Honda Motorcycle and Scooter India Pvt Ltd, Narsapura - CII ...

HMSI 3F

CII National Award for Excellence in Energy Management 2020

Presented by

1. A. Joseph Selvaraj - Div. Head - Plant Engineering

2. Ch. Sankar - Sec. Mgr. - Projects

3. Arun V - Dep. Mgr. - Maintenance

Honda Motorcycle and Scooter India Pvt Ltd, Narsapura

HMSI 3F

Contents Slides Time

Table of Contents

01

Total

02Energy data

Energy Resources, Specific Fuel Consumption, Internal and National Benchmarking

03Encon Projects

Zero Investment Encon Projects and Other Encon Projects

04Innovative Ideas

VAM for Paint Shop, Induction hardening, Heat less PT and ED RO Process

05Renewable & Green Energy

Renewable energy usage in Narsapura Plant, Renewable energy projects

06GHG Emissions, Green Supply Chain and Capacity Building

07

08Way Forward

Introduction & Energy Management

4-8 1 min

1 min1-3

9-10 1 min

11-19 5 min

20-24 3 min

25-30 2 min

31-41 2 min

42 2 min

GHG Benchmarking, Supplier EMS Certification, Green Dealer development, Supplier and dealer awareness

Major Improvements, Review Mechanism, Employee EngagementMajor Improvement themes, Performance review mechanism, employee engagement events

Positive Spiral, Long terms energy and Environment Improvements and Greenco Platinum Plus journey

Honda Global and HMSI presence, Honda’s Environment journey, Honda’sCommitment for Energy Excellence, Honda Motor’s 2030 vision, HMSIPolicies

HMSI 3F Honda Motorcycle and Scooter India-At a Glance

Honda Narsapura is located in Kolar, Karnataka.

It is Honda’s largest factory globally with a capacity of 2.4 Million vehicles per year

Total 4 Factories in India

Capacity 6.4 mil units/year

Associates 24,000 people

Activa Sales 2.4 mil Units/year

Plant Image

Land Area ：4,81,757 m2

Built up Area ：2,65,706 m2

Manpower ：7041

Capacity ：2.4 MillionModels ：Activa, SP125, Shine SP, Livo, Dio

OVERALL HMSI

Won Most Innovative Project and Most Useful Project Award at CII Environment Best Practices Award 2018 and 2019

Won Excellent Energy Efficient Unit and Innovative Project at CII National Award for Energy Excellence 2018 and 2019

Mr. Soichiro Honda

(1906 – 1992)

Honda operates in 150 countries

Automobiles Motorcycles Power Products

Robotics Honda jet

Honda Motor Co Was

Founded In 1948 Aero Engine

HONDA MOTOR COMPANY, GLOBAL OPERATIONS

HONDA MOTORCYCLE AND SCOOTER INDIA

01/42

HMSI 3F

Water Energy Waste

Rain water harvesting

& Reuse

REDUCE

Co-processing

Honda’s Commitment for Environment Excellence

The Triple Zero Approach propel our Environment initiatives at every stage of lifecycle so as

to achieve a liveable & sustainable society

02/42

HMSI 3F 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

03/42

HMSI 3F


Table of Contents

01

Total

02Energy data


03Encon Projects


04 Innovative Ideas


05 Renewable & Green Energy



07

08Way Forward



Improvements, Review Mechanism Employee Engagement

Major Improvement themes, Performance review mechanism, employee engagement events



4-8 1 min

1 min1-3

9-10 1 min

11-19 5 min

20-24 3 min

25-30 2 min

31-41 2 min

42 2 min

HMSI 3F Energy Resources being used in HMSI Narsapura

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

Electrical ThermalTotal Energy usage pattern Electrical Energy usage pattern Thermal Energy Usage pattern

