2019 Hero MotoCorp Ltd. - Haridwar - CII - Sohrabji Godrej ...

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National Award for Excellence in Energy Management -2019

Hero MotoCorp Ltd. - Haridwar

16th Sep. – 18th Sep’2019

Harendra SinghSection Head -Plant Maintenance

Udit VashisthaTeam Manager - Prod. Engg.

National Award for “Excellence in Energy Management – 2016 2National Award for “Excellence in Energy Management – 2019” 2

Agenda

Brief introduction on Company/Unit

1. Energy Consumption Overview

2. Specific Energy Consumption in last 3 years

3. Information on Competitors, National & Global benchmark

4. Energy Saving projects implemented

4.1. 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 Innovative technologies implemented12. Long Term vision energy efficiency

13. Other relevant information

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Agenda
















Brief introduction on HMCH - Journey

Hero Honda Motors Ltd. Incorporated –

Dharuhera Plant (1st)First motorcycle

"CD 100" rolled out

Gurgaon plant inaugurated (2nd)

Haridwar plant inaugurated (3rd)

1984

Journey Started

1985 1997

HHML-World No.1 2W Manufacturer

2001

20082011

New Identity -Hero MotoCorp Ltd.

2014

Most Effective Brand Transition Award by CNBC

20172018

2015

4th plant & GPC operational at Neemrana, Rajasthan

1st overseas plant Operational at

Colombia

2019

2016

CIT Started at Jaipur, Rajasthan

Start of Hero Tech Centre Germany

GmbH

2013

2016

2019

2nd overseas Plant started manufacturing at Bangladesh

Foundation Stone of Chittoor Plant (6th - Andhra Pradesh)

Milestone of 90 million cumulative Production

5th plant was Made Operational at

Vadodara

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Range of ProductsBrief introduction on HMCH - Range of Products

Hero MotoCorp is in business of manufacturing motorcycles & Scooters ranging from 100cc to 225 cc for different segments with different variants.

100 cc 110 cc 125 cc 150 cc 225 cc Scooters

Karizma ZMRXtreme Sports

Achiever

New Glamour

Glamour Programmed FI

Super Splendor

Splendor iSmart 110

Splendor PROSplendor +

HF Deluxe ECOHF Deluxe

Maestro Edge

Pleasure

DuetGlamour

PASSION PRO i3s

* HM3H-Hero MotoCorp, Haridwar

Range of products manufactured at Haridwar Plant

PASSION PRO 110


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

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Energy Policy- HM3H

PDCA & bench marking is an integral part of our energy policy

Use of renewable energy

PDCA Approach

VFD

IE4 Motors

Use of Energy saving equipment's


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54%46%

Hot water generator Paint Shop

24%

22%20%

16%

9%8%

Utility Other Machine shop

Paint Weld Assembly

64%

36%

Thermal Energy Electrical Energy


Achieved Continual improvement in resource conservation

ENERGY

ELECTRICAL THERMAL

Total energy consumption FY 18-19 (TOE)

Thermal energy consumption (TOE)Electrical energy consumption (TOE) TOE*-4794

TOE-3062TOE-1731

Electricity and Natural gas are the major source of energy for our factory

1.1 Energy Tree

*TOE-Ton Of Oil Equivalent



Achieved Continual improvement in resource conservationPlant fixed consumption is 21% and variable is 79%

PLANT POWER CONSUMPTION

VARIABLE POWER CONSUMPTION

PAINT SHOP

WELD SHOP

STEEL PHASE

AL. PHASE

ASSLY. SHOP

AIR COMPRESSOR

FIXED POWER CONSUMPTION

OFFICE + CANTEEN

LIGHTING & POWER POINT

FDV’S

CHILLER

VARIABLE CONSUMPTION

79%

FIXED CONSUMPTIO

N 21%

PLANT FIXED AND VARIABLE KWH SHARE

LIGHTING 45.%

FDV 32%

CHILLER 11%

OFFICE & CANTEEN

10%

1.2 Electrical Energy Tree

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Achieved Continual improvement in resource conservationHot water generator is the major contributor 54% in thermal energy consumption

