110 May 2010

TATA MOTORS

210 May 2010

310 May 2010

TATA GROUPThe Group was founded by Jamsetji Tata in the mid 19th centur y, q 96 plus operating companiesq In seven business sectors:

Information s ystems & CommunicationsEngineering Material Services Energy Consumer products Chemicals.

q The Tata Group is one of India' s largest busine ss group , withrevenues of $70.8billion

q Tata companies together emplo yees some 3,63,000 people. q Operations in more tha n 80 countries across six continents, q Export products and services to 85 nations.q The Tata name is a uniq ue asset representing

leadership with trust & Our heritage of returning to society

410 May 2010

TATA MOTORS

q Tata Motors Limited is India's largest automobile company

q Consolidated R evenues of $15.4 billion ( 2008-09)

q Leader in commercial vehicles in each segment in India

q India’s 3rd largest passenger vehicles manufacturer

qWorld's 3rd largest medium and heavy commercial vehicle

manufacturer

q World’s 2nd largest bus manufacturer.

q 2,000 touch points in India

q 24,000 employees

510 May 2010

TATA Motors

610 May 2010

Tata Motors – Indian MNCq First Indian Engine ering Company to be listed in

the New York Stock Exchange ( Year 2004)

q Acquired the Daewoo Commercial Vehicles Company, Korea's second largest truck maker ( Year 2004)

q Acquired Hispano Carrocera, Spanish bus and coach manufactur er (Year 2009)

q Joint Venture w ith Brazil-based Marcopolo for Bus body Building (Year 2006)

q MOU with Fiat for v ehicle sales & manufacture

q 2008 – Acquired Jaguar & Land Rover

710 May 2010

PLANTASSEMBLY LINEMAJOR MARKETS

Tata Motors – Global Footprint

810 May 2010

Pune

1966

Jamshedpur

1945

Lucknow

1992

Dharwad

1997

Tata Motors 1945-2010Pantnagar

2007

Tata Motors Manufacturing facilities in India

Ahmedabad

2009

India Operations

910 May 2010

Energy conservation at TATA MOTORS

1010 May 2010

Energy Conservation

Government

Industries

Policy EC Act 2001

National Energ y Policy

Renewable Energy policy

Bureau Of Energ y Efficiency ( BEE )Monitoring Agenc yMinistry of Power

Declare the Polic yTeam FormationImplementation

Monitoring

Encouragement Incentive , Taxation , Aw ard

1110 May 2010

Team

Energy Conservation Team at TML Pantnagar

ReduceRecycleReuse

1210 May 2010

Implementation

Tata Business Excellence Model

Strategy Level Vision, Mission, Core Value

Strategic Direction, Leadership System

Business Process Level

Implementation Level

Framework of Process(Enterprise Process Model - EPM)

21 Top Level Processes (Level 1)

Define Business Processes(Enterprise Processes & Sub Processes Manual)

104 + Sub processes (Level 2)

Physical Plant, Machinery, Facilities &

Computer Hardware, Software & network(Level 3)

1310 May 2010

Since 2006

TATA MOTORS Pantnagar

Implementation

1410 May 2010

To Delhi 250 Km

To Lucknow 350 Km

TML Pantnagar

TATA MOTORS, PANTNAGAR

Implementation

1510 May 2010

TATA MOTORS, PANTNAGAR

• Tata Motors ’ 5th and youngest plant. Time from acquisition of land to start of production w as in 11 months; a benchmark in the auto industr y.

• Tata Motors Pantnagar received IMS (Integrated Management S ystem) certification in 1 st ,18 months of operations.

(Including ISO TS:16949, OHSAS 18001, ISO 14001).

• Tata Motors ’ 1st plant with an integrated vendor park, to keep inventories low and to ensure supplies JIT.

