CII National Award for Excellence in Energy Management 2019

22-09-2019

1

CII National Award for Excellence in Energy Management 2019

Presented by

Arun V –Deputy Manager-Plant Engineering

Cheruvu Sankar –Deputy Manager-Plant Engineering

Contents Slides Time

Table of Contents

01 Honda Motor’s 2030 vision & how HMSI targets are aligned to it, Introduction aboutof factory, its key features and Energy, Water Management Cell & Energy Policy

Total

02Energy data

Energy Resources, Specific Fuel Consumption, Internal and National Benchmarking

03Encon ProjectsZero Investment Encon Projects and Other Encon Projects

04 Innovative IdeasEnergy Saving through Mono Coat, Compressor Waste heat recovery and Inductioncooking.

05 Renewable & Green EnergyRenewable energy usage in Narsapura Plant, Renewable energy projects

06 Water &GHG Emissions

07Green Supply chain

08Employee Engagement

Introduction & Energy Management

7-11 1 min

1 min1-6

12 1 min

13-23 5 min

24-28 3 min

29-37 2 min

38-44 2 min

45-50 2 min

22-09-2019

2

HMSI Narsapura –At a Glance

Factory location Product mix

Our factory is the largest Manufacturing Facility of Honda GloballyAnnual production is ~ 25 mill Veh

Press Shop Weld Shop Paint Shop

BOP Parts Machine ShopAl & FE

Assy Engine

Assy Frame VQ LogisticsFra

me

Part

s

En

gin

e

Part

s

Manufacturing process

Honda Global Environment Commitment

Use of renewable energy & resource reduction is one of the core features of our global policy

Baseline Year 200030%

CO2 Reduction

Vision 2020

Vision 2050

Lead efforts to realize a

“Carbon-Free Society”

Vision 2030

Baseline Year 200050%

CO2 Reduction

2 Wheelers2 Wheelers

2 WheelersFuture Challenge

Triple ZERO Approach

CO2Emissions

Energy Risk

Resource & Disposal Risk

TripleZERO

Honda Vision

Solar

Wind Bio-Mass

Serve people worldwide with the “joy of expanding their life’s potential”

-Vision 2030

22-09-2019

3

Energy & Water Management Cell

We have a very strong energy cell working in our company

Energy & water Management cell

•Internal /External Benchmarking• Resource Allocation• Reviewing Energy Performance•Challenges, Risk Mgmt. & Opportunities

• Projects prioritization• Energy Conservation Plan• Communication & Training• project progress Review• Variance review

•Daily Variance Analysis & Correction•ENCON Ideas Generation• Implementation of ENCONs•Implementation of small ENCONs

Roles & responsibilities

Naveen Awal

(V.P , Plant Head)

Energy Policy –Narsapura plant

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

Key policy highlights

Use of renewable

energy PDCA Approach Use of monitoring

systems

Use of Energy saving

equipment's

VFD

IE3

IE4

Timers

22-09-2019

4

HMSI 3F Awards & accolades

Confederation of India Industries (CII)conducts assessment based on their rating system to drive excellence in resource conservation, base-line improvement, green corporate image

HMSI 3F Focused all the environment management Indices to achieve top most rating (Platinum) and lead efforts in sustainable green manufacturing Factory

❖ First factory in Honda India Group to achieve “Greenco” rating

❖ First Manufacturing facility in Karnataka to achieve Platinum rating

❖ Among the top 10 scoring Greenco companies in India

❖ National best in Waste management and Innovation

CII National Excellent energy efficient award 2018

CII Best Environment practices award 2018

Energy Efficiency

Water

Renewable Energy

Carbon emission

Raw Material Conservation

Green Supply Chain

Product Stewardship

Sir. M .VishveshwarayaManufacturing Excellence

Award 2017

Certification ceremony

Other Awards

Life Cycle Assessment

Waste

management

Innovation

HMSI 3F → Took initiative amongst all HONDA Genpos in India & got Platinum Rating

Platinum rating from CII is a recognition for the numerous sustainable practises in 3F


Table Of Contents

01 Honda Motor’s 2030 vision & how HMSI targets are aligned to it, Introduction aboutof factory, its key features and Energy & Water Management Cell

Total

02Energy data









7-11 3 min

2 min1-6

12 1 min

13-23 5 min

24-28 3 min

29-37 2 min

38-44 5 min

45-50 3 min

22-09-2019

5

Energy Resources being used in HMSI Narsapura

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

Total Energyusage pattern

Electrical Energy usage pattern Propane Usage pattern

HMSI – 3F

31%

26%

15%

8%

8%

Utility

PA

MA

Pr & We

Others

Utility PA MA Pr & We Others

Govt.Power

DG Power Third party Solar

InhouseSolar

PropaneSolar

DishesWaste Heat Recovery

29.59

26.79 26.0924.86 24.02

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

Specific energy consumption-Electricity

8% reduction

Specific power consumption (kwh/veh)

Natural lighting

AC BMS

VFD for major load EMS system

Compressor heat recovery

for Vaporizercohesive painting

technology

Specific Electrical consumption is in reducing trend

HMSI – 3F

High efficiency motors

(worlds first IE4 compressors)

