11 Ashok Leyland Hosur - greenbusinesscentre.comgreenbusinesscentre.com/energyaward2017presentations/Auto Engg/11... · v P Ç D v P u v K P v ] Ì ] } v ^ µ µ 9D } v ] } ] v P

8/30/2017

1

ASHOK LEYLAND, UNIT 1

175, SIPCOT INDUSTRIAL AREA

HOSUR – 635 126 (TN)

CII 18th National Award for Excellence in Energy Management 2017

CII 2017 Energy Award 2

COMPANY PROFILE

Buses Trucks

Light Commercial Vehicles

Defense Vehicles

Power Solution

Ashokleyland Seven Manufacturing Plants in India

Products

Ashokleyland , Hosur unit 1

Resources Hosur-1

Total Area (Acres) 102.58

Plant and Machinery ~ 566 Rs. Cr

Permitted Maximum Demand 6000 kVA

Manpower (Associates +Exe) 832

Trees (no's) 4592

CII 2017 Energy Award

Process

3

AL Energy Policy Energy Improvement

Energy Management Policy

12891153

1038

500

700

900

1100

1300

2015-16 2016-17 2017-18

Kwh per HECU - Hosur, Unit1

Hosur, Unit1 - Key Mile stone

Setting targets for energy reduction and achieving them through Energy Management and regular monitoring.• FY 17 : 10.55% reduction • FY 18 : Target reduction 10%


Specific Energy Consumption (SEC) Benchmarking

995 963 1042 962905 909 953

100

300

500

700

900

1100

2016-17 2015-16 2014-15 2013-14

Kwh

/veh

icle

National Bench marking - Kwh per Eq Vehicle

1153 1289

999 10441080 1083 1110 1123956 970

11261209

0

200

400

600

800

1000

1200

1400

2016-17 2015-16 2014-15 2013-14

Internal Bench Marking - Kwh per HECU

Hosur, Unit 1 Ennore Panthnagar

0.730.82 0.77

0.67

0.83 0.83 0.93

0.00

0.20

0.40

0.60

0.80

1.00

2016-17 2015-16 2014-15 2013-14

National Bench Marking % Power cost to Mfg cost

Energy and Cost Bench marking is difficult… Since :

Ashokleyland Nearest Competitor


8/30/2017

5

Energy Management Organization Structure

Monitoring & Reporting- SAP Continual improvement

Improvement activities Awareness thro’ campaigns Promoting involvement

Horizontal deployment Best practices Waste elimination

Self-Calibration System compliances

Energy awareness at the Gemba Level - Deep rooted in the AL culture.

Continuous improvement through Power Cost Management initiatives. Review & Monitoring from Plant Head till Line executive.


• Cloud hosted infrastructure to all manufacturing units can be accessed by any internet enabled devices.

• Effective utilization of internal expertise across all Units.

6

Energy Management – Implementation methodology

ERP –IT Based GEMBA Mpower Programme

Continuous improvements through Small group activity / Cross Functional team. Projects identified & registration is done in the ERP portal. The ideas generated through brainstorming is evaluated and approved by TQM and Process Leader. The idea is then implemented and tracked for consistency & Successful project will be awarded.


7

Energy Management : Review of Reports

Shopwise wise: Reviewed dailyPlant wise: Reviewed daily Shift wise / Component wise (Daily)

Current Power consumption patternDaily • Plant-wise, Aggregate-wise reports circulated to Line Executives & Section Heads

Weekly • Power cost discussed weekly with the respective Sponsors and Process owners.

Monthly•Gap Analysis reviewed by Plant head on monthly basis.• Inter-unit comparison by AL Manufacturing Head in Plant Performance Meets


Team work & Motivation

• Best among the best 70 projects selected from Plants and Corporate functions

• Held at BANGALORE

• Hosur 1 team won One ‘Gold’ award in support Service category , One ‘Silver ’ award in support services category and Two ‘Merit’ awards

2014-15• Best among the best 70 projects selected from all

Plants.

