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1 BAL-Waluj Bajaj Auto Ltd. Aurangabad Division Welcomes you all Energy Management 2013 Slide 2 2 BAL-Waluj i.Company profile ii.Manufacturing process iii.Energy Conservation cell iv.Scope v.Energy Indices /Benchmarks vi.Energy Conservation Methodology vii.Energy Conservation Approach viii.Energy cost loss Tree ix.Innovative Projects x.Other Encon Projects a.Electrical b.Use of renewable energy c.Thermal xi.Environment & Carbon Reduction xii.Utilization of waste x.Results xi.Sustenance xii.Future Project xiii. Achievements Contents Slide 3 3 BAL-Waluj Bajaj Auto Limited - The flagship Company of the Bajaj Group. Current world market standing Ranked as the Worlds fourth largest two & three wheeler manufacturer Automotive Electrical & Home Appliances Steel & Engineering Finance & Insurance Power & Infrastructure Bajaj Group The Bajaj group was established in 1945 by Shri. Jamanalal Bajaj, a close associate and disciple of Mahatma Gandhi. He believed in sound and fair business practices based on respect for customers and integrity Bajaj remains committed to these VALUES Company Profile Slide 4 4 BAL-Waluj Chakan Plant - Tries and tests various new concepts. Manufacturing of High Performance bikes. Pantnagar Plant Plant and its vendors in the same premises. Plant produces Discover, Boxer & Platina range of motorcycles. Waluj MC Plant - Manufacturing of 2-wheelers Caters to the major export needs. Waluj CV Plant - Manufacturing of 3-wheelers & parts thereof. Bajaj Auto Ltd- Corporate Office Akurdi, Pune Manufacturing locations Company Profile Slide 5 5 BAL-Waluj Approach for Improvement Key Management Index Key Performance Index Key Activity Index Company Vision Company Mission TPM ISO 9001 ISO 14001 OHSAS 18001 ISO 50001- Initiated Slide 6 6 BAL-Waluj Process Flow Chart Total Number of Equipments - 1840 nos. Press & Fab. Vendor parts Aluminium Shop Steel Shop Heat Treatment Central Gear Shop Paint Engine Assly Vehicle Assly Export Dispatch Domestic Dispatch Slide 7 7 BAL-Waluj Flow Chart - Energy Conservation Program Company Vision/Mission Plant Vision/Mission Shop Level Target Encon ProjectsEnergy Manager Management Review Budget Allocation Execution & Monitoring Slide 8 8 BAL-Waluj Energy Conservation Cell MachineShops Paint Shop Press & Fab Dept. Head Div Head Energy Mgr. Assembly Div Head CGS/HT Utility Energy Captains Plant Head Dept. Head Monthly Review Fortnightly Corporate Bi-Monthly Review Weekly Daily Slide 9 9 BAL-Waluj Time spent by Senior Executives in various functions Sr No.FunctionsAverage time spent % 1Manufacturing excellence TPM- Review/Implementation 25 2Green Manufacturing Initiatives 20 3Technological & Developmental activities 15 4New Products 15 5Quality Management systems 10 6Supply Chain Management 10 7Administrative Issues 5 Sr No.Review Mechanism Level 1Plant HeadMonthly Level 2DIV HeadFortnightly Level 3Energy ManagerWeekly Level 4Energy CaptainDaily Slide 10 10 BAL-Waluj Encon Strategy Eliminate wastage of Resources by maximizing Productivity of all operations & Processes Adopt in the faster pace for Deployment of all ideas in all areas of Business Thru Maximizing Involvement of People Focus on accomplishing investment projects, with Payback less than two year at faster pace & its horizontal deployment Procurement of Energy Efficient Equipment for new installation Earlier- Conserve + Preserve + Reserve Now- in addition to above: Reduce + Reuse + Recycle Share the best practices among employees, vendors,suppliers & other partners Implement More & More ENERGY KAIZEN Slide 11 11 BAL-Waluj Working on Legacy system Energy Conservation Techniques- Localized control Human Dependent systems Energy Conservation Techniques- Localized control Human Dependent systems Technology Up gradations Energy Optimization System Auto controls Waste Minimization Micro Level Monitoring Judicial Energy Utilization Harnessing Solar & Wind Energy Carbon Emission Reduction Sustainable Business Growth Green Factory Micro Level Monitoring Judicial Energy Utilization Harnessing Solar & Wind Energy Carbon Emission Reduction Sustainable Business Growth Green Factory Improvements Year 1985-1997 1998-2001 2002-2009 2010 -2015 Approach towards Encon Slide 12 12 BAL-Waluj Energy Unit Base Year AchievedTarget 2003-042004-052005-062006-072007-082008-092009-102010-112011-122012-132013-14 ElectricityKwh/veh67.5449.3145.8142.9936.7234.931.4525.4122.6121.1520.1 LPG Kg / veh 2.532.752.42.82.42.22.11.771.451.331.26 Water m 3 / veh 0.890.650.620.580.540.520.410.350.410.270.25 Energy Consumption per unit of production Specific Energy Consumption SEC Reduction % Sr.EnergyIn 10 