37%

27%

15%

8%

8%

Utility

Paint

MA

Pr & WE

Others

68%

32%

Electrical Thermal

56%44%

Paint Shop Boiler

04/42

HMSI 3F

29.5926.79 26.09 24.86 24.02 23.13

2014-15 2015-16 2016-17 2017-18 2018-19 2019-20

Power kWh/Veh

Specific energy consumption-Electricity

Specific Electrical consumption is in reducing trend

kW

h/v

eh

VFD for major load

cohesive painting

technology

VFD for major load

Compressor heat recovery

for Vaporizer VAM for Paint

EMS system

AC BMS

05/42

HMSI 3F

1.3 1.23 1.21 1.191.06 1.00

2014-15 2015-16 2016-17 2017-18 2018-19 2019-20

Kg

/Ve

hPropane Kg/Veh

Specific energy consumption-Propane

Specific propane consumption is in reducing trend

Compressor heat recovery for

hot water generation

VAM for Paint Shop Solar Dishes

OF MEE OF ETP

LNG

WHE

Magnetic Resonator

06/42

HMSI 3F

2 1.9 1.8

1

HMSI-Manesar HMSI-Tapukhera HMSI-Vithlapur HMSI-Narsapura

Specific Energy consumption-Internal Bench marking

We are bench mark for all the HMSI factory in India

Kg

/veh

kW

h/v

eh

29

44

36

23

HMSI-Manesar HMSI-Tapukhera HMSI-Vithalapur HMSI-Narsapura

Specific Propane consumption

52%

Less

50%

Less

Specific Power consumption

Mfg process not similar

Mfg process not similar

07/42

HMSI 3F Specific Energy consumption-National Bench marking

We are striving towards being the national bench mark

Specific Power consumption

Kg

/veh

kW

h/v

eh

25.1425.66

23

Comp 1 Comp 2 HMSI

0.76

1

comp 1 HMSI

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

08/42

HMSI 3F


Table of Contents

01

Total

02Energy data


03Encon Projects


04 Innovative Ideas





07

08Way Forward







4-8 1 min

1 min1-3

9-10 1 min

11-19 5 min

20-24 3 min

25-30 2 min

31-41 2 min

42 2 min

HMSI 3F Encon Projects Without Investment

S. No. Parameter Projects implemented Environmental benefits Total Investment

made (Rs. In lakhs)

Monetary

Benefits

(in lakhs)

Intangible benefitsSavings in Quantity

1 RE Third party solar power procurement

Renewable energy,

kWh44000000

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, tons

CO235772

2 EEPropane saving through heat free treatment

technology

Thermal energy,

Mill KCal290

0 144

Reduced water, energy and equipment

efficiency losses in heating process.

Insulation from market fluctuations in

prices of propaneGHG emission, tons

CO2724

3 EEEnergy saving through Cohesive painting

technology

Electrical energy, kWh 1973000

0 123 Reduction in VOC emissionGHG emission, tons

CO21605

4 EE Boiler Pressure reduction from 6 bar to 4 bar

Thermal energy,

Mill KCal645.3

0 24Safety improvement with regard to

handling of highly dangerous steamGHG emission, tons

CO21611

5 EE AHU Frequency Optimization

Electrical Energy, kWh 600000

0 40Reduced wear and tear in motors and

reduced Preventive MaintenanceGHG emission, tons

CO2436

6 EEACED Pumps & Fans Auto Sequence ON/OFF

Operation During empty Mode


0 2.3

Reduced wear and tear in motors and

reduced Preventive MaintenanceGHG emission, tons

CO22.3

7 EE Elimination of Induction Hardening process


0 159

Reduction in downtime and Repair and

Maintenance leading to production loss.

Safety risk associated with heating

machines has been reduced.GHG emission, tons

CO21725

Total 0 1570

Without Investment Savings – 1570 Lakhs/Annum

09/42

HMSI 3F Encon Projects With Investment

With Investment of 4091 Lakhs/Annum, annual savings of around 1207 Lakhs achieved

S. No. Parameter Projects implemented Environmental benefits Total Investment

made (Rs. In

lakhs)