• Held at DUBAI between 14-17th Sep15

• Hosur 1 won One ‘Bronze’ award in Manufacturing support services category & One ‘Super Merit’ awards and Four ‘Merit’ awards

2015-16

• Best among the best 72 projects selected from Plants and Corporate functions

• Held at AGRA between 16-19th Oct’16

• Hosur 1 won One ‘Silver’ award in support Service category, One ‘Bronze’ award in Manufacturing category Three ‘Super Merit’ awards and Two ‘Merit’ awards

2016-17


8/30/2017

9

Significant Energy saving Projects – FY14-15

S.no Project Description

Rs In LakhsROI

MonthInvestment Saving /Annum

1Energy regeneration during Engine testing.

… 10.6 …

2Engine testing cycle modification to reduce cycle time & HSD consumption

0 0.70 0

3Energy saving through Programmodification 7nos CNC machines.

0.5 0.5 12

4

Restriction of main air to shop 3 and using portable compressor avoiding wastage of 100cfm/Hour.

0.5 1.6 4

5Energy saving through air circuit modification in 2areas.

0.70 2.60 3


Rs In LakhsROI


6Replacement of Power hoist instead of air hoist.

1.5 1.8 10

7Elimination of idle running by circuit modification in 22 SPMmachines.

2.20 38.60 1

8

Energy saving through introduction of VFD and Derating of Motors in 4 machines.

2.70 9.50 3

9

Energy saving through rescheduling of Production plan and optimized usage of Captive Power & TNEB Demand.

3.00 112.2 0

10Energy saving through introduction LED/CFL/T5 lamps in 13areas/650nos.

10.70 6.40 20




Rs In LakhsROI


1

Energy cost saving through utilization of demand/resource management & power mix 3projects.

3.00 49.7 1

2Energy regeneration during Engine testing.

… 10.0 ….

3Energy saving through boiler steam for canteen plate washing.

0.50 0.80 7.7

4Idle running elimination through set up time reduction

0.50 3.00 2

5Energy saving through introduction LED/CFL/T5 lamps in 9areas/132nos.

1.00 1.10 11.2


Rs In LakhsROI


6Energy saving through Pressure regulating valve for compressor running optimization .

0.00 49.7 0.0

7

Energy saving through introduction of VFD and Derating of Motors in 17 machines.

0.00 10.0 0.0

8

Energy saving through Elimination of idle running by circuit modification in 36 machines.

0.50 0.80 7.7

9

Energy saving through incorporation of Mingling valve in airline for compressor running optimization .

0.50 3.00 2

10Kwh Cost reduction through introduction of alternate power source.

1.00 1.10 11.2


11


S.no Project DescriptionRs In Lakhs

ROI Month

Investment Saving /Annum

1Energy regeneration during Engine testing .

0.00 10.00 0

2Energy saving through rough Block weight reduction

0.00 0.04 0

3 Rainwater for Process 0.50 1.70 4

4Energy saving through introduction of VFD and Derating of Motors

2.50 6.00 5

5Energy saving through Heat recovery in screw compressor

3.80 4.40 10


Rs In LakhsROI


6Turbo Ventilator for shop ventilation

7.50 13.00 7

7Daylight improvement in Machine shops

8.00 19.50 5

8Energy saving through introduction LED/CFL/T5 lamps in shop floor/Office/Street light

9.70 9.10 13

9Derating of Man cooler to air circulator

11.30 8.10 17

10Introduction of Heat pumps instead of Electrical heaters in High intensive washing M/Cs

24.90 18.90 16


#1 Innovative Project

Elimination of Stress Relieving Process in Cylinder Head by introduction of multi-stage milling

Before : After:

Power consumed 38 Kwh / Cy head

2 Rocker Face Rough Milling

3 Combustion Face Rough Milling

4 Rocker Face Finish Milling

5 Combustion Face Finish Milling 1

6 Valve Guide Valve Seat Parent Bore

7 Injector mouth profile forming

8 Valve Guide Valve Seat Insitu Bore

9 Combustion Face Dowel

Stress Relieving in Muffle Furnace

1

1Rocker Face Rough Milling

2Combustion Face Rough Milling

3Combustion Face Semi finish Milling

4Combustion Face Finish Milling 1

5Rocker Face Finish Milling

6Combustion Face Finish Milling 1 & Valve Guide Valve Seat Parent Bore

7Injector mouth profile forming , Valve Guide

valve seat insitu bore & Combustion dowel

Stress Relieving in Muffle Furnace

41,209Number of head / year

13Reduction Kwh / Cy

head

5.33 lakhsSavings in Kwh / year

37.50Cost Saving Rs. In lakhs

By modifying the milling process and introducing semi-finish milling, furnace operation is eliminated.

