TTR energy project - ASQasq.org/sixsigma/bb/pdf/ttr_energy_project_presentation.pdf · This Six Sigma project, undertaken in 2003-04, assisted in channeling the efforts of team members

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Project Duration: Aug 03 - Aug 04

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• Joint Venture between PartnersTata Auto Components (TACO): 51%Toyo of Japan: 40.25%Mitsubishi Non Ferrous of Japan: 8.75%

• Equity BaseUS $ 6.95 million

• Initial Project CostUS $ 11.3 million

• Integrated Plant Facility• Equivalent Capacity

625,000 Heat Exchangers• No. of Employees: 221• Land : 7 Acres• Plant : 100,000 sq.ft.

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Tata Toyo Radiators today is one of the largest manufacturers of

Heat Exchangers in India.

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• Integrated Plant Facility

Press, Tube Mill, Fin Forming, Degreasing,

Core Assembly, Brazing Oven, Tank Clinching &

Leak Testing

• Products

Aluminum Brazed Radiator, Intercooler,

Heater Core, Condenser

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Acknowledgements��

This report presents the work done by the team for reducing energy consumption and improving brazing oven productivity.

Energy conservation has been an integral effort for Tata Toyo Radiators (TTR) since its inception in 1998. This Six Sigma project, undertaken in 2003-04, assisted in channeling the efforts of team members through astructured and systematic data driven approach for enhancing productivity, planning, and energy planning.

We would like thank our management champion, Mr. R. Sundar, CEO, for providing us guidance and support for moving this project forward. We would also like to express our thanks to Mr. A. Alur & Mr. R. Shete. Our special thanks to the technical advisors of Toyo Radiators, Japan, and also to the management and the board members of Tata Auto Comp Systems (TACO), the parent company of TTR, for supporting the Six Sigma movement in TTR.

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Summary of Project Achievements � �� !��

28 % reduction in energy consumption levels. Energy levels were reduced from about 9.87 kwh / equivalent heat exchanger between April 02 and July 03 (16 months data) to about 7.05kwh / equivalent heat exchanger between Jan 04 and Aug 04 (8 months data).

Hard savings of Rs 5.5 million / year or US $ 122,200 / yearare achieved based on 2004 - 05 actual volumes.

The “Actual” energy cost per equivalent heat exchanger paid by TTR’s finance department to the electric power company dropped from about Rs 48 per heat exchanger between April 02 and July 03 (16 month data) to about Rs 30 per heat exchanger between Jan 04 and Aug 04 (8 months data) - tremendous achievement.

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Summary of Project Achievements

Productivity Improvement:

Brazing oven productivity increased 42 % from 76 equivalent heat exchangers in July / Aug 03 to 108equivalent heat exchangers in Jan to Aug 04.

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Project Statement :– The present energy consumption for “Entire

TTR Factory” is about 4577318 kilo watt hour (kwh) while producing 463729 equivalent heat exchangers. This gives us an energy consumption level per radiator of 9.87 kwh / heat exchanger.

This is based on 16 months of data (April 02 to July 03)

Note

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• Project Objective:– To reduce the plant energy consumption level by about 2 kwh /

equivalent heat exchanger, i.e., reduce current levels from about 9.87 to 7.9 kwh / rad by 31 Dec 03. This will result in hard recurring energy savings of about Rs 4 Million / year (US $ 88,800) based on 2004 annual volumes.

Equivalent Heat Exchangers = 1*Radiator volumes + 1.5 * Intercooler volumes + 1/6 * Heat Core Volumes

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Concept of Equivalent Heat Exchanger: Intercoolers are about 1.5 times the size of radiators and heater cores are about1/6 times the size of radiators. The following equivalent heat exchanger formula was used for this project:

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02-03 Apr-Jul 03

9.829.9

Kwh /eq heat exchanger

9.0

9.5

10.0

8.5

8.0

7.5

Aug Sept Oct Nov Dec Jan 04 Feb Mar

Target: 7.9 Target: 7.9 KwhKwh / / radrad

Expected Savings of

RsRs. 4 . 4 Million / yrMillion / yr

Before Project DataEnergy Consumption between Apr 02 to Jul 03 is 9.87 Kwh / rad

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•• Expected Date to complete DMAI Phases: Expected Date to complete DMAI Phases: On / before 30 Nov 2003 On / before 30 Nov 2003

•• Expected Date to complete Control Phase: Expected Date to complete Control Phase: On / before 31 March 2004On / before 31 March 2004

