National Award for Excellence in Energy Management -2018

National Award for Excellence in Energy Management -2018

Hero MotoCorp Ltd. - Haridwar

29th Aug – 31st Aug’2018

Ashu TyagiSection Head Utility

Satyendra Gupta Section Head Prod. Engg

National Award for “Excellence in Energy Management – 2016 2National Award for “Excellence in Energy Management – 2018” 2

Agenda

Brief introduction on Company/Unit

1. Specific Energy Consumption in last 3 years

2. Information on Competitors, National & Global benchmark

3. Energy Saving projects implemented

4. Innovative Projects implemented

5. Utilisation of renewable energy sources

6. Utilisation of waste material as fuel

7. GHG Inventorisation

8. Green Supply Chain

9. Team work, Employee Involvement & Monitoring

10. Implementation of ISO 50001/Green Co-rating

11. Other relevant information


Agenda














Brief introduction on HMCH - Journey

Hero Honda Motors Ltd.

IncorporatedFirst motorcycle

"CD 100" rolled out

Gurgaon plant inaugurated

Haridwar plant inaugurated

1984

Journey Started

1985 1997

HHML-World No.1 2W Manufacturer

2001

20082011

New Identity -Hero MotoCorp Ltd.

2013

Most Effective Brand Transition Award by CNBC

20162016

Start of 5th plant in India at Vadodara, Gujarat

2014 2015

2016

Start of 4th plant & GPC at Neemrana, Rajasthan

Start of 1st overseas plant at Columbia

Start of CIT at Jaipur, Rajasthan

Milestone of 70 million cumulative Production


Processes & Major Equipments:

Supplier Haridwar

Supplier NCR

Dealer

Customer

Major equipments are in Paint & utilities of electrical and thermal nature.

Machine ShopsEngine Assly

Frame Assly

Final Insp.

Disp

atch

Weld Shop Paint shop

Decentralized Supply Hubs

Decentralized Supply Hubs


Agenda














1. Plant Specific Energy Consumption

Resource Unit

Start Year Achieved Target

FY 08-09

FY 09-10

FY10-11

FY11-12

FY12-13

FY13-14

FY14-15

FY15-16

FY16-17

FY17-18

FY18-19

Electricity Kwh / Veh 24.61 17.31 16.37 15.61 15.72 14.74 15.79 15.12 14.75 13.64 12.83

HWG Fuel SCM / Veh 0.714 0.609 0.474 0.428 0.427 0.447 0.476 0.368 0.291 0.260 0.234

Increased due to installation of comfort cooling on expansion lines along with new models commissioning and trials.

Extensive efforts made in FY 16-17 to bring down SFC

Achieved Continual improvement in resource conservationAchieved Continual improvement in resource conservation

24.61

17.3116.37

15.61 15.7214.74

15.7915.12 14.75

13.6412.83

10.0

12.0

14.0

16.0

18.0

20.0

22.0

24.0

26.0

FY08-09

FY09-10

FY10-11

FY11-12

FY12-13

FY13-14

FY14-15

FY15-16

FY16-17

FY17-18

FY18-19Target

Kw

h/V

eh

Specific Energy Consumption

0.714

0.609

0.4740.428 0.427 0.447

0.476

0.368

0.2910.260

0.234

0.2

0.3

0.4

0.5

0.6

0.7

0.8

FY08-09

FY09-10

FY10-11

FY11-12

FY12-13

FY13-14

FY14-15

FY15-16

FY16-17

FY17-18

FY18-19Target

SCM

/Ve

h

Specific Fuel Consumption

Last 3 Year 13.5% Reduction Last 3 Year 46% Reduction


Agenda














2.1 External & Internal Benchmarking

Benchmarking done wrt to Competitors and Internal, though we are consuming lesser than them but yet we are striving for continual improvement

14

.7 15

.8

15

.1

14

.8

13

.6

19

.9

18

.9

17

.9

17

.7

27

.4

27

.4

27

.2

26

.5

25

.6

30

.99

29

.00

27

.71 3

0.3

7

29

.60

0

5

10

15

20

25

30

35

13-14 14-15 15-16 16-17 17-18

Kw

h/V

eh

Specific Energy Consumption

HM3H Competitior 1 HM1D HM2G


.

..

.2.2 Machine Family wise Benchmarking

Bench Marking done for energy consumption of each machine family

0.13

0.07 0.06

0.02 0.01

0.0

0.0

0.0

0.1

0.1

0.1

0.1

0.1

WashingM/c

RotaryMilling

Vigil M/c Face milling FRD OP-10

Kw

h/C

om

po

ne

nt

AL Phase Crank Case Machine kwh Consumption/Component

0.09 0.090.08 0.08

0.04

0.0

0.0

0.0

0.1

0.1

0.1

Vigil RotaryMilling

ChemferingM/c

Washing M/c FRD OP-20

Kw

h/C

om

po

ne

nt

AL Phase Cylinder Head Machine kwh Consumption/Component

0.090.07

0.06

0.02 0.02 0.01

0.0

0.0

0.0

0.1

0.1

0.1

WashingM/c

InductionHardening

HorningM/c

FineBoaring

Nachi FaceMilling

Kw

h/C

om

po

ne

nt

Steel Phase Machine kwh Consumption/Component

Monitoring of consumption of each machine family per

component complete process/cycle time

P

D

C

C

A


Agenda














Sr. No.