Year sIn Last 3 YearsIn last year 1Electrical ( Kwh/Veh)69%32%6.41% 2Fuel ( LPG) ( Kg/Veh)48%38%7.14% 3Water ( Cu.m /Veh)69%34% Slide 13 13 BAL-Waluj Specific Energy Consumption-Benchmark Sr.EnergyBAL, WalujNearest competitorGlobal 1Electrical ( Kwh/Veh)21.1524.55NA 2Fuel ( LPG) ( Kg/Veh)1.332.6NA 3Water ( Cub.Mtr/Veh.)0.270.41NA 4Diesel (Ltr/Veh)0.092.3NA No Standard Benchmarks are available for Automobile sector, However, we are setting our own internal targets as: Min 5 % Reduction in specific energy consumption wrt last year Slide 14 14 BAL-Waluj Stratification of Energy consumption Electrical Energy consumptionLPG Energy consumption Slide 15 15 BAL-Waluj Sr. No. Activity MethodologyTools used 1Audit To identify areas of energy conservation potential Weekly / Monthly data through Pie charts & brainstorming 2Analysis To identify equipments & Processes where energy conservation is possible Daily/weekly KWh, pressure, flow,volume etc.recording through bar charts,graphs 3Action Plan Identify activities for individual equipments with time frame Resource planning & activity charts 4 Implementation Action for procurement & implementation 6W2H Way Activity Charts 5Evaluation To analyze plan V/S Actual Gap Analysis & countermeasures 6Sustenance To Monitor the resultsInternal Audits Energy Conservation Methodology Slide 16 16 BAL-Waluj Electrical Energy Operational Control Loss Reduction / Elimination Sr.Idea 1 Transmission Loss 2Distribution Loss 3 Power Factor & Harmonic loss 4Light Power Loss 5Unwanted illumination 6Compressed air energy 7Inefficient Equipment 8Over Rated equipments Sr.Idea 1 Metering & Monitoring 2Auditing 3Energy Captain 4No Production on Off days Sr.Idea 1Biogas for Heating 2Solar Lighting 3Wind Power Generation 4Solar Water Heating 5LPG Heating 6Magnetic Energy Technological Improvement Sr.Idea 1LED/CFL/Induction Lamps 2Efficient Motor/Pumps 3Screw Compressor 4 Ceramic to Metal tube heater 5 Aluminium Pipes for compressed air.air 65 Star rating equipments 7VFD for high HP Motors 8Use of Soft Starter Loss Elimination Alternate Source Efficient Equipment Energy Conservation Methodology & Idea Slide 17 17 BAL-Waluj Reduction of Electrical Energy Consumption Per Vehicle Sr No. ApproachIdea 1 Eliminate wastage Switched off sodium vapor lamps of 250 watts in non moving areas Provided occupancy switches for lights in warehouse Switched off Hydraulics during machine idle time. 2Optimization Use of VFD for compressors at set pressure (70 psi 2) Optimization of motor size Task lighting 3 Energy Efficient Equipments Installation of Energy efficient motors for compressors(96.3 %) Installation of Energy efficient screw compressors (95 %) Process equipments 4 Alternate Methods Use of LPG heaters instead of electrical heaters. Use of 150W CFL/Induction Lamps in place of 250 W HPSV lamps Process change 5 Usage of renewable energy Installation of natural air draft in place of electrical exhaust fans Installation of transparent roofs/ Light Pipes for shops. Utilization of solar energy for heating /Lighting /Power generation ENCON Idea Table Slide 18 18 BAL-Waluj Reduction of Compressed Air Consumption Per Vehicle Sr No. ApproachIdea 1 Waste elimination -Arresting Leakages Air Leakage data collection through audits from shops Air leakage data through FAD tests. Efficient usage of compressed air Shut off valve during non working hours 2 Optimization of compressed air supply providing localized compressors Separation of air headers for Low pressure & High pressure requirement Rerouting & Resizing of compressed air headers Use of Air Boosters for High pressure application Use of Aluminium pipes for air distribution in assembly shops 3 Elimination of compressed air usage Use of Electrical operated tools ENCON Idea Table Slide 19 19 BAL-Waluj Fuel (LPG) Energy Operational Control Loss Sr.Idea 1 Heat Loss through oven skin 2Heat Loss Through Flue Gases 3Heat Loss to Jigs & Fixtures Sr.Idea 1 Metering & Monitoring 2Auditing 3Energy Captain 4No Production on Off days Sr.Idea 1Solar water heating 2Use LNG Technological Improvement Sr.Idea 1Direct heating 2Combustion Efficient Burner 3Low Temperature process 4Cycle Time Optimization Loss Elimination Alternate Source Efficient Equipment Energy Conservation Methodology & Idea Slide 20 20 BAL-Waluj Reduction of LPG consumption per Vehicle Sr.noApproachIdea 1Eliminate wastages Eliminate of heat loss through Furnace /oven skins-Improve insulation 2Optimization Tuning of burners Process change 3Reuse of waste process heat Use of low temperature flue gases heat energy ENCON Idea Table Slide 21 21 BAL-Waluj Innovative projects Slide 22 22 BAL-Waluj 132 KV supply from MSEDCL 