28

First Prize

Automobile Manufacturing

ASHOK LEYLAND, UNIT - 2

Perandapalli, Hosur (Tamil Nadu)

Unit Profile

Ashok Leyland Limited is the second largest commercial vehicle manufacturing

company based in Chennai, in the medium and heavy commercial vehicle (M&HCV)

segment with a market share of 26% and with revenues of Rs. 9943 Crs in 2013-14.

Ashok Leyland has six manufacturing plants in India - the mother plant at Ennore

near Chennai, two plants at Hosur (called Hosur 1 and Hosur 2, along with a press

shop), Alwar, Bhandara and at Pantnagar. Ashok Leyland also makes spare parts

and engines for industrial and marine applications. Company sells about 1,00,000

vehicles and about 20,000 engines annually.

Major aggregates produced at Hosur Unit – 2 are Axles, Frames, Frame Side

Member, Cabins and Vehicles.

Energy Conservation

Energy is monitored in terms of Per HECU (Hybrid Chassis Unit) across all units of

Ashok Leyland (AL). An Energy CFT is in place with members from all units of AL.

On a daily basis the production is converted to HECU in SAP and monitored.

29

Energy Conservation Projects Implemented (2013-14)

Sl.

No.

Area of Implementation

Project Title Savings (in Rs. Lakh)

Savings (in Lakh kWh)

Diesel (Savings in kL)

1. All Using "BIOMASS" Power and reducing Genset Diesel consumption

84 - 147

2. All Accommodating fenders along with CAB by skid modification there by

improving productivity to the extent of avoiding 3rd shift for manual line

75.36 4.50 96

3. CAP To optimize the Equipment running in PTED line by various improvements

15.45 2.81 -

4. Chassis Modification of airline in chassis assy to cater exclusively to night shift

9.63 1.75

5. CAP Auto control and ED start up

optimisation and interlinking with cab presence

21.5 1.20 28.26

6. Compressor

Maintaining the air temperature in compressor house to improve efficiency

6.3 1.15

7. ALL Provision of compressed air on need basis to individual lines

13 2.36

8. CAP Robo line Tag Rag Booth Air Supply Blower Motor VFD Introduction

8 1.45

9. KDC Local control of air at KDC 6.77 1.23

10. FAS Trans-vector nozzles to be used to reduce compressed air consumption in Frame Preparation Line

5.5 1.00

11. All Reducing fixed energy on a low production day

5.1 0.93

30

12. ALL MD control during peak hours and

load shedding in low volume areas boosted productivity

24.42 4.44

13. All Isolating Power during Lunch hours 3.85 0.70

14. CAP Avoiding idle running of exhaust fans in ovens during start up

2.17 0.39

15. CAW Provision of spring loaded cylinder in place of Pneumatic cylinder

1.77 0.32

16. FAS Elimination of compressed air usage in Shot blasting machine for

cleaning

1.62 0.29

17. All Switching off street light at RSO 1.53 0.28

18. FAP Frame paint reciprocator and Blower Motor VFD interlocking

1.44 0.26

19. CAP Final rinse agitation pumps interlocking with cab presence.

0.99 0.18

20. ETP Energy Efficient motors in STP Pump

0.99 0.18

21. All Switching OFF all the panel Air Conditioners of the equipment

0.96 0.17

22. All Replacement of inspection lights in CAP with T5 - 25 Watts

0.63 0.11

23. KDC Replacement of inspection lights in CAW with T5

0.54 0.10

24. CAS Energy saving in Tyre Mounting machine

0.54 0.10

Total Savings 267.65 25.92 271

1. Substituting Diesel by Biomass

Instead of running DG sets, Power from Green Energy source was used to run the

plant in the month of February and March 2014.

Total investment : Rs. 0.15 First year energy cost savings : Rs. 84.00 Lacs

After Before

31

2. Paint skid modification to increase painting surface area

In the painting process the cabins were first painted in one skid. In another skid

related parts like fenders and bumpers were getting painted. This was consuming

two rounds instead of one round per cabin painting. The skid system was modified.

Now the loose parts are getting painted along with cabin in single round. By this

process unit was able eliminate one shift in Paint booth.

Total investment : Rs.1.5 Lacs

Year of implementation : 2013-14

First year energy cost savings : Rs. 75.36 Lacs

3. Auto - individual control of air lines

Due to fluctuations in marked demand only selected production lines are being

operated in dual shift. The selection of line also varies on a weekly basis. To avoid

wastage of compressed air in these lines unit converted a manually operated valve

to automatic timer based operated valve. This results in Energy savings in running

of compressors.

