Download - TATA Motors, Lucknow
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Sohrabji Godrej Green Business Centre- CVBU LUCKNOW 1
Category Excellent Energy Efficient Unit
National Award In Excellence in Energy Management 2010
Unit Tata Motors Limited ,Tata Motors Limited ,CVBU CVBU -- LucknowLucknow
Sector Automobile
Results Best in class Sp. Energy consumption- Sp. Water consumption &- Sp. Fuel consumption
Lake View Within the Plant
Plant Greenery
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National Award In Excellence in Energy Management 2010
Tata Motors Limited Tata Motors Limited
CVBU CVBU -- LucknowLucknow
Presented By:-
Srinu Babu . Matta Div Manager Energy Auditor
Nitansh . Kamboj Manager Energy Manager
Md. Amir Manager
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vTata Motors Limited is Indias largest automobile company, Consolidated revenues of Rs. 92,519.25 crores in 2009-10.
(US $ 18.3 billion)
We are the leader in commercial vehicles in each segment, The company is worlds fourth largest truck manufacturer, Worlds second largest bus manufacturer.
TML - LucknowLake View Within the Plant
Plant Greenery
Company Profile:- Lucknow Plant
vTata Motors -CVBU Lucknow is Established in 1992 to meet the demand of Commercial
Vehicles in Indian & overseas market. Specialized in the designing and manufacturing of a range
of modern buses Low floor, Ultra Low floor, CNG & RE Buses. Prominent customers include DTC & STU.
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Lucknow WorksEASTERN COMPLEX LUCKNOW WORKS
Weld Shop
Cowl & Cabin
Vehicle Assembly
Paint Shop TCFVehicle Factory
Transmission Factory
Integral Bus Factory
Frame
Cowl
Vehicle Assembly
Machining
Heat Treatment
Module Assembly
Module Fabrication
Bus Focused
ERC setup
Recon
FBV Head
Quarter
TMML
Service Training center
Facilities @ LucknowWho are we
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* Delhi Transport Corporation
**State Transport Unit
Plant Process
SUPPLY CHAIN
Material from Vendor base -Local, Pune & Jamshedpur
Vehicle Assembly Line Western ComplexBus Assembly Line
TMMLVehicle Assembly Line
Eastern Complex
Engine Assembly
Transmission Assembly
AxleAssembly
ChassisAssembly
CowlAssembly
BIW Shop
Paint Shop
DIS
PAT
CH DTC*
Private Operator
STU**
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Plant Energy Policy
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We have Energy Management Cell in our Plant, Which initiates & Manages all sorts of Energy Conservation measures across the Plant. The structure of the Energy Management Cell is,
Energy Management Cell
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ENCON Summary
Low Investment < Rs 10,000/-
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ENCON Projects 2006-2007
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ENCON Projects 2006-2007
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ENCON Projects 2006-2007
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ENCON Projects 2006-2007
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ENCON Projects 2006-2007
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ENCON Projects 2006-2007
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ENCON Projects 2006-2007
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ENCON Projects 2007-2008
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ENCON Projects 2007-2008
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ENCON Projects 2007-2008
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ENCON Projects 2007-2008
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ENCON Projects 2007-2008
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ENCON Projects 2007-2008
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ENCON Projects 2007-2008
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ENCON Projects 2007-2008
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ENCON Projects 2008-2009
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ENCON Projects 2008-2009
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ENCON Projects 2008-2009
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ENCON Projects 2008-2009
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ENCON Projects 2008-2009
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ENCON Projects 2008-2009
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ENCON Projects 2008-2009
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ENCON Projects 2008-2009
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ENCON Projects 2008-2009
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ENCON Projects 2008-2009
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ENCON Projects 2008-2009
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ENCON Projects 2008-2009
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ENCON Projects 2008-2009
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ENCON Projects 2008-2009
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ENCON Projects 2008-2009
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ENCON Projects 2008-2009
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ENCON Projects 2008-2009
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ENCON Projects 2009-2010
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ENCON Projects 2009-2010
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ENCON Projects 2009-2010
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ENCON Projects 2009-2010
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ENCON Projects 2009-2010
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ENCON Projects 2009-2010
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ENCON Projects 2009-2010
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ENCON Projects 2009-2010
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Burner
SEALER OVEN
Air
BlowerBurner
Air
BlowerBurner
Air
BlowerBurner
Temp 150 0 C
Blower
No FlameAir
BlowerBurner
Air
BlowerBurner
SEALER OVEN
Before: Top mounted three burners oven maintains inside oven temperature i.e. 150 0 C for full baking of Cowl body.
After:After Consultation with OEM and Internal Quality controller, we found baking of Cowl after sealant paint at 110 0C at its pregel stage, which fulfills the requirement. Accordingly one Burner out of three Burners has been stopped.
Optimisation of Sealer Oven- Cowl Baking in Paint Shop
Temp 110 0 C
After CED process , Seam Sealant and Under body sealant is applied on body. After Sealant application it goes for baking in sealant Oven at 150 C. After Baking body goes for sanding , top coat application and again baking up to 150C. So sealant gets baked twice in one cycle.
Make:Maxon-Oven Pak400
Thermal O/p-426 KW
Vol-60,000 M3/Hr
ENCON Projects Zero Investment
Total Investment : 0 Lakh Total Savings : 43.84 T CO2/annumPayback :Immediate
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In Phase 1 : 2008-09 : The compressed air pr. of 6.2 bar was under usage earlier. The Line pressure of the Compressed air reduced to 5.9 bar with no effect on the pressure delivered at the end user.
In Phase 2 :2009-10: After detailed study and agreement from end user, further reduced the pressure setting optimally at 5.7 bar.
Before Condition Phase 1
Total Investment : 0 Lakh Total Savings : 0.92 Lakh/annumPayback :Immediate
Optimizing the Compressor PressureENCON Projects Zero Investment
Compressor House Phase 2
6.2 bar 5.9 bar 5.7 bar
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After :Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop, after Top Coat & Sealer Oven ,cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower.
Before:Roller bed conveyor operates with three motor which connected with roller operated conveyor belt.
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment : 0 Lakh Total Savings : 1,085 KWH/annumPayback : 5 Months
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Energy Conservation AchievementsInnovative approach with Zero & Low Investment
Total ENCONs in last 4 years: 331
71
38 222
Total ENCONS Zero Investments ENCONsLow Investment ENCONs
21
486
Total ENCONs Zero Investments ENCONs Low Investment ENCONs
Total Low Investment ENCONs : 71
Total Savings: Rs. 72.734 Million
Total zero investment ENCONs : 38 Total Savings thru. Zero investment ENCONs : Rs. 6.32 Millions
Total Savings thru. Low Investment ENCONs : Rs. 21.22 Million
Low Investments mean < Rs. 10,000 /- of investment
ENCONs Savings
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Specific Energy ConsumptionYear
Electrical KWH / Ton or unit of
prodn
Thermal tons or kL per ton or
unit of prodn
Electrical Thermal
KWH * Million
Rs Million Type of fuel
Tons/KL (KL)
Rs Million Eq. Veh. KWH/Eq.Veh.