132 KV supply from MSEDCL GTL Limited Energy meter MSEB Metered consumption MSEB Metered consumption Plant Metering Distribution Loss Sr. Key Initiative Saving Achieved 1 Optimization of transformer loading 4.6 L Kwh 2 Switch off standby distribution transformer through isolation switches 3 Overhauling of distribution transformers 4 Power Factor Improvement by APFC 5 Harmonic suppression by active filters Sr.Key InitiativeBenefit 1 Electronic Energy meters Idea generation, Prioritization of Energy work 2 Data logging system ( Cockpit) 3 Feedback Transformer(CT/PT) Calibration Eliminate Metering error + = MRS Shop Wise Energy meters Distribution Loss reduction Innovative Project -1 Slide 23 23 BAL-Waluj Reduce Losses of distribution network Sr. Actions for loss reduction ActivitySavingTotal savingInvestment 1 Over hauling of distribution transformer MS plate at secondary terminals replaced with SS plate 0.5 Kwh/Hr/ Transformer 1.27 L kwh/YrRs.6.23 L 2 Switching off standby transformers Standby transformer switched off with Isolator switch on transformer keeping 11 Kv cable charged-8 Nos. 2 Kwh/Hr/ Transformer 2.1 L Kwh /YrRS.4.8 L 3 Load balancing ( between 50 to 70%) of transformers & switched off 4 Nos. transformers Distribution Transformer-2 MVA( 11 KV/433 Volts) 29 Nos. in Waluj Plant Innovative Project -1 Slide 24 24 BAL-Waluj Reduction of Inductive load losses Power Factor /Reactive power compensation at Press & Fabrication shop Unity Power Factor Ensures reduction in distribution loss & get Incentives. Balanced & stable Load can be catered using switched capacitors & can be contactor or Thyrister based. Capacitors contributes in amplifying harmonics in system due to resonance. Unbalanced load are large single phase loads distributed on 3 phase system with lot of diversity Two Phase MIG welding machines are in use in large no. This is typical form of unbalanced load. As a result KVAR requirement differs in each phase & also changes very quickly. It is not possible to compensate such requirement with simple switching capacitors. Innovative Project -2 Slide 25 25 BAL-Waluj Reduction of Inductive load losses Innovative Project -2 Slide 26 26 BAL-Waluj Power Factor /Reactive power compensation at Press & Fabrication shop Reduction of Inductive load losses Before We can see KVAR requirement varies from 75 KVAR to 200 KVAr Current varies from 500 A to 1200 A Different in different phase Typical unbalanced load Power factor also varies from 0.6 to 0.95 & correction required is also unequal Innovative Project -2 Slide 27 27 BAL-Waluj After Power Factor /Reactive power compensation at Press & Fabrication shop Reduction of Inductive load losses Innovative Project -2 Slide 28 28 BAL-Waluj Reduction of Inductive load losses Innovative Project -2 Saving : 1.26 LKwh/ Yr Investment : Rs. 15 lacs Slide 29 29 BAL-Waluj Sr.Phase 1Phase 2 BeforeAfter 1 Consumption 17 % of Plant Consumption Shop wise Metering for Compressed air Conducted Compressed air audit for leakages for plant through external agency Conducted compressed air Audit for Pressure pattern Total Air leakages 1231 CFM Mostly air leakages found through Air Gauges Air leakages through pneumatic fittings Result : Saving of one compressor of 1000 CFM. Use of ultra sound Leakage identification unit Regular leakage Audit internally. Cell wise Compressed air Pipe lines for better control Provided auto shutoff valves on lines Electrically operated auto drain valves with level sensing on all air receivers Identify all improper fittings & Replace with suitable model & Size Reduction of compressed air loss Innovative Project -3 Slide 30 30 BAL-Waluj Sr.Phase 1Phase 2 BeforeAfter Air for Job Check No air on off valve, Air Gauge continuous ON Foot valve( ON -OFF) in pneumatic circuit Job Sensor & Valve control Air for machine Direct air connection to machines - Manual on/off valves Soft Start valves to stop air when machine idle Air shutoff valves for air feeders to production cell Time controlled Dial Gauge No Job No Air Sensor Switch Solenoid valve Reduction of compressed air loss Slide 31 31 BAL-Waluj Sr.Phase 1Phase 2 BeforeAfter Street Light 300 Watt SV lamps 650 No.s Lamps Connected Load 195 Kw Consumption 7.11 L Kwh/Yr 150 Watt CFL lamps 650 No.s Lamps Connected Load 97.5 Kw Consumption 3.55 L Kwh/Yr 72 Watts LED lamps 80 Nos. Lamps Connected Load 5.76 Kw Consumption -0.21 L kwh/Yr Energy saving : 3.56 L Kwh /Yr : Rs.24.95L/Yr Investment : Rs.12.6 Lacs Energy saving : 0.23 L Kwh /Yr : Rs.1.61 L/Yr Investment : Rs.8.0 Lacs Electrical- Lighting Slide 32 32 BAL-Waluj Sr.Phase 1Phase 2 BeforeAfter Shop Lights 300 watts SV High bay lamps 590 Nos. Lamps Connected Load -177 Kw Consumption- 4.24 L Kwh/Yr 156 watts Induction lamps 302 Nos. Lamps Connected Load 47.0 Kw Consumption- 1.13 L Kwh/Yr 120 W LED High bay lamps Under trials Energy saving : 3.12 L Kwh /Yr : Rs.21.87 L/Yr Investment : Rs. 31.71 Lacs Office & assly line FTL T8 ( 40 Watts) for shop & storage area lighting FTL T5 ( 30 Watts) for shop & storage area lighting 1200 No.s T5 fitted CFL /LED Lights : 200 Fittings of 80 Watts Saving : 0.48 LKwh/ Yr Investment : Rs. 9.18 Lacs Saving : 0.43 L Kwh /Yr Rs. 3 Lacs Investment : 8 Lacs Electrical- Lighting Slide 33 33 BAL-Waluj Task Lighting in machine shops Use of Structure Tube lights (2*40 Watt) at 5 meter height Use of 36 W Tube light at 1 Meter Height Saving : 0.35 LKwh / Yr Investment : Rs. 2.5 lacs Electrical- Lighting BeforeAfter Saving : 1.26 LKwh/ Yr Investment : Rs. 30 lacs BeforeAfter Paint Booth Lighting( flame proof) Use of 8 X 40 W TubesUse of 6X 36 W CFL 300 Fittings Slide 34 34 BAL-Waluj AfterBefore 350 Watts air circulators Saving : 1.21 Lacs Kwh /Year Investment : Rs. 7.5 Lacs Replacement of 30 inch size Air circulator by 24 inch ( 150 Nos) Electrical- Fans & Blowers 200 Watts air circulators Installation of Spot cooling System to replace Old type ARP system BeforeAfter Centralized ARP cooling system With 100HP motor Breeze air spot coolers used With 2 HP blowers (18 No.) Saving : 1.28 Lac kwh/Yr. Investment : Rs.16 lacs Slide 35 35 BAL-Waluj BeforeAfter Energy Saving : Rs. 13.28 Lacs/Yr Investment : Rs.26 Lacs 37 Kw Motor Total Load -67 Kw Pump Optimization Electrical- Pumps & Motors Application :Therrmic fluid circulation Motor power-25HP 25 HP gland pump replaced with mechanical seal pump. Also eliminate gland cooling pump of 5 HP Pump Elimination BeforeAfter Energy Saving : Rs. 2.27 Lacs/Yr Investment : Rs. 2.68 Lacs Horizontal deployment 3 Locations 75 Kw Motor Total Load -102 Kw Slide 36 36 BAL-Waluj Electrical- Pumps & Motors Use of Energy Efficient motors Conventional Motor used for Actual Load 37 KW Energy Efficient motor IE3 motors in paint shop Saving : Rs. 0.56 Lacs / Yr Investment : Rs. 0.78 Lacs Horizontal deployment : 5 BeforeAfter No VFD, Exhaust blowers-7 Nos. running at constant speed for 18 hours /day Installation of VFD for Exhaust blower in paint shop AfterBefore Blowers running at 50 % speed in recess time VFD Installed Saving : 0.35 Lacs Kwh/Year Rs. 2.45 Lacs Investment :Rs. 4.3 Lacs Horizontal deployment : 2 Slide 37 37 BAL-Waluj Sr.Phase 1Phase 2 BeforeAfter Compr essed air Reciprocating compressors are running in central compressor houses. @ 4.5 to 6 Bar Atlas Copco /Ingersoll Rand screw compressors. Capacity 1000 CFM each @ 4.5 Bar High Pressure compressed air -6 Bar through local compressor Demand side management : Variable speed IR make NIRVAN compressor 1000 CFM -2 Nos. Supply side Management : Controller for compressor operation Installed air boosters for high pressure at 4 Locations ( 4.5 Bar to 6 Bar) Saving ( Kwh) :12.0 Lacs /Year Investment : Rs. 90 Lacs Saving ( Kwh) : 2.0 Lacs /Year Investment : Rs. 8 Lacs Electrical- Compressed air Slide 38 38 BAL-Waluj Localised storage tank Electrical- Cooling Optimum temperature for ACs / coolers S NDescriptionBefore ( Deg.C.) After ( Deg.C.) 1Room AC2124 2Panel AC3034 3Water coolers1824 Temperature settings Saving : 0.1 Lacs kwh/Yr. Investment : Zero Before After Fanless Cooling Tower Air Movement in cooling Tower induced with the help of Exhaust Fan of 4 HP Provided cooling tower equipped with water jet technology. i.e. Air movement in cooling tower induced with the help of water Jet. Energy Saving : Rs.1 Lacs/Yr Investment : Rs.1.8 Lacs Horizontal deployment : 3 locations Slide 39 39 BAL-Waluj BeforeAfter Energy Efficient equipment installation CED Reciprocating chiller 110 TR (0.9 Kw/TR) Screw chiller 80 TR (0.71Kw/TR) Energy saving : 0.4 Lacs Kwh /Annum Investment: 13 Lacs Electrical- Cooling Air Dryers -5000 CFM capacity With Reciprocating compressors replaced with Scroll compressors air dryers 4 Nos. Energy saving : 0.8 Lacs Kwh /Annum Investment: 8 Lacs Slide 40 40 BAL-Waluj Electrical Heating TO LPG Heating Before After Saving : Rs.3.26L / Year Investment : Rs. 3.5 Lacs Electric Heater was used for Water heating of pre washer on CGC Furnace - 54 KW LPG Heating is used Electric Heater LPG Burner For Heating Electrical Method change Electrical Heating TO Heat Pump Electric Heater was used for Water heating of washing machine Heat pump For washing machine water heating Electric Heater Before After Saving : Rs.1.75L / Year Investment : Rs. 3.1 Lacs Horizontal deployment : 20 locations Slide 41 41 BAL-Waluj We have conducted Thermal Imaging for identifying heat losses in paint ovens Thermal Total Identified Points 24 Heat Loss- 63456 K Cal /Hr Rectified Insulation of High heat Zone Saving - 27 Ton LPG /Year Slide 42 42 BAL-Waluj Sr. no.Shop NameDiscriptionYearAnnual Thermal Investment made Units (Mn T) Rs. (Mn) Rs Lacs 1Paint Shop Reduced hanger weight to minimize heat loss.