Top 10 Energy Saving Projects

Annual Savings

Kwh in Lacs

Rs in Lacs

1 Reduced voltage supply for lighting energy saving through Dry Trafo 2.2 11.58

2Elimination of Shift from Aluminium Crank Case by Reducing cycle time of Robotic cell from 76.5 Sec/Line to 72 Sec/Line to reduce energy consumption and improve productivity

2.0 9.91

3Elimination of Shift from Aluminium Cylinder Head by Reducing cycle time of Robotic cell to reduce energy consumption and improve productivity

1.9 9.40

4To Eliminate Chiller used after Dry off Oven for Fast Cooling of Components in SM Paint Shop by extending conveyor length Component through Natural Cooling of air Shower

1.7 8.74

5Switching off Steel & Aluminium Phase FDV's in Lunch, Dinner & C-shift to reduce energy consumption

1.5 7.67

6Reduction of KWH consumption in Engine Assembly by using 1 common washing machine in Line-4 & Line-3 by re-layouting & trolley arrangement

1.5 7.58

To be continue..To be continued..

3.1 EnCon Projects in last 3 year – Electrical (Zero Investment)


Sr. No.

Top 10 Energy Saving Projects

Annual Savings

Kwh in Lacs

Rs in Lacs

7Sparing 1 washing machines of engine assembly by rearranging design parts feeding.

1.5 7.58

8Optimisation of 1500 CFM Air compressor auto mode VFD (Variable Frequency Drive) to reduce energy consumption.

1.4 7.01

9Gun drill machine coolant circuit modify to run machine with 2 pumps in place of 4 pumps to save the energy & MTTR in Machine Shop.

1.2 5.92

10Optimize the process in Lacquer Paint shop and run 2No's Water pump place of 3No's.

0.8 4.27

Total Saving (Top 10 Projects) 15.7 79.6

Total Projects Saving (50 Nos.) 27 140

Total 50 No’s Zero investment projects Implemented and conserved 27 Lacs kwh and cost saving of Rs 140 Lacs/year

3.2 EnCon Projects in last 3 year – Electrical (Zero Investment)


Sr. No.

Top 10 Energy Saving ProjectsAnnual Savings

Kwh in Lacs

Rs in Lacs

1 Conventional task lights replacement with LED Lights (3000 Nos) 3.53 20.63

2Installation of VFD (Variable Frequency Drive) FDV's of Machine Shop and Assembly area FDV Blowers by reviewing & balancing velocity at FDV drops to save energy consumption.

1.37 7.36

3Installation of VFD (Variable Frequency Drive) in 4No's FDV's of Machine Shop FDV Blowers by reviewing & balancing velocity at FDV drops to save energy consumption.

1.23 6.22

4VFD Installation in lacquer exhaust blowers, EA washing Pumps, ACED Water rinse pump (FPM combined)

1.87 10.90

5Finding opportunities of variable speed requirements in Utility & installing VFD’s in them

1.06 6.18

6 EC fans installation in place of blowers in ASU (Air Supply Unit) 1.03 6.04

To be continue..To be continued..

3.3 EnCon Projects in last 3 year– Electrical


Sr. No.

Top 10 Energy Saving ProjectsAnnual Savings

Kwh in Lacs

Rs in Lacs

7 Reduction in power consumption of old paint shop pumps /Blowers 0.86 4.63

8 Conventional tube light replacement with LED 0.86 4.63

9HPSV ( High Pressure Sodium Vapour) Street Light replacement with LED light

0.77 4.13

10Replacement of electrical heaters with Plate heat exchanger in weld washing machine

0.54 3.19

Total Saving (Top 10 Projects) 13.12 73.91

Total Projects Saving (32 Nos.) 24.6 136

Total 32 No’s Investment Projects Implemented and conserved 24.6 Lacs kwh and cost saving of Rs 136 Lacs/year

3.4 EnCon Projects in last 3 year – Electrical


3.5 EnCon Projects in last 3 year – Thermal

Sr. No.

Top Energy Saving ProjectsAnnual Savings

SCM in Tons

Rs in Lacs

1Canteen Relayouting (new equipment's to be added having better SFC)

240 59.8

2Shift operation reduction in ACED Paint shop by provision of 3 frame Body loading in one hanger to Synchronize ACED Line production with Frame Assembly production requirement

210 73.1

3 Baking oven temperature reduction from 195 to 185 deg c 161 40.0

4Dry Off Temperature Reduction from 140 deg to 110 deg with introduction of NIHON PT Chemical

161 40.0

5Hot water generator temperature Reduction by 5 deg C and efficiency improvement in paint shop

102 31.2

6 Phosphate temp reduction from 50 to 42 deg - SM 87 21.6

7 Phosphate bath temperature reduction from 65 to 55 deg c - ACED 26 6.3

Total Saving (Top 7 Projects) 985 272

7 Projects implemented & Conserved 985 Ton SCM Natural Gas resulting in cost saving of Rs. 272 Lacs /year

Projects with Zero Investment


Agenda














Cost saving of Rs. 178 Lac/Annum through various Innovative Projects

S. No.

Section Improvement ProjectResource Saved/ Annum

Cost Saving

1Lacquer Paint Shop

To replace conventional blowers with High Efficiency EC Fans in Lacquer Paint shop ASU ( Air Supply Unit) to save energy

