cii national award for excellence in energy management 2020

August 26, 2020External Confidential

Presenter-

Rajeev Kumar SaxenaSandeep Dhangar

Harpreet Singh Kuttal

Global Parts Center

Neemrana

CII National Award for Excellence in Energy Management 2020

CII - National Award for "Excellence in Energy Management"- 2020

S. No Content

1 Introduction of Company

2 Energy Consumption Overview

3 Specific Energy Consumption

4 National or Global Benchmarking

5 Energy Saving Projects

6 Innovative Projects

7 Renewable Energy Sources

8 Waste Utilization and Management

9 GHG Inventorisation

10 Green Supply Chain

11 Teamwork, Employee Involvement & Monitoring

12 Implementation of ISO 50001/Green Co/IGBC rating

13 Other Innovative technologies

14 Long Term Vision on EE

2

Table of Contents


3

3

5-Zonal Offices

Mobile Station

Service Har Jagah

6 –Plants- India

Registered & Corporate Offices

22-Regional Offices

Dealers

Spares & Service Centers

Authorized Reps of Dlrs

Stockists

Dharuhera Plant HM1D69 km from DelhiIn Haryana( 1st Plant, Year 1984)

Haridwar Plant HM3H 250 km from Delhi in Uttarakhand (3rd

Plant, Year 2008 )

Neemrana Plant HM4N & Global Parts Center (HP3N) 120 km from Delhi In Rajasthan (Year 2014)

Hero Centre of Global Innovation & R&D

Rajasthan 270 Km From

Delhi

North Zone Office, New Delhi

West Zone Office, Pune

South Zone Office, Bangalore

East Zone Office, Kolkata

Gurgaon Plant HM2G 34Km from Delhi in Haryana (2nd Plant , Year 1997 )

Corporate Office, New Delhi , India

More Than 8000 Customer Touch Points

Vadodara Plant 953 km from Delhi In Gujarat (5th Plant , year 2017)

Hero is having 8000+ touch points across India. It includes plants, zonal offices, service centers & mobile service. We have 6 manufacturing plants in India, 2 in overseas and are present in 40+ countries.

Colombia Plant, Year 2014 Capacity

0.12 mn/Yr

Dhaka Plant Year 2015, Capacity 0.08 mn /Yr

Overseas 02 Plants

1 –Global Part Center

2 – R&D Center

Central Zone Office, Jaipur

Chittoor Plant HM6C 2144 Km from Delhi in Andhra PradeshYear 2019

Global presence to 40+ countries across Asia, Africa and South and Central America

Overseas : 02 Plants & 01 R &D Centre in Germany

1.0.1 Hero MotoCorp Plants1.0 Introduction to Company

CII - National Award for "Excellence in Energy Management"- 2020 4

1.0.2 Company History

2017 5th Mfg. Plant started its Operation at Halol, Gujrat

2018 6th

Manufacturing Plant in Chittoor, Andhra Pradesh & First Vehicle Rolled Out on 23rd Dec 2019

4th Manufacturing Plant & Global Parts Centre at Neemrana

Foundation Stone Laid

1.0 Introduction to Company


Awards and Recognition- TPM Excellence Award-2019 (“1st Parts Center on Globe” )

Certificates for ISO 9001,14001 and 45001 in Sept’19 from DNV-GL.

Zero Waste to Landfill with above 99% diversion rate by Intertek in 2019.

Assurance for Water Positive Plant by Bureau-Veritas in 2019.

State Safety Award for Excellence in compliance of Safety, Health and Welfare provisions by RajasthanGovernment in 2019.

GPC has been awarded the coveted and prestigious CII- BCG Industry 4.0 award in 2016.

IGBC Green Factory Platinum Award in 2014.5

1.0.3 Global Parts Center-

An Industry 4.O Parts Centre

Business : Spare Parts Division

Plant Started : 2014

SKUs : 27824 Nos

Capacity : 54 Lacs Parts / Day

Connected Load : 4.8 MW

Green Power : 1.2 MW

5



1.0.4 Layout & Equipment Details

6

Major Areas in GPCPallet ASRS 02 Nos

Bins ASRS 01 No

Pallet FM 01 No

Bin FM (Fast Moving) 01 No

Reserve ASRS 01 No

Receipt Section 01 No

Production Shop 01 No

Final Checking & Packing 01 No

Dispatch Section 01 No

Bin Loading Station Area 03 Nos

Manual Packing Station 12 Nos

Major Equipment in GPC

Stacker Cranes 53 Nos

Rail Guided Vehicles 21 Nos

Unishuttle 10 Nos

Automatic Sorting System 02 Nos

Auto Packaging Lines 09 Nos

Manual Packaging Lines 16 Nos

Telescopic Conveyors 24 Nos

Conveyor (8 KMs) 01 Nos



1.0.5 Plant Operations Process

LEGENDS Material Flow Processing area Storage area

DLP CHUTE

FPP CHUTE

CHUTE

CHUTE

PALL

ET

FM

CHUTE

CHUTE

AU

TO L

INE

PA

LLET

ASR

S PALL

ET "