A Team Commitment

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Tube Mill Machine

Press 1 Press 2 Press 3

Fin Forming Machine

Plastic Tank & O Ring

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Testing

Tube weld Tube mill Cut to size

Degrease

Clinching

Fitment of drain plug, pressure

cap etc

Packaging and Dispatch

Leak Testing

Fin Forming Cut to size

Core Assembly

Brazing Area

Header Plate Core Support

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Brazing FDV

612000

123000

Kwh

600,000

Air Comp

Others

500,000

400,000

300,000

200,000

100,000

119700

Tube Mill

70320

Pump House

48180

Admin Bldg

27820

Fin Forming

26240

Press

20000

Pareto Analysis

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Main Focus Area:

Brazing Area

Secondary Focus Areas:

FDV (Ventilation System), Air Comp (Air Compressor), and Pump House

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Tata Toyo Radiators (TTR)

Brazing Area

Force Draft Ventilation

(FDV)

Air Compressor (Air Comp)

Tube Mill

Pump House

Admin Bldg Fin Forming Press

Tank Clinching and Leak Testing

IC

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Based on Pareto Analysis, project will focus primarily on‘Brazing Area’ and secondarily on areas like FDV, Air Comp, Tube Mill and Pump House

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Plant Energy Levels

July – Aug 03

76

90

100

110

80

70

60

Target = 90

Brazing Area Productivity Levels

Productivity figures include change over times, however, exclude planned shut downs

02-03 Apr to July 03

9.82

Kwh / Equivalent Heat Exchangers

8.5

9.0

9.5

8.0

7.5

7.0

Target = 7.9

10.0 9.9

Kwh / Equivalent Heat Exchangers

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Burn Off Fluxing Dry Off 1 Dry Off 2

Brazing Oven Cooling Section

7.5 kw blower motor

12 heater, 10 kw each. Total = 120 kw load (t Deg C)

7.5 kw blower motor 7.5 kw blower motor

12 heater, 10 kw each. Total = 120 kw load

9 heater, 9 kw each. Total = 81 kw load

8 top and bottom zones. 8 Heaters = 360 kw.Varying from t1 to t2 Deg C

Product must reach T +/- T1 Deg C for minimum ‘x’ minutes

7.5 kw blower motor

7.5 kw exhaust system blower

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The ‘Brazing Oven’ is the biggest source of energy consumption in the Brazing Area.

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Temp Zone 1

Temp Zone 2

Temp Zone 3

Brazing Oven Cooling Section

Burn Off, Fluxing and Dry Off

Start to Finish Length of the Brazing Area: 46 meters

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� %� ��!%�%��@ %�• After many brainstorming sessions the team identified the

following causes for “High Energy Consumption” for the areas highlighted in the Pareto Analysis. Causes for “Lower Productivity in Brazing Area” were also brainstormed.

Wherever possible, the team attempted to quantify financial losses per individual causes. Simultaneously, counteractions for the causes were also brainstormed. Approximate costs for implementing counteractions were also discussed for management to take immediate decision.

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� %��"�A��!%�%�!��!�� %Area Causes & Losses in Rs

Million per yr Counteractions

Burnoff • Burnoff ‘ON’ during heater core brazing (Rs 0.314 M/yr)

• Inadequate utilization due to frequent temp / speed changes (Rs 0.214 M/yr)

• Shut off burnoff as last radiator exits before HC starts

• See “Brazing Oven” section

Fluxer • Fluxer ‘ON’ during heater core brazing (Rs 0.011 M/yr)

• Inadequate utilization due to frequent temp / speed changes (Rs 0.015 M/yr)

• Fluxer Breakdown (Rs 0.2 M/yr)

• Fluxer nozzle setting problem

(Rs 0.15 M/yr)

• Shut off burnoff as last radiator exits before HC starts

• See “Brazing Oven” section • Keep spare fluxer balls. Spare kit for

fluxer pump • Procure and install video camera in

the fluxer area to assist the loading operator

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Detailed calculations for ‘financial losses’ are available

Note

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Area Causes & Losses in Rs Million per yr

Counteractions

Dry Off • Inadequate utilization due to frequent temp / speed changes (Rs 0.4 M/yr)

• Air Blower not functioning properly (Rs 0.075 M/yr)

See “Brazing Oven” section • Procure bearing and other motor spares

Cooling Section

• Muffle between oven and cooling section has no insulation, causing heat loss

• Air blower remains

‘on’ during idle condition changes (Rs 0.03 M/yr)