1.06 lac Kwh INR 6.2 lacs

2 Weld ShopTo replace Electrical energy heating with natural gas system.

0.54 lac kWh INR 3.19 lacs

3 Machine shopIGBT (VRp-Voltage Regulate Precision) Transformer installation

0.85 Lac kWh INR 5.0 Lac

Total Saving Per Annum INR 14.5 Lacs

Total Projects Saving (10 Nos.) INR 178 Lacs

Innovative Projects Summary4 Energy Conservation


Painting Booth

Exhaust System

Environment Air Inlet

Booth Air Inlet

4.1 Replacement of conventional blowers with High Efficiency EC FansInnovative Project -1

Exhaust Blower with VFD to maintain positive pressure

Current system-

Blower used in Lacquer Paint shop refines the air and maintain positive pressure thus not allowing external dust around the paint booth to enter into the paint booth.

Single centrifugal blower of 90KW

Blower running with conventional motor to maintain positive pressure in booth

Total Intake Volume = 124,000 CFM Static Pressure = 1270 PaMotor Rating = 90kW

•first filtration process herewith the help of bag filtersPrimary filters zone

•it undergoes secondary filtration by bag filters

Secondary filters zone

•The ASU burner Heats up the coming air at the required temperature.

ASU Burner Zone

•Spray nozzles humidify the air at the required humidity level.Humidity Zone

•Then flowing air is supplied to the sound damper by the supply blower

Supply Blower

•In Sound Damper Zone, vibrations due to the flowing air is absorbed by the dampers.

Sound Damper

•Finally filtered and sent to the painting booth.Final Filters Zone


Background:Centrifugal blowers used for conditioned air supply in ASU of Paint Shop

Results:

Centrifugal Blower EC FAN

It Consist of Blower, Motor, Pulley, Belt

Direct coupled Impeller without any Pulley & Belts, hence no transmission loss

3 Ph AC InductionMotor

DC Motor-Improved efficiency upto 90%

Separate VFD PanelInbuilt VFD at Fan unit. No VFD circuit filter losses.

ASU flow – 75K cfmStatic Pr – 1270 Pa

- Energy saving of 60% due to reduction in losses- Runs at same static & delivers same flow

Compact Design - Replaced Centrifugal Fan + Motor +VFD by Single unit• High Motor Efficiency -90%

1144822

0

1000

2000

Before After

KWH/Day Power Consumption (KWH/Day)

321

EC Fan installation resulted Saving of Rs. 6.2 Lac /year

Improvements Done:Installation of 12 no. EC fans (5.8 kw each) in place of one big blower (90 KW).

4.1 Replacement of conventional blowers with High Efficiency EC FansInnovative Project -1

Methodology/Approach Adopted: -

Painting Booth

Exhaust System

Environment Air Inlet

Booth Air Inlet

Exhaust Blower with VFD to maintain positive pressure

Single centrifugal blower of 90KW

EC FAN ( Horizontal Deployment)

Sl.No. LocationDesign CFM

Design Power in

KwQty/unit

Total Power in

Kw

Total Power Savings

% 1 Primer 82500 110 12 72 38.00

2 Base Coat 82500 110 12 72 38.00

3 Top Coat 82500 110 12 72 38.00


4.2 Replacement of Electrical heating with gas heating in washing machine Innovative Project -2

Washing machine used for component washing in weld shop

Fuel tank washing machine used for cleaning components and eliminating the foreign particles.

Electrical-AC415V~ 120AmpCompressed Air-6 BarSpace-1600 mm*4132 mm*2260 mmWeight-Approx 1500KG

Conveyor speed-It should be between 20-30 Hz, Drying Temp.-Temp. should be between 45-55 degree.

HeatersHot Water

Conveyor

Washing Machine

Air BlowerNozzle for

water spray

Fuel Tank

Pump


4.2 Replacement of Electrical heating with gas heating in washing machine Innovative Project -2

Background:

.

After Condition – Washing m/c water temp Maintained by Heat Exchanger Plate

Before condition :Washing M/c (7 no) of weld shop water temperature maintained by Electric Heaters.

Improvements Done

2076

1065

0

1000

2000

3000

Before After

Energy Cost/Day

Power Consumption (Energy Cost/Day)

Hot Water using in washing m/c resulted Saving of Rs. 3.19 Lac /year

Methodology/Approach Adopted: -Results: Energy Comparison Electricity to Natural Gas

Avg heater rating 36 KW

Heater on Hrs during A & B shift 10 HRS

Total kwh consumption/day 356 KWH

Electrical Energy Cost/Day 2079 INR

Heat requirement/Day 305,914 Kcal

Natural Gas Requirement to meet above 36 SCM

Natural Gas cost 1014 INR

Saving on Natural Gas over Electrical Heating

1065 INR

Saving /Year 319,844 INR Lac

Investment 400,000 INR Lac

ROI 1.25 Years

Horizontal deployment planned in 14 m/c for Weld shop & Engine Assembly in FY18-19 to save the INR 38.7

Lacs/Year

Heaters Hot Water

Conveyor

Washing MachineAir Blower Nozzle for water spray

Fuel Tank

Pump


4.3 IGBT (VRp-Voltage Regulate Precision) Transformer installation

Background

Advantages

Voltage Stabilizer

Isolation X-mer

VRP Line Conditioner

• Voltage Regulation through IGBT

• RS485 communication port

• Space Saving due to compact design.

