Johnson Matthey Industrial Report
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30 August 2019 - 17:00, by , in PGDM, Comments off

Johnson Matthey is a Chemical processing plant headquartered in UK, and located in various countries. It has completed over 202 years of delivering technology that provides a cleaner and healthier world. It gives positive solutions by providing cleaner air, enabling food supply, pharmaceuticals and energy storage. Their vision is to optimize the natural resources thus enhancing the day to day performance.

Policies

  • Zero metal policy
  • Zero liquidity policy

Following the Safety rules and regulations at JM

  • Follows a metal free policy
  • No sharp objects are allowed in plant
  • Photography is prohibited
  • No garbage littering
  • Wear proper safety gear, aprons, goggles, shoes before entering into the plant.
  • Incase  you are  an insider  you are required  to have proper permit  to bring your equipments in order to work with the staff.
  • You need to know full information in case of any hazards pertaining to your job.
  • Working in safe condition is the utmost priority.

The emergency is declared through the siren.

  • Onsite siren for individual plant
  • Total site siren in case of major emergency
  • All clear siren (For 10 sec ON,10 sec OFF)

OHC (Occupational Health Centre)

All MNC Companies have OHC department. Wellness programs are organized by Dr Varun. It is branch of medicine that takes care of the working employees by giving them:

  • Primary health advice of employees (500)
  • Emergency care of factory in Hazardous areas
  • Health service (medical surveillance -bio monitoring)
  • OHC is mandatory for hazardous industry mental wellness being index (maintaining work life).
  • Out of 500 employees in Taloja plant,60 are first aid trained employees.
  • For the mental wellbeing programs of the company sessions on yoga, laughter therapy is conducted.

Raw Material

The  principle  raw material  they use are nickel.  Also, they use platinum,  palladium and cadmium, Sunflower oil NiSO4 for their processing.

Plant Etiquette

Fire Network system

  • CO2 Extraction 171m3 per hr
  • Fire Water tank – 320m3 each
  • It can fight fire for about 4 hrs.
  • Process H2O tank – 510m3

Storage area for petroleum

  • Class B- 15.00 KL
  • Class C- 30.00 KL
  • Foam chemical used for fire fighting

Maintenance engineer is Mr. Mahesh Kamble who showed us in and around the plant.

A  boiler  is a closed  vessel in which  fluid (generally water)  is heated. The fluid does  not necessarily boil. The heated or vaporized fluid exits the boiler for use in various processes or heating applications

There are three types of boilers.

  1. Bagasse boiler: – A typical application for biomass power generation is utilization of the bagasse in sugar factory. The sugar cane is crushed first and squeezed in a mill to extract the sugar content. The remaining fibrous is called bagasse, and is used as fuel for power boilers. The sugarcane burnt is 3.5 ton at 12000C.Generally used for generating steam.

Fuel type: Bagasse Briquette

Max Working pressure: 10.55 kg/cm2

Max Operating pressure: 9kg/cm2

2. Combi boiler: – A combination or ‘combi’ boiler is both a high efficiency water heater and a central heating boiler in a single compact unit. Combi boilers heat water directly from the mains when you turn on a tap, so you won’t need a hot water storage cylinder or a cold-water storage tank in the roof space. Its capacity is 3 ton.

3.Fuel boiler: – All  boiler  systems employ  a fuel mechanism  which basically comprises  of the apparatus needed to supply fuel for heat generation. The design of the apparatus in use varies according to the kind of fuel employed in the system. It uses furnace oil at 180-1900C. Variety of fuels is available for application in boilers, each having different chemical properties. Major chemical characteristics of boiler fuels include:

  1. Natural Gas
  2. Propane
  3. Oil
  4. Electricity
  5. Solids Fuels like Coal & Wood
  6. Renewable Energy

If  low water  or extra low  water ceases foreign  safety is required which  is done through steam/safety control.

Air compressor – dry gas – supplied to plant

Liquid nitrogen

  • Temperature -1860C
  • Capacity- 6000L {5.8Kg Working Pressure}
  • 100% concentrated
  • Safety control 15kg RDI

Pressure is balanced

LPG Tank

It has 8-9 metric ton capacity

You need Chief Controller of Explosives (CCOE) license to use the tank

Neutralization

  • ETP- Efficient Treatment Plant
  • 8-9 setting chamber, pH=1-7.5
  • ETP Settler Hydrogen Yard
  • Hydrogen gas storage,900-cylinder license

 

There are body static charge panels, we have to put both our hands-on panel to remove static charge from the body.

Bagasse boiler

Fuel boiler

Manufacturing Process Overview

  • NiSO4 and soda ash solution are mixed to make Nickel catalyst
  • EHS Performance (Room for meeting & planning)
  • It monitored via monthly Audit
  • Plant layout
  • Tabular-process layout

Quality control

  • Nickel catalyst is used in making edible oil, soap industry by process of Hydrogenation.
  • C=C converted to saturated carbon
  • 3.5-4.5 metric ton production
  • 50-ton minimum stock material kept in inventory which lasts for 12-13 days.
  • 80% is exported and 20% is used for local purposes.

Warehouse

  • 175kg MSD pack
  • Materials are handled by means of force cliff.
  • The materials are kept on pallets which makes it easier to lift.
  • Nickel is used majorly with lot of variations.
  • For radiation source license and BARC permission is taken.

Supply chain overview

It was explained by Mr. Vishwanath Kamble.

Presentation of Johnson Matthey by (Sr. Manager Mr. Satish)

Four parts to strategy

  1. Science
  2. Customer
  3. Operations
  4. People

JM has over 14000 employees working in over 30 locations across the world. Out of which 14 are in Europe and the rest are in Asia, North America etc.

It has revenue of 14122 million € approx. worldwide.

The process flow is

 

 

 

 

 

Stages in Supply chain

  1. Cashflow
  2. Material flow
  3. Information flow

The products are made on made to order basis and sometimes on stock. It is 90% customized effecting the lead time.

Major Sales in: – Telangana, Andhra Pradesh

Customers: –

  1. Active Pharmaceutical Ingredient (API)
  2. Drug manufacturing
  3. Pharmaceutical companies

 

Focus: –

  1. Fuel cells and battery technology which are sustainable
  2. To reduce waste to minimum

 

Manufacturing  one product (Nickel)  and all utilities, chemicals,  gases, raw material are supplied from vendors.

Core values

  • Creating the right culture
  • Protecting people and plant
  • Acting with integrity
  • Working together
  • Innovating and improving
  • Owning to what we do
  • Sustainable technology-less impact on others

Biggest utility plant is in Manesar, Delhi.

Sales & production team plan

  • Receive orders through sales team
  • Schedule mentioned
  • Further Arrangement
  • Average production 100 metric ton per month
  • Inventory not more than 15 metric ton

 

Issues

Vessel issues, Transport, Vessel booking not done.

CONCLUSION

As this was our first industrial visit, we got a practical insight about a manufacturing plant. We learnt about the production and supply chain in a chemical plant right from each stage process to  the distribution till the final product. Thus, we successfully completed our first trip to Johnson Matthey, Taloja.