national award for excellence in energy management -2018
TRANSCRIPT
National Award for Excellence in Energy Management -2018
Hero MotoCorp Ltd. - Haridwar
29th Aug – 31st Aug’2018
Ashu TyagiSection Head Utility
Satyendra Gupta Section Head Prod. Engg
National Award for “Excellence in Energy Management – 2016 2National Award for “Excellence in Energy Management – 2018” 2
Agenda
Brief introduction on Company/Unit
1. Specific Energy Consumption in last 3 years
2. Information on Competitors, National & Global benchmark
3. Energy Saving projects implemented
4. Innovative Projects implemented
5. Utilisation of renewable energy sources
6. Utilisation of waste material as fuel
7. GHG Inventorisation
8. Green Supply Chain
9. Team work, Employee Involvement & Monitoring
10. Implementation of ISO 50001/Green Co-rating
11. Other relevant information
National Award for “Excellence in Energy Management – 2016 3National Award for “Excellence in Energy Management – 2018” 3
Agenda
Brief introduction on Company/Unit
1. Specific Energy Consumption in last 3 years
2. Information on Competitors, National & Global benchmark
3. Energy Saving projects implemented
4. Innovative Projects implemented
5. Utilisation of renewable energy sources
6. Utilisation of waste material as fuel
7. GHG Inventorisation
8. Green Supply Chain
9. Team work, Employee Involvement & Monitoring
10. Implementation of ISO 50001/Green Co-rating
11. Other relevant information
National Award for “Excellence in Energy Management – 2016 4National Award for “Excellence in Energy Management – 2018” 4
Brief introduction on HMCH - Journey
Hero Honda Motors Ltd.
IncorporatedFirst motorcycle
"CD 100" rolled out
Gurgaon plant inaugurated
Haridwar plant inaugurated
1984
Journey Started
1985 1997
HHML-World No.1 2W Manufacturer
2001
20082011
New Identity -Hero MotoCorp Ltd.
2013
Most Effective Brand Transition Award by CNBC
20162016
Start of 5th plant in India at Vadodara, Gujarat
2014 2015
2016
Start of 4th plant & GPC at Neemrana, Rajasthan
Start of 1st overseas plant at Columbia
Start of CIT at Jaipur, Rajasthan
Milestone of 70 million cumulative Production
National Award for “Excellence in Energy Management – 2016 5National Award for “Excellence in Energy Management – 2018” 5
Processes & Major Equipments:
Supplier Haridwar
Supplier NCR
Dealer
Customer
Major equipments are in Paint & utilities of electrical and thermal nature.
Machine ShopsEngine Assly
Frame Assly
Final Insp.
Disp
atch
Weld Shop Paint shop
Decentralized Supply Hubs
Decentralized Supply Hubs
National Award for “Excellence in Energy Management – 2016 6National Award for “Excellence in Energy Management – 2018” 6
Agenda
Brief introduction on Company/Unit
1. Specific Energy Consumption in last 3 years
2. Information on Competitors, National & Global benchmark
3. Energy Saving projects implemented
4. Innovative Projects implemented
5. Utilisation of renewable energy sources
6. Utilisation of waste material as fuel
7. GHG Inventorisation
8. Green Supply Chain
9. Team work, Employee Involvement & Monitoring
10. Implementation of ISO 50001/Green Co-rating
11. Other relevant information
National Award for “Excellence in Energy Management – 2016 7National Award for “Excellence in Energy Management – 2018” 7
1. Plant Specific Energy Consumption
Resource Unit
Start Year Achieved Target
FY 08-09
FY 09-10
FY10-11
FY11-12
FY12-13
FY13-14
FY14-15
FY15-16
FY16-17
FY17-18
FY18-19
Electricity Kwh / Veh 24.61 17.31 16.37 15.61 15.72 14.74 15.79 15.12 14.75 13.64 12.83
HWG Fuel SCM / Veh 0.714 0.609 0.474 0.428 0.427 0.447 0.476 0.368 0.291 0.260 0.234
Increased due to installation of comfort cooling on expansion lines along with new models commissioning and trials.
Extensive efforts made in FY 16-17 to bring down SFC
Achieved Continual improvement in resource conservationAchieved Continual improvement in resource conservation
24.61
17.3116.37
15.61 15.7214.74
15.7915.12 14.75
13.6412.83
10.0
12.0
14.0
16.0
18.0
20.0
22.0
24.0
26.0
FY08-09
FY09-10
FY10-11
FY11-12
FY12-13
FY13-14
FY14-15
FY15-16
FY16-17
FY17-18
FY18-19Target
Kw
h/V
eh
Specific Energy Consumption
0.714
0.609
0.4740.428 0.427 0.447
0.476
0.368
0.2910.260
0.234
0.2
0.3
0.4
0.5
0.6
0.7
0.8
FY08-09
FY09-10
FY10-11
FY11-12
FY12-13
FY13-14
FY14-15
FY15-16
FY16-17
FY17-18
FY18-19Target
SCM
/Ve
h
Specific Fuel Consumption
Last 3 Year 13.5% Reduction Last 3 Year 46% Reduction
National Award for “Excellence in Energy Management – 2016 8National Award for “Excellence in Energy Management – 2018” 8
Agenda
Brief introduction on Company/Unit
1. Specific Energy Consumption in last 3 years
2. Information on Competitors, National & Global benchmark
3. Energy Saving projects implemented
4. Innovative Projects implemented
5. Utilisation of renewable energy sources
6. Utilisation of waste material as fuel
7. GHG Inventorisation
8. Green Supply Chain
9. Team work, Employee Involvement & Monitoring
10. Implementation of ISO 50001/Green Co-rating
11. Other relevant information
National Award for “Excellence in Energy Management – 2016 9National Award for “Excellence in Energy Management – 2018” 9
2.1 External & Internal Benchmarking
Benchmarking done wrt to Competitors and Internal, though we are consuming lesser than them but yet we are striving for continual improvement
14
.7 15
.8
15
.1
14
.8
13
.6
19
.9
18
.9
17
.9
17
.7
27
.4
27
.4
27
.2
26
.5
25
.6
30
.99
29
.00
27
.71 3
0.3
7
29
.60
0
5
10
15
20
25
30
35
13-14 14-15 15-16 16-17 17-18
Kw
h/V
eh
Specific Energy Consumption
HM3H Competitior 1 HM1D HM2G
National Award for “Excellence in Energy Management – 2016 10National Award for “Excellence in Energy Management – 2018” 10
.
..