• Voltage regulation in real time (<20ms)

• Soft Switching

Energy savings due to efficiency improvement of 10%: Rs. 0.5 lacs per VRp installation

Reduction in maintenance cost (less network cards or PCB failures)

High replication possibility as no of machines are ~200 nos

All the CNC machines are connected with Voltage stabilizer and Isolation transformer for quality power supply in machine shop.

11 No’s VRP installed as pilot project and resulted saving Rs. 5 Lac/Year

Improvements Done


Innovative Project -3

Stabilizer+ IsolationTransformer

Voltage Regulate Precision (VRp)

Efficiency of Stabilizer: 92%Efficiency of Xmer: 94%

Total Efficiency: 86%

Replaced with single VRp unit

Efficiency : 96%

Moving parts – VariacResponse Time: 1-2 Sec

IGBT based switchingResponse Time: <20 ms

Higher core losses Less Core losses


Agenda














Natural Air ventilators installed 38 no.

Translucent Sheet in plant roof Green roof coverage 45000 Sqm

Natural Ventilator , Translucent sheet , Plant green roof initiative saved 1200 kwh/Day

5.1 Renewable Energy Source

Utilization of Renewable Energy Utilization by using Solar Plant, Solar heater, sky light, Natural ventilator, Translucent sheet and green roof


1. Solar Generation capacity will increase to 1.95 MW 2. Solar Power Sharing will be 10% of total daily Energy

We have ground mounted solar plant having capacity of 1MWp which is able to produce almost 5% of energy consumption of whole plant for a day.

There were huge area on roof top which can be use for Solar power generation. We have proposed to install rooftop plant of 950KW capacity which may increase the solar share to 10% of total energy consumption for the day.

5.3 Solar PV project for roof top

Previous Condition Improvements Proposed

Benefit:


Target Results:

1 MW1.95 MW

0.00

0.50

1.00

1.50

2.00

2.50

Before After

MWSolar Generation

0.95 MW

Project installation is under progress for roof top solar.

Target Date: - 31/12/2018


58 83

1,150 1,150 1,150 1,150

0418

1,392 1,412 1,712

2,512

281530

866 10201500 1500

339

1031

3408 3582

4362

5162

0

1000

2000

3000

4000

5000

6000

FY 14-15 FY 15-16 FY 16-17 FY 17-18 FY 18-19PROJECTED

FY 19-20PROJECTED

MW

H

Utilization of Renewable Energy

Solar Heating & Lighting Solar Power RE IEX Trading Total

14%

5.2 Renewable Energy Utilization

Current Utilization of Renewable Energy - 10% , we are in process of installation of roof top solar of 950 kWp by Nov-18.

1%3%

10%

12%


Agenda














Co-Processing of paint sludge will result in savings of 50 LPA

6.1 Utilization of paint sludge (waste) as a fuel

• Co- processing technology is an eco-friendly solution for Sustainable Waste Management.

• It uses cement kiln technology to treat hazardous and non-hazardous waste in a sustainable manner ensuring regulatory compliance.

Project Details:

Background:

Concept:

Benefits:

• After incineration paint sludge convert into ashwhich disposed in SLF.

• Approx. 23000 kg paint sludge generate monthly,which is being incinerated in the one incinerator

• Approx cost of Paint sludge incineration = Rs 27/kg

Advantages of Co-Processing :1. End to end waste disposal2. Environmental friendly3. CO2 emission reduction

Co-processing ( Rs/Kg) 9.00

Per kg Paint Sludge Incineration Cost 27.00

Saving per kg paint sludge 18.00

Monthly average Paint Sludge generation ( (kg) 23230

Monthly Saving by Co-processing ( Rs. Lac) 4.18

Yearly Saving by Co-processing ( Rs. Lac) 50.18

Co-processing for Disposal of Paint Sludge


Thinner Recovery unit & its reuse in bell & Gun cleaning Advantage :- Saving of 180

Litres of cleaning thinner per day

Recycling & Reuse of Waste resources based on 3R approach

Waste Food Energy Utilization Thinner (Waste) Recovery System

6.2 Waste Utilization

Food Compositing Machine Manure usages in horticulture

Hygienic Disposal of waste: 500 Kg./Day Manure Generation : 200 Kg./Day


Agenda














GHG Emission Inventorisation

CO2e (MT) FY 17-18

Scope –I

3,968 CO2e (MT)

Scope-II

50,083 CO2e (MT)

GHG Inventorisation

60007000 7519 8028 8325 8526 8739 8941

10500 10825

0

2000

4000

6000

8000

10000

12000

20

08

-09

20

09

-10

20

10

-11

20

11

-12

20

12

-13

20

13

-14

20

14

-15

20

15

-16

20

16

-17

20

17

-18

No

’s o

f Tr

ee

Cumulative Nos of Tree (Inside Plant)

Better

Maintaining 10,825 trees inside plant which reduced 422 Ton CO2 emission/year

7.1 GHG Inventorization

51,881 53,940 53,999 49,545 50,083

7,655 8,891 5,4203,541 3,968

59,536 62,831 59,41953,086 54,051

010,00020,00030,00040,00050,00060,00070,000

20

13

-14

20

14

-15

20

15

-16

20

16

-17

20

17

-18

Co

2e

CO2 Emissions (MT)

SCOPE-1 SCOPE-2 TOTALBetter

23.7723.4

24.0523.69

22.08

20.32

18

19

20

21

22

23

24

25

20

12

-13

20

13

-14

20

14

-15

20

15

-16

20

16

-17

20

17

-18

Kg/

Ve

h

CO2 Gas Emission (kg/veh)Better


• Technology developed & Patented by Hero MotoCorp Ltd.