Power consumed 25 Kwh / Cy head


8/30/2017

13


Introduction of General purpose CNC route machining using guide pad tooling and multi spindle Honing SPM by replacing conventional SPM route machining.Before : After :

Power consumed 16.4 units Per Block Power consumed 9.5 units Per Block

Head face Dowel

Head finish

Milling Finish BoringLine Bore Honing

Line Bore Honing

Line Bore HoningFinish Boring

Finish Boring

Head Face Dowel & Finish

Milling

Line Bore Finish Boring

Multistage Honing

44,267Number of block / year

6.90Reduction in

Kwh / Cy block

3.05 Total Units

saved / year in lakhs

21.38Cost Saving Rs. In Lakhs

By introducing multi-spindle machines and combining processes in a single machine, energy per component reduced.



Introduction of Tempering in Induction Hardening SPM and eliminated conventional tempering furnace

Before : After :

Power consumed 2.6 units Per Camshaft

Induction Hardening

Tempering Furnace

Straightening Operation

Induction Hardening Tempering

Tempering Furnace

Straightening Operation

Power consumed 1.6 units Per Camshaft

50,587Number of CS / year

1.00Reduction in Kwh per CS

0.51Savings / year Kwh in lakhs

3.54Cost Saving Rs. in lakhs

By combining tempering operation along with hardening process, Eliminated tempering furnace.


15


HEAT PUMP for Power Intensive washing machines:

Before : After :

No of Engines / year 47573

Reduction / year Kwh 6.34 L

Savings Rs in lakhs 44.39

Investment Rs in lakhs 32.50

Payback in years 1.37

Electric heaters replaced by HEAT PUMP in four washing machines & realized 60% reduction in fluid heating by maintain same tempt & Quality parameters

No of Machines 4

Heating load in KW 72 x 4 = 288

Fluid Tempt in Deg C 52

Kwh per Engine 38.83

Reduction in Kwh NIL

No of machine 4

Heat pump load in KW 10 X 4 = 40

Fluid Tempt in Deg C 52

Kwh per Engine 25.50

Reduction in Kwh 13.33



Waste HEAT RECOVERY from Rotary Screw Compressor

Before : After :

Washing Tempt : 55 Deg CElectrical heaters : 48 KW Units / per Aggregate : 2.01

Heat Exchanger Retrofit unit fixed with

existing air Compressor + piping

31,410Number / year

0.59 Kwh / setReduction

Kwh 0.19 in LUnits saved / year

Rs 1.30 L / YrROI – 2.5 years

Cost Savings

Recovered heat utilized in two washing machines at P15 Engine Assembly

Washing Tempt : 55 Deg CPump : 1 KW Units / per Aggregate : 1.42


8/30/2017

17


Cylinder Block Casting modifications to optimize casting weight and machining allowance in rough machining

Before : After :

Power consumption in rough machining (13 m/cs) per Cy Block : 12.48 Kwh

Power consumption in rough machining (13 m/cs) per Cy block : 10.91 Kwh

8,200Number of block / year

1.57Reduction Kwh / Cy block

0.13Savings Kwh in lakhs / Yr

0.90Savings Rs in lakhs

Rough casting weight optimized 3% by reducing the stock in specified areas.



SMED Set-up change time reduction in Cy block machining to minimize idle running

Before : After :

Setup change time in 12 m/cs : 300 MinConsumption : 270 Kwh

Position for B-platform

knob

Position for A- platform

Movable guide

Fixed guide

Guide for B-platform Guide for A-platform

Setup change time in 12 m/cs : 12 Min Consumption : 11 Kwh

24No of setup change / Year

259Reduction in Kwh / Change

6,216Kwh savings / year

0.44Savings Rs in lakhs

Idle running of auxiliary equipment minimized during setup change through single minute die change concept (SMED).


