PowerPoint Presentation

KIRLOSKAR BROTHERS LIMITEDA Kirloskar Group CompanyKirloskar Brothers Limited Sanand.

Presentation on Material Conservation and Recycling

Presentation by : MCR TeamThis is a proprietary document of Kirloskar Brothers Limited#1Leader in fluid handling and one of thelargest manufacturers and exporters of centrifugal pumpsYamuna Global Headquarter Kirloskar Brothers Limited, India, LEED Certified Platinum Rated Green BuildingCentrifugal pumps, Valves, Hydro Turbines, Pumping ProjectsCore businessEstablished1888Incorporated1920

Corporate Profile This is a proprietary document of Kirloskar Brothers Limited# Kirloskar Brothers Limited Sanand Plant

ESTABLISHED YEAR: 2012Area: 14 AcresAnnual turn over fy 14-15: 1044 Mn ISO 9001:2008 certified BS OHSAS 18001:2007 certified ISO 14001:2004 certified SA 8000 certified Nation Award for Excellence in Energy Management 2014 Certified as Energy efficient unit. CII - Exim Bank award for Business Excellence: Significant achievement award This is a proprietary document of Kirloskar Brothers Limited#Green Co JourneyISO9001,1993ISO14001,1998OHSAS18001,2008

This is a proprietary document of Kirloskar Brothers Limited#

RM StoreMachine shopCED CoatingAssembly lineOn line TestingPackingFG StorePerformance testing

Operation Sequence This is a proprietary document of Kirloskar Brothers Limited#Reducing consumption of virgin material :

1. Reducing raw material consumption

2. Reducing Packing material consumption

3. Re use packing material Material Conservation Project

This is a proprietary document of Kirloskar Brothers Limited#6Raw material consumption reduction We have reduced the consumption of raw materials through design change with out affecting the performance of the product. In this project, we have reduced the material consumption by Avg. 10 % to 90 % through material reduction and by changing of material of construction. Our internal work, planning and review diary is made from recycled paper and it inspires us to achieve company goals for environment protection and natural resource saving

Material Conservation Project This is a proprietary document of Kirloskar Brothers Limited#7 Material Conservation Project Material of Construction change from Cast iron to Noryl plastic

Before Moc: Cast ironAfter Moc: Noryl Plastic Noryl plastic is 100% recyclable

Weight of the component also reduce to 89.76 %Material CodeDescriptionPrevious Wt./ Kg.Present Wt./Kg.Reduction In Wt./Kg.Reduction %Qty ProcuredTotal Wt.Saved in Kg.01543130Noryl Dol ABCD0.6540.0670.58789.76%94575551 Breakage issue.

Machining and coating requiredThis is a proprietary document of Kirloskar Brothers Limited#8Before Moc: Sheet metalAfter Moc: Noryl Plastic Noryl plastic is 100% recyclable

Weight of the component also reduce to 48.05 %Material CodeDescriptionPrevious Wt./ Kg.Present Wt./Kg.Reduction In Wt./Kg.Reduction %Qty ProcuredTotal Wt.Saved in Kg.01530150NORYL BOWL KP4N - 07 SERIES0.0770.0400.03748.05 %572582118.55

Material Conservation Project Material of Construction change from Sheet Metal to Noryl plastic

This is a proprietary document of Kirloskar Brothers Limited#9

Before Moc: Cast iron

After Moc: SS investment casting Weight of the component reduce by 65.12 % with increased life of BearingMaterial CodeDescriptionPrevious Wt./ Kg.Present Wt./Kg.Reduction In Wt./Kg.Reduction %Qty ProcuredTotal Wt.Saved in Kg.03660160Fixed Thrust Bearing1.0750.3750.70065.12%1827812794.6 Material Conservation Project Value addition in Thrust bearing by MOC & Design Change

This is a proprietary document of Kirloskar Brothers Limited#10 Before Moc: Cast ironAfter Moc: SS investment casting Weight of the component reduce by 62.35 % with increased life of Bearing

Material CodeDescriptionPrevious Wt./ Kg.Present Wt./Kg.Reduction In Wt./Kg.Reduction %Qty ProcuredTotal Wt.Saved in Kg.03660170Tilting pad Thrust Bearing0.8500.3200.53062.35 %27261445 Material Conservation Project Value addition in Thrust bearing by MOC & Design Change

This is a proprietary document of Kirloskar Brothers Limited#11

Material CodeDescriptionPrevious Wt./ Kg.Present Wt./Kg.Reduction In Wt./Kg.Reduction %Qty ProcuredTotal Wt.Saved in Kg.61008411SS Imp For KS6D Pump Clock-wise1.1250.9240.20117.87%95761924.77661008833 61009152IMP For KS6EA Pump Anti Clock-wise1.4161.1200.29620.90%49681470.5286100883161009151SS Imp For KS6F Pump Anti Clock-wise1.2481.1070.14111.30%97921380.672 Benefits : Increased Pump efficiency. Motor power consumption reduced Supplier machining time and power consumption reduced Reduce product weight and transport cost and Co2 emission