• Insulate muffle • Modify current circuit

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Area Causes & Losses in Rs Million per

yr

Counteractions

Brazing

Oven

Production Schedule

• Inadequate utilization of brazing oven due to frequent speed and temperature changes (~ Rs 2 M / yr)

• Pitch not

optimized, leading to lower radiator output per hour

• No systematic

plan for feeding the clinching line, leading to higher number of changes for the brazing oven

• Commonization of temp for at least 80 % of all products. • Commonization of s1 brazing conveyor speed and speed

increase for double row cores up to truck model • Commonization of conveyor speed for 43 mm and 65 mm

intercoolers at s2 mm/min • Zig zag loading of Sumo / Safari intercoolers, hereby increasing

output for different mm radiator cores • Increase conveyor speed for18 mm cores from s3 to s4 mm/min

and heater core speed from s5 to s6 mm/min • Decrease product pitch on conveyor for Sumo and Indica type

radiators. Decrease Sumo pitch from p1 to p2 mm and Indica pitch from p3 to p4 mm; helped increase output by about ‘x’ eq heat exchangers / hr

• Daily production schedule indicating sequence of production

was developed by the team • Adhering to the scheduled plan would lead to reduction in

number of changes in the brazing oven, leading to better utilization of the brazing oven

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Counteractions

Brazing Area

• Brazing conveyor running at Sx mm/min during idle condition

• Core Band Shortages (Rs

0.49 M / yr)

• Reduced conveyor speed to Sy for idle condition reducing heat loss and switched off blower during non-brazing time (by introducing new electrical logic)

• Procured new core bands

Force Draft

Ventilation System (FDV)

• FDV does not have a cut off timer, thus many times FDV keeps running during the night also (when not actually needed) (Rs 0.16 M / yr)

• Exhaust fans do not start automatically after power failure

• Install 6 timers on FDV • Circuit modification

Employees • Employees’ involvement and awareness for energy conversation

• Generated operator awareness for energy / utility cost. Mr. Purandhare, an energy conservation expert, conducted “Energy Conservation Awareness” program for the factory on 15 Nov 03.

• Also the team initiated a poster campaign in TTR.

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Counteractions

Air Comp • Press drop due to leakages in air comp line

• Due to inadequate brazing oven utilization, more use of comp air

• Fix leakages • Reduced brazing oven running hours. This

reduced load on air compressor, saving money

Core Assy & Clinching

Admin Building

• Hydraulic power packs remain “ON” during lunch and changeovers (Rs 0.17 M / yr)

• Electrical heating elements are

used to heat food in cafeteria

• Completed work instructions and conduct operator awareness session for shutting power packs during lunch, tea breaks, and dinner

• Install solar heating system

(payback period is about 8 months)

Pump House • Pumps operate continuously during no-production time as the pump switches are located far away from production area (for example tube mill area)

• Provided remote switches for tube mill pumps (near machine control board)

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For improving brazing oven utilization, around 25 planned experiments were conducted over a period of about a month. Heat Exchanger cores with temperature loggers (profilers) connected to cores were passed through the brazing oven for recording the temperatures that the cores were actually attaining when the cores were actually passing through the various heating and cooling zones in the brazing oven. Brazing zone temperatures, speeds, and pitch were systematically varied and the actual core temperatures (on three places on the radiator core) were measured and analyzed.

Through these experiments, we successfully commonized temperatures, speeds, and optimized pitch for about 80 % of heat exchangers manufactured by us. This, along with other improvement actions, led to a 42 % improvement in brazing oven output, thereby reducing energy cost per heat exchanger core.

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Radiator cores moving on the brazing oven conveyor just before entering the brazing oven

Speed of ConveyorRadiator Core

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Pitch

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Experimental Radiator core (with data logger) moving on the brazing oven conveyor just before entering the brazing oven

Speed of ConveyorRadiator Core

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PitchData Logger Insulation Box

Thermocouples attached to radiator core for recording brazing temp profile

Data Logger

Radiator Core Temperature Profile Analysis

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Radiator Temperature Profile (through Brazing Oven)

Temp Ramp Up

Temp Ramp Down

Temp Stabilization

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00:0

0

00:4

1

01:2

2

02:0

3

02:4

4

03:2

5

04:0

6

04:4

7

05:2

8

06:0

9

06:5

0

07:3

1

08:1

2

08:5

3

09:3

4

10:1

5

10:5

6

11:3

7

12:1

8

12:5

9

13:4

0

14:2

1

15:0

2

15:4

3

16:2

4

17:0

5

17:4

6

18:2

7

19:0

8

19:4

9

20:3

0

21:1

1

21:5

2

22:3

3

TIME (MM:SS)

TEM

PE

RA

TUR

E

Channel 1Channel 2Channel 3

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Specifications:

T +/- t temp to be maintained for ‘x’ minutes in the brazing oven

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The progress of the project action items was tracked through a detailed action item worksheet.

