Aug-16

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BAL-Waluj

August 22, 2016

Bajaj Auto Ltd.Waluj Plant

National Award for Excellence in Energy Management 2016

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BAL-WalujContentsSr. No. Topics

1 Company profile2 Manufacturing process3 Energy Conservation cell4 Scope 5 Energy Indices /Benchmarks6 Energy Conservation Methodology7 Energy Conservation Approach8 Energy cost loss Tree 9 Innovative Projects

10 Other Encon Projectsa) Electricalb) Use of renewable energyc) Thermal11 Environment & Carbon Reduction12 Utilization of waste 13 Results14 Sustenance15 Future Project16 Achievements

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BAL-Waluj

A Group Built on Trust• One of the oldest business

conglomerates in India• A group comprising of 25

companies• Turnover over INR 280 Billion • Around 36,000 Employees.

• Headed by Mr. RahulBajaj, Chairman of the Boardof many companies. Awarded

the third highest civilianaward ’Padma Bhushan’ in

2001.

Electrical & Home Appliances

Finance & Insurance

Power & Infrastructure

Bajaj Auto Ltd. is amongst the FIVE MostInnovative Indian Companies and the onlyautomotive company featuring in thecoveted list of Forbes World’s Top 100 MostInnovative Companies of the year 2014.(Announced by Forbes on August 21,2014)

Automotive

Steel & Engineering

Bajaj Auto Ltd. The flagship Company of the

Bajaj Group.

Company Profile

4

BAL-WalujApproach for Improvement

KeyManagement Index

KeyPerformance Index

KeyActivity Index

Company Vision

Company Mission

“Vendor Improvement” pillar is created to focus on “Vendor Supplies”

Individ

ual Im

provem

ent(Ko

betsu K

aizen)

Educat

ion & T

raining

Develo

pment

Ma

nagem

ent

Planne

d Main

tenanc

e

Autono

mous M

ainten

ance

(Jishu

Hozen)

Quality

Mainte

nance

(Hinshit

su Hoze

n)

Office

TPM

Safety

, Health

&Env

ironme

nt

Flexibility, Reliability, Capability, Profitability “ Safe and participative work environment ”

TPM - The Prime Mover Towards Excellence

Vendor

Impro

vement

ISO 9001

ISO 14001

OHSAS 18001ISO 50001- Initiated

Company Vision & Mission … through KMI, KPI & KAI

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BAL-WalujManufacturing Process Flow Chart

Press & Fabrication

Aluminium Shop

Steel Shop

Heat Treatment

Central Gear Shop

Paint

Engine Assembly

•Vehicle Assembly•Export Assembly

•& Packing

Domestic Dispatch

Export Dispatch

Vendorparts

Total Number of Equipments - 1840 nos.

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BAL-WalujFlow Chart - Energy Conservation Program

Company Vision/Mission

Plant Vision/Mission

Shop Level Target

Encon Projects Energy Manager

Management Review

Budget Allocation

Execution & Monitoring

Cost Reduction-KK Pillar

Environment Improvement Energy - SHE Pillar

Technical Improvement PM Pillar

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BAL-WalujEnergy Conservation Cell

Monthly ReviewFortnightly

Bi-Monthly Review

Weekly

Daily

Div Head Div Head Div Head Div Head Div Head Div Head

CorporatePlant Head

Machine Shops CGS/HT Paint

Shop Press & Fab Assembly Utility

Dept Head Dept Head Dept Head Dept Head Dept Head Dept Head

Energy Captain Energy Captain Energy Captain Energy Captain Energy Captain Energy Captain

Energy Manager

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BAL-Waluj1985-87 1988-2001 2002-09 After 2010

Measurement system (LAN based)Micro mapping through power analyzerEliminate needTechnology Up GradationsLCC (Life cycle cost ) analysisDeep mining of Solar & Wind Energy

Measurement at feeder (Manual) Sharing best practices with stake holders Energy Optimization Energy OptimizationSystem Auto controls System Auto controls Eliminate waste Eliminate waste

Eliminate resource wastage Eliminate resource wastage Eliminate resource wastage Localized control Localized control Localized control Human Dependent systems Human Dependent systems Human Dependent systems

Working on Legacy system

Details of year-wise efforts made in Technology Absorption relating to Energy

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BAL-WalujEnergy Consumption per unit of production & Capacity Utilization

Specific Energy Consumption

Energy UnitBase Year Achieved Target2003-04 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17

Electricity Kwh/veh 67.54 36.72 34.9 31.45 25.41 22.61 21.15 19.92 18.89 17.91 16.0

LPG Kg / veh 2.53 2.4 2.2 2.1 1.77 1.45 1.33 1.1 1.0 0.95 0.85

Water m3 / veh 0.89 0.54 0.52 0.41 0.35 0.41 0.27 0.18 0.17 0.15 0.10

Capacity Utilization % 92.3 64.75 76 96.15 100 98 98 100 85 82 100

Energy Consumption per unit of production & Capacity Utilization

Sr. Energy SEC Reduction % In 13 Year s In Last 3 Years In last year

1 Electrical ( Kwh/Veh) 73.5% 10% 5.2%2 Fuel ( LPG) ( Kg/Veh) 62.5% 14% 5%3 Water ( Cu.m /Veh) 83% 17% 12%

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BAL-WalujAbsolute Energy Saving

Year Elect. Saving(Lacs Kwh)

Thermal(Fuel) saving

M KcalElect. Consumption

Lacs KwhThermal

(Fuel) Consumption M KcalElect.