Intelligent air managers

Timers for AHU&

exhaust syst

22-09-2019

6

1.28 1.21 1.20 1.19

1.06

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

Specific energy consumption-Propane

12% reduction

Specific propane consumption (Kg/veh)


for Hot water generation

Specific propane consumption is in reducing trend

HMSI – 3F

Magnetic resonator for

propane lines

Waste heat evaporator

OF MEE OF ETP Boiler burner optimization

Solar Dishes to

generate Hot waterSolar sludge drying

Induction equipments

Specific energy consumption-Internal Bench marking

We are constantly striving to better our consumption & set new bench mark figures year on year

2.62

3.58

2.03

1.06

Manesar Tapukhera Vithlapur Narsapura

Kg

/ve

hK

WH

/ve

h

34.8

46

38

24.02

Manesar Tapukhera Vithalapur Narsapura

Specific Propane consumption

60% Less

30% Less

Specific Power consumption

HMSI – 3F

Mfg process not similar

Mfg process not similar

22-09-2019

7

Specific energy consumption-National Bench marking

We are striving towards being the national bench mark

Specific Power consumption

Kg

/veh

KW

H/v

eh 16

27.724.02

Comp 1 Comp 2 Narsapura

0.76

1.06

comp 1 Narsapura

Specific Propane consumption

➢ No Standard Benchmarks are available for Automobile sector , These are collected from various presentation.

Our target

Understand the best practises in other

factories and strive to be the national bench

mark

HMSI – 3F


Table Of Contents


Total

02Energy data









7-11 3 min

2 min1-6

12 1 min

13-23 5 min

24-28 3 min

29-37 2 min

38-44 5 min

45-50 3 min

22-09-2019

8

Encon Projects Without Investment

S. No. Parameter Projects implemented

Environmental benefitsTotal Investment

made (Rs. In lakhs)

Monetary Benefits

(in lakhs)Intangible benefits

Savings in Quantity

1 RE Third party power procurement

Renewable energy 44000000

0 1078

Through third party solar power procurement by wheeling, power

requirement is met 24 x 7 irrespective of seasonal variation as

state grid back up is always available.

GHG emission 35772

2 EEPropane saving through heat free treatment

technology

Thermal energy 121500

0 144

Reduced water, energy and equipment efficiency losses in

heating process. Insulation from market fluctuations in prices of

propaneGHG emission 724

3 EEEnergy saving through Cohesive painting

technology

Electrical energy 1973000

0 123 Reduction in VOC emission

GHG emission 1605

Total 0 1345

Without Investment Savings – 1345 Lakhs/Annum

HMSI – 3F

Encon Projects With Investment

With Investment Savings – 943.5 Lakhs/Annum

S. No. Parameter Projects implemented

Environmental benefitsTotal Investment

made (Rs. In lakhs)

Monetary Benefits in

lakhsIntangible benefits

Savings in Quantity

1 REInstallation of solar roof top panels

of capacity 7MW

Renewable energy 88000002870 580

Dependency on external agency for power supply reduced

GHG emission 8330

2 REHot water generation through solar

dishes


250 134Sope 3 emission reduction on propane

transport. Impact reduction due to market rate fluctuation and fossil fuel dependanceGHG emission 681

3 RE Waste heat Evaporator in ETP


250 100

Waste water treatment is a Legal Compliance which is a 24 X 7

requirement. Through solar sludge drying, the risk of dependancy on a single fossil fuel for wastewater treatment is reduced

GHG emission 607

4 RE Solar solution for sludge dryingThermal energy 55000

30 55Improvement in safety wrt handling of

propaneGHG emission 317

5 EEInterconnection of compressors

through integration of three compressor houses

Electrical energy 1100000

12.39 72

Compressed air is a production requirement in two wheeler

manufacturing. Through interconnection, the availability has been ensured thereby increasing reliability of the whole system

GHG emission 924

Total 3424.39 943.5

HMSI – 3F

22-09-2019

9


Table Of Contents


Total

02Energy data





06Water &GHG Emissions




7-11 3 min

2 min1-6

12 1 min

13-23 5 min

24-28 3 min

29-37 2 min

38-44 5 min

45-50 3 min

Background & Situation Analysis Need, Purpose & Target

Content of Execution Investment, ROI Calculation

HMSI 3F Replacement of Heaters with Hot water

Investment 10 Mill Rs

Saving 5.15 Mill Rs

ROI 23 months

Continuous cost reduction initiatives taken to reduce utility cost.Electrical based heating→ Hot water based heating

0.431.29

2.15 3.003.86 4.72

5.586.44

7.308.15

9.019.87

10.73

M1 M2 M3 M4 M5 M6 M7 M8 M9 M10M11M12M13M14M15M16M17M18M19M20M21M22M23M24M25

ROI – 23 Months

in M

illion R

s.

❖ Electrical heaters are installed in washing machines.❖ Heaters are used to heat the coolant used to clean the components in washing machines❖Total power consumption ~3,264 Kwh

Need: To reduce the power consumption in the washing machines in MA

Purpose: To reduce the utility cost /veh by taking various CR initiatives

Target: To reduce utility cost/veh by 2.1 Rs/veh

TARGET SETTING

class

Control item UOM Plan

S Process type - Non hazardous

C Minimum investment Mill Rs 10

C Power cost /veh reduction Rs/veh 2.1

D Heater working - To be switched off

❖Hot water can be used to heat coolant instead of electricc heaters❖The power consumption for the heaters can be saved❖The hot water generated from solar dishes and compressor hot water recovery will be used