U"

SHA

PE

CHUTE

CHUTE

CHUTE

BIN

FM

CHUTE

CHUTE

MA

NU

AL

LIN

E CHUTE

BIN

G L

INE CHUTE

CHUTE

BIN

ASR

S BIN

U

SHA

PE

UN

I SH

UTT

LE

FCP

SOR

TER

S

CHUTE

REC

IEP

T

RES

ERV

E A

SRS

RM STORAGE

FG STORAGETRUCK

LOADINGPICKING & DISPATCH

PACKAGING AREA

MATERIAL RECEIPT

Pallet and Bin Handling Areas

MP

SA

UTO

P

AC

KA

GIN

G L

INE

MA

NU

AL

PA

CK

AG

ING

LIN

E

PICKING DISPATCH

7



Roles in EMC

Projects & Budget Approver

Energy Management Cell (EMC)

Projects and SEC Evaluator

Projects progress reviewers

Idea generators

Projects Implementers

Employee Awareness

Technology evaluators

Budget Allocators

Energy Management Cell formed and defined their roles and responsibilities.

GPC Head

1.0.6 Energy Management cell & roles

8



Plant has framed its own Energy Policy considering the major focus on Energy Efficiency

1.0.7 Energy conservation Policy

9



2.0.1 Energy Sources for GPC

Steel

Phase

F/AsslyE/Assly.

Stores,

DG

House

Utility

HR

Canteen

Electrical Energy Distribution

Mainly HSD,GRID & SOLAR are the sources of power generation.

HSD

(1) GRID (RSEB) (2) Solar

Sources of Electrical Energy Thermal Energy

External -Confidential

(3) HSD GEN.

GRID(RSEB)

SOLAR PLANT

HSD GEN.

11KV TO

415V

ESS-

5

DP

-1

ESS-

6

DP

-2D

P-3

DP

-n

PALLET ASRS

BIN ASRS

RECIEPT/DISPATCH

EXTENSION PLANT

CONVEYOR SYSTEM

NOT USED IN PLANT PROCESS.

RSEB83%

Solar16%

DG1%

RSEB

Solar

DG

Energy %age Usage in Plant

2.0 Energy Consumption Overview


5354

63755645

3000

4000

5000

6000

7000

FY 18 FY 19 FY 20

MW

H

Total Power Consumption Better

2.0.2 Energy Cons. Trend - Last 3 Years

GPC expansion work started in 2018 to increase the throughput of system by increasing the dispatch boxes from 40000 to 75000 box per day.

4700

4720

4716903

3000

3500

4000

4500

5000

5500

6000

FY 18 FY 19 FY 20

MW

H

RSEB Power Consumption Better

800 796929

0

200

400

600

800

1000

FY 18 FY 19 FY 20

MW

H

Solar Power Consumption Better

GPCExpansion

5623

2.0 Energy Consumption Overview

Solar Capacity Addition in Feb-20


0.460.45

0.38

0.30

0.32

0.34

0.36

0.38

0.40

0.42

0.44

0.46

0.48

FY18 FY19 FY20

KW

H/B

OX

SEC Trend (KWH/Box)

Better

Power consumption/box is in reducing trend due to Kaizens and Energy Saving Projects.

17% Reduction

Key Projects contributing to reduction

Big foot LED Lights

HVLS FanPower saving logic in 8 KMs

Conveyor

3.0.1 Power Consumption (KWH/Box)3.0 Specific Energy Consumption

Total 57 Energy Saving Projects Executed in 3 consecutive years.


4.0 National or Global Benchmarking

Global Parts Center is integrated with all international standard systems like automated storage and retrieval system (ASRS), on-line tracking of parts through Warehouse Management System (WMS), Warehouse Control System (WCS), automated packaging and sorting system, lean manufacturing systems and most importantly the Green Building Concept.

Global Parts Centre –First Automated Storage & Retrieval System(ASRS)warehouse facility in ASIA (Automobile Sector).


