Upload
others
View
3
Download
0
Embed Size (px)
Citation preview
August 26, 2020External Confidential
Presenter-
Rajeev Kumar SaxenaSandeep Dhangar
Harpreet Singh Kuttal
Global Parts Center
Neemrana
CII National Award for Excellence in Energy Management 2020
CII - National Award for "Excellence in Energy Management"- 2020
S. No Content
1 Introduction of Company
2 Energy Consumption Overview
3 Specific Energy Consumption
4 National or Global Benchmarking
5 Energy Saving Projects
6 Innovative Projects
7 Renewable Energy Sources
8 Waste Utilization and Management
9 GHG Inventorisation
10 Green Supply Chain
11 Teamwork, Employee Involvement & Monitoring
12 Implementation of ISO 50001/Green Co/IGBC rating
13 Other Innovative technologies
14 Long Term Vision on EE
2
Table of Contents
CII - National Award for "Excellence in Energy Management"- 2020
3
3
5-Zonal Offices
Mobile Station
Service Har Jagah
6 –Plants- India
Registered & Corporate Offices
22-Regional Offices
Dealers
Spares & Service Centers
Authorized Reps of Dlrs
Stockists
Dharuhera Plant HM1D69 km from DelhiIn Haryana( 1st Plant, Year 1984)
Haridwar Plant HM3H 250 km from Delhi in Uttarakhand (3rd
Plant, Year 2008 )
Neemrana Plant HM4N & Global Parts Center (HP3N) 120 km from Delhi In Rajasthan (Year 2014)
Hero Centre of Global Innovation & R&D
Rajasthan 270 Km From
Delhi
North Zone Office, New Delhi
West Zone Office, Pune
South Zone Office, Bangalore
East Zone Office, Kolkata
Gurgaon Plant HM2G 34Km from Delhi in Haryana (2nd Plant , Year 1997 )
Corporate Office, New Delhi , India
More Than 8000 Customer Touch Points
Vadodara Plant 953 km from Delhi In Gujarat (5th Plant , year 2017)
Hero is having 8000+ touch points across India. It includes plants, zonal offices, service centers & mobile service. We have 6 manufacturing plants in India, 2 in overseas and are present in 40+ countries.
Colombia Plant, Year 2014 Capacity
0.12 mn/Yr
Dhaka Plant Year 2015, Capacity 0.08 mn /Yr
Overseas 02 Plants
1 –Global Part Center
2 – R&D Center
Central Zone Office, Jaipur
Chittoor Plant HM6C 2144 Km from Delhi in Andhra PradeshYear 2019
Global presence to 40+ countries across Asia, Africa and South and Central America
Overseas : 02 Plants & 01 R &D Centre in Germany
1.0.1 Hero MotoCorp Plants1.0 Introduction to Company
CII - National Award for "Excellence in Energy Management"- 2020 4
1.0.2 Company History
2017 5th Mfg. Plant started its Operation at Halol, Gujrat
2018 6th
Manufacturing Plant in Chittoor, Andhra Pradesh & First Vehicle Rolled Out on 23rd Dec 2019
4th Manufacturing Plant & Global Parts Centre at Neemrana
Foundation Stone Laid
1.0 Introduction to Company
CII - National Award for "Excellence in Energy Management"- 2020
Awards and Recognition- TPM Excellence Award-2019 (“1st Parts Center on Globe” )
Certificates for ISO 9001,14001 and 45001 in Sept’19 from DNV-GL.
Zero Waste to Landfill with above 99% diversion rate by Intertek in 2019.
Assurance for Water Positive Plant by Bureau-Veritas in 2019.
State Safety Award for Excellence in compliance of Safety, Health and Welfare provisions by RajasthanGovernment in 2019.
GPC has been awarded the coveted and prestigious CII- BCG Industry 4.0 award in 2016.