KL/Eq.Veh. % redn. % redn.
200506 13.81 55.45 HSD 600 - - 31,049 445 0.0193 - - - -
200607 15.52 62.49 HSD 720 24.85 43,073 360 0.0167 18.962 13.498
200708 15.77 64.30 HSD 768 25.52 46,725 337 0.0164 6.343 1.670
200809 12.02 50.64 HSD 612 20.31 33,366 359 0.0183 -6.379 -11.593
200910 14.27 60.93 HSD 715 27.30 65,495 218 0.0109 39.276 40.451
(April - March)
Annual Energy consumption Prodn. in tons or any other unit of
prodn.
Specific Energy Consumption
Redn. in Specific Energy consn. Over previous year
**Electrical Thermal
Best in Class
Copper
Text ile Ceramic - kJ / kg
Ferti lizer Foundry Sugar Power Plant
Specific energy consumption during 2007 - 08 = (B)
- kWh/Tone of Cane & % of Steam on
Reduct ion in Sp. Energy Consumption = B A x 100 = %
- % Auxiliary power consumption & Heat Rate (kCals/kWh)
** Specific energy consumption during 2008 - 09 = (A)Example
- G Cal / Ton
- kWh / kg
- G Cal / Ton- kWh/MT & KL or MT/MT of Product
200
300
400
500
600
2003
04
2004
05
2005
06
2006
07
2007
08
2008
09
2009
10
TML-LKO
Specific Energy Consumption per Equivalent Vehicle produced
The Energy conservation measures resulted in managing the Sp Energy consumption at 218 KWH/Eq Vehicle. This is National & International Bench mark across the class.
Benchmark data : Reduction over 6 yrs
Mahindra & Mahindra Ltd : 35 %
Tata Motors Lucknow : 60 %
KW
H/E
q. V
ehic
le
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Specific Energy Consumption ( KWH / Eq Vehicle) & Specific Water Consumption ( M3/Eq. Vehicle) details
SEC Comparison data
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Specific Fuel Consumption ( M Kcal / Eq Vehicle) details :SEC Comparison data
Based on above comparative SEC data of various companies, TATA Motors CVBU Lucknow plant is the Most Energy Efficient Automobile company. As part of continual improvement we would further reinvestigate all our processes to achieve further cost reduction by reducing Energy consumptions at all levels.
To sustain the best achieved level :-We are following robust process of assessment of performance vis-a-vis comparative information / benchmark
from different organisation & standards. Our emphasis is on:- To optimise the use of Resources while using appropriate and innovative method to reduce the energy
consumption in all the areas of operation on the continuous basis through evaluation and improvement. Use of Latest technologies wherever possible. Maximize the use of non-conventional Energy resources wherever possible.
Ultimate Object :
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Energy Audit & Review ; Put up ENCONs thru Capex10-11
Energy Audit & review ; TBEM ; ENCON Implementation
WED Celebrations; Energy Audit & ENCON Implementation
CII Energy Exim Award; TQMS Trg; Energy Audit & Review
Energy Mgmt Trg -CII; Energy Audit,Review & Sugg. scheme
Assessment of CDM project ; Energy Audit & Review
Assessment of CDM project; Energy Week Celebrations.
Carbon Foot printing of Lucknow Plant External
Bench Marking with other Plants
May10
Apr10
Jun10
Jul10
Aug10
Oct10
Nov10
Feb11
Dec10
Road Map set for 2010-11 ::
15% Reduction
Sp. Suggestion campaign, Energy Audit & ReviewJan11
Energ
y
Mgmt
Cell
Road Map for Sustaining Benchmark
Completed
Planned
In progress
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Better
35% of the volumes are
from New Models
Introducing New Products becomes more essential in the situation where the market is keen about fuel efficiency & alternate fuels with least impact on the environment.
Lucknow Plant constantly focuses on NPI (New Product Introduction) to a great extent.
The number of NPI rose to 98 from 62 nos till last year. We also monitor the Percentage contribution of the New Products in terms of Performance, Volume & Revenue to ensure effectiveness in addition to the NPI index.
Innovation:- Way of Life at TML
26
62
98
0
20
40
60
80
100
120
2007-08 2008-09 2009-10
New Products Introduced
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Tata Motors, Lucknow celebrated its first Innovation and Technology festival- Mastishkotsavfrom 18th to 20th September 2008 with the following objectiveCreating awareness amongst employees on the Innovation initiative taken at Tata Motors, Lucknow in line with group initiativeEncourage employee participation in generating new ideasExposure on new technologies
Novel Ideas in Suggestion
Scheme
Novel Ideas in Kaizen & CFT
Special Campaigns on "Innovation"
Posting to "Innovation Council"
I.P.R
Tata Innovation Day
TrialExecution
Campaigns LaunchedOpportunity Identification Campaign
Ideas campaign launched for all gradesParticipation promoted through multiple communication
Implementation campaign
6 Task forces constituted for execution of ideas generated in campaign (low hanging fruits)Around 80 Lacs has been realized rest are in pipeline for execution
Innovation and Technology Fest
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LPG Burners
Before :
Method used to raise the water temperature:-LPG burner were used to raise the temperature of water to 60C.
Post Wash operation:-After the quenching process the metaquench42 oil layers needs to be cleaned from the components. To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60C.
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project :
MACHINE : 200 Kg/Hr CCHF
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LPG Burners
(Partial Load)
Method used to raise the water temperature:-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash.
The temperature of flue gases when burnt is 275C and with the help of heat exchanger we recovered the heat. And this extracted heat is used to raise the water temperature of post wash to the required level.
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum : 45 T CO2
Benefits :
Innovation Project :
After :
X
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Optimisation of Cooling Zone Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting. In Paint shop, it passes first from Pretreatment stage, where oil, grease, dust & dirt is removed by hot water spray. Next, the Cowl body passes from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition).
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for baking & drying at defined temperature i.e. 150C. This oven is horizontally connected with cooling zone, where cowls gets cooled by two axial flow fans i.e.. 22KW & 30 KW.Before:The Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown below. The Cooling fans automatically comes into operation as soon as the conveyor starts. It is found always in running mode once the line gets started. Cowl takes almost 2 hrs time to reach the oven from Pretreatment stage.
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project :
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After :A Position sensor has been provided at the starting end of cooling zone, which senses the entry of cowl into oven subsequently it gives the start signal to the axial flow fan to run.