Saving %Thermal Saving %

2010-11 18.9 646.1 573.56 41527 3 2

2011-12 24.1 255.2 587.14 39703 4 1

2012-13 18.7 816.8 540.93 36067 3 2

2013-14 22.63 586.5 510.8 31740 4 2

2014-15 20.2 638.0 503.8 30939 4 2

2015-16 25.2 560.0 457.0 27881 5.5 2.0

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BAL-WalujSpecific Energy Consumption-Benchmark

Sr. Energy BAL , Waluj Nearest competitor Global 1 Electrical ( Kwh/Veh) 17.91 21.2 NA2 Fuel ( LPG) ( Kg/Veh) 0.95 1.9 NA3 Water ( Cub.Mtr/Veh.) 0.15 ( Water Positive ) 0.23 NA4 Diesel (Ltr/Veh) 0.09 2.3 NA

No Standard Benchmarks are available for Automobile sector , These are collected as per our information's

However, we are setting our own internal targets as:Min 5 % Reduction in specific energy consumption wrt last year

12

BAL-WalujStratification of Energy consumption

6 166

60

12

%

Lighting Compressed airCooling Process

22.8

75

2.2%

Heat treatment Paint shop Canteen

Electrical Energy consumption LPG Energy consumption

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BAL-Waluj

Sr.No. Activity Methodology Tools/ Techniques used1 Audit To identify areas of energy conservation

potential ( Internal & External) Weekly / Monthly data through Pie charts & brainstorming

2 Analysis To identify equipments & Processes where energy conservation is possible Daily/weekly KWh, pressure, flow,volume etc.recording through bar charts,graphs

3 Action Plan Identify activities for individual equipments with time frame Resource planning & activity charts

4 Implementation Action for procurement & implementation 6W2H Way Activity Charts5 Evaluation To analyze plan V/S Actual Gap Analysis & countermeasures

6 Sustenance To Monitor the results Internal Audits

Energy Conservation Methodology

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BAL-WalujEnergy Conservation Methodology & IdeaElectrical Energy

Operational Control Loss Reduction / Elimination

Sr. Idea 1 Light Power Loss2 Unwanted illumination 3 Compressed air energy 4 Inefficient Equipment 5 Transmission Loss

• Power Factor • Harmonics

6 Transformer Loss7 Micro Level Analysis

Sr. Idea1 Metering & Monitoring 2 Auditing 3 Energy Captain4 No Production on Off days 5 Sharing Best practices with stake holders

Sr. Idea 1 Biogas for Heating 2 Solar Lighting 3 Solar Power generation4 Wind Power Generation5 Solar Water Heating 6 LPG Heating 7 IR Heating 8 Energy Recovery-HeatPump

Technological Improvement

Sr. Idea 1 LED/CFL/Induction Lamps2 Efficient Motor/Pumps3 Screw Compressor4 Ceramic to Metal tube heater5 Aluminium Pipes for compressed air .air6 5 Star rating equipments 7 VFD for high HP Motors8 Use of Soft Starter 9 Scroll Compressors

10 LCCA

Alternate Source/Recovery Alternate Source/Recovery Efficient Equipment

Loss Idea

Visible Loss

Invisible LossDistribution

Loss

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BAL-WalujEnergy Conservation Methodology & Idea

Fuel (LPG) Energy

Operational Control Loss

Sr. Idea 1 Heat Loss through oven skin2 Heat Loss Through Flue Gases3 Heat Loss to Jigs & Fixtures

Sr. Idea1 Metering & Monitoring 2 Auditing 3 Energy Captain4 No Production on Off days

Sr. Idea 1 Solar water heating2 Use LNG 3 Infrared Heating 4 Bio Gas

Technological Improvement

Sr. Idea 1 Direct heating IR2 Combustion Efficient Burner 3 Low Temperature process4 Cycle Time Optimization

Loss Elimination Alternate Source Efficient Equipment Monitoring & Audits

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BAL-WalujTo achieve specific Electrical energy consumption per Vehicle to 16 Kwh in year 16-17 We require :

Consumption reduction

Operational Control Efficient Equipment Wastage reduction

Fix Load reductionVariable Load reduction

Consumption reduction Per month by 2.25 Lacs Kwh• Per Day by 9000 Kwh

• Per Hour by 562 Kwh Target

How to achieve

Alternate

Load Reduction by 200 Kwh Load Reduction by 362 Kwh

Target Setting

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BAL-Waluj

Auto cycle element level Monitoring

Cell level Energy Monitoring

Periodic monitoring of energy using cell wise energy meters

Current meters are used for eqp. energy measurements

Hidden energy

loss

Equipment level Energy Monitoring

Objective - Energy cost reduction by micro level analysis

Monitor electrical parameters like current, voltage

Monitor energy consumption in different modes –Actual cycle, idle mode, power save mode, emergency off modeDetect instances when consumption is deviated from bench mark value

Equipment mapping of one cell

Set targets and execute action plan

Monitor energy consumption trends

Diagnose specific area of energy wastage

Monitor results

Micro Level monitoring

Methodology

Energy Saving through Micro level AnalysisInnovative Project 1

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BAL-WalujEquipment Mapping – P6 Crank Case cellCell Layout – P6 crank case

Equipmentfamily Nishida Washing AMS FRD Brother MTD SPMNo. of Machines 1 1 1 16 1 1