Heating skid

22-09-2019

10

1

L4 ETP

➢ Present condition we are using steam based ATFD for sludge drying

➢ Steam required for ATFD is 350 Kg/hr

➢ propane required for generating steam: 396 Kg/day

Process

Make up water(20KLD)

ETP(RO

plant)

Effluent water(115KLD)

Recycle water(75KLD)

Reject water(40KLD)

Recycle water & Condensate(20KLD)

Multi Effect evaporator

Steam

ETP location

ETP300KLD

MEE40KLD

WTP

Cooling tower

ATFD

Rejectwater

Dry Sludge

Intelligent Evaporator

Total cost of evaporation in MEE is 5.5 mill Rs

➢ Hot water from solar dishes is fed to evaporate the reject water from MEE

HMSI – 3F Solar Sludge dryer

Solar Solution for Sludge Drying

Hot water PanAmbient Air Fan

Moist Air

ECU Management based on:1. Tank temperature2. Ambient Temperature3. RH4. Wind speed

Injection of hot waterSmart ECU Control

109 Tons of Propane/annum

55 Lakhs/annum 30 Lakhs 7 Months

Key project highlights

317 Tons/Annum

Theme is being horizontally deployed in all HONDA factories


HMSI – 3F

22-09-2019

11

Total cost of evaporation in MEE is 10.5 mill Rs. ~4.2 Rs/veh.

HMSI – 3F Waste heat evaporator for effluent evaporation

Existing effluent treatment system

1

L4 ETP

➢ Present condition we are using steam for waste water evaporation

➢ The steam using in Evaporation & drying for 40kld water :280 kgs/kl. day = 11.2Tons/day.

➢ propane required for generating steam: 746 Kgs/day @ 51Rs/kg

➢ Cost of Propane/annum @ 51 Rs/kgs: 10.5 Mill Rs.

Process

Make up water(20KLD)

ETP(RO

plant)

Effluent water(115KLD)

Recycle water(75KLD)

Reject water(40KLD)

Recycle water & Condensate(20KLD)

Multi Effect evaporator

Steam

ETP location

ETP300KLD

MEE40KLD

WTP➢ Steam used in evaporation is

generated from propane fired boilers

➢ The water getting evaporated is topped up fresh water from WTP

Cooling tower

Evaporation20KLD

Stage WHE is being proposed for 3F,Energy required is 100,000 Kcal/hr


Process

Make up water

ETPRejectwater

Recycle water

Rejectwater(40KL)

Recycle water & Condensate(26KL)

WHE

Solar Dishes

Hot water

The heart of the system

Steam or Air Ducting

Water Piping- Heating Membranes

or Foils- Steam Separation- Energy Recycling

Vaccumapplication

collection of good water

Polymeric film

Polymeric film Modules Different Stages

➢ Multiple polymeric films added will make one module

➢ Each module will act as a stage of evaporation

Waste heat recovery from compressor

Wastewater is Concentrated in the following way:

➢ Heat is transferred from the hot water to the wastewater surface

➢ Wastewater evaporates from the surface

➢ Wastewater vapor diffuses through the membrane

➢ Wastewater vapor condenses on the other side of the membrane

22-09-2019

12

With Implementation of WHE ,steam consumption in our factory is only for paint shop process application


Hot water Stage 1 Stage 2

Heat energy

Effluent→

Condenser

Stage 3

➢ The entire process is carried out a vacuum to increase the efficiency of evaporation

To ATFD

Module 1 Module 2 Condenser

204 Tons of Propane/annum

100 Lakhs/annum 250 Lakhs 29 Months


607 Tons/Annum

Solvent to water based primer techniqueHMSI 3F

To implement Water Based Primer Technique in ABS Line

Plastic Parts

Appln: Manual Appln: Robot + Manual

Primer Base Coat Oven Painted Part

➢ All the plastic parts passes through two stage painting process

➢ In primer stage conductive primer is being applied for making plastic parts

22-09-2019

13


Water based conductive agent will be used after pre treatment

Conductive primer application

Existing process New technology

• Water based conducting agent

used in place of conductive

primer application

Water based chemical

BEF

OR

EA

FTER

ABS painting process

Loading

PTDry Off Oven

Air blow Zone

Primer Zone

B/C Zone

T/C Zone

Baking Oven

Baking Oven

Drain zone

Loading

PTDry Off Oven

Air blow Zone

Primer Zone

B/C Zone

T/C Zone

Baking Oven

Baking Oven

W B Cond. Agent


Theme Installation is under progress across all factory

Horizontal deployment to HMSI in other plants


24 Million 10 Million

S.N Plant Implementation

1 Manesar Under progress

2 Tapukhera Under progress

3 Vithalpur Under progress

4 Months 91.7 KL/annum

54.1 Tonnes

22-09-2019

14



Total

02Energy data





06Water &GHG Emissions




7-11 3 min

2 min1-6

12 1 min

13-23 5 min

24-28 3 min

29-37 2 min

38-44 5 min

45-50 3 min

Table Of Contents

Dec-18

7MW solar roof top

Jan-19

Solar dishes

Jul-19

Solar effluent evaporators

Oct-17

Third party Solar power

Mar-15

Test track Solar lights

Renewable Energy Usage in Narsapura Plant

2020 target of substituting 70% energy with RE already achievedStrong road map available to achieve the target

HMSI – 3F

Feb-19

PFET for effluent

treatment

Sep-19

Heat less pretreatment

Mar-20

Additional 2.5 MW Solar Power

June-20

2 MW Wind Procurement

June-20

Solar/Wind group captive

June-24

Bio mass heater

22-09-2019

15

Renewable Energy Usage in Narsapura Plant

This is Zero Investment project

Govt. Network HMSI 3F

➢ Third party solar power purchase to meet Plant Power requirement

➢ The agreement is for a period of 10 years

➢ Plant located ~200 KM away from factory

80%

16%

power Utilization

4%

Private Generator Public


37,000 ton/annum

440 lakh KWH

1078 LakhRs/year

Zero -NA-

HMSI – 3F

On-site RE Generation-7MW solar roof top plant

7 MW solar rooftop to meet 12% of total electrical requirement


8330 ton/annum

88 lakh KWH

580 lakhRs/year

287 lakh Rs 59 Months

➢ 7MW Solar Roof Top Installation done on Factory Roof Top.

