310 May 2010
TATA GROUPThe Group was founded by Jamsetji Tata in the mid 19th centur y, q 96 plus operating companiesq In seven business sectors:
Information s ystems & CommunicationsEngineering Material Services Energy Consumer products Chemicals.
q The Tata Group is one of India' s largest busine ss group , withrevenues of $70.8billion
q Tata companies together emplo yees some 3,63,000 people. q Operations in more tha n 80 countries across six continents, q Export products and services to 85 nations.q The Tata name is a uniq ue asset representing
leadership with trust & Our heritage of returning to society
410 May 2010
TATA MOTORS
q Tata Motors Limited is India's largest automobile company
q Consolidated R evenues of $15.4 billion ( 2008-09)
q Leader in commercial vehicles in each segment in India
q India’s 3rd largest passenger vehicles manufacturer
qWorld's 3rd largest medium and heavy commercial vehicle
manufacturer
q World’s 2nd largest bus manufacturer.
q 2,000 touch points in India
q 24,000 employees
610 May 2010
Tata Motors – Indian MNCq First Indian Engine ering Company to be listed in
the New York Stock Exchange ( Year 2004)
q Acquired the Daewoo Commercial Vehicles Company, Korea's second largest truck maker ( Year 2004)
q Acquired Hispano Carrocera, Spanish bus and coach manufactur er (Year 2009)
q Joint Venture w ith Brazil-based Marcopolo for Bus body Building (Year 2006)
q MOU with Fiat for v ehicle sales & manufacture
q 2008 – Acquired Jaguar & Land Rover
810 May 2010
Pune
1966
Jamshedpur
1945
Lucknow
1992
Dharwad
1997
Tata Motors 1945-2010Pantnagar
2007
Tata Motors Manufacturing facilities in India
Ahmedabad
2009
India Operations
1010 May 2010
Energy Conservation
Government
Industries
Policy EC Act 2001
National Energ y Policy
Renewable Energy policy
Bureau Of Energ y Efficiency ( BEE )Monitoring Agenc yMinistry of Power
Declare the Polic yTeam FormationImplementation
Monitoring
Encouragement Incentive , Taxation , Aw ard
1210 May 2010
Implementation
Tata Business Excellence Model
Strategy Level Vision, Mission, Core Value
Strategic Direction, Leadership System
Business Process Level
Implementation Level
Framework of Process(Enterprise Process Model - EPM)
21 Top Level Processes (Level 1)
Define Business Processes(Enterprise Processes & Sub Processes Manual)
104 + Sub processes (Level 2)
Physical Plant, Machinery, Facilities &
Computer Hardware, Software & network(Level 3)
1510 May 2010
TATA MOTORS, PANTNAGAR
• Tata Motors ’ 5th and youngest plant. Time from acquisition of land to start of production w as in 11 months; a benchmark in the auto industr y.
• Tata Motors Pantnagar received IMS (Integrated Management S ystem) certification in 1 st ,18 months of operations.
(Including ISO TS:16949, OHSAS 18001, ISO 14001).
• Tata Motors ’ 1st plant with an integrated vendor park, to keep inventories low and to ensure supplies JIT.
