PCBU 1

TEAM MEMBERS

S G Nandanwadkar A P Gosavi K M Kulkarni

Deputy Manager Senior Engineer Senior Engineer
(Heat Treatment) (Paint Shop) (Engine Shop)

FACILITATOR
J K Tawade T.C.Patni
Assistant General Manager Deputy General Manager
(Manufacturing) (Manufacturing)

PCBU 2
 COMPANY PROFILE
TATA MOTORS
 One of India’s largest private sector companies
 The leading commercial vehicle manufacturer
 Annual turnover of over Rs 108 billion.
 The company has manufacturing plants at Jamshedpur,Pune and
Lucknow in UP.

PASSENGER CAR BUSINESS UNIT AT PUNE

 Born out of a vision to offer the Indian customer all the comfort of a big
car, at the price of a small car.
 The country’s first indigenously designed, developed and manufactured
passenger car.
 Launched the Tata Indigo, a sedan last year.
 Has a strong client following not only in India but also in Europe.

PCBU 3
 Plant Layout

T.Axle Engine

Comp
Offices Materials House

ETP CVBU
Press BIW

LPG
Paint Shop
Yard

Assy. Shop
Pump
N Sub Stn. House

PCBU 4
 Plant Profile: PCBU Pune

 Spread of Plant - 178 acres.

 Production Level - 82000 Units (2002-03)

Total shop Sub-stations - 27 Nos.

 Total connected load - 65 Mw.

 Maximum demand - 15 MVA

PCBU 5
 MANUFACTURING PROCESS

Committed Material
Human Resources
Transaxle &
Resource Stamping
Heat Treatment

BIW

Pretreatment,
Engine
coat & Painting

Vehicle
Efficient Assembly
Machinery Enabled
& Processes
Equipment
Dispatch

PCBU 6
 BREAK UP OF VARIABLE COST
2002-2003

12%

Indirect Materials

47% 26% Machinary Spares

(2001-02 58%)
Tools

Power, Fuel & Water

15%

ENCON DRIVERS

 TATA BUSINESS EXCELLENCE MODEL

 ISO 9000
 ISO 14000
 TPM
 KAIZEN

PCBU 7
 Assembly
Comp. House 3%
13%
Heat treatment Paint
9% 39%
2001-02

1002 Kwh /Car

Engine
23%
Press Weld
6% 7%
Shop wise consumption
Comp. Assembly
house 4%
Heat 14% 851 Kwh /Car
treatment
9%

2002-03
Engine
22% Paint
Press Weld 38%
5% 8%

PCBU 8
 ENCON ACHIEVEMENTS

TOTAL ENCON PROJECTS IMPLEMENTED

DURING 1999-2003

• TOTAL PROJECTS 105

• TOTAL SAVINGS (Rs Lakh/Year) 643.93

Savings 39%
(Over the base figure of 1999-2000)

PCBU 9
 JOURNEY TOWARDS ENERGY EXCELLENCE
THE METHODOLOGY

 Benchmarking

 Enhanced Capacity Utilization through Technology up gradation

 Energy Audits

 Energy Conservation through low cost automation

 Thermography :An Innovative way of Energy Conservation

 Energy Conservation through Process Optimisation

 Energy Conservation through rework elimination.

TEP : Energy Conservation, An Attitude of mind & not the effort.

 Sustainability through Continual Improvement

PCBU 10
 Benchmarking

 Inputs from M/s Harbor & Associates(USA) on various Automobile

Manufacturing aspects such as:
- Level of Automation
- AMH per Car
- Quality norms and standards followed internationally
- Throughput
 Study of processes and practices followed in similar industries
 Information sharing with domestic and international players

PCBU 11
 Benchmarking
• Processing of Mercedes Benz Cars In Indica Paint Shop has helped
us to Benchmark our processes and practices with that of Mercedes
Benz
• Added benefit of Paint shop capacity utilisation.