➢ The installation of On site solar power plant was completed in Dec 2018.

80%

Offsite solar Generator Public

Solar roof top

12%

4%4%

HMSI – 3F

22-09-2019

16

Solar heating system

Hot water

Return waterProcess

application

Hot water tank


681,000

kg/annum292,000 kg134 Lakh

Rs/year

280 Lakh

Rs/year 25 months

➢ Total 300 numbers of dishes are installed in the factory , which is been distributed in Four Locations .

Thermal energy utilization

Propane cost has been reduced by implementing Solar Dishes in FactoryThe dishes contribute 5% of the total heat demand in our factory

Hot water generation through Solar energyHMSI – 3F

Line 4 Canteen Line 4 Open Area Line 4 Subs Fac B

➢ Installation of Solar Lighting in Test Track Area➢ 20 nos LED light fitting installed for test track


10.2 ton/annum

7884 KWH 50,000 Rs/year

4 Lakh Rs 80 Months

Solar Panels & LED lights installation 0.05 Savings/Yr

Installation Of Solar Panels In Test Track AreaHMSI – 3F

22-09-2019

17



Total

02Energy data





06Water ,GHG Emissions & Waste Management




7-11 3 min

2 min1-6

12 1 min

13-23 5 min

24-28 3 min

29-37 2 min

38-44 5 min

45-50 3 min

Table Of Contents

➢ Water for us is a very

precious commodity

➢ Each drop counts

Dependence on Ground water(in KL)

100% reduction

➢ Plant requirement is met by storing and re

use of rain water

➢ Roof water and road wash water is collected

and reused .

Rain water Utilization (KLD)

Tank 1 Tank 2

Storage tank locations

Storage volume: 76000 KL

Water Situation In Narsapura Plant-Rain water reuse 29/50HMSI – 3F

With construction of third tank,100% water requirement is met through rain water

210

320

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

450

17-18

New line added

18-19

420400

0

250

160

37

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

0

17-18

0

18-19

0

22-09-2019

18

Benchmarking and Uniqueness

Benchmark performance in water consumption and rainwater harvesting

310270

440 410

310

620

66

Thailand Indonesia Phillipines vietnam Bangladesh Pakistan HMSI Narsapura

Among Asian Group companies,Lit/veh

120

150

66

Competitor 1 Competitor 2 HMSI Narsapura

Among competitors in India,Lit/veh189

169189

66

HMSI -Manesar HMSI-Tapukera HMSI-Vithlapur HMSI Narsapura

Among HMSI,Lit/veh

Uniqueness

➢ One of the first industries in the country to meet 100% requirement through only rainwater.

➢ Net water positive factory within the fence.

➢ 90% of the process water requirement is met through recycled water.

➢ 90% Rainwater is utilized for domestic application only.

➢ Design and implementation through in-house expertise and PDCA.

HMSI-Narsapura is the lowest

water consuming factory in India

and Asia region

Benchmarking

HMSI – 3F

25.83

13.55

9.37

4.14

2016-17 2017-18 2018-19 2019-20

Honda’s Global commitment

* Compared to 2000 emission levels

Specific CO2 emission

HMSI Environment policy is closely linked to our Global Policy

GHG emission-Policy & vision

34.7

25.75

9.37

Asia & oceania HMSI Narsapura

Internal bench marking

Kg

/veh

HMSI – 3F

22-09-2019

19

CO2 emissions-Benchmarking

Benchmark performance in energy and CO2 emissions

Mono Coat painting technology VFD for major load


Solar dishes

AC BMS

Magnetic resonator

33.7

40.4

9.37

34.8

HMSI-Manesar HMSI-Tapukera HMSI-Narsapura HMSI-Vithalpur

72% Less

One of the lowest specific CO2 emissions

in India

23.8 22.9 22.020.4

23.7 23.3

0 0

24.225.8

13.5

9.4

2015-16 2016-17 2017-18 2018-19

Competitor-1 Competitor-2 HMSI-3F

Arihant Honda-PuneANSH Honda-UP

Replication Potential

Stakeholder Category Numbers

Suppliers 3

HMSI Genpos 4

Dealers 22

HMSI has provided training to 25

supplier companies on solar rooftop

and solar dishes and many of them

have implemented the same at

their facility

HMSI – 3F

Waste Management

Various initiatives were been taken to reduce the Scrap generation –23% reduction Till date

TYPES OF NON HAZARDOUS WASTE

Metal scrapCorrugated Material*Aluminium Casting

*Sheet metal scrap

*Misc. Iron

*Al & Fe Borings

*Packing Cartons

*Mill core

5.31 5.274.77

4.1

5.33 5.28

4.854.2

2015-16 2016-17 2017-18 2018-19

Actual Plan

SCRAP GENERATION KG/VEH

23% REDUCTION

INTIATIVES TAKEN TO REDUCE NON HAZARDOUS WASTE GENERATION

Chips to Briquette

Reuse of Carton Box for PackingReduced Rejection Rate

Packing material Reduction

Blank size reduction

Increase in Tool Lifespan

HMSI – 3F

22-09-2019

20

Waste Management

TYPES OF HAZARDOUS WASTE

ETP sludge, Grinding Sludge, CTP

Sludge, Incinerable waste, Paint

sludge.

