Energy Efficiency -...

1

Energy EfficiencyTM

ISO 9001:2008& 14001:2004 CERTIFIED COMPANY

3

Our Process

In coming of Raw material

Shearing/ Cutting

Notching/ Punching

Bending

Welding

Deburring / finishing

Powder Coating

Assembly/ Packing/ Dispatch.

4

Shearing

machine

Energy Mission

Ahmedabad

Coil cutting

Line from

Dimeco Italy

Our Shop Floor & Machines

5

Power Press

Press

CnC Bending

Accurpress


6

Welding Assembly Packing Area

Tek Welding LineOur Shop Floor & Machines

7

Turret LVD

Global 20 -1225


Powder coating

8

•Mobile storage systems

•Shelving’s

•Cabinets

•Movable Panels

•Compactor Storage systems

•Cupboards

•Industrial Racks

•ATM Drop Box Cabinets

•Lockers & safes

•Claddings

•Drive unit covers

•Vertical filling cabinets

•Protection equipment's( safety products)

Our Products, What We Do?

9

Energy Scenario in 2016-17

➢Only electricity is used as energy source.

➢Sanctioned demand by MSEB is 80 KVA

➢ Electrical Power consumption in 2016-17 is 65460 KWH

Electicity

10

Green Vision

Energy

Conservation

Min 5 % reduction in Specific Energy

consumption YoY.

Water

Conservation

Min 5% reduction in Specific Water

consumption YoY,

Rain water harvesting.

Material

Conservation

Optimum Utilization of Material

Waste

Reduction

Zero Waste to Land Fill

11

Quality, Environment Policy

At Jay Industries, we are manufacturing sheet metal furniture products for optimizing business storage space

solutions.

Our Vision: To be known for manufacturing excellence through Reliability, Quality, and customer satisfaction.

We are committed to: -

• Manufacture and supply products that meet customer satisfaction through consistent quality and

environment performance.

• Regularly review impact of our activities on environment.

• Conserve key resources like energy, water and raw material by optimizing its use.

• Adopt best possible energy efficient technologies, equipment and processes.

• Apply waste management hierarchy of prevention of pollution, reduction of waste generation at source,

reuse and recycling.

• Reduce carbon footprint by optimizing processes and transportation.

• Ensure appropriate training and awareness on environmental systems, best practices and on shared

responsibility towards environmental protection among employees.

• Increase share of renewable energy.

• Prevent pollution and comply with all the current applicable legal and other requirements.

Rajesh Panchal

Chief Executive Officer

Commitment & Target Setting

12

ISO 9001 :2008 & ISO 14001:2004 Certified Company

13

EE Credit 1.1 Commitment & Target Setting

Mr. Rajesh Panchal (CEO) of M/s Jay Industries Signed Energy Conservation pledge at Godrej Interio.

On 1)14.09.2015 to reduce specific energy consumption by minimum 10 %

2) 27.08.2016 to reduce specific energy consumption by minimum 5 %


14.09.2015 27.08.2016

14 14


Approach for Target

Basis for energy target setting

➢ Supplier energy conservation pledge at Godrej Interio.

➢ Environmental Conservation Pledge at Godrej Interio.

➢ Project planned to reduce energy consumption.

➢ Measurement and monitoring system for energy.

➢ Better capacity utilization.

15 15

Approach followed for target setting

EQUIPMENTS Can this be

eliminated ?

Alternate

process

?

Increase

Efficiency

?

Reduce

Consumption

?

New

Technology ?

Use of

renewable

energy ?