Implementation

1610 May 2010

§

Strategy

…. towards green plant…. towards green plant

Reducing Environmental

Foot print

Reducing Environmental

Foot printInfrastructure§Integrated

Manufacturing§ Modular concept§ Innovative construction§ Less Cement§ Efficient Facilities§ Water conservation

Logistics§ Vendor Park Near Mother

Plant§ Transportation§ Recyclable bins , pallets

Manufacturing§ System§ Process

§ Ramp up plan

New Products§ CNG vehicles

§ BS III & IV

1710 May 2010

Actions :q To reduce 30% Steel for building structureq Modular conceptq To reduce heat load on ventilation by installing Double

insulated side and roof walls .q To reduce illumination load by installing Sky light sheetsq To install energy efficient motors for blowers, conveyorsq To install Screw chillers for AC systemq VFD for Compressor and all High powered motorsq Servo controller for Compressed Air Supply . q Fan less cooling towers for compressorq Propane for process heating, instead of

conventional fuel e.g. HSD/LDO/FOq Use of natural resource Artisan wellsq CFL Lamps, Solar Lamps, Wind Ventilatorsq Lakes & Rain water harvesting

Infrastructure ManufacturingActions :q Efficient Washing Machinesq Inter Shop Conveyorq Friction roller conveyorq “Wet on Wet” Painting processq Process Optimizationq Power & Free Conveyorq Electrified Monorail Systemq CNC Machinesq Reuse, Recycle, Reduce process waste

Strategy - To reducing Environmental Footprint

New Product Introduction

Actions :q CNG Vehicle q Fuel Efficient Vehicle – with Start-Stop arrangementq Adherence to emission norms

Logistics Actions :q Vendor park near the mother plant to reduce inbound

transportationq Out bound Transportation - Railwaysq Transportation internal & employee transport

Implementation

1810 May 2010

Infrastructure

Strategy

…. towards green plant

Reducing environmental foot print

Innovative ConstructionInnovative

Construction

q To meet the production ramp up a Modular concept & Pre fabricated steel structures are used

q 30% steel & 15 % cement less used

Hence reduced environmental impact during production of parts

q To meet the production ramp up a Modular concept & Pre fabricated steel structures are used

q 30% steel & 15 % cement less used

Hence reduced environmental impact during production of parts

1910 May 2010

Infrastructure

Strategy

…. towards green plant

Reducing environmental foot print

Modular Concept

Modular Concept

q Phase wise shops in sets

q Fast production Ram up

q Less inventory

Hence reduced environmental impact during production of parts

q Phase wise shops in sets

q Fast production Ram up

q Less inventory

Hence reduced environmental impact during production of parts

Engine &

Gear Box

Paint Shop

Wel

d Sh

op 3

Wel

d Sh

op 2

Wel

d Sh

op 1

Vehi

cle

Ass

y1

Vehi

cle

Ass

y2

Vehi

cle A

ssy3

UtilityAir, Water, Power, Fuel

ETP,STP

Ready

Inter shop Conveyor Weld shops to Paint to

Assy Lines1.5 Km long

Engine &

Gear Box

Paint Shop

Wel

d Sh

op 3

Wel

d Sh

op 2

Wel

d Sh

op 1

Vehi

cle

Ass

y1

Vehi

cle

Ass

y2

Vehi

cle A

ssy3

UtilityAir, Water, Power, Fuel

ETP,STP

WIP

Plant layout

Vehi

cle

Ass

y3Ve

hicl

e A

ssy4

Wel

d Sh

op 1

Wel

d Sh

op 4Engine

& Gear Box

Paint Shop

Wel

d Sh

op 3

Wel

d Sh

op 2

Wel

d Sh

op 1

Vehi

cle

Ass

y1

Vehi

cle

Ass

y2

Vehi

cle A

ssy3

UtilityAir, Water, Power, Fuel

ETP,STP

Ready

Inter shop Conveyor Weld shops to Paint to

Assy Lines1.5 Km long

Engine &

Gear Box

Paint Shop

Wel

d Sh

op 3

Wel

d Sh

op 2

Wel

d Sh

op 1

Vehi

cle

Ass

y1

Vehi

cle

Ass

y2

Vehi

cle A

ssy3

UtilityAir, Water, Power, Fuel

ETP,STP

WIP

Plant layout

Vehi

cle

Ass

y3Ve

hicl

e A

ssy4

Wel

d Sh

op 1

Wel

d Sh

op 4

2010 May 2010

Strategy

…. towards green plant

Reducing environmental foot print

Solar street lamp

Use of Renewable Energy

Use of Renewable Energy

CFL Tube lights

Advantages:

