cii - k suryaprakash · 2018. 8. 31. · co operation respect & concern for people creative...

GREEN FOUNDRY

– CASCADING THE VISION

K Suryaprakash DIRECTOR(OPERATIONS)

Brakes India Limited

1Foundry Division

Sholinghur

Year of establishment 1981

Brakes India Foundry - Profile

Year of establishment 1981

Location Sholinghur, 120 Kilometer from Chennai

N b f l 727Number of employees 727

Total area 76 Acres

Built up area 28,000 Sq. Mts.

Sales turnover (2010-2011) Rs 601 Crores (US $ 131 Millions)

Production volume (2010-2011)

Exports share of turnover

74284 MT

42%

Industries catered to

- Automotive

R f i ti & Ai diti i

87%

13%

2

- Refrigeration & Air conditioning 13%

Vendors as partners

VISIONReturn to stock holders

Customer satisfaction

PUSH PULLstock holders satisfaction

Employees’ quality of life

3

q y

Excellence

Cultural values

Excellence

Commitment

Cultural values

Orderliness

Vibrancy

Cleanliness

H &

TransparencyOpennessCore Values

Harmony & Co operation

Respect & concern for people

Creative values

Humility Trust & Integrity

Basic Values

4Innovativeness Social

Responsibility

Human side of BI

B i i t

Atmosphere of care

D l t l i ti

Institute:• Free –Medical centre• Vocational training centre

Provide:• Housing for

employees

Basic requirements Developmental aspirations

Dedicated employeesocat o a t a g ce t e• Own vehicle scheme• Recreational club• Free –Education for wards• Computer literacy classes

• Subsidised food • Fair-price shops• Uniform • Health check ups

Empowerment of

Employees

p y

p

Vision Improve the quality of lifePUSH PULL BI one large

Employees

Vision Improve the quality of lifePUSH PULL family

Social meets Employee participation

• Periodical Family visits to foundry

• Sports day

• Awards of recognition

• Suggestion schemes

Ownership and accountability

Social meets p y p p

5Atmosphere of trust / Organisational climate

BIF – A responsible corporate citizenSocietal needs

Infrastructure EnvironmentProvided:• Drinking water• Communication facilities• Banking facilities

• Rain water harvesting• Zero discharge of

pollutants• Transport facilities• Housing scheme• Direct and Indirect

employment of local people

• Utilisation of waste• Utilisation of green power• Green belt development

p y p p

PUSH

Brakes India’s total identification with

Harmony with SholinghurUpliftment of Sholinghur PULLPUSH

SholinghurSholinghurp g PULL

Health Education

Setting up: Blood bankprimary health centre

Established:Higher secondary schoolTechnical training centre

6

centreAccident relief centre

Computer literacy classesComputer centres at V.I.T.

Individual needs

Improving Manufacturing Sustainability:An Overview

Th l f t i bilitThe goal of sustainability.

Every company when it comes to green manufacturing should be conserving natural resources for future generationsconserving natural resources for future generations.

Problem Statement Emphasisp

7

GREEN FOUNDRY – CASCADING THE VISIONGREEN FOUNDRY CASCADING THE VISION

Environmental issues Environmental issues have become part of every foundry’s core y y

activities.

To be successful & to survive, foundries have to be wise to how environmental issues affect our business.

8


Foundries with their skill, knowledge andFoundries with their skill, knowledge andpractical information, need to unlockthese resources to reduce impact on theenvironment.

Recyclability is the Good environmentalpractice is not an

t di i li b tbiggest advantage of the foundry industry.

extra discipline but anintegral part of overallbusiness acumen.

9


Foundries need to recognize how much waste iscosting them & identify benefits of reducing wastegeneration which is approximately 4% of the turnover

t d R M t d tiliti & k– wasted R.M, wasted utilities & rework.

Foundries need to L k f tFoundries need to measure environmental

Inappropriate use of water could be

Lack of top management commitment is

performance to assess the scope

could be costing foundries 1%

commitment is a big barrier to action

10

for improvements / savings.

%of turnover.

action.


Foundries need to recognize how much waste iscosting them & identify benefits of reducing wastegeneration which is approximately 4% of the turnover

t d R M t d tiliti & k– wasted R.M, wasted utilities & rework.