.2.2 Machine Family wise Benchmarking
Bench Marking done for energy consumption of each machine family
0.13
0.07 0.06
0.02 0.01
0.0
0.0
0.0
0.1
0.1
0.1
0.1
0.1
WashingM/c
RotaryMilling
Vigil M/c Face milling FRD OP-10
Kw
h/C
om
po
ne
nt
AL Phase Crank Case Machine kwh Consumption/Component
0.09 0.090.08 0.08
0.04
0.0
0.0
0.0
0.1
0.1
0.1
Vigil RotaryMilling
ChemferingM/c
Washing M/c FRD OP-20
Kw
h/C
om
po
ne
nt
AL Phase Cylinder Head Machine kwh Consumption/Component
0.090.07
0.06
0.02 0.02 0.01
0.0
0.0
0.0
0.1
0.1
0.1
WashingM/c
InductionHardening
HorningM/c
FineBoaring
Nachi FaceMilling
Kw
h/C
om
po
ne
nt
Steel Phase Machine kwh Consumption/Component
Monitoring of consumption of each machine family per
component complete process/cycle time
P
D
C
C
A
National Award for “Excellence in Energy Management – 2016 11National Award for “Excellence in Energy Management – 2018” 11
Agenda
Brief introduction on Company/Unit
1. Specific Energy Consumption in last 3 years
2. Information on Competitors, National & Global benchmark
3. Energy Saving projects implemented
4. Innovative Projects implemented
5. Utilisation of renewable energy sources
6. Utilisation of waste material as fuel
7. GHG Inventorisation
8. Green Supply Chain
9. Team work, Employee Involvement & Monitoring
10. Implementation of ISO 50001/Green Co-rating
11. Other relevant information
National Award for “Excellence in Energy Management – 2016 12National Award for “Excellence in Energy Management – 2018” 12
Sr. No.
Top 10 Energy Saving Projects
Annual Savings
Kwh in Lacs
Rs in Lacs
1 Reduced voltage supply for lighting energy saving through Dry Trafo 2.2 11.58
2Elimination of Shift from Aluminium Crank Case by Reducing cycle time of Robotic cell from 76.5 Sec/Line to 72 Sec/Line to reduce energy consumption and improve productivity
2.0 9.91
3Elimination of Shift from Aluminium Cylinder Head by Reducing cycle time of Robotic cell to reduce energy consumption and improve productivity
1.9 9.40
4To Eliminate Chiller used after Dry off Oven for Fast Cooling of Components in SM Paint Shop by extending conveyor length Component through Natural Cooling of air Shower
1.7 8.74
5Switching off Steel & Aluminium Phase FDV's in Lunch, Dinner & C-shift to reduce energy consumption
1.5 7.67
6Reduction of KWH consumption in Engine Assembly by using 1 common washing machine in Line-4 & Line-3 by re-layouting & trolley arrangement
1.5 7.58
To be continue..To be continued..
3.1 EnCon Projects in last 3 year – Electrical (Zero Investment)
National Award for “Excellence in Energy Management – 2016 13National Award for “Excellence in Energy Management – 2018” 13
Sr. No.
Top 10 Energy Saving Projects
Annual Savings
Kwh in Lacs
Rs in Lacs
7Sparing 1 washing machines of engine assembly by rearranging design parts feeding.
1.5 7.58
8Optimisation of 1500 CFM Air compressor auto mode VFD (Variable Frequency Drive) to reduce energy consumption.
1.4 7.01
9Gun drill machine coolant circuit modify to run machine with 2 pumps in place of 4 pumps to save the energy & MTTR in Machine Shop.
1.2 5.92
10Optimize the process in Lacquer Paint shop and run 2No's Water pump place of 3No's.
0.8 4.27
Total Saving (Top 10 Projects) 15.7 79.6
Total Projects Saving (50 Nos.) 27 140
Total 50 No’s Zero investment projects Implemented and conserved 27 Lacs kwh and cost saving of Rs 140 Lacs/year
3.2 EnCon Projects in last 3 year – Electrical (Zero Investment)
National Award for “Excellence in Energy Management – 2016 14National Award for “Excellence in Energy Management – 2018” 14
Sr. No.
Top 10 Energy Saving ProjectsAnnual Savings
Kwh in Lacs
Rs in Lacs
1 Conventional task lights replacement with LED Lights (3000 Nos) 3.53 20.63
2Installation of VFD (Variable Frequency Drive) FDV's of Machine Shop and Assembly area FDV Blowers by reviewing & balancing velocity at FDV drops to save energy consumption.
1.37 7.36
3Installation of VFD (Variable Frequency Drive) in 4No's FDV's of Machine Shop FDV Blowers by reviewing & balancing velocity at FDV drops to save energy consumption.
1.23 6.22
4VFD Installation in lacquer exhaust blowers, EA washing Pumps, ACED Water rinse pump (FPM combined)
1.87 10.90
5Finding opportunities of variable speed requirements in Utility & installing VFD’s in them
1.06 6.18
6 EC fans installation in place of blowers in ASU (Air Supply Unit) 1.03 6.04
To be continue..To be continued..
3.3 EnCon Projects in last 3 year– Electrical
National Award for “Excellence in Energy Management – 2016 15National Award for “Excellence in Energy Management – 2018” 15
Sr. No.
Top 10 Energy Saving ProjectsAnnual Savings
Kwh in Lacs
Rs in Lacs
7 Reduction in power consumption of old paint shop pumps /Blowers 0.86 4.63
8 Conventional tube light replacement with LED 0.86 4.63
9HPSV ( High Pressure Sodium Vapour) Street Light replacement with LED light
0.77 4.13
10Replacement of electrical heaters with Plate heat exchanger in weld washing machine
0.54 3.19
Total Saving (Top 10 Projects) 13.12 73.91
Total Projects Saving (32 Nos.) 24.6 136
Total 32 No’s Investment Projects Implemented and conserved 24.6 Lacs kwh and cost saving of Rs 136 Lacs/year
3.4 EnCon Projects in last 3 year – Electrical
National Award for “Excellence in Energy Management – 2016 16National Award for “Excellence in Energy Management – 2018” 16
3.5 EnCon Projects in last 3 year – Thermal
Sr. No.