1 40% Energy saved

2. Illumination uniform & better

3. Load on Air Conditioning reduced

4. 43200 KWH per year saved

Advantages:

1 Installed at Strategic Locations

2. Illumination at emergency

Wind Ventilators Infrastructure

Day light Transparent Sheets

q Wind Ventilators, Day light sheets

q Double insulated sheets for wall & roof

q Solar Street Lights

q CFL LampsHence reduced environmental impact

q Wind Ventilators, Day light sheets

q Double insulated sheets for wall & roof

q Solar Street Lights

q CFL LampsHence reduced environmental impact

Cum Sum Saving in Lacs Kwh

18.349.83

3.11

30.4642.57

54.6866.80 78.91

0.0010.0020.0030.0040.0050.0060.0070.0080.0090.00

2002 2003 2004 2005 2006 2007 2008 2009

>5000

2110 May 2010

Infrastructure

Strategy

…. towards green plant

Reducing environmental foot print

Efficient FacilitiesEfficient Facilities

Screw CompressorWith VFD Savings 250 MWH/Yr

Fan less cooling tower

Servo Control Valve

q Screw Compressor with VFD

q Servo controlled Compressed Air

q Fan Less cooling tower

Hence reduced environmental impact during production of parts

q Screw Compressor with VFD

q Servo controlled Compressed Air

q Fan Less cooling tower

Hence reduced environmental impact during production of parts

2210 May 2010

Strategy

…. towards green plant

Reducing environmental foot print

Efficient FacilitiesWater conservationEfficient Facilities

Water conservation

Solar Water He ating for Canteen

Saving - 150 KWH/day

The Artesian well is Supplying Raw water to WTP with out power

Reduce the energy consumption for water pumps for WTP q Use of Natural Resource

Hence reduced environmental impactq Use of Natural Resource

Hence reduced environmental impact

Natural Resource

5% Reduction of Power Consumption for ETP Water Pumping

Since 2001 3945.8 Lacs Wind Units

2310 May 2010

ManufacturingStrategy

ProcessProcess

q New Technology at Paintshop

3C1B Process, Direct Heating, RTO (Regenerative

Thermal Oxidizer) for incineration of thinner / fumes

q Reduced heat loss by providing insulation

q New Technology at Paintshop

3C1B Process, Direct Heating, RTO (Regenerative

Thermal Oxidizer) for incineration of thinner / fumes

q Reduced heat loss by providing insulation

Hot surface insulated by glass wool6 to 8% energy saving , ROI is 6 Month

Manufacturing

Propane – Clean Fuel

Reducing environmental foot print

2410 May 2010

LogisticsStrategy

TransportationTransportation >600 t CO2 Reduced>20,000 Vehicles dispatched

35 t CO2 Reduced /YearEntry for 100 Vehicles / day restricted

Reduce environmental Impact of transporting finished vehiclesReduce environmental Impact of transporting finished vehicles

q Finished Goods Transport by Railways

qTransport facility to Employees,

q Internal Shuttle

Hence reduced environmental impact

q Finished Goods Transport by Railways

qTransport facility to Employees,

q Internal Shuttle

Hence reduced environmental impact

Logistics

Reducing environmental foot print

2510 May 2010

ManufacturingStrategy

Innovative ProductsInnovative Products

qWorlds Lowest Priced Car

q CNG Vehicle, New Efficient Products

qWorlds Lowest Priced Car

q CNG Vehicle, New Efficient Products

New Products

ACE CNG Magic CNG ACE -Fuel Efficient

Reducing environmental foot print

2610 May 2010

Innovation

Loss Elimination

Process improvement or Eff iciency Improvement

Use of God Gift

Use of New Technology

Our Journey

2710 May 2010

SPECIFIC ENERGY CONSUMPTION OF Plant 1 AND Plant 2

0

200

400

600

800

1000

1200

1400

02

-03

20

03

-04

20

04

-05

20

05

-06

20

06

-07

20

07

-08

20

08

-09

20

09

-10

(Up

to

MA

R'1

0)

kW

h /

Eq

. U

nit

47 %Stagnancy

SPECIFIC COMPRESSED AIR ENERGY CONSUMPTION OF Plant 1 AND Plant 2

20

40

60

80

100

120

140

20

02

-03

20

03

-04

20

04

-05

20

05

-06

20

06

-07

20

07

-08

20

08

-09

20

09

-10

(Up

to

MA

R'1

0)

kW

h /

Eq

. U

nit

50 %Stagnancy

Compressed Air Consumption, New Plant KWH / Veh.

