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Minimizing Carbon Foot Print for Sustainable Growth By Subros Ltd 13 th May’2013 . Subros : An Update. Established in 1985, Subros is the Largest AC company in India. A Joint Venture company between & Suri Group Suzuki Denso . Facilities. Existing. New. Total. Plants. Noida - PowerPoint PPT Presentation
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Minimizing Carbon Foot Print for Sus-tainable Growth
By Subros Ltd
13th May’2013
No. of Employees (Regular) 1,600
Investment ( Gross ) Rs 840 Crs
Installed Capacity 1.2 million pa
Turnover - FY 2012-13 Rs 1,435 Crs
Quality Certifications ISO 14001, TS 16949, OHSAS 18001
Subros : An Update
Established in 1985, Subros is the Largest AC company in India. A Joint Venture company between
&
Suri Group Suzuki Denso.
1003,0314,50023,5667,000Bldg. (Sq Mtr.)
40,00016,0008,94038,68811,840Land (Sq Mtr.)
ChennaiSanandTool Room
NoidaCompr / HX
NoidaR&D
Plants
Facilities
71,910
211,348
Existing New Total
22,517
39,940
Manesar
11,196
55,940
Pune
Engineering & Development Centres :Denso Subros Engineering Services Centre ( Design JV ) - NoidaCentral R&D – NoidaProduct Engg Centres – Pune, Chennai
Plant wise Product Profile :Noida – Compressors, RS Evaporators, PDC, Precision Press Shop, Tool room, Backup facilities.Manesar – Car ACsPune – Car / CV ACs, ECM productsChennai – Car / CV ACs, ECM products, Off Road ECM / ACs, Bus AC, Truck Refrigeration
Existing
Under Constrn.
8,000 19,000 11,000
8,000 46,000
Product RangeExisting Products Range
Compressors
Condenser
HVACs & Evaporator
Hose & Tubes
Car Aircon Systems Engine Cooling Systems
Oil Coolers, CAC
Rail A/C
Bus A/C
Truck A/c
Cooling module
Commercial Vehicle ACs
Future Products Range
SOP already started
Cooling Fan
Condenser
Thermal Systems Group Main Products
Heater Core
Evaporator
BlowerCompressor
ServoMotor
Control PanelECU
Radiator
HVAC
Bus A/C System
Air Purifier
Key Customers
Spreading Wings For
Customer Care
CHENNAIBANGALORE
HYDERABAD
EAST
CALCUTTAWEST
MUMBAI
JAIPUR
PUNE
NORTH
DELHI
KOCHI
NOIDA
AHMEDABAD
SOUTH
SL Service Centres provide
Training Support to OE Dealers
& Service Stations
SL Service Centres also used
for After Sales Service
Service Network
Compressor Endurance
Testing Machine
Injection Moulding Machine
CNC Tube Bender
Compressor blocks machining line
Vacuum Brazing Furnace for Evaporators
Condenser Core Assembly Line
Nocolok Brazing Furnace for Condenser
Squeeze & Vacuum Die Casting Machine
Chipless Cutting MachineFor Aluminum Tubes
Robotic Vision Inspection
Manufacturing Infrastructure
Vibration Testing
Calorimeter
CAE
Environment Test Chamber
CNC Machines
Wire EDM
Product Development Infrastructure: R&D / Tool Room
Information Technology enablement at Subros
Training Session on Shop floor
Skill workshop with support from DNJP
Chairman & Top Management Team
Skill workshop in progress
Our People, Our StrengthOur People, Our Strength
Achievements &
Future Plans
Achievements
Awards 2012~13 from MSIL
Gold Trophy for Overall Shield for Quality Sys-
tems Certificate for Focused
Cost Down Certificate for Inner Part
Localization
Year 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 2014-15Sales Volume HVAC Basis(no. in K) 393 467 506 619 748 895 848 1017 1291Capacity - 3 Shift Basis (no. in K) 500 750 750 1000 1000 1200 1500 1500 2000Gross Sales Value (Rs. Crs) 657 755 774 787 984 1203 1235 1435 1791
393 467 506619
748895 848
1017
1291
500
750 750 10001000 1200
15001500
2000
657 755 774 787984
12031235 1435
1791
0
200
400
600
800
1000
1200
1400
1600
1800
2000
0
500
1000
1500
2000
2500
2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 2014-15
Gros
s Sa
les
Valu
e ( R
s. Cr
s)
No.
of U
nit
(,000
)
Sales Volume HVAC Basis(no. in K)
Capacity - 3 Shift Basis (no. in K)
Gross Sales Value (Rs. Crs)
Projected
Capacity Plan to Meet Future Customer Demand
Indian Market Share - 40%
Capacity to be enhanced – under review for 2014-15
15
Background for Sustainability
The Major Impacts to Automotive Industry
17
Regulation in Auto Industry
The Life Cycle Concept
Emission/Wastes from Vehicle Production
Vehicle Life Cycle Analysis
Vehicle Life Cycle Analysis
Auto Industry – Evolving View of the Environment
Trends in Vehicle Design
Trend in Vehicle Manufacturing
25
Subros Expe-rience
MM. 5
Global Standards
Subros Logo
Customer Focus
Innovation
World Class
To deliver products & Services to Customers with superior Performance in Speed, Quality & Cost
Subros Vision Subros Mission
• Adherence to the Rules & Regulations.
