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BAL-Waluj
Contents
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
x.
Company profile
Manufacturing process
Energy Conservation cell
Scope
Energy Indices /Benchmarks
Energy Conservation Methodology
Energy Conservation Approach
Energy cost loss Tree
Innovative Projects
Other Encon Projects
a.
Electrical
b.
Use of renewable energy
c.
Thermal
xi. Environment & Carbon Reduction
xii. Utilization of waste
x.
Results
xi. Sustenance
xii. Future Project
xiii. Achievements
2
BAL-Waluj
Company Profile
BAL-Waluj
Automotive
Finance &
Insurance
Power &
Infrastructure
Company Profile
BAL-Waluj
Manufacturing locations
Pantnagar Plant
Plant and its vendors in
the same premises.
Plant produces Discover,
Boxer & Platina range of
motorcycles.
BAL-Waluj
Company
Vision
Company
Mission
Key
Management
Index
TPM
Key
Performance
Index
Key
Activity
Index
ISO
ISO9001
9001
ISO
ISO14001
14001
OHSAS
OHSAS
18001
18001
ISO
ISO5000150001-Initiated
Initiated
5
BAL-Waluj
Aluminium
Shop
Vendor
parts
Domestic
Dispatch
Paint
Steel Shop
Vehicle Assly
Engine Assly
Heat Treatment
Export
Dispatch
Central Gear
Shop
BAL-Waluj
Energy Manager
Plant
Vision/Mission
Management
Review
Execution &
Monitoring
Encon Projects
Budget Allocation
BAL-Waluj
Bi-Monthly Review
Plant Head
Monthly Review
Fortnightly
Div Head
Machine
Shops
Div Head
Div Head
CGS/HT
Paint Shop
Div Head
Div Head
Div Head
Assembly
Utility
Dept. Head
Dept. Head
Energy
Captains
Energy
Captains
Energy
Mgr.
Weekly
Dept. Head
Dept. Head
Dept. Head
Dept. Head
Energy
Captains
Energy
Captains
Energy
Captains
Daily
Energy
Captains
BAL-Waluj
Functions
Manufacturing excellence
TPM- Review/Implementation
25
20
15
New Products
15
10
10
Administrative Issues
Sr No.
Level 1
Review Mechanism
Plant Head
Monthly
Level 2
DIV Head
Fortnightly
Level 3
Energy Manager
Weekly
Level 4
Energy Captain
Daily
9
Encon Strategy
BAL-Waluj
BAL-Waluj
Micro
MicroLevel
LevelMonitoring
Monitoring
Judicial
JudicialEnergy
EnergyUtilization
Utilization
Harnessing
HarnessingSolar
Solar&&Wind
WindEnergy
Energy
Carbon
CarbonEmission
EmissionReduction
Reduction
Sustainable
Sustainable Business
BusinessGrowth
Growth
Green
GreenFactory
Factory
Improvements
Technology Up gradations
Energy Optimization
System Auto controls
Waste Minimization
Energy
EnergyConservation
ConservationTechniquesTechniquesLocalized
Localizedcontrol
control
Human
HumanDependent
Dependentsystems
systems
Working
Workingon
on
Legacy
Legacysystem
system
2010 -2015
2002-2009
1998-2001
1985-1997
Year
11
BAL-Waluj
Base
Year
Unit
Achieved
Target
2003-04
2004-05
2005-06
2006-07
2007-08
2008-09
2009-10
2010-11
2011-12
2012-13
2013-14
Kwh/
veh
67.54
49.31
45.81
42.99
36.72
34.9
31.45
25.41
22.61
21.15
20.1
LPG
Kg / veh
2.53
2.75
2.4
2.8
2.4
2.2
2.1
1.77
1.45
1.33
1.26
Water
m3 / veh
0.89
0.65
0.62
0.58
0.54
0.52
0.41
0.35
0.41
0.27
0.25
Electricity
Sr.
Energy
In 10 Year s
SEC Reduction %
In Last 3 Years
In last year
1
2
Electrical ( Kwh/Veh)
Fuel ( LPG) ( Kg/Veh)
69%
48%
32%
38%
6.41%
7.14%
69%
34%
34%
12
BAL-Waluj
Sr.