- 3.7 Kg/Hanger 2012-130.00410.21731.00 2Paint Shop Scheduled running of ED process Line Running -18 Hrs /Day 2012-130.0573.0210.00 3Heat treatmentSalt heating by Quenching hot empty fixtures2012-130.0010.0531.00 4Heat treatmentOptimize fixture weight to reduce heat loss2012-130.0010.0530.50 5Heat treatment Maintaining furnace temperature 700 O C on Weekly Off days 2012-130.0010.0530.00 6Heat treatment Single pilot flame with flame sensor for burning exhaust gases of furnaces 2012-130.0010.0530.00 7 Paint Shop MCD Provided Low temperature degreasing chemicals.Paint shop 2012-130.0010.0530.00 8 Reduced Meri oven cycle time. 3.0 Hrs/ Cycle 2012-130.0060.3180.00 9Heat Treatment Less process time for 0.45 mm Case depth of KTM Gear - Shaving route 2012-130.0020.1060.00 10Paint Shop MCDCleaning of PTCED Loading rods in shot blasting2012-130.0020.1061.00 11Heat TreatmentUse burners Flue gases for heating dryer.2012-130.0010.0531.00 0.07714.08634.5 Thermal Slide 43 43 BAL-Waluj Installation of transparent roofs in dispatch yard Saving : Rs. 4 Lacs / Year Investment : Rs. 3.12 Lacs Transparent roofs- Qty: 78 No.s Use of Renewable Energy LPG Saving : 3396 Kg / Year Saving : Rs.1.4 Lacs / Year Investment : Rs. 5 Lacs Make up water is heated by Solar water heating system which reduces load on LPG water heater Solar water Heating System Slide 44 44 BAL-Waluj Solar Lighting Use of Light Pipes in assemblyLight Collector & diffuser Reflective system Roof Installation Light Pipe Size Eqv. Wattage Light out Put Area Coverage Energy Saving InvestmentCarbon reduction 530 Mm300 Watts 4000 Lux 500 Sq Ft1100 Kwh/Year 0.21 Lacs0.88 Ton/Year Use of Renewable Energy Horizontal Deployment : 25 Slide 45 45 BAL-Waluj Generation of Electrical Energy with Windmill Power Project YearInstalled Capacity Wind power Generated Waluj Plant consumption Wind Power adjusted Contrib ution Equiv. CO2 emission reduction (MW)( L kwh) %Tons 2010-1165949573.48239.284119142 2011-12651076589.86268.684521494 2012-1365888540.7260.684820854 At SATARA & SUPA area in Maharashtra Wind mills are installed for Electrical Power Generation. Use of Renewable Energy Target Slide 46 46 BAL-Waluj Use of Renewable Energy Solar Photo Voltaic Power Plant -20 Kw Installed at Bal Waluj Capacity20 kWp Grid Connected Solar Power Plant LocationRoof compressor House -8 Area Utilised240 M 2 No. of Solar Panel72 Solar Module280 watts each Solar ChipPolycrystelline Solar Moduel MakeLanco DC voltage720 Volt Invertor MakeRefu Invertor ModelRefusol Invertor capacity19.2 Kva Invertor Output3 Phase/415 V /50 Hz Power generation90 Kwh/day ( Avg) / 32850 Kwh/Year Supplied ByM/s Lanco Solar Energy Pvt Ltd. Commissioning byM/s Lanco Solar Energy Pvt Ltd. Slide 47 47 BAL-Waluj Use of Renewable Energy Solar Photo voltaic Power Plant- 20 Kw Future Projects : Rooftop Solar Power Plant Up to 10 MW Open access Power trading Slide 48 48 BAL-Waluj Year of Implementation No. of Projects Savings Rs. Million Investment* 2009-2010365.53.6 2010-20113510.57.9 2011-20122113.2112.58 2012-20134417.3522.2 Grand Total13646.5646.28 Summary of ENCON projects Slide 49 49 BAL-Waluj Energy Unit Base Year AchievedTarget 2003-04 2004- 05 2005-062006-072007-08 2008- 09 2009-102010-112011-122012-13 Electricity Kwh / veh67.54 49.3 1 45.8142.9936.7234.931.4525.4122.6121.1519.0 Electrical Energy Consumption / Vehicle Electrical Energy Consumption / Vehicle Result 69 % Kwh/Veh Slide 50 50 BAL-Waluj Energy Unit Base Year Achieved Targe t 2003-04 2004- 05 2005-062006-072007-08 2008- 09 2009-102010-112011-122012-13 LPG Kg / veh 2.532.752.42.82.42.22.11.771.451.31.17 Thermal Energy Consumption / Vehicle Thermal Energy Consumption / Vehicle Result Kg/Veh 48 % Slide 51 51 BAL-Waluj Result Energy Unit Base Year AchievedTarget 2003-042004-052005-062006-072007-082008-092009-102010-112011-122012-132013-14 Water m 3 / veh 0.890.650.620.580.540.520.410.350.410.270.20 Water Consumption / vehicle 69 % Slide 52 52 BAL-Waluj SUSTENANCE Sustenance Activities Review Audits Monitoring & Measurement Loss Identification& Corrective actions Technology Up gradation Technology Up gradation Education & Training Regular Shop Audit by Energy Captains Regular Shop Audit by Energy Captains Internal Audits Internal Audits Consumption Data Analysis Consumption Data Analysis Daily/Monthly Electrical Energy Daily/Monthly Electrical Energy Daily Review