Implementation
1610 May 2010
§
Strategy
…. towards green plant…. towards green plant
Reducing Environmental
Foot print
Reducing Environmental
Foot printInfrastructure§Integrated
Manufacturing§ Modular concept§ Innovative construction§ Less Cement§ Efficient Facilities§ Water conservation
Logistics§ Vendor Park Near Mother
Plant§ Transportation§ Recyclable bins , pallets
Manufacturing§ System§ Process
§ Ramp up plan
New Products§ CNG vehicles
§ BS III & IV
1710 May 2010
Actions :q To reduce 30% Steel for building structureq Modular conceptq To reduce heat load on ventilation by installing Double
insulated side and roof walls .q To reduce illumination load by installing Sky light sheetsq To install energy efficient motors for blowers, conveyorsq To install Screw chillers for AC systemq VFD for Compressor and all High powered motorsq Servo controller for Compressed Air Supply . q Fan less cooling towers for compressorq Propane for process heating, instead of
conventional fuel e.g. HSD/LDO/FOq Use of natural resource Artisan wellsq CFL Lamps, Solar Lamps, Wind Ventilatorsq Lakes & Rain water harvesting
Infrastructure ManufacturingActions :q Efficient Washing Machinesq Inter Shop Conveyorq Friction roller conveyorq “Wet on Wet” Painting processq Process Optimizationq Power & Free Conveyorq Electrified Monorail Systemq CNC Machinesq Reuse, Recycle, Reduce process waste
Strategy - To reducing Environmental Footprint
New Product Introduction
Actions :q CNG Vehicle q Fuel Efficient Vehicle – with Start-Stop arrangementq Adherence to emission norms
Logistics Actions :q Vendor park near the mother plant to reduce inbound
transportationq Out bound Transportation - Railwaysq Transportation internal & employee transport
Implementation
1810 May 2010
Infrastructure
Strategy
…. towards green plant
Reducing environmental foot print
Innovative ConstructionInnovative
Construction
q To meet the production ramp up a Modular concept & Pre fabricated steel structures are used
q 30% steel & 15 % cement less used
Hence reduced environmental impact during production of parts
q To meet the production ramp up a Modular concept & Pre fabricated steel structures are used
q 30% steel & 15 % cement less used
Hence reduced environmental impact during production of parts
1910 May 2010
Infrastructure
Strategy
…. towards green plant
Reducing environmental foot print
Modular Concept
Modular Concept
q Phase wise shops in sets
q Fast production Ram up
q Less inventory
Hence reduced environmental impact during production of parts
q Phase wise shops in sets
q Fast production Ram up
q Less inventory
Hence reduced environmental impact during production of parts
Engine &
Gear Box
Paint Shop
Wel
d Sh
op 3
Wel
d Sh
op 2
Wel
d Sh
op 1
Vehi
cle
Ass
y1
Vehi
cle
Ass
y2
Vehi
cle A
ssy3
UtilityAir, Water, Power, Fuel
ETP,STP
Ready
Inter shop Conveyor Weld shops to Paint to
Assy Lines1.5 Km long
Engine &
Gear Box
Paint Shop
Wel
d Sh
op 3
Wel
d Sh
op 2
Wel
d Sh
op 1
Vehi
cle
Ass
y1
Vehi
cle
Ass
y2
Vehi
cle A
ssy3
UtilityAir, Water, Power, Fuel
ETP,STP
WIP
Plant layout
Vehi
cle
Ass
y3Ve
hicl
e A
ssy4
Wel
d Sh
op 1
Wel
d Sh
op 4Engine
& Gear Box
Paint Shop
Wel
d Sh
op 3
Wel
d Sh
op 2
Wel
d Sh
op 1
Vehi
cle
Ass
y1
Vehi
cle
Ass
y2
Vehi
cle A
ssy3
UtilityAir, Water, Power, Fuel
ETP,STP
Ready
Inter shop Conveyor Weld shops to Paint to
Assy Lines1.5 Km long
Engine &
Gear Box
Paint Shop
Wel
d Sh
op 3
Wel
d Sh
op 2
Wel
d Sh
op 1
Vehi
cle
Ass
y1
Vehi
cle
Ass
y2
Vehi
cle A
ssy3
UtilityAir, Water, Power, Fuel
ETP,STP
WIP
Plant layout
Vehi
cle
Ass
y3Ve
hicl
e A
ssy4
Wel
d Sh
op 1
Wel
d Sh
op 4
2010 May 2010
Strategy
…. towards green plant
Reducing environmental foot print
Solar street lamp
Use of Renewable Energy
Use of Renewable Energy
CFL Tube lights
Advantages:
1 40% Energy saved
2. Illumination uniform & better