Energy
BAL , Waluj
Nearest competitor
Global
Electrical ( Kwh/Veh)
21.15
24.55
NA
1.33
2.6
NA
Water ( Cub.Mtr/Veh.)
0.27
0.41
NA
Diesel (Ltr/Veh)
0.09
2.3
NA
13
BAL-Waluj
14
BAL-Waluj
Sr.
Activity
No.
Methodology
Tools used
Weekly / Monthly data through Pie
charts & brainstorming
Audit
conservation potential
2
Analysis
Action Plan
Implementation
Evaluation
Sustenance
Internal Audits
15
BAL-Waluj
Loss Reduction /
Elimination
Technological
Improvement
Loss
Elimination
Alternate
Source
Sr
.
Operational Control
Efficient
Equipment
Sr
.
1
Sr.
Idea
Transmission Loss
1 LED/CFL/Induction Lamps
Distribution Loss
2 Solar Lighting
2 Efficient Motor/Pumps
Auditing
3 Screw Compressor
Energy Captain
Idea
Idea
Sr.
5 LPG Heating
6 Magnetic Energy
Idea
7 Inefficient Equipment
16
BAL-Waluj
Approach
Idea
Eliminate
wastage
Switched off sodium vapor lamps of 250 watts in non moving areas
Provided occupancy switches for lights in warehouse
Switched off Hydraulics during machine idle time.
Optimization
Alternate
Methods
Usage of
renewable
energy
BAL-Waluj
Approach
Idea
Optimization of compressed
air supply
18
BAL-Waluj
Technological
Improvement
Loss
Loss
Elimination
Alternate
Source
Sr
.
Sr.
Idea
Operational Control
Efficient
Equipment
Sr.
Idea
Idea
Sr.
1 Direct heating
Idea
2 Use LNG
Auditing
Energy Captain
19
BAL-Waluj
Approach
Idea
Eliminate wastages
Optimization
Tuning of burners
Process change
20
BAL-Waluj
Innovative projects
21
BAL-Waluj
Innovative Project -1
132 KV supply
from MSEDCL
MSEB
Metered
consumption
Sr.
GTL Limited
Energy meter
Plant
Metering
Key Initiative
Shop Wise
Energy meters
MRS
Benefit
Idea generation,
Prioritization of Energy
work
Feedback Transformer(CT/PT)
Calibration
Eliminate Metering
error
22
Distribution
Loss
Sr
.
1
Key Initiative
Saving
Achieved
Optimization of transformer
loading
3 transformers
4.6 L Kwh
BAL-Waluj
Sr.
Activity
MS plate at secondary
Over hauling of distribution
terminals replaced with SS
transformer
plate
2
Switching off standby
transformers
Standby transformer
switched off with Isolator
switch on transformer
keeping 11 Kv cable
charged-8 Nos.
Load balancing ( between
50 to 70%) of transformers
& switched off 4 Nos.
transformers
Saving
Total saving
Investment
0.5
Kwh/Hr/
Transforme
r
1.27 L kwh/Yr
Rs.6.23 L
2 Kwh/Hr/
Transforme
r
RS.4.8 L
23
BAL-Waluj
Innovative Project -2
Power Factor /Reactive power compensation at Press & Fabrication shop
Unity Power Factor Ensures reduction in distribution loss & get Incentives .
Balanced & stable Load can be catered using switched capacitors & can be contactor
or Thyrister based.
Capacitors contributes in amplifying harmonics in system due to resonance.
Unbalanced load are large single phase loads distributed on 3 phase system with lot of
diversity
Two Phase MIG welding machines are in use in large no. This is typical form of
unbalanced load . As a result KVAR requirement differs in each phase & also changes
very quickly .