Waste coolant, Used Oil, Spent

Thinner, Discarded Containers.

HAZARDOUS SLUDGE GENERATION KG/VEH

25% REDUCTION

INTIATIVES TAKEN TO REDUCE NON HAZARDOUS WASTE GENERATION

INSTALLATION OF SOLVENT RECOVERY SYSTEM

HAZARDOUS SLUDGE STORAGE/ DRYING YARD

UPGRADATION OF ETP – ETP SLUDGE REDUCTION

HMSI – 3F

Various initiatives were been taken to reduce Hazardous Sludge generation – 25% reduction Till date

Utilization of Waste Material As fuel

This program has been well received by all our dealers

https://ilsr.org/wp-content/uploads/2015/05/toxicash.jpg

CO-PROCESSING OF PAINT SLUDGE IN CEMENT INDUSTRY

PAINT SLUDGE

Incineration

Landfill

Co-process

OPTIONS OF DISPOSAL

CEMENT INDUSTRY

Coal Replacement in

Cement Industry

No residual waste

from Co-processingZERO Investment


330 Ton of Co2/annum

➢ 662 tons of paint sludge has been sent to cement industry for co processing

Paint Sludge which is been Generated is sent to Cement Industry

HMSI – 3F

22-09-2019

21



Total

02Energy data





06Water ,GHG Emissions & Waste Management




7-11 3 min

2 min1-6

12 1 min

13-23 5 min

24-28 3 min

29-37 2 min

38-44 5 min

45-50 3 min

Table Of Contents

Green Supply Chain Management

Supplier CO2 reduction has been in the forefront of all our effortsProjects & Kaizens are shared with suppliers for HD

Honda Awards for Environmental Initiatives

Year 2013-14 2014-152015-

162016-17 2017-18 2018-19

Winner

AdvikHitech

Denso India

Lucas TVS

EnkeiWheels

Shriram Piston &

Rings

Star Engineers

Pune

2017-18 2018-19

CO2 reduction through Kaizens

Objective:

Reduce the Global Warming through energy saving initiatives.

Reduction Target @ 1% Per YearStarted from 92ki

Reduction Result :

Year 91ki 92ki 93ki 94ki 95ki

No. of Splrs 46 49 54 52 55

Reduction 2% 4% 4% 6% In 96ki

❑ Splrs kaizens receiving status

3845

60

2535 37

25

10

3020

4335

Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar

Past Winners

95ki Improvement:▪ Horizontal Deployment b/w Splrs & HMSI Mfg & improve Kaizen quality

▪ Verification / Effectiveness check of new Implemented Splrs Kaizens

❑ Examples of CO2 Reduction Kaizens ❑ Energy Efficient Compressor

CO2 Reduction35 Ton / Year


❑ Installation of VFD


❑ Water level Controller

22-09-2019

22

EMS certification of Suppliers

1. NPR Auto parts

2. TVS

3. Velkalyan Products

4. T S Tech (Mandal)

5. Tata Autocomp

6. Sentec India

7. Royal Auto tech

❑ EMS Certification Status

6273

90

114130

139153

168175

182189

FY 08 FY 09 FY 10 FY 11 FY 12 FY 13 FY 14 FY15 FY16 FY17 FY18

❑ EMS Certification History & 2018~19 target Suppliers

96ki tgt. : Splrs 13

Infrastructure : Good

Financial situation: Strong

HMSI SOB : High


Infrastructure : Good

Financial situation : Weak

HMSI SOB : High


Infrastructure : Not Good


HMSI SOB : Medium


Infrastructure : Not Good


HMSI SOB : Low

Total Supplier

240

Non Certified

51

Remaining Splrs. Certi. Target

Certified 189

❑ Methodology ❑ 95ki Schedule

Target : Minimum 7 splrs certification every year

241711 07151491604 07 07

Activity95ki

Jun Jul Aug Sep Oct Nov Dec Jan Feb

Splrs Certi. plan

Support to Splrs

Implement verification

Follow up for cert.

Receive certificates

Report to Top Mgmt.

