Marelli Motherson Automotive lighting India Pvt. Ltd.,Pune

21st National Award for Excellence in Energy Management

Marelli Motherson Automotive lighting India Pvt.

Ltd.,PunePresented By:-

Sarvesh Raut (AVP–Operations)

Shridhar Deshmukh (Unit Head-Operations)

Sahebrao Bhosale (Div. Manager –Maint. & Energy)

Magneti Marelli Motherson Auto System Pvt. Ltd., Pune 2

50 : 50 Joint Venture between Marelli (formerly known as Magneti Marelli) & Samvardhana Motherson (India) to cater the growing Indian Automotive Market.

Marelli Motherson – Company Introduction

SMG GROUP REVENUES(in billion USD)

CAGR 27.7%

2.08

4.14

5.40 6.106.90 7.20

9.10

10.5011.70

2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 2018-19

*

4.60 5.405.80 6.01

6.507.30

7.90 8.20

15.20

2010 2011 2012 2013 2014 2015 2016 2017 2018

MARELLI GROUP REVENUES(in billion Euro)

Bawal

Pune -1

Pune- 2

Sanand


Company Introduction – Products


ProductHead lamp Rear Lamp

Air Intake manifold

PBA

Process

HL housing Moulding

HL reflector Moulding

Hl bezel Moulding

Hl lens Mouldin

g

RL housing Molding

RL lens Molding

Upper and Lower cover

Molding

Base coating

MetalizingHard

coating Metalizing

Assembly Assembly Assembly Assembly

Company Introduction -Process Outline


Ele

ctr

ic E

nerg

y 3

3 K

V G

rid

DG Sets 2 Nos-750 KVA

DG Set 1 No-1500 KVA

Company Introduction-Energy Sources

X’m

er,

VC

B, LT

Room

DG Set

Solar Plants-

1. 608 kWpSolar Panels 1905 nos

Solar Plants-

2. 275 kWpSolar Panels 360 nos


Energy Consumption Overview

24.6%

75.4%

Plant Transformation Cost 2019-20

Energy (70.01 Mil. INR)

Labor+Mainte.+Scrap+Consumables+Packaging (214.00)

85.20%

9.20%5.60% 0.00%

Electrical Sources stratification 19-20

MSEDCL Solar Fuel Thermal Energy


0.0

2.0

4.0

6.0

8.0

10.0

12.0

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

6.78.6

11.310.2

8.57

Mil

. kW

h

Total Electrical Energy Consumption (MSEDCL + Solar+

DG)

0.0

50.0

100.0

150.0

200.0

250.0

300.0

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

220.0260.0 260.0

78.8

0.0

Mil

. kC

al

Total Thermal Energy Consumption

10961508

25182993

3360

0

1200

2400

3600

4800

Ac

t. 2

01

5-1

6

Ac

t. 2

01

6-1

7

Ac

t 2

017

-18

Ac

t 2

018

-19

Ac

t. 2

01

9-2

0Sales Turnover in M. INR

1.16

1.85

2.262.54

2.24

0

1

2

3

Ac

t.20

15-1

6

Ac

t.20

16-1

7

Ac

t.20

17-1

8

Ac

t.20

18-1

9

Ac

t.20

19-2

0

Volume in Million Nos.

Energy Consumption Overview


0.00

1.00

2.00

3.00

4.00

5.00

6.00

7.00

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

6.115.60

4.94 4.554.09 3.93

kW

h/L

am

p

36% Reduction from

2014-15

Last one year 3.92%

SEC reduction

Specific Energy consumption Electrical, KWh/FG

Specific Energy consumption Thermal, Kg Lpg /Lamp

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

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

0.77 0.68 0.68

0.21

0

kg

/Lam

p

100% LPG and washing

process eliminated with

new technology

machine

Specific Energy Consumption – Last 6 years

Specific Energy consumption kWh/Kg plant level

5.04 5.01 4.98

4.734.81

4.98

4.764.88

4.75 4.69 4.674.84

4.00

5.00


0.00

1.00

2.00

3.00

4.00

5.00

6.00

7.00

8.00

MMLISanand

MMLIBawal

MMLIPune

Comp 1. Comp 2. AL-CN AL-IT

5.325.04

3.93

5.905.71

4.213.91

kW

h/F

G

kWh/FG- FY 2019-20

Global Business

Line

Competitors, National & Global Benchmark


Major Encon Projects Planned in 2021-22

Short Term Plans

MTC Interlock with IMM-18 Nos.

