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National Award for Excellence in Energy Management 2013

BAL-Waluj

Bajaj Auto Ltd.


Aurangabad Division

Welcomes you all

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

The Bajaj group was established in 1945 by Shri. Jamanalal


Bajaj, a close associate and disciple of Mahatma Gandhi.

He believed in sound and fair business practices based on


respect for customers and integrity

Bajaj remains committed to these VALUES


Bajaj Group

Automotive

Electrical & Home


Appliances

Steel & Engineering

Finance &
Insurance

Power &
Infrastructure

Bajaj Auto Limited - The flagship Company of the Bajaj Group.


Current world market standing
Ranked as the Worlds fourth largest two & three wheeler manufacturer
3

Company Profile

BAL-Waluj

Manufacturing locations

Pantnagar Plant
Plant and its vendors in
the same premises.
Plant produces Discover,
Boxer & Platina range of
motorcycles.

Bajaj Auto LtdCorporate Office


Akurdi, Pune

Waluj MC Plant Manufacturing of


2-wheelers
Caters to the major export
needs.

Chakan Plant Tries and tests various


new concepts.
Manufacturing of High
Performance bikes.

Waluj CV Plant Manufacturing of


3-wheelers & parts thereof.

BAL-Waluj

Approach for Improvement

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

Process Flow Chart

BAL-Waluj

Press & Fab.

Aluminium
Shop
Vendor
parts

Domestic
Dispatch

Paint
Steel Shop

Vehicle Assly
Engine Assly

Heat Treatment

Export
Dispatch

Central Gear
Shop

Total Number of Equipments - 1840 nos.


6

BAL-Waluj

Flow Chart - Energy Conservation Program


Company
Vision/Mission

Energy Manager

Plant
Vision/Mission

Management
Review

Shop Level Target

Execution &
Monitoring

Encon Projects

Budget Allocation

BAL-Waluj

Energy Conservation Cell


Corporate

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

Press & Fab

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

Time spent by Senior Executives in various functions


Sr No.

Functions

Average time spent %

Manufacturing excellence
TPM- Review/Implementation

25

Green Manufacturing Initiatives

20

Technological & Developmental activities

15

New Products

15

Quality Management systems

10

Supply Chain Management

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

Eliminate wastage of Resources by maximizing Productivity of all


operations & Processes
Adopt in the faster pace for Deployment of all ideas in all areas
of Business Thru Maximizing Involvement of People
Focus on accomplishing investment projects , with Payback
less than two year at faster pace & its horizontal deployment
Procurement of Energy Efficient Equipment for new installation
EarlierConserve + Preserve + Reserve
Now- in addition to above: Reduce + Reuse + Recycle

Share the best practices among employees, vendors,suppliers


& other partners Implement More & More ENERGY KAIZEN
10

BAL-Waluj

Approach towards Encon

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

Specific Energy Consumption


Energy Consumption per unit of production
Energy

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%

Water ( Cu.m /Veh)

69%

34%

34%

12

Specific Energy Consumption-Benchmark

BAL-Waluj

Sr.

Energy

BAL , Waluj

Nearest competitor

Global

Electrical ( Kwh/Veh)

21.15

24.55

NA

Fuel ( LPG) ( Kg/Veh)

1.33

2.6

NA

Water ( Cub.Mtr/Veh.)

0.27

0.41

NA

Diesel (Ltr/Veh)

0.09

2.3

NA

No Standard Benchmarks are available for Automobile sector ,


However, we are setting our own internal targets as:

Min 5 % Reduction in specific energy consumption wrt last year

13

Stratification of Energy consumption


Electrical Energy consumption

BAL-Waluj

LPG Energy consumption

14

BAL-Waluj

Energy Conservation Methodology

Sr.

Activity

No.