KVA rating 40 37 25 13 9.5 5

FRD-5 LH FRD-RH OILHOLEBROTHER LH WASHINGAMS LH R-FACE

RHFINSH

FRD -RH R-FACE

NISHIDA LH RIVET PRESS

1 2 3 4 5

JH Cell Board Rej. AreaLH FIinishMaterial

Cell Monthly Board

A

FRD-1 LH FRD-3 LH

FRD-2 LH FRD-4 LH FRD-6 LH

FRD-RH FINE

FRD- 6RH

FRD-2 RHFRD-4 RHFRD-5RH

FRD-1RHFRD-3 RH

EmptybinRH Fine Bore

File Stand

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BAL-Waluj

0.501.001.502.002.503.003.504.004.505.005.50

kW

12/6/2014 3:47.510 (min:s)

Fanuc Robo Drill 128251

Machine energy consumption trend

Idle mode One cycle

Scale – On X axis 1 div = 45 Sec. On Y axis 1 div = 0.50 Kw

X axis

Y axis

Time (Sec)0 9045 135 180

Micro level monitoring

• It is monitored using equipment Power Analyzer

• High current spikes, specific energy loss can be detected

• Monitoring of special parameters like KW, KVA, PF, Harmonics is possible Power analyzer

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BAL-WalujMachine energy consumption in different modes

Optimum valueDeviated value (22 cases)High value (6 cases)

Sr. No Equipment Operation Actual Cycle Idle mode Power saving mode Emg. off modeKwh Kwh Kwh Kwh

1 Nishida Fine Boring 2.48 1.680 1.190 0.6102 CES Washing Washing 27.57 23.12 22.12 0.2353 AMS R-face 0.55 0.291 0.140 0.1104 Fanuc Robo Drill Fine Boring 1.95 1.780 0.270 0.1505 Fanuc Robo Drill Drill Tap 1.45 0.660 0.270 0.1506 Brother Fine Boring 2.44 0.790 0.290 0.1837 MTD Leak test 1.84 0.850 0.070 0.050

• Highest energy consumption machine is washing machine

• Green marked are the optimum values in Fanuc Robo Drill family

• Yellow marked are deviated values in Fanuc Robo Drill family

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BAL-Waluj

ARestore deviation to bench mark

BOptimize high consumption

CImprove bench mark

BM

Deviation

0.660 Kwh

1.780 Kwh

Target

Consumption

20.0 Kwh

23.12 Kwh

BM

0.400 Kwh

0.660 Kwh

Target

Action plan

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BAL-WalujObservation & AnalysisSr No Observation Analysis Potential saving (kwh/shift) Possible actions1 Idle mode consumption is more onFRD 128251 & 130247 Spindle through coolant pump continuous on after cycle finish 2 Pump off by M code at part program end

2 ahighest power consuming machine in cell is washing machine

Coolant spray pump consumption more –On-Off operation of spray pump 5.4 Continuous on operation of spray pump for each cycle2 b Heater consumption more – inefficient control 7.6 Use of precise electronics control for heaters2 c Heater consumption more – heat loss through coolant pipes 3.2 Prevent heat loss by Insulation over coolant pipes3 FRD machine hydraulic motor consumption more Open loop system – motor continuous on with 100% rpm 2.5 Close loop system using inverter drive with pressure transmitter for system pressure feedback

4 a Nishida machine power consumption is moreStep down transformer is consuming power 3.5 Use central step down transformer

4 b Panel AC is consuming more power 2.4 Restoration of panel AC

5 Power consumption during machine idle time Machine all elements remains on as machine is ready for next cycle 1.6 Start power save mode at cycle end by generating new M code.

27 In EMG mode FRD 122276 is consuming less power (0.150Kw) as compared to other FRD’s Machine internal tube light continuous on even after machine at power save mode 1 Switch off machine light in power saving mode

28 SPM machine 120675 hydraulicmotor consumption more Inefficient control over hyd motor, motor continuous on – open loop system 2.4 Close loop system using inverter drive with pressure transmitter for feedback

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BAL-WalujKaizen : Reduce energy cost by providing thyristor control to the washing machine

heaters Deeply Interface -OEM

Before AfterStatus : Washing machine energy consumption is 6750 Kwh/Month & Cost is 50000 Rs/MonthHeater load is 24 Kw.

Idea : Reduce energy consumption by providing precise control of heater

Present Status : 1) Heater power is controlled through Radix on-off controller which is not precise 2) On-off controller hysteresis is 4 °C due to this temp. curve gets overshoot & undershoot

from set value

Countermeasure :1)Precise control using PID controller & thyristor2)Phase angle controlled output3)Adjustable ramp up & ramp down time

Result : Washing machine energy consumption after providing thyristor control is 6143 Kwh/Month.