Total Carbon emission reductions per annum : 112 T CO2
Benefits :
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project :
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To identify most energy & cost effective solution for transportation of modules from TML, Lucknow to TMML, Dharwad
Trials and proving of best solution
Models to be covered: LPO-1618 RE LE- CNG & Diesel
Scope & ObjectiveScope & Objective
Innovation Project:Energy & Cost Optimisation
for transportation of modules from Lucknow to Dharwad
Innovation Project :
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By Road - DAC
By Road On 40 Ft Trailer
By Road On HCV Truck
By Road On MCV Truck
By Train
Scenario-II
Scenario-III
Despatch of Modules from TML Lucknow to TMML Dharwad
Options
Scenario- I : Transportation of 1.5 Chassis through Trailer
Scenario-II : Transportation of 2 Chassis through Trailer
Scenario-III : Transportation of Chassis through road (DAC)
Innovation Project :
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1
2Front module
Rear module
Transportation of 1 Chassis ( 1 Front & 1 Rear module) in 28 ft Trailer ( Existing Practice)
Trailer Bed
Existing Practice
Innovation Project :
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1
2
3
Front module
Rear module
Transportation of 1.5 Chassis ( 1 Front & 2 Rear module ) in 40 ft Trailer (Existing Practice)
Trailer Bed
Scenario -I
Innovation Project :
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Front module
1
2
3
Rear module
Transportation of 1.5 Chassis ( 2 Front & 1 Rear module ) in 40 ft Trailer (Existing Practice)
Scenario -I
Trailer Bed
Innovation Project :
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Improved method ofmodule transportation
Scenario-II Improvement in stacking of modules and maximizing
trailer utilisation Transportation trials of 2 Chassis (2 Front & 2 Rear)
in a 40 ft Flat Bed Trailer
Innovation Project :
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2 Front & 2 Rear modules loaded on 40 ft flat bed trailer1
4
3
2Space created on trailer bed for storage of CNG cylinders and other spares
Rear module
Front module
Scenario -II
Innovation Project :
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Stand welded with trailer bed
Stand welded with trailer bedEngine side
Suspension side
Wheel movement arrestedby wheel chock
Scenario -II
Arrangement for Rear moduleInnovation Project :
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Rear Module
Front Module
Provisions for Front module
Front end of front modulerested on rear module frameand clamped by U-bolt
Front module tyressupported on stand
Rear end Supported on stand
a
b
c
Scenario -II
Arrangement for Front moduleInnovation Project :
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Engine sideResting at front side
c
U BOLT
Both the front modules rested on commonstand
Front module restedon rear module and clamped with the help of U-bolt
b a
Supporting stand fortyres
Arrangement for Front moduleInnovation Project :
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Results of transportation trial conductedin August09 (Scenario-II)
Scenario -II
Innovation Project :
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Front module unloaded atDharwad
Rear module unloaded atDharwad
Rear module
Trailer on the way to Dharwad
Transportation Trial
Scenario -II
Innovation Project :
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Improved method ofchassis transportation
Drive Away Chassis- Transportation of LPO-1618 RE LEChassis through road
Scenario-III
Innovation Project :
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To integrate the front and rear module so that complete chassis can be driven down to Dharwad as a Drive away chassis for Bus body building.
Front Module
Rear Module
Integrated Chassis
Objective
Innovation Project :
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Proper ground clearance
at engine side
6300 mmWheel base
Requirements for Drive Away ChassisRequirements for Drive Away Chassis
Temporary Support Structure to be used for connecting Front & Rear Modules
Innovation Project :
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Box section support with pre-tensioning members to arrest the sagging of rear module
Temporary Support Structure
Rear Module
Details of Temporary Support StructureInnovation Project :
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320mm 220mm
390mm530mm
Ground Clearance-Before Improvement(Bellows in fully inflated condition)
Ground Clearance-After Improvement(Bellows in fully inflated condition)
In-house Trial ResultsInnovation Project :
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IN-HOUSE TRIAL RESULTS OF LPO-1618 RE LE
Innovation Project :
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Status of chassis at Jhansi
Transportation trial-DAC
Status of chassis at Dewas
Innovation Project :
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Improved method ofchassis transportation
2-Tier Drive Away Chassis- Transportation of LPO-1624 RE LE Chassis through road.
Scenario -IV
Innovation Project :
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Objectives:
To monitor the performance of 2-Tier Drive Away Chassis and collect transit observations for further improvement in design of temporary support structure and other accessories
To establish the process of dismantling LPO 1624 RE LE front & rear modules which is loaded on the DAC along with temporary support structure at TMML, Dharwad
To establish the process of recycling of temporary support structure and other accessories.
Innovation Project :
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LPOLPO--16181618--RELE CHASSIS AT LUCKNOW BEFORE RELE CHASSIS AT LUCKNOW BEFORE DISPATCH.DISPATCH.
Innovation Project :
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Status of chassis at Dewas
No sagging of Rear module
No sagging of Front module
Innovation Project :
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Status of Chassis at Pune
Innovation Project :
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Transit Observations checklist:
Innovation Project :
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Transit Observation Photographs.
Complete module at a glance at TMML Complete module at a glance at TMML DharwadDharwad
Rear End sideRear End side Front End Front End sideside
Innovation Project :
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Information shared with Dharwad
Process of DismantlingProcess of Dismantling
Front module U bolt unfastening
U bolt unfastening of Middle cross-member Unfastening of rear module mtg. bolts from middle stand.
Unfastening of tension rod from rear module.Unfastening of bolts from rear stand.
Unfastening of additional plate at rear end of rear module and re-bolting after removing both the additional plate.
Lift Rear module & keep on stand.
Lift Front module & keep on stand.
Upper tear is unloaded and kept aside.
Innovation Project :
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Information shared with Dharwad
Process of DismantlingProcess of Dismantling
Rear Module resting on stand
Front Module resting on stand
Place jack at the base of middle structure.
U-bolt dismantling on rear module
Wiring harness removal
Air pipe unfastening
Unfastening from inside of Front module.
Spare wheel removal
Rear module dismantling. From outside
Rear module dismantling from inside
Front module dismantling.
Front module unfastened from middle structure.
Middle structure removed Rear and Front module separated.
Middle pillar dismantling
Additional structure Unfastening
Unfastening of U bolts front mod. side.
Innovation Project :
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vv TML Quality Check pointsTML Quality Check points::
Mounting of rear and front modules to be checked thoroughly.
All the bolts to be tightened with nyloc nut and properly torqued.
All the quality checkpoints e.g PDI, Dynamometer testing, road testing etc to be assured before dispatch.
vv TMML Quality Check points:TMML Quality Check points:
Check for module sagging by measuring heights from ground level at pre-defined positions on front and rear module
Check for tyre wear
Functional testing of chassis to be done prior to dismantling of modules
Hole elongations to be checked after dismantling of modules
Innovation Project :
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Observation after Dismantling
No elongation of mounting holes at front and rear module mounting locations
Uniform rear module height from ground level . No prominent tyre wear
Innovation Project :
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Scenario-I -1.5 Chassis/Trailer II - 3 Chassis/Trailer III Drive away Chassis IV2 Tier Drive away Chassis
Learning from successful implementation of this Project :
Raise the bar when the solution is too obvious.
Experiment & experiment and don't let the idea fail.
Keep on exploring newer ways of solving the problem till you succeed.