Methodology

Tools used
Weekly / Monthly data through Pie
charts & brainstorming

To identify areas of energy

Audit

conservation potential
2

Analysis

To identify equipments &


Processes where energy
conservation is possible

Daily/weekly KWh, pressure,


flow,volume etc.recording through
bar charts,graphs

Action Plan

Identify activities for individual


equipments with time frame

Resource planning & activity charts

Implementation

Action for procurement &


implementation

6W2H Way Activity Charts

Evaluation

To analyze plan V/S Actual

Gap Analysis & countermeasures

Sustenance

To Monitor the results

Internal Audits

15

BAL-Waluj

Energy Conservation Methodology & Idea


Electrical Energy

Loss Reduction /
Elimination

Technological
Improvement

Loss
Elimination

Alternate
Source
Sr
.

Operational Control

Efficient
Equipment

Sr
.
1

Sr.

Idea

Transmission Loss

1 Biogas for Heating

1 LED/CFL/Induction Lamps

Metering & Monitoring

Distribution Loss

2 Solar Lighting

2 Efficient Motor/Pumps

Auditing

Power Factor &


Harmonic loss

3 Wind Power Generation

3 Screw Compressor

Energy Captain

4 Solar Water Heating

Ceramic to Metal tube


heater
Aluminium Pipes for
5
compressed air .air

No Production on Off days

Idea

4 Light Power Loss


5 Unwanted illumination
6 Compressed air energy

Idea

Sr.

5 LPG Heating
6 Magnetic Energy

Idea

6 5 Star rating equipments

7 Inefficient Equipment

7 VFD for high HP Motors

8 Over Rated equipments

8 Use of Soft Starter

16

BAL-Waluj

ENCON Idea Table


Reduction of Electrical Energy Consumption Per Vehicle
Sr No.

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

Use of VFD for compressors at set pressure (70 psi 2)


Optimization of motor size
Task lighting

Installation of Energy efficient motors for compressors(96.3 %)


Energy Efficient
Installation of Energy efficient screw compressors (95 %)
Equipments
Process equipments

Alternate
Methods

Use of LPG heaters instead of electrical heaters .


Use of 150W CFL/Induction Lamps in place of 250 W HPSV lamps
Process change

Usage of
renewable
energy

Installation of natural air draft in place of electrical exhaust fans


Installation of transparent roofs/ Light Pipes for shops .
Utilization of solar energy for heating /Lighting /Power generation
17

BAL-Waluj

ENCON Idea Table


Reduction of Compressed Air Consumption Per Vehicle
Sr No.

Approach

Idea

Waste elimination -Arresting


Leakages

Air Leakage data collection through audits from shops


Air leakage data through FAD tests.
Efficient usage of compressed air
Shut off valve during non working hours

Optimization of compressed
air supply

providing localized compressors


Separation of air headers for Low pressure & High
pressure requirement
Rerouting & Resizing of compressed air headers
Use of Air Boosters for High pressure application
Use of Aluminium pipes for air distribution in
assembly shops

Elimination of compressed air


usage

Use of Electrical operated tools

18

BAL-Waluj

Energy Conservation Methodology & Idea


Fuel (LPG) Energy

Technological
Improvement

Loss
Loss
Elimination

Alternate
Source
Sr
.

Sr.

Idea

Heat Loss through oven skin

Heat Loss Through Flue Gases

Heat Loss to Jigs & Fixtures

Operational Control

Efficient
Equipment
Sr.

Idea

1 Solar water heating

Idea

Sr.

1 Direct heating

Idea

Metering & Monitoring

2 Use LNG

2 Combustion Efficient Burner

Auditing

3 Low Temperature process

Energy Captain

4 Cycle Time Optimization

No Production on Off days

19

BAL-Waluj

ENCON Idea Table


Reduction of LPG consumption per Vehicle
Sr.no

Approach

Idea

Eliminate wastages

Eliminate of heat loss through Furnace /oven


skins-Improve insulation

Optimization

Tuning of burners
Process change

Reuse of waste process heat

Use of low temperature flue gases heat energy

20

BAL-Waluj

Innovative projects

21

BAL-Waluj

Distribution Loss reduction

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

Electronic Energy meters

Data logging system ( Cockpit)

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

Switch off standby distribution

2 transformer through isolation


switches
Overhauling of distribution

3 transformers

Power Factor Improvement by


4 APFC
Harmonic suppression by active
5 filters

4.6 L Kwh

BAL-Waluj

Reduce Losses of distribution network


Innovative Project -1

Distribution Transformer-2 MVA( 11 KV/433 Volts) 29 Nos. in Waluj Plant

Sr.