Root Cause : More energy consumption due to On-Off control system used to control heaters

Benefit : Heater life increased from 6 months to 8 months.Horizontal deployment : 35 Machines in Waluj plant & 12 Machines in Chakan plant

Heaters

Contactor

On / off controller

New Technology

Temper

ature

Phase angle control

T i m e ( s e c . )0 0 . 2 0 . 4 0 . 6 0 . 80

0 . 2

0 . 4

0 . 6

0 . 8

1

1 . 2

1 . 4F r o m : U ( 1 )

Time (S)

PID controller

Thyristor

Heater

6750

6143580060006200640066006800

Before(Nov-14) After(Mar-15)

Energy consumption of washing machine9% Reduction

KWh / Month 5062546073

420004400046000480005000052000

Before(Nov-14) After(Mar-15)

Rs./mo

nth

Rs / month

9% Reduction

Kaizen Example : Micro level Analysis

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BAL-Waluj

HD on 17 machines

Idea is Inverter based Hydraulic

Pack with IE4 motors

Full Load condition

No Load condition

Kaizen Example : Micro level Analysis

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BAL-WalujResult- Micro Level Analysis

Cell Mar-15 May-15 Aug-16Model cell (P6 crank case) √Crank case P0, P2, P4, P5 (4 cells) √Remaining 18 cells WIPOverall results

10334

8835

6000

7000

8000

9000

10000

11000

Before After

Rs / shift

Before (Nov -14) After

(Till May -15)

46875

30000

35000

40000

45000

50000

Before After

Rs / shiftTill May-15 – HD 4 cells Expected result after all HD– Aug-16

Before (May -15)

Target (Aug-16)

Horizontal deployment status

14.5 %Better

14 %

40300

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BAL-WalujKaizen : Energy cost reduction by eliminating IR Oven Deeply Interface – Decal Supplier

Before After Problem : More energy cost at IR heating of decals Idea: No heating to remove micro air & ink solvents entrapment in decal filmDecal film needs to heated to remove micro air bubble & ink solvent from decal film.

Kaizen : Changed decal film structure for easy removal of micro air & Ink solvents during application.

Root Cause: Heating required to remove micro air & ink solvents entrapment in decal film

Result : Energy cost reduced from 7.7 to 5.11 Rs./ Veh.Energy saving of Rs. 46.6 lakh / year.

|Date of kaizen :-10.10.2014 Horizontal deployment : Nil

Eliminate heating

ABC

IR Heating Oven Decal Application

Lacquer Line

Total Energy required for IR Oven - 105 Kw/Hr

ABC

Decal Application

Lacquer Line

IR Oven is eliminated No energy required for Decal heating

Eliminate need of Infrared heater oven

IR Heating oven to remove entrapped Ink solvent & micro air from Decals

Innovative Project 2

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BAL-Waluj

Theme :Use of Solar Energy for pretreatment water heating Sr. No. 50289 PM Cell : Pre Treatment

Machine : PT Line Deeply

Before After Problem: High Energy Cost for Pumps in Paint shop Idea: Use of Renewable Solar Energy for water heating Present Status: Pretreatment water heating through LPG Fired Hot water generator

Energy Required :270000 K Cal /Hr. Annual Fuel cost : Rs.46.73 Lacs

Countermeasure: Use of Solar Concentrator for water heating

Analysis : High Purchase cost of Electrical EnergyResult : Annual Saving – Rs. 9 Lacs

Payback – 24 Months Sustenance Action : Prepared JH and PM standard and Scheduled PM Activity.

Root Cause : Use of LPG for water heating Horizontal deployment : 3 Locations planned

Photo / Sketch Photo / Sketch

Solar Concentrator ,With sun tracking System Capacity : 52000Kcal /Hr.

Kaizen – Energy cost reduction by using Renewable Energy source

Hot Water Generator ApplicationClient

100 Deg C

90 Deg C

Solar ConcentratorHot WaterGenerator Application

Legends: Water Circulating pump for ARUNHOT WATER GENERATION ARUN TECHNOLOGY.

Clients Existing SystemAutomated Valves

Client

100Deg C100 Deg C outlet90 deg cInlet

90 Deg C

Clients Scope

Fuel Cost Reduction

Deeply

Innovative Project 3

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BAL-WalujKaizen : To eliminate electrical energy wastage of Transformers in standby mode Deeply Interface – OEM

Before After Problem: Standby mode transformer energy loss is more. Idea: Facility for isolation of HT cable & transformer.Present Status:• 2 MVA Distribution Transformers under ground HT cables length from 750 to 1500 meters.• Necessary to keep the cables & transformers charged to avoid failure due to moisture. • No Load loss of a 2 MVA Transformer is 2 KW/Hr. • Total 08 transformers are in standby mode.• Energy wastage per Month :0.115 lakh units

Countermeasure: Provided Isolation switch between Transformer and HT Cable to keep the 2 MVA Transformers OFF but the HT cable charged.

Result : Standby mode transformer loss reduced to zero.

Root Cause : No facility for isolation of HT cable & transformer Benefit : Saving of Rs. 0.92 Lakh per Month.Payback period – 19 months

Date of Kaizen :- 10.12.14 Horizontal deployment : 21

Eliminate wastage

0.11500.000

0.0400.0800.120

Dec-13 Dec-14

Reduced by 100 %

L KWH /

Yea

r750 to 1500 meter Underground HT cable

Distribution transformer

11 KV / 440 VMain

Transformer132 KV / 11 KV

Main Transformer

Isolation switchMains Receiving

StationSub Station

750 to 1500 meter Underground HT cableVCB

VCB

Distribution Loss reduction

Standby

In Use

P

P

ODistribution Transformer

In Use

StandbyOON

OFF

Industry-Breaker in

Sub-station Bajaj –

Isolator on Transformer

Innovative Project 4

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BAL-WalujKaizen : Energy cost reduction on centralized coolant system Deeply

Before After Status : Power consumption is High (58000 KWH/Month) Idea: Optimization of flow & pump capacity with closed loop control systemPresent Status:1. Coolant system was designed for High flow & head requirement. (Split casing Pump coupled with motor used)2. Open loop control, Pumps operating at full capacity even if machine requirement is reduced . 3. Power consumption more due to coolant supply to machine when not in use.

