning the system. If PLC system is shut
down due to failure of power, I/O cards processor ext., the drives are not running in local mode. The
challenge was to provide uninterrupted operations of all drives.
Improvement:
As per the original Switch Gear scheme there was one NO & one NC contacts for start and stop
command, whereas drive Stop command required NC contact consciously to MCC from PLC panel.
From the existing logic we were unable to generate Local start for all the drives. Plant System
operation is provided in Local and Auto mode. At time of PLC system is shutdown; Local mode
operation provision was provided all for all drives without Interruption operation. ETP Drives are
Operating from PLC in Auto and Local mode. If PLC system is shutdown, the drives were running in
local mode. ETP Drives are Operating from PLC and Local / remote mode. If PLC system is
shutdown, the drives are not running in local mode
Benefits:
• Uninterrupted operations
• Employee satisfaction
Page 29 of 152
7. Reduction in Vibration in Dosing Skid
Team Details
Anil Kumar
Challenge:
We had to install dosing skids of Calcium Chloride,
Sodium Bicarbonate Poly Silicate to improve the
quality of Service water supplied by vendor. The
scheme developed by the vendor was under
design leading to absorbing of vibrations in
hesitaters of the skids. The motor was directly
mounted on fibre tank and hesitators were
connected with motor. During running it was
creating huge vibration and noise in the skid. The
challenge was to have a smooth operation.
Improvement:
When this skid was not installed, the service water
quality which was going to ash sealing system and
fire fighting system. The internal surface of the pipe
was rusting and degrading the water quality and
reducing the pipe lifetime. By installing the skid, it
improved the water quality parameters and
increased the system life and power station life.
This helped in increase lifetime of the project. We
controlled the huge vibration occurred at the time
of commissioning by designing of supporting
arrangement.
Benefits:
• Vibration arresting,
• cost saving to project
Page 30 of 152
PG-100040-NTPC-LARA
If I had an hour to solve a problem, I’d spend 55 minutes thinking

about the problem and 5 minutes thinking about solutions”
- Albert Einstein
Page 31 of 152
Innoways Celebrations @ NTPC-LARA
Page 32 of 152
8. Design Mix
Team Details
Chandrakant Chandrakar | Nityanand Pathak | Arnuv Sinha Roy | Praveen Kumar
Challenge:
The Mix Design used at NTPC Lara project had cement quantity of 367kg per Cubic meter, which was
high. The objective was to develop a design mix to reduce the cement quantity without compromising
the Quality and concrete specifications issued by NTPC.
Improvement:
A new design mix with cement quantity of 340kg per cubic meter was developed. The design mix was
tested in NCCBM- Hyderabad. The tests were conducted with reduced quantity of cement for the
design of M25 & M35 respectively. The trials were conducted with same recipe/ ingredient at our site
and found satisfactory result for its 7 & 28 days cube compressive strength, and other parameters i.e.
Slump and Homogeneous of concrete was also found satisfactory. We went through with the same
recipe of M25 & M35 grade of concrete at CHP area with due approval of client Ms NTPC ltd, and
successfully completed 25000 cum of concrete with meeting desire Strength and other parameters.
Benefits:
• Cost Saving
Page 33 of 152
9. Silo air filter
Team Details
Raju Nagure | Dheeraj Kumar | Shiva Kumar C | Krishna Pradhan | Subhani Basha Sd
Challenge:
During loading of cement in the silo of batching
plant from bulker, due to high pressure from the
blower while feeding cement there was pilferage of
cement . Due to the high pressure it was observed
that around 4% of cement was getting wasted due to
the filter plate in the silo. Apart from the wastage, this
would cause lot of air pollution. The challenge was to
reduce the cement wastage in batching plant and
reduce air pollution.
Improvement:
We analysed and observed that during loading of
cement in the silo of batching plant from bulker, due
to high pressure from the blower while feeding
cement there was pilferage of cement. This was
due to direct contact with the filter element resulting
in damage of the filer material. To minimise the
direct contract of air blown to the filter, we have
fabricated a buffer plate on the top filter cover.
During operation, the air is contacted with the buffer
plate instead of filter resulting in cement being
captured in the silo and air passing through the filter.
This modification resulted in less wastage &
reduced pollution.
Benefits:
• Reduction in cement wastage in silo
• Reduction in air pollution
• Cost saving
Page 34 of 152
PG-100036-PGPL-MIDC-BHAGAD
Kaizen means on-going improvement involving everybody,

without spending much money
-Masaaki Imai
Page 35 of 152
Innoways Celebration @ PGPL-MIDC-BHAGAD
Page 36 of 152
10. Process Improvement of Air Compressor System
Team Details
C Gnanasekhar | Saurabh Kumar Suman | Avinash Pal | Gurmeet Singh | Benu Charan Giri
Challenge:
During execution of cooling water pipe line for
compressor system, we noticed that only one
pressure gauge is installed in cooling water inlet
line and there was no pressure transmitter erected
in the line. As a result of which continuous
monitoring of pressure in the DCS was not
available, this was not recommended.
Compressor being critical equipment’s for
operation of plant, it is mandatory to monitor all the
parameters to avoid disturbance of generation. In
addition, in future, there could be a chance of
failure of pressure gauge, then ensuring of cooling
water availability for Compressor air system would
be difficult. This would lead to tripping of
compressor system and plant operation
Improvement:
As per the P&ID, 2 Nos of Pressure Transmitters
are installed in Intermediate Air Header to
monitoring the pressure. As both the air receiver
Tank-1&2 are connected to common header, we
proposed our client to install one Pressure
Transmitter in the common Header and another
Pressure Transmitter to be installed at the Cooling
Water Supply to monitor the pressure.
Benefits:
• Easy monitoring & control
• Safe Working
Page 37 of 152
PG-100039-TSL-KHONDBOND
Never be afraid to fail. Failure is only a stepping stone to improvement.

Never be overconfident because that will block your improvement.
-Tony Jaa
Page 38 of 152
11. Optimization of Structural BOQ for Scrubber building
Team Details
A Sekhar | Nagapadmaja
Challenge:
M/s. DCPL initially submitted the design in STAAD for Scrubber building superstructure
[41(L)x21(W)x55m(H)] with a steel quantity of 843T excluding the quantity of secondary beams, base
plates, purlins, runners and connections. Weight of secondary beams worked out to be 202T as per
drawings or STAAD and the total quantity for main frames and secondary beams was 1045T. The
challenge was to reduce the steel quantities.
Improvement:
Modeling the main frame without secondary beams and applying the equipment loads on main
beams is conservative, but not an economical approach which would be followed when the layout is
not finalized. M/s. DCPL disagreed thrice to model the secondary beams in STAAD and produced a
separate calculation for design of secondary beams. As the mechanical GA was finalized, we insisted
M/s. DCPL to model the secondary beams in STAAD and apply the equipment loads on secondary
beams. Through which, the load transfer would be proper; stiffness of the structure increases and
section sizes reduce. By modeling the secondary beams in STAAD model and applying the loads on
secondary beams, the total tonnage for main frame and secondary beams is 914T. On further
optimization of columns, main beams and secondary beams, the tonnage reduced to 818T. We
further scrutinized the member sizes and reduced the tonnage to 778T.
Total reduction of about 267T (Cost reduction of 2.15 Cr) has been achieved by modeling secondary
beams in STAAD by optimizing the member sections.
Benefits:
• Conservation of Natural resource
• Cost Savings
Page 39 of 152
Vivek Gautam
BU Head
Business Unit - Transmission & Distribution is a leader in setting up Transmission

infrastructure in India. Advanced designing, engineering capabilities and cutting edge
software tools enables the business unit to provide optimal design solutions for towers and
substation structures. T&D has the expertise to execute complex projects, especially in
tough, hilly and snowy terrains. T&D has successfully commissioned more than 12,000
CKT Kms of transmission lines across multiple voltage levels including 800 kV HV double
circuit projects.
BU-TRANSMISSION & DISTRIBUTION
Whenever I go on a ride, I'm always thinking of

what's wrong with the thing and how it can be improved
– Walt Disney
Page 40 of 152
TD-200108-ISOLUX-MAINPUR BARA 2B
I think frugality drives innovation, just like other constraints do.

One of the only ways to get out of a tight box is to invent your way out
- Jeff Bezos
Page 41 of 152
12. Improving Safety in pulley
Team Details
Bijender Singh | Akhilesh Kumar Singh | S Madhukar | Karamchand Pandey | Prabhu Sah
Challenge:
Pulleys are used during the stringing activity in T&D.
While using hook type of pulleys at tower leg & beam
during insulator hoisting and final sag work, there was
always a risk of jumping out of pulleys from slings & wire
rope in open type pulleys. This would result in first aid
and accidents as men will be working. The challenge
was to provide a safety for workforce & equipment at
T&D.
Improvement:
We have developed and the implements from “S” type
hook with Eye type hook & locking system in the pulleys.
This is modified with different mechanism for better
safety & reliability.
Benefits:
• Safe Operations
Page 42 of 152
TD-200090-PGCIL-KISHENPUR-WANPO-A2
Continuous improvement is better than delayed perfection

– Mark Twain
Page 43 of 152
13. Innovation in Span Roller for Tower materials
Team Details
Narendra Kumar | Raizada S K | Rohit Bhatt
Challenge:
T&D is executing project in tough hilly terrain in Kashmir. The tower materials need to be transported
manually using head loading in a tough and steep hilly terrain. To transport the tower parts and
materials the labours would head load the material and transport it to the respective area of
construction. The head loading method of handling material by labour is expensive and time
consuming. There are severe safety hazards due to tough and steep hilly terrain. Sometimes it was
also not possible to climb with material on such steep hills.
The approximate materials to be head loaded was 1,600 MT tower material, 2,400 Numbers
insulators, 68 MT hardware fittings, etc. To access the location it takes at least 3 hrs. It was difficult
task to head load the construction material up the hill top. Any slippage by labour while carrying the
material through narrow path on steep hills would be catastrophic would affect the moral and delay
the project. The challenge was to provide safe material transport.
Improvement:
In many areas in the hills, ropes way are used for crossing of rivers, material transportation from road
to house on the hill. Generally in hills normal spans are being used with the help of wooden support
and normal motorized machine, which has not having facility of speed control and break. The Team
had surveyed the feasible route for erecting the rope way. After finalization of route, wire rope was
pulled through PP ropes. Motorized winch machine were used for tightening the wire ropes. These
were no place on the footing of hill for placing the prime mover. The speed control and breaking was
difficult so Recovery Crain was selected. The recovery crane has speed control with breaking facility
for transporting the materials. The Tower materials and accessories are transported from the lower
part of the hill to the upper desk using span rollers with recovery crane facility
Benefits:
• Time Saving
• Cost optimization
• Safe operations
Page 44 of 152
TD-200136-PVV-RAPDRP (PART-B) ALLAHABAD
Excellence is not a destination; it is a continuous journey that never ends

– Brain Tracy
Page 45 of 152
14. Safety Helmet for power detection
Team Details
Anil Kumar Chaubey
Challenge:
Business Unit – T&D is executing the urban
electrification project at Allahabad. The scope of the
work is to renovate and modernization of existing
network for High Voltage / Low Voltage distribution
networks. Before renovating / modernization of
existing network the feeder was shutdown. Even after
shutdown it was required to cross verify that the
network is not charged from other feeder. The
challenge was to develop a device that would caution
on the power availability in the network that would
improve safe operation and human safety.
Improvement:
We had a brainstorming with the team and developed
possible solutions for indicating the availability of
power. An out of the box idea was to include a sensor
that will indicate the availability of power using
frequency. We developed the frequency driven power
detector which would be placed in the helmet. The
sensor would provide alarm when the line is live on
and around 3m from the network. Then the respective
line engineer would identify the feeder and shutdown
for renovation of the network for safe operations.
Benefits:
• Safe Operation
Page 46 of 152
15. Pole Climber for safe operation
Team Details
Anil Kumar Chaubey
Challenge:
Business Unit – T&D is executing the urban electrification
project at Allahabad. The scope of the work is to renovate
and modernization of existing network for High Voltage /
Low Voltage distribution networks. During shutdown and
maintenance work it was observed that access to ladder
was not available or ladder could not be reached at
particular area. During maintenance work 4 to 5 workforce
is required, for handling the ladder. The challenge was to
develop an tool for climbing the pools with safety.
Improvement:
We had a brainstorming session to identify an innovative
method to climb the poles without ladder. We developed a
device “Pole Pro” which could be used to climb the poles
without any ladder. The workforce would wear the pole pro
device on his shoes. As the climber lifts the leg, the pole
pro moves along the pole in upward or downward
direction. The climber needs to press his legs side ways to
provide himself with a firm foot hold by locking pole with
pole and then repeating the procedure for other leg. The
pole climber enables the climber to ascend or descend on
the pole conveniently.
Benefits:
• Time Saving
• Safe Operations
Page 47 of 152
TOWER MANUFACTURING UNIT, UMRED, NAGPUR
"Quality depends on good data.