Compressor • • •

Hydraulic power

pack• •

Press shop • • • •

Fabrication Shop • • • •

Plant Lighting • • • • •

LVD Turret • • • •


16

Energy reduction Target Setting

Year 2014-15 2015-16 2016-17

2017-18

Short

Term

2018-19

Medium

Term

2019-20

Long

Term

Specific

Energy

consumption

(kWh/Ton)

86.9627 61.4091 56.647 53.81 51.12 48.56

Target 5% reduction YoY

Actual

17 17

Action Plan & Financial allocation

Sr.No PlanPlan

S

(2017-18)

M

(2018-19)

L

(2019-20)

1 VFD for air compressor •

2 LED lighting to replace all lamps in shop •

3Reduction in fixed energy consumption –

(Lighting load)•

4Purchase of energy efficient machines –

( AC, Monitor, Machines)• •

5 Capability training of employees • • •

6 OEE and productivity improvement • • •

7 Minimising Air leakages •

18

Mr. Siddhant Patil

(Energy Manager)

Mr. Yogesh Panchal

Jay Green Team

(Production head)

Mr. Datta Gaikar

(Press shop supervisor)

Mr. Kamala Yadav

(safe Assembly in-charge)

Mr. Shyam Bhoye

Jay Green Team

( Head admin)

Mr. RavindraMaid

(Store In-charge)

Mr. Dharmesh

(Fabrication Su pervisor)

Fund Allocation,Rewards &

Recognition

Energy Management Team

Energy Management Team – Roles & Responsibilities

Identification & Approval of Project,Sustenance

Monitoring,Follow Up,Analysis

Target Setting,Training & Awareness Programs, Activity Review

Data Collection,Suggestions,Kaizen Inputs

Mr. Dashrath Panchal

Plant Head

Mr. Rajesh Panchal

CEO

19

Strategies Adopted for Employee Involvement

Daily

MeetingKaizen

Events Recognition

Employee Involvement

Daily monitoring of energy.Analysis of abnormal situations

Suggestion scheme.

Reward for

energy Saving

ideas , poster competition

Celebrations of various days like environmental

day, competitions

20 20

To bring commitment and sense of ownership energy conservation pledge taken

by all employee.