BAL-Waluj
25
BAL-Waluj
Before
250k
1.05
1
0.95
200k
0.9
0.85
0.8
var
150k
0.75
0.7
0.65
100k
0.6
0.55
0.5
50k
0.45
2/14/2013
11:45:29.492 AM
3:14.421 (min:s)
38 s/Div
2/14/2013
11:41:11.161 AM
2/14/2013
11:48:43.912 AM
We can see
KVAR requirement varies from 75
KVAR to 200 KVAr
Current varies from 500 A to 1200 A
Different in different phase Typical
unbalanced load
7:54.380 (min:s)
1 min/Div
2/14/2013
11:49:05.542 AM
26
BAL-Waluj
After
1.05
100k
0.95
50k
0.9
var
0.85
0k
0.8
-50k
0.75
0.7
06-07-2013
11:54:02.110
5:52.678 (min:s)
1 min/Div
06-07-2013
11:43:42.581
06-07-2013
11:59:54.788
25:51.039 (min:s)
5 min/Div
06-07-2013
12:09:33.620
27
Saving
Investment
: 1.26 LKwh/ Yr
: Rs. 15 lacs
28
BAL-Waluj
Innovative Project -3
Sr.
BAL-Waluj
Before
Phase 2
After
After
Consumption 17 % of Plant
Consumption
Shop wise Metering for
Compressed air
29
BAL-Waluj
Phase 1
Before
No air on off valve, Air Gauge
continuous ON
Phase 2
After
After
Foot valve( ON -OFF)
in pneumatic circuit
Air for
Job
Check
Dial
Gauge
Air for
machine
30
Solenoid
valve
Sensor
Switch
Electrical- Lighting
Sr.
Phase 1
After
Phase 2
After
Before
300 Watt SV lamps
650 No.s Lamps
Connected Load 195 Kw
Consumption 7.11 L Kwh/Yr
BAL-Waluj
Street
Light
31
Electrical- Lighting
Sr.
Phase 1
Phase 2
Before
Shop
Lights
BAL-Waluj
After
After
Saving
Investment
32
: 0.48 LKwh/ Yr
: Rs. 9.18 Lacs
BAL-Waluj
Electrical- Lighting
Paint Booth Lighting( flame proof)
Before
After
Use of 8 X 40 W Tubes
Saving
Investment
Use of 6X 36 W CFL
300 Fittings
Before
After
Use of Structure
Use of 36 W Tube light at 1
Tube lights (2*40 Watt) Meter Height
at 5 meter height
Saving
Investment
: 1.26 LKwh/ Yr
: Rs. 30 lacs
: 0.35 LKwh / Yr
: Rs. 2.5 lacs
33
Saving
Investment
BAL-Waluj
Before
After
Centralized ARP
Breeze air spot
cooling system With coolers used With 2
100HP motor
HP blowers (18 No.)
Saving
Investment
34
Pump Elimination
Pump Optimization
Before
75 Kw Motor
Total Load -102
Kw
BAL-Waluj
Before
After
37 Kw Motor
Total Load -67
Kw
After
BAL-Waluj
After
No VFD,
Exhaust blowers-7
Nos. running at
constant speed for
18 hours /day
Conventional Motor
used for
Actual Load 37 KW
VFD Installed
Blowers running at 50 %
speed in recess time
Saving
: Rs. 0.56 Lacs / Yr
Investment : Rs. 0.78 Lacs
Horizontal deployment : 5
BAL-Waluj
Phase 1
Before
Phase 2
After
After
Compr
essed
air
37
BAL-Waluj
Electrical- Cooling
Fanless Cooling Tower
Before
After
Air Movement in
cooling Tower induced
with the help of Exhaust
Fan of 4 HP
Description
Room AC
Panel AC
Water coolers
Saving
Investment
38
Before
( Deg.C.)
After
( Deg.C.)
21
24
30
34
18
24
Electrical- Cooling
BAL-Waluj
After
After
Electric Heater
BAL-Waluj
After
Heat pump For
washing machine
water heating
Saving
Investment
: Rs.3.26L / Year
: Rs. 3.5 Lacs
Saving
: Rs.1.75L / Year
Investment
: Rs. 3.1 Lacs
Horizontal deployment : 20 locations
40
BAL-Waluj
Thermal
41
BAL-Waluj
Thermal
Sr. no. Shop Name
Paint Shop
Paint Shop
Heat treatment
Heat treatment
Discription
Year
Annual Thermal
Investment
made
Units
(Mn T)
Rs.