It also depends on executive leadership in using that data."
- Juran Institute, Inc
Page 48 of 152
16 . Visual Store Management
Team Details
Ninad B Pathak | Ritesh Ramesh Jaiswal | Shekhar Prabhakar Kolhe | Bhabani Shankar Dash
Challenge:
At Tower Manufacturing Unit tracing the material to issue
against job card due to section, thickness, embossing,
grade, customer type is very important. Wrong issue of
the material will lead of whole lot being rejected by the
customer resulting in rework and cost increase,
Improvement:
To simplify the problem of traceability of raw material as
per job card we have distributed the entire raw yard into
bin wise, then again redistributed the bins in 2 category
PG and NONPG, these 2 categories are again sub
divided in grade i.e. HT and MS(HIGH TENSILE and
MILD STEEL), one more thing is adopted for
simplification in tracing the material is the rafters that are
used for stacking of raw material is distributed in 2
colours i.e. GREEN and BLUE, the use of green rafters
will be restricted only for the section 75x75x5 and above,
the rafters of blue colour will be used only in case of below
75x75x5.
These all simplification process is displayed properly in
the Raw Yard through banners and posters, so any one
can understand how the material is kept in Raw Yard.
Benefits:
• Easy identification of Material
• Easy deployment of T&P
• Improved Housekeeping
• Safety
Page 49 of 152
17. Renovation of C- Frame of CNC machine
Team Details
Bhushan Janak | Sunil Sambhshiv Sakharkar | Ravindra Gorakh Wasnik
Challenge:
In tower fabrication, there are several operations such as cutting, punching / drilling, stamping,
notching, bending and hole after bending. Among these operations, punching is major operation as it
is needed to be done multiple times on a single piece. On CNC machine, punching is done with the
help of punch and die. To keep the punch and die aligned, a fixture called C- frame along with punch
holder and dia holder is used. Due to continuous use, the C frame gets wear out or bend or damaged.
Due to its heaviness and critical design, the cost becomes very high. Further this lead to high
consumption of punches, productivity reduction due to frequent changing of die and punches. The
challenge is improve the reliability of C frame without hampering the design and performance.
Improvement:
It was observed that the C frame was mainly getting worn out at the area, where the punch holder
moves up and down. Once it gets damaged, alignment of punch and die disturbs frequently leading to
damage of die and breakage of punch. We understood for repairing of the area where punch holder
moves. But it was not possible as its length is around 100 cm and repairing from inside (i.e. welding /
grinding) is not possible. To overcome this we designed one sleeve to put inside the C – frame. This
sleeve is changeable and can be replaced in-house. The cost of the sleeve is Rs. 3500 per sleeve.
Now we can use same C frame again by only changing the sleeve.
Benefits:
• Cost optimization
• Productivity improvement
Page 50 of 152
18. Cost optimization using CNC punch
Team Details
Sunil Sambhshiv Sakharkar
Challenge:
In tower fabrication, there are several operations such as cutting, punching / drilling, stamping,
notching, bending and hole after bending. Among these operations, punching is major operation as it
is needed to be done multiple times in a single piece. Hence the consumption of tool required i.e.
punch is also high. During year 2014-15, the cost of CNC punch was Rs.170 / Piece. The challenge
was to reduce the punch cost per piece by 20%.
Improvement:
A group comprising of tooling Engineer, Shop floor engineer, CNC operator and Production Head is
formed. Brainstorming was done and related causes were discussed. Based on the discussions we
have identified following points as major reasons in relation to the problem detected:
• Due to Bigger size, punch cost is more.
• Long size punches tends to more breakage
• Frequent breakages leads to time wastage for changing.
We analysed these major reasons and concluded to redesign the punch holder by reducing the length
of the punch. The punch holder design is to compensate the reduction in length of punch.
Benefits:
• Cost savings
Page 51 of 152
19. Minimize the Scrap by 0.4%
Team Details
Ritesh Ramesh Jaiswal | Sanjay Bommana | Mohsin Mustafa Khan | Shekhar Prabhakar Kolhe |
Bhabani Shankar Dash
Challenge:
We manufacture various types of transmission towers at TMU. The section range from 55x55 to
45x30 carries mark numbers in Tower parts. This activity is time consuming as we need develop
cutting plan for said section & further indenting of same. Fabrication department has to prepare
cutting plan before going for production with where in there 2 % scrap is generated. The challenge is
to reduce the scrap and improve productivity.
So to minimize further consumption of steel we have decided to explore the automation through which
we can get optimize output for steel saving productivity improvement
The average of requirement of 55x55x4 to 45x30x4 in tower is about 15% of total tower weight. If we
produce 36000 MT/Year at TMU then 15% of said section will be 5400 MT/Year This is huge quantum
and we thought if we can reduce wastage from 2% to further lower, then it will be a good saving.
Improvement:
We formed a working group of Planning Head, Planning Engineer and Yard supervisor. We analyse
the trend of year 2014-15 and done brain storming. One of the ideas during the brainstorming was
exploring the optimizer Software & found 1-D Cutting Optimizer.
Subsequently we have started using software by applying several permutation combination thus
progressively from 2.0% we got the effective desire result of 1.6 % from August onwards, the output of
1-D Optimizer is been added to Every Job cards & MIR is been prepared accordingly as per cutting
plan for smoother & faster production.
Benefits:
• Improved Productivity
• Reduction in waste
Page 52 of 152
20. Optimisation of acid consumption
Team Details
Vinayak Retar | Bhushan Murlidhar Janak | Anilkumar Rameshwarji Bahekar |
Shailesh Balasaheb Shrigirwar | Moreshwar Kashinath Kolate
Challenge:
In the Tower Manufacturing process, galvanizing is the critical process which involves chemical
reactions. The galvanizing process is mainly divided in to three parts:
• Pre-treatment
• Hot dip galvanizing
• Post treatment
In pre-treatment process, rust cleaning of material is done by Hydrochloric acid. It was observed the
consumption of hydrochloric acid was high up to 39Kg/MT impacting the conversion cost. The
challenge was to reduce the hydrochloric acid consumption.
Improvement:
We formed a team consisting of QA Engineer, Galvanizing Engineer, Shop floor supervisors.
Following actions were taken for attacking acid consumption problem. We prepared a new tank with
ratio of 60:40 with adequate percentage of inhibitor is added (0.32 % of acid as recommended by
supplier). This prevents the excess pickling resulting in reduction of acid consumption. We decided
not to use fresh tank directly for pickling. The material put in the pickling tank is checked at an interval
of 15 minutes to avoid extra pickling. After partial pickling, material is taken out and put in the air
contact for oxidation. It increases the speed of pickling process. Precise monitoring of pickling timing
is done and recorded it regularly.
We developed a standard operating procedure and trained operators for monitoring the consumption
in each shift.
Benefits:
• Cost saving
Page 53 of 152
21. Indigenous design and development of Tent house for site labour
Team Details
Mohaideen Khaja | Deepali Pradeep Chaudhari | Shrikant Suryakant Pensalwar |
Akash Kumar | Susil Kumar Nayak
Challenge:
At T&D Project site during the erection and
stringing operations, the working gang needs to
stay at a certain place for a limited period to
complete the work. Once the tower is erected the
gang needs to move to next working area to
complete the work. At every temporary location,
they require a make shift camp shelter to stay for
the purpose of rest, food etc. At present they used
to build a temporary tent which does not provide
required security against strong winds or cold
weather. The challenge was to develop a
temporary detachable arrangement, which could
be carried along the way and provide comfort
during the stay.
Improvement:
We had a brainstorming session to identify
different possible arrangement. We came up with
the idea to developin-house detachable tents
made up of steel. We piloted this by supplying &
installing the detachable tent at T&D Kargil
and Srinagar project site. Based on the feedback
we redesigned the tent so that it can be used as
ADJUSTABLE TENT to accommodate in
available area at site to accommodate the gang
size of 25-30 people or 15 to 20 people.
Benefits:
• Comfort
• Safe storage of material
Page 54 of 152
Saket Mathur
BU Head
Business Unit - Metals and Minerals provides end to end customized solutions for Ferrous
and Non-Ferrous industries with cutting edge technology. Metals & Minerals is executing
Blast Furnaces, Ore Beneficiation plants, Palletisation plants and other large and complex
projects in this sector. It also provide solutions for extraction of Aluminium and Copper,
Mineral processing, Coal handling and Coke Oven Batteries.
M&M has dedicated centres of engineering excellence for metals and minerals enabling it
to provide effective end to end solutions - covering all the stages from concept, design,
supply, construction to commissioning of the project. It has a zero tolerance on safety and
compliance with quality and environment norms.
BU-METALS & MINERALS
"Excellent firms don't believe in excellence -

only in constant improvement and constant change”
- Tom Peters
Page 55 of 152
MM-700022-SAIL-AGN-BOKARO
Almost all quality improvement comes via simplification of

design, manufacturing... layout, processes, and procedures.
- Tom Peters
Page 56 of 152
22. Reengineering in Design of Slag Pot Stand
Team Details
Saket Mathur | Kunal Ranjan Jha | Sudhir Tripathi | Bibhas Mandal
Challenge:
Slag Pot stand is a stand for supporting and Earlier Drawing
tipping a slag pot. The stand has a pair of arms 50 mm plate 150 mm Thk. Slab
50 mm plate
normally disposed in a horizontal direction and 50 MM thk. Plate x 03 Nos.
50 mm plate
rotatable about a horizontal axis. The slag pot is
lowered onto the arms with its centre of gravity
offset from the axis of rotation of the arms. The arms are provided at their outer ends with hook-like
projections which engage the side portions of the slag pot supporting lugs to prevent the pot from
sliding as the arms rotate downwardly from the horizontal position. Counterbalances are provided to
return the arms to a horizontal position when the ladle is lifted off the stand. The challenge was to
fabricate using 150 mm thick slab of available size with reduced waste.
Improvement:
For making the Slag pot stand base plate with 150 Re-designed drawing Butt Weld
Butt Weld
mm slab TPL had to purchase two slabs of 150 160 mm Thk Slab.
mm. While making the base plates with 50 mm 40 mm Thk x 03 Nos.
20 Mmm Thk. Plate x 02 Nos.
plate, we were getting a Butt Joint welding in same
axis in the Middle of Base plate for all the three
plates. The axis cannot be changed as we do not
get 50mm thick Plate of higher width. For that we had to purchase extra 50 mm thick plate and make
the joints accordingly. To avoid Butt Joint in the same axis or procurement of extra plates as well as
use the off-cut plates available at site, we redesigned the base plate of available thickness (20mm &
40mm) and to fabricate the Slag pot stand at site. During re-designing we proposed to provide 20 mm
plate between 40 mm plate, so that there is a breakage of welding joints in same axis. Further, to
maintain the strength 30 mm dia Stud Pins being provided as shown in the drawing. In this proposal
the total thickness of base plate became 160 mm thick and with fixing of Stud pins, the composite
plate fixing proposal was accepted to DC/MECON/BSL.
Benefits:
• Cost Saving
Page 57 of 152
MM-700014-NMDC-NAGARNAR
“It is not necessary to change. Survival is not mandatory.”

- W. Edwards Deming
Page 58 of 152
Innoways Celebrations @ NMDC-NAGARNAR
Page 59 of 152
23. Effective utilization of forklift
Team Details
Prabhat Mishra | Girwar Singh | Manish Kumar | Mohana Rao
Challenge:
The insulating bricks used for Blast Furnace inner lining are imported. The consignments of insulating
bricks are dispatched in the close container. To unload these boxes of insulation bricks, forklift has to
go inside the container. The height of the consignment was 2.29m and the height of the high mast of
the forklift is 2.34m. At project site the forklift for handling materials having high mast was unable to go
inside the container to unload the boxes of the insulating bricks. This was a challenge.
Improvement:
We analysed cost of purchasing 3MT low mast forklift. We also brainstormed for hiring a low mast
forklift. Then we did the cost benefit analysis of purchase and hire options with a viability for the project
period of 2 years. Cogitation was done
and it was decided to fit low mast
assembly to the same forklift available
at the project site as hire / purchase was
not cost effective.
We contacted the manufacturer who
has experience of manufacturing
container based application for forklifts.
The container based application was
manufactured with a load calculation of
3MT capacity. It was successfully fitted
and the problem was resolved. Now we have both the mast for our forklift. Whichever is applicable, we
fit it to the forklift and do the needful.
Benefits:
• Cost Savings
Page 60 of 152
24. Fit-up & Alignment of BF Cooling Water Piping Header
Team Details
Vadlamani Ilaya Piran
Challenge:
In the Blast Furnace cooling water piping header the branch lines needs to be welded with the mother
header in alignment all branches form a single straight row. The challenge was to maintain the
insertion of branches in same length as this was done at the project site and not in fabrication yard by
the team of fitters and welders. Any extra length inserted inside the mother header line would causes
obstruction of process inside the header line.
Improvement:
At the project site the following process was followed,
• Branch Joints maintained proper Straightness in a single straight row by using threads.
• Hold the reinforcement bar with help of other bar as shown in pic. This will give the same bottom
level for all branch lines, and will help to avoid any extra insertion inside the Header.
Benefits:
• Timely completion of activity
Straighteningof branch lineswith helpof thread Reinforcement bar used for providing
base to branch lines, to avoid
extra insertion inside the mother line
Page 61 of 152
25. Operational Safety in Hydra Crane
Team Details
Prabhat Mishra | Girwar Singh | Manish Kumar | Mohana Rao
Challenge:
While lifting load by hydra crane, an over load limit switch is provided to inform the operator that the
load he is lifting is beyond the permissible limit. The signal provides given by the means of Hooter. A
buzzer starts blowing suggesting that the load is beyond the permissible limit. However the hooter
gets wearied and the operator doesn’t receive the signal. Safety of the equipment and safety of the
operator is the challenge.
Improvement:
A fluctuating light system was installed which is equipped with a flasher & limit switch and will come
into action if the load exceeds beyond the permissible limits. Both the conventional hooter system and
the light system is fitted so that even if one system fails, the other will inform the operator about the
over load.
Benefits:
• Safety
Page 62 of 152
26. Safe working platform
Team Details
Aditya Kashyap |Chandan Kumar M | John Jerone Raj | Bijay Kumar Behera | Aboobacker C
Challenge:
Height work is always critical in construction sites. In our
project the stock house structures had 36 Numbers of
columns of 56 M height. These columns required columns in
that butt welding of star columns required at the elevation
of 17.25 m. At least 5 personals are required to be
accommodated for fit up and do welding works for week time.
Providing temporary platform for each individual column
incurs huge cost and once completion of job the dismantling
is difficult. Dismantled materials cannot be utilized properly since after cutting it’s converted to scrap.
Safe loading factor may be questionable since temporary platform are not designed or tested.
Prolong working hours may create ergonomic problems for welders in temporary platforms and it may
affect the quality of the job also. Working in such height in windy condition is not advisable in
temporary platform without guard rails. The challenge was to provide Safety and safe working
condition of the personals working at the height doing welding with optimized cost.
Improvement:
We designed Ready fix safe working platform which can
be easily fixed, removed and easy to handle, cost
effective and eco-friendly. In place of 36 Individual rigid
welded temporary platforms we made 3 ready fix
removable and reusable type platforms. On completion of
design the proto type ready fix platform been fabricated at
site, and the same been fixed at 1mtr height of star
column, and load test carried out in consideration of load
test factors in front of Third party competent personals
and our Customers for approval.
On approval of same additional ready fix platforms
fabricated at site and allowed for height works.
Benefits:
• Highly cost effective
• Expedite erection works
• Reduce time and resources
• Safety
Page 63 of 152
27. Multipurpose Precast base assembly bed.
Team Details
Aditya Kashyap | Chandan Kumar M | John Jerone Raj | Vivek Kumar Sinha | Bijay Kumar Behera
Challenge:
Bunker girder of width 19m and height 12m for stock
house was weighing between 100m to 237m. It was not
possible to completely fabricate the complete bunker
girder & transport it to the project site from the fabrication
yard. We decided to bring it part by part to site from the
fabrication yard and assemble it at the project site and
complete the welding before erection. To complete this
activity we required assembly beds which having
dimension of 10m width X 18.6m length X 0.9m height, as
universal practices for making assembly bed we need
beam of size ISMB 900 X. The following difficulties are needs to be faced with this kind of assemble
beds:-
1. Cost of purchasing beams for the same is huge impact on total cost of project.
2. Handling of ISMB 900 beam of this length is difficult job and its required adequate manpower
and hydra utilization.
3. Time taking process.
4. Wastage of national and natural resource.
5. Due to huge welding and cutting in bunker the
beams may get damaged and cannot be reused.
The challenge was to complete the assembly, welding
and erection using alternate method with effective cost
manner and safety.
Improvement:
We designed multipurpose precast concrete block with hooks, this block can be shifted by hydra
crane with only one worker. This block will provide even heights for proper placing of fabrication bed.
Benefits:
• Cost Optimization
• Optimization of natural resource
• Improvement Productivity
• Safety
Page 64 of 152
28. Improved Bunker Erection and arresting Methodology
Team Details
Aditya Kashyap | Chandra Sekaran S | Chandan Kumar M | Bijay Kumar Behera | John Jerone Raj
Challenge:
Erection of any bunker at height is always a challenging job in
construction because of its dimension, weight and welding at
height and it’s also required higher capacity crane. Normally
after erection of bunkers the end mother plate is bolted with the
column cleats. But here we have received a new type of bunker
design, where the bunker is integrated with the columns and the
whole assembly is setting on the top cap of bottom column with
the help of rocker plate. There is no welding between bottom
column and the bunker column as per the design there is only
bolting between two columns with HT bolts. The following
problems needs to be solved for this critical work:-
1. As there is no welding between columns so arresting of
bunker panel is required after erection.
2. Arresting member can take bunker live load and dead
load.
3. It can be easily removed before erection of connecting
bunker girder.
4. Withstand heavy windy condition/cyclone.
Improvement:
The following Solution we have done :-
1. Identified the location in 23m girder beam and with bunker
girder column.
2. Identify ISMB 200, ISMB 350 and laced bracing.
3. Calculating slope and length of beam with Pythagoras
theorem.
We made sketch of arresting member to withstand the entire
load, and got it approved by our consultant MECON design
department at site.
As per the approved sketch we did the erection of bunker girder safely and successfully
Benefits:
• Faster execution of work
• Optimized crane holding cost
• Time & Cost Optimization
• Safety
Page 65 of 152
29. Assembly & Erection of Mill Housing of PCI
Team Details
Bijay Kumar Behera | Aditya Kashyap | Vedpal Singh | Aboobacker C | John Jerone Raj
Challenge:
PCI Mill top part has 3 no of grinding journal assembly with mill housing. The total weight of the
grinding journal assembly is around 70MT. As per the erection manual provided by M/s ALSTOM
assembling of MILL HOUSING with GRINDING JURNAL should be done at the height of EL+7.34 Mtr
with temporary platform to match the bottom part with its top part with precision. The following were
the constraints for making temporary platform
• Financial Impact : Making of temporary platform by
using of MS Steel materials cost around Rs.
588088.00 /-
• Time Factor – it requires week time.
• Resources - for making of this temporary platform
requires group of work man (7 personals) and a
high capacity crane of 90MT.
• Separate contractor to be finalized and other back
officer works are more.
• Making a temporary working platform with
available sketch (without any detailed drawing) is a
difficult task at site.
The challenge was to simplify the erection methodology
with minimum cost and resources.
Improvement:
In place of making temporary working platform we have
done the assembly on ground at existing bed itself. As
per the erection manual the journal assembly should be
hold with hydraulic arrangement (shown in sketch
above) but the same job was done with chain block and
fabricated lifting arm. To maintain the required inclination
of grinding journal against mill housing we have used
total station to calculate it and after getting of the required
inclination we have transfer the same on grinding journal
and adjust it with the help of the chain block as per
requirement.
Benefits:
• Cost Savings
• Conservation of resources
• Safety
Page 66 of 152
S A A Irfan
BU Head
Business Unit – Transportation is a specialist in the design and execution of complete
integrated railway projects. Its competence comprises of design engineering,
electrification, related signalling & telecommunications works, bridges, earthworks and
other civil works. The company's expertise and experience has enabled it to successfully
manage and deliver technically complex projects.
Business Unit – Transportation has done detailed design, erection, testing and
commissioning of all the electric systems for overhead equipment and substations for
conventional railways, high speed lines, underground rail and tramway. It has strong
relationships with leading global railway infrastructure companies and are executing large
and complex projects such as the Dedicated Freight Corridor project.
BU-TRANSPORTATION
The world we have created is a product of our thinking;