IGBC Green Factory Platinum Award in 2014.5
1.0.3 Global Parts Center-
An Industry 4.O Parts Centre
Business : Spare Parts Division
Plant Started : 2014
SKUs : 27824 Nos
Capacity : 54 Lacs Parts / Day
Connected Load : 4.8 MW
Green Power : 1.2 MW
5
1.0 Introduction to Company
CII - National Award for "Excellence in Energy Management"- 2020
1.0.4 Layout & Equipment Details
6
Major Areas in GPCPallet ASRS 02 Nos
Bins ASRS 01 No
Pallet FM 01 No
Bin FM (Fast Moving) 01 No
Reserve ASRS 01 No
Receipt Section 01 No
Production Shop 01 No
Final Checking & Packing 01 No
Dispatch Section 01 No
Bin Loading Station Area 03 Nos
Manual Packing Station 12 Nos
Major Equipment in GPC
Stacker Cranes 53 Nos
Rail Guided Vehicles 21 Nos
Unishuttle 10 Nos
Automatic Sorting System 02 Nos
Auto Packaging Lines 09 Nos
Manual Packaging Lines 16 Nos
Telescopic Conveyors 24 Nos
Conveyor (8 KMs) 01 Nos
1.0 Introduction to Company
CII - National Award for "Excellence in Energy Management"- 2020
1.0.5 Plant Operations Process
LEGENDS Material Flow Processing area Storage area
DLP CHUTE
FPP CHUTE
CHUTE
CHUTE
PALL
ET
FM
CHUTE
CHUTE
AU
TO L
INE
PA
LLET
ASR
S PALL
ET "
U"
SHA
PE
CHUTE
CHUTE
CHUTE
BIN
FM
CHUTE
CHUTE
MA
NU
AL
LIN
E CHUTE
BIN
G L
INE CHUTE
CHUTE
BIN
ASR
S BIN
U
SHA
PE
UN
I SH
UTT
LE
FCP
SOR
TER
S
CHUTE
REC
IEP
T
RES
ERV
E A
SRS
RM STORAGE
FG STORAGETRUCK
LOADINGPICKING & DISPATCH
PACKAGING AREA
MATERIAL RECEIPT
Pallet and Bin Handling Areas
MP
SA
UTO
P
AC
KA
GIN
G L
INE
MA
NU
AL
PA
CK
AG
ING
LIN
E
PICKING DISPATCH
7
1.0 Introduction to Company
CII - National Award for "Excellence in Energy Management"- 2020
Roles in EMC
Projects & Budget Approver
Energy Management Cell (EMC)
Projects and SEC Evaluator
Projects progress reviewers
Idea generators
Projects Implementers
Employee Awareness
Technology evaluators
Budget Allocators
Energy Management Cell formed and defined their roles and responsibilities.
GPC Head
1.0.6 Energy Management cell & roles
8
1.0 Introduction to Company
CII - National Award for "Excellence in Energy Management"- 2020
Plant has framed its own Energy Policy considering the major focus on Energy Efficiency
1.0.7 Energy conservation Policy
9
1.0 Introduction to Company
CII - National Award for "Excellence in Energy Management"- 2020 10
2.0.1 Energy Sources for GPC
Steel
Phase
F/AsslyE/Assly.
Stores,
DG
House
Utility
HR
Canteen
Electrical Energy Distribution
Mainly HSD,GRID & SOLAR are the sources of power generation.
HSD
(1) GRID (RSEB) (2) Solar
Sources of Electrical Energy Thermal Energy
External -Confidential
(3) HSD GEN.
GRID(RSEB)
SOLAR PLANT
HSD GEN.
11KV TO
415V
ESS-
5
DP
-1
ESS-
6
DP
-2D
P-3
DP
-n
PALLET ASRS
BIN ASRS
RECIEPT/DISPATCH
EXTENSION PLANT
CONVEYOR SYSTEM
NOT USED IN PLANT PROCESS.
RSEB83%
Solar16%
DG1%
RSEB
Solar
DG
Energy %age Usage in Plant
2.0 Energy Consumption Overview
CII - National Award for "Excellence in Energy Management"- 2020 11
5354
63755645
3000
4000
5000
6000
7000
FY 18 FY 19 FY 20
MW
H
Total Power Consumption Better
2.0.2 Energy Cons. Trend - Last 3 Years
GPC expansion work started in 2018 to increase the throughput of system by increasing the dispatch boxes from 40000 to 75000 box per day.