This action item work sheet was reviewed in the “Six Sigma CEO Review Meeting” held every 15 days during the course of the project. This meeting was very instrumental in giving direction to the project and helped the project move forward.

A Sample of the Action Item Work Sheet is shown on the next page...

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ENERGY PROJECT Main task/sub task Responsibility Support Start date End date

I.) Minimize Converyor Speed and Temp Changes Kiran SSK/MMK/SH 1-Oct 31-Octa.) Study different combinations of speed and temp settings for 1512 & Indica D. 1-Oct 31-Octb.) Validate study for other models also at the optimised settings 15-Novc.) Quantify benefits of the optimization study Kiran SSK/MMK/SH 15-Oct 31-Octd.) Standardize set up. Modify process sheets and work instructions 15-Oct 31-Oct

2.) Burnoff / Fluxer Shut Offa.) Shut Burn Off & Fluxer as last radiator exits before HC starts Sanjay AG 1-Oct 15-Octb.) Visual Control and Work Instructions Sanjay AG 1-Oct 31-Oct

3.) Order Spare Fluxer Balls a.) PO to be released Alur KPK / RS 15-Oct 1-Nov

4.) Spare Kit for Fluxer Pump a.) PO to be released Alur KPK / RS 15-Oct 1-Nov

5.) Install TV / Camera for Fluxer Monitoring Sanjay RNS 15-Oct 31-Oct

6.) Spares for 'Dry Off' Air Blowera.) Bearing, Air Blower, Motor Alur KPK / RS 15-Oct 5-Nov

7.) Procure Core Bandsa.) Finalize quantity required Alur KPK / RS 15-Oct 30-Novb.) PO release

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New Circuit Breaker installed for switching off air blower during non-production hours of brazing oven.

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Cooling Section

Remote switch installed for the cooling water pumps (at tube mill control panel). Now the tube mill operator can shut the pumps during non-production hours due to this remote arrangement, saving energy.

Pump House

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Solar water heating system installed for cafeteria (replacing the existing electrical heating system ) leading to energy savings (pay back period was only 8 months).

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Fluxer Solar Heating System

TV monitor and video camera in fluxing area installed for assisting the brazing oven operator in real-time monitoring of the fluxing area. This helped reduce breakdown time thereby reducing energy during brazing oven ‘ON’ time.

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Posters displayed on the shop floor and office area to increase energy saving awareness

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02-03 Apr-Jul 03

9.829.9

Kwh / heat exchanger

9.0

9.5

8.5

8.0

7.5

Aug Sept Oct Nov Dec Jan 04

8.79

Project Start

Feb Mar

8.32 8.34

7.507.72

7.07.14

10.0

6.56.42

6.92

Apr

7.54

May

7.43

Jun

7.26

Jul

7.20

Aug 04

6.7

Target = 7.9 kwh / Eq Heat Exchanger

Control Phase

Before: 9.87 kwh / eq heat exchanger (Apr 02 through July 03 - 16 month data)

After: 7.05 kwh / eq heat exchanger (Jan 04 through Aug 04 - 8 month data)

28 % Reduction in Energy Levels

RESULTS

35

02-03 Apr-Jul 03

48.5647.17

Rs / heat exchanger

42

45

39

36

33


40.48

Project Start

Feb Mar

37.02

47.19

33.9

28.0530

27.07

48

27

29.44 28.9

Apr

34.67

May

31.5

Jun

31.2

Jul

27.63

Aug 04

27.62

Control Phase

Before: ~ Rs 48 / equivalent heat exchanger (Apr 02 through July 03 - 16 month data)

After: ~ Rs 30 / equivalent heat exchanger (Jan 04 through Aug 04 - 8 month data)

37.5 % Reduction in Actual Energy Bills per heat exchanger manufactured by TTR.