Employee Involvement

Commitment leads to an action

21

Employee Involvement-Awareness

Training on Energy Saving & Preventive maintenance

Pledge – various day celebrationsAwareness in daily meetings

Poster competition to bring awareness and sense of ownership

22

Employee Involvement-Awareness

Drawing Competition for all employee Drawings on Energy Conservation

23 23

TRAINING CALENDER FY 2016-17

MONTH

TRAINING

PROGRAM

SUBJECT

TARGET

AUDIENCE

ACTUAL

TRAINING

DATE

TRAINING FACULTY

APRIL 3M , KAIZEN PDN 13.04.16 Mr. ROHIT SANKPAL

MAYElimination of

MUDAPDN 22.05.16 Mr. ROHIT SANKPAL

JUNE Poka Yoke PDN 23.06.16

MR.RAJESNDRA INGALE

&MR.AVINASH

SONAWANE

JULY

Preventive

Maintenance of

Compressor

PDN 05.07.16 Mr. ROHIT SANKPAL

AUGUST

My Machine

Stage 1 ,2

activity

PDN 04.08.16 MR.RAJESNDRA INGALE

AUGUSTMy Machine

Stage 3 activityPDN 18.08.16 MR.SIDDHANT PATIL

SEPTEMBERThroughput

Time ReductionALL DEPT. 07.09.16 MR.ROHIT SANKPAL

Internal Training program

24 24

OCTOBERWASTE

REDUCTIONPDN 27.10.16

MR.DATTA

GAIKAR

NOVEMBER

SUPPLIER

AWRENESS

PROGRAMME ON

RESORCE

CONSERVATION

Staff 17.11.16MR.SIDDHANT

PATIL

DECEMBERGREENCO

AWARENESSALL DEPT. 15.12.2016

MR.RAJESNDRA

INGALE

&MR.AVINASH

SONAWANE

DECEMBERENERGY

EFFICIENCYALL DEPT. 20.12.2016

MR.SIDDHANT

PATIL

DECEMBER Water Conservation ALL DEPT. 26.12.2016MR.SIDDHANT

PATIL

JANUARYREDUCTION OF

CARBON ENISSIONALL DEPT. 08.01.2017

MR.SIDDHANT

PATIL

JANUARYMATERIAL

CONSERVATIONMANGEMENT 15.01.2017

MR.RAJESH

PANCHAL

Internal Training program

25 25

JANUARY

IMPORTANCE OF

RENEWABLE

ENERGY

ALL DEPT. 22.01.2017MR.SIDDHANT

PATIL

JANUARYWASTE

MANAGEMENTMANGEMENT/PDN 27.01.2017

MR.DASHRATH

PANCHAL

FEBRUARYPRODUCTIVITY

IMPROVEMENTPDN 05.02.2017

MR.RAJESH

PANCHAL

FEBRUARY SCRAP REDUCTION PDN 21.02.2017MR.SIDDHANT

PATIL

MARCH2S AND 3 M

REVISIONALL DEPT. 12.03.2017

MR.SIDDHANT

PATIL

MARCH SAFETY ALL DEPT. 18.03.2017MR.SIDDHANT

PATIL

MARCHPREVENTIVE

MAINTENACEPDN/ASSLY. 25.03.2017

MR.SIDDHANT

PATIL

Internal Training programs

26 26

TRAINING CALENDER FY 2017-18

MONTHTRAINING PROGRAM

SUBJECT

TARGET

AUDIENCETRAINING FACULTY

APRILOperating, Setting of

Spot welding machinePDN Mr. Ashish

APRILPreventive Maintenance

of Screw CompressorPDN Mr.Pandurang

MAY 5S AND 3 M ALL DEPT. MR.SIDDHANT PATIL

JUN SAFETY ALL DEPT. MR.SIDDHANT PATIL

JULY MY MACHINE PDN/ASSLY. MR.SIDDHANT PATIL

AUGUST Water Conservation PDN MR.SIDDHANT PATIL

SEPTEMBER AWARENESS ON GHG ALL DEPT. MR.DATTA GAIKAR

OCTOBERENERGY EFFICIENCY

PRACTICESALL DEPT. MR.SIDDHANT PATIL

OCTOBER WASTE REDUCTION PDN MR.DATTA GAIKAR

NOVEMBER KAIZEN/POKA YOKE ALL DEPT. MR.SIDDHANT PATIL

NOVEMBER

ENVIRONMENT

AWARENESS

PROGRAMME

ALL DEPT. MR.RAJESH PANCHAL


27 27

DECEMBERREDUCTION OF

CARBON ENISSIONALL DEPT. MR.RAJESH PANCHAL

DECEMBER Water Conservation ALL DEPT. MR.YOGESH PANCHAL

JANUARYMATERIAL

CONSERVATIONALL DEPT. MR.SIDDHANT PATIL

JANUARYIMPORTANCE OF

RENEWABLE ENERGYALL DEPT. MR.SIDDHANT PATIL

FEBRUARYPRODUCTIVITY

IMPROVEMENTPDN MR.RAJESH PANCHAL

FEBRUARY SCRAP REDUCTION PDNMR.DATTA GAIKAR

MARCHMATERIAL

CONSERVATIONALL DEPT. MR.SIDDHANT PATIL

MARCH 7 QC TOOLS ALL DEPT.MR.SIDDHANT PATIL

MARCH OEE STAFFMR.SIDDHANT PATIL


28

External Training programs & Capacity building

SR.N

O.TRANING TITLE ORGANIZED BY

TRAINING

DATEPARTICIPANTS BENIFIT ACHIEVED

1 Training on key indicators

CII 01/09/2014

1)MR.RAJESH

PANCHAL 2)

MR.ROHIT SANKPAL

first time right concept &reduction in cc, cr & ipra) Primary Key Indicators

b) Secndary key Indicators

2 Energy Cost SavingsCII Mr.Rajendra

Ingale14/11/2014

1) MR.RAJESH

PANCHAL 2)

MR.ROHIT SANKPAL

Energy saving initiatives

3 3M &Kaizen CII 22/05/2014

1) MR.RAJESH

PANCHAL 2)

MR.ROHIT SANKPAL

Elimination of MUDA MURI & MURA &PQDSM

Improvement by kaizen

4 Training On 3S, 4S &5S CII 06/07/2015

1) MR.RAJESH

PANCHAL 2)

MR.ROHIT SANKPAL

Management of Abnormalities & leakages

5Training Programme on

Energy Conservation

Internal Green Cell

Godrej Interio14/09/2015

1) MR.RAJESH

PANCHAL 2)