4700
4720
4716903
3000
3500
4000
4500
5000
5500
6000
FY 18 FY 19 FY 20
MW
H
RSEB Power Consumption Better
800 796929
0
200
400
600
800
1000
FY 18 FY 19 FY 20
MW
H
Solar Power Consumption Better
GPCExpansion
5623
2.0 Energy Consumption Overview
Solar Capacity Addition in Feb-20
CII - National Award for "Excellence in Energy Management"- 2020 12
0.460.45
0.38
0.30
0.32
0.34
0.36
0.38
0.40
0.42
0.44
0.46
0.48
FY18 FY19 FY20
KW
H/B
OX
SEC Trend (KWH/Box)
Better
Power consumption/box is in reducing trend due to Kaizens and Energy Saving Projects.
17% Reduction
Key Projects contributing to reduction
Big foot LED Lights
HVLS FanPower saving logic in 8 KMs
Conveyor
3.0.1 Power Consumption (KWH/Box)3.0 Specific Energy Consumption
Total 57 Energy Saving Projects Executed in 3 consecutive years.
CII - National Award for "Excellence in Energy Management"- 2020 13
4.0 National or Global Benchmarking
Global Parts Center is integrated with all international standard systems like automated storage and retrieval system (ASRS), on-line tracking of parts through Warehouse Management System (WMS), Warehouse Control System (WCS), automated packaging and sorting system, lean manufacturing systems and most importantly the Green Building Concept.
Global Parts Centre –First Automated Storage & Retrieval System(ASRS)warehouse facility in ASIA (Automobile Sector).
CII - National Award for "Excellence in Energy Management"- 2020 14
5.0.1 Energy consumption mapping –FY18, FY19, FY20 5.0 Energy Saving Project
CII - National Award for "Excellence in Energy Management"- 2020 15
5.0.2 Energy Conservation Projects –FY18, FY19, FY20
FY-18
FY-19
5.0 Energy Saving Project
FY-20
CII - National Award for "Excellence in Energy Management"- 2020 16
5.0.3 Energy Conservation Projects – FY185.0 Energy Saving Project
Total 15 Energy Saving Projects Executed in different areas.
CII - National Award for "Excellence in Energy Management"- 2020 17
5.0.4 Energy Conservation Projects - FY195.0 Energy Saving Project
Total 18 Energy Saving Projects Executed in different areas.
CII - National Award for "Excellence in Energy Management"- 2020 18
5.0.5 Energy Conservation Projects - FY205.0 Energy Saving Project
In-house Development
CRC
Indoor
Remote
Total 24 Energy Saving Projects Executed in different areas.
CII - National Award for "Excellence in Energy Management"- 2020 19
Operational Control Creation in Centralized Cooling System (Bigfoot)
Before After
Previous Scenario:-
1. Bigfoot has only 2 operating modes.2. It has 2 Schedule transition.3. Blowers of AHUs runs continuously
during entire day.4. High power consumption due to
mode limitations.
Benefits:-1. Operating modes generated in PLC
software.2. Schedule transition increased from 2 to 4.3. One Blower switched off during C shift.
6.0 Innovative Project -1
MODE A TEMP 77 F Blower speed 60-90 %
MODE B TEMP 80 F Blower speed 50-60 %
MODE A TEMP 77 F Blower speed 60-90 %
MODE B TEMP 80 F Blower speed 50-60 %
MODE C TEMP 85 F Blower speed 30-50 %
16271491
1000
1400
1800
FY19 FY20
MW
H/Y
ear
Bigfoot Power Consumption (MWH)
8%
Apr-19
CII - National Award for "Excellence in Energy Management"- 2020 20
6.0 Innovative Project-2
To reduce the running time of ASRS cranes by consolidation of Picking bins
Previous Scenario:-1. When load (Dispatch Cutoff) is
applied to the system, crane used to retrieve and store same bin multiple time for picking for multiple deliveries.
2. Cut off time also more due to multiple retrievals.
Benefits:-Now we put the consolidation logic into the system, we can pick multiple deliveries bin from single source bins , resulted in more business with less equipment running time.
Before After
Running time/Day/Crane:- 10.9 Hrs Running time/Day/Crane:- 7.2 Hrs
Multiple Source Bin
Destination binSource Bin
Multiple Destination bin
19 CranesMay-19
39.2 31.3
02040
Before (FY19) After (FY20)MW
H /
Mo
nth
Energy Saving (MWH / Month)
20%
CII - National Award for "Excellence in Energy Management"- 2020 21
6.0 Innovative Project-3
To reduce idle running of Okura conveyor by putting power saving logic.