Top Energy Saving ProjectsAnnual Savings
SCM in Tons
Rs in Lacs
1Canteen Relayouting (new equipment's to be added having better SFC)
240 59.8
2Shift operation reduction in ACED Paint shop by provision of 3 frame Body loading in one hanger to Synchronize ACED Line production with Frame Assembly production requirement
210 73.1
3 Baking oven temperature reduction from 195 to 185 deg c 161 40.0
4Dry Off Temperature Reduction from 140 deg to 110 deg with introduction of NIHON PT Chemical
161 40.0
5Hot water generator temperature Reduction by 5 deg C and efficiency improvement in paint shop
102 31.2
6 Phosphate temp reduction from 50 to 42 deg - SM 87 21.6
7 Phosphate bath temperature reduction from 65 to 55 deg c - ACED 26 6.3
Total Saving (Top 7 Projects) 985 272
7 Projects implemented & Conserved 985 Ton SCM Natural Gas resulting in cost saving of Rs. 272 Lacs /year
Projects with Zero Investment
National Award for “Excellence in Energy Management – 2016 17National Award for “Excellence in Energy Management – 2018” 17
Agenda
Brief introduction on Company/Unit
1. Specific Energy Consumption in last 3 years
2. Information on Competitors, National & Global benchmark
3. Energy Saving projects implemented
4. Innovative Projects implemented
5. Utilisation of renewable energy sources
6. Utilisation of waste material as fuel
7. GHG Inventorisation
8. Green Supply Chain
9. Team work, Employee Involvement & Monitoring
10. Implementation of ISO 50001/Green Co-rating
11. Other relevant information
National Award for “Excellence in Energy Management – 2016 18National Award for “Excellence in Energy Management – 2018” 18
Cost saving of Rs. 178 Lac/Annum through various Innovative Projects
S. No.
Section Improvement ProjectResource Saved/ Annum
Cost Saving
1Lacquer Paint Shop
To replace conventional blowers with High Efficiency EC Fans in Lacquer Paint shop ASU ( Air Supply Unit) to save energy
1.06 lac Kwh INR 6.2 lacs
2 Weld ShopTo replace Electrical energy heating with natural gas system.
0.54 lac kWh INR 3.19 lacs
3 Machine shopIGBT (VRp-Voltage Regulate Precision) Transformer installation
0.85 Lac kWh INR 5.0 Lac
Total Saving Per Annum INR 14.5 Lacs
Total Projects Saving (10 Nos.) INR 178 Lacs
Innovative Projects Summary4 Energy Conservation
National Award for “Excellence in Energy Management – 2016 19National Award for “Excellence in Energy Management – 2018” 19
Painting Booth
Exhaust System
Environment Air Inlet
Booth Air Inlet
4.1 Replacement of conventional blowers with High Efficiency EC FansInnovative Project -1
Exhaust Blower with VFD to maintain positive pressure
Current system-
Blower used in Lacquer Paint shop refines the air and maintain positive pressure thus not allowing external dust around the paint booth to enter into the paint booth.
Single centrifugal blower of 90KW
Blower running with conventional motor to maintain positive pressure in booth
Total Intake Volume = 124,000 CFM Static Pressure = 1270 PaMotor Rating = 90kW
•first filtration process herewith the help of bag filtersPrimary filters zone
•it undergoes secondary filtration by bag filters
Secondary filters zone
•The ASU burner Heats up the coming air at the required temperature.
ASU Burner Zone
•Spray nozzles humidify the air at the required humidity level.Humidity Zone
•Then flowing air is supplied to the sound damper by the supply blower
Supply Blower
•In Sound Damper Zone, vibrations due to the flowing air is absorbed by the dampers.
Sound Damper
•Finally filtered and sent to the painting booth.Final Filters Zone
National Award for “Excellence in Energy Management – 2016 20National Award for “Excellence in Energy Management – 2018” 20
Background:Centrifugal blowers used for conditioned air supply in ASU of Paint Shop
Results:
Centrifugal Blower EC FAN
It Consist of Blower, Motor, Pulley, Belt
Direct coupled Impeller without any Pulley & Belts, hence no transmission loss
3 Ph AC InductionMotor
DC Motor-Improved efficiency upto 90%
Separate VFD PanelInbuilt VFD at Fan unit. No VFD circuit filter losses.
ASU flow – 75K cfmStatic Pr – 1270 Pa
- Energy saving of 60% due to reduction in losses- Runs at same static & delivers same flow
Compact Design - Replaced Centrifugal Fan + Motor +VFD by Single unit• High Motor Efficiency -90%
1144822
0
1000
2000
Before After
KWH/Day Power Consumption (KWH/Day)
321
EC Fan installation resulted Saving of Rs. 6.2 Lac /year
Improvements Done:Installation of 12 no. EC fans (5.8 kw each) in place of one big blower (90 KW).
4.1 Replacement of conventional blowers with High Efficiency EC FansInnovative Project -1
Methodology/Approach Adopted: -
Painting Booth
Exhaust System
Environment Air Inlet
Booth Air Inlet
Exhaust Blower with VFD to maintain positive pressure
Single centrifugal blower of 90KW
EC FAN ( Horizontal Deployment)
Sl.No. LocationDesign CFM
Design Power in
KwQty/unit
Total Power in
Kw
Total Power Savings
% 1 Primer 82500 110 12 72 38.00
2 Base Coat 82500 110 12 72 38.00
3 Top Coat 82500 110 12 72 38.00
National Award for “Excellence in Energy Management – 2016 21National Award for “Excellence in Energy Management – 2018” 21
4.2 Replacement of Electrical heating with gas heating in washing machine Innovative Project -2
Washing machine used for component washing in weld shop
Fuel tank washing machine used for cleaning components and eliminating the foreign particles.
Electrical-AC415V~ 120AmpCompressed Air-6 BarSpace-1600 mm*4132 mm*2260 mmWeight-Approx 1500KG
Conveyor speed-It should be between 20-30 Hz, Drying Temp.-Temp. should be between 45-55 degree.
HeatersHot Water
Conveyor
Washing Machine
Air BlowerNozzle for
water spray
Fuel Tank
Pump
National Award for “Excellence in Energy Management – 2016 22National Award for “Excellence in Energy Management – 2018” 22
4.2 Replacement of Electrical heating with gas heating in washing machine Innovative Project -2
Background:
.
After Condition – Washing m/c water temp Maintained by Heat Exchanger Plate
Before condition :Washing M/c (7 no) of weld shop water temperature maintained by Electric Heaters.
Improvements Done
2076
1065
0
1000
2000
3000
Before After
Energy Cost/Day
Power Consumption (Energy Cost/Day)
Hot Water using in washing m/c resulted Saving of Rs. 3.19 Lac /year
Methodology/Approach Adopted: -Results: Energy Comparison Electricity to Natural Gas
Avg heater rating 36 KW
Heater on Hrs during A & B shift 10 HRS
Total kwh consumption/day 356 KWH
Electrical Energy Cost/Day 2079 INR
Heat requirement/Day 305,914 Kcal
Natural Gas Requirement to meet above 36 SCM
Natural Gas cost 1014 INR
Saving on Natural Gas over Electrical Heating
1065 INR
Saving /Year 319,844 INR Lac
Investment 400,000 INR Lac
ROI 1.25 Years
Horizontal deployment planned in 14 m/c for Weld shop & Engine Assembly in FY18-19 to save the INR 38.7
Lacs/Year
Heaters Hot Water
Conveyor
Washing MachineAir Blower Nozzle for water spray
Fuel Tank
Pump
National Award for “Excellence in Energy Management – 2016 23National Award for “Excellence in Energy Management – 2018” 23
4.3 IGBT (VRp-Voltage Regulate Precision) Transformer installation
Background
Advantages
Voltage Stabilizer
Isolation X-mer
VRP Line Conditioner
• Voltage Regulation through IGBT
• RS485 communication port
• Space Saving due to compact design.