by Div Head Daily Review by Div Head Adoption of Energy efficient Technology for Manufacturing, Monitoring Adoption of Energy efficient Technology for Manufacturing, Monitoring Energy Managers Training Energy Managers Training External Audits External Audits Daily/Monthly LPG Daily/Monthly LPG Daily/Monthly Water Daily/Monthly Water Daily/Monthly Fuel Daily/Monthly Fuel Daily/ Weekly Review by Plant Head Daily/ Weekly Review by Plant Head Energy Index Review by Corporate Energy Index Review by Corporate Energy Captains Training Energy Captains Training Group Leaders Training Group Leaders Training Leakage Identification Leakage Identification HD of Kaizen Implement ENCON project Implement ENCON project HD of ENCON project in other shops. Plant, Vendors HD of ENCON project in other shops. Plant, Vendors Vendor Training Vendor Training EMS Slide 53 53 BAL-Waluj Energy consumption monitoring & Measurement 300 Electrical Energy Meters Monitoring up to shop Feeder 55 Water meters Monitoring up to shop 10 LPG Flow Meters Monitoring up to Oven 10 Air Flow meters Monitoring up to shop SCADA Slide 54 54 BAL-Waluj Energy consumption monitoring & Measurement Slide 55 55 BAL-Waluj Energy consumption monitoring & Measurement Slide 56 56 BAL-Waluj Monitoring and Reporting system External Audit Sr.YearAudit forProjects ( Nos. )Saving PotentialStatus 12008Electrical, Thermal21 20 L kwh17 L kwh 22011Compressed Air3 6.5 L Kwh5.5 L KWh 32011Water system3 1500 Cub m/day1500 Cub.M. /d 42012 Power System- PF & Harmonics 8 1.2 L Kwh0.8 L Kwh 52012Process Pumps & Motors10 2.7 L KwhWIP 62012 Thermal - Thermography for Ovens 7 63456K CalWIP 72012 Compressed Air System3 7 L KwhWIP 82012 Compressed Air Leakages5 6 L KWh3 L KWh 92013 Chillers1 2.62 L KwhWIP Slide 57 57 BAL-Waluj Awareness creation TrainingKaizenAppreciationEventCompetition Awareness through communication Energy Captains 5 Axis Training Latest Technology Small Group Activity Karakuri Engineering Kaizen Managerial Kaizen Energy Boards at shop Best Kaizen Award Best Energy Captain Energy Efficient Shop ENCON week Poster display Energy Seminar New Product display Monthly Kaizen Karakuri State & National level Slide 58 58 BAL-Waluj Celebration of Energy conservation day-14 th Dec -12 14 th -20 th Dec Energy Conservation Week - 14 th -20 th Dec Participant on Energy Day Energy Efficient product display for vendors Awareness creation Slide 59 59 BAL-Waluj Sr. Loss Elimination Alternate source Efficient Equipment Operational Control Total 1Machining152145 36 2Paint234153 45 3Press & Fab.161127 36 4Assembly12133 19 5Utility231184 46 Total 8996222 182 Kaizen matrix Awareness creation Kaizen Ideas generated & implementation through our 105 Energy Captains Slide 60 60 BAL-Waluj Environment & carbon Reduction Environment Improvement Slide 61 61 BAL-Waluj Scenario - Water Consumption at Waluj: Water consumption Down by 44 % Production Up by 55 % Constructed Recharging of Ground Water : 2190 Cu. Mtr / Day Recharging of Ground Water Water Conservation Slide 62 62 BAL-Waluj Sr.WaterIndustrial coolingProcessDomestic 1Water consumption - %75934 Stratification of Water consumption Slide 63 63 BAL-Waluj Sr.noApproachIdea 1Eliminate wastages Optimization of network & eliminate water leakages from supply lines Use of one Touch Tap orifice ( 4mm ) for domestic water taps. Localized water tanks for shops 2Reuse of waste water Use of treated water for horticulture. Use of Treated water with UF & RO for process. 3Use of Rain Water Storage in water harvesting ponds. Ground recharging with rain water. Reduction of Water Consumption Per Vehicle ENCON Idea Table Slide 64 64 BAL-Waluj Unicef Report Media Publications Slide 65 65 BAL-Waluj Media Publications Slide 66 66 BAL-Waluj Media Publications Sakal Slide 67 67 BAL-Waluj Media Publications Slide 68 68 BAL-Waluj Sr No.Environment Improvement 1No water is discharged outside the company. 2Tree Plantation by all employees in plant 4500 Plants 3Rain water harvesting pond capacity increased to 10000 Cub Mtr 4Implementing E-waste norms prescribed by MPCB. 5Ground water recharging with rain water (Patented with KEDIA FARM PATTERN) by deep percolation technique. Capacity -8 L kL 6100 % recycling of Industrial effluent by Installation of RO + UF Plant of capacity 1000 M 3 / day. This being used for process. 