• First implemented in iSmart 100 cc bike & then horizontally deployed in other Models.

• Function: When you stop the bike; the i3S system puts the engine into hibernate mode. The Idle Stop Start System turns off the engine after waiting for about 5 seconds for e.g. at a traffic signal. It restarts the engine automatically when press the clutch.

Passion Pro Spl Plus

HF Deluxe

Glamour 125

Achiever 150 Super Splendour

iSmart 110cc

CO2 reduction of 85,076 TPA by Technological Innovations in Product design

7.2 GHG Inventorization - Initiatives by increasing product efficiency


28 Villages of district Uttarakhand @ Haridwar, Dehradun, Uttarakashi provided with 7W LED Bulbs & street lights. Saving 1.07 Crore of Electricity Units/Year for our State.

Total 560 Solar Street Lights provided to following villages:A. Village Dobnagar PathriB. Village Mishraas PattiC. Village DoiwalaD. Village ChamasarieTotal Beneficiaries families from thesevillages are 2964 saving 4.03 lac units for our State

28 Villages of Uttarakhand @ Haridwar, Dehradun, Uttarakashi provided with 7W LED Bulbs.We saved 1.03 Crore kwh of Electricity Per Year for our State.

Total families benefitted with this project are 12,727 nos.

7.3 GHG Inventorization - CSR Activity for Energy Conservation


Sr. No.

Description UOM Target

1 Budget Rs. Cr 7.75

2Completion Time

Months 10

3 Water Saving KL/ Annum 73000

4 Cost SavingRs. Lacs / year

5

Zero liquid discharge (ZLD) plant and use this water in our process

ZLD Plant impact to reduce 200KLD RAW water drawing from ground

ZLD Plant Operation monitoring through SCADA

7.4 GHG Inventorization - Environment - Conservation


Agenda














8.1 Green Supply Chain Dispatch Truck Capacity Enhancement

Reduced Total 48 nos. Trucks trip per day from Haridwar Plant

5 Vehicles / Row 50 vehicles/ Truck

4 Vehicles / Row40 Vehicles/ Truck

Before After

Rider and Pillion step at resting position

Sari Guard assly in single piece

Sari Guard assly made in 2 Pieces and wrapped

Rider and Pillion step folded with rubber bands

Total 238 Trucks/ Day for Dispatch of 9500 Veh. Total 190 Trucks/ Day for Dispatch of 9500 Veh.


EnCon Projects Saving

Sr. No.

Top Energy Saving ProjectsName of the Associate /

Vendor

Annual Savings

KWH inLacs

Rs in Lacs

1Power & Fuel saving considered by optimization of Chiller usage cycling timer mount 1 hour On Off

Rinder 4.0 23.4

2 To reduce energy consumption around 15% at AIR CompressorMunjal Showa

Ltd1.0 5.8

3Reduce Power consumption by changing heating element by higher bonding silicon carbide element

Rockman 0.8 4.9

4 Light Replacement with conventional light Endurance 0.8 4.7

5Reduce Power consumption in cooling tower and hydraulic motor by running in star connection

Rockman 0.8 4.6

6 Re-arrange of Compressor Layout Endurance 0.6 3.3

7To reduce Electrical Energy consumption of Hydrogen De Embrittlement oven.

Nipman 0.6 3.3

8 Install more capacitors to raise Power Factor to motor end. Rinder 0.6 3.3

9 tube lights replaced with LEDMunjal Showa

Ltd0.5 3.2

10 Replacing Higher efficiency air dryer Endurance 0.5 3.1

To be continued..

8.2 Green Supply Chain


EnCon Projects Saving

Sr. No.

Top Energy Saving ProjectsName of the Associate /

Vendor

Annual Savings

KwhRs in Lacs

11 C0-Excal fan system in exhaust system Satyam 0.5 2.8

12 Reduce Air Compressor consumption by installation of VFD Nipman 0.5 2.6

13 Compressed Air saving project through leakage control Satyam 0.4 2.5

14 Material change in holding Furnace Endurance 0.4 2.5

15 Installation high efficiency pump Endurance 0.4 2.4

Top 15 project saving 13.6 79.7

Top 10 Vendor total project saving 23.6 137.7

Various project implemented at vendor end & Conserved 23.6 Lac kwh resulted cost saving of Rs. 137.7 Lacs /year



Before After

8.4 Green Supply Chain GVDP - Vendor Industry Initiative

Waste heat of DG stack used in VAM

Before After

Various projects implemented under GVDP program by Rockman Industries

Halogen light Sky light

Reduce Natural Gas consumption by using Induction furnace in place of Gas fired furnace for CI ring heating

Reduce Power Consumption by Replacing the Halogen light to Sky Light at Shop Floor Machine shop


Before After

VFD installed at Air Compressor to reduce energy consumption


Stop timer installed during Idle condition for CNC M/C.