Countermeasure:1. Use of Optimum capacity pump & Motor for required head & Flow (Short coupled Pump)2. Closed loop control feedback to operate pump at reqd. set pressure.3. Stopped coolant through shutoff valve on individual machines when not in use.

Result :Investment -Rs. 16 LacsCost Saving – Rs. 2.06 Lac/MonthPayback -8 Months

Root Cause :• Higher capacity Pumps & Motor in use (440M3/hr. & 75KW) • Pump running to deliver full flow & head all the time. Throttling of Pump output• Wastage of coolant flow, Individual machine coolant ON when not in use.

Horizontal deployment :Centralized coolant system 2 Nos.

Energy Cost Reduction

Cr. Case P6 cellCr. Case P6 cell

Parameter UnitMotor Capacity 75KWMotor efficiency 89%Pump Capacity 440 M3/hr.Pump Flow 7333 LPMPump Efficiency 56%Head 40 Meter

Machine 1Machine 2

Parameter UnitMotor Capacity 45KWMotor efficiency 93.5 % Pump Capacity 381 M3/hr.Pump Flow 6344 LPMPump Efficiency 76.9%Head 30 Meter

Machine 1

Machine 2

58,00033,779

15,00030,00045,00060,000

Before (TillNov'14) After (Dec'14)

Kwh/MonthCoolant tank

PumpMotor

MotorpumpThrottle valve

Star delta contactor controlCoolant tank

MotorMulti pump control using VFD

pump

pump

MotorThrottle valve

Pressure switch

Feedback

Added Shutoff Valve

No Throttling

Hydro pressure monitoring

High efficient motor(IE1,93.5%) & Pump (76.9 %)

Innovative Project 5

BAL-WalujKaizen theme :To reduce energyconsumption by Efficiency Improvement Idea : High Efficiency Result :Power consumption reduced by : 2574 kWh / month

Before After

Power Saving : 30800 kWh/ Annum

Earlier blower consisted of • AC induction motor • Indirect drive through V belt• Heavy fan designAC motor loses torque as speed increases.Root Cause : Low Efficiency (75%)

AC blower replaced with BLDC motor blower.• It provides flat torque over a

wide range speed.• It has lightweight fan with

improved fins design.• BLDC motor has 90% efficiency

Power Consumption (kWh/month)

62263702

02000400060008000

Before After

Motor

Impeller & CasingShaft & pulley B

elt

BLDC Motor Impeller

Blower Capacity 15000CFM Single motor 15 KW

Blower Capacity 15000 CFM3 Motor 3.4 KW each

41 %

Innovative Project 6 Energy Cost Reduction - Efficiency Improvement

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BAL-WalujGeneration of Electrical Energy with Windmill Power Project

Year Installed Capacity Wind power Generated Waluj Plant consumption Wind Power adjusted Contribution Equiv. CO2 emission reduction (MW) ( L kwh) ( L kwh) ( L kwh) % Tons

2010-11 65 949 573.48 239.28 41 191422011-12 65 1076 589.86 268.68 45 214942012-13 65 888 540.7 260.68 48 208542013-14 65 1043 510.8 278.32 54 222392014-15 65 980 503.8 0 Nil ***2015-16 65 860 455 177 39 14143

At SATARA & SUPA area in Maharashtra Wind mills are installedfor Electrical Power Generation.

41.00 45.00 48.00 54.0039.00

50.00

10

35

60

85

2010-11 2011-12 2012-13 2013-14 2014-15 2015 -16 2016 -17

Use of Renewable Energy

Target

*** Wind energy generated is transferred to other Bajaj auto associates for 2014-15

Wind energy generated is transferred to

other Bajaj auto associates for

2014-15

32

BAL-WalujSustenance Sustenance Activities

ReviewAuditsMonitoring & MeasurementLoss Identification& Corrective actions

Technology Up gradation

Education & Training

Regular Shop Audit Regular Shop Audit by Energy Captains

Internal Audits

Consumption Data Analysis

Daily/MonthlyElectrical Energy

Daily Review by Div Head

Adoption of Energy efficient Technology for Manufacturing,

Monitoring

Energy Managers Training

External Audits Daily/MonthlyLPG

Daily/MonthlyWater

Daily/MonthlyFuel

Daily/Weekly

Review by Plant Head

Energy Index Review by Corporate

Energy Captains Training Group

Leaders Training

LeakageIdentification

HD of Kaizen

Implement ENCON project

HD of ENCON project in other shops. Plant, Vendors

Vendor Training EMS

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BAL-WalujEnergy consumption monitoring & Measurement

• 300 Electrical Energy Meters • Monitoring up to shop Feeder

• 55 Water meters• Monitoring up to shop

• 10 LPG Flow Meters • Monitoring up to Oven

• 14 Air Flow meters • Monitoring up to shop

On Line real Time Monitoring SCADA

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BAL-WalujEnergy consumption monitoring & Measurement

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BAL-WalujAwareness creation

Training

Kaizen

AppreciationEvent

Competition

• Awareness through communication• Energy Captains• 5 Axis Training• Latest Technology

• Small Group Activity• Karakuri• Engineering Kaizen• Managerial Kaizen• Energy Boards at shop

• Best Kaizen Award• Best Energy Captain • Energy Efficient Shop

• ENCON week• Poster display• Energy Seminar• New Product display

• Monthly Kaizen • Karakuri • State & National level

36

BAL-WalujKaizen Idea matrix

ENCON Awareness creation

4650 Kaizen implemented by all employees with support from 200 Energy Captains

Sr. LossElimination Alternate source Efficient Equipment Operational Control Total 1 Machining 30 2 18 4 542 Paint 28 2 21 2 533 Press & Fab. 19 0 8 3 304 Assembly 25 1 3 8 375 Utility 23 1 12 11 47

Total 126 5 62 28 221

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BAL-WalujIdea By Energy Captains Kaizen theme : To reduce energy consumption by design change. Idea :- Less Weight Result : LPG consumption reduced by 0.16 kg / Dolly.