(Mn)
Rs Lacs
0.0041
0.2173
1.00
0.057
3.021
0.00
2012-13
0.001
0.053
1.00
2012-13
0.001
0.053
0.50
2012-13
0.001
0.053
0.00
2012-13
0.001
0.053
0.00
2012-13
0.001
0.053
0.00
2012-13
0.006
0.318
0.00
2012-13
0.002
0.106
0.00
0.002
0.106
1.00
11 Heat Treatment
0.001
0.053
1.00
0.0771
4.0863
4.5
Heat treatment
Heat treatment
7
Paint Shop MCD
8
9
Heat Treatment
42
2012-13
BAL-Waluj
Saving
Investment
43
BAL-Waluj
Light Collector
& diffuser
Reflective system
Roof Installation
Light Pipe
Size
Eqv.
Wattage
Light
out Put
Area
Coverage
Energy
Saving
Investment
Carbon
reduction
530 Mm
300
Watts
4000
Lux
500 Sq Ft
1100
Kwh/Year
0.21 Lacs
0.88 Ton/Year
Horizontal Deployment : 25
44
BAL-Waluj
Year
Installed
Capacity
Wind power
Generated
Waluj Plant
consumption
Wind Power
adjusted
Contrib
ution
(MW)
( L kwh)
( L kwh)
( L kwh)
Tons
2010-11
65
949
573.48
239.28
41
19142
2011-12
65
1076
589.86
268.68
45
21494
2012-13
65
888
540.7
260.68
48
20854
45
BAL-Waluj
Location
Area Utilised
72
280 watts each
Solar Chip
Polycrystelline
Lanco
DC voltage
720 Volt
Invertor Make
Invertor Model
Refu
Refusol
Invertor capacity
Invertor Output
19.2 Kva
3 Phase/415 V /50 Hz
Power generation
Supplied By
Commissioning by
BAL-Waluj
Future Projects :
Rooftop Solar Power Plant Up to 10 MW
Open access Power trading
47
BAL-Waluj
Year of
Implementation
No. of
Projects
Savings
Investment*
Rs. Million
Rs. Million
2009-2010
36
5.5
3.6
2010-2011
35
10.5
7.9
2011-2012
21
13.21
12.58
2012-2013
44
17.35
22.2
Grand Total
136
46.56
46.28
48
BAL-Waluj
Result
Electrical Energy Consumption / Vehicle
Kwh/Veh
69 %
Energy
Electricity
Unit
Kwh
/
veh
Base
Year
Targe
t
Achieved
2003-04
200405
2005-06
2006-07
2007-08
200809
2009-10
2010-11
2011-12
2012-13
2012-13
67.54
49.3
1
45.81
42.99
36.72
34.9
31.45
25.41
22.61
21.15
19.0
49
BAL-Waluj
Result
Thermal Energy Consumption / Vehicle
Kg/Veh
Energy
LPG
48 %
Unit
Kg /
veh
Base
Year
Targe
t
Achieved
2003-04
200405
2005-06
2006-07
2007-08
200809
2009-10
2010-11
2011-12
2012-13
2012-13
2.53
2.75
2.4
2.8
2.4
2.2
2.1
1.77
1.45
1.3
1.17
50
BAL-Waluj
Result
Water Consumption / vehicle
69 %
Energy
Water
Unit
m3 /
veh
Base
Year
Achieved
Target
2003-04
2004-05
2005-06
2006-07
2007-08
2008-09
2009-10
2010-11
2011-12
2012-13
2013-14
0.89
0.65
0.62
0.58
0.54
0.52
0.41
0.35
0.41
0.27
0.20
51
BAL-Waluj
SUSTENANCE
Sustenance
Activities
Loss
Loss
Identification&
Identification&
Corrective
Correctiveactions
actions
Monitoring
Monitoring&&
Measurement
Measurement
Audits
Audits
Review
Review
Daily/Monthly
Electrical Energy
Internal
Audits
Daily
Review by
Div Head
Leakage
Identification
Daily/Monthly
LPG
External
Audits
Consumption
Data Analysis
Daily/Monthly
Water
Daily/Monthly
Fuel
Daily/
Weekly
Review by
Plant Head
Energy Index
Review by
Corporate
EMS
52
Technology
Technology
Up
Upgradation
gradation
Adoption of
Energy efficient
Technology for
Manufacturing,
Monitoring
Education
Education&&
Training
Training
Energy
Managers
Training
Energy
Captains
Training
Group
Leaders
Training
Vendor
Training
HD
HDofof
Kaizen
Kaizen
Implement
ENCON project
HD of
ENCON project
in other shops.