3. Load on Air Conditioning reduced
4. 43200 KWH per year saved
Advantages:
1 Installed at Strategic Locations
2. Illumination at emergency
Wind Ventilators Infrastructure
Day light Transparent Sheets
q Wind Ventilators, Day light sheets
q Double insulated sheets for wall & roof
q Solar Street Lights
q CFL LampsHence reduced environmental impact
q Wind Ventilators, Day light sheets
q Double insulated sheets for wall & roof
q Solar Street Lights
q CFL LampsHence reduced environmental impact
Cum Sum Saving in Lacs Kwh
18.349.83
3.11
30.4642.57
54.6866.80 78.91
0.0010.0020.0030.0040.0050.0060.0070.0080.0090.00
2002 2003 2004 2005 2006 2007 2008 2009
>5000
2110 May 2010
Infrastructure
Strategy
…. towards green plant
Reducing environmental foot print
Efficient FacilitiesEfficient Facilities
Screw CompressorWith VFD Savings 250 MWH/Yr
Fan less cooling tower
Servo Control Valve
q Screw Compressor with VFD
q Servo controlled Compressed Air
q Fan Less cooling tower
Hence reduced environmental impact during production of parts
q Screw Compressor with VFD
q Servo controlled Compressed Air
q Fan Less cooling tower
Hence reduced environmental impact during production of parts
2210 May 2010
Strategy
…. towards green plant
Reducing environmental foot print
Efficient FacilitiesWater conservationEfficient Facilities
Water conservation
Solar Water He ating for Canteen
Saving - 150 KWH/day
The Artesian well is Supplying Raw water to WTP with out power
Reduce the energy consumption for water pumps for WTP q Use of Natural Resource
Hence reduced environmental impactq Use of Natural Resource
Hence reduced environmental impact
Natural Resource
5% Reduction of Power Consumption for ETP Water Pumping
Since 2001 3945.8 Lacs Wind Units
2310 May 2010
ManufacturingStrategy
ProcessProcess
q New Technology at Paintshop
3C1B Process, Direct Heating, RTO (Regenerative
Thermal Oxidizer) for incineration of thinner / fumes
q Reduced heat loss by providing insulation
q New Technology at Paintshop
3C1B Process, Direct Heating, RTO (Regenerative
Thermal Oxidizer) for incineration of thinner / fumes
q Reduced heat loss by providing insulation
Hot surface insulated by glass wool6 to 8% energy saving , ROI is 6 Month
Manufacturing
Propane – Clean Fuel
Reducing environmental foot print
2410 May 2010
LogisticsStrategy
TransportationTransportation >600 t CO2 Reduced>20,000 Vehicles dispatched
35 t CO2 Reduced /YearEntry for 100 Vehicles / day restricted
Reduce environmental Impact of transporting finished vehiclesReduce environmental Impact of transporting finished vehicles
q Finished Goods Transport by Railways
qTransport facility to Employees,
q Internal Shuttle
Hence reduced environmental impact
q Finished Goods Transport by Railways
qTransport facility to Employees,
q Internal Shuttle
Hence reduced environmental impact
Logistics
Reducing environmental foot print
2510 May 2010
ManufacturingStrategy
Innovative ProductsInnovative Products
qWorlds Lowest Priced Car
q CNG Vehicle, New Efficient Products
qWorlds Lowest Priced Car
q CNG Vehicle, New Efficient Products
New Products
ACE CNG Magic CNG ACE -Fuel Efficient
Reducing environmental foot print
2610 May 2010
Innovation
Loss Elimination
Process improvement or Eff iciency Improvement
Use of God Gift
Use of New Technology
Our Journey
2710 May 2010
SPECIFIC ENERGY CONSUMPTION OF Plant 1 AND Plant 2
0
200
400
600
800
1000
1200
1400
02
-03
20
03
-04
20
04
-05
20
05
-06
20
06
-07
20
07
-08
20
08
-09
20
09
-10
(Up
to
MA
R'1
0)
kW
h /
Eq
. U
nit
47 %Stagnancy
SPECIFIC COMPRESSED AIR ENERGY CONSUMPTION OF Plant 1 AND Plant 2
20
40
60
80
100
120
140
20
02
-03
20
03
-04
20
04
-05
20
05
-06
20
06
-07
20
07
-08
20
08
-09
20
09
-10
(Up
to
MA
R'1
0)
kW
h /
Eq
. U
nit
50 %Stagnancy
Compressed Air Consumption, New Plant KWH / Veh.