• Voltage regulation in real time (<20ms)
• Soft Switching
Energy savings due to efficiency improvement of 10%: Rs. 0.5 lacs per VRp installation
Reduction in maintenance cost (less network cards or PCB failures)
High replication possibility as no of machines are ~200 nos
All the CNC machines are connected with Voltage stabilizer and Isolation transformer for quality power supply in machine shop.
11 No’s VRP installed as pilot project and resulted saving Rs. 5 Lac/Year
Improvements Done
Methodology/Approach Adopted: -
Innovative Project -3
Stabilizer+ IsolationTransformer
Voltage Regulate Precision (VRp)
Efficiency of Stabilizer: 92%Efficiency of Xmer: 94%
Total Efficiency: 86%
Replaced with single VRp unit
Efficiency : 96%
Moving parts – VariacResponse Time: 1-2 Sec
IGBT based switchingResponse Time: <20 ms
Higher core losses Less Core losses
National Award for “Excellence in Energy Management – 2016 24National Award for “Excellence in Energy Management – 2018” 24
Agenda
Brief introduction on Company/Unit
1. Specific Energy Consumption in last 3 years
2. Information on Competitors, National & Global benchmark
3. Energy Saving projects implemented
4. Innovative Projects implemented
5. Utilisation of renewable energy sources
6. Utilisation of waste material as fuel
7. GHG Inventorisation
8. Green Supply Chain
9. Team work, Employee Involvement & Monitoring
10. Implementation of ISO 50001/Green Co-rating
11. Other relevant information
National Award for “Excellence in Energy Management – 2016 25National Award for “Excellence in Energy Management – 2018” 25
Natural Air ventilators installed 38 no.
Translucent Sheet in plant roof Green roof coverage 45000 Sqm
Natural Ventilator , Translucent sheet , Plant green roof initiative saved 1200 kwh/Day
5.1 Renewable Energy Source
Utilization of Renewable Energy Utilization by using Solar Plant, Solar heater, sky light, Natural ventilator, Translucent sheet and green roof
National Award for “Excellence in Energy Management – 2016 26National Award for “Excellence in Energy Management – 2018” 26
1. Solar Generation capacity will increase to 1.95 MW 2. Solar Power Sharing will be 10% of total daily Energy
We have ground mounted solar plant having capacity of 1MWp which is able to produce almost 5% of energy consumption of whole plant for a day.
There were huge area on roof top which can be use for Solar power generation. We have proposed to install rooftop plant of 950KW capacity which may increase the solar share to 10% of total energy consumption for the day.
5.3 Solar PV project for roof top
Previous Condition Improvements Proposed
Benefit:
Methodology/Approach Adopted: -
Target Results:
1 MW1.95 MW
0.00
0.50
1.00
1.50
2.00
2.50
Before After
MWSolar Generation
0.95 MW
Project installation is under progress for roof top solar.
Target Date: - 31/12/2018
National Award for “Excellence in Energy Management – 2016 27National Award for “Excellence in Energy Management – 2018” 27
58 83
1,150 1,150 1,150 1,150
0418
1,392 1,412 1,712
2,512
281530
866 10201500 1500
339
1031
3408 3582
4362
5162
0
1000
2000
3000
4000
5000
6000
FY 14-15 FY 15-16 FY 16-17 FY 17-18 FY 18-19PROJECTED
FY 19-20PROJECTED
MW
H
Utilization of Renewable Energy
Solar Heating & Lighting Solar Power RE IEX Trading Total
14%
5.2 Renewable Energy Utilization
Current Utilization of Renewable Energy - 10% , we are in process of installation of roof top solar of 950 kWp by Nov-18.
1%3%
10%
12%
National Award for “Excellence in Energy Management – 2016 28National Award for “Excellence in Energy Management – 2018” 28
Agenda
Brief introduction on Company/Unit
1. Specific Energy Consumption in last 3 years
2. Information on Competitors, National & Global benchmark
3. Energy Saving projects implemented
4. Innovative Projects implemented
5. Utilisation of renewable energy sources
6. Utilisation of waste material as fuel
7. GHG Inventorisation
8. Green Supply Chain
9. Team work, Employee Involvement & Monitoring
10. Implementation of ISO 50001/Green Co-rating
11. Other relevant information
National Award for “Excellence in Energy Management – 2016 29National Award for “Excellence in Energy Management – 2018” 29
Co-Processing of paint sludge will result in savings of 50 LPA
6.1 Utilization of paint sludge (waste) as a fuel
• Co- processing technology is an eco-friendly solution for Sustainable Waste Management.
• It uses cement kiln technology to treat hazardous and non-hazardous waste in a sustainable manner ensuring regulatory compliance.
Project Details:
Background:
Concept:
Benefits:
• After incineration paint sludge convert into ashwhich disposed in SLF.
• Approx. 23000 kg paint sludge generate monthly,which is being incinerated in the one incinerator
• Approx cost of Paint sludge incineration = Rs 27/kg
Advantages of Co-Processing :1. End to end waste disposal2. Environmental friendly3. CO2 emission reduction
Co-processing ( Rs/Kg) 9.00
Per kg Paint Sludge Incineration Cost 27.00
Saving per kg paint sludge 18.00
Monthly average Paint Sludge generation ( (kg) 23230
Monthly Saving by Co-processing ( Rs. Lac) 4.18
Yearly Saving by Co-processing ( Rs. Lac) 50.18
Co-processing for Disposal of Paint Sludge
National Award for “Excellence in Energy Management – 2016 30National Award for “Excellence in Energy Management – 2018” 30
Thinner Recovery unit & its reuse in bell & Gun cleaning Advantage :- Saving of 180
Litres of cleaning thinner per day
Recycling & Reuse of Waste resources based on 3R approach
Waste Food Energy Utilization Thinner (Waste) Recovery System
6.2 Waste Utilization
Food Compositing Machine Manure usages in horticulture
Hygienic Disposal of waste: 500 Kg./Day Manure Generation : 200 Kg./Day
National Award for “Excellence in Energy Management – 2016 31National Award for “Excellence in Energy Management – 2018” 31
Agenda
Brief introduction on Company/Unit
1. Specific Energy Consumption in last 3 years
2. Information on Competitors, National & Global benchmark
3. Energy Saving projects implemented
4. Innovative Projects implemented
5. Utilisation of renewable energy sources
6. Utilisation of waste material as fuel
7. GHG Inventorisation
8. Green Supply Chain
9. Team work, Employee Involvement & Monitoring
10. Implementation of ISO 50001/Green Co-rating
11. Other relevant information
National Award for “Excellence in Energy Management – 2016 32National Award for “Excellence in Energy Management – 2018” 32
GHG Emission Inventorisation
CO2e (MT) FY 17-18
Scope –I
3,968 CO2e (MT)
Scope-II
50,083 CO2e (MT)
GHG Inventorisation
60007000 7519 8028 8325 8526 8739 8941
10500 10825
0
2000
4000
6000
8000
10000
12000
20
08
-09
20
09
-10
20
10
-11
20
11
-12
20
12
-13
20
13
-14
20
14
-15
20
15
-16
20
16
-17
20
17
-18
No
’s o
f Tr
ee
Cumulative Nos of Tree (Inside Plant)
Better
Maintaining 10,825 trees inside plant which reduced 422 Ton CO2 emission/year
7.1 GHG Inventorization
51,881 53,940 53,999 49,545 50,083
7,655 8,891 5,4203,541 3,968
59,536 62,831 59,41953,086 54,051
010,00020,00030,00040,00050,00060,00070,000
20
13
-14
20
14
-15
20
15
-16
20
16
-17
20
17
-18
Co
2e
CO2 Emissions (MT)
SCOPE-1 SCOPE-2 TOTALBetter
23.7723.4
24.0523.69
22.08
20.32
18
19
20
21
22
23
24
25
20
12
-13
20
13
-14
20
14
-15
20
15
-16
20
16
-17
20
17
-18
Kg/
Ve
h
CO2 Gas Emission (kg/veh)Better
National Award for “Excellence in Energy Management – 2016 33National Award for “Excellence in Energy Management – 2018” 33
• Technology developed & Patented by Hero MotoCorp Ltd.