Water Temp. optimization for Thermoset machine

Centralized Cooling for Assembly

Mid Term Plans

Roof solar expansion

EC fan motors for AHU’s

IE 4 motors for Water pumps

ISO 50001 certification

IR heating for IMM-Small tonnage

Long Term Plans

Biogas to electricity generation

WHRS-Compressor

Oil from waste plastic

Drive for Negri bossi machines

Rain Water Harvesting


Sr. Type of ProjectNo of

Projects

kWh

Saving

Annual

Cost

Saved

Annual

Mil. INR

Investment

Made

Mil. INR

ROI

Months

1Roof Top 608 kWp & Ground mounted

275 kWp Solar projects2 0 2.3 0.2 1

2 Thermal jackets to IMM barrel heaters 10 110989 0.88 0.37 5

3

Usage of new technology Equipment,

LED, Deionizers, APFC, Occupancy

Sensoors,etc.

7 76452 3.2 1.17 5

4Machine Software & hardware

upgradation for idle off, efficiency, etc.9 125080 0.95 0.11 2

Energy saving projects 2017-18

Total

Projects

kWh Saved Annual Savings Mil

INR

Investment

Mil INR

28 312521 7.28 1.84

Reduction in

SEC 7.9% over

last year



Projects

kWh

Saving

Annual

Cost

Saved

Annual

Mil. INR

Investment

Made

Mil. INR

ROI

Months

1Advance technology reflector cleaning-

Elimination of LPG & reduction of EE01 295121 5.33 2.57 06

2 Installation of artic master on chillers 02 96574 1.24 1.37 13

3 IFC controller to air compressor 01 48384 0.35 0.34 12

4Thermojacket installation on IMM

barrels03 21686 0.16 0.08 13

5Advanced technology equipment usage

ie deionizers ,LED, etc14 95876 0.78 1.51 23

6Elimination of Type 1 loss on

equipment's (Idle Consumption)17 156644 1.28 1.96 18


Total Projects kWh Saved Annual Savings

Mil INR

Investment

Mil INR

38 714285 9.14 7.83

Reduction in

SEC over last

year 10.1%



Projects

kWh Saving

Annual

Cost Saved

Annual Mil.

INR

Investment

Made

Mil. INR

ROI

Months

1 Diffusion Pump Energy Saving Kit 05 180000 1.53 0.1 1

2Heating idle off on annealing oven and hot

plate welding machines10 127810 1.08 0.32 4

3VRF systems installation instead of Old Split

and cassette AC04 168898 1.44 5.1 3.5

4Exhaust Fans and Cooling tower fan close

loop control with temp.14 21788 0.18 0.04 3

5Adiabatic cooling and condenser coil

replacements on chillers03 79266 0.70 1.0 17

6MTC, Conveyors auto off & DH weekly timer

optimization in Molding area82 21090 0.25 0.12 6

7Heating optimization –Inductive heating on

molding, Thyrister control heating on Oven 03 20898 0.18 0.12 8

8

Eco plug to AC, Solar netmeteriing, Solar

street lights, Roof transparent sheet

replacement

16 21070 0.80 0.8 12


Total

Projects

kWh Saved Annual Savings

Mil INR

Investment Mil INR

138 640920 6.16 7.0

Reduction in

SEC 3.92%

Over last year


Horizontal Deployment

1. Chiller 2-75TR

2. Chiller 1-75 TR P2

Before- Normal ambient Air using for

cooling the condenser coil

After- Ambient Air pre cooled by

additional cooling fins. Adiabatic

cooling system installed

Major Project 1: 2019-20Adiabatic cooling for chillers

69

62

58

60

62

64

66

68

70

Before After

kWh

Before After

Benefit-411000

RS/year

Cost-60000 RS

ROI-2 months


High Energy Consumption of

Conventional Split & Cassette AC..

