Hyundai, Chennai

© Confederation of Indian Industry

HYUNDAI MOTOR INDIA LIMITEDHYUNDAI MOTOR INDIA LIMITED

© Confederation of Indian Industry1

19th National Award for Excellence in Energy Management 2018 29, 30 & 31 August 2018, Hyderabad

Team :� Balan, Energy Manager

� Ragunathan, Energy Manager

� Selvanathan, ME Energy Engg


A. Company Profile

Chennai Plant/HO

Delhi Sales & Marketing HQ

Hyderabad R&D

Plant/HO LocationPlant/HO Location Chennai, Tamil Nadu

FoundationFoundation 6th May ‘96 (Mass Production Sep ’98)

Contracted demandContracted demand 48,000 KW

Renewable energyRenewable energy 64%

CapacityCapacity 700,000 cars/Year

Production Model

(10)

Production Model

(10)P1 : Eon, Elite i20, Creta, Elantra, Santa Fe

P2 : i10, Grand i10, Verna, Xcent,Tucson

Co-companyCo-company - 119 Vendors (Korean-42, Indian-77)

ConsumptionConsumption 81,500 TOE/Year

NetworkNetwork - 430 Dealerships

- 1,020 Workshops


A. Company Layout

Phase I

Phase II

Eng III


B. Process Flow

PRESS SHOP

BODY SHOP PAINT SHOP

ASSEMBLY SHOP

TRANSMISSION SHOP

ENGINE SHOPAL FOUNDRY

COMPLETE CAR

Passenger Car

Power Train


C. Energy Policy

Continual Improvement to improve energy

performance

Setting & review of Energy

Objectives & targets

Continuous training to increase

awareness level

Lowest

Specific

Energy

consumer


D. Energy Mapping


1. Sp. Energy Consumption in last 3 years

Electrical

Energy

Thermal

Energy

100 X97 X

95 X

89X

2015 2016 2017 2018

CUMULATIVE IN KWH /CAR

3% ↓

2% ↓6% ↓

Major Projects carried out:

� 100% Illumination through LED

� Chiller optimization

� Energy Efficient Screw Compressor

� Coolant circulation system optimization

� Intelligent flow control for compressed air

pressure control

100 Y

98.3Y96.8Y

92Y

2015 2016 2017 2018

CUMULATIVE IN MILLION KCAL/CAR

1.7% ↓

1.5% ↓4.8% ↓

Major Projects carried out:

� Waste Heat recovery through Regenerative

Thermal Oxidizer

� Oven Temperature optimization

� Energy Efficient Boiler with O₂ trimmer, Auto

blowdown, Rotary cup burner

� Propane reduction through cross linked polymer


2. Information on Competitors, National & Global benchmark

Global

Benchmark(in KgOE/car)

National

Benchmark(in KgOE/car)

120.2

118.4117.8

116.4

2017 HMI Actual Hyundai Global best Headquarters taget 2018 Actual

(Jan~July'18)

KgOE/car

1.5% ↓

2.1% ↓

3.1% ↓

120.2

118.7

117.2

116.4

2017 HMI Actual Competitor's best Internal Target 2018 Actual

(Jan~July'18)

KgOE/car

1.3% ↓

2.5% ↓

3.1% ↓


� Major Energy Saving Activities Glimpse

9


3a. Energy Saving projects implemented in FY 2015-16

S. NO Major ProjectInvestment

Rs Lakhs

Annual Savings

KWH

1 ALF#2 Compressor Installation near supply end 33 20,20,541

2 Engine-3 Model Change, power saving mode in chillers - 9,25,170

3 Touch up booth Elimination in Assy#2 - 9,00,680

4 VFD for Shop ventilation # 1 & # 2 5 8,80,680

5 CCS CHILLER & COOLING WATER LINE PUMP CUT-OFF DURING NON PRODUCTION TIME - 6,25,741

6 Localized Alf#2 Compressor operation in Sundays to cater PT needs, instead of Compressor -2. - 6,15,374

7 Base coat Compressor Pressure OpLmizaLon from 8 bar→6 bar and one compressor reducLon - 5,28,378

8 CCS PUMP OPTIMIZATION IN NON OPERATING AND IDLE HOURS - 4,49,189

9 Interior booth automation – automatic switch off 0.2 3,76,643

10 Shaving Machine idle Time reduction during CF models(4 Nos) - 3,26,578

11 CCS Motor Idle time Elimination in Sundays and Non Working Days by PLC program with Gantry loader - 3,00,952

12 3 Chiller Operation to 2 Chiller Operation by Cooling towers pipeline Interconnection - 2,88,980