PCBU 12
 Capacity Utilization
Introduction of Various new Models on Indica Platform
1 E+05
Indica : Base Model

9 0000

Kwh / Car 81892

8 0000

1174
7 0000
64541 City Rover
6 0000

46720
5 0000

Indica Estate
4 0000
1002

3 0000

2 0000

Indica Sports 851

1 0000

Tata Indigo 2000-01 2001-02 2002-03 Volumes

PCBU 13
 Energy Audits : IF You Measure, You can Control
Conducted various Internal and Third party energy audits
Sr Area Auditing Measures Implemented as per audit Savings
No Agency findings achieved
1 Distribution M/s BSES Harmonic Analysis with corrective 7 Kwh/Car
system and M/s measures
Nelco Redistribution of LT supply system and
installation of HT Capacitors in view of
:Voltage drop optimization
Optimum Transformer loading
Overall Power Factor Improvement
2 Pumps, Fans M/s Nelco Installation of VFDs at 25 locations 12 Kwh/Car
and Blowers (Rs. 62.4
Lakhs/Annum)
3 Compressed M/s ARS Systematic approach to determine and 8 Kwh/Car
Air System Engineeri arrest compressed air leakages
ng &
CPED

PCBU 14
 Energy Audits : IF You Measure, You can Control
Conducted various Internal and Third party energy audits
Sr Area Auditing Measures Implemented as per Savings
No Agency audit findings achieved
4 Heating and M/s IIPM Re-insulation, Replacement of worn 2 Kg/Car
cooling out glass wool and cladding (LPG/Propane)
systems
5 Water M/s Gaytri Leakage arrestance for underground 3 M3 / Car
distribution Erectors water piping, & Increased frequency (Water)
and usage of booth water replenishment with
the use of biocides
6 Lighting Internal Use of latest lamps luminaries and 2 Kwh/Car
gears, Optimization of lux level by
selective controls for day and night
time requirements

PCBU 15
 Case Study 1
Energy Conservation through low cost automation

Underbody spray application at Paint Shop

Situation Before

• Manual Operation
•High amount of air supply
and Exhaust was required to
minimize the overspray and
to provide comfort to the
operator
•Painters were required to
go underneath of the cab to
perform the operation,
making it highly unsafe

Power Consumption :290 KWH

PCBU 16
 Case Study 1
Energy Conservation through low cost automation
Underbody spray application (Automatic) at Paint Shop
Encon Measure Implemented
• Designed and installed a low
cost under body spray machine
from salvaged machine
components
•Reduced Air Supply Blowers
motor pulley diameter from 300
mm to 242 mm and switched off
2# 30 Kw Exhaust blowers

Benefits achieved
• Elimination of manual work and
thereby overspray and comfort
requirements
•Improved ergonomics

•Power Consumption : 204 Kwh Net Saving Achieved 420000 Kwh/annum

PCBU 17
 CASE STUDY 2: OVEN HEAT BALANCE

Radiation Loss
Heat Input
Exhaust Loss
Air Seal and
Heat Zone
Air Seal and
and doors Heat
exchanger to
pre heat
Paint fresh air

Paint Baking Oven

PCBU 18
 CASE STUDY 2: OVEN HEAT BALANCE
Thermography : An Innovative way
Location Descriptions:- Paint Shop Surfacer Paint Oven/ Heat zone-1 (north side) AR01
Temperature (max.) 137.3°C
Observations:- AR01 & AR02 are showing the hot zones on right side middle portion.
SP01 shows the normal temperature observed on the shell which is 60 °C
Corrective Measures:- Attended the welding leakage and replaced the lining
128.0°C

120

AR02 100
AR01
LI01

80

60
SP01

40
36.8°C

Total locations identified and attended: 113

PCBU 19
 CASE STUDY 2: OVEN HEAT BALANCE

Thermography : An Innovative way

Location Descriptions:- CED Oven HZ-1 / East side 
AR01 Temperature (max.) 113.6°C
Observations:- AR01 shows a localized hot spot, where as the normal temperature observed on
the same surface is around 60°C only.
Corrective Measures:- Attended the welding leakage and replaced the lining
103.9°C
SP01
100

