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About Godrej
Established in 1897, the Godrej Group today enjoys the patronage of 1.1 billion consumers globally acrossconsumer goods, real estate, appliances, agriculture and many other businesses- with its geographical footprint extending beyond Earth, as Godrej engines power many of India's space missions. With a revenue of overUSD 4.1 billion, Godrej looks to bring together their passion and purpose to make a difference through a‘Good & Green strategy’ of shared value, in order to create a more inclusive and greener India.
Segments:Aerospace | Agriculture | Consumer Goods | Home Appliances | Chemicals | Construction | Electronics | Furniture | Real Estate | Security Solutions | Infotech
Operations:The Godrej group can be broadly divided into two major holding companies, working independently:Godrej Industries LtdGodrej & Boyce
Godrej and Boyce: A Godrej Group Company
14 SBU's catering to diverse markets- India, Europe, U.S., Middle East, Africa and South East Asia.
Segments:Consumer durables, products for institutions, Industrial products
Products:• High quality locks• Durables (refrigerators, washing machines, air conditioners, home security systems and safes, furniture)• Products for institutions (office furniture, audio-visual solutions, access control systems, perimeter security
solutions, bank security solutions, beverage vending machines, interior solutions, hospital and laboratory furniture)
• Industrial products (process equipment, materials handling equipment, industrial storage solutions, tooling, precision equipment)
Godrej embarks on its Industry 4.0 Journey with SmartSense -Implements IoT powered Asset and Energy Insights for optimizing
operations in its Indian Plants.
About Godrej Interio
One of the largest divisions of Godrej & Boyce and the Market leader in its segment.
India’s largest furniture brand with 50 exclusive showrooms in 18 cities and through 800 dealer outlets.
Offerings: Customers home and office furniture, solutions for laboratories, hospitals and healthcare establishments,education and training institutes, shipyards and navy, auditoriums and stadiums.176 product solutions for home and institution spaces.
Manufacturing Facilities:Supported by 5 Manufacturing Facilities in Bhagwanpur, Haridwar, Bhiwandi, Vikhroli & Shirwal Plant
IGBC GOLD certified showroom
IGBC GOLD pre - certified factory – Shirwal Phase 2
National and International Green certifications
Green Buildings Green Company Rating
For FY 15-16 revenue contribution of green certified products = 16%
12
6 GRIHAcertified products
3 BIFMA Level certified products
Green Products
35 GREENGUARDcertified products
Plant Vikhroli Silver rating June2014
Plant Shirwal Goldrating May2015
Plant Vikhroli Goldrating March 2016
PlantShirwal Platinum rating May 2016
Fostering a culture of Sustainability
Continual improvementbeyond Platinum
Challenges
• Lack of a common infrastructure to capture and collate data from different models and makes of equipment• Machinery level data not available because they were connected to PLC• Lack of means to collect data from machines/equipment from different makes and models• Lack of visibility of all organisational KPI’s
Energy Efficiency• Resources deployed in manual data collection• Errors from manual data collection• Inaccurate data/non-availability of critical data• Lack of a common infrastructure to capture and collate data from different models and makes of equipment
Productivity• Inability to troubleshoot and find reasons for decreased production• Non-visibility of production parameters such as OEE, SEC• Inability to capture and collate data from different systems and sources
Unscheduled downtime• Unnecessary maintenance activity/costs• Sub-optimal/inefficiently functioning of industrial assets (also resulting in a proportionate increase in
energy consumption/costs)• Production losses from unscheduled breakdown
Step 1: Digitization
SmartSense Implementation (Acquire)
SmartSense link+ gateways were implemented for data to be sent to the SmartSense cloud
using GPRS
Step 2: Converting Data into Insights
Converting data into Insights #EnergyEfficiency
Customised widgets using SmartSense Widget MakerAutomated MIS ReportsReal time Dashboard for all Energy and Process ParametersReal time Energy Audit to track any AnomaliesUser Defined and automated alerts for key situations
SmartSense helped reduce energy losses from 13% to 2.5% within 6 months- by detectingunusual consumption and line losses through reports.
