Lucas-TVS Limited Padi (Chennai)

UNIT PROFILE Lucas-TVS is a part of the TVS group. It was setup in 1961 as a joint venture of Lucas Industries plc, UK and TV Sundaram Iyengar and Sons at Chennai to manufacture automotive electrical systems.

Lucas-TVS has since inception has been maintaining its leadership as an automobile electrical systems supplier. Lucas-TVS manufactures a complete range of auto electrical products consisting of direct drive and gear reduction Starters, internal and external fan alternators, wipers, fan motors, blower motors, window lift motors, mechanical and electronic distributors, cam sensors, headlamps etc. The Auto Electricals division now has three plants situated in Padi, Pondicherry and Rewari. The Padi plant, which is the mother plant, manufactures all range of electrical automobile products. “ ENERGY MANAGEMENT POLICY “ We are committed to reduce the Specific Energy consumption (Electrical units per Equivalent Starter Unit) for our products comparing to the previous year consumption THROUGH 1. Maximize the Capacity utilization. 2. Fine tuning our Operations and Maintenance continuously to achieve the above goal. 3. Technology up-gradation with energy efficient processes and equipment’s. 4. People involvement – suggestion, Small group activities, quality improvement team and work team. 5. Waste elimination – reduce, reuse and recycling. 6. Promote awareness in every employee through training, competition and factory visit. 7. Large cell formation. 8. Process changes. 9. Setting up a system to continuously monitor the progress. 10. Comply with Energy legislation and Environment regulation. APPROACH

• Training • Formation of Task force team • Cross functional Team • QC story • Employees involvement through

1. S.G.A. (Small Group Activities) – 60 2. Suggestion Scheme & Voluntary – 1200 / year 3. Work Teams (5S, TPM, ENVIRO, SAFETY) – 520 members 4. Energy Audits (Internal & External) 5. Quality Improvement Team (QIT).

ROLE OF ENERGY MANAGER

• Prepares Annual Plan with Targets and Budget • Establish an Energy conservation cell within the firm with managements concern about the mandate

and task of the cell. • Acts as a Facilitator in implementing the Encon Projects • Interacts with core team members / cross functional team periodically to review the progress • Constitutes a team of Auditors to monitor the Retainment of Improvements • Presents the achievements to Top Management

MONITORING AND REPORTING SYSTEM

AWARENESS OF POTENTIAL SAVINGS

TOP MANAGEMENT COMMITMENT

PRELIMINARY ENERGY AUDIT

DETAILED ENERGY AUDIT

IMPLEMENT QUICK HITS

TRAINING MONITOR FEASIBILITY STUDIES

IMPLEMENT HIGHERCOST MEASURES

Feed back to topmanagement

TEAM FORMATION BY ENERGY MANAGER

HIGH COST PROJECTS

ENERGY CONSERVATION ORGANISATION - STRUCTURE

ENERGY CONSERVATION ACHIEVEMENTS

Saving = Rs. 8.37 Lakhs / Annum

C. Replacing high consumption Air conditioners 15 Nos.

BEFORE AFTER

BEFORE AFTER Before installation: Forced cooling tower with 15 HP jack water pump and 10HP blower motor for cooling the engine. Power consumption per annum = 0.90 Lakhs

J. Introduction of Solid State Power source in place of MG set in Starter Performance testing rig

Before installation: 25 HP motor is used as prime mover for DC Generator which produces 0 – 30 VDC for a load upto 2000 Amperes. The motor runs throughout the day. Motor capacity = 25 HP Power consumption per annum = 0.78 Lakhs units Operating cost = Rs 3.9 Lakhs / Annum After installation:Solid State electronics controlled power supply that consumes power only during Testing is used. The average testing time per starter is 10 seconds and daily production per line is 400 nos. The power consumption during idle time is 150 Watts. Idle power consumption = 150 Watts Power consumption per annum = 0.048 Lakhs units Operating cost = Rs 0.24 Lakhs / Annum Saving = Rs. 3.66 Lakhs / Annum