MR.ROHIT SANKPAL

Energy Audit Methodology How to measure

Energy & life cycle cost

68 th CII National

Summit(Delhi)CII

23/11/2015

24/11/2015

MR.RAJESH

PANCHALGreen Initiatives by Companies , Industrial visit

7 4Q's of quality CII 03/12/2015

1) MR.RAJESH

PANCHAL 2)

MR.ROHIT SANKPAL

100% capturing of CTQ, LCA, SPC, Pokayoke

& Dock Audit

8Advaced Energy training

Program

CII Mr.Sanjay

Namdeo

04/03/2016

&05/03/2016

1) MR.RAJESH

PANCHAL 2)

MR.ROHIT SANKPAL

Advance techniques in energy savings Energy

29 29

External Training programs & Capacity building

9 Problem Solving Steps & Tools CII Mr.Jayant kulkarni 04/04/2016

1) MR.RAJESH

PANCHAL 2)

MR.ROHIT

SANKPAL

Dent & Damage Mapping, 100% checking by system &

Zero Defect

10Poka Yoke & Autonomous

MaintenanceCII Mr.Jayant kulkarni 23/05/2016

1) MR.RAJESH

PANCHAL 2)

MR.ROHIT

SANKPAL

Zero ppm, Zero Defect, Red Tagging &White Tagging

11 Training on CAPAPurchase & Quality team


1) MR.ROHIT

SANKPALPDCI Why WHY analysis & Fish bone diagram

12Training on Resource

Conservation

Internal Green Cell


1) MR.ROHIT

SANKPAL

Procuring Env consent & Renewing Env Consent. Water

Balance

13 OEE, Layout & SMED CII Mr. jayant kulkarni 31/08/2016

1) MR.RAJESH

PANCHAL 2)

MR.ROHIT

SANKPAL

Improving the layout, Performance Monitoring & Reduction

in Job change over

14National Quality Summit 2016

(Bangalore)CII 23/11/2016

1)MR.RAJESH

PANCHALQuality topic presentations by Various companies

15PQ Analysis & Flow

ManufacturingCII Mr.Jayant kulkarni 05/12/2016

1) MR.ROHIT

SANKPAL 2)

MR.SIDDHANT

PATIL

Improving Throughput time & Identifying Runners,

Strangers & Repeaters

16 9th CII National Summit CII01/12/2016

&03/12/2016

1) MR.ROHIT

SANKPAL 2)

MR.SIDDHANT

PATIL 3)

MR.RAJESH

PANCHAL

Green Initiatives by Companies , Industrial visit to Hero

Motocorp & Sandhar Automobiles

30

MSEB

Welding section

compressorTurret

machinePress Shop Office

30

Energy Monitoring

Distribution of electricity

Energy meter installed

100 % of energy consumed is monitored

41.26 % 12.92 % 10.92 % 17.10 % 17.77 %

31

Electricity Monitoring - MIS

MONTHLY

Month UnitsTotal Steel

Consumption (Ton)

Electricity / Ton(kWh/Ton)

Average Yearly Electricity / Ton

(kWh/Ton)

Power Factor

Apr-14 3996 72.18 55.36

86.96

1.000

May-14 3676 35.67 103.06 0.999

Jun-14 3984 17.39 229.10 0.999

Jul-14 3308 41.87 79.01 0.999

Aug-14 3060 57.74 53.00 1.000

Sep-14 3716 61.86 60.07 0.997

Oct-14 3748 51.35 72.99 1.000

Nov-14 3480 54.02 64.42 1.000

Dec-14 4652 53.06 87.67 1.000

Jan-15 5888 57.86 101.76 1.000

Feb-15 7600 56.36 134.85 1.000

Mar-15 6728 59.71 112.68 1.000

32

57.12

53.2

62.83

57.65

51.98

55.83

58.7558.0260.07

67.81

54.7155.8357.75

58.91

55.81

52.6351.7150.83

53.75

57.9155.81

53.34

57.8156.0655.9156.41

0

10

20

30

40

50

60

70

80

Kwh/Ton

Daily Variance Analysis

Electricity Consumption (KWH)

32

Daily Variance Analysis

Rework

in Filo

Child

component

production

Labour Job

on turret

(less stroke)

Labour Job

on turret

(less stroke)

33 33

Corrective actions for deviation

ZONE: 1

KAIZEN THEME: KAIZEN IDEA: Team:Fabrication Team

Idea By:DASHRATH PANCHAL

Starting Date: 24.06.2015

Completion Date: 20.07.2015

PROBLEM STATUS COUNTER MEASURE Bench Mark:

Target

Results Achived

Benefits

PROBLEM ANALYSIS P

WHY?1. Why high IPR in

door welding ?BEFORE AFTER Q

WHY?