Major Project 2: 2019-20Reduction in Energy Consumption of Clean room AC

New technology VRF system Installed .

21.83

18.45

16

17

18

19

20

21

22

23

AC-27 TR VRF-30 TR

kWh

AC-27 TR VRF-30 TR


1. Canteen -13 HP

2. LAB-18 HP

3. Office -18 HP

Cost:-12,25,000

Benefit:-4,13,000 INR


Cost :-55000 INR

Benefit – 04 Heater off 24 min in

1 hour

INR 1,80,000


Arzuffi -2,3,4,5

Tecnovacuum

Innovative Project 1: 2019-20Diffusion Pump Optimization

Heating Command given to Diffusion

pump second heater bank only when

High vacuum will on

44

40.8

39

40

41

42

43

44

45

Before After

kWh

Before After

Pump Status R.V. GD Pre HD Pre Evapor

ation

HD

post

Rotary Required Yes Yes Yes Yes Yes

Actual Yes Yes Yes Yes Yes

Roots Required Yes Yes Yes Yes Yes


D.P. Required No No No Yes No

Actual Stand

By

Stand

By

Stand

By

Yes Stand

By

Diffusion Pump Continuous On during

high vacuum off ..

Pump Status R.V. GD Pre HD Pre Evapor

ation

HD

post

Rotary Required Yes Yes Yes Yes Yes


Roots Required Yes Yes Yes Yes Yes


D.P. Required No No No Yes No


0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

Rough Vacuum GD Pre HD Pre Evaporation HD Post

1.00X 10 -1 1.00X 10 -2 7.00X 10 -3 1.00X 10 -4 1.00X 10 -2

Cycle -VMM


Cost :-53000 INR

Benefit – 40257 INR

ROI -16 Months


All IMM 19 Nos.

Innovative Project 2: 2019-20Induction Heaters on IMM Barrel

Barrel Heating high consumption in Zone 1 Induction heater provided on Zone 1

1.96

1.21

0

0.5

1

1.5

2

2.5

Before After

kWh

Before After

Zone 4 Zone 3 Zone 2 Zone 1

ZONE

1

ZONE

2

ZONE 3 ZONE

4

ZONE

5

TOTAL

Load

kW

5 5 5 5 5 25

Consu.

kWh

1.96 0.99 1.04 1.03 1.01 6.03

ZONE

1

ZONE

2

ZONE

3

ZONE

4

ZONE

5

TOTAL

Load kW 2.5 5 5 5 5 25

Consu.

kWh

1.21 0.97 1.07 1.01 1.08 5.34


Horizontal Deployment Planned

1. Annealing ovens-04 Nos

Before- Annealing oven temp. controller by

contactor with PID.Only on @100% & off

commands were their.

After- thyrister control provided it will

draw current as per diff. between

actual and set temp. difference

Benefit-146390 INR

Cost-25000 RS

B/C = 5.85

19.5

20

20.5

21

21.5

22

22.5

23

Before After

23

20.7

KWH/HR

KWH/HR

Innovative Project 3: 2019-20Annealing oven heating optimization


Utilization of renewable energy source

99.395.1

92.490

85

04.2

6.79.2

12.5

0.7 0.7 0.9 0.92.5

75

80

85

90

95

100

105

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

UTILIZATION OF RENEWABLE SOURCES

MSEDCL Renewable DG

Total units

kWh

6664899 8693047 11279868 10260381 8573770

Renewable kWh 0 365113 756738 939584 1088696

% of renewable 0 4.2 6.7 9.2 12.50

Tonnes of CO2

Offset

0 310 643 799 925

Installed

capacity Mil

Kcal /annum

(Thermal)

Inst. Plant

capacity –Plant

onsite(Electrical )

kWp

Generation

kWh

% of

electrical

energy

Onsite Inst.