THERMAL ENERGY

UTILITY

HOT WATER GENERATOR

PAINT SHOP

SM PAINT SHOP

BAKEOVEN

DRY OVEN

ASU

ACED PAINT SHOP

PRE HEAT OVEN

BAKEOVEN-1

BAKEOVEN-2

LACQUER PAINT SHOP

BAKEOVEN-1

BAKEOVEN-2

ASU

OTHER

ZLD

54%

46%

Hot water generator Paint Shop

THERMAL ENERGY CONSUMPTION

1.3 Thermal Energy Tree


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2. Plant Specific Energy Consumption

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

Achieved Continual improvement in resource conservationAchieved Continual improvement in resource conservation

24.61

17.31

16.3715.61 15.72

14.7415.79 15.12 14.75

13.64 13.43 13.51

10.0

12.0

14.0

16.0

18.0

20.0

22.0

24.0

26.0

FY 0

8-0

9

FY 0

9-1

0

FY1

0-1

1

FY 1

1-1

2

FY 1

2-1

3

FY 1

3-1

4

FY 1

4-1

5

FY 1

5-1

6

FY 1

6-1

7

FY 1

7-1

8

FY 1

8-1

9

FY 1

9-

20

Tar

get

Kw

h/V

eh

Specific Energy Consumption

Last 3 Year 12% Reduction

Legend

Key Projects contributing to reduction

Artic Master

in Chiller

Washing heating System 12000 LED replacement

VFD for major

improvementDry Trafo for

energy saving

2.1 Historical Trend -Electrical


0.714

0.609

0.4740.428 0.427 0.447 0.476

0.368

0.291 0.2600.260

0.200

0.0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

FY 0

8-0

9

FY 0

9-1

0

FY 1

0-1

1

FY 1

1-1

2

FY 1

2-1

3

FY 1

3-1

4

FY 1

4-1

5

FY 1

5-1

6

FY 1

6-1

7

FY 1

7-1

8

FY 1

8-1

9

FY 1

9-2

0Ta

rget

SCM

/Ve

h

Specific Fuel Consumption

2. Plant Specific Energy Consumption

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

Achieved Continual improvement in resource conservation30% thermal consumption reduction in last three year

Last 3 Year 30 % Reduction

Legend

Heat pump in Hot water

generator

Key Projects contributing to reduction

Temperature optimization

through plate increase Phosphate bath

temp. reduction Oven temp. reduction

2.2 Historical Trend -Thermal

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3. External & Internal Benchmarking

Benchmarking done w.r.t. Competitors and Internal, though we are consuming lesser than them , still we are striving for continual improvement

15.8

15.1

14.8

13.6

13.4

27.7

24.6

22.5

21.1

27.4

27.2

26

.5

25.6

25.7

29

.00

27.7

1 30.3

7

29.6

0

25.1

4

0

5

10

15

20

25

30

35

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

Kw

h/V

eh

Specific Energy Consumption

HM3H Competitior 1 HM1D HM2G

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.

..

.

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

nen

t

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

3. External & Internal Benchmarking


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To be continue..


Total 87 No’s projects Implemented and cost saving of Rs 502 lakhs achieved

FISCAL YEARTOTAL No. PROJECTS

TOTALINVESTMENTS (IN Rs. LAKHS)

SAVINGS(IN Rs. LAKHS)

FY 16-17 36 33 237

FY 17-18 28 55 119

FY 18-19 23 255 146

TOTAL 87 343 502

4.1 Project summary


Sr. No.

Top 10 Energy Saving Projects – Zero InvestmentAnnual Savings

Kwh in Lakhs

Rs in Lakhs

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

2 KWH Saving thru optimization of solvent temperature from 45-60 to 45-50 0.9 5.49

3Recurring energy saving in Fanuc Robo drill machines by optimizing consumption of compressed air with Zero investment of capital

0.8 4.91

4 15% reduction in Power consumption of washing Machine 0.8 4.47

5 KWH reduction in ASU by speed optimization- blower 0.8 4.38

6 Kwh consumption reduction in FDV by 2% 0.7 3.89

7 Switching Off the Fume Suction System during Lunch and dinner 0.6 3.22

8 ASU speed Reduction in SMPS( Lunch time) 0.6 3.14

9 Power consumption saving by execution of MOP of SPOT m/c. 0.4 2.57

10 Switching off Power in FA Dol Ground & First floor 0.4 2.15

Total Saving (Top 10 Projects) 8.1 45.8

Total Projects Saving (41 Nos.) 12.6 71.79

To be continue..