2. Why wrong

positioning of door

while welding ?

C

WHY?

3. Why there is no

provision to fix door

position ?

D

WHY? S

WHY? M

Sustenance:

ROUT CAUSE

WHERE WHO WHEN STATUS

TO REDUCE INPROCESS

REJECTION OF FILO DOOR

To provide locating pin for positioning

of door

Name: Kaizen no:167

SOP For welding

Benefits

KAIZEN SHEET

RESULT:

Provided a pin to to locate door High Inprocess rejection of

filo door

There is no provision to fix

door position

To all

Similar

product

4781 ppm Rejection

0 Inprocess Rejection

Zero Inprocess rejection due to wrong

positioning of door

Muri Eliminated

0 Inprocess Rejection

Horizontal Deployment: On other Safe Doors

Zero inprocess

34

ZONE : 1

NAME : Mr. Dharmesh

PROBLEM PREVENTION ALARM

ORIGIN

PROCESS

SOLUTION

KEY IMPROVEMENT

POKE YOKE SHEET DATE : 05.06.2016

BEFORE AFTER

Threaded inserts pin is welded on back side of door instead of front side

Inprocess Rejection of Door

Welding

In Fixture added Pin

Fixture modified to include guide pins to guarantee correct positioning

DETECTION CONTROL

SHUTDOWN

POKA YOKE


35

POKA YOKE

BEFORE

Difficulties in identification of front and back side of door.

AFTER

Insert pin is provided for proper positioning of door


36

Reduction in Specific Energy Consumption

33.17 % of Specific Energy Reduction from 2014-15 to 2016-17

86.96

61.41 56.65

0

10

20

30

40

50

60

70

80

90

100

2014-15 2015-16 2016-17

Yearly A

vera

ge k

wh/T

on

Specific Energy Consumption Reduction

7.75 %

33.17 %

29.4%

Year

Electricity

Consumptio

n (kwh)

Steel

processed

(Ton)

Specific

Energy

consumption

(kWh/Ton)

2014-15 53836 619.1 86.96

2015-16 65460 1066.0 61.41

2016-17 58900 1039.8 56.65

37

List of Energy saving projects


Sr.No PROJECTEnergy Saving

kWh/Annum

Benefit

(Rs.)/AnnumInvestment year

1 LED lighting to replace all lamps in shop 2880 25920 69195 2014-15

2 Installation of cut to length machine 2865.5 12078 2028723 2014-15

3 Installation of transparent sheet 1008 9072 96600 2014-15

4 Minimising Air leakages 423 3384 1383 2015-16

5 KAIZEN PROJECTS

A. GRINDING OF U/S ELIMINATED

(OPERATION ELIMINATION) 112 8280Nil

2015-16

B. FILO DOOR OPERATION CLUBBING 3133 120000 98000 2015-16

C. MULTIPLE OPERATION PUNCHING IN

U/S MEMBER-91 MM 3021 6800038243

2016-17

D. INSTALATION OF AIR VENTAILATORS

ON ROOF (elimination of forced exaust) 895.2 7800016000

2016-17

6 SMED project on turret 623 36866 175000 2016-17

7Purchase of energy efficient machines -

Invertor welding machines 1783.5 16051.5 310000 2014-15

8 Capability training of employees

9 OEE and productivity improvement 623 67820

38

23

16

8

1

PROBLEM : 44 % of total change over time is on Turret punching

Benefits : 1) 623 kwh energy saved per annum.

2) Zero Change Over for 39 Tools.

3) Change over time of Optimizer Rail reduced by 19 mins.