• Respect for HierarchyDiscipline
• In the ability of people
• In Inter-personal relationsTrust
• Personal and Professional
• Work EthicsIntegrity
• PDCA cycle, knowledge sharing & knowledge acquisitionWork Style
Core Values
Vision, Mission & Core Value
Respect for the Individual • Irrespective of the Level
SUSTAINABILITY ROAD MAP
29
Sustainability Matrix at Subros
Contents Major Work Done
Environment Management System since 2003 & Environment Health & Safety 2004
• 74 Management Programs completed related to Energy, Water, Yield Improvement.
• Implementation of V.C. to reduce traveling of people from one plant to other plants
• Tree Plantation thru Green Delhi, Green Noida campaign, One day in a year Tree plantation (Pune Plant campaign)
• Launch Company Intranet & Extranet to reduce paper waste by 70%.• During Summer A.C. temperature optimization 27~28oC.• Reduction of water discharge (target for Zero discharge in the
running year)• Electronic & paperless – marketing communication.• Implementation of EMS at 34 Vendor Partners.• Rain water harvesting• Resource saving potential – Reduction of Scraps • Elimination of Hazardous chemicals (Kerosene, Ethyl Alcohol etc.)
Innovation in Product/Process/ Technology
• New Generation Product implementation @ every two year (high efficient, low weight/compact)
• Shift from R-12 Refrigerant to R-134a Refrigerant in 2002 for all the products.
Future Plant – Green Building Concept • Existing Plant – No artificial light during day time.
Pyramid of Waste
Environment Policy
Selections of Options from – Immediate, Short term, Medium & Long term
Environment, Health & safety Fair• EHS Fair twice in a year. o Activities like EHS pledge, o Poster & slogan competitions, quizzes and
awareness trainings like Safety, fire & safety on the shop-floor.
• Environment consciousness is reinforced by conducting PUC checks for vehicles of employees.
• Fire & Safety week celebrations and mock-drills are an integral part of our safety awareness campaigns.
World Health DayWorld health day celebrations are carried out with view to creating awareness. Activities like Health check up, Quizzes , Yoga Session & Health talk
Slide - 31
EHS Activities
32
Oath ceremony on occasion of safety week
MM. 15Wastes & Measures taken
No Shot WtPresent
Shot WtAfter Modification
Proposed Saving/shot
1 10S11 FCB2.569 Kg
2.131 Kg 0.438 Kg(17.01 %)
2 10S11RCB2.597 Kg
1.947 Kg 0.422 Kg(16.17 %)
3 10S11FHC3.501 Kg
2.937 Kg 0.564 Kg(16.1 %)
4 10S11RHC2.806 Kg
2.228 Kg 0.578 Kg(20.5 %)
10S11RHC already Improvement Done
Die Casting Die Yield Improvement by optimizing Runner and Gate Designs - Model 10S11
Yield Improvement
Yield Improvement by reduction in Machining allowance
Natural LightingBefore After
Benefits-
• Day Time Only Natural Light & No artificial Light is required
Other Improvements - Natural LightingCompressor Plant
Innovation in Product &
Technology
z
- Subros has implemented R134a since 2002- Subros is Technology ready for implementation of HFO1234yf
Up-gradation of System vs. Refrigerant
Evaporator technology Vs weight reduction
Next Level is under Development
Heater technology Vs weight reduction
41
Compressor technology Vs weight reduction
Next Technology
Under Proto
Development
42
Condenser technology Vs weight reduction
HVAC technology and weight reduction
44
Subros strategy towards environment
Green Building - Subros
S# Green Building Concept Advantages
1 ESM (Energy Saving Measures)
15-20% saving in non-process energy ( by Natural & optimized Lighting, occupancy sensors, HVAC, Building Automation etc.)
2 Water conservation 15-20% reduction in Water usage( flow
control devices, aerators, sensors)
3 Water recycle/reuse Optimizing Depletion of natural resources
4 Ensuring Sustainability Building material use recycled content in
the form of fly ash, recycled paper, Low VOC Paints
5 Green Cover
Act as modifier in micro Climate. Enhancement in the Landscape
Trends of Resource Saving Potentials
Summary Our learning with the Journey for
Environment Management System &
Sustainability is not only it reduces the
Carbon content, but also gives the
positive impact on our business.
For future we are working on measurement
of CO2e for all our products & Plants for
Green Generation & following it
backward to our Vendor & forward to
Customer. (Full Value Chain)
Thanks