48000
36000
24000
12000
I II III IV
Reduction by 75%3.75
2.81
1.91
0.94
I II III IV
Carbon emission in T CO2 per Chassis transportation
Freight - Rs/Chassis or module set
Scenario Scenario
Learnings
Results :
Summary
Jun09 July09 Aug09 Sep09 Nov09 Dec09 Feb10
Innovation Project :
Sohrabji Godrej Green Business Centre- CVBU LUCKNOW 9494
S.No Name of EnCon idea * Source of EnCON idea*
Ideaoriginated in
FY **
Extent of man-power involved***
Progress ofimplementation
1 Ins tallation of VFD in AHU of CAB office block at Metrology and Plant Head building
Middle Management & Maintenance Engineer
2007-08 Top Management, corporateoffice, Middle Management,Energy Cell, Project Execution Group, Maintenance Team.
Idea Implemented
2 Replaced all the conventional cu ballas t used in tube lights with the energy efficient electronic choke
Workmen & Supervisor 2007-08 Workmen, Supervisor, Sectional Head, Energy Cell & Divisional Head
Idea Implemented
3 Ins tallation of energy saver at ETP & HT shop to reduce the energy consumption by without effecting the required lux level
Middle Management & Maintenance Engineer
2008-09 Top Management, corporateoffice, Middle Management,Energy Cell, Project Execution Group, Maintenance Team.
Idea Implemented
4 Ins tallation of cpacitor bank at Transmission factory to improve the PF
Middle Management & Maintenance Engineer
2008-09 Top Management, corporateoffice, Middle Management,Energy Cell, Project Execution Group, Maintenance Team.
Idea Implemented
5 In HT shop previously the whole cooling plant used to be put ON through out the year now cold sump pump and cooling tower fan switched off during winters (approx 120 days). And the pipe line of Hot sump is directly connected to the feeder in which cooling
Workmen & Supervisor 2009-10 Workmen, Supervisor, Sectional Head, Energy Cell & Divisional Head
Idea Implemented
6 Frame Shop: Previous ly the long member transfer roller conveyors were running continiously whether the member is present over it or not. Now the provision is provided in which once the member is reached its desired location the motors of the conveyors get
Middle Management & Maintenance Engineer
2009-10 Top Management, corporateoffice, Middle Management,Energy Cell, Project Execution Group, Maintenance Team.
Idea Implemented
Involvement of Employees & Extent of team work in Encon
Towards Excellence
-
Sohrabji Godrej Green Business Centre- CVBU LUCKNOW 95
Preliminary Energy audit
Detailed Energy audit
Plant Coordinator
GO AHEAD
Energy savings discussion and presentation
GO AHEAD for Implementation
Energy savings monitoring and interim report to Energy Mgmt Cell
Acceptance of Proposal
Submission of Techno commercial proposal
Team formation
Energy Management Cell Implementation Methodology
Sohrabji Godrej Green Business Centre- CVBU LUCKNOW 96
Frequency of review of energy consumption and energy conservation projects: Daily, Weekly, Monthly Quarterly, Half-yearly & Annually
Daily Energy Consumption Performance Report: -Daily monitoring, analyzing and reporting of various key energy resources such as Electricity, Water, Compressed Air,
Fuels. The Report is analyzed in detail at each shop Level in-charge w r t to production activity on daily basis. The daily Energy Performance vis--vis target is also displayed at shop floor to increase the awareness within entire teams in the shop.Monthly Performance Report: -
Monthly report is generated on the basis of data from monthly consumption along with data of production and indicates the Monthly and cumulative Performance Ratios of major areas like CV,IBF,TMML,HT shop. All the Sp. energy, Sp. Compressed air, Sp. Compressed air is reported to the individual departmental heads.
Monthly Report To Plant Head & Divisions: -Executive summary Report giving monthly and cumulative performance and the variance with respect to targets set ,
previous year's performance, etc for the whole year and the corresponding period is sent to respective Divisional Heads for information & initiating necessary improvement actions. The report is also send to Plant Head for his perusal & information. Plant Head also reviews the Monthly report in the monthly Variable Conversion Cost (VCC) review meeting.
Quarterly Performance Report:-This report gives the consumption, Monthly and cumulative, performance trends, and efforts taken. This report is sent
to Plant Head (CVBU - Pune) & respective Divisional Heads.
Half yearly Performance Feed back to Plant Head & Divisions: -
The performance of the Divisions with reference to the target both monthly and cumulative along with the performance expected to achieve w r t the Target.
Annual Performance Report: -This report giving consumption performance of various areas along with the efforts taken by various Divisions. This
report is released to - Finance Division as Input for disclosures for Director's Report.
Energy Management Cell Prepares the Energy report Daily, Monthly( M), Quarterly (Q), Half-yearly (H) & Annual reports. Plant Head & MD reviews M, QY, HY, Annual reports
Review by : Energy Auditor & Managers
Review by : Energy Auditor & Asst GM
Review by : Energy Auditor ,Asst GM, GM & Plant Head
Review by : Energy Auditor ,Asst GM, GM, Plant Head, Sr. VP &MD
Review by : Energy Auditor ,Asst GM, GM, Plant Head, Sr. VP &MD
Review by : Energy Auditor ,Asst GM, GM, Plant Head, Sr. VP &MD
Monitoring & reporting
-
Sohrabji Godrej Green Business Centre- CVBU LUCKNOW 97
Monthly Energy Report to Top Management
Q,H & Annual Energy Report to Top ManagementVARIABLE CONV COST (Rs. /Eq. Veh. ) 09-10
CV Factory VARIABLE CONV COST (Rs. /Eq. Veh. ) 09-10 Transmission Factory
Shop wise Energy consumption VARIABLE CONV COST (Rs. /Eq. Veh. ) 09-109
38404098 4001
4600462148115011
4409 4145
50834740 4717
3611 367737053733 3919 3920 3820 3794
38903605 36894671
Ap
r-0
9
Ma
y-0
9
Ju
n-0
9
Ju
ly-0
9
Au
g-0
9
Se
pt-
09
Oc
t-0
9
No
v-0
9
De
c-0
9
Ja
n-1
0
Fe
b-1
0
Ma
rch
-10
Actual 09-10 Actual 08-09
584639 610
747772856
925
701 662
885774
935937 916933 890 885 863 840
790863
963 951869
Ap
r-0
9
Ma
y-0
9
Ju
n-0
9
Ju
ly-0
9
Au
g-0
9
Se
pt-
09
Oc
t-0
9
No
v-0
9
De
c-0
9
Ja
n-1
0
Fe
b-1
0
Ma
rch
-10
Actual 09-10 Actual 08-09
OTHERS7%
RECON2%
EAST COMP46%
IBF6%
TRAN FACT12%
CV FACT11%
MARCOPLO16%
8631011 942
1259
13431472
1618
1167 1074
17571794 1724
14091346
1395
1305 1274 1249 1231 12191427 1434 14261424
Ap
r-0
9
Ma
y-0
9
Ju
n-0
9
Ju
ly-0
9
Au
g-0
9
Se
pt-
09
Oc
t-0
9
No
v-0
9
De
c-0
9
Ja
n-1
0
Fe
b-1
0
Ma
rc
h-1
0
Actual 09-10 TGT 09-10
To Plant Head
Prev Yr Consp
Prev Yr Eq. Veh
Specific Energy
Consp till Dec
Eq. veh till Dec
Specific Energy
Consp till Dec Eq. Veh till Dec
Specific Energy
08-09 08-09 08-09 08-09 08-09 till Dec 08 09-10 09-10 till Dec 09Units Nos. KWH/Eq. Veh Units Nos KWH/Eq. veh Units Nos. KWH/Eq. veh
CV + IB Fact 5707472 29,101 196 4,479,432 22,069 203 5,408,501 36,580 148
Trans Fact 3834062 4,265 899 3,026,580 3,251 931 2,905,410 2,833 1,026
Others 2453210 33,366 74 2,202,250 25,320 87 2,157,571 39,412 55
Total 11994744 33,366 359 9,708,262 25,320 383 10,471,482 39,412 266
FromEnergy Auditor Asst General ManagerEnergy Auditor Cell Central Maint & Plant Services
YTD Status
Area
Ist Jan 10
Sohrabji Godrej Green Business Centre- CVBU LUCKNOW 98
10686
20686
29236
37836
45436
57436
0
10000
20000
30000
40000
50000
60000
2004-05 2005-06 2006-07 2007-08 2008-09 2009-10
Tress Planned for plantation in 2009-10 In the Plant Premises : 12,000 nosThru. CSR & at Vendor end (Through Associates) : 1 Lakh no.s
Cum
. No.