4) 11 More tools can be used with automatic indexing function.

BEFORE AFTER

Countermeasure : Tool Holder Modifies to increase the Varity of Tools and No of Tools

Every Change Over tool Change

NeededNo tool Change Needed

RESULT

110

28

0

20

40

60

80

100

120

Before After

Setting Time in mins


39

Problem : Low productivity and high energy consumption of shearing machine.

Benefits : 1) 2865.5 kwh energy saved per annum

BEFORE AFTER


40

PROBLEM : Tool Searching Time is 94 sec and activity is in series

Benefits : 1) Time saving of 94 sec. per change over.

2 ) 283.6 kwh energy saved per annum.

SMED Trolley

BEFORE AFTER


41

Objective : To reduce electricity consumption.

Benefits : 1) 2880 kwh energy saved per annum

BEFORE AFTER


42

PROBLEM : High energy consumption(lighting load) in day time

Benefits : 1) 1008 kwh energy saved per annum

BEFORE AFTER

Transparent sheet


43

WELDING OUTSIDE

BEFORE AFTER

WELDING INSIDE

GRINDING OPERATION REQUIRED NO GRINDING OPERATION REQUIRED

Benefits : 1)112 kwh/Annum 2) Productivity increased by 40%. 3) elimination of

grinding process


44

Team Photo Machine PhotoFrequent breakdown of machine leads to selection of power press for Autonomous maintenance

“ My Machine “

Energy Efficiency operational Practices

45

CLASSROOM TRAINING ON JOB TRAINING

Training To Employee on Autonomous maintenance


46

System Subsystem

Motor i) Bearing housing

ii) Pulley

iii) Belt

Flywheel i) Casing

ii) Flywheel

iii) Belt

Ram i) Body holder

ii) Ram

iii) Eccentric bush

vii) Stopper

Meshing Gears i) Driving gear

ii) Driven gear

Punch and Die i) Punch holder

ii) Die block

iii) Punch and die

iv) Die base

v) Clamps

Base i) Scrap Bin

Paddle i) Lever

ii) Foot pedal

Power unit i) Power On/Off switch

ii) Wires

AM Step – 0Preparation of cleaning map


47

MOTORF

L

Y

W

H

E

E

L

RAM

M

E

S

H

G

E

A

R

PUNCH & DIE

BASE(SCRAP BIN)

POWER

SWITCH

OIL

TANK

PADDLE

MR.LAXMAN

MR.DHARMESH

MR.YOGESH

MR.POPAT

MR.DATTA

MR.TIWARI

AM Step – 0 : Machine Block Diagram

Machine Block diagram made to allocate the responsibility and to follow the sequence for AM.


48Cotton gloves Brush

White PaperCotton waste

Arrangement of tools : AM Step - 0

48

Red Tag White Tag


49

AM Step - 1 : Activity

Machine Name : Power Prees 2

No. of hours spend for Initial Cleaning : 1 hour 47 mins

No. of People involved Machine Shop : 3 Persons

Other Department members : 5 Persons

49

removing of gear assemblycover

Cleaning of wheel Cleaning of gears


50

AM Step - 1 : Abnormality Photo

Dirt Excess nut height Gear cover not transparent

50

Unwanted Material Dirt and dust accumulated on gear Loose belt tension

Add Photo Add Photo


51

AM Step - 1 : Countermeasures on abnormality

Before After

Belt Slackness is more Belt Tension adjusted

51


52

AM Step - 1 : Countermeasures on abnormality

Before After

Loose Clamp bolt Tighten clamp bolt

52


53

Abnormality Classification

Abnormality Effect

JH Step -1 :

Abnormality Classification & its Effect

53

11

6

3

63

8

5

1 61

Dirt

Leak

Splash/Spillage

Loose

Misalignment

Wear

Broken

Wrong Hardware

Hanging Wire

Unnessary

Jam

Mis Up

Tightining

Tightining Bend

7

0

0

2Breakdowns

Quality Rejects

Cost Increase

Cost


54

RESULT:-

Before After

JH Step - 2 : Kaizen of Hard to Access area C L I TP

Cleaning time reduced from 8 min. to 50 Sec.