Total 41 No’s Zero investment projects Implemented and conserved 12.6 Lacs kwh and cost saving of Rs 71 Lakhs/year

4.1 Zero investment

Co2 Reduction 1071 tons

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Sr. No.

Top 10 Energy Saving Projects- With InvestmentAnnual Savings

Kwh in Lakhs

Rs in Lakhs

1 Conventional task lights replacement with LED Lights (8592 Nos) 6.9 41.60

2 Conventional task lights replacement with LED Lights (3000 Nos) 3.5 20.63

3Heaters elimination in washing machines of Engine assembly to save the energy cost (2 M/C)

2.0 12.04

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

1.9 10.90

5 10 Nos VFD installation through out the plant to save the power cost 1.7 9.90

6 Energy saving through VFD in FDV’s of machine and assembly shop 1.4 7.36

7Replacement of electrical heaters with Plate heat exchanger in weld washing machine

1.1 6.24

8 VFD installation Utility 1.1 6.18

9 EC fan installation in Lacquer Paint Shop Auto-Booth 1.0 6.15

10 EC fan installation in place of ASU Blowers in PC-Booth and Manual-Booth 1.0 6.04

Total Saving (Top 10 Projects) 21.6 127.1

Total Projects Saving (39 Nos.) 33.0 191.01

To be continue..


Total 39 No’s Investment Projects Implemented and conserved 33 Lakhs kwh and cost saving of Rs 191 Lakhs/year

4.2 With investment




Sr. No.

Top Energy Saving Projects – ThermalAnnual Savings

SCM in Tons

Rs in Lakhs

1 Canteen Relay outing (new equipment's to be added having better SFC 240 59.76

2 Installation of AHP to reduce energy consumption 120 40.80

3 Baking oven temp”. red from 195 to 185 °C 161 40.00

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

161 40.00

5Hot water generator temperature Reduction by 5°Cand efficiency improvement in paint shop

102 31.22

6 Phosphate temp reduction from 50 to 42°C - SM 87 21.59

7 Phosphate bath temp. reduction from 65 to 55°C- ACED 26 6.35

Total Saving (Top 7 Projects) 895 239.7

7 Projects implemented & Conserved 895 Ton SCM Natural Gas resulting in cost saving of Rs. 239.7 Lakh /year

Projects with Zero Investment

4.3 Thermal Energy


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Agenda
















Cost saving of Rs. 198 Lakh/Annum through various Innovative Projects

S. No.

Section Improvement ProjectResource

Saved/ Annum

Cost Saving

1 Utility -HWGInstallation of AHP to reduce energy consumption

120 KSCM INR 40.8 Lakh

2 ACEDEnergy Saving through heat balancing in ACED Oven

42 KSCM INR 16.5 Lakh

3 Engine Assembly Cost saving in Oil dispensing machine of Engine assy through optimization of operational energy cost

171MWH INR 10.0 Lakh

Total Saving Per Annum INR 66.5 Lakh

Total Projects Saving (10 Nos.) INR 198 Lakh


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Background:

HWG was required to maintain hot water temperature at 75 – 80 °C. Paint shop requires hot water in rangeof 75-78 °C for different stages like Hot water rinse, pre degreasing, degreasing and phosphating stages ofSM paint shop & ACED for which hot water is supplied by Hot water generator (HWG) and it consumes fuel(Natural gas) as well as power.

PAINT SHOP

Hot Water Generation (

Utility)PHE

75-78°C

73-74°C

Heat pump Concept studied for feasibility in hot water generator

Concept :-

Thermodynamics 2nd Law says that heat can not flow from cooler body to a hotter body without some work being done by an external source.

4.1.1 Absorption Heat Pump


Concept /Approach Adopted: - Improvements Proposed:-

Benefits

167

127

0

100

200

Before After

Running Cost for HWG

Total cost saving in HWG – 67 lakh/year


Evaporator

Generator

Absorber

Condenser

Step-01 Step-02

Step-03 Step-04

40 Lakh/year saving through absorption heat pump

Lakh

RS.