Before After

Fuel (LPG) Saving : 84240 Kg/Annum

Old Dolly used for top coat painting of sets on robotic conveyor Modified Dolly

Root Cause : More Weight Benefit : 1. EMS performance improved (No air pollution)

140 KG

95 KG

1 Old Dolly Weight 140 Kg2 Ambient Temp. 35 ‘C3 Dolly Temp in Heat up zone 89.7 ‘C4 Dolly Temp in Keep up zone 141 ‘C5 Heat Load per Dolly 5194 Kcal6 LPG Cons. Per dolly 0.49 Kg

1 New Dolly Weight 95 Kg2 Ambient Temp. 35 ‘C3 Dolly Temp in Heat up zone 89.7 ‘C4 Dolly Temp in Keep up zone 141 ‘C5 Heat Load per Dolly 3525 Kcal6 LPG Cons. Per dolly 0.34 Kg

LPG Consumption (Kg/Dolly)

Kg/Dolly0.49 0.34

00.20.40.6

Before After

31 %

38

BAL-WalujEnergy Conservation through external AuditsSr. Year Audit for Projects ( Nos. ) Saving Potential Status1 2011 Compressed Air 3 6.5 L Kwh 5.5 L KWh2 2011 Water system 3 1500 Cu Mtr/day 1500 Cu Mtr/d3 2012 Power System- PF & Harmonics 8 1.2 L Kwh 0.8 L Kwh4 2012 Process Pumps & Motors 10 2.7 L Kwh 2.15 L Kwh5 2012 Thermal - Thermography for Ovens 7 63456K Cal 61058 K Cal6 2012 Compressed Air System 3 7 L Kwh 6.2 L Kwh7 2012 Compressed Air Leakages(On going) 5 6 L KWh 3 L KWh8 2013 Chillers 1 2.62 L Kwh 2.1 L Kwh 9 2014 Lighting System 3 1.2 L Kwh 0.7 L Kwh

10 2015 Use Of Renewable energy 2 100 Ton LPG WIP11 2015 CII Water Audit 2 200 Cu Mtr/Day 237 Cu Mtr12 2016 Thermal Audit for HT & Paint Shop 4 20 Ton LPG WIP

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BAL-WalujSr No. Environment Improvement

1 No water is discharged outside the company.-Water Positive Plant 2 Tree Plantation by all employees in plant – 75000 Plants 3 Rain water harvesting pond capacity increased to 50000 Cub Mtr 4 Implemented E-waste norms prescribed by MPCB.5 Ground water recharging with rain water (Patented with KEDIA FARM PATTERN) by deep percolation technique. Capacity -8 L kL 6 100 % recycling of Industrial effluent by Installation of RO + UF Plant of capacity 1000 M3

/ day. This being used for process. 7 Reduce consumption of packaging material by 40 % (Polythene bags, corrugated boxes) in last 8 years. No packaging materials for transporting material from vendors 8 Effluent treatment plant (ETP) has been upgraded to separate industrial & domestic effluent resulting in better quality of treated water. 9 Paint Sludge reduction by paint yield improvement – Use of high transfer efficiency painting bells

List of major environmental improvements 2011-16

40

BAL-WalujOur water conservation activities has grown from within fence to Out side Fence

• Measurement & monitoring• Operational control

• Using Innovative ideas

• Reduce Water consumption to • 1548 M3/Day in FY 15-16 (50% ) • Water Positive through harvesting

• Sharing learnings /Techniques /initiative of water conservation in Plant

• Water harvesting• Contribution in Draught free Maharashtra

• Creating awareness• Sharing Knowledge

• Finance support

Society-CSR Activities throughJBGVS

Vendors –Activities Through BAVABAL Waluj Plant

BAL Waluj Plant Vendors –Activities Through BAVA

BAL Waluj Plant

• Reduce Water consumption to 900 M3/Day in FY 15-16 (53% )

• Water harvesting Ponds -55000 M3

Approach

Target

Our water conservation activities has grown from within fence to Outside Fence

Aug-16

21

41

BAL-Waluj

Water

Operational Control Loss Reduction / Elimination

Sr. Idea 1 Distribution leakages Loss2 Optimization of water pipe line network 3 Re-routing of water lines –Above ground4 Use Of water saving taps 5 Use of Breeze air coolers to reduce the evaporation loss6 Use of natural draft cooling towers

Sr. Idea1 Metering & Monitoring 2 Auditing 3 Energy Captain4 No Production on Off days 5 Controlled Pumping Hours6 Water level controller & synchronized pumping

Sr. Idea 1 Use of Tek-Talis Process in place of Phosphating 2 Use of air cooled compressors instead of water cooled 3 Use of Drip Irrigation / Sprinkler system for horticulture 4 Rain water harvesting ponds.5 Ground recharging with rain water .