Monetary

Benefits in

lakhs

Intangible benefitsSavings in Quantity

1 REInstallation of solar roof top panels of

capacity 7MW

Renewable energy, kWh 88000002870 580

Dependency on external agency for power

supply reducedGHG emission 8330

2 REHot water generation through solar

dishes

Renewable energy, kWh 146000250 134

Sope 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

Thermal energy, Mill KCal 102000

250 100

Waste water treatment is a Legal Compliance

which is a 24 X 7 requirement. Through solar

sludge drying, the risk of dependency on a

single fossil fuel for wastewater treatment is

reduced

GHG emission, tons CO2 607

4 RE Solar solution for sludge dryingThermal energy, Mill KCal 55000

30 55 Improvement in safety wrt handling of propaneGHG emission, tons CO2 317

5 EEInterconnection of compressors through

integration of three compressor houses


12.39 72

Compressed air requirement for the entire

factory has been optimized by reducing the air

pressureGHG emission, tons CO2 924

6 EE VAM for Paint Shop


490 163

VAM can result in reduction of usage of ODS

and GHG Potential Refrigerants currently used

in chillers. Further, handling of steam has been

eliminated thus addressing safety risks

Thermal energy, Mill KCal 2936

GHG Emissions, tons CO2 1591

7 EE Installation of EC FansElectrical energy, kWh 222750

75 15Less Maintenance intensive as the technology is

electrically controlledGHG Emissions, tons CO2 162

8 EE Power Factor Improvement to 0.99Electrical energy, kWh

29.5 12Fixed charges has been reduced in Electricity

billGHG Emissions, tons CO2

9 EERobotic Washing Machine in Machine

Shop

Electrical energy, kWh 111729283.1 75

Quality improvement in machine shop process

and reduction in market complaints of the

productGHG Emissions, tons CO2 811

10 EE Installation of VFD in Paint ShopElectrical energy, kWh 142560

2 1.0Reduced wear and tear of the motors and less

preventive maintenance requiredGHG Emissions, tons CO2 104

Total 4091 1207

10/42

HMSI 3F


Table of Contents

01

Total

02Energy data


03Encon Projects


04 Innovative Ideas





07

08Way Forward







4-8 1 min

1 min1-3

9-10 1 min

11-19 5 min

20-24 3 min

25-30 2 min

31-41 2 min

42 2 min

HMSI 3F

Honda Narsapura is having Two Paint Shop consisting of three Electro Deposition lines (2 ACED & 1 CED)

High temperature hot water(80°c) is required for ED process

Chilled water is also required for ED process

Hot water from Boiler Steam + Chilled water from Chiller

Current Situation : ED pre-treatment process

1760

939

Paint 1 Paint 2

Energy required for process ~32.25

mill Kcal/day

Propane consumption/day (in Kg)

Propane

/LNG ED process

(Rinse, Predegreasing,

degreasing, phosphating)

80°c

Hot water

Boiler

Steam @150°c

ED Pretreatment process

Hot water Rinse (80ºC)

Pre degreasing

(70ºC)

Degreasing

(70ºC)

Phosphating & Oil separation

(55ºC)

Purpose:

To have clean oil & grease free surface

Fine & crystalline corrosion inhibiting

base to enhance the performance of

post treatment

The hot water required in the process in

made from steam

Current Hot water generation process

Hot water is generated by boiler steam ( use LNG )

Cold water is generated by chiller ( use Electricity )

3187

Ton/annum

The Chilled water obtained in heat pump can be utilized instead of ED chiller saving power cost

ED+ SPC booth cooling

Chilled water @ 7°cChiller

Electricity

3222

1890

Paint 1 Paint 2

Power consumption/day (in Kwh)

Energy required for process ~5112

Kwh/day 1385

731

Power (MWH) Propane (Tons)

Energy Requirement/Year

11/42

HMSI 3F

The high temperature requirement in the process can be met through installing a heat pump

VAM will be fired through propane/Natural gas

Chilled water is obtained at free of cost as aby-product which can be used in the process

Proposed Situation : ED pre-treatment process

Propane

ED process



80°c

Hot water

ED+ SPC booth cooling

Chilled waterChiller

Electricity X

Hot & Cold water can be generated by VAM only.

Hot water through high efficiency process & Cold water as by-product ( FOC )

VAM

1136

606

Line 1~3 Line 4

Energy required for heating ~20.8 mill

Kcal/day

Propane consumption/day (in Kg)

1535

Ton/annum

432

216

Line 1~3 Line 4

Power consumption/day (in Kwh)Energy required for cooling ~648

kwh/day

Overall reduction: 35% Overall reduction:80%

Key information:

80%Power Saving

35%Gas Saving

Vapor absorption machine (VAM)

can be installed to generate Hot

water at 90ºc

VAM will be operated in A & B shift

Steam supply for the process can be

stopped

Chilled water at 7ºc is generated as

a byproduct which will be used in

process

By using chilled water electrical

chiller will be stopped during A & B

shift operation

Hot water from Boiler steam + chilled water from chiller => Hot water from VAM + Free chilled water

175

472

Power (MWH) Propane (Tons)

Energy Requirement/Year

Overall

reduction:52%

12/42

HMSI 3F New Generation VAM

Before Current

New Generation VAM operates without cooling tower

Eliminates the water & power required for cooling tower Improves Process efficiency

Indian Patent: 25/09/2018

US Patent: 23/09/2014

60

0

Before After

Water consumption (in KLD)

Working principle

VAM works on the Vapour absorption refrigeration cycle

Previous generation VAM heater required a cooling tower for part of heat rejection

The current generation VAM heater doesn’t require a cooling tower and rejects the heat into process water heating