Material Conservation Project Reduction in Raw material weight of impellers

This is a proprietary document of Kirloskar Brothers Limited#12

Material CodeDescriptionPrevious Wt./ Kg.Present Wt./Kg.Reduction In Wt./Kg.Reduction %Qty ProcuredTotal Wt.Saved in Kg.61008841SS Imp For KS6G Pump Clock-wise1.3521.250.1027.54 %4920501.8461008851SS Imp KS8P Dia. 140mm2.4002.1930.2078.62 %31565.21 Material Conservation Project Reduction in Raw material weight of impellers

Benefits : Increased Pump efficiency. Motor power consumption reduced Supplier machining time and power consumption reduced Reduce product weight and transport cost and Co2 emission

This is a proprietary document of Kirloskar Brothers Limited#13Material CodeDescriptionPrevious Wt./ Kg.Present Wt./Kg.Reduction In Wt./Kg.Reduction %Qty ProcuredTotal Wt.Saved in Kg.61009121 Impeller SS 100 HHN Series 0.8340.3650.46956.24%1273597 Benefits : Weight of the component reduced by 56.24 % Increase Pump efficiency. Power Consumption reduce Reduce product weight and transport cost and Co2 emission

Before Moc: Steel castAfter Moc: SS Fabricated Material Conservation Project Material of Construction change from Steel Cast to Sheet metal

This is a proprietary document of Kirloskar Brothers Limited#14Significant Improvement: Packaging waste reduction (KS4 Pump set)For packing KS4 Pump set twin packing corrugated Kraft tube was used.

Transit damage issues were there in this type of packing.Tube is bulky and heavy.

Light weight easy to handle Corrugated Sq.box developed.

CodeDescriptionPrevious Wt. (Kg)Present Wt. (Kg)Reduction In Wt. (Kg)Reduction %Purchase Qty.Total Wt. Saved in (Kg)06080990Corrugated Box Sq. For KS4 640 mm2.531.7520.77830.75%14831153.7706081600Corrugated Box Sq. For KS4 760 mm2.972.0080.96232.39%22992211.6306081780Corrugated Box Sq. For KS4 855 mm3.472.2721.19834.52%28273386.7406081800Corrugated Box Sq. For KS4 940 mm3.812.4921.31834.59%22452958.91-KS4 Single Craft Tube4.252.4051.84543.41%14622697.39-KS4 Single Craft Tube4.912.9251.98540.43%271537.94 TotalAverage reduction in %36.02%1058712946ParticularsDetails Of SavingMaterial Code-DescriptionSq. box with 2 tubeWt. Saved / Kg.8.086Purchased Qty10587Purchase in Kgs.12946Conv. Factor per Kg to 1 Tree.54Number of Trees Saved240BeforeAfter

Material Conservation Project This is a proprietary document of Kirloskar Brothers Limited#Significant Improvement: Weight reduction in plastic cap in packing (KS4 pump set) For packing KS4 Pump set in twin packing corrugated Kraft tube twin caps were also used.

Since new corrugated box was developed with 2 separate thin inner tubes hence there are four small low weight caps are used instead of two twin caps.BeforeAfter

CodeDescriptionPrevious Wt./ Kg.(2Pc)Present Wt./Kg. (4 Pc)Reduction In Wt./Kg.Reduction %Purchase qtyTotal Wt. Saved in Kg.06080990Corrugated Box Sq. For KS4 640 mm0.180.0720.10860.00%1483160.16406081600Corrugated Box Sq. For KS4 760 mm0.180.0720.10860.00%2299248.29206081780Corrugated Box Sq. For KS4 855 mm0.180.0720.10860.00%2827305.31606081800Corrugated Box Sq. For KS4 940 mm0.180.0720.10860.00%2245242.46-KS4 Single Craft Tube0.180.0720.10860.00%1462157.896-KS4 Single Craft Tube0.180.0720.10860.00%27129.268TotalAverage weight reduction60.00%105871143.40 Material Conservation Project This is a proprietary document of Kirloskar Brothers Limited#Significant Improvement: Packaging waste reduction (BIGflow Pump set)For packing BIGflow Pump set twin packing corrugated Kraft tube was used.

Transit damage issues were there in this type of packing.Tube is bulky and heavy.

Suppliers box which was scraped earlier is used as internal packing and a light weight easy to handle Corrugated box developed for external packing.