Technological Improvement

Sr. Idea 1 Use of treated water for horticulture 2 Use of Treated water with RO for process.3 Use of Treated water with UF for Domestic uses.

Loss Elimination

Alternate Method Recycle/Reuse

Water Conservation activities in Plant

Methodology & Idea

42

BAL-WalujWater ConservationSustainable DevelopmentGround Water Recharge

2200 1915

1186 850

2190 2190 219014.33

19.4622.37 22.20 22.50 22.50 22.5

0.005.0010.0015.0020.0025.00

0500

1,0001,5002,0002,5003,000

2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16…

Water Consumption (Cu. Mtr. / Day ) Production / Year (Lacs)consumption Down by 47 %

Production Up by 57 %

Recharging of Ground Water

Annual Consumption 4.23 Lakh KlAnnual ground Recharge Capacity 8.0 Lakh KL

We, at Waluj Plant ,giving more to ground through

recharging rain water than we consume

This makes usWATER POSITIVE

This water available for Farmers /Society

Aug-16

22

43

BAL-Waluj

Total Green Plantation Area 75% (Total tree planted :

more than 50000 nos.)

Environment Improvement through Green Initiatives

Rain Water Harvesting

Rain water Pond No. 1 : 10000 M3Rain water Pond No. 3 : 15000 M3

Rain water Pond No 2 : 10000 M3FY 12-13 ( Investment Rs 12 Lacs) FY 13-15( Investment Rs 24 Lacs)

Rain water Pond No. 4 : 14000 M3FY 15-16( Investment Rs 60 Lacs)

44

BAL-Waluj

Sr. Description Before After Remarks1 Waste paint separation at sedimentation tank / slugger

600 Kg /day(Wet) 300 Kg / day( Dry) Weight reduction of sludge : after use of centrifugal sludge dryer

2 Paint filling in cotton bag 150 Bags(4 kg paint sludge / bag) No bag(dry paint sludge) Saving of 2.28 Lacs / annum(150 Bags X 5 Rs / bag X 305 Days )

3 Transportation of wet paint sludge Wet sludge to weighing bridge & incinerator. Dry sludge to weighing bridge & incinerator.Wet sludge transportation : leakages / undesirable.

4 Storing of paint sludge Stored @ 15 to 30 days to get it semi dry. Dry sludge by centrifuge separator Undesirable to keep the stock for a month

Centrifuge separator

Environment Improvement Install Paint sludge dryer :

Aug-16

23

45

BAL-Waluj

Inventorisation Mitigation

Year* Scope 1 EmissionsCO2e (MT)

Scope 2 EmissionsCO2e (MT)

Scope 3 EmissionsCO2e (MT)**

Total reduction in emissions intensity since baseline year studyCO2e (MT)2010–11 12615 30078.4 NA Base Year2011-12 12139 28906.7 NA 16482012-13 11166 30394.7 NA 11332013-14 8948.5 23661.5 NA 100832014-15 9022 47610 NA -139382015-16 8173 27959 NA 6561.4

Carbon Foot print

46

BAL-WalujCarbon foot printCarbon foot print

CO2 Absorption

Direct Emissions

CO2 emission (owned / controlled by company)

Fuel consumption

CO2 emission sources (not owned / directly controlled by company)

1.Electricity losses in trans.& distribution2.External vendor part movement

3.Vehicle Distribution &Employee Commuting

CO2 absorption by tree plantation

Direct Absorption

CO2 Emission Better Better

Indirect Emissions

CO2 emissions (generation of purchased Electricity)

Purchased electricity Consumed in manufacturing of product

Internal Movement Testing

Material / Engine

HandlingVehicle Shifting

Manufacturing shops

M/c & Equipment Running

Lights, AC, Air circulators Running

Paint shop

Oven Heating Vehicle

testing Engine testing Compressors

Running

Approach for Carbon Reduction

Aug-16

24

47

BAL-Waluj

1) O2 releasing shrubs :"Tulsi gives out oxygen for 20

hours and ozone for four hours a day along with the formation of nascent oxygen which absorbs

harmful gases like carbon monoxide, carbon dioxide and

sulphur dioxide from the environment,"

"Tulsi gives out oxygen for 20 hours and ozone for four hours a day along with the formation of nascent oxygen which absorbs

harmful gases like carbon monoxide, carbon dioxide and

sulphur dioxide from the environment,"

Plantation of Tulsi Clusters 1. Near MCD Office : Completed2. Near CVD Office : Completed3. Near Works Office : Completed4. New Spares Ware House : Completed5. Near Dispensary : Completed

Plan for O2 releasing tree plantation

SrNo.

Name of plant

Year of plantation

Location Target of tree plantation (Nos.)