Foundries need to L k f tFoundries need to measure environmental

Inappropriate use of water could be

Lack of top management commitment is

performance to assess the scope

could be costing foundries 1%

commitment is a big barrier to action

11

for improvements / savings.

%of turnover.

action.

Making Money is the Goal of the Organisation

The Goal……

Making Money is the Goal of the Organisation

Prof. Shiba san always says, “PROFIT should not be the only motive for a company.

A company should have noble goals, far beyond the immediate financial results.”

GovernmentInvestorsSociety

Stake-holder f th Fi ManagementLenders of the Firm g

EmployeesSuppliers

12H

EmployeesCustomers

Suppliers

GOING GREEN

Waste Management Solid

Waste ManagementWater

Resource Conservation

Internal environment

controlEco friendly

packingcontrol p g

13

GOING GREEN





controlEco friendly

packingcontrol p g

14

New Market Value in foundry –Utilisation of solid waste

• Support from IISc• Concepts from

Stricter statutory and regulatory

Concepts from French Architect

PUSH

g ycompliance

Maximize Revenue f t PULL

Improvement in bottom line3-4% of the

PUSHBench Mark

Status in EMS performance

from waste PULLtop line

Solid Waste Disposal

Allocation of

Problem

Core Team

15

resourcesFormation

Sludge

Packing wood Buildings External

Office materialsLeaves

Paper Manures

g

Roads environment

Generation cycle

Sand

Incoming materials

Application cycleGreen belt

Utilization of solid waste

Dust Slag

Sand

Recycling Manufacturing

Lining

Stillages

16

Solid Waste Management


Towards ZERO solid waste discharge

Utilization of solid waste Sand

Land FillsBrick Manufacturing

Development of green belt

Concrete manufacturing

17

Solid Waste ManagementBrick Manufacturing

Compressive Strength : 20 to 25 Kg / cm2

8 3 1.5 1

Slag Return Sand River Sand Cement

0% 20% 40% 60% 80% 100%

Being used for non bearing loads

Compressive Strength of regular brick

18

20 to 25 Kg / cm2

Solid Waste ManagementBrick Manufacturing

Buildings constructed with stabilized mud blocks using foundry return sand

Administrative building

Executive Director’s Office

X – Ray laboratory

Buildings constructed with stabilized mud blocks using foundry return sand

19Roads constructed with return sand

For Compound wall construction

For Cupola lining & as base sand for floor moulding


Utili ti f lid t






20

Solid Waste ManagementConcrete Manufacturing

Compressive Strength : 200 to 250 Kg / cm2

Slag Return Sand cement Graded Gravel

1.5 1 1 4

0% 20% 40% 60% 80% 100%

75 mmFinish Layer - ConcreteConcrete

road – Cross section

150 mm

200 mm

Second Layer – Lean Mix

Sub base - Concrete

21For construction of reinforced concrete works

300 / 600 mm

Sub grade - Concrete

Construction of reinforced concrete works

Concrete ManufacturingConstruction of reinforced concrete works

75 mm

150 mm

Finish Layer - Concrete

Second Layer – Lean Mix

Concrete road – Cross

section

22

200 mm

300 / 600 mm

Sub base - Concrete

Sub grade - Concrete








23

Green belt development

Non-Cultivable Land to Cultivable Land

The foundry’s waste sand contains bentonite, which has

moisture retaining propertiesmoisture-retaining properties.

Arid land is made cultivable by filling up waste sand to aArid land is made cultivable by filling up waste sand to a

depth of 500 mm to develop green belt.

BIF converted 6 acres of arid land to green belt (Kitchen

24garden, lawn & flowering trees)


25Pilot project for a lawn and kitchen garden (2.5 acres)