Flywheel Pulley cover made easy to openFlywheel Pulley cover hard to open


55

Cover removed. Easy to lubricate. Unnecessary Cover on Plummer block,

hard to lubricate.

RESULT:-Lubrication time reduced from 3 min. to 30 Sec.

Before After

JH Step - 2 : Kaizen of Hard to Access area

C L I T

P


56

Belt visible for slackness inspectionBelt Invisible due to cover

RESULT:- Cleaning time reduced from 7 min. to 39 Sec easily openable & belt slackness can be visually inspected

Before After

JH Step - 2 : Kaizen of Hard to Access area C L I T

P


Machine Standard power press

ROTATION OF MOTOR √ √ D OPERATOR INFORM TO SH

VIBRATION √ √ W NO VIBRATION OPERATOR INFORM TO SH

ABNORMAL NOISE √ √ W NORMAL NOISE OPERATOR INFORM TO PO

6.2 FOUNDATION BOLT MATCH MARK ON BOLTS √ √ WNO MISMATCH OF

MATCH MARKOPERATOR RETIGHTNING

6.3 MOTOR FAN DUST,DIRT √ DFREE FROM

DUST&DIRTOPERATOR CLEANING

7.1 PULLEY WEAR (GROOVE AREA),DIRT √ √ DNO SHINING ,NO

DIRTOPERATOR CLEANING & REPLACE

TIGHTNESS √ √ W TIGHTENED OPERATOR RETIGHTNING

CRACK ON BELT √ √ W NO CRACK OPERATOR REPLACE

ROTATION OF MOTOR √ √ W OPERATOR INFORM TO PO

VIBRATION √ √ W NO VIBRATION OPERATOR INFORM TO PO

ABNORMAL NOISE √ √ W NORMAL NOISE OPERATOR INFORM TO PO

7.4 MOTOR FAN DUST,DIRT √ DFREE FROM

DUST,DIRTOPERATOR CLEANING

7.5 BUSH DAMAGE,DIRT ,DUST √ DFREE FROM

DAMAGE,DIRTOPERATOR CLEANING & REPLACE

7.6 PULLEY GUARD DIRT ,DUST √ DFREE FROM

DUST,DIRTOPERATOR CLEANING

BELT7.2

7.3 MOTOR

MOTOR 6.1

7.0 RAM ADJUSTMENT ASSLY

6.0 MOTOR

JH Step - 2 : Preventive Check list


9/4/2017 58

Machine Standard Turret

5.1 OILY SURFACE,DIRT ,DUST √ √ DFREE FROM

DIRT,DUSTOPERATOR

CLEAING &

LUBRICATION

5.2 TEMPRATURE √ √ D 38 DEGREE OPERATOR REPAIR

FILLTER MFREE FROM

DIRT,DUSTOPERATOR CLEANING

OILY SURFACE,DIRT ,DUST √ √ DFREE FROM

DIRT,DUSTOPERATOR INFORM TO SH

METER √ √ W 5 BAR RANGE OPERATOR INFORM TO SH

6.1 AIR BLOW

AIR BLOW FOR MACHINE

5.0 COOLER FOR MACHINE

COOLER

JH Step - 2 : Preventive Check list


Check List for Power Press


9/4/2017 60

Air Leakage = Loading Time/ (Loading Time + Unloading Time )

= 3.25/(3.25+10.67)

=10.67 %


Compressed Air Leakage Test - Before

Start Time End Time Loading Time Unloading Time

10.31 10.37

10.37 11.03 26

11.03 11.06 3

11.06 11.36 26

11.36 11.39 3

11.39 12.06 27

12.06 12.10 4

12.10 12.39 29

12.39 12.42 3

12.42 1.10 28

Total Time 13 136

Avg. Time 3.25 27.2

9/4/2017 61

Air Leakage = Loading Time/ (Loading Time + Unloading Time )

=1.53/(1.53+22.184)