AR01 80

60
LI01

40
39.3°C

Total locations identified and attended: 113

PCBU 20
 Thermography : An Innovative way
Thermal Images of Ovens, Furnace and Gas Generator
AR01
224.1°C 172.9°C 101.9°C
SP01
100
160
200
90
SP01 140
SP01 80

150 120
AR01 70
LI01
AR01
AR02 100 60
AR02

100 LI01 80 50

72.6°C 46.7°C
82.0°C LI01

88.4°C
169.0°C
LI01 AR01 LI01 168.1°C
SP01 AR02
160 160
80
AR01 140 140
SP01
70 120
120
AR01
AR02
100 100
60
LI01
80 80
50
60 SP01 60

43.1°C
42.8°C 43.7°C

110.5°C
66.2°C
LI01 148.4°C

140 100
AR01
SP01 60

120 AR01
80
50 AR01 AR02
100 SP01
LI01
SP01 60
80
40
LI01
60 40

32.3°C
41.0°C
29.6°C

PCBU 21
 Thermography : An Innovative way
Some More Thermal Images
58.0°C 61.9°C 83.3°C

60 SP01 80
55
LI01 LI01 AR02
AR01
AR01 55 70
50 SP01
SP01

AR02 50
60
45 AR01

45
40 50
AR02
40

35.7°C 38.7°C 41.7°C

LI01

TCO-2 / Incinerator top portion TCO-2 / Hot air duct above heat zone-2) TCO-1 / Incinerator, on burner matting plate

69.5°C 139.3°C AR01 LI01 168.1°C

AR01
LI01 AR02 160

120 140

SP01 60 AR01 100 120

SP01 80 100

50 LI01 80
60

SP01 60
40

40.7°C 27.4°C 43.7°C

TCO-1 / West side TCO-1 / Incinerator left side joint portion SO-2 / Heat zone-1

PCBU 22
 Case Study 3: Paint Booth
Energy Conservation through Process Optimisation

Filters 1 Filters 3

Air Supply Blower

Filters 2

Filters 4

Filters 5

Exhaust Blower

PCBU 23
 Case Study 3
Energy Conservation through Process Optimisation

Bypass damper

M #

Paint booth fresh air supply blower with bypass damper to adjust the down draft

PCBU 24
 Removed bypass damper and blower RPM
controlled with the help of VFD

VFD

M #

Saving achieved 1365000 kwh/annum

PCBU 25
 Case Study 4
Energy Conservation through Process Optimisation

Heat Treatment

Continuous Case Hardening Furnace

PCBU 26
 O.K.

Rework

M M M

Fresh Components

Continuous Case Hardening Furnace

PCBU 27
Rework 0.5 %

Rework per day 75 Kg

Required Energy per year. 45000 units

PCBU 28
PCBU 29
 Continuous Case Hardening Furnace

M M M

Fresh Components

PCBU 30
 Continuous Case Hardening Furnace

M M M

Furnace Test Piece

O.K.

Low Case Depth

PCBU 31
 M M M

Extend the cycle if the Case Depth is low

PCBU 32
 TEP
TOTAL EMPLOYEE PARTICIPATION

•Awareness generation through: Training, Suggestion box & Unique

Suggestion schemes, Slogans and Picture competition
•Shop floor publicity to ENCON measures
•In 2002-03 Total 3253 suggestions received from 1835 employees
Details of Unique Suggestion Scheme held in Jan 2003 for IMC
reduction
Total no of suggestions 924
received
Electrical Encon 175
Water Conservation 25
Fuel Encon 16
Compressed air Encon 31
Oils, Thinners, Sealants, 677
Tools etc

PCBU 33
 TEP
TOTAL EMPLOYEE PARTICIPATION

•Knowledge sharing Platforms :