Total investment : Rs.0.15 Lacs

Year of implementation : 2013-14

First year energy cost savings : Rs. 9.63 Lacs

Before After

Before After

32

4. Temperature reduction in Compressor house

For every 3 °C reduction in compressor temperature, the efficiency will improve by

1%. The temperature inside compressor house was brought by installing free flow

duct and ventilators. After installation of ducts the temperature inside came down

by 8 °C. Due to this the compressor energy consumption reduced.

Total investment : Rs. 0.15 Lacs

Year of implementation : 2013-14

First year energy cost savings : Rs. 6.30 Lacs

Energy Policy

33

Second Prize

Automobile Manufacturing

TATA MOTORS LIMITED

Dharwad (Karnataka)

Unit Profile

Tata Motors Limited is India's largest automobile company, with consolidated

revenues of INR 2,33,662 crores (USD 38.6 billion) in 2013-14. Through

subsidiaries and associate companies, Tata Motors has operations in the UK,

South Korea, Thailand, South Africa and Indonesia. It also has an industrial joint

venture with Fiat in India. It is the leader in commercial vehicles in each

segment, and among the top in passenger vehicles with winning products in the

compact, midsize car and utility vehicle segments. It is also the world's fifth

largest truck manufacturer and fourth largest bus manufacturer. The company's

manufacturing base in India is spread across Jamshedpur (Jharkhand), Pune

(Maharashtra), Lucknow (Uttar Pradesh), Pantnagar (Uttarakhand), Sanand

(Gujarat) and Dharwad (Karnataka).

Tata Motors Ltd, Dharwad Plant is the youngest plant amongst other TATA

MOTORS plant, started manufacturing Small Commercial Vehicles (Tata Ace Zip)

in March, 2012. Dharwad Plant has an installed capacity of 150 per Shift for

manufacturing Small Commercial Vehicles and 40 per shift for manufacturing

Light/ Medium Commercial Vehicles. Tata Motors, Dharwad is certified Platinum

Rating by Indian Green Building Council (IGBC) and certified ISO 14001,

ISO 50001, TS 16949 and in the process of implementing OHSAS 18001.

34

3,242.09

3,517.70

3100

3200

3300

3400

3500

3600

2012-2013 2013-2014

No

of

Ve

hic

le's

Absolute Thermal Energy Consumption (MKcal)

60.32

63.81

58

60

62

64

66

2012-2013 2013-2014

No

of

Ve

hic

le's

Absolute Power Consumption (Lakh

Kwh)

0.211

0.141

0

0.05

0.1

0.15

0.2

0.25

2012-2013 2013-2014

No

of

Ve

hic

le's

Specific Thermal Energy Consumption In

Million kCal/Veh

250

193

0

50

100

150

200

250

300

2012-2013 2013-2014

No

of

Ve

hic

le's

Specific energy consumption Kwh/Veh.

Energy Consumption Details

The energy consumption has risen only by 6.39% compared to last FY 12-13

even though there is significant raise of production by 62%. However the

specific energy consumption has a steady decline from Last FY 12-13 due to

various conservation measures taken .The energy scenario of TML Dharwad for

past two years is given below.

Absolute Energy Consumption

Specific Energy Consumption

DESCRIPTION UNIT 2012-13 2013-14

Annual production ACE ZIP Nos. 15382 24992

Total Electrical Energy

consumption/annum Lakhs kWh 60.32 63.81

Specific Energy consumption- Electrical kWh/ Veh. 250 193

Total Thermal Energy consumption/annum

million kCal 3242.09 3517.69

Specific Energy consumption- Thermal million kCal/Veh. 0.211 0.141

Energy Cost as a % of manufacturing cost Percentage 1.4%

35

Annual energy savings Achievement in 2013-14

Sl. No.

Project description Electricity HSD Total savings (Rs. Lakh)

Investment (Rs.

(Lakh)

(Lakh kWh)

(KL)