it cannot be changed without changing our thinking.
- Albert Einstein
Page 67 of 152
850001/2/3-DFCC-101/2/3-
BHAPUR-ETAWAH-CHAMROLA-KHURJA
Our future growth relies on competitiveness and innovation, skills

and productivity... and these in turn rely on the education of our people.
- Julia Gillard
Page 68 of 152
30. Design of Formwork & Construction of RCC Circular Piers
Team Details
D Ramesh | Rajmohan Awadhiya | Anupam Kumar | Subodh Choudhary | Ajit Singh Rana
Challenge:
For construction of Bridges at DFCC project, Piers of
varying diameters ranging from 2.0 m to 2.5 meter
and height varying up to 8m were required at various
locations. The following were the challenges for
executing the work.
High number of reinforcement, shuttering and
concreting operations in remote locations leads to
higher cost of equipment, transportation and
increased delays. More construction joints require
additional time, and expenses in maintaining
concrete quality.
Improvement:
Conventionally these piers are constructed using plywood or steel formwork in stages 2 to 3 per lift.
However, to reduce number pours and construction joints, special self-supporting formwork was
designed using steel plates and rolled channels. This formwork (shuttering) was designed in modules
of 0.5m, 1.0m, 1.5m and 2.0m in such a way to be able to suit varying heights of the bridges at different
locations. Also, there was no. tie rod requirement for this shuttering.
Benefits:
• Joints less construction with excellent quality of concrete
• Cost Savings
• Safe operations
Page 69 of 152
31. Utilization of Piling Rig and TMR for pile reinforcement and
concreting
Team Details
Rajmohan Awadhiya | Dasari Ramesh | Srinivasa Rao E | Yashwant Rao | Srinivasa Rao Bonthu
Challenge:
Piling work was required for bridge foundations for Bridge no. 42, ETMJ1, 304, 312 & Bhaupur RFO
for Lot 101. In general practice, a Crawler crane is used for placing reinforcement cage inside pile
bore and concrete placement through tremie pipe in the pile. Mobilisation of crawler crane only for
reinforcement and concreting of 15 piles per month is very uneconomical. Mobilisation of crawler
crane only for this work in the remote area without proper approach road was very costly and tedious.
The challenge was to optimize the cost.
Improvement:
An alternate solution for the same was explored and tried with using piling rig & TMR for placing
reinforcement cage and concreting. The scheme was very much successful and replicated in other
locations as well.
Benefits:
• Cost Saving
• Replication at other locations
Page 70 of 152
32. Rail Panel Loading & Unloading using Synchronized Gantry arrangement
Team Details
Parasuram K | Vishwa Pandey | Rajsingh Tak | Kamal Kishore Singh | Sankara Narayana M
Challenge:
In DFCCIL railway project as per the specification the railway track should be laid by 260m length rail
panel or more and track linking shall be done by using New Track Construction (NTC) Machine.
Laying the 260m rail single length panel as per the project, loading and unloading by traditional way
by using 40 nos hydras or other mode with adherence to quality and safety was a challenge.
Improvement:
A brainstorming session was initiated to work out to
overcome the problem of laying the 260m rail panel. We
decided erection gantry system for loading and
unloading fully auto system which is generally not
operated anywhere in India.
By suitability and requirement and meet our
specification the gantry designed and erected at our
Maitha, Bhadhan and Daudhkhan Yard for loading and
unloading by Synchronised Gantry Arrangement. For
unloading and loading Rail panel required 21 gantries
and erected by REWA Cranes based on the
requirement.
• Erection of foundation gantry
• Erection of Portal Frame
• Linkage of portal frame
• Erection of 3T hoist in each gantry
• Prgramming hoist operation & Monitoring the same in the centralised cabin
• Installation of cameras in each gatntry to be able get display and monitoring the lifting and
lowering operations by single operator
• Stacking of rails on firm concrete base
• Supporting the rail stacking as per RDSO Guidelines duly supporting rail panels at every 4 Metres
• NTC wagons will come in to the gantry area on the railway track already laid inside the gantry
• Stacked rails panels will be lifted by the gantries from the centralised cabin and will be placed on
the NTC wagon.
• The sane way the rail panels coming from THE STEEL PALNT will be lowered from the rail wagon
on the stacking area
Benefits:
• Cost Savings
Page 71 of 152
33. Application of Precast
Team Details
Parasuram K | Kamal Kishore Singh | Neeraj Kumar Sinha | Ramanjaneyulu Davuluri | Viswanatha L D
Challenge:
The DFCCIL-Lot 101 involved 135km new railway
track construction including Major & Minor Bridges
including 32 nos of RUBs in Level Crossings. The
RUBs foundation levels are coming around 9m below
top of rail and as per IR rule 6mWork being done
beyond 6 meters from centre of IR track subject to
heavy cuttings nearby existing Railway track. In
normal construction in situ construction of RUBs are
taking about 10 weeks from excavation stage to
finishing stage with all aspects. About 10 weeks we cannot leave excavated area about 9m deep and
9m wide in nearby as existing running railway track, it is involved very high risk, there is high potential
to collapse soil with IR railway track and also there no enough scope to maintain slope for excavation.
Improvement:
In this juncture we consulted with our design
team and explained the way of construction
method to improve quality and safety and time.
Our design team also convinced and given
detailed drawing. Based detailed drawing we
have prepared method statement for
construction and erection of Buried Boxes and
submitted methodology DFCCIL Client and PMC for construction and erection of pre-cast
segment(Buried Box) size about 6M Width X4.65 Height X1.5M Length mentioning that improving
quality, safety and speed of construction. The RUB length about 15 meters and length of buried box
has divided in to 10 parts as load calculation and length of buried box kept 1.5M. The DFCCIL and
Consultant has agreed our proposal and approved methodology for construction and erection of
Buried Boxes.
Benefits:
• Ease in installation
• Safety
Page 72 of 152
34. Alternative Testing Procedure for in situ safe bearing Capacity(SBC)
Team Details
Ramanjaneyulu Davuluri | Parasuram K | Kamal Kishore Singh | Suresh Babu Gera | Rajnesh Kumar
Challenge:
In DFCCIL-101, the scope includes construction of 103 minor
bridges by TPL and soil investigation and design finalised by STUP
Consultants Pvt Ltd. The foundation level structure designed
based on safe bearing capacity of soil (SBC) in respective location.
Every structure shall be constructed after achieved/reached
foundation level as per drawing provided satisfying of SBC. Every
structure designed different SBC values and before finalising
foundation level, the respective SBC shall be carried out and re
confirmed as per drawing. Generally for finding in situ SBC, the
standard penetration Test (SPT) is commonly used and universally known test. But here 135
Kilometres stretch and 103 structures and practically handling SPT equipment it very difficult and it
required huge man power and machinery to handling the equipment. The challenge was find an
alternate method for cost & time optimization.
Improvement:
We developed an alternative Testing Method for safe bearing
capacity of soil (SBC). The Direct Shear test is carried out with an
apparatus consisting of a square or circular box divided into two
halves. The specimen, contained in the box, is subjected to a
constant normal load while an increasing horizontal force is
applied to one of the sections of the shear box. This force causes a
shear failure along the juncture between the box sections. The
shear force and the normal load are measured directly. The rate of
strain is adjusted by the speed of the horizontal force applied. The
loading unit has V-Strips on which the shear box housing rests. The pre-calibrated load yoke helps
counter balance the loading system. The load yoke with direct and through level system for applying
normal load up to 8 Kg/cm2 capacity. Fixtures for proving ring, brackets for holding consolidation and
strain dial gauges are provided. The lead screw connected to the shear box housing helps application
of shear stress. Shear strength of the soil is its maximum resistance to shearing stress.
The shear strength is expressed as -s = c’ + σ’ tan ø’, Where c’ = effective cohesion σ’ = effective
stress Ø’ = effective angle.
Benefits:
• Cost Savings
• Cycle Time reduction
Page 73 of 152
35. Transportation of Mark VI temper machine (ODC)
Team Details
Rajsingh Tak | Rama Shankar Sharma | Anjaneya Murthy Bh
Challenge:
Mark VI – Temper machine had to be reach at Bhadanyard
for Railway track lying. The machine was stuck up at
Railway Level Crossing barricade as consignment height
is more than 16’ 3” whereas height gauge clearance is
15’6” only. The machine was urgently required at site; it
could not reach at unloading point. The challenge was to
safe transport the Mark VI – Temper machine at the site.
Improvement:
The first option considered to reduce the height of machine
on trailer for crossing the Level Crossing. We analysed to
remove the wooden packing below Mark VI wheels which
will reduce height by 5-6”. Then, remove an angle support
to provide another 2” margin in height. Then, shift the axle
of machine to adjust within gaps on trailer flooring which
may give another 2-3” margin. But this analysis was
dropped.
Due to following;
• As per RDSO, due to heavy induction from OHE there should be minimum 1 meter gap between
Mark VI & OHE, After all these practices the gap between OHE and Mark VI was remaining less
than 0.7 meter.
• For that movement, we need to take the OHE power block from Railway officials.
• Reducing the height of machine on trailer and taking the permission for OHE power block lead to
take lot of time and money.
The second option considered as an alternative route to deliver the Mark VI at Bhadan yard to be
surveyed. Accordingly we have done alternative route survey and found that it had also many hurdles
i.e rough, narrow & congested roads and two Road under Bridges for which Railway official
permission was required. We opted for second option and coordinated meeting with Railway officials
seeking their help for crossing RUB. We arranged wire men with vehicles for taking care of overhead
wires & boards.
Benefits:
• Cost Saving
• Safe transport of machine
Page 74 of 152
36. Application of Self compacting concrete for PSC Girders casting
Team Details
Thandapani R | Manikyala Rao G S V | Mukesh Kumar | Kanaka Syam Yenugu | Jagdish Kumar
Challenge:
PSC Girder consists of congested reinforcement in the end block area and lifting bracket area. As per
the approved design mix of concerting, in the congested reinforcement area of PSC Girder post
concrete honeycombing and major defects were observed. This resulted in rework and rejections.
The challenge was to reduce honeycombing & defects in PSC girder.
Improvement:
We developed a concentre mix to satisfy the High slump, Cohesiveness, flow ability, No segregation
and bleeding during casting. The design mix was prepared with high range water reducing poly
carboxyl based admixture for self-compacting concrete.
Benefits:
• Reduction in defects
• Cycle time reduction
• Customer Engagement
Page 75 of 152
Pralhad Pawar
BU Head
Business Unit - Oil, Gas and Hydrocarbon offers solutions in Oil, Gas and Hydrocarbons to
the Indian and overseas markets. It has competency in executing downstream projects in
this sector including main plant installation, refinery expansion, tank farms, terminals, on-
shore oil field development and processing plants. It has the ability to design, build and
deliver the best solution within a specified timeline. It has recently completed the
construction of LP Gas processing and compression facilities for ONGC at Rajahmundry.
BU-OIL,GAS & HYDROCARBON
Without change there is no innovation, creativity, or incentive for improvement. Those