95ki Cert. Splrs

Target Suppliers Selection

Receive Certification Plan

Monitor Plan Vs Actual

Certificate Receiving & Status update

Provide “Green Supplier Manual” to splrs

Monitoring & Verify of GSM adherence

If Supplier ready to

Implement

Communication & Awareness for ISO 14001

No

Yes

79% Suppliers Certification completed

Plan : 7

Actual : 7

Major Benefits

▪ Resource loss reduction and energy conservation▪ Reduction in environmental liability & Hazardous chemical contamination in parts▪ Minimization of harmful impact on associates, society & environment

HMSI – 3F

Green Supply Chain Management-Plant Level activity

Narsapura factory encourages suppliers to adopt green initiatives

They are encouraged to do more initiatives through the annual supplier Best practices award

Supplier Environment Best Practices award

Questionnaires shared to suppliers

Filled questionnaires submitted by

suppliers

Evaluation of questionnaires by

HMSI

Shortlisted suppliers were asked to give

presentation

Environment best practices award to

suppliers

Green ProjectMusashi Auto Parts, Doddaballapur

Green ProjectSansera Engineering, Bangalore

Sustainable ProjectTriton valves Ltd, Mysore

Most Sustainable ProjectKiehin Fie Pvt Ltd, Doddaballapur

Evaluation Criteria

Chief Guest: Mr MB Kulkarni

16

Participating

companies

29

Themes received

Jury: Division head & CII

representative

❖ 7 companies who were shortlisted ,gave presentation in

front of our jury (including member from CII)

❖ 4 Companies shortlisted for award

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23

Site visit, explaining initiatives of HMSI towards zero CO2 emission and self sustenance on water consumption

Sharing of Best Practices to Other Companies

IMTMA Members visit to Narsapura Factory

HMSI – 3F

❖ Explanation about our Greenco

Journey

❖ Site visit highlighting various EE

,RE projects

❖ Visit to our water harvesting and

recycling facilities

❖ 5 companies have initiated the

Greenco journey

52

Total delegates

Green Dealer Certification

Strengthen Green Dealer Implementation at Dealerships

Methodology Green Dealer Certification Trend

Awareness TrainingDealer

RegistrationImplementation

Promotion at

DealershipCertification L1 & L2

Evaluation

Action Taken

Major Focus Dlrs:

➢95 Ki Certified Green Dealers

➢Dlrs scoring between 70%~80% in 95 Ki L2

Eval

➢Newly inaugurated Dlrs

2050

75109

173

228

300

335

368

88 Ki 89 Ki 90 Ki 91 Ki 92 Ki 93 Ki 94 Ki 95 Ki 96 KiPlan

Target

up by

10%

Green

Dlrs

57 57

95 Ki Plan 95 Ki Actual

Green Dealer Training Status

330 335

0

50

100

150

200

250

300

350

400

Plan Actual

Certification Plan-95Ki

HMSI – 3F

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24

Major Events conducted at dealer end

World Environment Day

Promotion-Media Coverage

Activity ContributionDlrs participated 970

Awareness Message

through Invoices305855

Plantation & saplings 18627

Quiz & Rally 52

Green Consumer Day

Activity Contribution

No of Leaflet distributed 9655

Awareness Sticker pasted on Vehicles

5450

Awareness Sticker pasted on Invoices

6566

Dlr Participated 371 Dlrs

National Pollution Control Day-2nd Dec’18

HM

SI

Campaign Creative

• Banner

• Standee

• Pamphlet

• Badge

• T-Shirt

• Sticker

Activity Guidelines

National Pollution

Control Day

<2nd Dec’18

Activity Felicitation

National Pollution

Control Day

<2nd Dec’18

World Forestry Day-21st Mar

Campaigns focused to increase the awareness among our customers about environment

Activity Contribution

No of Leaflet distributed 3212

SMS to customers 25120

Awareness Sticker pasted on Invoices

6540

Dlr Participated 398 Dlrs


We have taken the target for elimination of packaging materials in the dispatch operation

Hybrid Mode Transportation System for Delivering the products

Truck Mode Delivery

Befo

re

Elimination of Packaging materials for all products

After Before

Long Trailer Trucks

Train Mode

Aft

er

HMSI – 3F

22-09-2019

25


Nearly 32% of Packing Materials were reduced in last Three Years

After Before Just in Time Part supply system for all suppliers

Trucks and TrolleyWere covered wholearea

Easy movement of Trucks and Trolleys

Truck Arrival Pallet Movement Unpacking Keeping In trolley

Truck Arrival Trolley Movement Trolley Storage

Befo

re

Aft

er

Before After Reduction of 75% Packing Materials

Elimination of Carton Boxes

Multiple wrap of stretch films

Cage pallets for storage

HMSI – 3F



Total

02Energy data





06 Water ,GHG Emissions & Waste Management




7-11 3 min

2 min1-6

12 1 min

13-23 5 min

24-28 3 min

29-37 2 min

38-44 5 min

45-50 3 min

Table Of Contents

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26

Review Mechanism

Comprehensive review mechanism in place for energy consumption

Plant head

Finance Energy Manager

Lead/Advisor cell

Energy coordinator

Core cell member

Facility member

Monthly consumption report

Monthly variance analysis

Daily variance analysis

Daily shop consumption

Board review

Monthly MRMDaily morning

reviewMonthly MIS

Daily variance

analysisDaily shop

mailers

HMSI – 3F

Purpose of Kaizen Activity Evaluation Method:

Awards Recognition

1st prize winners will participate in

World Kaizen Convention

Kaizen participation Kaizen system

started in Narsapura factory in 2016

Associate involvement-Kaizen

Kaizen is a part of our daily work routine

HMSI – 3F

4142

9360

16319

2016-17 2017-18 2018-19

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27

HMSI 3F ENVIRONMENT WEEK CELEBRATION

Environment week celebrated to create awareness and spread the message about the need to protect environment