- Share Café : A unique Intranet site with access to
all employees

- Tata World : An internet site for all Tata group employees

PCBU 34
 TATA MOTORS

PCBU

Sustainability

Through Continual Improvement

PCBU 35
 Trend for Specific Energy Consumption

Electricity (KWH/Car) Compressed air (KWH/Car)

1500 140
1387.66
1400 129 127.28
1300
1174.22 120
1200
108.72
1100 1002.93
Target = 90 100.68
1000
851.36 100
900 Target = 800
800
700 99-00 00-01 '01-02 '02-03 80
99-00 00-01 '01-02 '02-03
LPG (Kg/Car) Water (M3/Car)
60 16
13.25 12.88
46.78
50
44.64 12
40
8.53
28.52 8
26.14
30
Target = 24 Target = 5 5.16
20 4
99-00 00-01 '01-02 '02-03 99-00 00-01 '01-02 '02-03

PCBU 36
 Energy Monitoring Formats
ELECTRICITY CONSUMPTION
ELECTRICITY (KWH/Car)
CONS. PER CAR 440
TA
FOR THE FOR THE CUMM. R
DATE DAY DAY MONTH G
02-03 329.4 ## 329.4
420
03-04 308.29 ## 308.29
LAST MONTH 300.11 ## 300.11
1-Oct 136608 303.13 303.13 ##
2-Oct 21198 350.17 400
##
3-Oct 126906 468.00 396.18 ##
4-Oct 420.91 ##
5-Oct 122366 286.40 370.79 ##
380
6-Oct 131970 313.90 355.55 ##
7-Oct 136158 314.29 346.62 ##
8-Oct 140766 312.88 340.63 ##
9-Oct 23280 349.98 360
##
10-Oct 127524 304.73 349.98 ##
11-Oct 128332 287.35 343.34 ##
12-Oct 129582 310.85 335.80 ##
13-Oct 125688 277.41 333.02
340
##
14-Oct 125238 267.31 327.00 ##
15-Oct 122238 286.93 320.99 ##
16-Oct 15654 318.14 320
##
17-Oct 126372 264.18 321.22 ##
18-Oct 129990 315.22 316.13 ##
19-Oct 134581 311.80 316.24 ##
20-Oct 135972 297.64 315.94
300
##
21-Oct 129096 307.08 314.92 ##
22-Oct 130080 284.18 314.28 ##
23-Oct 17118 312.50 280
##
24-Oct 12894 314.71 ##
25-Oct 14508 316.37 ##
26-Oct 23346 318.25 ##
260
##
LAST M ONTH

27-Oct 123336 279.22 321.27

10-Oct

13-Oct

15-Oct

18-Oct

21-Oct

26-Oct

28-Oct

30-Oct
11-Oct
12-Oct

14-Oct

16-Oct
17-Oct

19-Oct
20-Oct

22-Oct
23-Oct
24-Oct
25-Oct

27-Oct

29-Oct

31-Oct
02-03
03-04

5-Oct
1-Oct
2-Oct
3-Oct
4-Oct

6-Oct
7-Oct
8-Oct
9-Oct

28-Oct 120990 278.27 319.00 ##

29-Oct 122274 257.87 316.94 ##

PCBU 37
 Energy Monitoring Formats
LPG CONSUMPTION
CONS. PER CAR TA
FOR THE FOR THE CUMM. R
DATE DAY DAY MONTH G26
02-03 22.4 22 22.4
03-04 20.5 22 20.5
LAST MONTH 20.44 22 20.44
25
1-Oct 9309.95 20.64 20.64 22
2-Oct 20.64 22
3-Oct 91.05.79 33.60 25.61 22
4-Oct 25.61 24
22
5-Oct 9204.61 21.51 24.02 22
6-Oct 9562.08 22.77 23.48 22
7-Oct 9070.98 20.95 22.93 22
8-Oct 9482.24 21.07 22.89 23
22
9-Oct 22.89 22
10-Oct 9108.1 21.79 22.61 22
11-Oct 8874.34 19.85 22.22 22
22
12-Oct 9388.06 22.51 22.27 22
13-Oct 8805.93 19.44 21.96 22
14-Oct 9214.72 19.65 21.73 22 TARGET = 22 KG/Car
15-Oct 9337.06 21.92 21.75 21
22
16-Oct 21.75 22
17-Oct 9754.05 20.41 21.63 22
18-Oct 9748.9 23.66 21.77 22
19-Oct 9559.55 22.13 21.80 20
22
20-Oct 9399.2 20.57 21.71 22
21-Oct 9888.13 23.54 21.82 22
22-Oct 9208.8 20.11 21.72 22
19
23-Oct 21.72 22
24-Oct 21.72 22
25-Oct 21.72 22
26-Oct 21.72 18
22
LAST M ONTH