who initiate change will have a better opportunity to manage the change that is inevitable.
- William Pollard
Page 76 of 152
OG-500036-HAZEL-CHEMTERMINAL
Innovation happens because there are people

out there doing and trying a lot of different things
-Edward Felten
Page 77 of 152
37. Motor Operated Rolling Mechanism
Team Details
Ramana Reddy Y | Kiran Nilkanth Mohitkar | Selva Kumar R | Vishwas Govind Khardenavis
Challenge:
Business Unit - OGH is executing the chemical storage project at Sharjah which required execution of
30 no tank of 27 mtr height using jacking method. The congested layout at the site resulted in difficulty
for feeding of 10 mtr. x 3 mtr. rolled plates vertically from bottom for erection of tanks.. After erecting
4 shells of 29 out of 30 tanks, the crane could not be accessed from all the sides of these tanks. The
cranes could feed the plates only from one side and the plates were required to be shifted manually to
desired location. This activity was time consuming and unsafe. The other alternative was to deploy
higher capacity cranes, which would result in higher cost. The challenge was to execute the work with
optimum cost with safety.
Improvement:
10 structural steel frames with solid bar rollers and collapsible guide posts were fabricated and fixed
on the tank elevator jigs at the time of lifting each shell course. We connected one of the roller to
electric motor through gear box. The shell plates were fed from bottom after lifting the earlier erected
and welded shells by hydraulic jacks. Once each plate for new shell course is installed on the roller
frames vertically, the guide posts were erected to secure the plate vertically and guide during the
movement. After ensuring safety of personnel and material, the motor is switched on and plate is
guided on the roller to its final location. This has reduced the time required for shifting and erection of
shell plates.
Benefits:
• Faster execution
• Safety
Page 78 of 152
K Satyanarayana
BU Head
Business Unit - Construction has rich experience in executing Civil, Electrical and
Mechanical works for process plants like Steel, Power, Metals, etc. It has in-house
capability and advanced construction methods to execute complex construction projects in
the most challenging terrains. Construction Service Business Unit has become today one of
the leading players in the construction services industry by delivering many first of its kind
projects on-time across India and abroad.
Water and Waste Department provides end to end industrial and municipal water treatment
solutions. It has expertise in filtration, desalination and effluent treatment. Access to leading
technology providers from across the world ensures the application of industry best
practices in every project.
The water cycle is custom designed for each individual project based on input source,
desired usage and desired residual output. Thus optimal design and construction solutions
are arrived at using various input treatment and residual treatment options. The company
has the capability to execute turnkey projects related to water.
BU-CONSTRUCTION & ENVIRONMENT
“Continuous improvement is better than delayed perfection”.

- Mark Twain
Page 79 of 152
CS-340030-ITC-PANCHLA
Watch the little things; a small leak will sink a great ship.
-Benjamin Franklin
Page 80 of 152
38. Resource optimization in piling
Team Details
A Sekhar | Nagapadmaja | Srinivas Regulavalasa | Gautam Acharyya
Challenge:
During the kick off meeting, client suggested us to use only 500 dia and 600 dia piles for all buildings in
ITC project and have given us the test pile report only for those two diameter piles. While designing
the pile foundation for main plant building, we noticed that the forces, lateral forces in the internal
columns are very low and 2 nos. of 400 diameter piles are more than sufficient for internal columns.
Diameter and no. of piles in ITC project were reduced drastically by increasing the capacity of piles,
use of 400 diameter piles, increasing the spring constant of piles and by developing a composite
model in STAAD tieing the pile caps; changing the base support condition from fixed to pinned to
reduce the foundation forces and by reducing the longitudinal wind and seismic forces. The challenge
was to optimize the resources and optimise cost.
Improvement:
The pile foundation was designed for Pipe caps for the given forces on pedestals, a minimum of 3 to 4
piles are to be provided under each pedestal. But due to the modelling of pile caps along with
pedestals and tie beams (connecting the pile cap to pile cap) in STAAD by providing a spring support
at pile location, lateral forces are distributed from one pile cap to other resulting in reduction of lateral
force in piles. Due to the integral model, no. of piles were reduced to 2 for all external columns. The
capacity of 85T given in the soil report is for 3 mm deflection and 110T for a displacement
corresponding to 2/3 of 12mm settlement. Though the code IS2911 recommends to take the capacity
of pile corresponding to 2/3 of 12mm settlement, the soil report recommends to take capacity
corresponding to 3mm. Initially client disagreed to take capacity of 110T; we informed them that we
strictly follow the IS code provisions and limit the capacity to 110T. They then discussed with their soil
consultant and agreed.
Initially the vendor has submitted the calculation for longitudinal seismic wind forces distributing the
longitudinal wind/seismic forces in the first four bays, but in the force diagram, the same force is being
used for the intermediate bracings. Also they have increased the forces than that obtained from the
calculation. We have asked them to strictly give the actual forces in the force diagram and reduce the
forces in the intermediate bracings. Due to the reduction in longitudinal forces, we could be able to
reduce at least 1 pile per columns for all external columns.
Also vendor submitted the STAAD models for some buildings with support condition as fixed at the
base plate level due to which we have provide 3 to 4 nos. of 500 diameter piles for each column. But
during the tendor stage, the vendor has given the forces with base as pinned connection due to which
the foundation forces are less and accordingly the bid has been submitted. We strictly insisted them to
change the support condition though they disagreed several times. Piles diameter and atleast 1 to 2
piles reduction could be achieved due to the change of support condition to pinned.
Benefits:
• Cost saving
Page 81 of 152
CS-340022-MANTRI WEB CITY 3
Waste is worse than loss. The time is coming when every person who lays claim to ability
will keep the question of waste before him constantly. The scope of thrift is limitless.
-Thomas A. Edison
Page 82 of 152
39. Suspended Platform
Team Details
R S K Chaitanya Kotagiri | Kapaganti S Mangaraju | Soujarla Anvesh | Onteru Prasad | Govindaraju Gidla
Challenge:
During the external plastering and painting works
in high rise towers requires lot of scaffolding
material. Storage, erection and dismantling of
external scaffolding are an area of concern.
Tracking and reconciliation of the scaffolding
material is a challenge. There is pilferage of
scaffolding materials which leads to non-
availability of scaffolding materials during
erection. These scaffolding materials requires
dedicated manpower for erection and dismantling
adding any safety lapse would be a catastrophic
for a G+7 stories buildings are the challenges.
Improvement:
We have used “Rope Suspended Platform” for
external plastering, elevation architectural and
painting works “
Benefits:
• Cost Saving
• Optimization of resource.
Page 83 of 152
40. Modular Shuttering for Shear walls and Columns
Team Details
R S K Chaitanya Kotagiri | Rajmohan Awadhiya | Kapaganti S Mangaraju | Soujarla Anvesh |
Govardan D | B Ram Babu | Singarakonda Koniki
Challenge:
• High cost of consumables like plywood and timber in shuttering work
• High labour cost in shuttering
• Low productivity of carpenters in conventional formwork system
• Overall delay of projects due to high slab cycle time
Improvement:
• Capital investment in Modular formwork was done for columns and shear walls after analysing
cost and productivity effectiveness.
• Overall Formwork Labour productivity increased from 4.5 in conventional system to 10+ using
new system.
• Due to columns completion in 5 days per floor, average floor cycle time reduced to 15-16 days
as compared to 21+ days in conventional system.
• Cost of labour reduced to 80-85/- per sqm compared to conventional 100+ per sqm for a total
column shuttering area of 1.17 Lacs Sqm.
Benefits:
• Cost savings
• Cycle time reduction of slab
• Improvement in Quality
• Enhanced safety
Page 84 of 152
41. Lean for Construction & Demolition waste
Team Details
R S K Chaitanya Kotagiri | Suneel Kumar Gutti | Mangaraju Kapaganti S | Soujarla Anvesh |
Sharanappa Mailarappa Sortur
Challenge:
During the civil construction in the high rise buildings lot of
construction and demolition waste gets generated at every
floor. Handling the construction and demolition waste floor
wise leads to tripping hazard for the safety of the construction
workforce. We had six unskilled manpower for each floor in
each tower for manual Shifting and housekeeping. The builder
didn’t permit to use the material hoist to shift the materials &
unwanted concrete waste from upper floors. The challenge
was to adopt lean practices in handling of construction &
demolition waste generated at each floor of the building.
Improvement:
We had an brainstorming session with the team on
Construction & demolition waste material handling. Our focus
was to use the waste material at the project site and convert
that for material handling. We developed a chute from the
scrap drums available at the project sites as the shaft for
material handling. At each floor we had an opening for
gathering & dumping the waste which was collected at the
ground. A trolley was used to shift the waste material to the
specified area.
Benefits:
• Improved Housekeeping
• Safety
Page 85 of 152
WW-300034-TSL-KALINGANAGAR
“Innovation is the central issue in economic prosperity.”

- Michael Porter
Page 86 of 152
Innoways Celebrations @ TSL-KALINGANAGAR
Page 87 of 152
42. Alternate Method for Pullout Test
Team Details
Parasuram K | Aman Kumar | Pidimi Ramaswamy | Shubhakanta Maharana | Prabhulal Pradhan
Challenge:
During the erection of Hopper Feeder at Sinster Storage Building in RMHS
package the insert plate fell down from Beam soffit. There were around 128
insert plates installed in the RMHS package. The client instructed to re-
strengthen complete 128 nos of Insert Plates (Size 800X300) by providing
Mechanical Anchor Fasteners of HILTI/FISCHER having size 16 mm dia
anchor bolts by fixing with modified plates consideration vibro feeder load and
vibration. The strengthening activity was very tedious task as it required
drilling using hand drill machine and fixing of the insert plate by using Fisher
Wedge Anchor Fastener. This would increase the cost & duration of the
activity for handing over. Further this method of re-strengthening hazardous
and unsafe. The challenge was to identify the alternate method of testing to
save cost and time.
Improvement:
We had a brainstorming session and proposed for pull out test to be
performed for all the insert plates. In case any insert plate fails during the pull
out test that insert plate shall be strengthened. Pull out test was performed in
presence of customer by traditional method by using standard weights and
pulling the insert plates keeping design safe load about 500 kgs. After that
customer insisted that use 3000 kgs weights for testing for pull out test. But it
is very unsafe and 3000 kgs standard weight handling, very difficult to us and
we don’t have enough standard weights and weighing platform and it
requires Hydra to operate that load and hydra access was not provided
inside building. Then we thought that this is not the way and we have to
arrange alternative testing method.
Then we enquired in market and all other source we could not find any Embedment/Insert Plates Pull out
testing equipment. Then we searched for alternative testing equipment and found Load Test Gauge with
Hook Called DYNAMOMETER having capacity of 5000 kgs, that instrument generally used for load
testing of EOT Cranes. This instrument not for pull out test for inserts plate, even till now there is no
mechanism developed to testing of insert plates by pulling.
Then alternate arrangement we have made for this instrument to use Pull out Test of Insert Plates with
different method by pulling with Chain pulley provide by reverse load to give any of the structural member
and we need not to carry any standard weights and weighing platform.
Benefits:
• Cost Saving
• Time savings
• Employee Engagement.
Page 88 of 152
43. Concrete Lining
Team Details
Talloju Chakrapani | Surya Bhagavanulu P | Krishna Kumar S | Sasi Bhushana Rao A |
Anoop Dobriyal
Challenge:
As per the issued construction drawings, 6 Lakhs numbers of PCC precast member’s needs to be
placed over sand filling of 75mm thick. Again 2mm thick Geo Membrane material needs to be placed
over 75mm thick sand filling at a slope of 27°.
Geo membrane is frictionless material, placing of Sand in slope length of 40.25 meters over Geo
membrane is not easy and it’s almost impossible to retain the material. Placing of 6,00,000 numbers
of precast members over Sand filling is a critical task. The challenge was filling of sand over geo
membrane in a sloped area.
Improvement:
We had a brainstorming session on the challenges for filling sand over geo membrane. We proposed
to cancel the Sand filling over Geo-membrane and Precast Membranes. We proposed to use cast in
site Concrete with skin reinforcement which is tied & anchored at the top of embankment to give
friction to concrete over Geo-membrane material instead of placing precast members. This was
approved by client. This helped us to achieved the targets and complete 5700 Cum of Lining
concrete.
Benefits:
• Resource optimization
• Cost Saving
Page 89 of 152
44. Optimization of Generator Transformer Rating
Team Details
D Nagalatchoumy | Saurabh Kumar Suman | Naresh Kumar V
Challenge:
Tata Project is executing 12MW CDQ Project at TSL Kalinganagar. The specification covers the
design, engineering, manufacture, inspection, testing and delivery, erection, testing and
commissioning of a GeneratorTransformer rated16/20MVA, outdoor, two winding, 3 phase, 50Hz,
11kV/34.5kV. BHEL had confirmed that the maximum swallowing capacity (VWO condition) at 95.0
bar(a)/515.0deg.Cis120 TPH and corresponding power output at generator terminals is 11.93MW
only (i.e.14.04 MVA). As the Generator maximum output was 14.04MVA, considering 16/20MVA
Generator Transformer will result in increase of losses and Aux power consumption of plant. Losses
of Generator transformer had been finalized by Client during Pre-Biddis cussion. The challenge was
to cost optimization & minimize the losses for 16/20 MVA of Generator Transformer Rating.
Improvement:
Generator transformers are connected directly to Generators. The rating of the transformers are
decided based on the Generator power output which is related with Turbine capacity at different
conditions.
BHEL (OEM of STG package) has confirmed that the maximum swallowing capacity (VWO condition)
at 95.0 bar (a)/515.0 deg.Cis 120 TPH and corresponding power output at generator terminals is
11.93MW only (i.e. 14.04 MVA). These details have been discussed with Client, TSL and Client
Consultant, TCE.
As the Generator maximum output was 14.04 MVA only, considering 16/20MVA Generator
Transformer will result in increase of losses and Aux power consumption of plant without adding any
advantage in performance of the system.
So, based on the maximum Generator terminal power output, Generator transformer was resized to
12/16 MVA and approval accorded from Client & Client’s consultant.
Benefits:
• Reduction of Auxiliary Power consumption
• Reduction of carbon footprint
• Reduction in Operation and maintenance cost.
• Reduction in Space
• Cost of the transformer
• Reduction in Space
Page 90 of 152
45. Rope Suspended Platform
Team Details
Subhashis Patra| Deepak Kumar Nayak | Arun KumarJha | Kuldeep Singh | Gautam Kumar Das
Challenge:
For executing the plastering and painting jobs for different buildings at KPO project, cup –lock system
was been used. This required huge amount of scaffolding material and skilled manpower to erection
and dismantling the scaffoldings. Safety of the workmen was one of the risk involved to execute the
job at height and inspection & certifying the scaffolding before every shift was time consuming. The
challenge was to implement an alternate method that was safe and faster for execute.
Improvement:
To address the problem for the first time Rope
Suspended Platform (RSP) was introduced by TPL
at Kalinganagar Site to execute the civil building
outer side wall plastering& painting job. Using the
rope suspended platform Engineers, supervisors
& workers could reach the required height of
building with safety.
Benefits:
• Safety
Page 91 of 152
46. Construction Methodology for Piping Fit-ups
Team Details
K Parasuram | Syed Sharief | Ravi Yadav | S Chakraborti | Ravi Sekhar K
Challenge:
The pipes are aligned along the approved ROW as per the drawing and are kept ready for welding.
The pipes need to be joined through welding. At the KPO project the pipes of DN1000, DN400 and
DN600 used for the Under Ground Yard piping. As per the conventional method of joining the pipes
the process involves, alignment, fit-up using MS flats, root pass and final welding. The following were
the challenges in the conventional process;
• Time consuming as the Fitters/welders are engaged in welding temporary cleats on pipes to
match the pipes.
• Wastage of MS steel & time for preparing temporary cleats and welding these cleats to mother pipe.
• After completion of welding all the cleats on the mother pipe required to be removed by gas cutting
and these requires smoothing by grinding process.
• Damage to the pipes during removing cleats by gas cutting
These resulted in low productivity and caused delay in achieving the progress as per the milestone
schedule
Improvement:
The team working on Under Ground Yard Piping project had a brainstorming and came out with an
idea of developing a special Jig for fit-up of pipes.
Jig is designed and fabricated at site from available materials