Before After

Projects implemented under GVDP program by M/s Munjal Showa Ltd.

GVDP - Vendor Industry Initiative


Agenda














March-18

Substation online monitoring Transformer online monitoring

Resource conservation project registration format

Energy Consumption Monitoring & Daily Review shop wise

Online Monitoring system deployed to identify and analyze Abnormalities

Monitoring & Reporting Systems9.1 Energy Management

DG online Monitoring System


9.2 Encon Cell

Energy Conservation Cell driven from top with involvement of all employees

Plant Head

HOD (QA)

Team Mgr.

Team Mgr.

Team Mgr.

Team Mgr.

Team Mgr.

HOD (Prod)

HOD (Maint/Encon

Leader)

HOD (HR)

HOD (SCM)

Section Heads (SCM)

Section Heads(Prod)

Sec Head Utility(RCT

Leader)

Section Heads (HR)

Section Heads (QA)

Facilitators

Review Frequency -Monthly

Review Frequency -Fortnightly

Review Frequency -Weekly

Review Frequency -Daily

Manufacturing Head


.

• Emphasis on Resource conservation

• Plant Visits & sharing of resource conservation Projects

On-joining program

• Trainings by internal & external team.

• Discussion of recent improvements

Continuous Energy

Awareness

• Poster & slogan competition.

• Idea generation contest.Employee

Involvement

Implementation of ideas by Team

Kaizen awards to successfully

implemented ideas.

All Employees

9.3 Energy Management Total Employee Involvement

93 staff & 1024 team members covered for Environment and Energy Conservation



9.4.1 OP80 Operation Rebalancing In Cell In Cylinder Head Shop

Three machines eliminated and saved 1.29 Lac kwh annually

Present Condition


Improvements Done/Kaizens done: -

Results:

Operation -Exhaust face at OP801. Boring and facing operation (Hole No.208 ) at right Side Fixture (ø33±0.20)2. Drilling (Hole No. 209 & 210) at left fixture.OP80 : Cycle Time of operation 24 sec

Machine CT Before Operation AddedOperation

ShiftedCycle Time

After

0P20 51 OP80, 209+210, 208 204,206 59

OP30 53 Comp Marking - 56

OP40 55 204,206 205,207 53

OP50 60 205.207108, Comp

Marking55

OP60 52 108 - 60OP80 24 - - Not req.

AFTERBEFORE

1

Kaizen-1 OP 80 (ø 33±0.20 & ø 5.45+0.15 ) operation will be done at OP20 with fixture modification

Kaizen-2- Trial Of PCD Thread Mill for tappet face operation in place of Drilling and tapping Operation thereby reducing cycle time by 5 sec.

2

Horizontal Deployment StatusLine L1 L2 L3 L4 L5 L6 L7 L8 L9

Plan Feb-18 Feb-18 Feb-18 Feb-18 Feb-18 Feb-18 Sep-17 Oct-17 Oct-17

Actual Done Done Done Done Done Done Done Done Done

Operation Rebalancing :- This operation is shifted in Cell (ie, OP20 –OP60) by rebalancing the tool operation

209 & 210

208

SPM

OP30OP20 OP40 OP50 OP 60 OP 70 OP 80Rotary OP 10A

1. 8 manpower - Rs. 16 Lacs2. Productivity will increase from 57.61 to 61.063. Power saving= 1.29 Lacs Kwh per annum,


S. No

Description Module 1 Module 2 Module 3Modul

e 4

1Flow Direction

2Capacity distribution

2430 3038 3038 1215

3Manpower -nos

70 86 82 41

Background Improvements Done

Results:

Weld line 1&2 capacity was under-utilized (2400 FT/Day) wrt Line 3&4 (3000 FT/Day) due to layout constraint

To utilise Weld line 1&2 Capacity & enhance Manpower productivity from 35.22 to 38.46through Layout Change similar to Line 3&4

# DescriptionUOM

Before After

1 Capacity nos 2430 3038

2 Productivity nos 35.22 38.46

3 Layout --

Annual Savings of Rs 36 lakhsSavings of 10 Manpower = Rs 2 x 10 = Rs 20 lakhs,Power Savings 806kwh = Rs 14.5 lakhsPPE’s Rs 1.5lakhs

Investments: Investment of Rs 15.5 lakhs(FDV’s, Electrical, New Booths, New Brazing system, Piping, Underground Piping work, etc)

Process flow streamlined with minimal changes (Half Line)

L1

L2

L3

L4

L5

L6

L7

9.4.2 Productivity Enhancement through Weld Line 1&2 Relayout

Energy Savings of Rs 14.5 Lacs through layout modification



9.4.3 Improvement through Automated Guided Vehicle

Improvements Done

Results:

In current condition, Material feeding from store to Line is being done through MHE.

Laser based Natural navigation type Automated Guided vehicle deployed for material feeding.

• Total 170 nos. Manpower used in different sections for material transfer.