5.0.1 Energy consumption mapping –FY18, FY19, FY20 5.0 Energy Saving Project


5.0.2 Energy Conservation Projects –FY18, FY19, FY20

FY-18

FY-19

5.0 Energy Saving Project

FY-20


5.0.3 Energy Conservation Projects – FY185.0 Energy Saving Project

Total 15 Energy Saving Projects Executed in different areas.


5.0.4 Energy Conservation Projects - FY195.0 Energy Saving Project



5.0.5 Energy Conservation Projects - FY205.0 Energy Saving Project

In-house Development

CRC

Indoor

Remote



Operational Control Creation in Centralized Cooling System (Bigfoot)

Before After

Previous Scenario:-

1. Bigfoot has only 2 operating modes.2. It has 2 Schedule transition.3. Blowers of AHUs runs continuously

during entire day.4. High power consumption due to

mode limitations.

Benefits:-1. Operating modes generated in PLC

software.2. Schedule transition increased from 2 to 4.3. One Blower switched off during C shift.

6.0 Innovative Project -1

MODE A TEMP 77 F Blower speed 60-90 %

MODE B TEMP 80 F Blower speed 50-60 %

MODE A TEMP 77 F Blower speed 60-90 %

MODE B TEMP 80 F Blower speed 50-60 %

MODE C TEMP 85 F Blower speed 30-50 %

16271491

1000

1400

1800

FY19 FY20

MW

H/Y

ear

Bigfoot Power Consumption (MWH)

8%

Apr-19


6.0 Innovative Project-2

To reduce the running time of ASRS cranes by consolidation of Picking bins

Previous Scenario:-1. When load (Dispatch Cutoff) is

applied to the system, crane used to retrieve and store same bin multiple time for picking for multiple deliveries.

2. Cut off time also more due to multiple retrievals.

Benefits:-Now we put the consolidation logic into the system, we can pick multiple deliveries bin from single source bins , resulted in more business with less equipment running time.

Before After

Running time/Day/Crane:- 10.9 Hrs Running time/Day/Crane:- 7.2 Hrs

Multiple Source Bin

Destination binSource Bin

Multiple Destination bin

19 CranesMay-19

39.2 31.3

02040

Before (FY19) After (FY20)MW

H /

Mo

nth

Energy Saving (MWH / Month)

20%



To reduce idle running of Okura conveyor by putting power saving logic.

Previous Scenario:-1. Conveyor with 578 motors keeps on

running during no load condition. 2. High wear and tear in rollers and

nylon belts.3. High checking frequency for moving

parts.4. High power consumption during idle

time.

95.1

0

5

10

Before After

MW

H /

Mo

nth

Energy Saving (MWH / Month)

Benefits:-1. Saving of 3.9 MWH / Month.2. Less wear and tear in moving parts.3. Increased MTBPM.

43%

Before After Apr-19


Installation of HVLS fans in shop floor to achieve uniform Air Flow.

Previous Scenario:-1. Uneven Air Flow in Shop Floor.2. More power consumption due to high

loading of centralized cooling system (Bigfoot).

3. Uneasy atmosphere for operators during summer season.

4. Difficult to maintain the spares.5. More wiring in the shop floor.6. Risk of operator safety while repairing

online.

250 Nos 15 Nos 110 Nos

105

85

80

90

100

110

Before After

MW

H /

Mo

nth

Power Consumption

Before After

Benefits:-1. Delay of 15 days provided in start-up of

Bigfoot due to induction of HVLS fans during start-up of summer and vice versa.

2. Uniform Air Flow in Shop Floor.


19%

Jan-19


7.0.1 Renewable and Green Energy

23

7.0 Renewable and Green Energy


Installation of additional 500 KWp solar plant

24

Phase-1 (2014)Capacity-684 KWp


Previous Scenario:-1. GPC expansion resulted in increasing

load. Hence we planned to induce more Green Power into the system.

2. Power and Fuel cost starts increasing after plant expansion.

3. Temperature of shop floor was increasing due to exposure of direct sun light.

684

1184

500

1000

1500

FY-15 FY-20K

Wp

Solar Plant Capacity (KWp)

Benefits:-1. Generation of Green Power increased by 73%.2. Power and Fuel cost reduces.3. Heating of roof reduced up to some extent.

Before After

7.0.2 On-site Renewable Energy Expansion

73%

7.0 Renewable and Green Energy


84.50% 87.52%83.10% 80.70%

15.50%12.48%

16.90% 19.30%

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

FY 18 FY 19 FY 20 FY21

% C

on

trib

uti

on

RSEB Contribution (%)

Solar Contribution (%)

In FY 19, it was observed that green power contribution was going down so in order to maintain sustainable environment hence planning done for addition of green power.