19


Energy saving through Pressure regulating valve

Before : After :

300No of working days

200Reduction in Kwh / WD

0.60Savings in Kwh / year in lakhs

4.20Savings Rs in lakhs / year

High Pressure air converted to low pressure air through pressure regulating valve & unloading of compressors hours minimized.



Energy saving by interconnecting two production lines through ring main distribution

Before : After :

Power consumption / day = 3000 units Power consumption / day = 2700 units

300No of Working days

300Reduction in Kwh / WD

0.9 lakhSavings in Kwh / year

Rs 6.30 LSavings per year

Two Engine Assembly & Machine interconnected with ring main & avoided running of dedicated Air compressor


8/30/2017

21

Elimination of Painting in Engine Assembly by introduction of pre-painted casting without Heat treatment

Before : After :

Casting Red Oxide Painting

Machining Operation

Painting

Engine Assembly

Casting Enamel Painting

Machining Operation

Painting

Engine Assembly

54,000No of Engines / Year

0.60Reduction in Kwh / Engine

0.32Reduction / year Kwh in lakhs

2.27Cost Saving Rs. In lakhs / Yr

In line with change in heat treatment process, Painting operation Eliminated in Engine Assembly


Power consumption by paint booth: 0.60 Kwh / Engine

Painting Eliminated


Reduction of SEC Trend

1013 966

13291207

FY13-14 FY14-15 FY15-16 FY16-17

H Engine: SEC – kWh/HECU

11521000 1026

863

FY13-14 FY14-15 FY15-16 FY16-17

P15: Engine SEC – kWh/HECU

2.552.90

3.20 3.19

FY13-14 FY14-15 FY15-16 FY16-17

Fixed Power: kWh/month in lacs

The increase in FY 15-16 is due to MS 1 renovation , decrease in

volume, increase in Engine R&D activity (BS4) & introduction of

Spare parts warehouse.

9.1 % 15.9%

• More focus on renovation of process manufacturing

• Introduction of Energy Efficient Products

• Lean manufacturing

• Synergy between Production plan & Energy Management

• Total Employee involvement

• Energy cross audits by other plants (Horizontal deployment)

Energy Conservation @ Hosur 1 (Approach adopted)


23

Reduction of SEC – H Engine & P15 Engine

H Engine Production

Lines

P15 Engine Production

Lines

9181013

784

FY14-15 FY15-16 FY16-17

H-Block SEC – kWh/HECU

619

785669

FY14-15 FY15-16 FY16-17

H-Head SEC – kWh/HECU

1467 14411207

FY14-15 FY15-16 FY16-17

H-Engine Assy SEC – kWh/HECU

932 933

816

FY14-15 FY15-16 FY16-17

P15-Block SEC – kWh/HECU

670 669

523

FY14-15 FY15-16 FY16-17

P15-Head SEC – kWh/HECU

691 741614

FY14-15 FY15-16 FY16-17

P15-Engine Assy SEC – kWh/HECU

23% 15% 16%

13% 22% 17%


Specific Energy Reduction Trend

11

910

8

0

24

6

8

1012

2013-14 2014-15 2015-16 2016-17

Water KL / HECU20%26

2016

10

0

10

20

30

2013-14 2014-15 2015-16 2016-17

Diesel Litre / HECU

37%Good

13 13 12

8

0

5

10

15

2013-14 2014-15 2015-16 2016-17

Cutting & Hyd Fluids Litre / HECU

33%Good

130109

156 166

0

50

100

150

200

2013-14 2014-15 2015-16 2016-17

Compressed Air Unit / HECU

Increased no of Shifts & Lines


8/30/2017

25

Renewable Energy Sources

Hosur 1 – Shop 1 & 2 (1 MW)

Sh1

Sh2

Roof Top Solar : Shift towards clean, reliable, affordable Electricity

Key Differentiation factors: 1st Major Solar Renewable

Power project. ZERO CAPEX by AL. Existing metallic roof tops

used to generate own power within our premises.