0
10
20
30
40
50
FY
07-
08
FY
08-
09
FY
09-
10
59 %
Power Consumption(UPCL+DG), New Plant KWH / Veh.
-100
50
200
350
500
FY 0
7-08
FY 0
8-09
FY
09-
10
50 %
Specific Consumption Trend
Plant 2
Plant 1
Plant 2
Plant 1
2810 May 2010
Specific Fuel Consumption Trend in Million KCal / Veh.
New Plant, Fuel Consumption, MKcal / Veh.
0.00
0.15
0.30
0.45
FY 07
-08
FY 08
-09
FY 09
-10
48 %
Plant 2, Fuel Consumption, MKcal / Veh.
0
0.15
0.3
0.45
FY 07
-08
FY 08
-09
FY 09
-10
16 %
2910 May 2010
Theme: Reduce Energy Consumption in Illumination
Patent No – 203430 – Energy saving Device for High Pressure Gas Discharge Lamp
PatentPatent
Case Study - 1
3010 May 2010
Theme: Use of New Technology & Innovation to reduce energy consumption
Picture/ sketch/ drawing before modification
Picture/ sketch/ drawing after modification
Yearly consumption trend for illumination CVBU
152.5
61.0 56.4 53.045.1
1996 2000 2003 2005 2006
Year
Lakh
s Unit
s
1000W bulbs & 5000 Nos
1000 W to 4000 W
400W to 250W (1000Nos)
Out of 5000nos 1500 nos brought under saving scheme
Target - After implementation by 2006 for all 5000nos
60% 7.5
%6%
20%
What Next?
3110 May 2010
FY07-08 FY08-09 FY09-10
DG Power Nil DG Power 1% DG Power 18%
Case Study - 2Result
Power Consumtion KWH / day & KWH / Veh.
020000400006000080000
100000120000140000
FY-07-08 FY-08-09 FY-09-10
KWH
/ Day
0
100
200
300
400
500
KWH
/ Veh
.
KWH/ Day kwh / Veh.
KWH / Da y
Power Consumtion in MWH & KWH / Veh.
0
10000
20000
30000
40000
50000
FY-07-08 FY-08-09 FY-09-10
MW
H
0
100
200
300
400
500
KWH
/ Veh
.
Total Power (UPCL + DG) MWHkwh / Veh.
49%
31%
0
15000
30000
45000
MW
H
FY-07-09 FY-08-10 FY-09-10
Power Consumption UPCL vs DG in MWH DG -Power (MWH)UPCL Energy (MWH)
3210 May 2010
Sharing Best Practices
1. Intranet Site
2. Cross Locational Team
3. Knowledge Book
4. Innovision – Tata Motors Level
5. Innovista – Tata Group Level
3410 May 2010
ü 2009 – TML Pantnagar - National Energy Conservation Award BEE, 1st Prize in Automobile Industry
ü 2008 - TML Pune – Excellence in Energy Management – CII
ü 2006 - TML Pune – Excellence in Energy Management – CII
ü 2005 - TML Pune – Excellence in Energy Management – CII
ü 2004 - TML Pune – Excellence in Energy Management – CII
ü 2004 - TML Pune – Excellence in Water Management – CII
ü 2003 - TML Pune – National Energy Conservation Award BEE, 2nd Prize in Automobile Industry
Achievements in the field of Energy Cons ervation