25

Expected Outcome

7.0.3 RSEB Vs Solar (%) Contribution7.0 Renewable and Green Energy


Financial Year

Technological Improvement

Type of Energy

Onsite / Off site

Installed Capacity (MW)

Generation (million of KWH)

% of overall Electrical

Energy

FY-18 Solar Power Plant

Solar Onsite 0.684 0.825 15.57


Solar Onsite 0.684 0.786 12.48


Solar Onsite 1.1 0.967 16.96

26



7.0.4 Utilization of Renewable Energy7.0 Renewable and Green Energy


Type of Waste Generation Collection Segregation Transfer Storage/Treatment Disposal

Bio Medical waste

Occupational Health Center

BinsAt source of generation

By Bins OHCDisposed to

Authorized agency

Batteries wasteUtilities/Final

Insp.Bins

At source of generation

By TrolleyWaste Management

YardDisposed to

Authorized agency

E-waste Utilities/IT TrolleyAt source of generation

By TrolleyWaste Management

YardDisposed to

Authorized agency

Bio-medical waste collection bins E-waste

27

8.0.1 Waste Types & Collection Method8.0 Waste Utilization & Management


8.0.2 Process flow & Waste Management Yard

Source of generation

Collection & transfer in

Trollies/Bins

Segregation at WMY of some

wastes

Storage at WMY

Disposal to Authorized

recycler

Waste Management Yard (WMY)

Waste Management Process Flow

E- Waste Corrugation Box Poly Packaging

28

8.0 Waste Utilization & Management


17467 17673

15360

12000

13000

14000

15000

16000

17000

18000

19000

20000

FY18 FY 19 FY 20

Kg

CO

2/T

on

kgCO2 / Ton of Final Product

Plant Expansion

Started

9.0 Green House Gases – Last 3 Years.

1. GPC expansion work started in 2018 to increase the throughput of system by increasing the dispatch boxes from 40000 to 75000 box per day.

2. Short term target - Reduction of 35% emissions (Baseline year 2017-18) till 2021-22.

3. Long Term Target - Become carbon neutral by 2025-26.

29

Solar plant added.

Data belongs to Neemrana location


10.0 Green Supply Chain

Tier 2 Supplier Tier 1 Supplier IBL Warehouse GPCPart

Distributor

Green Procuremen

t

Green Warehousing

Green Packaging

Green Logistics

Supplier & Dealer

Performance Up

gradation

Inbound

(3PL)

Logistic

s

Outbound

Logistics

Inbound

(3PL)

Logistics

BASED ON FUNCTION

BASED ON OPERATION

1

2 5

43


10.0 Green Supply Chain


11.0 Team Work and Employee Involvement

Overall employees involvement through different methods to promote energy efficient activities.

6

4559 55

644

57 53

0

20

40

60

80

100

Dec-19 Jan-20 Feb-20 Mar-20 Apr-20 May-20 Jun-20 Jul-20

No

s

Energy saving Ideas Idea Received

Idea Implemented

1. Celebration of Green Month for Ideas generation.

2. DISHA Suggestion Scheme 2.0 to motivate

employees to give value added Suggestions

3. Total energy saving Idea implemented is 160 Nos

against 165 Nos.

Summary

32

Due to Covid-19 plant operation halted


11.0 Team Work and Employee Involvement

Training Imparted to all stake holders

Participants UOMYear

2017-18 2018-19 2019-20

1. Area Specific Training to Team

members

and Contract Workers.

2. IMS Training (From 2019-20)

(ISO-14001)

Staff Nos. 128 121 98

Lead Auditor Nos. - - 2

Internal Auditor Nos. - - 24

Team Members Nos. - 596 976

Induction Training of team members % 100 100 100

Induction Training of contract workers % 100 100 100

Plant Lightings % 100 100 100

Compressed Air System % 100 100 100

Chiller System % 100 100 100

Electrical troubleshooting % 100 100 100

33


FY20 Achievements

Team set a Benchmark in Sept’19 and In Feb’20 month with Average Daily Sales which is 11.62 Cr./Day (Highest ever Sales/Day)

We successfully challenged and achieved TPM Excellence Award-2019 and became “1st Parts Center on Globe” who achieve this coveted position.

We successfully established IMS in GPC and we received the Certificates for ISO 9001,14001 and 45001 in Sept’19 from DNV-GL.

Certified with Zero Waste to Landfill with above 99% diversion rate by Intertek.