13 Controlling Airleak with the Ultrasonic airleak detector & Sunday compressor running time reduction - 2,62,414

14 High Pressure Pump Switch Off During Non-Operation Of Robot - 2,36,892

15 PTED process pump switching off in break time in I and II shift. - 2,16,021


3b. Energy Saving projects implemented in FY 2016-17

S. NO Major Project PowerInvestment

Rs Lakhs

Annual Savings

KWH / Kg of fuel

1 LED installations - HPC Electricity 323 63,37,837

2 Compressed air elimination for Bio aeration process in WWTP 2 & STP 2. Electricity 6 9,18,918

3 Base compressor operation optimization Electricity - 8,76,031

4 Shop floor Roof light switch off automation Electricity 1.15 4,57,546

5 Head line OP ( 10-180 ) Hydraulic motor energy saving provision Electricity - 4,06,351

6 Air Handlnig unit to wall mounting for wax line A - Energy saving Electricity - 2,89,425

7 Engine block line - Hydraulic motors -ES Electricity - 2,72,685

8 Touch up Booth 3 -Elimination Electricity - 2,25,867

9 Booth velocity optimization during holiday cleaning Electricity - 2,15,487

10 Work duct #1 re-circulation pump elimination Electricity - 2,11,680

11 Switch off Work deck 1 -ASU during holidays Electricity - 2,03,926

12 New Fuel efficient boiler # 2 -F.O reduction Furnace Oil 188 1,87,429

13 Steam line elimination in Engine Assy Furnace Oil 1.42 1,43,703

14Magnetic resonator + Low bake clear implementation

T/C oven temp reduction (175 à165ºC)Propane 7.48 65650


3c. Energy Saving projects implemented in FY 2017-18

S. NO Major Project PowerInvestment

Rs Lakhs

Annual Savings

KWH / Kg of fuel

1 LPC (Low Power consumption) LED installation in shop floor Electricity

638

54,05,405

2 HPC (High Power consumption) LED installation in shop floor Electricity 20,19,595

3 Chiller optimization through cooling tower capacity enhancement Electricity 40 13,26,960

4 Replacement of Plant # 1 Screw compressor (SC) # 2 (62 NM3/Min.) Electricity 73 7,14,420

5 Cylinder block –Sub coolant tank filter pump energy saving Electricity - 5,68,079

6 Energy consumption reduction during facility maintenance. Electricity - 4,75,246

7Washing Machine Power Consumption reduction

in idle cycle - 40 secElectricity - 2,69,304

8 Compressed air leakage arresting through ZLL Electricity - 2,65,405

9 ED chiller pump & compress switch off during winter Electricity - 2,51,712

10 Chiller Cut off – 2 nos. in Jan & Chiller Cut off – 2 nos. in Feb: 150 KW Electricity - 1,68,000

11 A/S DR LINE HEMMING MOTOR ENERGY SAVING Electricity - 1,59,840

12 Compressed Air optimization by reducing IFC setting pressure Electricity - 1,52,842

13 Switch Off ED Preheat Burner During Holidays After Last Car Propane - 36,792

14 Paint Skid attachment modification Propane - 55,631


4. Innovative Projects implemented

AFTER

� Return line nozzle removed.

� Motor power consumption drastically reduced by 20%

BEFORE

� High Pressure Return line flow restricted by nozzle, during idle

Cycle time. (Total Cycle time : 56 Secs, Washing cycle time: 16

Secs & Idle cycle time : 40 Secs)

� Leading to motor power consumption high during idle cycle

EFFECTIVENESSIMPL.

DATE 25.05.2018� Energy Saving : 280,120 KWH/Year

4.1 Washing Machine Power Consumption optimization



AFTER

� Cooling tower replacement with ΔT – 7~9ºC

� Achieve chiller set temp – 9 ºC

� Effective utilization of chiller with higher efficiency -890TR with

modification

BEFORE

� Cooling tower fills damage & fan assembly rust

� Cooling tower replacement with ΔT – 4~6ºC

� Chiller not reach set Temp (9 ºC During Summer)

� Chiller not able to load > 65% (CT poor Performance due to

low capacity 500TR

EFFECTIVENESSIMPL.

DATE 05.02.2018� Energy Saving : 27,07,056 KWH/Year

4.2 Chiller efficiency ↑ by cooling tower load op5miza5on 500 TR →890 TR



AFTER

� Skid weight reduction 20.90kgs /skids.