of t
rees
pla
nted
Environmental Projects Tata Motors CVBU Lucknow is plant is having plot area of 600 Acres. We have Green cover of 52%. We celebrate World Environment Day, Earth Hour etc every year in the plant, at Vendor end and also at Villages through CSR teams ( Corporate Social Responsibility ). Utilise every opportunity for tree plantation & spreading the awareness on its importance across all the stake holders i.e. Community, Employees, Vendors & Business associates
Lucknow Plant Lake View
Afforestation
-
Sohrabji Godrej Green Business Centre- CVBU LUCKNOW 99
2006-07Environmental Projects
Sohrabji Godrej Green Business Centre- CVBU LUCKNOW 100100
2007-08Environmental Projects
-
Sohrabji Godrej Green Business Centre- CVBU LUCKNOW 101101
2008-09Environmental Projects S.No Year Area
Trigger for improvement
Process improvement Result achieved Photographs
1 2008-09 Whole Plant
Facility required at the bore well site to monitor the frequency variation in ground water level
Installation of Peizometer well at different location both in E.complex & W. complex to monitor th level of ground water aquifer & thereby complying consent conditions
Tracking/ mainting records for the depletion or incres in ground water table
2 2008-09 CTP site
Waste coolant is having very different coplex chemical property & needs separte treatment otherwise it contaminates th wholw homogenous mixture & hinders in treatment process
Instllation of Coolant treatment plant for the effective treatment of waste coolant as discharged from grinding machine at HT & Gear shop
Coolant is being treated to crack the heavy emulsion & attain a level of parameters which doesn't disrupt after mixing with the quality of industrial effluent
- -
3 2008-09
STP Site in Eastern Complex
Facilitates the provisions for heavy load of domestic effluent
Installation of one 1200 KLD FAB based STP for treating the effluent load generated from different process & activity & meeting statutory environmental norms
Complete treatment of sewage for achieving the parameters well below the statutory specified limiting value
4 2008-09
W.complex & Eastern complex
Analysis required for the quality of influent & & treated effleunt
Dedicated Environmental Laboratory for undertaking testing of essential parameters & also regulating the dosing of chemicals
Determination of chemical dosing quantity as per influent quality for effective treatment
- -
5 2008-09
STP Site in Western Complex
Inadequate provision for chemical & bilogical treatment of the increased sewage load
Enhancement of two no. of 400 KLD Fludized bed reactor (FAB) based STP to cater the enhanced domestic sewage load & meeting statutory environmental norms
Complete treatment of sewage for achieving the parameters well below the statutory specified limiting value
Sohrabji Godrej Green Business Centre- CVBU LUCKNOW 102102
2009-10Environmental Projects S.No Year Area Trigger for improvement
Process improvement Result achieved Photographs
1 2009-10
Primary ETP Site in Eastern Complex
Waste water generated from Paint shop contains very complex orgnic paint resins which essentially requires prior physical & chemical treatment before sending it to secondary treatment
Installation of one 450 KLD primary ETP at paint booth meeting for undertaking batch process treatment
Reduction & prcipitation of heavy organic particulates, heavy metals etc.
2 2009-10Western Complex
Uncontrolled use of fresh water resource at the major point sources
Installation of water flow meter at canteen, Recon shop, frame paint booth & cowl shop for tracking & regulating fresh water consumption
Tracking & regulating the water consumption rate
- -
3 2009-10
Eastern Complex
Expansion project Installtion of 6 nos. of new borewells in E. Complex to cater the high water demand for domestic, industrial, process, fire service etc.
Fullfillment of water demand for manufacturing process
- -
4 2009-10
Weatern Complex
Earlier we had no recirculation system for the wash water generated due to washing of cowls
Greater concern for water conservation has prompted us to install recirculation system
Fresh Water resourceConservation
5 2009-10
ETP Site in Western complex
Inadequate provision for chemical & bilogical treatment of the increased effluent load
Enhancement of one 400 KLD hi-tech ETP for treating the enhanced effluent load generated from different process & activity & meeting statutory environmental norms
Complete treatment of effluent for achieving the parameters well below the statutory specified limiting value
6 2008-09
ETP Site in Eastern complex
Heavy load of effluent discharged during the process & operation containg homogenous mixuture of different type of complex contaminants
Installation of one 1800 KLD hi-tech secondary ETP for treating the effluent load generated from different process & activity & meeting statutory environmental norms
Complete treatment of effluent for achieving the parameters well below the statutory specified limiting value
TCFPaint Shop
2009-10
-
Sohrabji Godrej Green Business Centre- CVBU LUCKNOW 103
Union LeadersGather for tree plantation
Senior LeadersMr. A Chharia and U Tauheedplanting a tree
Display of various posters and Paintings at the Service Provider site
Service providersteam planting trees at Eastern complex
Vendor end team planting trees at vendor end
CSR plantation at Jainabad village
Winners
Winners
Greenathon : Flag off by Mr.MC Pandey
World Environmental Day Celebrations In the Plant & at Vendors end
Sohrabji Godrej Green Business Centre- CVBU LUCKNOW 104
D . Projects linking with Carbon Emission ReductionLinking with Reduction in t CO2Environmental Projects : Few Examples
-
Sohrabji Godrej Green Business Centre- CVBU LUCKNOW 105
D . Projects linking with Carbon Emission ReductionLinking with Reduction in t CO2Environmental Projects : Few Examples
Sohrabji Godrej Green Business Centre- CVBU LUCKNOW 106
D . Projects linking with Carbon Emission ReductionLinking with Reduction in t CO2Environmental Projects : Few Examples
-
Sohrabji Godrej Green Business Centre- CVBU LUCKNOW 107
D . Projects linking with Carbon Emission ReductionLinking with Reduction in t CO2Environmental Projects : Few Examples
Sohrabji Godrej Green Business Centre- CVBU LUCKNOW 108
Solar Power Plant 25KW x
4 nos - Grid connect type
Solar Garden lights for
Lake lightingSolar Traffic controlling Road Flasher for Plant premises
Wind driven turbines-1200 nosTotal Capacity 39 Lakh CFM
Light Pipes 500 Nos
Switching to Renewable energy Source
Other Renewable Projects in pipe line for 2010-11 :
Energy Generated (Lac kWh)
Annual Savings (Rs. In
Millions)
Energy Generated (Lac kWh)
Annual Savings (Rs. In
Millions)
Energy Generated (Lac kWh)
Annual Savings (Rs. In Millions)
Wind 24.5 MW 559 167 576 227 529 175 Solar photovoltaic 110 W 1,318 0.005 1,318 0.005 1,318 0.005 Turbo ventillators
1,403,663 CFM 619,488 2.48 495,590 2.12 650,462 2.78
Type of RES Installed Capacity 2009-102007-08 2008-09
Replacement of Electrical Energy with RES
Replacement of Thermal Energy with RES
Equ Fuel Savings
Equ Fuel Savings
Equ Fuel Savings
(kL) (kL) (kL)Solar Thermal 700 LPD 0.53 16,960 0.53 19,080 0.73 26,280
2008-09Annual Savings
(Rs.)