Note: Figures include actual payments made by TTR to the electric power company

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RESULTS

36

C= �!3 �� !6��' ��$)��$!��

02-03 Apr-Jul 03

4.45

4.64

Kwh / heat exchanger

4.3

4.5

4.1

3.9

3.7


4.37

Project Start

Feb Mar

4.28

4.16

3.98

3.5

3.81

4.7

3.3 3.243.32

Apr

3.45

May

3.58

Jun

3.56

Jul

3.51

Aug 04

3.37




RESULTS

4.10

37

02 - 03 Apr - Jul 03

0.82

0.92

0.7

0.9

1.1

0.5

0.3

0.1

Project start up

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Jan – Apr 04

0.41

May – Aug 04

0.39




RESULTS

38

02 - 03 Apr - Jul 03

0.54

0.94

0.7

0.9

1.1

0.5

0.3

0.1

Project start up

C? �� )!� �� %�� 6��$!��Kwh / heat exchanger

Jan – Apr 04

0.39

May – Aug 04

0.49




RESULTS

39

02 - 03 Apr - Jul 03

0.34

0.37

0.3

0.35

0.4

0.25

0.2

0.15

Project start up

C� ,�( �%�6��$!��Kwh / heat exchanger

Jan – Apr 04

0.19

May – Aug 04

0.20




RESULTS

40

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Aug 03

76

90

Heat Exchanger / Hour

90

100

110

80

70

60

Project start up

79

Sept Oct Nov Jan 04 Feb

86

98

Dec

104

Mar

106

120

108106

Apr

111

May

109

Jun

112

July

112

Aug

RESULTS

41

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Energy Conservation Cell Created (Monitor and Hold on to the Gains)

Chief Executive Officer

(Six Sigma Management Champion)

Manager – PPC & Logistics

MR – ISO / QS

Vice President Operations

(Project Champion)

Manager – HR

Safety, Health, Environment & Water Conservation

Managers – Manufacturing & Maintenance

(Green Belts)

Energy Coordinator

(Process Owner)

General Manager – Quality Engineering

(Corporate Six Sigma Master Black Belt)

(Energy Conservation Facilitator)

42

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• Promote energy saving and conservation of resources• Use non-conventional sources of energy• Comply with the energy legislation and other regulations• Promote use of energy efficient alternatives and use of alternate fuels• Communicate energy management policy to all employees and

encourage their involvement through training and participation• Create awareness among all employees for innovative ideas towards

conservation of energy• Minimize waste generation and promote disposal, reuse, and recycling

in an environmentally friendly manner• Make an effort to reduce the cost continuously every year by adopting

effective “Energy Management Systems”

43

‘Shop Work Instructions’ posted on the brazing oven control panel (for operator reference) for the new optimized temperatures, conveyor speeds, and pitches (model wise)

These instructions are now part of the Quality System Documentation !

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44

� �� !�# ��)��$!%�Daily Energy Dashboard (Brazing Area)

3.39

3.133.31

3.14

3.53.67

3.36 3.333.2

2.82

3.56 3.5

3.98

3.39

3.73

3.35 3.363.5

3.68

3.193.37

4.03

3.18 3.213.02

0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

2 3 4 5 6 7 8 9 11 12 13 14 16 17 18 19 22 23 24 25 26 27 28 29 30Days

% V

aria

nce

Daily monitoring of energy levels has been started in the brazing area as part of the control phase. Total number of heat exchangers produced along with total kwh consumed during the day is used to calculate kwh / equivalent heat exchangers for brazing. This chart is maintained by the process owner and shop personnel. This chart gives real time signals to shop if the energy levels go beyond set norms. Also, we are monitoring energy levels for FDV, Air Comp, Tube Mill, and Pump House on a daily basis.

45

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Productivity levels are now being measured shift wise to make sure that the gains obtained from this project are sustained over time.

This chart is also maintained by the process owner and shop personnel.

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80.898.1122.2105.949.3101.471.9118.6106.60.00.0106.9105.197.8108.0Qty/hr

420510165420190510290510510420510450420510510Actual time

0034503200130000060000Breakdown time/Planned stoppage

420510510420510510420510510420510510420510510Std available Time

IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIShift

18-Jan17-Jan16-Jan14-Jan13-JanDate

46

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Documents

TTR energy project - ASQasq.org/sixsigma/bb/pdf/ttr_energy_project_presentation.pdf · This Six Sigma project, undertaken in 2003-04, assisted in channeling the efforts of team members