Zero discharge and reuse of solid waste


Zero discharge and reuse of solid waste

26Return sand / slag are used as base sand for developing green belt


Flowering Plants

27


Green belt development – Housing colony

28


Sand Foundry 1 & 2 Sand Foundry 3 Permanent Mould

Foundry – Bird’s eye view

Sand Foundry 1 & 2 Sand Foundry 3 Permanent Mould Foundry

Pattern & Die Shop Administrative office building

29


Biodegradable Materials

Withered LeavesMaterials

MANURE

30Sludge From Sewage

Treatment Plant

R lt


16.8

16

18Results

Bette

r

10.91

12.3

14.1

12

14

n

B

7.88

10

Rs. i

n M

illlio

n

ActualTarget

4.14

6

R

0

2

2004 2005 2006 2007 2008 2009

31

2004-05

2005-06

2006-07

2007-08

2008-09

2009-10

GOING GREEN





controlEco friendly

packingcontrol p g

32

Waste Management - Water

S ft Pl tSoftener Plant

Treated Sewage Water

For cooling towers

33Gardening Purpose Cupola Shell Cooling

GOING GREEN





control

Eco friendly packingcontrol p g

34

Dust mapping

O A

DR

Dust prone area

35Not to scale

Kaizen improvement activities – Dust reduction

Before AfterBefore After Before After Before After

Flat rollers to trough rollers to contain spillagesInclined to horizontal conveyors to contain spillages

B f Aft After Before After

36Improved negative suction through an additional dust collector

Providing U type skirting to avoid belt damage and sand spillages

Noise mapping

R O

A D

37Not to scaleSources of noise

Kaizen improvement activities –Noise reduction

Before After Before After

Rubber sheath over the wear plate of the vibro charger to contain noise

Replacement of didion drum with disa cool drum to contain noise and improve castings quality

R lt

94

100

110

120

Result Result Better

Better

97.9

86.382

88

dB

103.880

90

100dB

38

86.3

70

76

Before After

84.2

60

70

Before After

Heat mapping

R O

A

R

Sources of heat

39Not to scale

Kaizen improvement activities – Heat reduction

Casting conveyor for quicker removal of castings and thereby minimising the heat radiation

50 Result ResultB

ette

Bette

Turbo vents at the melting platform

4541 1

38

42

46

50

eg C

elsi

us

42.536

39

42

45

g C

elsi

us

Result Result er

er

40

41.1

30

34

De

Before After

38.5

30

33

36

Deg

Before After

Prevention of pollution Emission level reduction

Annealing furnace:Annealing furnace:

An alternate cleaner fuel (superior kerosene oil – SKO) which has higher combustion

efficiency and lower emission levels is being used instead of light diesel oil there by minimizing

the emission levels at the furnace outlet.

Sulphur di oxide

63

60

80

30.540

60

g/cu

.m

Before

0

20

µg Before

After

4141

0Usage of LDO Usage of SKO

Scrubber for cupola

4242

Installation of dust collector for cupola charging

4343

Establishment of environmental laboratory and air quality parameters

Environment Monitoring & Review

monitored fortnightly

Spectro photo meter Air ovenAir sampler p p Air oven p

4444

Incubator Distilled water plantAir sampler

Prevention of pollution

Activity: To improve the environmental performance to become uniqueActivity: To improve the environmental performance to become unique

Ambient air quality

Year SPM NOx SO2

Govt Norms

360µg/cu.m

80µg/cu.m

80µg/cu.m

244 29 21

232 27 11

238 21 9Air quality sampler

238 21 9

194 23 5

173 18 5

187 9 0.40

170 10 0.20

4545Dust extractors to improve

workplace environment

2003 199 9.7 0.12

2010 149 13 0.15

Kaizen improvement activities – Heat reduction

I l t ti f f i dl ffi i t ti liImplementation of eco-friendly energy efficient evaporative cooling system in the Die cast area

50

Result

Better

433834

38

42

46

Deg

Cel

sius

4646

38

30

34

Before After

Reduction in “leapfrogging from lily pad to lily pad.”

GREEN FIELD FOUNDRY AT JHAGADIA

With th i i t t f GettingWith the main intent of Getting closer to the customer and

thereby reducing the Carbon

4747

Foot-print

Global foot prints

Reduction in “leapfrogging from lily pad to lily pad.”