Actions for loss


reduction

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

2.1 L Kwh /Yr

RS.4.8 L

23

Reduction of Inductive load losses

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 .

It is not possible to compensate such requirement with simple switching


capacitors.
24

BAL-Waluj

Reduction of Inductive load losses


Innovative Project -2

25

BAL-Waluj

Reduction of Inductive load losses


Innovative Project -2

Power Factor /Reactive power compensation at Press & Fabrication shop

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

Power factor also varies from 0.6 to


0.95 & correction required is also
unequal

26

BAL-Waluj

Reduction of Inductive load losses


Innovative Project -2

Power Factor /Reactive power compensation at Press & Fabrication shop

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

Reduction of Inductive load losses


Innovative Project -2

Saving
Investment

: 1.26 LKwh/ Yr
: Rs. 15 lacs

28

BAL-Waluj

Innovative Project -3

Sr.

BAL-Waluj

Reduction of compressed air loss


Phase 1

Before

Phase 2
After

After

Consumption 17 % of Plant
Consumption
Shop wise Metering for
Compressed air

Conducted Compressed air audit


for leakages for plant through external
agency
Conducted compressed air Audit for
Pressure pattern
Total Air leakages 1231 CFM
Mostly air leakages found through Air
Gauges
Air leakages through pneumatic fittings
Result : Saving of one compressor of
1000 CFM .

Use of ultra sound Leakage


identification unit
Regular leakage Audit
internally .
Cell wise Compressed air
Pipe lines for better control
Provided auto shutoff valves
on lines
Electrically operated auto
drain valves with level sensing
on all air receivers
Identify all improper fittings
& Replace with suitable model
& Size

29

BAL-Waluj

Reduction of compressed air loss


Sr.

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

Job Sensor & Valve control


No Job No Air

Dial
Gauge

Direct air connection to


machines - Manual on/off
valves

Soft Start valves to stop air


when machine idle

Air for
machine

30

Solenoid
valve
Sensor
Switch

Air shutoff valves for air


feeders to production cell
Time controlled

Electrical- Lighting
Sr.

Phase 1
After

Phase 2
After

150 Watt CFL lamps


650 No.s Lamps
Connected Load 97.5 Kw
Consumption 3.55 L Kwh/Yr

72 Watts LED lamps


80 Nos. Lamps
Connected Load 5.76 Kw
Consumption -0.21 L kwh/Yr

Energy saving : 3.56 L Kwh /Yr


: Rs.24.95L/Yr
Investment : Rs.12.6 Lacs

Energy saving : 0.23 L Kwh /Yr


: Rs.1.61 L/Yr
Investment : Rs.8.0 Lacs

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

300 watts SV High bay lamps


590 Nos. Lamps
Connected Load -177 Kw
Consumption- 4.24 L Kwh/Yr

BAL-Waluj

After

After

156 watts Induction lamps


302 Nos. Lamps
Connected Load 47.0 Kw
Consumption- 1.13 L Kwh/Yr

120 W LED High bay lamps


Under trials

Energy saving : 3.12 L Kwh /Yr


: Rs.21.87 L/Yr
Investment : Rs. 31.71 Lacs
FTL T8 ( 40 Watts) for shop &
storage area lighting
Office
& assly
line

FTL T5 ( 30 Watts) for shop &


storage area lighting
1200 No.s T5 fitted

CFL /LED Lights : 200 Fittings


of 80 Watts

Saving
Investment

Saving : 0.43 L Kwh /Yr


Rs. 3 Lacs
Investment : 8 Lacs

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

Task Lighting in machine shops

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

Electrical- Fans & Blowers

Installation of Spot cooling System


to replace Old type ARP system

Replacement of 30 inch size Air


circulator by 24 inch ( 150 Nos)
Before
After

350 Watts air


circulators

Saving
Investment

200 Watts air


circulators

BAL-Waluj

Before

After

Centralized ARP
Breeze air spot
cooling system With coolers used With 2
100HP motor
HP blowers (18 No.)