PURPOSE OF ENVIRONMENT WEEK CELEBRATION

1. To create awareness among associatesand suppliers about Environment.

2. To create awareness about protectingEnvironment for future generation.

30-May 31-May 01-Jun 03-Jun 04-Jun 05-Jun

Thu Fri Sat Mon Tue Wed

1Slogan Competition - Kannada &

English

2Poster Competition - Family & HMSI

Members

3 Banner display at all gates

4Banner display inside shopfloor & in

canteen

5Commitment to environment by signing

on banner

6 Quiz competition

7 Scrap modelling

8Plantation by top management - In

House plants

9Training by an external agency on

environment

10 Environment Pledge

11 Awareness in near by schools

ENVIRONMENT WEEK CELEBRATION - 2019

Sl. No Activities

GLIMPSES OF ENVIRONMENT WEEK CELEBRATION

19

36

KANNADA SLOGAN

ENGLISH SLOGAN

05FAMILY

14ASSOCIATE

36TEAMS

PARTICIPATED

11TEAMS

PARTICIPATED44

Representatives from supplier companies attended

training by CII on Environment

HMSI 3F ENERGY WEEK CELEBRATION – 18TH – 22ND FEB

PURPOSE OF ENERGY WEEK CELEBRATION

1. To create awareness among associatesand suppliers about energy conservation.

2. To create awareness about switching torenewable energy from non renewableenergy.

GLIMPSES OF ENERGY WEEK CELEBRATION

Supplier companies attended training on energy conservation and renewable

energy15

Sl. No 18-Feb 19-Feb 20-Feb 21-Feb 22-Feb

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

Session by BOSCH on solar power generation

Session on solar dishes

Awareness to near by schools

Presentation by an external party (CII)

Energy audit by Energy Manager / CII

ENERGY WEEK ACTIVITY SCHEDULE

Energy model

Essay writing (Max 1000 words) - English

Essay writing (Max 1000 words) - Kannada

Quiz Competition

Slogan Competition - English

Commitment to Energy Conservation by signing on

banner

Activity

Poster Competition - Associate

Poster Competition - Family

Slogan Competition - Kannada

Banner display on all gates and factory entrance

25KANNADA SLOGAN

ENGLISH SLOGAN

FAMILY POSTERS

ASSOCIATE POSTERS

11TEAMS

PARTICIPATED

50

25

21

Energy week celebrated in line with National energy week

HMSI – 3F

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HMSI 3F /112WATER WEEK CELEBRATION – 19TH – 24TH MAR

PURPOSE OF WATER WEEK CELEBRATION

1. To create awareness among associatesand suppliers about water conservation.

2. To create awareness about conservingwater for future generation through waterharvesting methods.

GLIMPSES OF WATER WEEK CELEBRATION

Supplier companies attended training on water

conservation25

Sl. No Activity 18-Mar 19-Mar 20-Mar 21-Mar 22-Mar 23-Mar

1Banner display on all gates and factory

entrance

2 Poster Competition - Associate

3 Poster Competition - Family

4 Slogan Competition - Kannada

5 Slogan Competition - English

6Commitment to Water Conservation by

signing on banner

7 Quiz Competition

8 Training by KSPCB Official

9Training on Water Conservation by Water

Gandhi

WATER WEEK ACTIVITY SCHEDULE - MARCH 2019

30KANNADA SLOGAN

ENGLISH SLOGAN

FAMILY POSTERS

ASSOCIATE POSTERS

35TEAMS

PARTICIPATED

160

04

33

ALL THE ACTIVITIES PLANNED IN WATER WEEK COMPLETED

HMSI – 3F

HMSI 3F

2.9

Implementation of Cobots for Washing applications

Initial Concept Current Concept Proposed concept

96 Ki plan Installation of Cobot Benefits after Implementation

Cobots are planned for manpower saving as well as reducing the operating cost

Transfer machine concept applied in line 1 & 2, Less manpower used, One line – One Model, No flexibility

To meet market demand, flexibilityintroduced, manual transfer of parts, hence manpower increased

Lean robots, light weight, can work along with humans, easy to program & multi model flexible

Washing M/cWashing M/c

Before After

Cobot introduction in washing applicationsCobot installed in washing application

Background

To reduce manpower cost by implementing cobots for washing applications

Cobot Weight 29 kg, Payload – 12 kg, Speed 1 m/s, 6 Axis, Less space - 1.5 Sqm

Items Pay load No. of Robot

Cyl Head 5 Kg 9

Crank Case 10 Kg 8

Total 17 Stns

Manpower:(Nos )

In-house Part Cost:(Rs/Veh )

41

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29

HMSI 3F Static UPS for Assembly areas and compressor

Total installed capacity of UPS is ~9 MW ,first one installed in 2014Installation of UPS enabled us to put all the critical load on grid power

Static UPS Exploded view

Battery modules connected in parallel - Delivers higher availability

through redundant batteries.

•Configurable for N+1 internal redundancy - Provides high availability

through redundancy by allowing configuration with one more Power

Module than is necessary to support the connected load.

•Fully-rated power kVA equals kW - Reduces cost by eliminating the

need for an oversized UPS for Power Factor Corrected (PFC) loads.

•Modular design - Provides fast serviceability and reduced maintenance

requirements via self-diagnosing, field-replaceable modules.

•Power Modules connected in parallel - Enhances availability by

allowing immediate, seamless recovery from isolated module failures.

•Scalable power capacity - Reduces UPS over-sizing costs today by

allowing quick power upgrades, within the same footprint, later.