Plant LayoutGreen field foundry at oman being establishedGlobal foot prints

Planned Buildup Area 17725 Sqr Mts for 2 PhasesPlanned Buildup Area 17725 Sqr.Mts for 2 PhasesLocation Oman

Foundry 1 Foundry 2Capacity 18000 MT/Year 18000 MT/Year

4848

Capacity 18000 MT/Year 18000 MT/Year

Date of Commissioning Mar 2008 Mar 2011

GOING GREEN





controlEco friendly

packingcontrol p g

49

Resource conservation - Energy

BIF is focusing on the resources conservation implementation by adopting the best practices emerging out of Environmental Management System to ISO : 14001 : 2004 and Energy Management System to BS-EN : 16001 : 2009 through PolicyManagement System to BS-EN : 16001 : 2009 through Policy Deployment

50


Energy Distribution TreeInput Power-100%

Energy Distribution Tree

Available Power -96.7 %

Moulding-7.87%20 Kaizens

Melting-83.19%45 Kaizens

Utilities-3.86%11 Kaizens

Finishing-1.78%10 Kaizens

Sand Plant5.88%

Furnace79.71%

Auxiliary3.48%

Molding m/c1.95%

Melting69%

Holding10.71%

Cooling pumps2.99%

Crane & Hoist0.48%

Dust control3.44%

Mixer2.44%

51


Energy monitoring & reporting systems

110 KV15000 KVA

33 KV9950 KVA

33KV9850 KVA

Energy monitoring & reporting systems

15000 KVA 9950 KVA 9850 KVA

SAPTotal demand - 34800 KVATotal demand - 34800 KVA

Energy Report

52


Energy performance review

Frequency Review details Members


ency

Daily•Review of energy performance(heat wise and shift wise)

All circle committee members &Daily (heat wise and shift wise)

•Corrective and preventive actionsmembers & Supervisors

•Gap analysis Department head & Weekly

•Gap analysis•Corrective and preventive actions

pDeputy Energy chairman

Monthly

• Review of Monthly and yearly targets• Review of Policy deployment

I t ti iti

Deputy Energy chairman, Energy Chairman & CEO

53

• Improvement activities



Frequency Review details Members


ency

Daily•Review of energy performance(heat wise and shift wise)

All circle committee members &Daily (heat wise and shift wise)

•Corrective and preventive actionsmembers & Supervisors

•Gap analysis Department head & Weekly

•Gap analysis•Corrective and preventive actions

pDeputy Energy chairman

Monthly

• Review of Monthly and yearly targets• Review of Policy deployment

I t ti iti

Deputy Energy chairman, Energy Chairman & CEO

54

• Improvement activities

Implemented innovative energy management

Wind24%

2010-2011

BIF Energy consumption pattern 2001- 2011

Wind13%

2009-2010

24%

3rd Party18%

Gas48%

State grid10%

13%

3rd PartyGas50%

State grid29%

2008 2009Wind13%State Grid

45%

8%2008-2009

2006 2007Gas42%

Wind12%State grid

40%

2006-2007

Gas48%

2001-2002

5555


56


Energy cost as a % of Sales

24

21.7

21

18.7

16.218

14.013.1 13.4

13.915

122003-

042004-

052005-

062006-

072007-

082008-

092009-10

57Years

Actual Target

Resource conservation

- Water

58

Rain water harvesting

Resource conservation - Water

Rain water is being harvested in strategically located

59

Rain water is being harvested in strategically located harvesting plants

GOING GREEN





controlEco friendly

packingcontrol p g

60

Eco friendly Packing

Waste utilisation – Conservation of wood

StillagesWooden scraps

61

The wooden scraps from the incoming materials are used for making stillages

Waste utilisation Conservation of wood

Eco friendly Packing

To conserve wood, the wooden pallets are slowly being phased out by using reusablepallets / steel pallets.

Waste utilisation – Conservation of wood

Before After

W h l d d d ti b i i th i ht f ti / b Ab t

62

We have also reduced wood consumption by increasing the weight of castings / box. About 85 % of Indian customers receive their deliveries through steel pallets / gunny bags

Wage War on WasteWage War on Waste

GREEN MAKES BUSINESS SENSE

63

W W W tWage War on Waste

ReduceRefuse

Waste

ReuseRecycle Reusey

64

GREEN MAKES BUSINESS SENSEGREEN MAKES BUSINESS SENSE

DO YOU WANTDO YOU WANT

TO FLUSH THE PROFITS

DOWN THE DRAIN ?

65

Thank youThank you

66

cii - k suryaprakash · 2018. 8. 31. · co operation respect & concern for people creative...

Documents