: 1.21 Lacs Kwh /Year


: Rs. 7.5 Lacs

Saving
Investment
34

: 1.28 Lac kwh/Yr.


: Rs.16 lacs

Electrical- Pumps & Motors

Pump Elimination

Pump Optimization
Before

75 Kw Motor
Total Load -102
Kw

BAL-Waluj

Before

After

37 Kw Motor
Total Load -67
Kw

Energy Saving : Rs. 13.28 Lacs/Yr


Investment
: Rs.26 Lacs

After

Application :Therrmic fluid


circulation Motor power-25HP

25 HP gland pump replaced with


mechanical seal pump .
Also eliminate gland cooling pump of 5 HP
Energy Saving : Rs. 2.27 Lacs/Yr
Investment
: Rs. 2.68 Lacs
Horizontal deployment 3 Locations
35

Electrical- Pumps & Motors

Installation of VFD for


Exhaust blower in paint shop
Before
After

Use of Energy Efficient motors


Before

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

Energy Efficient motor


IE3 motors in paint
shop

VFD Installed
Blowers running at 50 %
speed in recess time

Saving
: Rs. 0.56 Lacs / Yr
Investment : Rs. 0.78 Lacs
Horizontal deployment : 5

Saving : 0.35 Lacs Kwh/Year Rs. 2.45 Lacs


Investment :Rs. 4.3 Lacs
Horizontal deployment : 2
36

BAL-Waluj

Electrical- Compressed air


Sr.

Phase 1
Before

Phase 2
After

After

Reciprocating compressors are


running in central compressor
houses. @ 4.5 to 6 Bar

Atlas Copco /Ingersoll Rand


screw compressors . Capacity
1000 CFM each @ 4.5 Bar
High Pressure compressed
air -6 Bar through local
compressor

Demand side management :


Variable speed IR make
NIRVAN compressor 1000
CFM -2 Nos.
Supply side Management :
Controller for compressor
operation
Installed air boosters for
high pressure at 4 Locations (
4.5 Bar to 6 Bar)

Saving ( Kwh) :12.0 Lacs /Year

Saving ( Kwh) : 2.0 Lacs /Year

Investment : Rs. 90 Lacs

Investment : Rs. 8 Lacs

Compr
essed
air

37

BAL-Waluj

Electrical- Cooling
Fanless Cooling Tower
Before
After

Optimum temperature for ACs / coolers


Temperature settings
SN

Air Movement in
cooling Tower induced
with the help of Exhaust
Fan of 4 HP

Provided cooling tower


equipped with water
jet technology. i.e. Air
movement in cooling
tower induced with the
help of water Jet.

Energy Saving : Rs.1 Lacs/Yr


Investment
: Rs.1.8 Lacs
Horizontal deployment : 3 locations

Description

Room AC

Panel AC

Water coolers

Saving
Investment

38

Before
( Deg.C.)

After
( Deg.C.)

21

24

Localised storage tank

30

34

18

24

: 0.1 Lacs kwh/Yr.


: Zero

Electrical- Cooling

BAL-Waluj

Energy Efficient equipment installation


Before

After

Air Dryers -5000 CFM capacity


With Reciprocating compressors
replaced with Scroll compressors
air dryers 4 Nos.

CED Reciprocating Screw chiller 80 TR


chiller 110 TR
(0.71Kw/TR)
(0.9 Kw/TR)
Energy saving : 0.4 Lacs Kwh /Annum
Investment: 13 Lacs

Energy saving : 0.8 Lacs Kwh /Annum


Investment: 8 Lacs
39

Electrical Method change


Electrical Heating TO LPG Heating
Before

After

Electric Heater

LPG Burner For


Heating

BAL-Waluj

Electrical Heating TO Heat Pump


Before
Electric Heater

Electric Heater was used


for Water heating of
pre washer on CGC
Furnace -54 KW

After
Heat pump For
washing machine
water heating

Electric Heater was used


for Water heating of
washing machine

LPG Heating is used

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

Total Identified Points 24


Heat Loss- 63456 K Cal /Hr
Rectified Insulation of High heat Zone
Saving - 27 Ton LPG /Year