Cooling tower is used in the old process

In cooling tower water is evaporated to take the

heat from the machine

Fresh water required on daily basis for cooling

tower top up

The water consumption is ~ 60 KL/Day

3F is not having water source like underground

water, Government water supply etc

Due to unavailability of water this theme was not

feasible in 3F

The latest technology machine operates without

cooling tower

Fresh water is not required on daily basis

Expansion valve

60

36

Before After

Power Consumption (in kWH)

Conventional system New system

13/42

HMSI 3F

Paint ED line needs high temperature (80°c) hot water and cold water for process

High temperature hot water is generated through steam from propane fired boilers

Cold water required in the process in made from electrically operated chillers

Hot water from Boiler steam + Cold water from chiller

Hot water from VAM+ Cold water as a by-product (FOC)

Proposed new generation VAM capable of high efficiency heating & eliminate Chiller

Comparison: Current Vs Proposed

VAM can generate hot water

& cold water as by-product (FOC)

Before

Propane/

Natural Gas

ED process



80°c

ED

cooling

Cold waterHot water

Boiler Chiller

Electricity Propane/

Natural Gas

FOC

Steam

@150°c

After

Hot water

90°c

ED process



80°c

ED

cooling

Cold waterHot water

VAM

22°c 22°c

113 Tons of

propane/annum

163

lakhs/annum

490

Lakhs

1580.32

Tons/year

37

Months

14/42

HMSI 3F Elimination of Crankshaft hardening operation

Current induction hardening process was highly energy consuming

In addition to energy water was also getting consumed in cooling towers

Induction hardening is done for crank shaft in machine shop operationProcess requires a cooling tower and power consumption is also very high

Present condition

Process requirements Challenge

Heating Quenching Hardening of a material will

happen after heating the

component to around 900

Degrees and then Quenching

the component suddenly.

28(± 2°C)

NRV

Valve

FilterFilter

3 Way4

0 °C

WaterQuench Tank 35 °C ( ± 2 °C )

35

(±2°C

)

water Water

24(± 2°C)

38(± 2°C)

PHE

28(± 2°C)

35(± 2°C)

Cooling water from Cooling tower

15/42

Water and Cooling Tower elimination

Energy and Electricity saving

Induction Hardening Machine

HMSI 3F

Need for induction hardening In-house Idea generation

Idea validation

Usage of alternate material was judged as successful to achieve the targets

Alternate materials where taken trials and concluded

To increase the wear and fatigue

resistance

Hardness 58-62 HRC case depth of 1.5 –

2mm

Together with core elasticity to absorb

high torque stresses

Elimination of Crankshaft hardening operation

Reduce

Induction

hardening

length

Alternate

process

Alternate

material

Reduce

frequency

from high

to low

Idea Pros Cons Judge

Reduction in length

Reduction in strengthDimensional change will drastically change the engine designEngine development will be very costly

X

Alternate processVery high investmentNot proven processNot used for mass production purpose

X

Reduce frequency from high to low

Reduce power consumptionQuality parameters are not met

X

Alternate materialHardening can be eliminated completelyNo water requiredAll quality parameters are met

O

16/42

HMSI 3F

Proposed material Resources used

Current process Benefits

Project horizontally deployed to all other Honda factories

This is a “Zero investment project”

Elimination of Crankshaft hardening operation

In house

material lab

In house

expertise

Honda R&D

(Japan)

Old material S48C

New material 38Mn VS5-M

C Si Mn P S Cr

0.45 0.15 0.60

0.51 0.35 0.90 0.030 max 0.035 max 0.20 max

C Si Mn P S Cr

0.35 0.5 1.2

0.38 0.7 1.6 0.035 max 0.065 max 0.20 max

100%

reduction

100%

reduction

23,76,000 Kwh of

electricity

159 lakhs/annum

0

Lakhs

1725

Tons/year

water Water

24(± 2°C)

38(± 2°C)

PHE

28(± 2°C)

35(± 2°C)

Cooling water from Cooling tower

17/42

540

KL/year

WATER SAVINGS

By changing the incoming material properties, the below process has been eliminated

HMSI 3F

Present Condition

Proposal Saving Analysis

Propane Saving through Heat Free Pre treatment Technology

Steam usage is completely eliminated by changing the process heating

Steam based Heating Room Temperature Heating

Appln:

Manual

Appln: Robot

+ Manual

Appln: Robot

+ Manual

Primer Base Coat Clear Coat Baking Oven

ASU

Main Frame Parts Plastic Parts

Dry Off OvenPre Treatment Final Part

All the frame & plastic parts

passes through four stages

(Pre-Treatment>Dry off

oven>Paint Booth>Baking

Oven).