1. Blower elimination in shower testing 0.51 NA 3.8981 0

2. Elimination of ETP/STP motor for Stirrers application

0.32 1.7800 0

3. Auto switching OFF the display of andon when line is not running more than 30 min

0.07 NA 0.4851 0

4. Auto switching OFF the display of

andon when line is not running more than 30 min at Slat area

0.01 NA 0.0517 0

5. Andon Safe Power off procedure to be developed through VB soft wear =

690*14*7

0.07 NA 0.4851 0

6. Optimization of PCC oven blower in paint shop while switching OFF operation

0.17 NA 1.3700 0

7. Reduce nozzle size of Hot water generator from 32 to 28

0.00 24.992 14.3954 0.019

8. VFD Blower Installation 0.54 NA 4.1580 3.3594

9. To reduce the Water re-circulation Power consumption

0.21 NA 1.6373 0

10. T0 reduce the ideal run of hydraulic motor of piercing machine

0.16 NA 1.2197 0

11. T0 reduce the ideal run of fume extractor

0.0030 NA 0.0231 0

12. Elimination idle running blower during breaks by interlocking with PLC logic

0.13 NA 0.9887 0

13. Idle running of Toilet blower by providing weekly timer

0.05 NA 0.3743 0.135

14. PRB motor made off when next prb slow sensor sense.

0.01 NA 0.0571 0

15. PLC control given for switch of water recirculation system

0.09 NA 0.6884 0

16. Eliminate idle running PRB-8 motors by logic modification in PLC

0.07 NA 0.5429 0

17. UPS Installation in BIW (4 Nos.) 1.29 NA 9.8952 57.836

18. 2 nos. of IRIS (Idle) Robots power off 0.05 NA 0.3885 0

19. Hot water pump automation 0.07 NA 0.5082 0.015

20. Eliminate idle running Nederman fume extractor by interlock with station

0.01 NA 0.0508 0

21. Turning on water rinse (3) spray pump when spray solenoid coil is activated

0.02 NA 0.1232 0.001

36

22. Turning on IR oven only when body is

present

0.16 NA 2.4948 0.075

23. Turning ON circulation pump for plate heat exchanger only when heat exchange is required for the tank

0.01 NA 0.0554 0.002

24. Providing separate switches for lights and fans in EMS unloading area

0.01 NA 0.1146 0.001

25. Turning off cooling fans when nobody

is present at disengage conveyor

0.00 NA 0.0266 0.001

26. Automatically Turning off circulation pump for hot water generator, with delay, after production

0.04 NA 0.3437 0.001

27. Providing the operating box in the under body booth itself

0.00 NA 0.0062 0

28. To modify the PLC logic at engine dressing so that when hold button is

pressed, the conveyor motors should stop

0.03 NA 0.1952 0

29. To reduce the power consumption of Washing Machine by reducing the idle

waiting time. Now the counts is reduced from 100 to 54 (As per calculation 4.6 minutes)

0.06 NA 0.4990 0

30. To reduce Power consumption of Main

Assembly conveyor by converting the bottom conveyor from continuously running to intermittent running

0.03 NA 0.2228 0

31. To make the sealant machine tube light optional by changing its electrical

circuit

0.01 NA 0.0462 0

32. Moreover the power to ANDON board has been rerouted through the PLC panel so that when the Engine dressing

line is switched off, the ANDON is also switched off.

0.02 NA 0.1441 0

33. Motion sensor in paint booth. 0.01 NA 0.0911 0.0095

34. Interlocking shower tester lights with

pump running

0.01 NA 0.0464 0

35. Ofc lamps optimization across shop floor

0.01 NA 0.0842 0

36. Canteen Lights optimization 0.02 NA 0.1590 0

37. Panel A/C disconnected from main source and connected to local control circuit.

0.04 NA 0.2833 0

38. Heater switched off in Glass glazing machine

0.20 NA 1.5649 0

39. Panel A/C switched off in Glass Glazing machine.

0.02 NA 0.1466 0

37

Before

After

40. Timer installed for blowers of paint

booth.

0.01 NA 0.1072 0

41. Under pit lightning modification. 0.01 NA 0.0742 0.025

42. Shower tester blower switch off 0.15 NA 1.1929 0

43. Air Supply to TCF reduced from 6.6 bar

to 5 bar

0.00 NA 0.0156 0

44. Roll & break test m/c exhaust fan (0.28 kW) not in corporate with the process cycle.

0.01 NA 0.1035 0

45. Glass glazing m/c when idle hours the robot (24 kW) switched OFF

0.58 NA 4.4452 0

Total 5.27 24.99 55.58 61.48

1. Reduction of HSD fuel consumption in Paint shop Hot water

generator.

In Paint shop hot water generator burner unit was using 35 GHP nozzle due to

which was having high HSD fuel consumption. It was consuming 17 liters per

vehicle. The Burner nozzle size was reduced to 28 GHP and the Experiment was

conducted and it was proved that 28 GHP nozzle was sufficient to produce the

required heat. Now it is consuming 16 liters per vehicle.

Total Investment made : Rs. 1900

First year Energy cost saving : Rs. 9.65 Lakh

2. Elimination of motorized stirrer operation in ETP/STP

Description of the energy conservation measure: The blower air used for regular

operation is used for mixing of chemicals in flash mixing and flocculation tank.

The agitation effect generated by blower air completely eliminated mechanical

agitators driven by 3.7 kW motor. The mechanical agitators were run 24 x 7.

35 GPH

28 GPH

38

Before After

Total Investment made : Nil

First year energy cost saving : Rs 1.78 Lakh

Energy Policy