=6 %

Benefits : 280 kwh energy saved per annum


Compressed Air Leakage Test - Before

Start Time End Time Loading Time Unloading Time

9.38 9.42

9.42 10.08 20.2

10.08 10.1 1.55

10.1 10.32 22.08

10.32 10.34 1.5

10.34 10.57 23.18

10.57 10.59 1.51

10.59 11.21 22.4

11.21 11.23 1.56

11.23 11.46 23.06

Total Time 6.12 110.92

Avg. Time 1.53 22.184

Control Panels with VFD’s (After Status)

Conventional Arrangement (Before Status)

Implementation of VFD for reduction in energy consumption

1 2 3 4

5 6

1.VFD for Blower 1 (40Hp)

2. VFD for Blower 2 (40Hp)

3. VFD for PCO (20Hp)

4. VFD for WDO (15Hp)

5. VFD for powder collectors.

6. VFD for conveyor

Benefits

Total 27.83 % reduction in specific

energy consumption of powder coating unit.

64

Benefits : 1) 2355 mins (3.5 days ) of product waiting is reduced.

2) 1200 mins (1.8 Days) of change of plan is reduced.

PROBLEM : 1) 45.11 % machine busy is in welding line.

BEFORE AFTER

Only one welding line for fabrication Two more welding line added.


1. Implementation of TPM, TQM, 5S practices

65

BEFORE

Benefits : 1) Productivity increased as production is target based now.

2) Projects identified from loss summary.

PROBLEM : 1) 1745 mins (12 % of total waiting time) loss due change in plan.

AFTER

No system for production loss capturing


1. Implementation of TPM, TQM, 5S practices

9/4/2017 66

Walkthrough Audit

Audit by Mr.Rumi and his Team Audit by Mr.Rumi and his Team

➢ KEEP A CHECK ON ELECTRICITY BILL CHARGES LIKE PENALTY, INCENTIVE, AREAR BENEFITS AND MD.

➢ SHOULD MAINTAIN RECORD OF MD, MD BILLED, MD RECORDED AND COST OF POWER ON MONTHLY BASIS.

➢ EXPLORE THE POTENTIAL OF HYD. PRESS. BREAK FOR INSTALLING CONST. TORQUE VFD

➢ PERIODIC CHECKS ON INLET FILTER (AIR SUCTION FILTER)

➢ EXLORE VFD TO OPTIMIZE THE SUPPLY DEMAND OF COMP. AIR.

➢ EXPLORE THE POTENTIAL OF HYD. PRESS. BREAK FOR INSTALLING CONST. TORQUE VFD

▪ Some Key Findings From Energy Audit

9/4/2017 67

Benchmarking

CompanyRadhe

Industries

Jay

Industries

Specific

Energy

Consumption

(Kw/Ton)

42.07 56.65

Benchmarking with similar type of industry

0

20

40

60

Radhe Industries Jay Industries

42.0756.65

Energy Consumption (Kw/Ton)

Specific Energy Consumption (Kw/Ton)

Specific EnergyConsumption (Kw/Ton)

Implementation of best 5S practices

5S Example in Safe Assembly Area 5S for carton storage

5S Example in Understure Assembly Area 5S in Shop floor

Implementation of best 5S practices

Visual for Turret Tool Stations Visual for Turret Stations

Visual for Turret Preventive Maintenance Visual for Turret Machine

Participation in various Conferences / Forums

Participated in 8th National cluster summit Participated in 9th National cluster summit

Participated in 3rd edition of Green Conclave 2016 Best case Study award in 12th MRM of Advance cluster

Award at 8th National Cluster Summit

2015 Top Contributor- KAIZEN

Supplier Excellence award 2011 -2nd Price

OUR CERTIFICATES & ACHIVEMENTS


Award at 9th National Cluster Summit 2016 Top

Contributor- KAIZEN

KAIZEN AWARDS AT GODREJ REVIEW MEETING DEC-

2016 FOR CONSERVATION OF RESOURCE


AWARD IN GREEN CONCLAVE FROM IGBC KAIZEN AWARDS AT GODREJ REVIEW MEETING


Greenco Gold AWARD in 6th Edition of Greenco Summit.


80

THANK YOU

Date post:	12-May-2018
Category:	Documents
Upload:	buicong
View:	217 times
Download:	1 times

Energy Efficiency -...

Documents