/Yea

r

4.1.1 Absorption Heat Pump


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Total cost saving in HWG – 67 lakh/yearOven heat balancing studied for further analysis

Pre heat Oven Zone

Touch up booth area

Baking BurnerChamber-2

Pre heat Burner Chamber

80 m3/min

180 m3/min


1070 m3/min 1070m3/min 540 m3/min

225 m3/min

12 m3/min

12 m3/min 11 m3/min

Line balancing study of ACED oven and calculating the heat loss in oven Background: -

AIR SUPPLY UNIT

4.1. Innovative Projects implemented 4.1.2 Heat Balancing in oven

Baking Oven Zone


Concept and Calculation: -

Area Circulation (m3/min) Exhaust

Pre Heat zone 540 80

Baking oven-1 1070 180

Baking oven-2 1070 N/A

Total 2680 260

Total circulation air Volume = 2680 m3/min

Exhaust air volume = 260 m3/min

Net air circulation volume = 2680 -260 = 2420 m3/min

Requirement of fresh air intake = 260 m3/min

Makeup from ASU = 225 m3/min

Fresh air incoming from chamber filter = 35 ~ 50 m3/min Q = area * velocity of air, Q= 0.5*0.5*15*60 = 225 m3/min

Requirement of fresh air intake= Makeup from ASU + fresh air Incoming from chamber filter

Air Flow calculation shows potential for optimization


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Line balancing for optimizing of fresh air intake by reducing ASU blower air intake to minimize heat loss

Total cost saving in HWG – 67 lakh/yearAir balancing done through reduction in ASU air flow and fresh air flow increment

Pre heat Oven Zone

Baking Oven Zone

Touch up booth area

Baking BurnerChambe-2

Pre heat Burner Chamber

80 m3/min 180 m3/min


1070m3/min 1070m3/min 540 m3/min

180 m3/min

20 m3/min

20 m3/min 40 m3/min

Improvement: -

AIR SUPPLY UNIT



Total cost saving in HWG – 67 lakh/yearRs 16.5 Lakh saving through heat balancing in oven

Result:-

Parameter Before After Remark

Air velocity (m/s) 15 12Velocity reduced through dampersetting

ASU Fresh air intake 225 180ASU fresh air intake reduced due to itshigh humidity low temp. (by adjustingdamper)

Fresh air intake from chamberfilter

35 80Intake from chamber increased whichis at ambient temp.

Requirement of fresh air intake( 260 m3/min)( A) =Makeup from ASU (180 m3/min) (X) + fresh air Incoming from chamber filter (80 m3/min) (Y)

Makeup from ASU (X) = 180 m3/min X = area * velocity of air X = 0.5*0.5*12*60 = 180 m3/min Fresh air incoming from chamber filter (Y) = 80 ~ 90 m3/min

Benefits:-

Total Gas saving /day – 140scm/dayTotal saving in Rs – 16.5Lakh/ Year


Co2 Reduction

95 tons

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Rs. 10 Lakh saving through optimization of oil dispensing processes

Background Improvements /Kaizens done or Concept:

Benefits & Results:

Proposed Scope:Investments:

Engine assembly each line having one oil dispensingmachine to feed the oil in engines. These 4 Nos machinesare operating with electrical energy and pneumatic energy

Energy saving in oil dispensing machine throughimplementation of energy saving idea

ComponentPower consumption (KWH/Day)

Current Cons.

Proposed Cons.

Saving/ Machine

Saving in all 4 Machines

Oil circulation pump 108 63 45 122

Heaters 96 0 96 259

Pneumatic pumps 7 0 70 190

Total 211 63 211 571

0

10

0

5

10

15

Before After

Cost Saving ( INR Lakh/Year) INR 10

Lacs saving in

all 4 machines

Investment cost – 1.5 Lakhs

Pneumatic Pump-1

Pneumatic Pump-2

Recirculation Pump

Oil Tank

He

ate

rH

eate

r

108 KWH/Day @ 24 Hrs Running

70 KWH/Day(Stand by)

96 KWH/Day

70 KWH/Day

Oil Tank

63 KWH/Day @ 17 Hrs running

Recirculation Pump

Process Proposed action

Oil circulation

Oil circulation to be done by 3.7 KW motor with 17 Hrs running

Heaters Heater elimination

Oil feeding

Pneumatic pumpremoved and oil feeding with circulation pump by circuit modification

4.1.3 Oil dispensing



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5. Renewable Energy Source

2.63MKWH generation from renewable energy sources

S.No. TechnologyType of Energy

Onsite/Offsite

Installed capacity

Generation(million

kwh)