0

10

20

30

40

50

FY

07-

08

FY

08-

09

FY

09-

10

59 %

Power Consumption(UPCL+DG), New Plant KWH / Veh.

-100

50

200

350

500

FY 0

7-08

FY 0

8-09

FY

09-

10

50 %

Specific Consumption Trend

Plant 2

Plant 1

Plant 2

Plant 1

2810 May 2010

Specific Fuel Consumption Trend in Million KCal / Veh.

New Plant, Fuel Consumption, MKcal / Veh.

0.00

0.15

0.30

0.45

FY 07

-08

FY 08

-09

FY 09

-10

48 %

Plant 2, Fuel Consumption, MKcal / Veh.

0

0.15

0.3

0.45

FY 07

-08

FY 08

-09

FY 09

-10

16 %

2910 May 2010

Theme: Reduce Energy Consumption in Illumination

Patent No – 203430 – Energy saving Device for High Pressure Gas Discharge Lamp

PatentPatent

Case Study - 1

3010 May 2010

Theme: Use of New Technology & Innovation to reduce energy consumption

Picture/ sketch/ drawing before modification

Picture/ sketch/ drawing after modification

Yearly consumption trend for illumination CVBU

152.5

61.0 56.4 53.045.1

1996 2000 2003 2005 2006

Year

Lakh

s Unit

s

1000W bulbs & 5000 Nos

1000 W to 4000 W

400W to 250W (1000Nos)

Out of 5000nos 1500 nos brought under saving scheme

Target - After implementation by 2006 for all 5000nos

60% 7.5

%6%

20%

What Next?

3110 May 2010

FY07-08 FY08-09 FY09-10

DG Power Nil DG Power 1% DG Power 18%

Case Study - 2Result

Power Consumtion KWH / day & KWH / Veh.

020000400006000080000

100000120000140000

FY-07-08 FY-08-09 FY-09-10

KWH

/ Day

0

100

200

300

400

500

KWH

/ Veh

.

KWH/ Day kwh / Veh.

KWH / Da y

Power Consumtion in MWH & KWH / Veh.

0

10000

20000

30000

40000

50000

FY-07-08 FY-08-09 FY-09-10

MW

H

0

100

200

300

400

500

KWH

/ Veh

.

Total Power (UPCL + DG) MWHkwh / Veh.

49%

31%

0

15000

30000

45000

MW

H

FY-07-09 FY-08-10 FY-09-10

Power Consumption UPCL vs DG in MWH DG -Power (MWH)UPCL Energy (MWH)

3210 May 2010

Sharing Best Practices

1. Intranet Site

2. Cross Locational Team

3. Knowledge Book

4. Innovision – Tata Motors Level

5. Innovista – Tata Group Level

3310 May 2010

National Energy Conservation Award - 2009 (1st Prize in Automobile Sector)

3410 May 2010

ü 2009 – TML Pantnagar - National Energy Conservation Award BEE, 1st Prize in Automobile Industry

ü 2008 - TML Pune – Excellence in Energy Management – CII

ü 2006 - TML Pune – Excellence in Energy Management – CII

ü 2005 - TML Pune – Excellence in Energy Management – CII

ü 2004 - TML Pune – Excellence in Energy Management – CII

ü 2004 - TML Pune – Excellence in Water Management – CII

ü 2003 - TML Pune – National Energy Conservation Award BEE, 2nd Prize in Automobile Industry

Achievements in the field of Energy Cons ervation

3510 May 2010

…. towards green plant

Reducing environmental foot print

TATA MOTORSPANTNAGAR

5M USD