Annual Savings (Rs.)
Type of RES Installed Capacity
2007-08 2009-10Annual
Savings (Rs.)
-
Sohrabji Godrej Green Business Centre- CVBU LUCKNOW 109
Saving Potential
Capital investment
KWH Rs in Lakhs1 Celltec Pad Instead of Water Jet
Nozzle388800 Less than jet
nozzlesISHRAE - Indian Society of Heating Refregirating & Airconditioning Engineers
MARCOPOLO, E.C 2007-08
2 VSD Air screw Compressor for compressed air
300000 45Lakhs/each
Atals copco, Sweden
Eastern Complex 2007-08
3 Energy saver in street lights 109500 200000 CII Seminar, Chandigarh
Eastern Complex 2007-08
4 LPG gas heating 20000 500000 BEE Seminar, Kanpur
Western Complex 2007-08
5 VFD for AHU 10000 125000 CII Seminar Chennai
Eastern Complex 2007-08
6 Insulation of Closed cell polyethylene with metalized layer in FDV ducting
14256 8.5 ISHRE SEMINAR All over E.C 2008-09
Photographyear of implementati
on
SN Details of Technology absorption
Absorbed/Learnt from
Implemented in Plant / Sub
location
Technology Absorption Details of year wise efforts made in technology absorption relating to energyTechnology Absorption
Sohrabji Godrej Green Business Centre- CVBU LUCKNOW 110
Saving Potential
Capital investment
KWH Rs in Lakhs7 Backward curve centrifugal
Blower instead of forward curve1069200 Almost same
as backward curve
KRUGER , Germany
All over E.C 2008-09
8 Centrifigual compressor for catering of air CFM base load.
200000 75 Lkhs/each
Atals copco, Sweden
Eastern Complex 2008-09
9 Microprocessor based ES system for centralised controlling of compressors as per air CFM demand.
180000 12 Lakh Chicago Pneumatic, US
Eastern Complex 2008-09
10 Energy efficient air circuit breakers
7884 4500000 CII Seminar, Chandigarh
Tata Motors Plant 2008-09
11 LED type street lights 52560 1500000 CII Seminar, Delhi Tata Motors Plant 2009-10
12 Emergency lights through solar panels
2000 160000 Seminar orgainised by TATA BP solar
Western Complex 2009-10
13 Solar based Power Plant 225000 7500000 Renewable Energy Work shop by MNRE-India at New Delhi
Western Complex 2010-11(Work in
progress)
year of implementati
on
PhotographSN Details of Technology absorption
Absorbed/Learnt from
Implemented in Plant / Sub
location
Technology Absorption Details of year wise efforts made in technology absorption relating to energyTechnology Absorption
-
Sohrabji Godrej Green Business Centre- CVBU LUCKNOW 111
Targets 20011-12 :: Reduction in total carbon emissions : 60 %
1657915114
11247
8500
6632
2000
4000
6000
8000
10000
12000
14000
16000
18000
20000
2007-08 2008-09 2009-10 2010-11 2011-12
T C
O2
Total Carbon reduction : T CO2 : 913Upto July10
60%
Summary Carbon Emission Reduction
Sohrabji Godrej Green Business Centre- CVBU LUCKNOW 112
Impact of ENCON, Innovation & Carbon emission reduction measures on reduction of cost of production goods.
Summary Impact on Plant Production
-
Sohrabji Godrej Green Business Centre- CVBU LUCKNOW 113
Process Waste
Output Waste
Input Waste
Nothing is Waste in this world !!!
Plant Internal &
External Authorized Agency
External Authorized Agency
Reuse
Incinerate
Recycle
Waste Management
Sohrabji Godrej Green Business Centre- CVBU LUCKNOW 114
Qty of waste generated
Qty of waste generated and
utilised2009-10 2009-10
1 Packing Wood From Packing Kg 3,079,418 3,079,418 13 For Tool Boxes, with Drive away Chassis, Stand or pallet for storing material
2 Packing Carton From Packing Kg 800,240 800,240 4 Sold to recycler for reuse of the same.
3 Packing Polythene From Packing Kg 79,210 71,289 2
4 Packing Jute Cartons From Packing Kg 167,310 158,945 11
5 Process Used Cutting oil From Machining & Grinding Lt 8,610 6,027 22 Sold to recycler for filteration and resale
6 Process Used Engine oil From Engine Reconditioning Kg 2,730 1,911 7 Sold to recycler for filteration and resale
7 Process Paint Sludge From Paint Booths Kg 30,000 30,000 9 Disposed as incinerable waste
8 Process Used Coolant From Machining & Grinding Kg 100,000 100,000 2 Disposed as incinerable waste
9 Process ETP Sludge From ETP Drying Bed Kg 30,000 30,000 0.05 Disposed as incinerable waste
10 Process Paint Drums - MS From Painting Process Nos. 35,000 35,000 - - Sold to recycler for re-use after cleaning
11 Process Plastic Drums - Coolant/ OilFrom Oil Process Nos. 3,000 2,100 0.002
Sold to recycler for re-use after cleaning
12 Process Chips From Gear Cutting Kg 60,000 39,000 - - Sold to recycler for secondary use of steel
13 Process MS OffcutsFrom Construction & Fabrication
Kg 100,000 77,000 - -
Sold to recycler forsecondary use of steel, for fabrication of stands and fixtures for internal use
SN Type of the
Waste used
Name of the Waste generated
Details of the Waste
generated
UOM
Present usage of the waste
Snap shotsWaste fuel as % of total
energy
Sold to recycler for reuse of the same.