Previous Scenario:-1. Conveyor with 578 motors keeps on
running during no load condition. 2. High wear and tear in rollers and
nylon belts.3. High checking frequency for moving
parts.4. High power consumption during idle
time.
95.1
0
5
10
Before After
MW
H /
Mo
nth
Energy Saving (MWH / Month)
Benefits:-1. Saving of 3.9 MWH / Month.2. Less wear and tear in moving parts.3. Increased MTBPM.
43%
Before After Apr-19
CII - National Award for "Excellence in Energy Management"- 2020 22
Installation of HVLS fans in shop floor to achieve uniform Air Flow.
Previous Scenario:-1. Uneven Air Flow in Shop Floor.2. More power consumption due to high
loading of centralized cooling system (Bigfoot).
3. Uneasy atmosphere for operators during summer season.
4. Difficult to maintain the spares.5. More wiring in the shop floor.6. Risk of operator safety while repairing
online.
250 Nos 15 Nos 110 Nos
105
85
80
90
100
110
Before After
MW
H /
Mo
nth
Power Consumption
Before After
Benefits:-1. Delay of 15 days provided in start-up of
Bigfoot due to induction of HVLS fans during start-up of summer and vice versa.
2. Uniform Air Flow in Shop Floor.
6.0 Innovative Project-4
19%
Jan-19
CII - National Award for "Excellence in Energy Management"- 2020
7.0.1 Renewable and Green Energy
23
7.0 Renewable and Green Energy
CII - National Award for "Excellence in Energy Management"- 2020
Installation of additional 500 KWp solar plant
24
Phase-1 (2014)Capacity-684 KWp
Phase-2 (2020)Capacity-1184 KWp
Previous Scenario:-1. GPC expansion resulted in increasing
load. Hence we planned to induce more Green Power into the system.
2. Power and Fuel cost starts increasing after plant expansion.
3. Temperature of shop floor was increasing due to exposure of direct sun light.
684
1184
500
1000
1500
FY-15 FY-20K
Wp
Solar Plant Capacity (KWp)
Benefits:-1. Generation of Green Power increased by 73%.2. Power and Fuel cost reduces.3. Heating of roof reduced up to some extent.
Before After
7.0.2 On-site Renewable Energy Expansion
73%
7.0 Renewable and Green Energy
CII - National Award for "Excellence in Energy Management"- 2020
84.50% 87.52%83.10% 80.70%
15.50%12.48%
16.90% 19.30%
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
FY 18 FY 19 FY 20 FY21
% C
on
trib
uti
on
RSEB Contribution (%)
Solar Contribution (%)
In FY 19, it was observed that green power contribution was going down so in order to maintain sustainable environment hence planning done for addition of green power.
25
Expected Outcome
7.0.3 RSEB Vs Solar (%) Contribution7.0 Renewable and Green Energy
CII - National Award for "Excellence in Energy Management"- 2020
Financial Year
Technological Improvement
Type of Energy
Onsite / Off site
Installed Capacity (MW)
Generation (million of KWH)
% of overall Electrical
Energy
FY-18 Solar Power Plant
Solar Onsite 0.684 0.825 15.57
FY-19 Solar Power Plant
Solar Onsite 0.684 0.786 12.48
FY-20 Solar Power Plant
Solar Onsite 1.1 0.967 16.96
26
Phase-1 (2014)Capacity-684 KWp
Phase-2 (2020)Capacity-1184 KWp
7.0.4 Utilization of Renewable Energy7.0 Renewable and Green Energy
CII - National Award for "Excellence in Energy Management"- 2020
Type of Waste Generation Collection Segregation Transfer Storage/Treatment Disposal
Bio Medical waste
Occupational Health Center
BinsAt source of generation
By Bins OHCDisposed to
Authorized agency
Batteries wasteUtilities/Final
Insp.Bins
At source of generation
By TrolleyWaste Management
YardDisposed to
Authorized agency
E-waste Utilities/IT TrolleyAt source of generation
By TrolleyWaste Management
YardDisposed to
Authorized agency
Bio-medical waste collection bins E-waste
27
8.0.1 Waste Types & Collection Method8.0 Waste Utilization & Management
CII - National Award for "Excellence in Energy Management"- 2020
8.0.2 Process flow & Waste Management Yard
Source of generation
Collection & transfer in
Trollies/Bins
Segregation at WMY of some
wastes
Storage at WMY
Disposal to Authorized
recycler
Waste Management Yard (WMY)