Page 92 of 152
10MT hydraulic jack is also arranged to provide the required torque
In this process fit up process is very easily, the bracket itself taking care with the help Jack for proper fit
up and holding of the pipes for proper welding.
Benefits:
• Reduces time of fit-up
• Enhances quality
• Eliminates chances of damaging mother pipe and repairing thereof.
Page 93 of 152
47. Spray Machine
Team Details
Gautam Kumar Das | Syam Sundar V | Santosh Baral | Pramod Penthei| ShobanPaidipati | Rinku Varma
Challenge:
At EMC (Energy Management Centre) Building we
had lots of area for Painting work. Generally during
Painting work we use Paint Brush at different areas.
This was a practice at TPL-KPO site. As per the
conventional method of painting, huge man-hours
and manpower is required and was time consuming.
The challenge was to improve productivity of
painting.
Improvement:
First time this type of Painting machines was
introduced by TPL at kalinganagarsite. The objective
was to execute fine finishing in painting ay applying
the putty. This increases the speed up of work with
ensuring safety of worker & considerably reduces /
save Labor, cost & Time.
Benefits:
Page 94 of 152
48. Sand Papering Machine
Team Details
Gautam Kumar Das | Syam Sundar V | Santosh Baral | Pramod Penthei | ShobanPaidipati
Challenge:
At EMC (Energy Management Centre) Building for getting smoother surface and good finish requires
putty work on ceiling and wall. Generally after completion of Putty work sand papering is to be done for
smoothing the surface of the structure. Conventionally sand papering is done manually requiring
huge man-days. The challenge is to improve productivity of sand papering.
Improvement:
After brainstorming, we introduced the Sand Papering machines. This
increases the speed up of work with ensuring safety of worker.
Benefits:
Page 95 of 152
49. Drains Inside the RWTP
Team Details
Adapa Srikanth | Chakrapani T | Sudipto Das | Anoop Dobriyal | Shoban Paidipati
Challenge:
We had to complete approximately 900 rmt drains for completing road side drains. We faced
manpower shortage and less progress due to small wall thickness (150mm only). Previously we had
engaged 6 No’s of manpower for completing the task which included getting the concrete in iron pan
and then dropping around walls. But due to small thickness of wall, dropping concrete from the iron
pans resulted in wastage of concrete by pouring outside the walls resulting in poor progress.
Improvement:
We added 2m to 3 mts (as per requirement) length
of 150mm Dia HDPE pipe to Concrete suite. We
directly poured the concrete inside the wall without
any wastage and with less manpower.
Benefits:
• Reduction in wastage
Page 96 of 152
50. Notch Trowel
Team Details
Susant Kumar Parida | Abhishek Chandra | Shailesh Prasad | Avinash Pal
Challenge:
During the tiling work in battery room at 3 x 67.5 MW CPP-1, Kalinganagar project. It was observed
that the acid resistant tiles which are being fixed with the substrate using the mortar contained voids or
air pockets inside the mortar layer. The uneven flooring resulted in breaking of tiles leading to low
mason productivity. The challenge was to reduce the air pockets for faster tiling work.
Improvement:
To solve the problem we went into the core of the
problem, we observed that even though the
mortar layer was evenly laid on the substrate
surface there was some voids left inside the
mortar due to the presence of trapped air inside.
After the application of the bonding material to the
substrate i.e. the mortar and slurry, it is to be
ensured that the tile must be in 100 per cent
contact with the surface of the bonding material
as the gaps might cause the tile to break, crack,
and separate from the substrate. To achieve optimal contact, the bonding material must be applied
completely, evenly, and to the desired thickness and the excess materials should be removed. This
was done using a normal hand trowel with sharp edges. But in this process some voids was always
left inside the binding material due to trapped air. To remove this trapped air we made a cut on the
consecutive edges of the trowel in the U shape. When the notched trowel is used, the notched edge of
the trowel is pressed against the substrate and moved across the surface as the trailing edge. Rows
of bonding material remain on the substrate after the notched trowel has been moved across it. The
angle which the notched trowel makes to the substrate affects the amount of bonding material
remaining on the substrate. The maximum amount is left when the notched edge is perpendicular to
the substrate and the amount decreases as the angle made by the notched edge to the substrate
decreases. This produces improved suction of the notches over the cement or adhesive to be spread
and that provides an improved, more consistent contact spread pattern of cement or adhesive.
Though we implemented this in the case of laying of acid resistant tiles we can use this method in all
kind of tiles (including vitrified tiles) and at all places.
Benefits:
• Productivity Improvement
• Reduction in wastage
Page 97 of 152
51. Waste Reduction in structural steel
Team Details
Sajin T | Subhash Singh | Birendra Kumar
Challenge:
Structural column fabrication mainly consists following activity/stages -
• Plate Marking & Cutting.
• Edge Preparation, Fit-up and Welding of different Items of structural columns.
• Inspection
All above activities requires minimum set-forth time for completion. It
was observed that there was wastage of structural steel. The challenge
was to reduce / utilize the structural steel without affecting the
drawing/design & project requirements.Trestle & Tower Fabrication
work depends on the availability of structural steel. Non availability of
structural steel delays the fabrication work, which in turn affects the pipe
lines erection works. Improper utilization of steel at fabrication works will
generate more steel wastage.
Improvement:
Supporting Member Supporting Member Supporting Member
We decided to reduce & reuse the structural steel. Beam Beam Plate
10 17
5
We studied the drawings & cutting plan of plates.
14
90
After study we arrived at a point where we can save
0
50
the time i.e. plate marking/cutting, edge
preparation, fit-up and welding of Ribs that are being 175
17
5
125
welded with column flange. We have prepared a
250
cutting plan which describes cutting of flange plates
including ribs from plates of standard size resulted
plate cutting, edge preparation, fit-up and welding of
Ribs with column flange plate has been eliminated & resulted the substantial amount of time & cost
saving and improved productivity.
Benefits:
• Reduction in steel wastage
Page 98 of 152
52. Post Concreting-Honeycombing reduction
Team Details
Parasuram K | Acharyulu G V R R N | Harshvardhan Pathak | Cyril Danthi | Anoop Dobriyal
Challenge:
It was observed from the post concrete inspection on non-conformity report raised by the
customer, for the period of Jan 2014 to July 2014 out of 361 NCRs, 12% (42 Nos) of these NCRs were
on honey comb formation, which results in 1.38 honey comb formation per cubic meter. This effects
the aesthetic look of the structure, resulting in rework and repair costs approximately Rs. 500000 /-.
for the concrete quantity of 1,34,252 Cum. The challenge was to reduce the honey comb formation
post concrete at TSL – Kalinganagar project.
Improvement:
Identified major Root Causes for formation of Honey Comb post concrete,
1) Gaps in shuttering material
2) Improper/Insufficient use of vibration done using vibrator Equipment
3) Workability of Concrete
4) Lack of supervision
Developed and implemented a method statement consisting of checklists and guidelines for pouring
the concrete with defined responsibility of site engineer & FQE. Trained the vibrator operators on
effective and adequate use of vibrator equipment during concertingTracking usage of shuttering
materials and disposal of over used shuttering material
Benefits:
• Reduction in re work cost
• Employees satisfaction
Page 99 of 152
53. Soil Stabilisation without cutting Cores
Team Details
Parasuram K | Ramanjaneyulu Davuluri | Thandapani R | Varun Sonkar | Ranganath Kumar Addanki
Challenge:
At KPO project at TR-06, Trestle Raft foundation along
with two Columns casted up to 2nd lift and final lift to be
casted after bolt fixing. While bolt fixing alignment it was
noticed during back filling the raft foundation got shifted
due to water logged soil condition is weak and slushy form
in below the raft foundation. The customer asked to
submit proposal for soil stabilisation below raft
foundation. In general practice, if any soil stabilisation to
be done in below concrete means, holes provided by core
cutting and cement slurry to be applied by pressure
grouting process. However with 800 mm thick heavy raft
with 32 dia reinforcement rods used with very closer
spacing as per design criteria. The challenge was cut core
at every 1 metre intervals and its raft width-2200m and
length-10000mm.
Improvement:
We had a brainstormed the problem and possible
solutions. We came around with an alternative method
for soil stabilization by pressure grouting with cement and
cebex-100 grout material slurry through 2 inch PVC Pipe
having length about one metre with one side conical
shape to facilitate to go inside the soil and one side to
facilitate fixing the reduced ½ inch nipple at every one
metre interval all periphery of raft foundation in 45
degrees angle.
Customer was convinced to perform that process without cutting any cores of the raft foundation
Safe Bearing Capacity for soil test was conducted with required load carrying capacity as per
approved design of the around foundation by using hand penetrometer.
Benefits:
• Safety
• Cost & Time optimization
• Employee Engagement
Page 100 of 152

CS-340028-MAHINDRA HOMES-GURGAON
Practice without improvement is meaningless

- Chuck Knox
Page 101 of 152

54. Use of modular formwork for casting of retaining wall 4m height
in single lift
Team Details
Rajmohan Awadhiya | Kasu Srinivasarao | Sunil Kumar Pandey | Sreekanth P
Challenge:
• Crucial project timelines of retaining wall being in critical path
• High cost of consumables like plywood and timber in shuttering work
• Low productivity of carpenters in conventional wall formwork system
• Overall delay of project due to high cycle time
Improvement:
• Selection of the suitable formwork system from available resources for ease of operations.
• Prepared cost benefit analysis as compared to conventional system as first time being used in
TPL.
• Developing confidence amongst team and management and client for achieving desired quality
and finish in single lift of 4m using the old modular formwork panels.
• Demonstration to site and customer and further training of site team for effective application of
the system to derive envisaged results.
• Deployed Modular formwork spared from another project (spare) for retaining walls after
analysing cost and productivity effectiveness.
• Overall Formwork Labour productivity increased by improved cycle time from 8-10 days in
conventional system (2 lifts) to 4-5 days in new system.
• Avoided consumables timber and plywood in retaining walls.
Benefits:
1) Cycle time reduction
2) Cost Saving
3) Improved Quality.
4) Improved safety
5) Employee Satisfaction
Page 102 of 152

CS-340021-MANTRI-CIVIL
“Strive for continuous improvement, instead of perfection”.

- Kim Collins
Page 103 of 152

55. Alternate for RCC Lintel
Team Details
S Arumuga Selvam | N S S Phani Kumar | Ashish Nayak | Surya Bhagavanulu P | Ramesh Datla
Challenge:
As per our work order and specifications we
suppose to cast RCC lintels over the openings of
doors and windows. Once the completion of
construction of block work up to lintel level, we have
to cast the RCC lintels. For casting RCC lintels, we
have to call carpenter for shuttering, bar bender for
rebar tying and mason for laying of concrete.
Duration for completion of entire process will take
minimum half day per lintel.
Improvement:
We have implemented 3mm thick GI lintel in place
of RCC lintels over the opening of doors and
windows. After casting of lintel, curing needs to be
done for minimum of next 7 days.
As an individual RCC lintel quantity is very less, the
cost of labour and wastage of material will be very
high and supplying of RCC also very difficult to shift
inside the flats. Hence we have proposed to client as an alternate method of GI lintel instead of RCC
lintel and got approval from the client for execution of the same at site
Benefits:
• Optimization of waste
• Improved Quality
• Better Housekeeping
Page 104 of 152

56. Drive System in Comansa Tower Crane
Team Details
AVS Prakash Rao | BSM Kumar | Syed Subhani Basha
Challenge:
At the Mantri project site we had installed Comansa make Tower crane for erection and lifting of
materials. Tower crane is the hard-core multipurpose equipment. Due to the lightning the Variable
Frequency Drive on the tower crane got damaged due to short circuit. Non availability of the Tower
Crane would hamper the progress of the project and any delay in rectification would add up the delay
in the project. The challenge was to ensure the availability of the tower crane.
Improvement:
The Original Equipment Manufacture technician attended the breakdown and recommended to
replace the entire drive system of Tower Crane. It was confirmed that the special drive was not
available in India and needs to be imported. The minimum time required for importing the drive was
around six weeks. We floated enquiry to drive unit manufactures and identified Fuji unit. The
parameters of the drive could not be matched with the requirements. We approached OEM and
collected the programing data and using technicians from the Digital instruments & control systems
we reinstalled the program suiting to the Tower Crane operations for safe operations.
Benefits:
Page 105 of 152

57. Waste concrete utilization
Team Details
P Surya Bhagavanulu | Ajja Srinivasarao | N S S Phani Kumar | Arumuga Selvam S | Jamaldeen S
Challenge:
As per the construction schedule and concreting
plan the concrete mix is developed and transported
to the project site. At the time of casting a slab or
any structural element using pump & pipe line, at
the end of the pour certain quantity of concrete gets
wasted. During dismantling of the piping system
the left over concretes from hopper and pipelines
are collected. Generally the collected concrete is of
no use and will be consider as waste. If the
concrete is not removed, it would harden and requires chipping for disposal the next day. While
dismantling the pipe line, the quantity of wastage is generated on an average is around 0.70 cu. M.
The challenge is to reduce concrete waste.
Improvement:
The Projects that is currently executed is a
residential flats. As the nature of project is
construction of residential flats, construction of
superstructure with concrete blocks is part project
scope. We have started to develop concrete blocks
at site by using the same waste concrete. As per the
requirement of slab cycle & other structures like
retaining wall, the concrete is being done around 20
days per month by pump & pipe line. So, 20 x 0.70 = 14.00 Cu. m of wastage per month is being
generated. We have developed 450 no of concrete bricks of 400 X 200X 200 mm blocks.
Benefits:
• Cost Saving
Page 106 of 152

CS-340012-JSPL-BFI-PH-II &
CS-340031- JSPL-COB-ANGUL
“Once you choose hope, anything’s possible.”