% of overall electrical

energy

1 Solar Electrical Onsite 2MW 1.63 4%

2 Solar Thermal Onsite 5KL 0.7 2%

3Solar ( skyLight/Translucent sheet

Light Onsite 252 0.3 1%

Total renewable energy generation 2.63MKWH


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


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

2MW

5.1. Renewable Energy Project

2301

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83

1,1501,150 1,150 1,150

418

1,392 1,4121,604

2,706

530866 1020

372650

1031

34083582

3126

4506

0

500

1000

1500

2000

2500

3000

3500

4000

4500

5000

FY 15-16 FY 16-17 FY 17-18 FY 18-19 FY 19-20PROJECTED

MW

HUtilization of Renewable Energy

Solar Heating & Lighting Solar Power RE IEX Trading Total

5.2 Renewable Energy Utilization

Current Utilization of Renewable Energy - 9% , we are in process of installation of 1MW Solar plant

3%

9%10%

13%

9%

RE iex trading less because of higher market rate Legend



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

6. Utilization of waste material as 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. Lakh) 4.18

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

Co-processing for Disposal of Paint Sludge

6.1 Paint Sludge



2.1 lakh M3/yr Rain water harvesting in plant

Rain water harvesting in plant

Total Recharge-2,11,109 M3 / ANNUM

Storm water Harvesting

129465 M3 / ANNUM.

Roof top Harvesting-81644 M3 / ANNUM

S No areasActual Rain Water Harvested

(cubic mts/yr)Ha =Aa*C*R

1 Run off area 129465

2 Roof top area 81644

Grand Total (M3/YR) 211109

Rain water lake Rain water Pit

Rain water Recharge to ground

Layout of rain water harvesting pits

6.2 Rain water

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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


Food Compositing Machine Manure usages in horticulture

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

6.3 Thinner & Food


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GHG Emission Inventorisation

CO2e (MT) FY 18-19

Scope –I

4,510 CO2e (MT)

Scope-II

27213 CO2e (MT)

GHG Inventorisation

60007000 7519 8028 8325 8526 8941 9381 9861 1051210776

0

2000

4000

6000

8000

10000

12000

2008

-09

2009

-10

2010

-11

2011

-12

2012

-13

2013

-14

2014

-15

2015

-16

2016

-17

2017

-18

2018

-19

No

’s o

f Tr

ee

Cumulative Nos of Tree (Inside Plant)

Better

Maintaining 10776 trees inside plant which reduced 237 Ton CO2 emission/year

7.1 GHG Inventorization

30,142 27,656 28,349 27,213

5,9864,001 3,982 4,511

36,12831,657 32,331 31,724

0

20,000

40,000

20

15

-16

20

16

-17

20

17

-18

20

18

-19

Co

2e

CO2 Emissions (MT)

SCOPE-1 SCOPE-2 TOTALBetter

Better

13.15

14.81 14.3313.17

12.15 11.96

0

2

4

6

8

10

12

14

16

2013-14 2014-15 2015-16 2016-17 2017-18 2018-19

CO2 Gas Emission (kg/veh)


• Technology developed & Patented by Hero MotoCorp Ltd.

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

• I3s Technology: 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. GHG Inventorization 7.2. Initiatives by increasing product efficiency

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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 Beneficiary families from thesevillages are 2964, saving 4.03 lac units for

our State

Total 12,727 Families of 28 Villages of Uttarakhand @ Haridwar, Dehradun, Uttarakashi were benifited with 7W LED Bulbs.

We saved 1.03 Crore kwh of Electricity Per Year for our State.

7. GHG Inventorization 7.3 CSR Activity for Energy Conservation


2.1 Lakh Tree plantation at external area

7. GHG Inventorization

Total 51,000 tree at the bank of river Ganga at Haridwar under Sparsh Ganga Abhiyaa.Survival rate of planted trees is 95%.Huge participation of community students and villagers in this drive.

Total 2.1 Lakh Fruit Tree Plantation done at Block Doiwala Dehradun.In this tree plantation drive 35,217 families participated.Total tree plantation done is 2,10,740

7.4 CSR Activity for tree plantation

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Sr. No.

Description UOM Target

1 Water Saving KL/ Annum 73000

2 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. GHG Inventorization 7.5. Environment - Conservation


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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.