7Reduce consumption of packaging material by 35 % (Polythene bags, corrugated boxes) in last 7 years. No packaging materials for transporting material from vendors 8Effluent treatment plant (ETP) has been upgraded to separate industrial & domestic effluent resulting in better quality of treated water. List of major environmental improvements 2012-13 Environment Improvement Slide 69 69 BAL-Waluj Water Conservation BeforeAfter Treated water was used only for Horticulture activities.Treated water is recycled through RO plant and used for processes. ThemeReduce Water consumption by recycling the water for processes Investment Rs.3.0 Cr Qty2 Nos. Water Saving / Day 700 Cu. Mtr. Recycling -Sustainable Development Effluent Use for Horticulture Effluent Treatment Plant Use for Process RO Plant Slide 70 70 BAL-Waluj Water Conservation Rain Water Harvesting Rain water Pond of Capacity enhanced to 10000 M 3 Investment Rs.12 Lacs Qty1 Water Storage Capacity 10000 Cu. Mtr. Recycling -Sustainable Development FY 12-13 FY 13-14 Investment Rs. 24 Lacs Qty1 Water Storage Capacity 10000 Cu. Mtr. Slide 71 71 BAL-Waluj Recycling -Sustainable Development Water Conservation Investment Rs.15 Lacs Qty (KFP)50 Nos. Water Recharging / year 1.5 Lac KL Ground Water Recharge Investment Rs.36 Lacs Qty (KFP)160 Nos. Water Recharging / year 8.0 Lac KL FY 12-13 FY 13-14 Slide 72 72 BAL-Waluj 6 8 Water Conservation Slide 73 73 BAL-Waluj Heat recovery from waste flue gases at Low Temperature are installed in Paint shops SN Waste Heat Recovery System installed at LPG Saving Kg/Year Investment ( Rs. Lacs) 1Paint shop ED oven exhaust 261009.75 2HWG Aquatherm PTCED Exhaust 104165.5 3HWG Aquatherm Paint shop Exhaust104165.5 4PTCED line Oven Exhaust386269 5Paint shop Exhaust Oven- 4 Locations3713512.5 Waste utilization Slide 74 74 BAL-Waluj LPG GAS USED FOR CANTEEN Saving 22 Kg /day LPG Saving = Rs 2.6 Lacs/ Annum Use of Bio Gas Plant in Canteen Before After Waste utilization Slide 75 75 BAL-Waluj Weekly Draining to ETP. No provision of Salt recovery Wastage of Quenching Salt during Washing of components. Salt recovery by evaporation of water. Before Salt +water components To ETP. Washer Reuse of Quenching Salt After Waste utilization Heat treatment Salt water inlet from Shop Hot water Burner Kulfi Pots for salt collection Investment Rs. 35 Lacs Slide 76 76 BAL-Waluj Re-Use of Waste Packing Material Waste utilization Waste Paper recycle Slide 77 77 BAL-Waluj Summary - Reduction in Carbon Emission / veh (Kgs.) : Reduction in Carbon Emission Total Carbon Reduction 19 % Slide 78 78 BAL-Waluj Tree for Carbon Mapping : Logistic Internal Movement Testing Employee Transportation Carbon Mapping External Vendor Part movement Vehicle Distribution Fuel Consumption Reduction Distance Reduction Under Companys Control Material Handling Vehicle Shifting EngineVehicle Carbon Reduction Slide 79 79 BAL-Waluj Idea Tree : Reduction of Carbon Emissions Internal Logistics External Logistics Carbon Emission From Sr.Idea 1Optimize Route 2Reduce No. of Trips 3Eliminate Movements 4Eliminate Multi-handling 5 Use of Alternate equipment ( e g. Use of BOPT ) 6Use of Belt for material movement Sr.Idea 1Optimize Route 2Increase Loadability 3Increase occupancy 4Milk Run Route 5 Reduce distance ( bring vendor near to BAL) 6Increase vehicle cube capacity Carbon Reduction Slide 80 80 BAL-Waluj Carbon Reduction through - Logistics Improvement M/s. BAL & M/s. Skoda Joint Initiative Carbon Reduction Slide 81 81 BAL-Waluj BALJNPT PORT SkodaJNPT PORT Import Container flow for SKODA Export Container flow for Bajaj Auto Before Condition Filled Container Empty Container Filled Container Empty Container Carbon Reduction Slide 82 82 BAL-Waluj Trip Distance Reduction - Container Transport SkodaBALJNPT PORT After Condition Filled Container Empty Container Filled Container Carbon Reduction Slide 83 83 BAL-Waluj Saving in travelling Distance per Trip Net reduction in Diesel per Trip Total Carbon Reduction per Trip No. of Trips per Year 960 Km Net Carbon Reduction Next objective Explore use of import containers from local industries 1832 Tons / Year Carbon Reduction through Logistics Improvement Trip Distance Reduction - Container Transport 192 Lit. 509 Kg. 3600 Nos. Carbon Reduction Slide 84 84 BAL-Waluj Formation of Vendor TPM Cell Inputs to Vendor on TPM Philosophy Handholding on Loss Reduction (16 type of Losses) Practical Training at Learning Centre - BAL Help to Identify Improvement Projects Consultation from Company Experts for Implementation Sharing of Improvements across the Bajaj Auto Vendor Association Appreciate the Improvements Promoting Renewed Partnership Methodology - Implementation of ENCON initiatives at Vendors end Slide 85 85 BAL-Waluj Sr Name of vendor Product Per unit Energy consumed % improvement Inputs / projects provided to the vendor/ associate BeforeAfter 1 M/s Duro valve (I) Pvt Ltd, Aurangabad Valves production 0.20Kwh/ Valve 0.17Kwh/Val ve 33 % Training, Visit to our plant, Help in Energy Audit & Implementation of