Total Waste fuel is 70% of the total energy consumption
Waste generated = Waste utilisedWaste Management
-
Sohrabji Godrej Green Business Centre- CVBU LUCKNOW 115
ISO 14001 certification
2003-04 2007-08 2009-10 2011-12
ISO/TS certification
OHSAS 18001:2007
Certifications for Lucknow
NABL certification
All Energy & Environment certifications
from regulatory bodies.
Implementation from TS/ISO/OHSAS
Sohrabji Godrej Green Business Centre- CVBU LUCKNOW 116
2005-06 2009-10 2011-12
ISO journey for vendors
ISO certified : 268
TS certified: 195
ISO 14001 - 30
Aim: 100% vendors ISO/TS certified
Certifications for Channel partnersImplementation from TS/ISO/OHSAS
-
Sohrabji Godrej Green Business Centre- CVBU LUCKNOW 117
S.No
Clause NCR Description Correction Corrective Action Status
1 4.5.2
Environmental board displayed outside the main entrance does not have updated information on Air & water consent with validity & analysis of treated effluent There is no evidence of analysis of used oil before disposal to authorised recyler
Updated information on Air and Water consent with validity & analysis report of treated effluent have been mentioned on the Environmental information board. Used oil to be disposed has been analysed.
Display of updated information on Air and Water consent, analysis report of treated effluent & analysis of used oil as per requirement will be reviewed in MR meeting in order to maintain continuity. Henceforth, used oil will be analysed before disposa
Closed
2 4.3.2
Following changes in applicable legal requirements not identified in Legal Register Hazardous Waste Management & Handling Rules amendments -2008 Petroleum rules 2002 Indian Electricity rules amendments-2002
The changes in applicable legal requirements have been identified in the Legal register and the register has been revised.
Subscription to legal update has been renewed and updates are being received. Moreover, henceforth, alongwith review of legal compliance ; updation of Legal register also will be reviewed in MR meeting.
Closed
3 4.3.1
Aspect-Impact related to the following activities not identified Storage and usage of CO2 Cylinders in Frame Shop Leakage of Compressed Air Generation of used oil filter
Use (in welding) and storage of CO2 cylinders in Frame shop has been identified in IER of Frame CX Leakage of compressed air has been identified in IER of Engg. Services dept. Generation of used oil filter has been identified in IER.s of HT shop.
Review of IER will be discussed in MR meeting as a regular review mechanism.
Closed
TS 16949, ISO 14001 & ISO 18001TS16949
OSHAS 18001 : 2007
Corrective actions & Status Report
S.No Clause NCR Description Correction Corrective Action Status
1 4.5.2
Ambient air monitoring doesnt include all the parameters i.e.Pb is not being monitored as per the Enviornmental Protection Rule 1986 clause 3(3B) and schedule VII.
Monitoring of Lead (Pb) concentration in ambient air quality has been started.
Identified legal and other requirements will be complied with in an unbiased manner
Closed
Sohrabji Godrej Green Business Centre- CVBU LUCKNOW 118
ISO 14001 : 2004
FORMAT OF Non-Conformity Reports
TS 16949, ISO 14001 & ISO 18001 Corrective actions & Status Report
S.No Clause NCR Description Correction Corrective Action Status
1 8.2.3.1
A systematic approach of performing process studies on new assembly processes to establish the objectives for process capability, reliability, maintainability and availability is not in place.
System made to establish and monitor targets for process capability, reliability, maintainability and availability. RFQ will capture all the requirements and in machine acceptance criteria form it will be communicated to the user
Procedure for product transfer process (LAPR-P02A) covering process design and development revised including targets for productivity, process capability, reliability, maintainability, availability.
Closed
2 8.1.2
Understanding on basic statistical concepts and utilization of control charts is inadequate.
(1) 1. Control limits established. UCL = 0.05, LCL = 02. Sample size increase 10 per day i.e 5 / shift(2) Cpk observed 3.87 was for ratio 41/6 pinion whereas during audit ratio running was 45/7 pinion. CpK study carried out for this ratio and found 0.7.
1. Training for SPC planned in 3rd week of Dec' 092. Ratio wise CpK will be calculated3. Inspection frequency will be decided based on the CpK results
Closed
3 7.3.3
Out put of manufacturing process design is not adequately addressed to facilitate effective process control. Ex. Control plan for machining for pinion 41/6 does not include surface finish and the process parameters such as speed, feed rate etc.
Control plan for pinion 41/6 revisited.
1. Training on control plan completed
Closed
All NCRs closed
-
Sohrabji Godrej Green Business Centre- CVBU LUCKNOW 119
Knowledge through Learning & Sharing Replication of Best Practices
TKC-Tata Knowledge ChainAll TATA Group companies can access the TKC internet based portal.Every one can learn & share the knowledge
Vibes- Tata Motors IntranetAll TATA Motors employees can access the VIBES-the Intra net portal through which knowledge can be
enhanced through learning & sharing.
Knowledge through Learning (KTL) of CVBU Lucknow Plant, in 2009-10 year contributed 3680 numbers of knowledge pieces in the KTL Book of CVBU. Also a CD comprising of all the improvements were released. The divisions /departments who contributed significantly were also felicitated subsequently.
In-house/External training program
Knowledge sharing throughPlant visits
Sharing of the best practices implemented though Video Conferencing
Divisions / Departments which contributed significantly were
Planning, Manufacturing, Central Quality, Transmission
Factory, Assembly Line planning, Sourcing,
Vehicle Factory, Lean Manufacturing, PTPA,
PE, Integral Bus Factory, Sustenance &
Training Centre
Plant head inaugurating the KTL CD
Yugandhara Is the thought at the core of the Tata Motors Climate Change web site. It brings together information and experiences regarding Climate Change & Energy Conservation initiatives across the Tata Motors. Every employee across the Tata Motors is having the access this web site.