We have conducted Thermal


Imaging for identifying
heat losses in paint ovens

41

BAL-Waluj

Thermal
Sr. no. Shop Name

Paint Shop

Paint Shop

Heat treatment

Heat treatment

Discription

Year

Reduced hanger weight to minimize heat loss.2012-13


3.7 Kg/Hanger
Scheduled running of ED process
2012-13
Line Running -18 Hrs /Day

Annual Thermal

Investment
made

Units
(Mn T)

Rs.
(Mn)

Rs Lacs

0.0041

0.2173

1.00

0.057

3.021

0.00

Salt heating by Quenching hot empty fixtures

2012-13

0.001

0.053

1.00

Optimize fixture weight to reduce heat loss

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

10 Paint Shop MCD

Cleaning of PTCED Loading rods in shot blasting 2012-13

0.002

0.106

1.00

11 Heat Treatment

Use burners Flue gases for heating dryer.

0.001

0.053

1.00

0.0771

4.0863

4.5

Heat treatment

Heat treatment

7
Paint Shop MCD
8
9

Heat Treatment

Maintaining furnace temperature 700O C on


Weekly Off days
Single pilot flame with flame sensor for
burning exhaust gases of furnaces
Provided Low temperature degreasing
chemicals.Paint shop
Reduced Meri oven cycle time.
3.0 Hrs/ Cycle
Less process time for 0.45 mm Case depth of
KTM Gear - Shaving route

42

2012-13

BAL-Waluj

Use of Renewable Energy

Installation of transparent roofs


in dispatch yard

Solar water Heating System

Make up water is heated by Solar


water heating system which reduces
load on LPG water heater
LPG Saving : 3396 Kg / Year
Saving
: Rs.1.4 Lacs / Year
Investment : Rs. 5 Lacs

Transparent roofsQty: 78 No.s

Saving
Investment

: Rs. 4 Lacs / Year


: Rs. 3.12 Lacs

43

BAL-Waluj

Use of Renewable Energy


Solar Lighting Use of Light Pipes in assembly

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

Use of Renewable Energy


Generation of Electrical Energy with Windmill Power Project

At SATARA & SUPA area in Maharashtra Wind mills are installed


for Electrical Power Generation.
Target

Year

Installed
Capacity

Wind power
Generated

Waluj Plant
consumption

Wind Power
adjusted

Contrib
ution

Equiv. CO2 emission


reduction

(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

Use of Renewable Energy

BAL-Waluj

Solar Photo Voltaic Power Plant -20 Kw Installed at Bal Waluj


Capacity

20 kWp Grid Connected Solar Power Plant

Location
Area Utilised

Roof compressor House -8


240 M2

No. of Solar Panel


Solar Module

72
280 watts each

Solar Chip

Polycrystelline

Solar Moduel Make

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

90 Kwh/day ( Avg) / 32850 Kwh/Year


M/s Lanco Solar Energy Pvt Ltd.

Commissioning by

M/s Lanco Solar Energy Pvt Ltd.


46

BAL-Waluj

Use of Renewable Energy


Solar Photo voltaic Power Plant- 20 Kw

Future Projects :
Rooftop Solar Power Plant Up to 10 MW
Open access Power trading

47

Summary of ENCON projects

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

Regular Shop Audit


by Energy Captains

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

Energy consumption monitoring & Measurement

BAL-Waluj

SCADA

10 Air Flow meters


Monitoring up to shop
53

Energy consumption monitoring & Measurement

54

BAL-Waluj

Energy consumption monitoring & Measurement

BAL-Waluj

55

BAL-Waluj

Monitoring and Reporting system


External Audit
Sr.

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/day

1500 Cub.M. /d

2012

Power System- PF & Harmonics

1.2 L Kwh

0.8 L Kwh

2012

Process Pumps & Motors

10

2.7 L Kwh

WIP

2012

Thermal - Thermography for


Ovens

63456K Cal

WIP

2012

Compressed Air System

7 L Kwh

WIP

2012

Compressed Air Leakages

6 L KWh

3 L KWh

2013

Chillers

2.62 L Kwh

WIP

56

Awareness creation

BAL-Waluj

Awareness through communication


Energy Captains
5 Axis Training
Latest Technology

Monthly Kaizen
Karakuri
State & National level

Small Group Activity


Karakuri
Engineering Kaizen
Managerial Kaizen
Energy Boards at shop

ENCON week
Poster display
Energy Seminar
New Product display

Best Kaizen Award


Best Energy Captain
Energy Efficient Shop

57

Awareness creation

BAL-Waluj

Celebration of Energy conservation dayday-14th Dec -12

Energy
Conservation Week
- 14th-20th Dec
Energy Efficient product display for vendors

Participant on Energy Day

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

Press & Fab.