Steam is been used for

maintaining temperature in

water baths.

Steam required for the

process is 13.2 Ton/day

Temperature required is

45deg

144 Lakhs/annum243 Tons of

propane/annum 724 Tons /annum ZeroNA

Elimination of Heating process

Propane savings

Reduction in Steam consumption.

Heat Exchanger cleaning Elimination

Pre Treatment

Dry off oven

Dry off oven

Before

After

18/42

HMSI 3F

Present Condition Proposal

Site Photos Benefits

Installation of ED RO System

With this ED/RO System Cost Saving of 4.64 Mil/Year in Paint and utility cost with

Investment of 15.34 Mil Rs

Existing Line ED recovery system

To maintain water conductivity1 NV- 0.45%

UF system

UF permeate

DI-1 DI-2 DI-3UF

Conc.

To drain

DI water

feed

7 ltr/min

2

C/V direction

UF-3UF-2UF-1

ED tank

NV-13.5%

Oven

NV- 0.45%Permeate

tank

ED Wastage : 3.32%

Water Drain : 168 KL/Month

Standards :-

♦ Permeate NV < 0.45%

♦ ED paint recovery is 96.68%

♦ DI water consumption is 7 LPM

Lines ED recovery calculation DI water consumption

ACED Line 1

CED Line 1

ACED Line 2

Recovery ratio

= (Bath NV% – UF3 NV%) / Bath NV%

= (13.5 – 0.45%) / 13.5% = 96.68%

DI water Supply in DI-3 is 7 L/min

Total DI Water Consumed=168 KL/Month

Single Stage Filtration System(Ultra Filtration System) is Used for recovering the ED Paint

Material(96.68% Recovery Percentage)

Stage-1

Merits :-

♦ ED paint recover is 99.26% (+2.8%)

♦ DI water consumption will reduced by 70%.

ACED – Line 1,2,3 CED – Line 1,2,3 ACED – Line 4

Monitoring Check Sheets

Efficiency

17,640

kWh/annum

46.4

Lakh/annum

12

Tons/annum

40

Months

153

Lakh

40

Lakh

19/42

HMSI 3F


Table of Contents

01

Total

02Energy data


03Encon Projects


04 Innovative Ideas





07

08Way Forward







4-8 1 min

1 min1-3

9-10 1 min

11-19 5 min

20-24 3 min

25-30 2 min

31-41 2 min

42 2 min

HMSI 3F

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 achieved

Strong road map available to achieve the target

Feb-19

PFET for effluent

treatment

Sep-19

Heat less pretreatment

Oct-20

Additional 2.5 MW Solar Power

Feb-21

2 MW Wind Procurement

Dec-20

Solar/Wind group captive

June-24

Bio mass heater

20/42

HMSI 3F 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

Plant Capacity is around 40 MW

40 MW Plant

37,000 ton/

annum440 lakh kWh 1078 Lakh

Rs/yearZero -NA-

80%

16%

power

Utilization

4%

Private Generator Public

OM Copy

PPA Signing

Site Photos

21/42

HMSI 3F On-site RE Generation-7MW solar roof top plant

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

Key project highlights

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%

22/42

HMSI 3F

Solar heating system

Hot water

Return waterProcess

application

Hot water tank

Key project highlights

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 Factory

Hot water generation through Solar energy

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

23/42

HMSI 3F

Background & Situation Analysis Proposal

Site Photos Benefits

Conversion of Propane to LNG

Investment 700 Lakhs

Saving 280 Lakhs

ROI 30 months

Continuous cost reduction initiatives taken to reduce utility cost.

Propane Heating LNG Heating

Propane

BoilerPaint Shop

Calorific Value of LNG is

more compared to Propane.

Greener ,cheaper & Safer

fuel compared to propane

158 Tons of

propane/annum

283

lakhs/annum

739

Tons/year

56% Usage of Propane 44% Usage of Propane

L

N

G

Separate Lines are laid in Shop floor for LNG usage (1300 mtrs).

Burner Modification has been done.