Plant, Vendors
BAL-Waluj
SCADA
54
BAL-Waluj
BAL-Waluj
55
BAL-Waluj
Year
2008
Audit for
Projects ( Nos. )
Saving Potential
Status
Electrical, Thermal
21
20 L kwh
17 L kwh
2011
Compressed Air
6.5 L Kwh
5.5 L KWh
2011
Water system
1500 Cub.M. /d
2012
1.2 L Kwh
0.8 L Kwh
2012
10
2.7 L Kwh
WIP
2012
63456K Cal
WIP
2012
7 L Kwh
WIP
2012
6 L KWh
3 L KWh
2013
Chillers
2.62 L Kwh
WIP
56
Awareness creation
BAL-Waluj
Monthly Kaizen
Karakuri
State & National level
ENCON week
Poster display
Energy Seminar
New Product display
57
Awareness creation
BAL-Waluj
Energy
Conservation Week
- 14th-20th Dec
Energy Efficient product display for vendors
58
BAL-Waluj
Awareness creation
Kaizen matrix
Sr.
Loss
Elimination
Alternate
source
Efficient
Equipment
Operational
Control
Total
Machining
15
14
36
Paint
23
15
45
16
12
36
Assembly
12
19
Utility
23
18
46
Total
89
62
22
182
Kaizen Ideas generated & implementation through our 105 Energy Captains
59
Environment Improvement
Environment &
carbon Reduction
60
BAL-Waluj
Water Conservation
BAL-Waluj
Production Up
by 55 %
Water consumption Down
by 44 %
Recharging
of Ground
Water
BAL-Waluj
Sr.
1
Water
Water consumption - %
Industrial cooling
Process
Domestic
59
34
62
BAL-Waluj
Approach
Idea
Eliminate wastages
63
Media Publications
Unicef Report
64
BAL-Waluj
Media Publications
BAL-Waluj
65
Media Publications
Sakal
66
BAL-Waluj
Media Publications
BAL-Waluj
67
Environment Improvement
BAL-Waluj
Ground water recharging with rain water (Patented with KEDIA FARM PATTERN) by
deep percolation technique. Capacity -8 L kL
Effluent treatment plant (ETP) has been upgraded to separate industrial & domestic
effluent resulting in better quality of treated water.
68
Water Conservation
BAL-Waluj
After
RO Plant
Effluent
Treatment Plant
Effluent
Use for
Horticulture
Investment
Rs.3.0 Cr
Qty
2 Nos.
69
Water Conservation
Rain Water Harvesting
BAL-Waluj
FY 13-14
Investment
Rs.12 Lacs
Qty
Investment
Rs. 24 Lacs
Qty
70
BAL-Waluj
Water Conservation
FY 12-13
FY 13-14
Investment
Rs.15 Lacs
Qty (KFP)
50 Nos.
Investment
Rs.36 Lacs
Qty (KFP)
160 Nos.
71
BAL-Waluj
Water Conservation
6
8
72
BAL-Waluj
Waste utilization
Heat recovery from waste flue gases at Low Temperature are installed in Paint shops
SN
LPG Saving
Kg/Year
Investment
( Rs. Lacs)
26100
9.75
10416
5.5
10416
5.5
38626
37135
12.5
73
BAL-Waluj
Waste utilization
Use of Bio Gas Plant in Canteen
After
Before
BAL-Waluj
Waste utilization
Reuse of Quenching Salt
Heat treatment
After
Before
Washer
components
Hot water
Salt +water
Burner
To ETP.
Waste utilization
BAL-Waluj
Waste Paper
recycle
Re-Use of Waste
Packing Material
76
BAL-Waluj
Carbon Reduction
Summary - Reduction in Carbon Emission / veh (Kgs.) :
19 %
BAL-Waluj
Carbon Reduction
Tree for Carbon Mapping : Logistic
Carbon
Mapping
Internal
Movement
Material
Handling
Vehicle
Shifting
External
Employee
Transportation
Testing
Engine
Vehicle
Vehicle
Distribution
Vendor Part
movement
Distance Reduction
BAL-Waluj
Carbon Reduction
Idea Tree : Reduction of Carbon Emissions
Carbon Emission
From
Internal
Logistics
Sr.