Waste Management Process Flow
E- Waste Corrugation Box Poly Packaging
28
8.0 Waste Utilization & Management
CII - National Award for "Excellence in Energy Management"- 2020
17467 17673
15360
12000
13000
14000
15000
16000
17000
18000
19000
20000
FY18 FY 19 FY 20
Kg
CO
2/T
on
kgCO2 / Ton of Final Product
Plant Expansion
Started
9.0 Green House Gases – Last 3 Years.
1. GPC expansion work started in 2018 to increase the throughput of system by increasing the dispatch boxes from 40000 to 75000 box per day.
2. Short term target - Reduction of 35% emissions (Baseline year 2017-18) till 2021-22.
3. Long Term Target - Become carbon neutral by 2025-26.
29
Solar plant added.
Data belongs to Neemrana location
CII - National Award for "Excellence in Energy Management"- 2020 30
10.0 Green Supply Chain
Tier 2 Supplier Tier 1 Supplier IBL Warehouse GPCPart
Distributor
Green Procuremen
t
Green Warehousing
Green Packaging
Green Logistics
Supplier & Dealer
Performance Up
gradation
Inbound
(3PL)
Logistic
s
Outbound
Logistics
Inbound
(3PL)
Logistics
BASED ON FUNCTION
BASED ON OPERATION
1
2 5
43
CII - National Award for "Excellence in Energy Management"- 2020
11.0 Team Work and Employee Involvement
Overall employees involvement through different methods to promote energy efficient activities.
6
4559 55
644
57 53
0
20
40
60
80
100
Dec-19 Jan-20 Feb-20 Mar-20 Apr-20 May-20 Jun-20 Jul-20
No
s
Energy saving Ideas Idea Received
Idea Implemented
1. Celebration of Green Month for Ideas generation.
2. DISHA Suggestion Scheme 2.0 to motivate
employees to give value added Suggestions
3. Total energy saving Idea implemented is 160 Nos
against 165 Nos.
Summary
32
Due to Covid-19 plant operation halted
CII - National Award for "Excellence in Energy Management"- 2020
11.0 Team Work and Employee Involvement
Training Imparted to all stake holders
Participants UOMYear
2017-18 2018-19 2019-20
1. Area Specific Training to Team
members
and Contract Workers.
2. IMS Training (From 2019-20)
(ISO-14001)
Staff Nos. 128 121 98
Lead Auditor Nos. - - 2
Internal Auditor Nos. - - 24
Team Members Nos. - 596 976
Induction Training of team members % 100 100 100
Induction Training of contract workers % 100 100 100
Plant Lightings % 100 100 100
Compressed Air System % 100 100 100
Chiller System % 100 100 100
Electrical troubleshooting % 100 100 100
33
CII - National Award for "Excellence in Energy Management"- 2020
FY20 Achievements
Team set a Benchmark in Sept’19 and In Feb’20 month with Average Daily Sales which is 11.62 Cr./Day (Highest ever Sales/Day)
We successfully challenged and achieved TPM Excellence Award-2019 and became “1st Parts Center on Globe” who achieve this coveted position.
We successfully established IMS in GPC and we received the Certificates for ISO 9001,14001 and 45001 in Sept’19 from DNV-GL.
Certified with Zero Waste to Landfill with above 99% diversion rate by Intertek.
Get Assurance for Water Positive Plant by Bureau-Veritas.
State Safety Award for Excellence in compliance of Safety, Health and Welfare provisions by Rajasthan Government
FY20 Direct Productivity improved by 25 % w.r.t. FY19 (0.63 Lakhs/Man/Day to 0.78 Lakhs/Man/Day) 267 Manpower/Day saved w.r.t. FY19 (17% reduction w.r.t. FY19) through Productivity improvement projects.
Customer Delight by reducing V.O.R. Claims < 2 Days V.O.R. FFR 96% which is improved by 20% w.r.t. FY19-76%.
Customer Satisfaction by interacting with customers through VC on daily basis and reducing PDR : 62 % Reduction (From 225 Claims/Month to 85 Claims/Month).