2.5 Y

8/12

Pipe line Modification

Installation of Yard & SCADA

700

Lakhs

30

Months

24/42

HMSI 3F


Table of Contents

01

Total

02Energy data


03Encon Projects


04 Innovative Ideas





07

08Way Forward







4-8 1 min

1 min1-3

9-10 1 min

11-19 5 min

20-24 3 min

25-30 2 min

31-41 2 min

42 2 min

HMSI 3F

HMSI-Narsapura is the lowest CO2 emission factory in India and Asia region

Benchmarking – CO2

6.1 28.6 35.4 38.3

HMSI

Narsapura

HMSI Vithalpur HMSI Tapukera HMSI Manesar

Among HMSI, Kg/Veh

6.1

22.9 23.35

HMSI Narsapura Competitor - 1 Competitor - 2

Among Indian Companies, Kg/Veh

6.1 6.24

25.4 26.91 28.71 31.7541.5

HMSINarsapura

PhilipinesHPI

PakistanAHL

VietnamHVN

BngladeshBSH

ThailandTH

IndonesiaAHJ

Among Asian Group Companies, Kg/Veh

Uniqueness

One of the first automobile industries in the country which has installed around 300 No's of Solar parabolic dishes.

Complete elimination of MEE and ATFD Operation through sequential alternatives.

Implementation of VAM to generate Hot water with chilled water as free by product

Lowest specific propane consumption among group companies with similar configuration.

One of the lowest specific CO2 emissions among Asian Group companies.

Easy to design and maintain and good reliability since last 3years.

25.83

13.559.37 6.1

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

Specific CO2 Emission reduction Trend YoY

Hydro

Power

25/42

HMSI 3F

Honda has separate Green Purchasing policy which mainly focusses on purchasing Environmentally

friendly materials

Green Purchasing PolicyHMSI – 3F

IE4 Motors

REDUCE

26/42

HMSI 3F CO2 Reduction Activity Status

CO2 Reduction activities are in progress as per ASH / HM Japan Guidelines

27/42

HMSI 3F EMS certification of Suppliers

Yearly targets are set to achieve ISO14001 certification to supplier companies

28/42

HMSI 3F Dealer : Green Consumer Day 28th Sept

Green consumer day is celebrated at dealer end to promote awareness

29/42

HMSI 3F Initiatives @ Dealers

Several initiatives are taken by dealers to reduce energy and environment impact

30/42

HMSI 3F


Table of Contents

01

Total

02Energy data


03Encon Projects


04 Innovative Ideas





07

08Way Forward



Major Improvements, Review Mechanism, Employee EngagementMajor Improvement themes, Performance review mechanism, employee engagement events



4-8 1 min

1 min1-3

9-10 1 min

11-19 5 min

20-24 3 min

25-30 2 min

31-41 2 min

42 2 min

HMSI 3F


Content of Execution Investment, ROI Calculation

Replacement of Electric Heaters with Renewable Heat Energy

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 through Renewable Energy

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

Hot water can be used to heat coolant instead of electric heatersThe power consumption for the heaters can be savedThe hot water generated from solar dishes and compressor hot water recovery will be used

Heating skid

Waste Heat

recovery

Solar DishesElectric heater

Hot

water

Hot

water

Ho

t wate

r

Hot water

Tank

Hot water

TankWashing

Machine

Washing

MachinePHE

9.79 Lakhs of

kWh/annum51.5

lakhs/annum711

Tons/year

100

Lakhs

23

Months

31/42

HMSI 3F


Saving Analysis Benefits

VFD Installation for VQ Chamber Blowers

Investment 1 Lakh

Saving 6.6 Lakhs

ROI 2 months

VFD Installations are envisaged in all areas where energy conservation is possible

54000

kWh/annum

6.6

lakhs/annum

1 lakh39

Tons/year

2

Months

PLC Program

Main Power

SupplyContractor Control

Circuit-PLC

4 Blower

Motors

There are 4 different capacity motors installed for VQ Blowers.

All the blowers were running at 50 Hz Frequency.

Increase in power consumption as there is no provision to reduce the

frequency.

Main Power

Supply4 No’s VFD 4 Fan

Motors

PLC Program

Contactor

PLC Control

4 No's of VFD installed for individual Blowers.

Frequency has been changed from 50 Hz to 35 Hz. There are 4 different capacity motors installed for VQ Blowers..

Total Savings Motor 1 Motor 2 Motor 3 Motor 4 Total

Energy Cons

kWh/Day 65 64 56 14 200

Energy Cons

Savings kWh /

Year

17777 17344 15219 4032 54373

Cost

Savings/Year180128 205010 167128 112341 664607

32/42

HMSI 3F

Installation of VFD in Oven Circulation Fan

Before After Benefits

Modification of ASU with EC fans

Before After Benefits

VFD Installation & EC fans installation

Fresh Air Fresh Air

EC FansASU

EC fans are installed instead of centrifugal

fans.