External
Logistics
Sr.
Idea
Idea
Optimize Route
Optimize Route
Increase Loadability
Eliminate Movements
Increase occupancy
Eliminate Multi-handling
Use of Alternate equipment ( e g. Use
of BOPT )
Use of Belt for material movement
5
6
5
6
79
Carbon Reduction
80
BAL-Waluj
BAL-Waluj
Carbon Reduction
Before Condition
Import
Container
flow for
SKODA
JNPT PORT
Skoda
Filled
Containe
r
JNPT PORT
Empty
Containe
r
Export
Container
flow for
Bajaj Auto
JNPT PORT
BAL
Empty
Containe
r
JNPT PORT
Filled
Containe
r
81
BAL-Waluj
Carbon Reduction
JNPT PORT
Skoda
Filled
Containe
r
BAL
Empty
Containe
r
82
JNPT PORT
Filled
Containe
r
BAL-Waluj
Carbon Reduction
192 Lit.
509 Kg.
3600 Nos.
Handholding on
Loss Reduction
Inputs to Vendor
on TPM Philosophy
Practical Training at
Learning Centre BAL
Help to Identify
Improvement
Projects
Appreciate the
Improvements
BAL-Waluj
Sharing of Improvements
across the Bajaj Auto
Vendor Association
84
Consultation from
Company Experts
for Implementation
Sr
Product
BAL-Waluj
%
Inputs / projects provided to the
improvement
vendor/ associate
After
0.20Kwh/
Valve
0.17Kwh/Val
ve
33 %
M/s
Badve
Engineering
Silencer
Unit
2, production
Aurangabad
3.6Kwh/Sile
ncer
3.3
Kwh/
Silencer
8.33 %
M/s
Varroc
Mirror
Polymers Pvt
production
Ltd. Pl. 2
0.32
Kwh/Unit
0.0.2
Kwh/Unit
37.5 %
Similar ENCON projects (453) are implemented across 58 Vendors. In last one year
.Average % improvement achieved is 17 %
85
BAL-Waluj
Future Projects
Sr.
no.
Shop Name
Description
Loss reduction
Transmission loss reduction by switch off standby transformer
Utility
Utility
Utility
Utilities
Utilities
6
7
All Shops
Machine shops
Office
All shops
Electrical
Thermal
LPG
Saving
Potential
(Rs./year)
Investment
to be made
Lkwh/
Year
Ton/
year
LRs. /Year
Rs Lacs
2.2
15.42
5.20
2.1
14.72
15.00
42.06
25.00
21.03
49.00
14.02
30.00
0.21
0.5
1.47
3.51
12.00
3.00
13
Machine shop
14
Paint Shops
15
Utilities
0.9
6.31
7.50
16
Machine shop
0.42
2.94
0.00
6.00
17
Utilities
1.5
10.52
80.00
18
Utilities
1.57
11.01
63.00
10
All shops
11
Paint shop
12
Machine shop
86
1.2
8.41
7.50
0.72
5.05
13.50
7.01
20.00
1.1
7.71
18.50
0.66
4.63
15.00
1.89
13.25
18.00
0.12
0.84
4.50
BAL-Waluj
Future Projects
Sr.
no.
Shop Name
Description
Electrical
Thermal
LPG
Saving
Potential
(Rs./year)
Investment
to be made
Lkwh/
Year
Ton/
year
LRs. /Year
Rs Lacs
0.65
2.00
2.6
3.00
1.3
12.00
Thermal
19
Paint
shop/Heat
treatment
20
Heat tretment
21
PTCED
22
Utilities
6.6
36.3
48.00
23
Utilities
0.5
2.75
6.00
24
MCD shop
0.45
34.64
2.25
2.00
235.8
465.7
87
BAL-Waluj
88
BAL-Waluj
89
BAL-Waluj
Sr
Year
2012
2012
2012
2009
2008
CII- GBC
2008
CII- GBC
2007
CII- GBC
2006
CII- GBC
2006
10
2006
CII-GBC
11
2005
CII- GBC
12
2005
CII- GBC
13
2004
Agency
MEDA
CII- GBC
Frost & Sullivan
MEDA
MEDA
MEDA
CII- GBC
BAL-Waluj
91