- Christopher Reeve
Page 107 of 152

Innoways Celebrations @ JSPL-ANGUL
Page 108 of 152

58. Conventional Formwork
Team Details
P C Mishra | Rajmohan Awadhiya | Tapan Kumar Das | Mantulal Bauri
Challenge:
The scope was to construct a 2.96m , thick RCC slab was to be casted at 9+ m height at blower
package in JSPL – Angul project site. This was an additional scope of work issued by the client during
the execution stage of the project. For construction of heavy slab, supporting systems are required
along with mobilisation of heavy duty systems & trestles. Heavy duty scaffolding / trestles were not
available and required to be procured/ fabricated which was a time and cost consuming job. Heavy
structural beams / channels were required to support he formwork of the heavy slab and need to be
procured. Provision of crane was required for erection and dismantling of Heavy Trestles and
structural supports which could be avoided due to use of conventional scaffolding and timber beams.
The challenge was to completing the additional scope within available resource with Quality and
safety.
Improvement:
Normally heavy duty scaffolding or Trestles and supporting system made of Rolled section are
required to support such heavy slabs. Considering high lead time and capex involved in heavy duty
scaffolding/ Trestles, custom design was made using a combination of cup lock system and MS pipes
together to support the formwork. Timber H beams were used in place of heavy structural members
for bottom formwork.
Benefits:
• Conservation of resource
Page 109 of 152

59. Shear keys design Optimization
Team Details
Sunil Kumar Pandey | Rajmohan Awadhiya | Sanjay Gaur
Challenge:
For casting the RCC Building Raft in two parts, Consultant suggested the shear keys of special
shapes. These shear keys were expected to be made of plywood and timber and to be removed after
casting. The following were the challenges
1. Shape of the shear keys was to be formed using special plywood and timber runners and dowel
bars to the other part of raft were to be passed through the same.
2. Shutter boards get completely broken while removal after casting could not be reusable.
Improvement:
Revised Proposal was made by –
Design of Shear key revised for easy and faster removal.
Eliminated use of plywood and timber
On reviewing the constructability and estimating the cost involved which was approved by the client.
Benefits:
• Cost saving.
Page 110 of 152

60. Casting of Splash Bar
Team Details
Saikat Das | Tapan Kumar Das | Alok Ranjan Pradhan | Bibhuti Bhusan Bisoyi | Ravinder Singh
Challenge:
Splash Bar is a pre-stressed concrete element having length of 2.6m and parabolic cross sectional
area is 75mm X 50mm. The element will be used at the GCP Cooling Tower Structure. This kind of
slender pre-stressed concrete element is mostly obsolete and was substituted by PVC splash bar.
However the client specification was for Splash Bar adopted at the project site. The cost viability of the
agency offering the splash bar was very high and quality assurance on daily basis was difficult as the
casting yard was located far away from the project site. Quality assurance was very important as pre-
stressing operations required daily monitoring and verification of elongation and force. The challenge
was to optimize the cost and deliver quality with the direct supervision by the client.
Improvement:
There are two main challenges for casting of Splash Bar in house.
• We required procuring a pre-stressing jack, hydraulic pump, HT wire and Wedge-barrel set for
pre-stressing operation.
• A casting bed is to be made for such unconventional parabolic shape of splash bar. The bed is
also required to have a provision of 7 days of submerge curing prior to de-moulding.
To overcome the first constraints we approach our senior management with details of price break-up.
After thorough review, our management approved our proposal of procurement of required
equipment and raw materials.
We developed layout drawing of casting bed and anchor block in accordance with the length and
shape of splash bar required for our site requirements. The drawing was finalised and approved by
our client. We have deployed the contractor for making of casting bed. We have also developed MS
frame fitted with a vibrator for compaction of such a slender section.
After the casting bed is ready, we did a trial for pre-stressing operation and concreting.
Benefits:
• Cost effectiveness.
• Quality assurance
• Customer satisfaction
Page 111 of 152

61. Joint Pin for Scaffolding
Team Details
Tapan Kumar Das | Bibhuti Bhusan Bisoyi | Santanu Mukherjee | Sushobhan Roy
Challenge:
At JSPL Angul project site scaffolding is been used for
height work purpose. Scaffolding pipes are erected to
reach the height works up to 15m for structures like
buildings, blower deck slab, Cooling tower, EOHT etc.
As per the regular practice the standing/supporting
pipes of scaffolding are connected through
readymade joint pins. However as the erection work
was executed parallel on a number of structures
arranging for joint pin was a challenge.
Improvement:
We developed a JOINT PIN at the project site using TMT BAR. These Joint Pins were welded through
a qualified welder and checked through stringent quality control process.
Benefits:
• Cost saving
• Usage of scrap TMT bars
Page 112 of 152

62. Removable scaffolding system
Team Details
Rajmohan Awadhiya | Sreeram Prasanna K | Pratap Chandra Mishra | Ramesh P |
Subba Rao Gurrala
Challenge:
A circular shaped dome and ring beam 21 m in
diameter, at +65 m height from ground level was to
be constructed for the Elevated overhead tank at
JSPL Angul Project site. As per the conventional
system, entire supporting arrangement of MS
pipes/ clamps or cuplock system needs to be
erected from the ground level. This requires large
quantity of scaffolding material and erection of
such huge amount of scaffolding is very tedious,
cost and time consuming activity. The challenge
was optimize the 750MT of concrete & supporting
assembly.
Improvement:
An idea triggered to take support from the tank
RCC walls, make structural bracket arrangement
and erect the scaffolding over the same. A
cantilever bracket were designed keeping the top
level +58m.Scaffolding system was designed
ensuring uniform load distribution on radial and
circumferential beams. Stop anchors were fixed on
the beam to avoid any slippage of the scaffolding.
Formwork Support for Parabolic walls was
simplified by using vertical MS Pipes bent to
shape.
Benefits:
• Enhanced Safety
• Optimization of Natural Resource
Page 113 of 152

63. Self-compactingconcrete
Team Details
Bibhuti Bhusana Bisoyi | Pratap Chandra Mishra | Tapan Kumar Das | Alok Ranjan Pradhan |
Umakant Dwivedi
Challenge:
At the Angul Blast Furnace project site. There was double
layer reinforcement with 20mm dia in both ways at the rate of
100 mm centre to centre. The gap between the reinforcement
was quite less. The access to place the boom placer chute is
impossible and also concrete fall of height was 1.5m. It was
difficult to do concreting in a critical Hooper section, as per the
concreting methodology using normal M30 grade concrete.
This resulted in poor concrete finish due to poor flow of
concrete from a sloped height of 9.5mts due to poor vibration.
The challenge was to provide homogeneousness of concrete
at cooling tower Hooper portion with quality and reliability.
Improvement:
We have done a MIX DESIGN OF SELF COMPACTING
CNCRETE and got approval from client for the same. The
concreting was done with SCC(M30 GRADE) which resulted
in good finish in post concrete with easier pouring sequence.
Benefits:
• Client was very much satisfied due to the quality of work resulted by the process adopted. Also
work was also being executed in a speed manner to achieve the target of completing the 10 no
of HOOPER in the stipulated time.
Page 114 of 152

64. Swellable Water Bar
Team Details
Bibhuti Bhusana Bisoyi |Tapan Kumar Das | Harshvardhan Pathak | Pratap Chandra Mishra |
Susant Kumar Parida
Challenge:
As per the approved drawings we are following the PVC water bar for the construction joint in water
retaining structures. The PVC water bar is laid before concreting at 50% of its height. Keeping the pipe
in alignment as per the drawing during the time of concreting was the challenge. Any misalignment or
breakage occurring due to any of the reason, will lead to slippage at that place. The challenge was to
apply alternate to PVC water bar.
Improvement:
We studied Swellable water bar which uses 50% concrete and 50% above. We found that the
swellable water bar is two times better than the PVC and ensure water tightness and performance
better than PVC. The added advantage was the lapping became easy as the process is simple. This
was adopted at the project site.
Benefits:
• Improved Quality
Page 115 of 152

65. Improving Shuttering Usage Ratio
Team Details
Saikat Das | Tapan Kumar Das | Alok Ranjan Pradhan | Murugan K | Subrat Kumar Baral
Challenge:
TPL has initiated a cost capturing process to control the cost of individual item of works. Cost of an
individual item can only be controlled when we optimize the usage of our resources. Shuttering
material occupies a huge space in the control budget of any construction project. Therefore we
need to derive such an indicator which indicates the level of optimization of usage of shuttering
material.
Based on this requirement the concept of shuttering usage ratio is established. It will indicates the
status of shuttering material such as underutilization, optimum or surplus materials in hand on
monthly basis.
Improvement:
Shuttering usage ratio can be explained as an indicator which indicates the level of optimization of
usage of Shuttering material available with us at our project site. It can be formulated as,
Shuttering Usage Ratio = Total quantity of Shuttering billed (certified) x

Total quantity of Usable Shuttering available at site
If the value of shuttering usage ratio is greater than 1, it indicates the repetition of shuttering
material. On the other hand if the value is less than 1, that indicates the underutilization of available
shuttering material. Being project personnel we should always try to maintain value above 1.
Benefits:
• Wastage reduction
Page 116 of 152

Strategic Business Unit - Urban Infrastructure offers end to end integrated
solutions for large urban projects. The SBU has the expertise, resources &
experience to design, construct and execute complex or critical civil backbone
infrastructure with particular emphasis on social infrastructure. By having
optimized its supply chain and implemented proprietary management techniques,
it focuses on delivering projects on time.
The company has designed, built and delivered multiple mega-projects in India
and overseas. It has significant expertise in integrating multiple supply chain
elements and diverse stakeholders. Delivering projects within budget, while
ensuring high quality, safety and sustainable working practices.
SBU-URBAN INFRASTRUCTURE
Process innovation is different from product innovation. It's about how do you create a
new product or develop a new product or manufacture a new product, but not a new product itself
- Nirmalya Kumar
Page 117 of 152

Sundar Chandramouli
BU Head
BU-BUILDINGS & AIRPORTS
“Strive for continuous improvement, instead of perfection”.

- Kim Collins
Page 118 of 152

UI-670001-TMC-KOLKATA
Creativity is thinking up new things. Innovation is doing new things."

- Theodore Levitt
Page 119 of 152

66. Erection of External Tower Crane inside the Lift Shaft
Team Details
Navdeep Singh Grewal
Challenge:
The cover age of the whole building without touching the existing building was the main objective.
Options were explored to see the location feasibility of erecting the crane outside the premises but
due to location and area constraint no such location was identified so that the whole area could be
covered
1. Risk of touching of the crane jib to the existing building
2. Zero error foundation bolts installation into the raft
3. Prevention of dislocation of the foundation bolts during pouring by welding of foundation stools
to the base
4. Erection of base mast, second mast & jibs of the tower crane without the use of 250 T telescopic
cranes
The challenge was to erect the tower crane.
Improvement:
• The additional cost for external foundation and concrete was saved since the 4 nos out
rigger/foundation bolts were embedded with utmost accuracy during the pouring of the raft.
• In case the crane was to be erected externally the extra cost of anchorages would have tobe
borne by the site which was saved in due process which at present will be taken care with the
help of just one box frame (received alongwith the crane at no additional cost) and insert plates.
Since the raft depth is 550mm, load calculations on the piles beneath were checked with the structural
engineer and were found within permissible limits and embedding the 4 nos foundation bolts was
easily accomplished. If internal climbing crane was to be erected, the extra design and steel
structural cost would have to be borne since the load had to be on the box frame with I beams and the
floor slab (as selected). This design & cost of the I beams structural steel is far more than the box
frame structure to be installed at present, the reason being that at present the total load of the crane is
on the 4 nos foundation bolts which reduces the risk of shear and twist due to deflections. If the
internal crane was to be selected, in order to consider these load and deflections a strong structural
support would have been required where in the load would be distributed on the slab. More over core
cutting of the lift walls would have to be done so as to take support of the I beams with the slab for an
internal climbing crane.
Page 120 of 152

UI-670007-TCS-INDORE
"Innovation is the process of turning ideas into manufacturable

and marketable form."
- Watts Humpre
Page 121 of 152

67. Alternate Material - Manufactured Sand
Team Details
Rama kant Sharma | Rajesh Sudhir Pandit | Mahesh Pandit B | Parag Agrawal | Avinash Mathur
Challenge:
As per the client specification issued for the project, natural sand needs to be used for construction
and in concrete. Due to statutory reasons, source of natural sand was closed and created sudden &
unforeseen scarcity of availability of natural Sand. The non-availability of natural sand directly
affected the progress of works resulted in delay in achieving the milestones. The challenge was
alternate material for replacement of natural sand.
Improvement:
Procurement of natural sand away from project site
was not feasible and cost effective. We decided for
alternative material for substituting natural sand.
The Site QMD team visited all the nearby crushers
& zeroed in on Crusher Fines (henceforth called as
manufactured sand) which comes as technically
close as possible to Natural sand. Matter was
discussed with Client & PMC. Preliminary approval
was sought and secured. Concrete was redesigned considering different replacement levels of
Natural sand with manufactured sand. Different Admixtures were sourced, tried & selected to
maintain all the desired properties of concrete in fresh and hardened stage. After numerous trials and
meticulous design, a most optimum concrete mix was arrived at for all grades of concrete including
high early strength for Pre-stressed slabs.
Benefits:
Page 122 of 152

UI-670003-MANTRI SERENITY
Innovation is the specific instrument of entrepreneurship.