93

76

55

105

FY13-14 FY14-15 FY15-16 FY16-17

Windmill Energy Utilization – Units in Lacs

Windmill Energy - % contribution to Overall Power

Overall Windmill energy generation in Tamil Nadu reduced in FY15-16 due to evacuation issues

Windmill utilization is up to 48% of total consumption

Expecting 8% Solar Energy contribution in FY’18

87.3, 47%

55.1, 30%

35.7, 19%

7.7, 4%

FY15-16

TNEB WM GCP DG

30.9, 14%104.9, 48%

78.3, 36%

4.5, 2%

FY16-17

TNEB WM GCP DG

Predominant Source is from Green Energy


27


Turbo Ventilators in M/C shop – 150 numbers installed Natural light through transparent sheets in M/C shop

Rainwater Harvesting - 500 KL Utilized for Process 9 KL Solar Water Heater for canteen dish washing


P15 M/C shop SH-5 M/C shop

SH-1 M/C shop

Shop2 E Assy

R&D Block

28

GHG Inventorization

Diesel Consumption reduction in Forklift by introducing a Tractor-Trailer arrangement which can hold up to 10 engines & by bringing stores and dispatch areas near to the shop floor

54.7

51.0

48.0

50.0

52.0

54.0

56.0

2015-16 2016-17

Cons

umpt

ion

in K

L

Fork Lift Diesel ConsumptionBefore After

• No .of Buses inducted : 8

• No of two wheelers reduced : 230

• Carbon emission reduction/Annum: 62 MT

Bio Diesel for Canteen BoilerCommon Pooling arrangement for Associates enabled the reduction of number of people

coming in bikes

-73

-161-137

Base Line 13-14 FY14-15 FY15-16 FY16-17

% E

MIS

SIO

N IN

TEN

SITY

RED

UCT

ION

Carbon foot print

6.7%

• HSD procurement minimized

• Cost Saving : Rs 0.50 millions per year

• GHG Emissions Reduction : 80%

• Carbon Neutral Initiatives


8/30/2017

29

Carbon Foot Print


• Increased green coverage from 27% to 30%.• Wind mill Generation increased up to 48 %

ASHOK LEYLAND - CARBON CREDITS / DEBITSCategory 2013-14 2014-15 2015-16 2016-17

Carbon debits: mtCO2e mtCO2e mtCO2e mtCO2eScope 1 Foot print -13-14 base year 2340 2021 1677 1825

Scope 2 Foot print (Electricity purchased) 5632 9899 13892 8063

Scope 1 & 2 Total emissions 7972 11920 15569 9888Carbon Credits:Wind Power 10295 9374 9223 13756Plantation 64 61 70 91KWH reduced through EC projects

396 218 343 358

Total credits earned 10755 9653 9636 14205Net credit / debit wrt Scope1 -8415 -7632 -7959 -12380Net credit / debit wrt Scope1 & Scope2 -2783 2267 5933 -4317

Remarks wrt Scope1 C -ve C -ve C -ve C - veRemarks wrt Scope1 & Scope2 C -ve C +ve C +ve C - ve Carbon negative in terms of

Scope 1 & Scope 2

30

Carbon foot print negative (scope 1 & 2)

Water consumption reduced by 20%

Food wastage reduced by 15%

Green coverage increased from 43.72 to 46.63 Sq.mt

Celebration of, • Earth day celebration• World Environment day • Energy conservation day • World water day

Biodiversity Enhancement

Implementation of Dr. Miyawaki Afforestation

Rainwater Perculation Well

Go Green Initiative


31

Sewage treatment Plant : Treated water to Garden 180 KLD Per day.

Effluent Treatment Plant : Treated water to RO, 25 KLD Per day for Industrial use.

Waste Coolant Recovery : Recovery, Recycle & Reuse of 3 KL of coolant per month.