1 Peepal 2016-17 Near ETP area

1002 Banyan

(Vad)2016-17 Near ETP

area100

2) O2 releasing plants :

Tulsi Peepal Banyan

Carbon Reduction

48

BAL-Waluj

Heat recovery from waste flue gases at Low Temperature are installed in Paint shops

Waste utilization

SN Waste Heat Recovery System installed at LPG Saving Kg/Year Investment ( Rs. Lacs)

1 Paint shop ED oven exhaust 26100 9.752 HWG Aquatherm PTCED Exhaust 10416 5.53 HWG Aquatherm Paint shop Exhaust 10416 5.54 PTCED line Oven Exhaust 38626 95 Paint shop Exhaust Oven- 4 Locations 37135 12.5

Aug-16

25

49

BAL-WalujImplementation of ENCON initiatives at Vendor’s endSr Name of vendor Product Per unit Energy consumed % improvement Inputs / projects provided to the vendor/ associate

Before After

1 M/s Duro valve(I) Pvt Ltd,AurangabadValvesproduction 0.20Kwh/Valve 0.17Kwh/Valve 33 % Training , Visit to our plant , Help inEnergy Audit & Implementation ofprojects

2M/s BadveEngineeringUnit 2,Aurangabad

Silencerproduction 3.6Kwh/Silencer 3.3 Kwh/Silencer 8.33 % Training , Visit to our plant , Wasteelimination, Timed control operation

3 M/s VarrocPolymers PvtLtd. Pl. 2Mirrorproduction 0.32Kwh/Unit 0.0.2Kwh/Unit 37.5 %

Training , Visit to our plant , Wasteelimination, Renewable energyusages, Efficient equipments ,Optimized heat utilization.

Similar ENCON projects (453) are implemented across 58 Vendors. In last one year .Average % improvement achieved is 17 %

50

BAL-Waluj

67.54

31.4525.41 22.61 21.15 19.92 18.9 17.91 16

01020304050607080

2003-04BM 09-10 10-11 11-12 12-13 13-14 14-15 15-16 16-17Target

Electrical Energy Consumption Result

Kwh/Veh 2.53

2.11.77

1.45 1.3 1.1 10.76 0.65

0112233

2003-04BM 09-10 10-11 11-12 12-13 13-14 14-15 15-16 16-17Target

Thermal Energy Consumption

0.89

0.41 0.35 0.410.27 0.18 0.16 0.083 0.05

000111

2003-04BM 09-10 10-11 11-12 12-13 13-14 14-15 15-16 16-17Target

Water Consumption

Kg/Veh.

M3/Veh.

Aug-16

26

51

BAL-WalujS.No. Title of Project Year

Annual Electrical Saving,

Million kWhAnnual Electrical

Cost Saving, Rs Million

Annual Thermal Saving,

Million kcal

Annual Thermal Saving,

Rs Million

Total Annual Savings, Million Rs

Investment Made (Rs

million)Payback months

1 Installation of inductuion high bay lamp 2016-17 0.0259 0.184 0.184 0.6 392 LED Task Lights for machines 2016-17 0.0173 0.123 0.123 0.21 213 LED lights in toilet blocks 2016-17 0.0219 0.155 0.155 0.2 154 Energy efficient LED lighting on assembly conveyours 2016-17 0.0499 0.354 0.354 1.3 445 Energy efficient Pump & Motor for central coolant System P2 2016-17 0.1920 1.363 1.363 1 96 Energy efficient Pumps & Motors for CGC rinse wash (HD) 2016-17 0.0384 0.273 0.273 0.4 187 Efficiency Improvementpf ARP through VFD 2016-17 0.0192 0.136 0.136 0.3 268 Energy efficient Blowers for exhaust oven(HD) 2016-17 0.0480 0.341 0.341 0.75 269 Replacement of Panel AC with efficient AC system 15 no. 2016-17 0.0903 0.641 0.641 1.75 3310 Heat Loss reduction through insulation on hot water lines of washing machines 2016-17 0.0744 0.528 0.528 0.62 1411 Use of heat Pump for washing machine -2 no. 2016-17 0.0720 0.511 0.511 1 2312 Solar water heating for Top up in washing machines 2016-17 0.0360 0.256 0.256 1 4713 Optimization of coolant system load through Coolant shutoff valve for machines 2016-17 0.0144 0.102 0.102 0.15 1814 Replacement of manual drain valves of Compressor Air receivers 2016-17 0.0144 0.102 0.102 0.525 6215 Micro mapping of air leakages & standardization of fittings 2016-17 0.0072 0.051 0.051 0.125 2916 Micro Mapping of Equipments in production cell & implement actions- 148 machines 2016-17 0.1000 0.710 0.710 0.2 317 Energy Efficient blowers & Motors 40 no. 2016-17 0.0720 0.511 0.511 0.3 718 HVLS fans -8 no. 2016-17 0.0720 0.511 0.511 0.3 719 Magnetic separator with earth magnet 2016-17 0.0150 0.107 0.107 0.8 9020 Thyrister controllers for heaters of washing machines - 10 no. 2016-17 0.0480 0.341 0.341 0.375 1321 ETP equipment mapping & actions 2016-17 0.0175 0.124 0.124 0.075 722 Actions on consumption reduction -Holidays 2016-17 0.0336 0.239 0.239 0 023 Air Leakage Audits & Countermeasures 2016-17 0.5759 4.089 4.089 0.6 224 Operation control in shops 2016-17 1.0000 7.100 7.100 0.5 125 Audits through Energy Captains & Countermeasures 2016-17 0.1200 0.852 0.852 0.8 1126 Magnetic Resonators for LPG fired burners -HD 2016-17 115 0.376 0.376 0.6 1927 Restoration of roof top Solar water heater 2016-17 86.25 0.282 0.282 0.8 3428 Heat Loss reduction through insulation on Oven 2016-17 230 0.752 0.752 1.5 24Total 2.7754 19.7052 431.2500 1.4108 21.116 16.780 643

Future Projects

52

BAL-WalujAwards & Accolades

CII- Efficient Unit Award 2012

MEDA- Excellence in Energy Conservation & Management Award 2013/2014/2015

CII- Excellence Unit Award 2013 CII- Excellence Unit Award 2014