• We have proposed Logistic automation though Automated guided vehicle for material feeding

BOSF Material feeding for Machine DOL to Shop Floor

• Crankshaft• Cylinder Block• Cylinder Head

• 05 Nos. of PPC manpower • Project Investment = Rs. 55.0 Lacs• Saving = Rs. 10.0 Lacs• ROI = 5.5 Years

• Max Speed = 90m/min• Stop accuracy = +/- 20mm• 3 zone safety = SIL-3• Battery backup = 8 hrs.

Saving of 05 nos. manpower will leads to cost saving of Rs. 10 Lacs/annum

Background



1. Conventional Cooking Equipment were used in Canteen

2. Natural gas Consumption / Annum = 1.17 Lakh SCM/Annum (2015-16 )

3. Cooking Oil Consumption/Annum = 0.45 Lakh Lt/Annum (2015-16)

Project Objective : To Replace Conventional Equipment with Modern Equipment for Cooking Oil, Natural Gas and Manpower Saving

Target Setting : Project was worked upon @ 7000 VPD so saving calculated accordingly

Canteen Re-layouting Saving Plan (Phase-2)

Description Before After Saving in Rs. lacsNatural gas 117,456 93,964 5.4

Frying Oil 45,803 38,738 9.0Manpower 125 122 6.0

Total Expected Saving = Rs. 20.4 Lakh

Rice Cooking Daal,

Vegetable Boiling

Patties,Tikki, Bread Roll

Utilization

For cooking Meeting related Snacks (Less Qty Snacks)

For Blanching Daal, Vegetables

Gravy Making

DescriptionProposed

Saving (Rs. Lakh)

Actual in Feb'17 (Rs. Lakh)

Actual Savings Annual

(Rs. Lakh)Natural gas 5.4 0.20 2.4

Frying Oil 9.0 0.90 10.8

Manpower 6.0 0.17 2.0Total 20.4 1.3 15.2

Previous Condition Improvements Done


Results:

Conventional inefficient equipment replaced with latest efficient equipment

9.4.4 Canteen Re-layouting with new equipment

AfterBefore


1. Energy consumption reduction.2. Saving of 317 units/day.

Split AC without Eco plug leading to high energy consumption.

Energy/Loss Reduction Plug generally compares the temperature of liquid line to the temperature of environment. If the desired temperature difference is maintained it switches of compressor of AC to save energy consumption• Eco Plug generally compares the

temperature of liquid line Eco Plug generally compares the temperature of liquid line to the temperature of environment. If the desired temperature difference is maintained it switches of compressor of AC to save energy consumption to the temperature of environment. If the desired temperature difference is maintained it switches of compressor of AC to save energy consumptionEco Plug installation resulting in Saving of Rs 3.85 Lacs/Year

Project: 5Innovative9.4.5 Adopting switching Technology (Eco Plug)


Benefit:


Results:

Eco plug benefits:•Saves Power up to 30%•Fits on almost all AC models•Increases Compressor Life•Helps in reducing Global Warming•An eco-friendly device

2.001.30

0.00

0.50

1.00

1.50

2.00

2.50

Before After

Lac Kwh/Year Split AC Kwh Consumption

0.70 Lac kwh

Eco Plug

Before After


1. Natural gas consumption reduction.2. Saving of 339 scm/day.

9.4.6 Optimization of temperature in Hot Water Generator


Benefit:

Methodology/Approach Adopted: - Results:

0.26 0.22

0

0

0

0

0

1

Before After

SCM/Veh.

0.4 SCM/Veh.

Before After

HWG set temp- 90 *C

Temperature reduced to 80*C , Savings Achieved - ₹ 19 Lakhs

There is High consumption share of Natural Gas in Hot water Generator -2550 SCM/day ( yearly average of Fy16-17) which shares almost 9 % in cost of total power & fuel cost.

By optimizing hot water supply temperature to paint shop baths , we are planning to reduce natural gas consumption by 15 % in summer & winter in phase manner

HWG set temp- 80 *C


9.4.7 Air Compressor Efficiency and Air leakages

Shop Wise Leakage Identification & Plant Wide Adherence Report Generation. Leakage Points Closure Status. (April 16 – July 17)Cross Functional projects taken to improve Air transfer efficiency

1011

10 10 1011

10 109 9

1011

0

2

4

6

8

10

12

April May June July Aug Sept OCT NOV DEC JAN FEB MAR

No

’s

Reporting Adherence

FAD TEST : Measurement of Efficiency at Source

S. NO

Compressor

Rated Capacity

at 8Kg/Cm2

(CFM)

Rated Input

Power (KW)

Avg. pressure (KG/cm2

Barg)

Avg. Actual

Capacity as per report (CFM)

AvgInput

Power (KW)

Specific Power (KW/ CFM)

1Centac

(NO6-1389)6018 930 5.7 5569 861 0.15

2Centac

(NO6-1388)4132 660 5.3 3948 617 0.16

3Centac

(09/555)2281 400 5.6 2244 342 0.15

4 SL-250WC 1597 250 5.7 1530 257 0.17

950890

970 1010 970 950 910 880850 860 840 850

0

200

400

600

800

1000

1200

April May June July Aug Sept OCT NOV DEC JAN FEB MAR

CFM

Plant Air Wastage Tracking (CFM)

5248

3733

2825

21

11 10 9 8

0

10

20

30

40

50

60

Al. CC AL. CH ST. PH Weld Paint FA34 EA12 EA34 FA12 ACED AL Exp

No

’s

Leakage Test : Total Plant Air Leakage Tracking

Leakage ReportedLeakage Corrected


9.4.8 Re-align air balancing in Paint Shop to reduce energy cons.

Motor Rating -110 KW

Air Supply Unit used for:-

Air Supply Unit (ASU) uses the atmospheric air from outside, refines the air, and supplies it to the Paint and maintain positive pressure and velocity 0.3 to 0.5 M/Sec thus not allowing external dust around the paint booth to enter into the paint booth.