The act that endows resources with a new capacity to create wealth.
- Peter Drucker
Page 123 of 152

68. Productivity Improvement using Weld Mesh
Team Details
Praveen Jagadevanavar | Vaibhav Chandrakant Warange
Challenge:
This urban infra project sites reinforcement work for the walls and slabs needs to be completed
before concerting work. Tunnel formwork is being used in the project and cycle period per floor was 7
days. With the conventional method of reinforcement work achievement of 7 days cycle was difficult.
As per construction plan 15 MT reinforcement was required to be placed for walls & slabs was and
tied within 5 hours. This activity was complex and tying heavy reinforcement manually was a difficult
& laborious. The requirement would increase, if multiple blocks are constructed at one time. The
challenge was to providing the ready reinforcement work as per the schedule.
Improvement:
We customised the weld mesh produced at
factory. There are around 40 types of mesh per
block with maximum dia of 16mm and minimum
spacing 120c/c. Each block is around 3B+G+ 28
floors and there are 5 block like this, shear wall
reinforcement work involves lot of time and
resources. So design was revised and simplified
for all tunnel form reinforcement for smooth
construction, which results in less time and
resources.
Benefits:
• Faster installation of reinforcement
• Wastage reduction
• Optimization of labour
• Safety
Page 124 of 152

Shaibal Roy
BU Head
BU-TRANSPORTATION & HYDRO
“Human beings, if they realize the strength of their power, they can turn every
curve ball of life thrown towards them into a chance of growth and improvement”.
- Senora Roy
Page 125 of 152

UI-750001-DMRC-DELHI METRO RAIL
Learning and innovation go hand in hand. The arrogance of success is

to think that what you did yesterday will be sufficient for tomorrow
- William Pollard
Page 126 of 152

69. Precast Platform
Team Details
Anant Mehendale | Anshul Kumar | Chiranjib Sarkar | Dinesh Vasant Karpe
Challenge:
Completion time of the project
Construction on busy highway
Quality of precast construction at casting yard
Challenges :-
1. The self-weight minimisation was important criteria as platforms are supported over tip of
cantilever.
2. This concept is finalised in such a manner to suit for construction programme and construction
cost. Where we conclude that Precast RCC will be more suitable over precast pretensioned
platforms
1. Saving in construction time so that key dates can be achieved.
2. Moderate obstruction to running traffic and which will result less inconvenience to road
commuters.
In Cast- In- situ construction staging on busy National highway are required in between heavy vehicle
movement. In worst case these heavy vehicle can collide/ hit the staging and may cause major
accident. All these are avoided by precast construction.
Improvement:
Delhi elevated metro generally having two types of stations viz.
1. Side Platform Station
2. Island Platform Station
These precast platform are used for all eight metro station locations and each metro station shall
consists of 10 no’s such spans of 18.5m for station length of 185 m.
Page 127 of 152

As all these stations are situated at busy highway and this method does not require any blockage to
moving traffic as compared to conventional cast in situ method therefore it will not create any
obstruction on road.
In this project the station type is side platform station which allows passengers to approach the train
from one side of the station. Platform structures are resting over pier cap and normally constructed as
casted in-situ.
The casting of platform was proposed in casting yard and to be launched over either side three piece
segmental pier cap. Total 160 Nos of 18.5 m platforms are proposed to construct as Precast to avoid
in-situ work i.e. staging for platform from ground. Precast platform structure each weighing 100 ton
proposed to launch with two cranes of 350 Mt capacity.
Figure 1- Precast RCC platform over Pre Cast pier cap of elevated metro
at DMRC metro station location
Detail Design of RCC Precast Platform is optimised to reduce the dead weight which will act as point
load over 10.5m cantilever.
Benefits:
• Cost Saving
Page 128 of 152

70. Value Engineering in Pile Cap design of Elevated Viaduct
Team Details
Chiranjib Sarkar | Anshul Kumar | Anant Ghanshyam Mehendale | Lakshmi Prasad Vesangi |
Somnath Nandan
Challenge:
At DMRC CC87 project, we have designed pile cap for elevated viaduct with very optimum steel
quantity. In the previous design, a minimum of 0.2% reinforcement was used for pile cap top. The
challenge was to reduce the steel consumption of 10-15 Kg/m3 per pile cap.
Improvement:
During designing of pile cap we have observed
that there is a nominal tension on pile cap top
under Seismic load combination, mainly under
RDSO Load combination. As seismic event is of
very short duration and tension on the top of
pile cap is not permanent. Therefore minimum
bending reinforcement criteria for beams which
are under permanent tension is not applicable in
pile cap stop reinforcement where tension is of
short duration. Now, Stresses in Concrete & steel, including Ultimate limit stress (ULS) check is very
safe under seismic load combination with 0.1% reinforcement at pile cap top in each direction.
In view of above, we have prepared some technical report with help of various literature, journal and
codes and we have discussed with DMRC design cell & their proof checker to technically convince.
Finally it was agreed by DMRC to provide 0.1% reinforcement at top of pile cap in each direction.
Benefits:
• Cost Optimization
• Optimization of Natural Resource
Page 129 of 152

SBU-QUALITY SERVICES
Strategic Business Unit - Urban Infrastructure offers end to end integrated solutions for
large urban projects. The SBU has the expertise, resources & experience to design,
construct and execute complex or critical civil backbone infrastructure with particular
emphasis on social infrastructure. By having optimized its supply chain and implemented
proprietary management techniques, it focuses on delivering projects on time.
The company has designed, built and delivered multiple mega-projects in India and
overseas. It has significant expertise in integrating multiple supply chain elements and
diverse stakeholders. Delivering projects within budget, while ensuring high quality,
safety and sustainable working practices.
Page 130 of 152

71. Digitalization
Project Location: QS – Hyd
Team Details
Sarat Pradhan | Abhishek Sharma | Pattabhi Rama Rao A V | Rajan Ananthanarayanan
Challenge:
Strategic Business Unit - Quality Services deals with the inspection, testing and certification
business. The business processes followed were Lead to Contract, Contract Service Request,
Service Request to Closure, Closure to Invoicing, Invoicing to Collection and complaint management.
While “Lead to Contract” process is in CRM, all other processes were being handled manually. This
required mammoth manual efforts in terms of resource and time. SBU Quality Services has following
challenges because of manual business processes:
• Difficulty in maintenance and collection of data
• Lack of timely and proper data poses challenges in decision making
• Sub-optimal operational efficiency
• Sub-optimal level of emergency preparedness
The challenge was to improve the efficacy of the business and enhance customer experience.
Improvement:
We had a brainstorming and identified three critical processes that have an impact on the business
and customer. We identified “Contract to Service Request”, “Service Request to Closure” and
“Closure to Invoicing” to be digitalized through development of work process and work flows. We
mapped the As-Is processes and To Be processes looking at customer requirements and
experiences. We developed Enterprise level processes through requirement gathering by the
developer, user acceptance test and training of key users. The business processes were simplified
leading to operational efficiency and online availability for flow of information and data.
As first step of debottlenecking QS business processes, three processes “Contract to Service
Request”, “Service Request to Closure” and “Closure to Invoicing” were set to be put on Digitisation
Platform.
Benefits:
• Improved operational efficiency
• Improved response time
• Improved Customer Satisfaction
• Scalability
• Improved Monitoring of the activities – Utilisation, Report Review, OSWI
• Driving towards “paperless” culture
• MIS and Analytics leading to informed decision making
• Collaboration
Page 131 of 152

72. Collection Management Tool
Team Details
Sourav Chakraborty | Krishna VVS | Syed Mohiuddin | Venkata Ramani L | Barkat Ali Khan
Challenge:
Receivable aging and receivable collections was a area of concern at SBU-QS. 3000 line items
required to be collected by 17 Spokes (Centre Heads) for 300 odd customers. To collect the
receivables from the client the KAM / Spoke has to gather information such as pending payments,
invoice details etc. from F&A. Accuracy of data, timely availability of the required data and cash
forecasting was challenge.
Improvement:
Developed an in-house “Collection Management Tool” where the invoice details are logged centrally.
The KAM / Spoke can view the pending payments details with respect to the customer and follow-up
for payments. The collection Management tool is hosted in the cloud which will enable the spoke/KAM
to view as per there requirement and time. Without the Without QS finance interference spokes/KAM
can check/ download the receivable of allocated clients.
Report in various formats i.e. “Consolidated data, Projects wise data, Invoice wise break up, pending
days and ageing as of date. Spokes can see and provide information
Benefits:
• Accurate & transparency in MIS reporting
• Collections value has increased by 18%.
• Ease in collections forecast and planning,
Page 132 of 152

UTILITY SERVICES
Utility Services offers water purification related solutions for Industrial and Commercial
segments. It has the expertise, resources & experience to manufacture high quality RO
based water purification plants with capacities of 200 litres per hour to 10,000 litres per
hour. The company has the technology expertise to treat contaminated water laden with
bacteria, viruses, total dissolved solids and other impurities like lead & arsenic, while
ensuring utmost purity & availability of safe drinking water.
Page 133 of 152

73. Solar Operated RO Plant
Team Details
J Anand Anil Kumar | Nataraja C B | N Sree Rama Murthy | Srinivas S | Satyanarayana MV
Challenge:
Business Unit – Utility Service has installed and commissioned RO plants in many villages
across PAN India. In few villages we identified that plant operational hours are getting effected due
to non-availability of electricity during day time. Earlier we designed, installed and commissioned
solar operated RO /UF plants with battery and invertor system (Hybrid system) to run Single phase
RO Pumps. We found many service& Maintenance issues with batteries and invertor system. The
challenge was to provide a efficient RO plant for providing safe drinking water to villagers.
Improvement:
To overcome the challenge, we considered the
power requirements and designed solar panels.
The solar panel will charge the batteries. During
day time RO plant is operated with DC power,
which used solar energy for operating the
plants. During night or when intensity of light is
very less the plant operated with AC power.
We ensured that the Pumps are designed to
operate both with DC(Solar) and AC grids.
Benefits:
• Community Satisfaction
Page 134 of 152

CORPORATE OFFICE
Companies have too many experts who block innovation.

True innovation really comes from perpendicular thinking.
-Peter Diamandis
Page 135 of 152

Innoways Celebrations @ Head Office
Page 136 of 152

74. Online Insurance claim Tracker
Team Details
Soumya A Kumar | Jyoti Dubey | Srilatha Cherukuri | Srinivas Iyer P A| Muralidhar B V
Challenge:
Processing of Insurance claims required proper documentation and coordination between site
personals and Business Units. As per the present process the documentation is done through excel
and these needs to be updated as and when the documentation is provided. Timely processing the
insurance claims with relevant documentation was the challenge. Further it was difficult to tracking
the claims & setting reminders for alerting for claim follow-up was the challenge.
Improvement:
We developed in-house IT based Insurance claims and monitoring system. The system captures and
tracks the information from the lodging the claim till its closure at various stages involved in Insurance
on real time basis.
Benefits:
• Online tracking of Stage wise claim status
• Reduction in cycle time and man hours spent
• Automatic alerts & on time information from Insurance Desk
• Data Accuracy
Page 137 of 152

75. Bank Guarantee Automation
Team Details
Mirza Mohd Fauwaad Baig | A V R Srinivasa Sharma | Ashok L | Sai Kiran D | Lakshman Rao R V
Challenge:
The volume of the Client BG has increased substantially i.e. from 1,318 Crs in Nov 2008 to 5,310 Crs
in Nov 15. Participation in tenders being quoted by TPL (both national and international) has
increased. The client BG was handled from HO only by 1 or 2 person with responsibility of
maintenance of accurate records and providing timely reports/MIS to all BU’s/FC’s. All the information
is maintained in Excel and was purely a manual activity, engaging one resource for the entire day,
throughout the month. It was a person centric activity and not process centric
Improvement:
We have developed a package to automate the Bank Guarantee the entire process of opening,
extending and closure of client BGs is linked to ERP.
Benefits:
• Data Accuracy and transparency
Page 138 of 152

76. Reconciliation Statements
Team Details
P Srinivas Uday Kiran | Balasubramanian R | Chandra Mohan T S S R |
A V R Srinivasa Sharma | Vasudeva Prasad T | Ujwal Kumar M P
Challenge:
About 260 site offices in India and abroad used to send the Bank Reconciliation statements (BRS),
bank statements, cash certificates and bank confirmations (only for annual audit) through mails and
couriers particularly for every quarter audit. With the growing business, it was getting increasingly
difficult to meet tight timelines in every quarter audit.
As cash and bank balances verification are the first task of the Auditor, The challenge was collating
the information received manually from all sites in time to complete the audit as per the schedule.
Improvement:
Developed a data base system, where in all the site accountants would provide data and upload in the
TPLnet
Benefits:
• Faster data collection
• Accuracy of data
• Standardization of data
Page 139 of 152

77. PF payment process improvement
Team Details
Ramakrishna D | Srilatha Cherukuri | Kalyani G V N | Ashok Kumar Shaw | Srinivasu M S
Challenge:
All payments were released on individual basis (employee/Labour wise) through separate cheque
printed for each settlement using the PF software. The volume of cheques printed are quite high and
getting the cheques signed by two authorised signatories and finally dispatching the same with
covering letters to various locations used to take lot of time. In view of large scale operations of the
company, spent one full dedicated approximately 10 man days were spent towards release of
employee/Labour PF Settlements and PF Loans.
Improvement:
Initiated and implemented "Bulk Settlements"(one to many) process for employees/labour
settlements. . PF settlements are uploaded in bulk in PF software with emp code, name and bank
account details. Csv file is generated from PF software and the same is uploaded into bank. The same
are authorised through net banking.
Benefits:
• Timely settlements
• Cost saving
Page 140 of 152