Power reduction by 2.2kWh lakhs/year

resulting to savings of 15 lakhs/year

Better control during operation.

Continuous energy efficiency are initiatives taken to reduce Utility cost

Running with centrifugal fan Running with EC Fan

VFD has been installed for Oven Fan

circulation.

Motor Frequency has been reduced from

50 Hz to 30 Hz.

Power reduction by 1.9kWh lakhs/year

resulting to savings of 9.5 lakhs/year

33/42

HMSI 3F Technology improvement through digitization

3F introduced the concept of IOT in 95 Ki through Mt-link. All fanuc machines are connected The way forward is to strengthen Daily work Management through introduction IOT

Activity95KI 96ki 97ki

RemarksH1 H2 H1 H2 H1 H2

Servo Motor Insulation Monitoring

Servo Load Monitoring10.4 Mill.

Daily Tool Change Plan2.4 Mil

Daily Equipment Management

Daily Equipment Management Exp. 2.5 Mil

Daily equipment check – current practice Proposed Method Schedule of execution:

206 Machine

206 Machine

171 Machine

13 Machine

15 Machine

2.7 Mil – Crank L1

Gap in Rule =

site

Writing error

No easy

readable

No continues

monitoringI/O Module

Mtlink Server

Machine

Parameter

INDUSTRIAL

INTERNET

Enhancing daily work management through IoTPredictive Maint.Connected Smart M/Cs

31 abnormality

identified

Daily report

triggered

Sr. Item97 Ki

Q1 Q2 Q3 Q4

1Crank Shaft Line 6 data validation

2 Indent for expansion

3 P.O

4 Implementation

Data shall be

validated and

further expansion to

be executed

Monitoring system implemented in Machine Shop validation Under process

Horizontal deployment for other lines will be done in 97 Ki

34/42

HMSI 3F SMS system for Maintenance Breakdown intimation

Breakdown information through SMS will be sent through SAP to all concerned members

Breakdown is reported by production telephonically or directly to maintenance Area by line executiveThen manually entered in SAP. Delay in Reporting in SAP in all the cases & not even reported sometimes

Manual Reporting Auto Reporting through SMS to reduce MTTR by 10%

Present Method

Benefits

Investment

Rs 0.24 mill.

Proposed Method

Action96Ki 97Ki

3Q 4Q 1Q 2Q 3Q

Concept approval

Approval & Quotation from SIS

Indent & PO

Development

Implementation

Implement sch

Breakdown

RectificationMachine

BD

Make phone

call to shift

Executive

If unable to call, visit

Maint area.

Maint Dashboard

As PC is not available in

every area, Reporting in

SAP is a parallel

process,

which is delayed &

skipped sometimes

Make SAP

Entry

No Delay in Communication to Maintenance & Reporting in SAP

Breakdown

RectificationMachine

BD

Type message, Auto

fetch by SAP server

Maint

Dashboard

SMS received by all

Maint. Team &

Section Head

Manual entry

not required

Immediate communication to all

100% Reporting of Breakdown in SAP as per actual time – Better

analysis due to improved data accuracy

Time spent on SAP reporting can be utilized on GENBA

35/42

HMSI 3F Review Mechanism

Comprehensive review mechanism in place for energy consumption

Plant

headFinance

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 MISDaily variance

analysis

Daily shop

mailers

36/42


Honda Motorcycle and Scooter India Private Limited

Budget :-

Plant :-

Cost Center :-

Press 89,809 89,809 86,102 79,052 82,517 71,882 86,223 85,859 89,809 989,498

Weld 402,731 402,731 386,255 356,436 340,592 299,407 387,299 384,167 402,731 4,656,515

Paint 1,748,367 1,748,367 1,680,726 1,599,005 1,562,780 1,440,283 1,698,580 1,645,019 1,748,367 19,463,895

Frame Assembly 106,238 106,238 102,132 97,228 99,129 91,222 103,234 99,928 106,238 1,218,421

Total 2,347,145 2,347,145 2,255,216 2,131,721 2,085,018 1,902,793 2,275,337 2,214,973 2,347,145 26,328,329

AL Machining 442,273 442,273 424,707 398,450 412,556 369,236 427,665 418,791 442,273 5,081,623

FE Machining 442,273 442,273 424,707 398,450 412,556 369,236 427,665 418,791 442,273 5,081,623