Capacity

MMLI

Group

2015-16 260 0 0 0 0

2016-17 260 608 365113 4.2 608

2017-18 260 891 756738 6.7 1490

2018-19 78.0 891 939584 9.2 1790

2019-20 0 891 1088696 12.5 2090

Target 20-21 0 1000 1372000 15 2800


Types of Waste

Waste

generation FY

19-20

CO2 emission

in TonnesProjects to reduce wastes

Plastic waste

(in Tonnes)210 1050

1) Online gate grinders for runner reusage

2) Sell of waste Plastic to reduce new demand in

market

Packaging

plastic waste

(in KG)

920 4.4

1) Eliminated wrapping of Internal parts by

developing dunnage in storage bins to avoid

scratches on part

2) Reduced wrapping roll sizes & polybag size as

per part size for outer parts

General Waste

(in Tonnes)20.13 14

1)Wooden pallets reusage

2)Reduction in general waste, stationery etc.

1057

1287

1127

920

0

200

400

600

800

1000

1200

1400

FY16-17 FY17-18 FY18-19 FY19-20

Packaging plastic waste in KG

213.75

468.49

221.45 210

0

50

100

150

200

250

300

350

400

450

500

FY16-17 FY17-18 FY18-19 FY19-20

Plastic waste in Tones

Waste Utilization & Management

100% Re usage of

waste plastic in 19-20


Project 1-Waste utilization

Saving– 1.0 Mil INR /year Investment–0.45 Mil. INRROI –6 Months

Benefit to EnvironmentPlastic waste reduced by

7257 kg/annum

CO2 emission is reduced by 36 Ton

BEFORE:

Scrapping plastic runners, gates & rejected parts

AFTER:

Online gate grinder installed.

Horizontal Deployment planned• 430T

• 900T-1• 850T


GHG Inventorisation

Indian CO2 emission contributors Maharashtra Power Contribution

Scope Parameters FY 16-17 FY 17-18 FY 18-19 FY 19-20

Scope 1MMM Operations

direct

CO2 emission in Tonnes 106.2 165.8 138.1 135.9

LPG Consumption in KG 12750 13050 5400 0

Diesel Consumption in Litre 25450 47345 45506 51217

Scope 2Supplier operation /

transportation

CO2 emission in Tonnes 7317.3 9613.4 8755.9 6277

Energy Consumption in MW 8608.5 11309.8 10301 7384


Electri

city

2018-19 CO2 offset 2019-20 CO2 offset

Solar 939584 kWH 798.6 Tonnes 1088696 kWH 926 Tonnes

Electricity

consumption

Savings

714285 kWH 607.2 Tonnes 640920 kWH 545 Tonnes

LPG

LPG gas saved 10850 Kg 32.3 Tonnes 13000 Kg 39 Tonnes

Plastic

RM

RM recycled 180 Tonnes 900 Tonnes 210 Tonnes 1050 Tonnes

Plastic

packagi

ng

Plastic packaging

reduced (49

Projects)

14.4 Tonnes 71 Tonnes 16 Tonnes 80 Tonnes

Total CO2 Offset 2446 Tonnes 2641 Tonnes

18.71 % of total CO2 emission

GHG Inventorisation

12.00 % of total CO2 emission


Green Supply Chain

24

Initiative taken to reduce energy consumption in green

supply chain1. Energy auditing at supplier end

2. Horizontal deployment of Encon kaizens done at plant

3. Assist suppliers to identify losses and attack same

4. ISO:14001 implement to 68% of suppliers, rest targeted to

complete by Q3- 20-21

5. Guidelines to procuring energy efficient equipment's


Leader

Core Team Member

Team Member

Energy Manager

AVP- Operations Utility Responsible

Molding

Manager

Finance

ManagerEngg –

Maint.

Engg –

AssemblyEngineer-

Coating

Environment

Manager

Plant Head

Teamwork, Employee Involvement & Monitoring



Installation of Electric energy Measurement instruments:

EMS with e mail and SMS alert for idle consumption



Energy saving practices

standardization

Communication &

ReviewVisuals


Energy Budget For next Financial Year

Energy Cost deployment (Loss

identification)