78. Cycle time reduction in PF reconciliation
Team Details
Ramakrishna D | Srilatha Cherukuri | Kalyani G V N |Srinivas Iyer P A | Ujwal Kumar M P
Challenge:
We receive PF data from approximately 100 project sites for about 2500 subcontractors and 1500
departmental gangs. On a monthly basis we get PF contributions for approximately 12000 to 15000
labours in the prescribed format shared by us in excel. The PF data received from various locations is
consolidated and member wise contributions are uploaded in PF Software. PF recoveries from
casuals and subcontractors are being booked in ERP at respective sites/ROs. To reconcile the
recoveries made in ERP against the contribution made to trust, the entire data is maintained manually
in excel. This process is taking lot of man hours, since the volumes are quite high. Maintaining the BU-
wise, Project-wise and Subcontractor-wise is a laborious activity and also time consuming. This
activity has become difficult to monitor manually on month on month basis.
Improvement:
We had discussed with IT team to find a solution for the above issue, which will help us to reduce
manual work hours spent to complete this activity. IT team has developed an in-house package which
will automate the PF reconciliation and also reconciliation statements are generated and
automatically mailed to concerned project personnel. We upload all PF payments received from
various project sites and recoveries extracted from ERP through data loader in software provided by
IT with minimal manual intervention. Upon updating in in-house package a detailed SBU wise, SBU
Project wise and SBU Project vendor wise reports are generated and mailed to the concerned.
Benefits:
• Timely compliance of statutory requirements
• Cost saving
Page 141 of 152

79. Improvement in Cash Management
Team Details
B V Muralidhar | Balasubramanian R | Jagadeesh A |Srilatha Cherukuri | Vasudeva Prasad T
Challenge:
We have been generating RTGS letters towards fund transfer to Project Sites, RO’s, SBU-QS and our
internal banks through TPL Net (which is out of ERP) and preparation of payment voucher manually
through Excel. For these transactions F&A used to spend more time towards accounting of the
transactions in ERP, generation of RTGS letter through TPL Net (out of ERP) and preparation of
manual payment voucher. There was no linkage between accounting & generation of RTGS letters
are two separate activities resulted into duplication of the work in both ERP & TPL net for the same
transaction. No maker & checker concept was available.
Improvement:
In view of very large scale of operations and also aimed at reducing cycle time in catering fund
transfers to project sites, RO’s & SBU-QS in day to day operations at Corporate Office it is considered
as appropriate to initiate & implement generation of RTGS letters & Payment Vouchers through ERP
to meet with the increased volume of operations.
Benefits:
• Reduction in cycle time
• Cost saving
Page 142 of 152

80. Sale In Transit Forms Tracking
Team Details
Krishnan K S | Rajendra Kumar Sharma | S.V.S Suryanarayana Rao
Challenge:
The proposed SIT Application (Sale in transit Invoice Tracker) is aimed to track the invoices for which
the C forms is not received / C form received for short value / C form received for excess value. It can
also be useful to track the C form status i.e. Pending / received / if received, Submitted to the
department or not etc. Currently, the tax team at HO track it using a spread sheet which has
limitations. Retrieving the historical data, especially for periods for which assessment is completed,
separate file has to be maintained to customise the requirement, resulting in confusion and time lags.
Especially in current scenario, if E-I/E-II forms are being received during a period of time, for each
receipt a separate statement to be maintained in MS Excel which lead to creating of more number of
working files for a single year’s SIT sale.
In the proposed tracker, customisation of reports is possible apart from making retrieval of data easy
and user friendly.
Reason for Failure
It was kept hold due to development and implementation of other projects like Way Bill Tracking,
Insurance and Travel
Benefits:
• Proposed Tracker would be helpful to follow up for timely collection of statutory forms
• Benefits of full tax exemption in SIT can be availed.
• Duplicity of data
Page 143 of 152

81. Process Repository
Team Details
Ramesh Vempati | Prasanna Venkatesan | Senthil Kumar P
Challenge:
Tata Projects has rolled out Enterprise Process Manuals as a part of Process Mapping exercise.
The objective of EPM is to establish and follow standard process across the organisation for process
efficacy. As per the process architecture followed at TPL, there are around 150 standard operating
processes. These processes need to be managed on real time bases so that latest process and
relevant formats are available to 60 plus locations. Providing accessibility of latest process
documents to process owners & intended users for easy Storage and tracking of all the processes &
formats was a concern.
Improvement:
We have created a folder structure in line with our EPM
classification in TPL Intranet portal. As per the EMP
structure, the processes are structured in four levels, L1,
L2, L3 and SOPs. L1 processes consist of respective
L2s, L3s & Standard Operating Procedures. As per the
process documentation, in each folder the relevant
process sheets and formats are uploaded. The user can
retrieve these documents online and use them for their
respective work.
Benefits:
• Easy access to the process across the organisation
• Easy tracking and monitoring of the processes.
Page 144 of 152

82. Methodology for Process Maturity
Team Details
Senthil Kumar P | Ramesh Vempati | Prasanna Venkatesan
Challenge:
Tata Projects has rolled out Enterprise Process Manuals. The objective of EPM is to establish and
follow standard process across the organisation for process efficacy. As per the EMP structure, the
processes are structured in four levels, L1, L2, L3 and SOPs. L1 processes consist of respective L2s,
L3s & Standard Operating Procedures. The processes are defined with objective, flow chart and
efficiency & effectiveness measures. These processes need to be followed by all. The challenge was
measuring the process maturity.
Improvement:
We have customized and developed a fitness rating criteria in a scale of 1 to 5 for measuring the
process maturity. Each rating has defined with set of criteria as follows,
Rating 1 - Approach is known to those who are working in it. No documentation or process
standards exist.
Rating 2 - Documentation of the process exists to include flowcharts, standards, checklists,
procedures, training Manuals, etc.
Rating 3 - Process Measures are reported in MIS and reviewed at defined forums.
Rating 4 - Process is deployed across the organization i.e. > 85% compliance.
Rating 5 - Process is improved through systematic E&I approach. Process is compared with
Benchmarks.
On the bias of desk top audit, a ratings based on the above criteria is provided to the L3 Level
Processes. The average of these sub-processes ratings forms the maturity of L2 processes. The
average of these L2 level process forms the L1 level maturity rating.
Benefits:
1. Process Efficacy
2. Process Improvements
3. Employee Engagement
Page 145 of 152

83. Hybrid Model for Rate contract
Team Details
Anjaneya Murthy | Satyajit Dutta
Challenge:
For any EPC company, it is very challenging to identify and solve logistics challenges in the
movement of a wide range of commodities and engineered equipment. “Km Basis” and “Point to
Point”, these two models are widely accepted and used by Industries. TPL also followed “Km Basis”
model prior to 2010 and to overcome challenges of difference of opinion between TPL and
Transporter, opposition from Transporter union, Rate was same for all zones and irrespective of the
distance resulted in transporters were more inclined to place vehicle for long distances over short
distance routes, which were addressed through “Point to Point Basis”. However as the business
growth following were the key challenge for logistics;
• New projects are coming up, for each new destination, rates have to be obtained afresh from
transporter, which is time consuming and causing delay in execution, involving internal
approvals etc.
• For pre-bid support and also while finalization on vendors (for inclusion of transportation in
Vendor’s scope), SCM team members need quicker reference/data for transportation rates for
several destinations, mostly being new destinations. Since these destinations are more, it
involves long time to get rates from Transporters, leading to delays in decision making.
Improvement:
We categorize our total operations into five distinct areas as follows;
1. Loading and unloading point distance is “Below or up to 300 Kms” for Full Load
2. Loading and unloading point distance is “Above 300 Kms” for Full Load
3. Part Load and Heavy Commercial vehicles (HCV up to 7MT)
4. Loading/Unloading at Extreme Regions Like Kargiletc
5. Loading/Unloading at North Eastern States
We developed a process with criteria and methodology for fixing the rates for a particular route and
vehicle. This includes Over This model also caters over dimension material up to a specific limit,
which covers approx.80% of total ODC movements.
Benefits:
• Faster decision making
• Cost saving
• Loyalty of Logistic vendor
Page 146 of 152

84. Cycle time reduction in PF reconciliation process
Team Details
Srilatha Cherukuri | Kalyani G V N |Srinivas Iyer P A | Ujwal Kumar M P
Challenge:
We receive PF data from approximately 100 project sites for about 2500 subcontractors and 1500
departmental gangs. On a monthly basis we get PF contributions for approximately 12000 to 15000
labours in the prescribed format shared by us in excel. The PF data received from various locations is
consolidated and member wise contributions are uploaded in PF Software. PF recoveries from
casuals and subcontractors are being booked in ERP at respective sites/ROs. To reconcile the
recoveries made in ERP against the contribution made to trust, the entire data is maintained manually
in excel. This process is taking lot of man hours, since the volumes are quite high. Maintaining the BU-
wise, Project-wise and Subcontractor-wise is a laborious activity and also time consuming. This
activity has become difficult to monitor manually on month on month basis.
Improvement:
We had discussed with IT team to find a solution for the above issue, which will help us to reduce
manual work hours spent to complete this activity. IT team has developed an in-house package which
will automate the PF reconciliation and also reconciliation statements are generated and
automatically mailed to concerned project personnel. We upload all PF payments received from
various project sites and recoveries extracted from ERP through data loader in software provided by
IT with minimal manual intervention. Upon updating in in-house package a detailed SBU wise, SBU
Project wise and SBU Project vendor wise reports are generated and mailed to the concerned.
Benefits:
• Timely compliance of statutory requirements
• Saving man hours
Page 147 of 152

85. Welfare Facility - CRECHE a Volunteering Initiative
Team Details
A V S V Narasimha Sarma | Mangaraju Kapaganti S
At the Mantri webcity–III project we have migrant workers. We witnessed that the labourers are
bringing their children alongwith them to the project site of work. We have started a Crèche at our
workers colony by allocating a class room with adequate ventilation, Lighting, Black board and wall
charts for teaching. We appointed care takers who will teach these children basic education
Page 148 of 152

NEW BUSINESS MODEL (SELECTED)
S.No. Team Details Project Title
Mr. S K Chaitanya Varma Y Waste to energy

1.
Mr. B S N Vasudeva Rao
Mr. Fakiresh Duragappa Jangali

Application of
2. Mr. Sundar Chandramouli
Polycae hallow block structures
Mr. Sandeep Tribhuvan Navlakhe
3. Mr. Abhijit Nandi Manufacturing potable water

O&M services for
4. Mr. Prakash K
business diversification for SBU-QS
Page 149 of 152

Best Innovation Award 2015
Bubble Deck Technology
Page 150 of 152

Innoways Project Teams Recognition by SLT-2015
Six Innoways projects were recognised by COO & SBU Head-Industrial Infra. The teams presented
their case studies on improvement and innovation to the SLT on 21st August 2015 at Hyderabad.
TAKE
UP
S.No. Member Project Title Project Location

Bibhuti Bhusan Bisoyi
Harshvardhan Pathak Application of
1 Latiful Pasha Kalinganagar & Angul
Bubble Deck Technology
Abhishek Chandra
Susant Kumar Parida
Surya Bhagavanulu P
Parasuram K Application of Kalinganagar
2 Kneading in compaction
Chakrapani T Construction
Krishna Kumar S
Santanu Mukherjee
Tapan Kumar Das Improvement in JSPL, Angul
3 shuttering framework
Latiful Pasha Construction
Soma Sundara Rao N
Jitendra Kumar Majhi
Hari Jana Rajasekhar Parapet anchorage for Kalinganagar
4 wall painting
Vishal Mamraj Dongare PG
Ravi Kumar M
Amrit Dural
Pankaj Kumar Srivastava Jharsuguda -
Manoj Kumar Jena Retractable block for
5 Dharamjaygarh
Tushar Parashar derrick erection
TL, T&D
Guru Swamy P
Bhim Singh Farthiyal
Vijay Kumar Tiwari Ranchi -
6 Lav Kumar Sharma Wheel Protection guard Dharamjaygarh
Tabrez Hassan TL, T&D
Ajay Kumar Gupta
Page 151 of 152

NOTES
Page 152 of 152

Case Study during Tata Sustainability Month
Registered Office: “Mithona Towers-1, # 1-7-80 to 87, Prenderghast Road, Secunderabad-500003, Telangana, India
EPABX: # 91-40-66238801, Fax: +91-40-66172535, Email: becs@tataprojects.com, Website: www.tataprojects.com
For more details, contact:

P Senthil Kumar Cyril Danthi A Raj Mohan
+91-40-66238973 +91-40-66238975 +91-40-66238971
+91-9848052426 +91-9505509099 +91-40-9948037330
psenthilkumar@tataprojects.com cyrildanthi@tataprojects.com rajmohan@tataprojects.com

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Mission

To make the world

I am sure Innoways will enable innovative culture in the journey of excellence.

Let us stay committed in our journey of continuous improvement and excellence.

innovation & improvement projects that were

as knowledge sharing. These improvement

CoP Implement End

Sanjeev Kumar Sanjay Kamat K Sunder Rao

Subrata Roy Bellamkonda Srinivasa Rao Pratosh Saxena

Srinivas C Sesha Anil Y Ramesh P

A V S Prakash Rao Eswara Prasad C R Rahul Paliwal

Manohar Sundaresan Venkatesh M P Senthil Kumar

Harsh Wardhan Pathak Rajmohan Awadhiya Jaikishan Hemant Chourasia

Vishvesh Tyagi Vasudeva Rao B S N Sree Ram Prasanna K

Cyril Danthi Manikyala Rao G S

Without continuous growth and progress, such words as

Business Unit - Power Generation, offers customized turnkey solutions

We cannot solve our problems with the same thinking we used

Everything can be improved.

If I had an hour to solve a problem, I’d spend 55 minutes thinking

Kaizen means on-going improvement involving everybody,

Never be afraid to fail. Failure is only a stepping stone to improvement.

Business Unit - Transmission & Distribution is a leader in setting up Transmission

BU-TRANSMISSION & DISTRIBUTION

Whenever I go on a ride, I'm always thinking of

I think frugality drives innovation, just like other constraints do.

Continuous improvement is better than delayed perfection

Excellence is not a destination; it is a continuous journey that never ends

"Quality depends on good data.

BU-METALS & MINERALS

"Excellent firms don't believe in excellence -

Almost all quality improvement comes via simplification of

“It is not necessary to change. Survival is not mandatory.”

The world we have created is a product of our thinking;

Our future growth relies on competitiveness and innovation, skills

BU-OIL,GAS & HYDROCARBON

Without change there is no innovation, creativity, or incentive for improvement. Those

Innovation happens because there are people

BU-CONSTRUCTION & ENVIRONMENT

“Continuous improvement is better than delayed perfection”.

“Innovation is the central issue in economic prosperity.”

Jig is designed and fabricated at site from available materials

We studied the drawings & cutting plan of plates.

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Practice without improvement is meaningless

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“Strive for continuous improvement, instead of perfection”.

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“Once you choose hope, anything’s possible.”

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Shuttering Usage Ratio = Total quantity of Shuttering billed (certified) x

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