• First implemented in iSmart 100 cc bike & then horizontally deployed in other Models.
• Function: When you stop the bike; the i3S system puts the engine into hibernate mode. The Idle Stop Start System turns off the engine after waiting for about 5 seconds for e.g. at a traffic signal. It restarts the engine automatically when press the clutch.
Passion Pro Spl Plus
HF Deluxe
Glamour 125
Achiever 150 Super Splendour
iSmart 110cc
CO2 reduction of 85,076 TPA by Technological Innovations in Product design
7.2 GHG Inventorization - Initiatives by increasing product efficiency
National Award for “Excellence in Energy Management – 2016 34National Award for “Excellence in Energy Management – 2018” 34
28 Villages of district Uttarakhand @ Haridwar, Dehradun, Uttarakashi provided with 7W LED Bulbs & street lights. Saving 1.07 Crore of Electricity Units/Year for our State.
Total 560 Solar Street Lights provided to following villages:A. Village Dobnagar PathriB. Village Mishraas PattiC. Village DoiwalaD. Village ChamasarieTotal Beneficiaries families from thesevillages are 2964 saving 4.03 lac units for our State
28 Villages of Uttarakhand @ Haridwar, Dehradun, Uttarakashi provided with 7W LED Bulbs.We saved 1.03 Crore kwh of Electricity Per Year for our State.
Total families benefitted with this project are 12,727 nos.
7.3 GHG Inventorization - CSR Activity for Energy Conservation
National Award for “Excellence in Energy Management – 2016 35National Award for “Excellence in Energy Management – 2018” 35
Sr. No.
Description UOM Target
1 Budget Rs. Cr 7.75
2Completion Time
Months 10
3 Water Saving KL/ Annum 73000
4 Cost SavingRs. Lacs / year
5
Zero liquid discharge (ZLD) plant and use this water in our process
ZLD Plant impact to reduce 200KLD RAW water drawing from ground
ZLD Plant Operation monitoring through SCADA
7.4 GHG Inventorization - Environment - Conservation
National Award for “Excellence in Energy Management – 2016 36National Award for “Excellence in Energy Management – 2018” 36
Agenda
Brief introduction on Company/Unit
1. Specific Energy Consumption in last 3 years
2. Information on Competitors, National & Global benchmark
3. Energy Saving projects implemented
4. Innovative Projects implemented
5. Utilisation of renewable energy sources
6. Utilisation of waste material as fuel
7. GHG Inventorisation
8. Green Supply Chain
9. Team work, Employee Involvement & Monitoring
10. Implementation of ISO 50001/Green Co-rating
11. Other relevant information
National Award for “Excellence in Energy Management – 2016 37National Award for “Excellence in Energy Management – 2018” 37
8.1 Green Supply Chain Dispatch Truck Capacity Enhancement
Reduced Total 48 nos. Trucks trip per day from Haridwar Plant
5 Vehicles / Row 50 vehicles/ Truck
4 Vehicles / Row40 Vehicles/ Truck
Before After
Rider and Pillion step at resting position
Sari Guard assly in single piece
Sari Guard assly made in 2 Pieces and wrapped
Rider and Pillion step folded with rubber bands
Total 238 Trucks/ Day for Dispatch of 9500 Veh. Total 190 Trucks/ Day for Dispatch of 9500 Veh.
National Award for “Excellence in Energy Management – 2016 38National Award for “Excellence in Energy Management – 2018” 38
EnCon Projects Saving
Sr. No.
Top Energy Saving ProjectsName of the Associate /
Vendor
Annual Savings
KWH inLacs
Rs in Lacs
1Power & Fuel saving considered by optimization of Chiller usage cycling timer mount 1 hour On Off
Rinder 4.0 23.4
2 To reduce energy consumption around 15% at AIR CompressorMunjal Showa
Ltd1.0 5.8
3Reduce Power consumption by changing heating element by higher bonding silicon carbide element
Rockman 0.8 4.9
4 Light Replacement with conventional light Endurance 0.8 4.7
5Reduce Power consumption in cooling tower and hydraulic motor by running in star connection
Rockman 0.8 4.6
6 Re-arrange of Compressor Layout Endurance 0.6 3.3
7To reduce Electrical Energy consumption of Hydrogen De Embrittlement oven.
Nipman 0.6 3.3
8 Install more capacitors to raise Power Factor to motor end. Rinder 0.6 3.3
9 tube lights replaced with LEDMunjal Showa
Ltd0.5 3.2
10 Replacing Higher efficiency air dryer Endurance 0.5 3.1
To be continued..
8.2 Green Supply Chain
National Award for “Excellence in Energy Management – 2016 39National Award for “Excellence in Energy Management – 2018” 39
EnCon Projects Saving
Sr. No.