Step towards Digital Enterprise by Implementing Online Loss monitoring , SPMS/ SAS enhancement , VOR Dashboard, Vendor Dashboard & FIFO Based ordering system.
Price Revision of 3898 SKU’s with MRP change in Aug’19, which is 23% of Total SKU’s and resulted in profit (Bottom line) of 45 Cr in FY20.
12.0 Key Achievements- HP3N (GPC)
34
CII - National Award for "Excellence in Energy Management"- 2020
13.0.1 Centralized cooling system for shop floor (Bigfoot)
Bigfoot SCADA
35
13.0 Innovative technologies
1It is an Ductless Air Conditioning system that works on building pressurization technology and provides a dust & humidity free environment and controls oxygen and CO2 levels and works on cradle to cradle approach.
2It has smart discharge heads that can respond to the heating and cooling needs of specific areas of a building or facility.
3 It is an Air Conditioning system that has Water as it’s by product. (10 KL/Day in Rainy season)
4 It is a first in the warehousing sector in INDIA.
5 It has 3 Air Cooled chillers of 300 TR and one Water cooled Chiller of 80 TR.
CII - National Award for "Excellence in Energy Management"- 2020
13.0.2 Lighting load Automation in Prodn. & Admin areas
Before After
Benefits:-1. Fully automatic system based on
software control.2. Chances of error are completely
eliminated.3. Provision of timely switching of
lights is made available.4. More life of lights due to dimming
option.
36
13.0 Innovative technologies
Introduction to
KNX System
Previous Scenario-1. Manual System to control the light.2. Chances of error due to human
intervention.3. Provision of timely switching is not
available.4. Dimming option is not available.
CII - National Award for "Excellence in Energy Management"- 2020 37
13.0.3 Green Wall & hydroponic farming
Previous Scenario-1. No Green Manufacturing Concept.2. No Hydroponic Farming Concept.3. Noise generated during machines
operation.4. Oxygen levels inside shop floor.
Benefits-1. Green wall concept introduced in the
plant for healthy environment.2. Hydroponic farming also introduced to
grow in-house vegetables 3. Noise generation from machines is also
absorbed by green wall.4. Green walls helps in maintaining oxygen
levels inside shop floor.
13.0 Innovative technologies
CII - National Award for "Excellence in Energy Management"- 2020
0.460.45
0.38
0.29
0.27
0.20
0.25
0.30
0.35
0.40
0.45
0.50
FY-18 FY-19 FY-20 FY-21 FY-22
KW
H/B
OX
Consumption Trend KWH/Box
2.1%
15.5%
23.6%
7%
14.0.1 Future plans
38
40% Reduction
in 5 Years
S. No
Future Project Details(FY-21 & FY-22)
1VFD Installation in Air Compressor to reduce loading unloading cycles
2Load Management in Sub Station to achieve maximum utilization of Green Power.
3Shop floor lights Automation by Lux Level monitoring
4Provision of day light inside shop floor by installing lighting tunnel.
5Automatic cleaning of Solar panels to achieve maximum efficiency.
14.0 Long Term Vision
CII - National Award for "Excellence in Energy Management"- 2020
14.0.2 VFD Installation in Air Compressor to reduce loading unloading cycles
Power Supply
Power Supply
VFD Control
27698
7828
0
10000
20000
30000
Star Delta Control VFD Control
KW
H/M
on
th
Power Consumption (KWh)
71 %
VFD
Star Delta Control
Air Compressors by VFD Control
1. At present compressor motor is controlled by
star delta starter.
2. After introduction of VFD speed of compressor
motor will vary with minimum power
consumption.
3. With this modification loading and unloading of
air compressor will be tuned with variable
demand of compressed air.
39
14.0 Long Term Vision
CII - National Award for "Excellence in Energy Management"- 2020
14.0.3 Shop floor lights Automation by Lux Level monitor
Lux Monitoring Sensor1.Lights of shop floor will be controlled by
day light monitoring sensor to maintain a
minimum Lux Level of 150.
2.During cloudy weather lights will
automatically turn ON as command
received from LUX Monitoring Sensor.
3.Power will also be saved as unnecessary
lights will be switched off automatically.
Lux Monitoring Sensor
40
14.0 Long Term Vision