BeforeAfter

Supplier boxCodeDescriptionPrevious Wt. (Kg)Present Wt. (Kg)Reduction In Wt. (Kg)Reduction %Purchase qtyTotal Wt. Saved in (Kg)06089490CORR BOX.BIGFLOW2.530.5811.94977.04%962118751ParticularsDetails Of SavingMaterial Code06089490DescriptionCorr. Box Sq. BIGflow 3Ply X 570 X 225 X130 mmWt. Saved / Kg.1.949Purchased Qty9621Purchase in Kgs.18751Conv. Factor per Kg to A Tree.54Number of Trees Saved347 Material Conservation Project This is a proprietary document of Kirloskar Brothers Limited#Significant Improvement: Elimination of use of plastic cap in packing (BIGflow pump set) For packing BIGflow Pump set in twin packing corrugated Kraft tube twin cap was also used.

Since new corrugated box was developed hence there is no twin cap required in that packing.BeforeAfter

No Twin cap requiredCodeDescriptionWeight of cap (Kg)Reduction %Purchase qtyTotal saving (Kg)06089490CORR BOX SQ. BIGFLOW 3PLYx570x225x130mm0.18100.00%96211732Material Conservation Project This is a proprietary document of Kirloskar Brothers Limited#Significant Improvement: Horizontal deployment of twin tubes reduction initiativeFor packing KS3 Pump set twin packing corrugated Kraft tube was used.

Transit damage issues were there in this type of packing.Tube is bulky and heavy.

Initiative taken to replace BIGFlow pump set twin packing Kraft tubes with corrugated box was deployed in this also.

BeforeAfter

Supplier box

CodeDescriptionPrevious Wt. (Kg)Present Wt. (Kg)Reduction In Wt. (Kg)Reduction %Purchase qtyTotal Wt. Saved in Kg.06085330CORRUGATED BOX SQ. FOR KS3 735x180x102MM1.530.590.9461.45%104229796.6806085320CORRUGATED BOX SQ. FOR KS3 660x180x102MM1.530.550.9864.06%422413.7806085340CORRUGATED BOX SQ. FOR KS3 810x180x102MM1.530.620.9159.49%20651879.15TotalAverage reduction in %65.51%1290912089ParticularsDetails Of SavingMaterial CodeDescriptionSq. box with 2 tubeWt. Saved / Kg.2.83Purchased Qty12909Purchase in Kgs.12089Conv. Factor per Kg to A Tree.54Number of Trees Saved224Material Conservation Project This is a proprietary document of Kirloskar Brothers Limited#Significant Improvement: Packaging waste elimination (KS4 Stator & Rotor)Stator and Rotor received from Supplier were supplied in Kraft tubes.

This tube was scraped.

We have developed new MS trolleys/pallets for receiving material from supplier.These trolleys resend to supplier for reuse.Kraft tube usage is 100% eliminated in this supply.

BeforeAfterSupplier trolley

CodeDescriptionPrevious Wt. (Kg)Present Wt. (Kg)Reduction In Wt. (Kg)Reduction %Purchase qtyTotal Wt. Saved in Kg.-Stator Rotor Craft Tube0.8600.86100.00%2692223153ParticularsDetails Of SavingMaterial Code-DescriptionSt_Rt TubeWt. Saved / Kg.0.86Purchased Qty26922Purchase in Kgs.23153Conv. Factor per Kg to A Tree.54Number of Trees Saved429 This initiative also results into saving plastic caps of Kraft tubes which were also scraped.

Cap weight: 0.013 Kg/Pc Saving in plastic waste = 834 Kg

Material Conservation Project This is a proprietary document of Kirloskar Brothers Limited#Craft tube and Plastic caps of Stator and Rotor are Reused

Previously these tubes and plastic cap sold as Scrap

Now, Stator and Rotor Packing tube with Cap re send to supplier for reuseYear Total packed Stator and Rotor receipt Total Scrap tube back to vendor as reuse % Recycled Material2012-13 206731048950.74%2013-14 222311027046.20%2014-15227551165051.20%Total 656593240949.38% Material Conservation Project In addition to above saving we have also reused 64819 plastic caps worth 6.42 Mt weight.This is a proprietary document of Kirloskar Brothers Limited#21Material Conservation ProjectResult: Packing MaterialTotal Tree Saved: 1411 Nos.

This is a proprietary document of Kirloskar Brothers Limited#22Material Conservation ProjectResult: Plastic MaterialThis is a proprietary document of Kirloskar Brothers Limited#Material Conservation ProjectResult: SS and CI MaterialThis is a proprietary document of Kirloskar Brothers Limited#THANK YOU

This is a proprietary document of Kirloskar Brothers Limited#