projects 2 M/s Badve Engineering Unit 2, Aurangabad Silencer production 3.6Kwh/Sile ncer 3.3 Kwh/ Silencer 8.33 % Training, Visit to our plant, Waste elimination, Timed control operation 3 M/s Varroc Polymers Pvt Ltd. Pl. 2 Mirror production 0.32 Kwh/Unit 0.0.2 Kwh/Unit 37.5 % Training, Visit to our plant, Waste elimination, Renewable energy usages, Efficient equipments, Optimized heat utilization. Implementation of ENCON initiatives at Vendors end Similar ENCON projects (453) are implemented across 58 Vendors. In last one year.Average % improvement achieved is 17 % Slide 86 86 BAL-Waluj Sr. no. Shop NameDescriptionElectrical Thermal LPG Saving Potential (Rs./year) Investment to be made Lkwh/ Year Ton/ year LRs. /YearRs Lacs Loss reduction 1UtilityTransmission loss reduction by switch off standby transformer2.2 15.425.20 2UtilityLoss reduction by Power Factor Improvement2.1 14.7215.00 3Utility Elimination of compressed air leakages through cell wise shutoff valves & replcement of fittings type. 6 42.0625.00 Lighting/cooling 4UtilitiesInduction Lighting for shops - 490 nos3 21.0349.00 5UtilitiesInstallation of LED lights for Offices & shops2 14.0230.00 6All ShopsInstallation of transparrent roof sheets for Shops0.21 1.4712.00 7Machine shopsInstallation of Occupancy sensors for Shop work places0.5 3.513.00 8Office Roof top garden for reduction of temperature inside offices by 10 deg c 1.2 8.417.50 9All shopsInstallation Of Breez air cooling system in place of ARP0.72 5.0513.50 10All shops Installation of Galvalume sheeting with insulation for temperature reduction by 3 Deg c 1 7.0120.00 11Paint shopInstallation of Water cooled scrol chiller for paint shop -60 TR1.1 7.7118.50 Method Change 12Machine shopUse of Heat pumps for Washing machine water heating0.66 4.6315.00 Pumps /AHU 13Machine shop Installation of energy efficient pumps for coolant system ( downsizining) -3 Nos. 1.89 13.2518.00 14Paint ShopsInstallation of VFD s for air handeling system0.12 0.844.50 15UtilitiesInstallation of energy efficient pumps- 15 no.0.9 6.317.50 16Machine shopInstallation of energy efficient motors- 7 no.0.42 2.946.00 Renewable Energy 0.00 17Utilities Installation of off grid solar power system-100 Kwp( Upto 10 MW) 1.5 10.5280.00 18UtilitiesSolar Air conditioners unit ( 30 TR)1.57 11.0163.00 Future Projects Slide 87 87 BAL-Waluj Sr. no. Shop NameDescriptionElectrical Thermal LPG Saving Potential (Rs./year) Investmen t to be made Lkwh/ Year Ton/ year LRs. /YearRs Lacs Thermal 19 Paint shop/Heat treatment Magnetic Resonanse for LPG lines for improving combustion 10.652.00 20Heat tretment Installtion of heat recovery for system for washing stage water heating 42.63.00 21 PTCEDDirect heating for phosphate tank 21.312.00 Air & Chillers 22Utilities Variale speed compressor -NIRVAN- 2 Nos. 1000CFM in place of Reciprocating compressors 6.6 36.348.00 23Utilities Installation of scroll compresor air dryers for compressed air -2 Nos. 0.5 2.756.00 24MCD shop Use of Air boosters for high pressure compressed air instead of localised compressors -2 No. 0.45 2.252.00 34.647235.8465.7 Total Projets : 24 No.s Total Saving Expected : 235 Lakhs Total Investment Expected : 465 Lakhs Future Projects Slide 88 88 BAL-Waluj Awards & Accolades CII- Efficient Unit Award 2012 CII- Excellent Energy Efficient Unit Award 2013 Slide 89 89 BAL-Waluj Awards & Accolades MEDA- Excellence in Energy Conservation & Management Award 2012 Slide 90 90 BAL-Waluj Sr Year YearAward Agency Agency 12013Excellent energy efficient unit award at National LevelCII- GBC 22012State Level award for Excellence in Energy conservation & ManagementMEDA 32012Energy Efficient unit award at National LevelCII- GBC 42012Green Manufacturing Excellence Award Challenger categoryFrost & Sullivan 52009State Level award for Excellence in Energy conservation & ManagementMEDA 62008Energy Efficient unit award at National LevelCII- GBC 72008Excellent water efficient unit award at National levelCII- GBC 82007Excellent energy efficient unit award at National LevelCII- GBC 92006Excellent energy efficient unit award at National LevelCII- GBC 102006State Level award for Excellence in Energy conservation & ManagementMEDA 112006Excellent water efficient unit award at National levelCII-GBC 122005Energy Efficient unit award at National LevelCII- GBC 132005Excellent water efficient unit award at National levelCII- GBC 142004State Level award for Excellence in Energy conservation & ManagementMEDA 152003/2004Excellent energy efficient unit award at National LevelCII- GBC Awards & Accolades Slide 91 91 BAL-Waluj Conserve for Today Preserve for Tomorrow. Reserve for future Generation.Also Reduce + Reuse + Recycle