BenefitsAreas covered

Machine ShopAl & FE

Assy Engine

Assy Frame VQ

Compressors

HMSI 3F Online Machine healthiness Monitoring

The monitoring system has been installed in all the 162 nos machines in machine shopSystem predicts failures of motors and other critical component before hand for preventive action

CountermeasureInterconnecting all M/Cs with Central monitoring system through suitable technology (MT-Link)

Failure Part DetectionPreventive Features

Leakage Detection in Motors

Cooling Fan Failure Warning Trouble Diagnosis

Failure Prevention & Failure Part Detection through MT Link to Reduce Critical Part Failure & Reduce Down time

MT Link System in Machine Shop:

162 CNC M/C

are Connected

3FMT Link

Abnormality

Review

Tool

Change

Control

Tool change

History

Machine: Key Way Milling–KWP–L1

Tool-1: Key way cutter

Tool-2: Chamfer toolKey Cutter life

monitor

Chamfer Cutter life

Monitor

Set value

Daily Tool change

Plan

RFI%

1.7 1.4

94Ki 95Ki

4742

94Ki 95Ki

MTTR

(Mins)

Tool Change Control through MT.Link

Overall Maint. Cost Saving by

Failure part detection &

Pro.active Correction :

2Rs/Veh

Factory94Ki 95Ki 96Ki 97Ki

2H 1H 2H 1H 2H 1H 2H

1F

2F

3F

4F

Model line + Digitalisation

Tool Change Monitor

HD in all lineTool Change Monitor

in Crank lineM-line + Digitalisation

Implementation Schedule

22-09-2019

30

HMSI 3FReplacement of Conventional Washing Machine to Robotic Washing Machine

Robotic Washing Machine are successfully implemented in HMSI 3F

Machine Photo Fixture LayoutLayout Image

L/UL Zone Washing Zone Air-Blow Zone 1 & 2

Machine Photo Layout Image

L/UL Zone Washing Zone Air-Blow Zone

Conventional Washing Machine

MC Overview

Working Principle Fixed pocket nozzles with Pneumatic CylindersNot cleaning

complicated profiles Cleaning

ArrangementMechanical Flange fitted fix pocket Nozzles

Filter Type Paper Band Filter (20µ) Chips filtration NG

System Pressure Low (6 ~ 13 Kg/cm2) Cleaning ineffective

Air Consumption 108 Nozzles

Power Consumption 69 KVA

<< Technical Details >>

Working Principle Nozzles with PROGRAMMABLE logic ControlComplicated profiles

can able to clean Cleaning

ArrangementROBOTIC hand fitted Nozzles

Filter Type Cyclone Filter (10µ) Chips filtration improved

System Pressure High (51 Kg/cm2)Cleaning effective

Air Consumption 38 Nozzles Less air consumption

Power Consumption 60 KVA Less power

consumption

<< Technical Details >>

3 Station Washing MC

MC Overview

Robotic ARM & Nozzles

ROBOTIC Washing Machine

L/ULZone

Air Blow Zone 2

Washing Zone

Air Blow Zone 1

L/UL Zone

Washing Zone

Air Blow Zone

4 Station Washing MC

HMSI 3F

3F has been awarded by CII for its sustainable environment practicesCII hosts the annual award ceremony to recognize the best Environment practises that companies follow

The award ceremony was held in the 8th Greenco summit held in New Delhi

Greenco Star Performer AwardMost Innovative Environment Best Practices award & Most Useful Presentation

2018-2019 2019-2020 2020-2022

Sustainability Journey-3F

3F will continue its journey toward implementing more Environmentally sustainable projects which is having very good financial viability also

❖ First factory in Honda India Group to achieve “Greenco” rating

❖ First Manufacturing facility in Karnatakato achieve Platinum rating

❖ National best in Waste management and Innovation

Greenco Star Performer award

Most Innovative Environment Best practises Award

Most Useful presentation(selected by Audience)

❖ Greenco Star performer award is given to Greenco rated companies

Project details97KI 98Ki

Q 1-2 Q3-4 Q 1-2 Q3-4

Zero land fill facility

Additional 2MW roof top PV

Additional Solar dishes installation

ASU hot water conversion project

310 410 440 620 66

AHJ ATAI HPI Atlas 3F

95ki Water consumption (L/veh)

310 410 440 620 66

AHJ ATAI HPI Atlas 3F

95ki Co2 emission(L/veh)

>850/1000 score

HMSI – 3F

22-09-2019

31

Way forward-Net Zero Energy and Carbon Negative

Energy & Resource Efficiency

Zero-emissions

Reducing Waste

Reducing toxic chemicals

Preventing Air & Water Pollution

Reducing Greenhouse Gas

Using New Energies

Management Systems

Activities to contribute to societyJoint-Community Activities

-Nov’19• Zero Waste to Landfill

-Nov’20• Paint sludge to primer

-Sept’19• Heat less pre-treatment

-Aug’20

-July’20• Carbon to Ink project

-Mar’20-Mar 21

• Vapour Absorption machine• Solar power-2MW

-Mar’20-Dec’23

• Propane to LNG• Biomass boiler

-Dec’20• ISO 50001:2011 certification

-Sep’22• External solar/wind park

-Mar’20• Common STP for neighbouring villages

• Pigmented plastic parts

Strong vision available for the future in terms of sustainability

Let’s make a better tomorrow for our Future Generation………

It is in our hand to protect our beautiful earth

THANK YOU

CII National Award for Excellence in Energy Management 2019

Documents

Transcript of CII National Award for Excellence in Energy Management 2019