K. Modification of Infra Red Heater array in Armature varnishing plant

Before modification: The armatures are pre heated and cured in the conveyorised plant, which has 180 IR heaters installed in the sides. Each heater is of 500 Watts. Total heater capacity = 90 KW Power consumption per annum = 2.70 Lakhs units Operating cost = Rs 13.5 Lakhs / Annum After modification:The IR Heater array was re-positioned to optimise heat radiation and 40 Heaters were removed retaining the operating efficiency of the plant. Now the no. of heaters is 140 only. Present heater capacity = 70 KW Power consumption per annum = 2.10 Lakhs units Operating cost = Rs 10.5 Lakhs / Annum Saving = Rs. 3.0 Lakhs / Annum

L. Elimination of ONE pump in 150 Ton Yoke Sizing Presses (two machines)

Before modification: One 75 HP and One 25 HP motors are used to drive 3 Pumps for a capacity of 150 Ton operation. The actual load requirement is 50 Ton. The actual usage time is 10 Hours (900 yokes X 20 seconds X 2 shifts) the idle power consumption is 400 KWH. Motor capacity = 100 HP Power consumption per annum = 3.0 Lakhs units Operating cost = Rs 15.0 Lakhs / Annum After modification:The utilized capacity is 50 Ton. The idle time power consumption is reduced by cutting off the 25HP motor and running only the 75HP motor. There is no increase in cycle time, which is 20 seconds. Present motor capacity = 75 HP Power consumption per annum = 2.6 Lakhs units Operating cost = Rs 13.0 Lakhs / Annum Saving = Rs. 4.0 Lakhs / Annum (For 2 machines)

M. MG set to static high current power source.

Before modification: MG set power consumption per annum = 789900 units Operating cost = Rs. 36.73 Lakhs

After modification: Power consumed by Static power source = 14400 units / annum Operating cost per annum = Rs. 0.67 Lakhs Savings = Rs. 36.06 Lakhs.

N. Elimination of High pressure compressed air for agitation by using High Volume Low

Pressure blower at auto plating

Before After

Before Installation: Power consumed per annum = 40500 units Operating cost = 1.88 Lakhs After Installation Power consumed by the compressor = 27000 units / annum Operating cost = Rs. 1.25 Lakhs Savings = 0.63 Lakhs / annum. Fuel savings Through solar water heater, LPG to SKO conversion

SKO RUN CANTEEN BOILERS

STEP CHANGES IN CANTEEN BOILER FUEL CONSERVATION

•12.89

•2.37

•7.71

•0

•2

•4

•6

•8

•10

•12

•14

•1997 •1999 •2004

•Sav

ings

/ A

nnum

-in

Rs.L

acs

LPG to HSD Conversion:• LPG:396 Kg/Day * Rs.20/Kg• HSD:432 Lts/Day * Rs.16.50/Lt

PRE-HEATING THE FEED WATER BYSOLAR PLATES

Savings: 32,400 Lts/Annum

HSD to SKO CONVERTIONSavings: Rs.5.18 Lacs/Annum

@ Rs.4 / Ltr.

Work In Progress

SOLAR PLATE HEATING FOR CANTEEN

20 PLATES-2000 LTS. CAPACITY

FUEL (LPG)CONSERVATION

• CONVERSION OF LPG FIRED BOILER INTO HSD FIRED REVOMAX BOILER.