Budget Sanction for energy projects

Project allocation to identified

engineers as per skill

Project status review & result

verification

Daily review in Meeting & Monthly

review in Operations review

meeting

Teamwork, Employee involvement & Monitoring

0.00

1.00

2.00

3.00

4.00

5.00

6.00

7.00

8.00

9.00

2015-16 2016-17 2017-18 2018-19 2019-20 TARGET 20-21

0.801.10

1.83

8.82

7.00

7.90

Mil

. IN

R

Year wise Investments for Energy Conservation


Energy Conservation week

celebration

Poster Competition Training on Energy Savings in

Pneumatics by SMC

CII Training on Energy

Conservation

Routine awareness Trainings on Energy

Conservations

Awards for best suggestions

Award for Best kaizen


Awareness Through

Poster & displays19 28

44 42

209

320

481 490

163

269

433451

0

100

200

300

400

500

600

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

No

/ Y

ear

Blue Collar Involvement in EC activities

Training Nos

Suggestions

Quick Kaizens26 Ideas

44 Projects


Implementation of ISO 50001:2011

Plan for ISO:5000

1• Sept.2019

Benchmarking Visit to

MMPIL Manesar

• Oct.2019

Team Formation

& RR definition

• Dec.2019

Training Plan &

Implementation

• Mar.2020

Documentation • Aug.2020

Preliminary Assessmen

t • Sept.2020

Stage 1 Assessmen

t

• Jan.2021

Stage 2 Assessmen

t May.2021

Sales turnover v/s Encon Investment %

Year Sales Turnover

M.Inr

Encon Investment

M. Inr

% of Encon

investment

2016-17 1508 0.9 0.06%

2017-18 2518 1.84 0.07%

2018-19 2993 7.83 0.26%

2019-20 3360 7.0 0.21%


Other innovative technologies implemented

• Auto data capturing for

Energy Consumption

• Auto SEC Live calculation to avoid losses

• Computerized maintenance management

system, Mobile app & alert for Maint.

Engineers

• Automated production monitoring system


Long term Vision on EE

Vision:-To create an energy-friendly plant, where each person takes responsibility for energy

consumption and actively works to reduce it.

Objectives:-Use new technologies and renewable sources to

• Reduce energy consumption,

• Reduce CO 2 emissions generated

Targets:-

• Reduction in Energy Consumption by 15% for FY 2020-21

• Increase Renewable energy Share up to 50%

Major Projects in Progress

1. Water Heat recovery for compressors

2. AHU motors & water pumps optimization

3. Servo conversion of Existing IMM

Support we are looking for

• Support for economical solutions in encon activities like

• Technical support for advanced vacuum metalizing energy optimization


Future Plans –Water heat recovery Compressor

• Plan- Waste heat recovery from Compressor and hot air to use in annealing ovens

• Expected Savings -4 kWh/Hour

• Investment Proposed – 26,00,000 INR

• ROI Proposed- 11 Months

• Target Completion Date :-Oct.-20

• Current status –Capex (negotiation phase)


Future Plans –Long Term Projects

Plan- Electricity From Biogas

Vendor-Bloom Energy

Plant Capacity-250 kW

Investment Proposed –6.65 Cr. INR/Opex

ROI Proposed-

Target Completion Date :-In Discussion

Plan- Oil generation from waste plastic

Vendor-Rudra Env.,Pune

Proposed Capacity-250 kg/Batch

Expected output -700 ml/kg

Investment Proposed – 28 Lacs INR

ROI Proposed- 23 Months

Target Completion Date :-Jan.-21


Energy Audits & Scope of Energy Savings, Outcomes

Emerson/SAS

Blue star

Magenti Marelli (Central Team)

Power tech (MEDA Empanel Auditor)

Intgeni.

• PF optimization

• Adiabatic cooling, Condenser replacement

• AHU energy efficiency

• Energy Efficient equipment

in lighting business line

• Water pumps

EC motor for AHU-In procurement

Adiabatic cooling-02 Nos installed

Condenser-02 Nos Replaced

Dry cleaning-Reflectors

Water pump/Motor replacement with

higher efficiency (P phase)

PF optimization, kWh to kVAh delta

reduction


First Price- FOR state level EnERGY Conservation AWARDS

COMPETITION in automobile and Engg category –By MEDA

(state government) -2019

Awards & Achievements

energy efficient Unit awards at National Energy awards by CII-2019

Second Price- at state level ENERGY CONSERVATION

Competition AWARDS in General category–By MEDA (state

government) -2018


Journey continuous..

Documents

Marelli Motherson Automotive lighting India Pvt. Ltd.,Pune