Get Assurance for Water Positive Plant by Bureau-Veritas.

State Safety Award for Excellence in compliance of Safety, Health and Welfare provisions by Rajasthan Government

FY20 Direct Productivity improved by 25 % w.r.t. FY19 (0.63 Lakhs/Man/Day to 0.78 Lakhs/Man/Day) 267 Manpower/Day saved w.r.t. FY19 (17% reduction w.r.t. FY19) through Productivity improvement projects.

Customer Delight by reducing V.O.R. Claims < 2 Days V.O.R. FFR 96% which is improved by 20% w.r.t. FY19-76%.

Customer Satisfaction by interacting with customers through VC on daily basis and reducing PDR : 62 % Reduction (From 225 Claims/Month to 85 Claims/Month).

Step towards Digital Enterprise by Implementing Online Loss monitoring , SPMS/ SAS enhancement , VOR Dashboard, Vendor Dashboard & FIFO Based ordering system.

Price Revision of 3898 SKU’s with MRP change in Aug’19, which is 23% of Total SKU’s and resulted in profit (Bottom line) of 45 Cr in FY20.

12.0 Key Achievements- HP3N (GPC)

34


13.0.1 Centralized cooling system for shop floor (Bigfoot)

Bigfoot SCADA

35

13.0 Innovative technologies

1It is an Ductless Air Conditioning system that works on building pressurization technology and provides a dust & humidity free environment and controls oxygen and CO2 levels and works on cradle to cradle approach.

2It has smart discharge heads that can respond to the heating and cooling needs of specific areas of a building or facility.

3 It is an Air Conditioning system that has Water as it’s by product. (10 KL/Day in Rainy season)

4 It is a first in the warehousing sector in INDIA.

5 It has 3 Air Cooled chillers of 300 TR and one Water cooled Chiller of 80 TR.


13.0.2 Lighting load Automation in Prodn. & Admin areas

Before After

Benefits:-1. Fully automatic system based on

software control.2. Chances of error are completely

eliminated.3. Provision of timely switching of

lights is made available.4. More life of lights due to dimming

option.

36


Introduction to

KNX System

Previous Scenario-1. Manual System to control the light.2. Chances of error due to human

intervention.3. Provision of timely switching is not

available.4. Dimming option is not available.


13.0.3 Green Wall & hydroponic farming

Previous Scenario-1. No Green Manufacturing Concept.2. No Hydroponic Farming Concept.3. Noise generated during machines

operation.4. Oxygen levels inside shop floor.

Benefits-1. Green wall concept introduced in the

plant for healthy environment.2. Hydroponic farming also introduced to

grow in-house vegetables 3. Noise generation from machines is also

absorbed by green wall.4. Green walls helps in maintaining oxygen

levels inside shop floor.



0.460.45

0.38

0.29

0.27

0.20

0.25

0.30

0.35

0.40

0.45

0.50

FY-18 FY-19 FY-20 FY-21 FY-22

KW

H/B

OX

Consumption Trend KWH/Box

2.1%

15.5%

23.6%

7%

14.0.1 Future plans

38

40% Reduction

in 5 Years

S. No

Future Project Details(FY-21 & FY-22)

1VFD Installation in Air Compressor to reduce loading unloading cycles

2Load Management in Sub Station to achieve maximum utilization of Green Power.

3Shop floor lights Automation by Lux Level monitoring

4Provision of day light inside shop floor by installing lighting tunnel.

5Automatic cleaning of Solar panels to achieve maximum efficiency.

14.0 Long Term Vision


14.0.2 VFD Installation in Air Compressor to reduce loading unloading cycles

Power Supply

Power Supply

VFD Control

27698

7828

0

10000

20000

30000

Star Delta Control VFD Control

KW

H/M

on

th

Power Consumption (KWh)

71 %

VFD

Star Delta Control

Air Compressors by VFD Control

1. At present compressor motor is controlled by

star delta starter.

2. After introduction of VFD speed of compressor

motor will vary with minimum power

consumption.

3. With this modification loading and unloading of

air compressor will be tuned with variable

demand of compressed air.

39



14.0.3 Shop floor lights Automation by Lux Level monitor

Lux Monitoring Sensor1.Lights of shop floor will be controlled by

day light monitoring sensor to maintain a

minimum Lux Level of 150.

2.During cloudy weather lights will

automatically turn ON as command

received from LUX Monitoring Sensor.

3.Power will also be saved as unnecessary

lights will be switched off automatically.

Lux Monitoring Sensor

40


Thank You!!

cii national award for excellence in energy management 2020

Documents