10-Oct

14-Oct

15-Oct

19-Oct

21-Oct

23-Oct

25-Oct
26-Oct

27-Oct

30-Oct
11-Oct

12-Oct
13-Oct

16-Oct

17-Oct

18-Oct

20-Oct

22-Oct

24-Oct

28-Oct

29-Oct

31-Oct
02-03
03-04

1-Oct
2-Oct

3-Oct
4-Oct

7-Oct

8-Oct
9-Oct
5-Oct

6-Oct

27-Oct 10279.8 23.26 21.80 22

28-Oct 10629.3 24.44 21.93 22
29-Oct 10841.3 22.87 21.98 22
30-Oct 22
31-Oct 22

PCBU 38
 Energy Monitoring Formats
WATER CONSUMPTION
CONS. PER CAR
5
TA
FOR THE FOR THE CUMM. R
DATE DAY DAY MONTH G
02-03 3.03 3 3.03
03-04 2.86 3 2.86
LAST MONTH 2.52 3 2.52
1-Oct 1010 2.24 2.24 3
2-Oct 940 4.33 3
3-Oct 830 3.07 3.85 4
3
4-Oct 510 4.56 3
5-Oct 1110 2.60 3.83 3
6-Oct 1110 2.64 3.51 3
TARGET 3 M3/ CAR
7-Oct 970 2.24 3.24 3
8-Oct 980 2.18 3.04 3
9-Oct 770 3.36 3
10-Oct 910 2.17 3.18 3
11-Oct 1060 2.17 3.07 3
3
12-Oct 1010 2.17 3.00 3
13-Oct 1100 2.42 2.94 3
14-Oct 1180 2.43 2.90 3
15-Oct 980 2.52 2.85 3
16-Oct 560 2.96 3
17-Oct 970 2.30 2.88 3
18-Oct 1160 2.03 2.87 3
19-Oct 1000 2.32 2.84
2
3
20-Oct 1090 2.39 2.81 3
21-Oct 1060 2.52 2.79 3
22-Oct 1100 2.40 2.85 3
23-Oct 660 2.92 3
24-Oct 510 3.04 3
25-Oct 950 3.17 3
26-Oct 970 3.15 3
1
L AST M ONTH

27-Oct 1250 2.83 3.11 3

20-Oct
21-Oct

29-Oct
30-Oct
10-Oct
11-Oct
12-Oct
13-Oct
14-Oct
15-Oct
16-Oct
17-Oct
18-Oct
19-Oct

22-Oct
23-Oct
24-Oct
25-Oct
26-Oct
27-Oct
28-Oct

31-Oct
02-03
03-04

7-Oct
1-Oct
2-Oct
3-Oct
4-Oct
5-Oct

6-Oct

8-Oct
9-Oct

28-Oct 1030 2.37 3.10 3

29-Oct 3
30-Oct 3
31-Oct 3

PCBU 39
 Law of Energy Conservation

• Energy Can Neither be generated nor be destroyed,

But………………….

• It can certainly be Conserved & Reused

PCBU 40
We must not be selfish or timid if we hope to
have a decent world for our children and
grandchildren. We simply must balance our
demand for energy with our rapidly shrinking
resources. By acting now we can control our
future instead of letting the future control us.

-Jimmy Carter

PCBU 41
Thank You

PCBU 42