8.1. Dispatch truck capacity enhancement


8.3. En Con 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..


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8.3. En Con 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



AfterBefore

8. Green Supply Chain 8.4.GVDP - Vendor Industry Initiative

Waste heat of DG stack used in VAM

Before After

Various projects implemented under GVDP program by JNS Instruments

Fume killer install to avoid soldering fumes emission in environment heating

Reduction in Plastic waste by using flip cover in cover material

Poly sheet cover Flip Cover

Exhaust system at station Fume killer

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Before AfterSaving of Energy Consumption in assembly Air conditioner


Saving of Energy , compress air and Manpower

Before After

Projects implemented under GVDP program by M/s JNS Instruments

8.4.GVDP - Vendor Industry Initiative

Earlier no capacitor 10 kvr capacitor installed


Agenda















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Energy Conservation Cell driven from top with involvement of all employees

9.1. Team work, Employee Involvement & Monitoring

Review Frequency Plant

headManufacturing

Head

Head of

Department

Energy

Manager

Section

Head - AreaEnergy coordinator

Monthly √ √ √ √ √ √

Fortnightly √ √ √ √ √

Weekly √ √ √ √ √

Daily √ √ √

Boardreview √ √ √

Monthly MRMDaily morningreview

Monthly MISDaily variance

analysis

Daily shop

mailers


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

9.Team work, Employee Involvement & Monitoring 9.1 En con cell

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.

• 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

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

9.Team work, Employee Involvement & Monitoring 9.2 Involvements


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

6 67

910

9 9

7 7

9

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

657

866

701 695 690 706650

702650

708 690 660

0

200

400

600

800

1000

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

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.Team work, Employee Involvement & Monitoring 9.3 Air Audit

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9.5. Energy saving through VFD’s in Blowers and pump

Background:

.

After Condition – VFD Installed in all Proposed Equipment and Submersible now running on 10% less KW than rated and rest all Blower Running on 15% less KW than Rated.

Improvements Done:

2840

2182

0

500

1000

1500

2000

2500

3000

Before After

KWH/Day Power Consumption (KWH/Day)

VFD installation in Equipment’s resulted in saving of Rs. 12 Lakh/year

Methodology/Approach Adopted: Results:

Total 10 Equipment's were proposed across plant where with the optimization of Speed and Frequency saving of power can be achieved: 1) Weld Shop Submersible pit Pump – 3 nos. 2) Sheet Metal Paint Shop Exhaust Blowers – 4 Nos.3) ACED Paint Shop Ultra Filtration Blowers – 3 nos.Proposed Blowers and Pumps were Running on STAR-DELTA control

SR. NO

EQUIPMENT Motor rating in KW

Per year Saving (KWH)

Cost Saving Lakhs/Year

(INR)(@ Rs 6/

unit)

ApproxInvest. Lakhs (INR)

Payback (Yrs)(Exclusive of taxes)

1 Sub. Pit Pump-1, 2 & 3 18.5 56610 3.40 5.25 1.5

2 (ACED) ED UF -1 ,2,3 7.5 53874 3.23 3.9 1.2

3 Base Coat - Ex Fan -1 18.5 25551 1.53 1.75 1.1

4 Top Coat - Ex fan -1 22 30406 1.82 2.25 1.2

5 Top Coat FOZ 15 20732 1.24 1.5 1.2

6 Primer Coat FOZ 7.5 10353 0.62 1.3 2.1

Total 197526 11.85 15.95 1.3

Total 658 Kwh/Day Saved

1


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9.5 Energy conservation in FI Dynamo test bench

8.52 Lakh/year saving through FI Dyno test bench

Background Improvements /Kaizens done or Concept:

Benefits & Results:

Investments:

Dynamo test bench equipment (8 nos) is placed in finalinspection lines to check the vehicle performance.

One hood typeexhaust collectionsystem installed inthis equipment tocollect the fume ofvehicles duringtesting cycle

Dyno Hood Exhaust Blower power consumption cost Saving

SN MachineMotor

KWRunning Hrs/day

Working Days

Actual KWH consumptio

n /Year/Machi

ne

No of M/C

Actual KWH

consumption

/Year

Saving Rs./year at Rs. 6

1Dyno hood ext. blower

3.7 16 300 17760 8 142080 852480

Dynamo test bench exhaust collection systemmodification in all final inspection lines

Dynamo test bench exhaust collection systemmodified by swivel type exhaust collection system toImprove suction capacity to Reduce the powerconsumption

Blower-13.7 KW

Blower-23.7 KW Blower-2

3.7 KWProposed Scope:

Investment cost – 1.0 Lakhs

3.2 Meter/Sec air suction velocity by 7.4 KW

11.2 Meter/Sec air suction velocity by 3.7 KW

948

474

0

400

800

Before After

474 KWH/Day saving in all lines

2



9.5.Replacement of Electrical heating with gas heating in washing machineBackground:

.