Top Energy Saving ProjectsName of the Associate /
Vendor
Annual Savings
KwhRs in Lacs
11 C0-Excal fan system in exhaust system Satyam 0.5 2.8
12 Reduce Air Compressor consumption by installation of VFD Nipman 0.5 2.6
13 Compressed Air saving project through leakage control Satyam 0.4 2.5
14 Material change in holding Furnace Endurance 0.4 2.5
15 Installation high efficiency pump Endurance 0.4 2.4
Top 15 project saving 13.6 79.7
Top 10 Vendor total project saving 23.6 137.7
Various project implemented at vendor end & Conserved 23.6 Lac kwh resulted cost saving of Rs. 137.7 Lacs /year
8.3 Green Supply Chain
National Award for “Excellence in Energy Management – 2016 40National Award for “Excellence in Energy Management – 2018” 40
Before After
8.4 Green Supply Chain GVDP - Vendor Industry Initiative
Waste heat of DG stack used in VAM
Before After
Various projects implemented under GVDP program by Rockman Industries
Halogen light Sky light
Reduce Natural Gas consumption by using Induction furnace in place of Gas fired furnace for CI ring heating
Reduce Power Consumption by Replacing the Halogen light to Sky Light at Shop Floor Machine shop
National Award for “Excellence in Energy Management – 2016 41National Award for “Excellence in Energy Management – 2018” 41
Before After
VFD installed at Air Compressor to reduce energy consumption
8.5 Green Supply Chain
Stop timer installed during Idle condition for CNC M/C.
Before After
Projects implemented under GVDP program by M/s Munjal Showa Ltd.
GVDP - Vendor Industry Initiative
National Award for “Excellence in Energy Management – 2016 42National Award for “Excellence in Energy Management – 2018” 42
Agenda
Brief introduction on Company/Unit
1. Specific Energy Consumption in last 3 years
2. Information on Competitors, National & Global benchmark
3. Energy Saving projects implemented
4. Innovative Projects implemented
5. Utilisation of renewable energy sources
6. Utilisation of waste material as fuel
7. GHG Inventorisation
8. Green Supply Chain
9. Team work, Employee Involvement & Monitoring
10. Implementation of ISO 50001/Green Co-rating
11. Other relevant information
National Award for “Excellence in Energy Management – 2016 43National Award for “Excellence in Energy Management – 2018” 43
March-18
Substation online monitoring Transformer online monitoring
Resource conservation project registration format
Energy Consumption Monitoring & Daily Review shop wise
Online Monitoring system deployed to identify and analyze Abnormalities
Monitoring & Reporting Systems9.1 Energy Management
DG online Monitoring System
National Award for “Excellence in Energy Management – 2016 44National Award for “Excellence in Energy Management – 2018” 44
9.2 Encon Cell
Energy Conservation Cell driven from top with involvement of all employees
Plant Head
HOD (QA)
Team Mgr.
Team Mgr.
Team Mgr.
Team Mgr.
Team Mgr.
HOD (Prod)
HOD (Maint/Encon
Leader)
HOD (HR)
HOD (SCM)
Section Heads (SCM)
Section Heads(Prod)
Sec Head Utility(RCT
Leader)
Section Heads (HR)
Section Heads (QA)
Facilitators
Review Frequency -Monthly
Review Frequency -Fortnightly
Review Frequency -Weekly
Review Frequency -Daily
Manufacturing Head
National Award for “Excellence in Energy Management – 2016 45National Award for “Excellence in Energy Management – 2018” 45
.
• Emphasis on Resource conservation
• Plant Visits & sharing of resource conservation Projects
On-joining program
• Trainings by internal & external team.
• Discussion of recent improvements
Continuous Energy
Awareness
• Poster & slogan competition.
• Idea generation contest.Employee
Involvement
Implementation of ideas by Team
Kaizen awards to successfully
implemented ideas.
All Employees
9.3 Energy Management Total Employee Involvement
93 staff & 1024 team members covered for Environment and Energy Conservation
National Award for “Excellence in Energy Management – 2016 46National Award for “Excellence in Energy Management – 2018” 46
National Award for “Excellence in Energy Management – 2016 47National Award for “Excellence in Energy Management – 2018” 47
9.4.1 OP80 Operation Rebalancing In Cell In Cylinder Head Shop
Three machines eliminated and saved 1.29 Lac kwh annually
Present Condition
Methodology/Approach Adopted: -
Improvements Done/Kaizens done: -
Results:
Operation -Exhaust face at OP801. Boring and facing operation (Hole No.208 ) at right Side Fixture (ø33±0.20)2. Drilling (Hole No. 209 & 210) at left fixture.OP80 : Cycle Time of operation 24 sec
Machine CT Before Operation AddedOperation
ShiftedCycle Time
After
0P20 51 OP80, 209+210, 208 204,206 59
OP30 53 Comp Marking - 56
OP40 55 204,206 205,207 53
OP50 60 205.207108, Comp
Marking55
OP60 52 108 - 60OP80 24 - - Not req.
AFTERBEFORE
1
Kaizen-1 OP 80 (ø 33±0.20 & ø 5.45+0.15 ) operation will be done at OP20 with fixture modification
Kaizen-2- Trial Of PCD Thread Mill for tappet face operation in place of Drilling and tapping Operation thereby reducing cycle time by 5 sec.
2
Horizontal Deployment StatusLine L1 L2 L3 L4 L5 L6 L7 L8 L9
Plan Feb-18 Feb-18 Feb-18 Feb-18 Feb-18 Feb-18 Sep-17 Oct-17 Oct-17
Actual Done Done Done Done Done Done Done Done Done
Operation Rebalancing :- This operation is shifted in Cell (ie, OP20 –OP60) by rebalancing the tool operation
209 & 210
208
SPM
OP30OP20 OP40 OP50 OP 60 OP 70 OP 80Rotary OP 10A
1. 8 manpower - Rs. 16 Lacs2. Productivity will increase from 57.61 to 61.063. Power saving= 1.29 Lacs Kwh per annum,
National Award for “Excellence in Energy Management – 2016 48National Award for “Excellence in Energy Management – 2018” 48
S. No
Description Module 1 Module 2 Module 3Modul
e 4
1Flow Direction
2Capacity distribution
2430 3038 3038 1215
3Manpower -nos
70 86 82 41
Background Improvements Done
Results:
Weld line 1&2 capacity was under-utilized (2400 FT/Day) wrt Line 3&4 (3000 FT/Day) due to layout constraint
To utilise Weld line 1&2 Capacity & enhance Manpower productivity from 35.22 to 38.46through Layout Change similar to Line 3&4
# DescriptionUOM
Before After
1 Capacity nos 2430 3038
2 Productivity nos 35.22 38.46
3 Layout --
Annual Savings of Rs 36 lakhsSavings of 10 Manpower = Rs 2 x 10 = Rs 20 lakhs,Power Savings 806kwh = Rs 14.5 lakhsPPE’s Rs 1.5lakhs
Investments: Investment of Rs 15.5 lakhs(FDV’s, Electrical, New Booths, New Brazing system, Piping, Underground Piping work, etc)
Process flow streamlined with minimal changes (Half Line)
L1
L2
L3
L4
L5
L6
L7
9.4.2 Productivity Enhancement through Weld Line 1&2 Relayout
Energy Savings of Rs 14.5 Lacs through layout modification
Methodology/Approach Adopted: -
National Award for “Excellence in Energy Management – 2016 49National Award for “Excellence in Energy Management – 2018” 49
9.4.3 Improvement through Automated Guided Vehicle
Improvements Done
Results:
In current condition, Material feeding from store to Line is being done through MHE.