Sohrabji Godrej Green Business Centre- CVBU LUCKNOW 120
KAIZEN Exercises within Plant & at TMLs Vendors
Kaizen Sustenance (%)
8278
8184 84 84
60
70
80
90
08
-09
Ist
Qtr
IIn
d Q
tr
IIIr
d Q
tr
IVth
Qtr
09
-10
Better
Target : 80
TM & LS Participation ( % )
81
21
40
76 82 82
0
20
40
60
80
100
08
-09
Ist
Qtr
IIn
d Q
tr
IIIr
d Q
tr
IVth
Qtr
09
-10
Better
Target : 80
No of Kaizen Events
103
21
48
88
108 108
020
4060
80
100120
08
-09
Ist
Qtr
IIn
d Q
tr
IIIr
d Q
tr
IVth
Qtr
09
-10
Better
Target : 100
Major Kaizen
Vendor Kaizen at M/s. Suprabha Industries
Productivity improvement kaizen at BIW
Installation and layout finalization at M/s. Lucknow Grinding (Recon)
Process streamlining to achieve single piece flow at M/s. Narayan Engg. (Recon)
3P for cost economic shedding for tyre yard
Re-arrangement of fastener store
Kanban implementation in Frame CX
Employee Participation in %
Kaizen Sustenance in %No. of Kaizen events
Replication of the Best Practices implemented on Energy conservation Through Associates
TATA Motors Ltd. - CVBU Lucknow has conducted special drives at business associates /Vendor end to optimise the over all vendor management process. We have conduced KAIZENs AT VENDORs END. The results of this special drive are,
-
Sohrabji Godrej Green Business Centre- CVBU LUCKNOW 121
Aligning associates to Changing Market Scenario & Optimising overall productivity process
TATA Motors Ltd. - CVBU Lucknow has conducted special drives at business associates /Vendor to optimise the over all vendor management process. We have conduced QUALITY AT SOURCE event in November09 & December09. The results of this special drive are,
Sohrabji Godrej Green Business Centre- CVBU LUCKNOW 122
TATA Motors Ltd. - CVBU Lucknow has conducted various programs like Technology Up gradation awareness program, Modern trend in vehicle assembly system, Green Initiatives, Energy Conservation measures etc to business associates / vendor to enhance the productivity & quality of material they supply inturn reduce the cost of poor quality.
The Quality Month communication has been conducted in December2009 at Tata Motors-Lucknow plant and all the associates/vendors participated the event. Various rewards been given to vendors for their good quality of product. Couple of snap shots are,
Replication of the Best Practices implemented on energy Through Associates
-
Sohrabji Godrej Green Business Centre- CVBU LUCKNOW 123
Senior Management team of TATA Motors Ltd. - CVBU Lucknow regularly visits the Associates/Vendors plant to constantly motivate their employees on Safety, Energy conservation, Quality, Cost, Deliverability & Environment. Here are couple of snap shots of sr. mgmt visit to neighboring Vendor plants.
Replication of the Best Practices implemented on energy Through Associates
Sohrabji Godrej Green Business Centre- CVBU LUCKNOW 124
Tata MotorsLucknow
Tata MotorsPune
Tata MotorsJamshedpur
Tata MotorsPantnagar
Tata MotorsSanand
Jagaur&
LandRover
Tata DaewooHispano
Vendors Associates
CIIBEEISHRAE
Earnst & YoungMckensy
TKCInnovista
CSR
Safety
Yugandhara
ISO 9001
OSHAS
TQMS
KNOME
EnterpriseSystem Manual
Knowledge Pond
Vibes
Climate Change
-
Sohrabji Godrej Green Business Centre- CVBU LUCKNOW 125
0.31
0.27
0.19
0.1
0.15
0.2
0.25
0.3
0.35
2007-08 2008-09 2009-10
%
Vendor Quality Incoming PPM level
Direct Material Cost reduction
Results of the replication arising out of Best Practices implemented on energy front through associates areProcess has been institutionalized at Lucknow
Rs
in C
rore
s
Energy Cost as a % of manufacturing cost
Energy Cost as a % of
manufacturing cost in 2009-10 is
0.192 % Best in Class
20
06
-07
Better
Better
Better
Sohrabji Godrej Green Business Centre- CVBU LUCKNOW 126
List of Certifications:-1) Quality Certification: ISO/TS -16949.2) Environment Certification: ISO -14001 : 20043) Occupational Health & Safety Management SYSTEM Certification: OHSAS - 18001
List of Awards
2007-2009Rewards & Recognitions
1) Tata Motors CVBU-Lucknow Plant bagged the most prestigious Excellent Energy Efficient Unit Award-2009 conducted by CIIon 19th & 20th of Nov2009 at Chennai.
2) CVBU Lucknow won the second prize in the prestigious INSSAN Award for Excellence in Suggestion Scheme at the Annual Regional Convention 2010 of INSSAN (Indian National Suggestion Schemes'' Association)- Eastern India Chapter.
3) Tata Motors CVBU-Lucknow Plant received the IME Award 2008.(IMEA-Indian Manufacturers Excellence Award)
4) Tata Motors bags the NDTV Profit Business Leadership Award 20085) Tata Motors has been ranked First in India in Investor Relations, in the Thomson Reuters
Extel Asia (ex-Japan) Survey 2008.6) Tata Motors has been awarded the 'Top Exporter Gold Trophy in the Large Enterprise category by the Engineering
Export Promotion Council (EEPC) for the year 2006-07.7) Tata Motors has received the Emerson Network Power and Express Computer Uptime Champion Award 2007 The Aggregates Business of Tata Motors' Commercial Vehicle Business Unit has won the 'Best Supplier Award 2007
from Escorts Construction Equipment Ltd (ECEL).
1)
2)
3)
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Sohrabji Godrej Green Business Centre- CVBU LUCKNOW 127
Our Message through this presentation is
Systematic, Sustainable, Continual improvements,
Knowledge sharing, Innovation, and Team Work
are the core pillars to make a plant an
Excellent Energy Efficient unit
Thank You ! ! !
Sohrabji Godrej Green Business Centre- CVBU LUCKNOW 128
SN Mode of transportation Rate Load Carrying Capacity
No of chassis per
Trailer
Cost per Chassis
Scenario
1 TRAILER-28 FT 48000 15T 1 48000 Existing Scenario
2 TRAILER-40 FT-3516 72000 20T 1.5 48000 Scenario - I
3 Two Chassis Transportation thru Trailer 40FT 72000 20T 2 36000 Scenario - II
4 Drive Away Chassis 1 Scenario - IIIDistance from LKO to Dharwad 1900KM, Milleage 4KMPL.Cost of fuel 17100 17100Driver - Daily allowance - Rs 250 for 6 days 1500 1500Return charges for driver 750 750Road Toll tax 4550 4550
23900Cost of Drive away Chassis transportation 24000 Scenario - III
5 2 Tier - Drive away Chassis 2 Scenario - IV
Fuel cost - 17100 9500Driver - Daily allowance - Rs 250 for 6 days 1500 750Return charges for driver 750 375Road Toll tax - Consolidated rebate 2799 1400
1202512000 Scenario - IV
Assumptions :Cost of temporary support recycling is not considered.
Innovation Project : Optimisation of Energy & Cost of Bus Module - transportation
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Sohrabji Godrej Green Business Centre- CVBU LUCKNOW 129
Heat contained in Flue Gas=Qg= m x Cp x TgFlow rate of flue gas=180 M3/hr
Density=(MW/359)x(492/(460+Tg)
Qg= 208 kcal/sec
Amount of heat required for heating the water=m x Cp x (T2-T1)
Where (T2-T1)=(65-40)=25 0 C ; m(flow rate)= 5.5 Kg/sec; Cp =1Kcal/kg c
=137.5 Kcal/ sec
Heat exchanger
Q=137.5=U A (LMTD)
U=Overall heat transfer Coeff
A= surface area
LMTD=Log Mean Temp difference
A=Q/(U x LMTD)= 0.95 M2
we selected GI coil with surface area of 1 M2