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

Before condition: Engine assembly washing m/c (2 nos.) maintain the temperature of hot water through electrical heaters

Improvements Done:

669

00

200

400

600

800

Before After


Hot Water using in washing m/c resulted Saving of Rs. 4.2 Lakh/year

Methodology/Approach Adopted:Results:

Pump

HeatersHot

Water

Heater Tank

Hot Water for Component washing

Removal of Electric Heaters saved 669 Kwh/Day

S.No. Description Value UOM

1 washing consumption with Electrical heating system 1092 KWH

2 Daily electricity cost in electrical heating 6552 INR

3 washing consumption with Hot water heating system 423 KWH

4 KWH saving with Hot water heating system (A) 669 KWH

5 Daily thermal energy requirement 575340 Kcal

6 Natural Gas requirement/Day/machine 68 SCM

7 Natural gas cost/day /machine ( B) 2531 INR

8Saving with Naturag gas over Electrical heating/day (C=AX5.86-B)

3920 INR

9Saving with Naturag gas over Electrical heating/year ( D= CX300)

416653 INR

11 Saving in Lakh on washing machine 4.2 INR

3

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Background:Before Condition: Centrifugal blowers used for conditioned air supply in ASU of Lacquer Paint Shop and SM Paint Shop

Results:Centrifugal Blower DC FAN

It Consist of Blower, Motor, Pulley, Belt

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

3 Ph AC Induction Motor DC Motor-Improved efficiency upto90%

Separate VFD Panel Inbuilt VFD at Fan unit. No VFD circuit filter losses

• Single centrifugal blower of 90KW• ASU flow – 75K cfm• Static Pr – 1270 Pa

Motor filter

Inverter Line Filter

- Energy saving up to 25-30% 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%• Maintenance Free

1144807

0

500

1000

1500

Before After


EC Fan installation resulted Saving of Rs. 5.97 Lakh /year

Improvements Done:After Condition: Installation of 12 no. DC fans (6 kw each) in place of one big blower (90 KW).

9.5. Replacement of conventional blowers with High Efficiency EC Fans

Methodology/Approach Adopted: -

Saving of 337 Kwh/Day Achieved

4


Agenda















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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

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Agenda
















11. Innovative technologies implemented

Saving of Rs 117 Lakhs/Annum (Rs 5.2/FT saving)

Background/Current Condition:1. One Auto Booth for Lacquer application with 2

reciprocators2. Two manual booth for dual tone painting3. Lacquer painting cost is Rs. 12.68 / FT

Results:1. Saving of Rs 5.2 / FT @20% paint transfer

efficiency improvement2. cost saving – Rs. 117 Lakhs/Annum @22.5

Lakhs vehicle/annum

Methodology / Approach Adopted:

Feasibility study for Robotic painting

Discussion with different supplier

Proposal readiness & approval

Installation & Handover

MB-1Auto BoothMB-2

Improvements Done:Installation of 3 Nos. Robots in Auto BoothTotal Investment – Rs. 416 Lakhs

11.1. Painting Robot

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Saving of Rs 4.17 Lakhs/year by using electrical pump

Results:1. Total KWH Saving /hr – 5 2. Total Rs saving /annum/ skid – 1.39Lakh3. Total 3 skid saving per annum- 4.17Lakh

Background/Current Condition:Pneumatic pump used for supply paint for

painting process

Improvements Done:Installation of Electrical Pump in paint kitchen to optimize energy

Methodology / Approach Adopted:

Compressed air pump to be replace with electrical pump and paint supply as per required pressure and flow only when needed and reduced paint shear

11.2. Paint electrical pump


11. Innovative technologies implementedImprovements 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


11.3. AGV

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1. Conventional Cooking Equipment were used in Canteen

2. Natural gas Consumption / Annum = 1.17 Lakh SCM/Annum Cooking Oil Consumption/Annum = 0.45 Lakh Lt/Annum

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. lacs

Natural gas 117,456 93,964 5.4

Frying Oil 45,803 38,738 9.0

Manpower 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 2.0

Total 20.4 1.3 15.2

Previous Condition Improvements Done


Results:

Conventional inefficient equipment replaced with latest efficient equipment


AfterBefore

11.4. Canteen equipment



ED RO System used to recovery ED paint and save DM water

Background: ED Paint recovery by UF module and after DM water used for cleaning purpose and DM water drain

frequently .