Laser based Natural navigation type Automated Guided vehicle deployed for material feeding.
• Total 170 nos. Manpower used in different sections for material transfer.
• We have proposed Logistic automation though Automated guided vehicle for material feeding
BOSF Material feeding for Machine DOL to Shop Floor
• Crankshaft• Cylinder Block• Cylinder Head
• 05 Nos. of PPC manpower • Project Investment = Rs. 55.0 Lacs• Saving = Rs. 10.0 Lacs• ROI = 5.5 Years
• Max Speed = 90m/min• Stop accuracy = +/- 20mm• 3 zone safety = SIL-3• Battery backup = 8 hrs.
Saving of 05 nos. manpower will leads to cost saving of Rs. 10 Lacs/annum
Background
Methodology/Approach Adopted: -
National Award for “Excellence in Energy Management – 2016 50National Award for “Excellence in Energy Management – 2018” 50
1. Conventional Cooking Equipment were used in Canteen
2. Natural gas Consumption / Annum = 1.17 Lakh SCM/Annum (2015-16 )
3. Cooking Oil Consumption/Annum = 0.45 Lakh Lt/Annum (2015-16)
Project Objective : To Replace Conventional Equipment with Modern Equipment for Cooking Oil, Natural Gas and Manpower Saving
Target Setting : Project was worked upon @ 7000 VPD so saving calculated accordingly
Canteen Re-layouting Saving Plan (Phase-2)
Description Before After Saving in Rs. lacsNatural gas 117,456 93,964 5.4
Frying Oil 45,803 38,738 9.0Manpower 125 122 6.0
Total Expected Saving = Rs. 20.4 Lakh
Rice Cooking Daal,
Vegetable Boiling
Patties,Tikki, Bread Roll
Utilization
For cooking Meeting related Snacks (Less Qty Snacks)
For Blanching Daal, Vegetables
Gravy Making
DescriptionProposed
Saving (Rs. Lakh)
Actual in Feb'17 (Rs. Lakh)
Actual Savings Annual
(Rs. Lakh)Natural gas 5.4 0.20 2.4
Frying Oil 9.0 0.90 10.8
Manpower 6.0 0.17 2.0Total 20.4 1.3 15.2
Previous Condition Improvements Done
Methodology/Approach Adopted: -
Results:
Conventional inefficient equipment replaced with latest efficient equipment
9.4.4 Canteen Re-layouting with new equipment
AfterBefore
National Award for “Excellence in Energy Management – 2016 51National Award for “Excellence in Energy Management – 2018” 51
1. Energy consumption reduction.2. Saving of 317 units/day.
Split AC without Eco plug leading to high energy consumption.
Energy/Loss Reduction Plug generally compares the temperature of liquid line to the temperature of environment. If the desired temperature difference is maintained it switches of compressor of AC to save energy consumption• Eco Plug generally compares the
temperature of liquid line Eco Plug generally compares the temperature of liquid line to the temperature of environment. If the desired temperature difference is maintained it switches of compressor of AC to save energy consumption to the temperature of environment. If the desired temperature difference is maintained it switches of compressor of AC to save energy consumptionEco Plug installation resulting in Saving of Rs 3.85 Lacs/Year
Project: 5Innovative9.4.5 Adopting switching Technology (Eco Plug)
Previous Condition Improvements Done
Benefit:
Methodology/Approach Adopted: -
Results:
Eco plug benefits:•Saves Power up to 30%•Fits on almost all AC models•Increases Compressor Life•Helps in reducing Global Warming•An eco-friendly device
2.001.30
0.00
0.50
1.00
1.50
2.00
2.50
Before After
Lac Kwh/Year Split AC Kwh Consumption
0.70 Lac kwh
Eco Plug
Before After
National Award for “Excellence in Energy Management – 2016 52National Award for “Excellence in Energy Management – 2018” 52
1. Natural gas consumption reduction.2. Saving of 339 scm/day.
9.4.6 Optimization of temperature in Hot Water Generator
Previous Condition Improvements Done
Benefit:
Methodology/Approach Adopted: - Results:
0.26 0.22
0
0
0
0
0
1
Before After
SCM/Veh.
0.4 SCM/Veh.
Before After
HWG set temp- 90 *C
Temperature reduced to 80*C , Savings Achieved - ₹ 19 Lakhs
There is High consumption share of Natural Gas in Hot water Generator -2550 SCM/day ( yearly average of Fy16-17) which shares almost 9 % in cost of total power & fuel cost.
By optimizing hot water supply temperature to paint shop baths , we are planning to reduce natural gas consumption by 15 % in summer & winter in phase manner
HWG set temp- 80 *C
National Award for “Excellence in Energy Management – 2016 53National Award for “Excellence in Energy Management – 2018” 53
9.4.7 Air Compressor Efficiency and Air leakages
Shop Wise Leakage Identification & Plant Wide Adherence Report Generation. Leakage Points Closure Status. (April 16 – July 17)Cross Functional projects taken to improve Air transfer efficiency
1011
10 10 1011
10 109 9
1011
0
2
4
6
8
10
12
April May June July Aug Sept OCT NOV DEC JAN FEB MAR
No
’s
Reporting Adherence
FAD TEST : Measurement of Efficiency at Source
S. NO
Compressor
Rated Capacity
at 8Kg/Cm2
(CFM)
Rated Input
Power (KW)
Avg. pressure (KG/cm2
Barg)
Avg. Actual
Capacity as per report (CFM)
AvgInput
Power (KW)
Specific Power (KW/ CFM)
1Centac
(NO6-1389)6018 930 5.7 5569 861 0.15
2Centac
(NO6-1388)4132 660 5.3 3948 617 0.16
3Centac
(09/555)2281 400 5.6 2244 342 0.15
4 SL-250WC 1597 250 5.7 1530 257 0.17
950890
970 1010 970 950 910 880850 860 840 850
0
200
400
600
800
1000
1200
April May June July Aug Sept OCT NOV DEC JAN FEB MAR
CFM
Plant Air Wastage Tracking (CFM)
5248
3733
2825
21
11 10 9 8
0
10
20
30
40
50
60
Al. CC AL. CH ST. PH Weld Paint FA34 EA12 EA34 FA12 ACED AL Exp
No
’s
Leakage Test : Total Plant Air Leakage Tracking
Leakage ReportedLeakage Corrected
National Award for “Excellence in Energy Management – 2016 54National Award for “Excellence in Energy Management – 2018” 54
9.4.8 Re-align air balancing in Paint Shop to reduce energy cons.
Motor Rating -110 KW
Air Supply Unit used for:-
Air Supply Unit (ASU) uses the atmospheric air from outside, refines the air, and supplies it to the Paint and maintain positive pressure and velocity 0.3 to 0.5 M/Sec thus not allowing external dust around the paint booth to enter into the paint booth.