After changing high efficiency booth velocity increased by 30% and we got opportunity to reduce frequency of blower motor.

Environment Air

Primer Coat Booth ASU at 45 HzAir Velocity 0.3 to 0.5 M/S

Exhaust System – 45 Hz

Air Supply System – 45 Hz

Base Coat Booth ASUAir Velocity 0.3 to 0.5 M/S

Top Coat Booth ASUAir Velocity 0.3 to 0.5 M/S


Exhaust air out Environment Air Exhaust air out Environment Air Exhaust air out

Air Supply System – 45 Hz


Air Supply System – 45Hz

Particles

Filter-medium

After

Dust-cake

Filter-medium

Before

Particle Filtration (Conventional)• Faster Choking • High Pressure difference • High Energy consumption

Depth Filtration • No Choking as particle suspended in non uniform media • High dust storage capacity • Low Pressure difference• Reduced Energy CostAir Velocity 0.3 to 0.5 M/S Air Velocity 0.4 to 0.6 M/S


Background:Air Supply Motor running at frequency of 45 Hz even when running idle (Black painting)


Improvements Done

Timer provided for ASU motor Frequency reduction after 5 Mins change over from colour

painting to idle stateResults:

1. Power consumption reduced.2. Automation done No manual intervention required

Benefit:

No provision of reducing the Frequency during Black painting

1144 822

0

1000

2000

Before After

KWH/Day Power Consumption (KWH/Day)

321

PHE installation in washing m/c resulted Saving of Rs. 5.1 Lac /year

1. ASU motor frequency reduction 45Hz to 40Hz in colour painting.

2. Top Coat ASU motor frequency reduction from 40Hz to 35 Hz during black painting.

3. Exhaust motor frequency reduction from 34Hz to 30Hz

9.4.9 Re-align air balancing in Paint Shop to reduced energy cons.


Agenda














ISO Certification Strategy10.1 Implementation of ISO 50001

Total Internal Auditors developed – 32 Nos.

We are certified company for ISO 50001


. .

HM3H won “Green Co Gold Rating- Green Company Rating System ”

Project DetailInvestmentin Crores

Robots for Paint Shop 12.00

0.95 MW Solar power plant 4.50

Zero Liquid Discharge Plant 7.75

Aero bells Upgradation 0.66

VFDs installation in motors 0.47

Solar Heating plant for Canteen 0.13

We are certified for CII Green Company Gold Rating

10.2 Green Co Rating Award

30346

0

5000

10000

15000

20000

25000

30000

35000

TURNOVER

Cro

re

Turnover of last 3 year

31

0

10

20

30

40

CAPITAL PROJECT

Cro

re

Investment of last 3 year

0.9

0.0

0.5

1.0

OTHER

Cro

re

Investment of last 3 year


Agenda














Prominent Awards – Haridwar Plant11.1 Major Milestones– Haridwar Plant

1st Motorcycle produced at Haridwar Plant

Prestigious awards won by Hero MotoCorp, Haridwar Plant

CII

CII

CII

CII

CII


Market Share & Growth11.2 Prominent Awards – HMCL

Indian MNC of the Year’ Award -2017

TIME INDIA ‘Manufacturing Innovator of the Year’ – 2016

Bike Maker of the Year Award - 2013Business Leader of the Year Award -2013

2-Wheeler Manufacturer of the Year Award at CNBC Awards - 2015

Prestigious awards won by Hero MotoCorp


11.3 Major Projects Planned for Current year

Sr.No

Description Year Resource UOM

Energy/ Resource

Saving Per Year

Proposed Savings in

Lac Rs.

1Energy saving through absorption heat pump in HWG

FY 18-19 Fuel Ton SCM 225 90

2Solar Based 950 KW Power Plant. (20% Expansion in existing Capacity)

FY 18-19 Power MWH 1302 77

4Power wheeling from Renewablesources

FY 18-19 Power MWH 7800 39

5 Light Pipe Installation in plant FY 18-19 Power MWH 43 2.58

6Changing of Air end of 6000 CFM compressor.

FY 18-19 Power MWH 210 12.26

7Conventional motors replacement with Energy efficient motor

FY 18-19 Power MWH 132 7.73

8 Epoxy FRP Fan in Comp CT FY 18-19 Power MWH 19.80 1.16

Total Saving Expected in Lac - 230

Various projects are in pipeline in our journey to enhance renewable resource utilization


The Journey continues ………

Thank You

Date post:	22-Oct-2021
Category:	Documents
Upload:	others
View:	1 times
Download:	0 times

National Award for Excellence in Energy Management -2018

Documents