Utilisation of waste & reuse


Waste Recovery trend …

4.00

1.48

2.80

0

2

4

6

2014-15 2015-16 2016-17

Reus

e in

kL

Coolant / Cutting Oil Recovery

3.2

1.5 1.6

1.0

2.0

3.0

4.0

2014-15 2015-16 2016-17

In M

tonn

e

Paint Sludge

48

81 82

0

50

100

2014-15 2015-16 2016-17

In M

T

Oil Soaked Waste

54,339 54,188

56,220

53000

54000

55000

56000

57000

2014-15 2015-16 2016-17

Reus

e in

kL

ETP Water for Garden

6,9007,260

7,467

6500

7000

7500

8000

2014-15 2015-16 2016-17

Re u

se in

KL

Canteen/Drinking RO Reject Reuse

4,350

4,260

4,440

4100

4200

4300

4400

4500

2014-15 2015-16 2016-17

Re u

se in

KL

Industrial RO Reject Reuse

Crusher Digester CookingFood Waste

Canteen Food wastage to Biogas


8/30/2017

33

Horizontal Deployment

Regeneration of Energy during Engine testing – Implemented at PNR & Technical Center (nine test beds completed & six in pipe line).

4.12 MW Roof top solar power plant Horizontally deployed at other four plants & Hosur Management development center.

Heat pumps for power intensive washing machines implemented at other three plants (six no completed & nine no in pipe line).

Elimination of tempering operation: Implemented in Ennore plant through program modification in induction heating.

On line monitoring: Comparing best practices with other plants & implemented Power Quality correction issues, Peak load management & eliminated wastages.


Significant Energy saving projects planned in FY 18

Sl.no Description Capex(Rs in L)

Payback in years PDC Remarks

1 Replace Reciprocating air comp by Energy efficient screw comp. 13.75 1 Jul'17 Completed

2 Introduce on line MOTOR ANALYTICS in powerintensive motors like Air comp, blowers & pumps 0.75 … Jul'17 System improvement , Completed in air

compressors

3 Implementation of energy saving products in works office renovation. 10.00 8 Jun'17 Completed

4 Eliminate CH stress relieving process in line 1 60.00 3.50 Sep'17 Work in progress

5 Heat Pump for P15 two ROBO washing machines 18.00 1 Dec'17 Horizontal deployment

6 Heat Recovery from screw compressor 30.00 2 Feb'18 Horizontal deployment

7 Power Quality Improvement at P15 machine shop 24 3 Oct '17 Low cost automation - Maintain PF & harmonics with in limit at load side

8 Introduce Energy efficient AHU, LED & Light pipe at new Engine assembly 30 4 Jan'18 Planned Energy saving products in

Project stage.

9 Replace & optimize 15 years old A/C Units & lighting at MS 5 & Metrology Lab 16 4 Dec '17 To reduce maintenance & operating cost

10 Improve process changes & avoid HT & gear machining in-house. … … Mar’18 Estimated 1500 Units reduction per WD

Total investment planned in FY’18 : 202.50 lakhsTotal investment planned in FY’18 : 202.50 lakhsCII 2017 Energy Award

35

ISO Certifications

TS16949:2009• Our Processes are getting

refined thru TS Standards

• ISO/ TS 16949 is expiring in Oct 2018

• New IATF Standard released by ISO

• This year, We are migrating to New Standard (IATF16949:2015)

• 17nos minor NC logged and resolved in the past 3years.

ISO14001:2015• Revised edition adopted in

2016

• Six major resource conservation projects captured through O & T and completed.

• 14 no OFIs logged during IRQS Audits & resolved in time


Accolades

ExternalExternal

InternalInternal

AL – 2014: Silver AwardAL - 2014 : Gold Award AL - 2015 : Bronze Award

CII - 2014 “Energy Efficient Unit” & Innovative Project Awards

2015 –IMTANational Productivity Merit Award

2017- CMO Asia“Asia Best CSR Practices Award”

AL - 2016 : Silver Award

CII - 2015 “Energy Efficient Unit”


8/30/2017

37

Journey from …


Documents

11 Ashok Leyland Hosur - greenbusinesscentre.comgreenbusinesscentre.com/energyaward2017presentations/Auto Engg/11... · v P Ç D v P u v K P v ] Ì ] } v ^ µ µ 9D } v ] } ] v P