• PURPOSE : ENERGY SAVING HAZARD MINIMIZATION& OPERATIONAL

ADVANTAGES 2(A13(N)17(I)-13(M)15822( )MCID 33 >>BD-0.137Tw 678 466.16 170.040.0518 re2287291.0118408 07(T -1.10.5362.43 0 0.9667.6603926151 -582.49 -173.525 129.515 6eSQEMC /P <</MCID 3 32 >>BDC BT/TT0 1 Tf-0.Tc 0 TwCID 33 0 0 10. 314 98.9997 4565(A)9(GES 2(A13(N)17( /InlineShap288256MCID 33 >80391 T1690.78 314.54 175.68 133 DoQEMC /P <</M5ID 34 >>BDC5-15(LTw 420.0239 Tc 420.031 T )T4.881 0 0 6.33B4(UFI)-1IT)-9-1(R(O)(RVAT)9(I)-11(O)5(10-1(E)-9(0011 1 Tf26750566 Tc26750 -7 m8.1 m60 0 8.1776 105833(AT )8P(N)1G(M)1 31B)1213(M)1IAT )8ET )8R)8(I)-21(N00 gBT18T3 1 00317 811 D.1776 10560 4(O)-pe(R )8ra)5(Ut-11(i96 -1ng hrs&)-10(I)-2L)-82)8(I)-21(1)-7(G)8(>>BDCw18 re4-72 D.1776 105596(AT 28P(N5(E)-23coI)-nI)-s -2.um)OM)ptioI)-nVIN18( )]TJ10ER

Improvements: × Exhaust system straight outlet chimney modified from canopy outlet. ×

1816 15 14.5

OVER ALL ELECTRICAL ESU TREND

162

203

163

193

180

163

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1614.5 14.5

13.5

11.34

9.879.05

8.7

15

19

13.4

150

160

170

180

190

200

210

UN

ITS

in la

cs

U N IT IN LAC S 163 162 163 180 193 203

PR OD .ESU IN LAC S 8 .7 9 .05 9 .87 11 .34 13 .5 14 .5

U N ITS/PR OD U C T 19 18 16 15 14 .5 13 .4

00 '-01 01 '-02 02 '-03 03 '-04 04 '-05 05-'06

22 21.5

2019

1817

1615 14.5

13.4 13

23.5

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05-0

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06-0

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YEAR

KW

HR

/ E

SU

SELF BENCH MARK SELF BENCH MARK (06 (06 –– 07)07)

Specific Energy Consumption Trend

IMPROVEMENT INIMPROVEMENT INPower FactorPower Factor

4. Replacement of in-efficient A/C units 1.2 2.00

5. Solar water heater for canteen 1.50 4.00

6. Replacement of in-efficient transformer 4.00 9.00

We at Lucas TVS are committed to Protection, preservation and improvement of the environment by continually orienting our activities, products and services . One of the remarkable contributions this year was the establishment of indigenous waste coolant treatment system, which was not done before by any of the industries in the world, which involves recovering waste oil from waste coolant, thereby the quantity of waste disposed has reduced by 55% compared to last year.

FACTORY

LUCAS - TVS

VALUE YARD

WASTE COOLANT WITH OIL

CPCB&

TNPCB

STOPPED

DISPOSAL TO RECYCLERWITH PAYMENT

FACTORYUSED COOLANT OIL

FROM FACTORY

COOLANT OIL STORAGE AREA

WATER

RO PLANT

WATER TREATMENTPLANT

RO

RE

JEC

TIO

NW

ITH

HIG

H

TD

S O

F 50

00

VALUE YARD( FOR SALE OF

OIL )

OIL BARREL

SUN

SOLAR POND

UNLOADING

STORAGE TANK( 2 LAKH LITRE CAPACITY )

HAZARDOUS WASTESTORAGE AREA

LUCAS - TVS

SOLID&

POWDER

INNOVATIVE TECHNOLOGY FOR ENERGY AND ENVIRONMENT

ENVIRONMENTAL AND ENERGY BENEFITS ü This process is unique one. It uses RO Rejection

water & solar evaporation for coolant oil treatment process. ü No Chemical treatment is involved in this process

whereas other companies are using chemicals & Electrolysis for treatment. ü High TDS water (RO Reject) disposal problem is

solved. ü Meeting out the PCB standard to sell the oil for

recycling (0.8% water & 99.2% oil against PCB norms of 15 % water & 85% Oil) ü Cost saving Rs 6.52 lacs per annum. ü Energy Consumption is very less

AFTER IMPROVEMENT BEFORE IMPROVEMENT

ENERGY SAVINGS DUE TO THE SOLAR EVAOPARTION OF POND IN PLACE OF ELECTRICAL HEATING SYSTEM