11.5. ED RO System

EDUF-1

UF-2UF-3

DM Rinse

UF Membrane

UF Permeate Tank

UF Permeate to UF-3

Fresh DM Water Spray

@1400 LPH

EDUF-1

UF-2UF-3

UF Membrane

UF Permeate

Tank

UF Permeate to RO System

DM Rinse

Fresh DM Water Spray

@512 LPH

RO System

RO Output to DI Rinse

Existing CED Layout Proposed CED Layout after RO

NV-16%

NV – 0.26%

NV-0.32% NV-16% NV-0.05%

NV - <0.1%

SN Parameters Saving

1. Paint Saving Rs. 8.23 Lakhs

2. Effluent Treatment Saving Rs. 3.74 Lakhs

3. DM Water Saving Rs. 0.82 Lakhs

4. Effluent Treatment Saving Rs. 3.74 Lakhs

Total Saving Rs. 12.80 Lakhs

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Agenda
















12. Long Term vision energy efficiency

15.12

13.43

11.93

8.43

0 2 4 6 8 10 12 14 16

FY 15-16

FY 18-19

FY 22-23

FY 29-30

Future Plan:-

KW

H/

Veh

.

Bench marking

Continue improvement in energy conservation

11% Energy conservation plan for next 3 year

37% Energy conservation plan for next 10year

• Renewable energy Source identify and usage • Reused of waste as a fuel and adopting new methodology to

reuse waste • Identify and adopt other efficient technologies• Digital Innovation to conserve energy • Continue and accelerate implantation of Energy conservation

project

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13.3.Major Projects Planned for Current year

Sr.No

Description Year Resource UOM

Energy/ Resource

Saving Per Year

Proposed Savings in Lakh Rs.

1Re-lay outing of AARCO and Fume suction Drop of Weld Shop

FY 19-20 Power MWH 78 4.7

2Laq. Paint Shop Conveyor Speed Increase from 3.1 to 3.5 mtr/min


4Energy saving In Engine assembly Chiller through Frigtech and ATC


5

To optimize compressed air consumption in CR washing machine and thus reducing power consumption by 50%


6Optimizations of Exhaust and process parameter in ASU Dc fan

FY 19-20 Power MWH 39 2.34

7 Chiller Temp. Optimization FY 19-20 Power MWH 30 1.8

Total Saving Expected in Lakh/annum - 19.34

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


Agenda















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2008-09

Prominent Awards – Haridwar Plant13.1 Major Milestones– Haridwar Plant

Prestigious awards won by Hero MotoCorp, Haridwar Plant

2009-10

2010-11

2011-12

2012-13

2013-14

2014-15

2015-16

Plant Inauguration

1 million ProductionCertified for ISO 9001, ISO 14001 & OHSAS-18001TPM Kick Off

Became World’s Largest 2W Plant

Completed 5 Million Cumm Production

TPM Excellence Award from JIPM

National Award for Excellence in Energy Management Completed 10 Million Production

5S Excellence award National Safety Council award

24.5Million cumulative productionat Haridwar Plant till Jul’19

1st Motorcycle produced at Haridwar Plant

2016-17

TPM Consistency AwardGreenCo Gold Rating AwardNational Safety Award

Energy Efficient AwardISO 50001 Certification1st prize in SMED competition by CII

Golden Peacock National Quality AwardInternational Safety AwardEnergy Efficient Unit Award

2017-18

National Safety AwardEnergy Efficient Award

2018-19


Market Share & Growth13.2 Prominent Awards – HMCL

Prestigious awards won by Hero MotoCorp

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 -

20132-Wheeler Manufacturer of the Year

Award at CNBC Awards - 2015

Honorary Doctorates from SMVD, Katra & NIT, Kurukshetra- 2018

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The Journey continues ………

Thank You

2019 Hero MotoCorp Ltd. - Haridwar - CII - Sohrabji Godrej ...

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Transcript of 2019 Hero MotoCorp Ltd. - Haridwar - CII - Sohrabji Godrej ...