Heat Map- aiding instant tracking of abnormalenergy consumption patterns
Deviation alerts sent for voltage imbalance through SMS & email
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2,000.00
4,000.00
6,000.00
8,000.00
10,000.00
12,000.00
14,000.0006:00 to 10:00(offpeak)
10:00 to 18:00(Peak)
18:00 to 22:00(Normal)
22:00 to 06:00(Night)
Department-wise monthly energy consumption trends where breaches are highlighted
SmartSense helped convert Production machine data into live KPIs that define the health of the machine
Vaccum Pump Oil Temperature Vaccum Pump Run Hours Cooling Tower Water Temperature Production Counter
Visualisation and tracking of live machine KPIs
Converting data into Insights #Productivity
Live Tracking of Machine PerformanceVaccum Pump Oil Temperature
Vaccum Pump Run Hours
Cooling Tower Water Temperature
Production Counter
SmartSense helped improve productivity by tracking machine performance and notifying any deviation for immediate action
SmartSense Motor Insights were implemented in critical motors of various makes in Godrej Interio.Using the PowerGenome Approach, Real Time health and issues were identified.
Identification of Motor
Mechanical Fault
Converting data into Insights #Unscheduled Downtime
SmartSense Motor Insights helped prevent unscheduled breakdown by predictingimpending failure. This also enabled Godrej Interio to optimize maintenanceand energy costs and prevent production losses
Identification of
Motor Electrical Fault
Godrej has acted upon all of the actionable recommendations provided by SmartSense
Converting data into Insights; Insights into Value
Energy Efficiency
Productivity
Unscheduled downtime
By solving the 3 fold challenges Godrej has been able to stride closer to its sustainability and profitability goals
MAINTENANCE COSTS
22% 13%
ENERGY COSTS
PREVENTION OF UNSCHEDULED BREAKDOWN
Godrej Interio recognised by Confederation of Indian Industries
Having addressed and shown significant improvements (savings) in terms of energy efficiency, productivityand unscheduled downtime, Godrej Interio was awarded the prestigious Greenco award by CII
Having heard about Godrej Interio’s partnership with Ecolibrium and the resulting CII recognition, a few other Godrej Interio and Godrej & Boyce plants also began their journey with Ecolibrium to
address similar concerns and challenges
SmartSense expands implementation
Enterprise Dashboards
Enterprise Insights
Productivity Insights
Condition Monitoring
Predictive Insights
OEE Optimization and Specific Energy consumption Tracks utilization of machines and cost of unit produced
# OverallEquipmentEffectiveness
Ecolibrium’s approach to all of its Godrej implementations
Reduce Asset Downtime and inefficienciesIdentifies degradation of assets with root cause analysis and recommendations
# PredictiveMaintenance
Reduce cost of powerAnalyzyses energy consumption patterns and identifies leakages with the root cause analysis and actionable Insights
# EnergyEfficiency
SmartSense across Godrej plants
EnergyEfficiency
Predictive Maintenance
Productivity
Shirwal Vikhroli
With operational and business benefits being witnessed and recognized at Godrej Interio, Ecolibrium's solutions have now been extended to all
Godrej & Boyce plants in India
Ecolibrium has recently partnered with Godrej & Boyce for a combined effort in creating Smarter factories in line with Industry 4.0.
Godrej & Boyce has 14 SBU's (including Godrej Interio) catering to diverse markets including India, Europe, U.S., Middle East, Africa and South East Asia.
SmartSense serves as the single interface that Godrej Groupuses to achieve their Sustainability Goals
Corporate Office:
504, Venus Atlantis, Prahladnagar,
Ahmedabad – 380015
India
[email protected] +91 79 4016 5151www.ecolibriumenergy.com
Mumbai | Delhi | Bangalore | Chennai | Pune| Singapore | Dubai | New York