� Revised paint curing schedule : 140C X 15 Mins

� Propane expected saving : 6.60 kg/car reduction

� Total saving in propane : 0.31kg/car.

BEFORE

� Common standardization of Skid through PA & RBI model

modification

� Existing paint curing schedule : 160ºC X 10 mins

� Propane usage : 6.91 kg /car

EFFECTIVENESSIMPL.

DATE 15.12.2017� Energy Saving : 142 Tons/ Year

4.3 Propane consumption optimization in Paint shop Oven


5. Utilisation of renewable energy sources

� Green Power (Wind & Co-Gen) usage & Exceeding Global Environment requirements of CO₂ ↓

PPA

100%

36%EB

Wind

Co-gen

2017

TNEBHMI

HMI

#PPA: Power Purchase Agreement

2018

20%

44%


6. Utilisation of waste material as fuel

S. No Waste material Processing methodAnnual Tons of coal saved /

year

1 Paint sludgeTransported to Cement industries for blending

with fuel.265 Tons / Year

2 Sealant sludgeProcessed into powder form → BriqueUed →

Fuel for co processing in cement industry167 Tons / year

Co-processing Transport to

Cement IndustryUsed as ARF

(Alternate Resource Fuel)

HMI

Cement Industry


7. GHG Inventorisation

INDC

(Indented

Nationally

Determined

Contribution)

# INDC framed by United NaLon Framework on Climate Change (UNFCC) is the commitment of global countries CO₂ emission ↓

Nation INDC commitment

India 33-35% reduction in emissions intensity by 2030, compared to 2005 levels

Republic of Korea37% reduction in Green house gas emissions from the business-as-usual (BAU,

850.6MtCO2eq)level by 2030

HMIAchieved Minimum 64% Reduction in Green house gas emissions from 2016 level

through Renewable power usage


8. Green Supply Chain

Identify Movement

intensive Parts

Identify methods to

reduce burden

1. Remove unnecessary

items on the way

2. Open additional gates

Move parts closer

1. Enhance lineside storage

• Space for more Gravity

feeding Conveyor

2. Supply vs. Assy sequence

synchronization

Increase feeding quantity

1. Optimize loose stuffing

2. Change packing material

Reduce bin size for same

quantity1. Systemized feeding techniques

2. Similar job activities to be

identified

3. Identifying unproductive

activities

Job reallocation

Target :

877 km/day

Actual :

984 km/day

2015 2016 2017

884

9

829

6 741

9

In Kms/day In Kms/day

6% �

(553 Kms)11 % �

(877 Kms)

In Kms/day

(121 %) (112%)

TREND 2017 PLAN Vs ACT ACHIEVEMENT


8. Green Supply Chain


9.a Team work - 「My Place My Pride」


9.a Team work - 「Daily Management System」


9.b Employee Involvement - 「Awareness」

Employee Awareness & Idea Generation

Drawing

Competition

for employee

Children


9.b Employee Involvement -「Promotion of Energy Efficient Appliances through EESL 」

Employee Participation

LED Bulbs LED Tube lights Energy efficient Fans

5872 914 285


9.b Employee Involvement -「National Energy Conservation Day – Dec’2017」


9.c Monitoring「Global Energy Monitoring System (GEMS)」


10. Implementation of ISO 50001「 Energy Management System (EnMS)」

Energy

Objectives

Till Dec’ 2017

Energy

Objectives

ISO 14001

Energy

Objectives

ISO 14001 ISO 50001

From Jan’2018

# HMI standardized its energy practices through ISO 50001


� Energy Pyramid

� Daily communication of utility consumptions

� Additional - Sunday Energy in charges delegate

� Daily walk through audits & Energy display in shop floors

� All AC units are switched off online & std temp – 26ºC

� Energy in HMI Weekly Magazine

� Internal & External Training

� Energy campaign

� Sharing ideas to operators through SMS alerts.

� Monthly energy coordinators meeting

� Energy saving as KPI for performance evaluation

� Monthly review of Energy saving projects

� Rewarding of Best Energy saving projects every year

� Dedicated Zero Leak Line team

� Artificial demand controller (IFC’s) control

� Festival , Shutdown period – Target based control


Awarded as Global Best SEC in HMC Group

30

HMI2 & HMI1 Ranked first &

Second in global rating for

Specific energy consumption

Hyundai, Chennai

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