LPDC -

HPDC -

Engine Assembly 77,497 77,497 74,305 68,309 71,243 62,184 74,434 74,048 77,497 916,498

Total 962,042 962,042 923,720 865,210 896,355 800,655 929,764 911,630 962,042 11,079,744

Production Support Production Support 1,859,966 1,859,966 1,785,848 1,695,952 1,672,800 1,533,873 1,805,295 1,746,955 1,859,966 21,141,747

Production Control Production Control 83,677 83,677 80,351 75,338 79,536 69,779 80,898 79,256 83,677 920,408

Quality Control Quality Control & DST 264,996 264,996 254,565 239,992 231,984 212,305 256,617 199,900 211,055 2,555,129

Non Mfg Logistics -

Non Mfg Office Area -

-

-

Sub Total 5,517,826 5,517,826 5,299,700 5,008,212 4,965,693 4,519,405 5,347,911 5,152,715 5,463,885 62,025,357

Division Shop Name Jul Aug Sep Oct

Production Body

Production Power Train

Power Genration -KWH Genration - 95 Ki Original Budget

Nov Dec Jan Feb Mar Total

Budget Submission to PPC

Situation Analysis 18-19 Budget Preparation 19-20

Meeting with Opt.Head

Target Setting by Self & PPC

Budget Approval

1 2 3

4 5 6

Target

Legal Requirements

Co

rpo

rate

ad

sit

e le

vel t

arge

ts

Benchmarking

Production Capacity

Bes

t A

vaila

ble

Te

chn

olo

gies

Co

nti

nu

al

Imp

rove

men

t

Target Setting is done and it is been approved by Board of directors

37/42


Cost Down Initiatives are discussed among all four Plants & data is shared till Directors

HO

1F 2F

3F4F

Energy Representative Energy Representative

Energy Representative Energy Representative

Themes Discussion

Applicable Themes Final Submission

Feasibility Study

Summary of Themes

Synergy Meeting

Cost Down

Initiatives

38/42

HMSI 3F

4142

9360

1631918425

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

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

39/42

HMSI 3F Energy Week Celebration– 17th – 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 energy17

20KANNADA SLOGAN

ENGLISH SLOGAN

FAMILY POSTERS

ASSOCIATE POSTERS

10TEAMS

PARTICIPATED

30

25

15

Total 1350 Participants in Energy Week celebration

HMSI – 3F

Sl. No 17-Feb 18-Feb 19-Feb 20-Feb 21-Feb 22-Feb

1

2

3

4

5

6

7

8

9

10

11

12

Commitment to Energy Conservation by signing on banner

Essay Writing Competition - English

Energy Model

Quiz Competition

Slogan Competition - English

Essay Writing Competition - Kannada

Activity

Poster Competition - Associate

Poster Competition - Family

Slogan Competition - Kannada

Banner display on all gates and factory entrance

ENERGY WEEK ACTIVITY SCHEDULE

Awareness to near by schools

Presentation by an external party (CII)

40/42

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 Karnataka to

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

96ki Water consumption (L/veh)

96ki Co2 emission(L/veh)

>850/1000

score

HMSI – 3F 41/42

HMSI 3F


Table of Contents

01

Total

02Energy data


03Encon Projects


04 Innovative Ideas





07

08Way Forward







4-8 1 min

1 min1-3

9-10 1 min

11-19 5 min

20-24 3 min

25-30 2 min

31-41 2 min

42 2 min

HMSI 3F Way forward-Net Zero Energy and Carbon Negative 42/42

Reducing Waste

Reducing toxic chemicals

Supply chain emission reduction

Energy Efficiency

Management Systems & Ratings

Activities to contribute to societyJoint-Community Activities

-Nov’20• Zero Waste to Landfill

-Nov’20• Liner Recycling

-Sept’20• Primerless Painting-Phase 3

• Milk run for south parts supply -Nov’20

-Sep’20• Vapour Absorption Machine

-Oct’20• Propane to LNG

-Dec’20• ISO 50001:2011 certification

-Sep’23• External solar/wind park

-Mar’21• Common STP for neighbouring villages

Zero-Waste

Advanced Treatment technologies

-Feb’21• Phytoremediation

-Jan’21• Decanter

• MBR for STP -Jan’21

Renewable Energy

• Offsite Wind energy -Jun’21

• External Greenbelt expansion

-Mar’22

• Greenco Platinum Plus -Mar’21

HMSI 3F

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

It is in our hand to protect our beautiful earth

THANK YOU

Honda Motorcycle and Scooter India Pvt Ltd, Narsapura - CII ...

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