After changing high efficiency booth velocity increased by 30% and we got opportunity to reduce frequency of blower motor.
Environment Air
Primer Coat Booth ASU at 45 HzAir Velocity 0.3 to 0.5 M/S
Exhaust System – 45 Hz
Air Supply System – 45 Hz
Base Coat Booth ASUAir Velocity 0.3 to 0.5 M/S
Top Coat Booth ASUAir Velocity 0.3 to 0.5 M/S
Exhaust System – 45 Hz
Exhaust air out Environment Air Exhaust air out Environment Air Exhaust air out
Air Supply System – 45 Hz
Exhaust System – 45 Hz
Air Supply System – 45Hz
Particles
Filter-medium
After
Dust-cake
Filter-medium
Before
Particle Filtration (Conventional)• Faster Choking • High Pressure difference • High Energy consumption
Depth Filtration • No Choking as particle suspended in non uniform media • High dust storage capacity • Low Pressure difference• Reduced Energy CostAir Velocity 0.3 to 0.5 M/S Air Velocity 0.4 to 0.6 M/S
National Award for “Excellence in Energy Management – 2016 55National Award for “Excellence in Energy Management – 2018” 55
Background:Air Supply Motor running at frequency of 45 Hz even when running idle (Black painting)
Methodology/Approach Adopted: -
Improvements Done
Timer provided for ASU motor Frequency reduction after 5 Mins change over from colour
painting to idle stateResults:
1. Power consumption reduced.2. Automation done No manual intervention required
Benefit:
No provision of reducing the Frequency during Black painting
1144 822
0
1000
2000
Before After
KWH/Day Power Consumption (KWH/Day)
321
PHE installation in washing m/c resulted Saving of Rs. 5.1 Lac /year
1. ASU motor frequency reduction 45Hz to 40Hz in colour painting.
2. Top Coat ASU motor frequency reduction from 40Hz to 35 Hz during black painting.
3. Exhaust motor frequency reduction from 34Hz to 30Hz
9.4.9 Re-align air balancing in Paint Shop to reduced energy cons.
National Award for “Excellence in Energy Management – 2016 56National Award for “Excellence in Energy Management – 2018” 56
Agenda
Brief introduction on Company/Unit
1. Specific Energy Consumption in last 3 years
2. Information on Competitors, National & Global benchmark
3. Energy Saving projects implemented
4. Innovative Projects implemented
5. Utilisation of renewable energy sources
6. Utilisation of waste material as fuel
7. GHG Inventorisation
8. Green Supply Chain
9. Team work, Employee Involvement & Monitoring
10. Implementation of ISO 50001/Green Co-rating
11. Other relevant information
National Award for “Excellence in Energy Management – 2016 57National Award for “Excellence in Energy Management – 2018” 57
ISO Certification Strategy10.1 Implementation of ISO 50001
Total Internal Auditors developed – 32 Nos.
We are certified company for ISO 50001
National Award for “Excellence in Energy Management – 2016 58National Award for “Excellence in Energy Management – 2018” 58
. .
HM3H won “Green Co Gold Rating- Green Company Rating System ”
Project DetailInvestmentin Crores
Robots for Paint Shop 12.00
0.95 MW Solar power plant 4.50
Zero Liquid Discharge Plant 7.75
Aero bells Upgradation 0.66
VFDs installation in motors 0.47
Solar Heating plant for Canteen 0.13
We are certified for CII Green Company Gold Rating
10.2 Green Co Rating Award
30346
0
5000
10000
15000
20000
25000
30000
35000
TURNOVER
Cro
re
Turnover of last 3 year
31
0
10
20
30
40
CAPITAL PROJECT
Cro
re
Investment of last 3 year
0.9
0.0
0.5
1.0
OTHER
Cro
re
Investment of last 3 year
National Award for “Excellence in Energy Management – 2016 59National Award for “Excellence in Energy Management – 2018” 59
Agenda
Brief introduction on Company/Unit
1. Specific Energy Consumption in last 3 years
2. Information on Competitors, National & Global benchmark
3. Energy Saving projects implemented
4. Innovative Projects implemented
5. Utilisation of renewable energy sources
6. Utilisation of waste material as fuel
7. GHG Inventorisation
8. Green Supply Chain
9. Team work, Employee Involvement & Monitoring
10. Implementation of ISO 50001/Green Co-rating
11. Other relevant information
National Award for “Excellence in Energy Management – 2016 60National Award for “Excellence in Energy Management – 2018” 60
Prominent Awards – Haridwar Plant11.1 Major Milestones– Haridwar Plant
1st Motorcycle produced at Haridwar Plant
Prestigious awards won by Hero MotoCorp, Haridwar Plant
CII
CII
CII
CII
CII
National Award for “Excellence in Energy Management – 2016 61National Award for “Excellence in Energy Management – 2018” 61
Market Share & Growth11.2 Prominent Awards – HMCL
Indian MNC of the Year’ Award -2017
TIME INDIA ‘Manufacturing Innovator of the Year’ – 2016
Bike Maker of the Year Award - 2013Business Leader of the Year Award -2013
2-Wheeler Manufacturer of the Year Award at CNBC Awards - 2015
Prestigious awards won by Hero MotoCorp
National Award for “Excellence in Energy Management – 2016 62National Award for “Excellence in Energy Management – 2018” 62
11.3 Major Projects Planned for Current year
Sr.No
Description Year Resource UOM
Energy/ Resource
Saving Per Year
Proposed Savings in
Lac Rs.
1Energy saving through absorption heat pump in HWG
FY 18-19 Fuel Ton SCM 225 90
2Solar Based 950 KW Power Plant. (20% Expansion in existing Capacity)
FY 18-19 Power MWH 1302 77
4Power wheeling from Renewablesources
FY 18-19 Power MWH 7800 39
5 Light Pipe Installation in plant FY 18-19 Power MWH 43 2.58
6Changing of Air end of 6000 CFM compressor.
FY 18-19 Power MWH 210 12.26
7Conventional motors replacement with Energy efficient motor
FY 18-19 Power MWH 132 7.73
8 Epoxy FRP Fan in Comp CT FY 18-19 Power MWH 19.80 1.16
Total Saving Expected in Lac - 230
Various projects are in pipeline in our journey to enhance renewable resource utilization
National Award for “Excellence in Energy Management – 2016 63National Award for “Excellence in Energy Management – 2018” 63
The Journey continues ………
Thank You