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

Scenario - Water Consumption at Waluj:

Production Up
by 55 %
Water consumption Down
by 44 %

Recharging
of Ground
Water

Constructed Recharging of Ground Water : 2190 Cu. Mtr / Day


61

BAL-Waluj

Stratification of Water consumption

Sr.
1

Water
Water consumption - %

Industrial cooling

Process

Domestic

59

34

62

BAL-Waluj

ENCON Idea Table


Reduction of Water Consumption Per Vehicle
Sr.no

Approach

Idea

Eliminate wastages

Optimization of network & eliminate water


leakages from supply lines
Use of one Touch Tap orifice ( 4mm ) for
domestic water taps .
Localized water tanks for shops

Reuse of waste water

Use of treated water for horticulture .


Use of Treated water with UF & RO for
process.

Use of Rain Water

Storage in water harvesting ponds.


Ground recharging with rain water .

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

List of major environmental improvements 2012-13


Sr No. Environment Improvement
1

No water is discharged outside the company.

Tree Plantation by all employees in plant 4500 Plants

Rain water harvesting pond capacity increased to 10000 Cub Mtr

Implementing E-waste norms prescribed by MPCB.

Ground water recharging with rain water (Patented with KEDIA FARM PATTERN) by
deep percolation technique. Capacity -8 L kL

100 % recycling of Industrial effluent by Installation of RO + UF Plant of capacity 1000


M3 / day. This being used for process.

Reduce consumption of packaging material by 35 % (Polythene bags, corrugated boxes)


in last 7 years. No packaging materials for transporting material from vendors

Effluent treatment plant (ETP) has been upgraded to separate industrial & domestic
effluent resulting in better quality of treated water.
68

Water Conservation

BAL-Waluj

Recycling -Sustainable Development


Theme

Reduce Water consumption by recycling the water for processes


Before

After
RO Plant
Effluent
Treatment Plant

Effluent

Use for
Horticulture

Use for Process

Treated water was used only for Horticulture activities.

Investment

Rs.3.0 Cr

Qty

2 Nos.

Treated water is recycled through RO plant and used


for processes.

Water Saving / Day


700 Cu. Mtr.

69

Water Conservation
Rain Water Harvesting

BAL-Waluj

Recycling -Sustainable Development

Rain water Pond of Capacity enhanced to 10000 M3


FY 12-13

FY 13-14

Investment

Rs.12 Lacs

Qty

Investment

Rs. 24 Lacs

Qty

Water Storage Capacity


10000 Cu. Mtr.

Water Storage Capacity


10000 Cu. Mtr.

70

BAL-Waluj

Water Conservation

Recycling -Sustainable Development

Ground Water Recharge

FY 12-13

FY 13-14

Investment

Rs.15 Lacs

Qty (KFP)

50 Nos.

Investment

Rs.36 Lacs

Qty (KFP)

160 Nos.

Water Recharging / year


1.5 Lac KL

Water Recharging / year


8.0 Lac KL

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

Waste Heat Recovery System


installed at

LPG Saving
Kg/Year

Investment
( Rs. Lacs)

Paint shop ED oven exhaust

26100

9.75

HWG Aquatherm PTCED Exhaust

10416

5.5

HWG Aquatherm Paint shop Exhaust

10416

5.5

PTCED line Oven Exhaust

38626

Paint shop Exhaust Oven- 4 Locations

37135

12.5

73

BAL-Waluj

Waste utilization
Use of Bio Gas Plant in Canteen
After

Before

LPG GAS USED FOR


CANTEEN

Saving 22 Kg /day LPG


Saving = Rs 2.6 Lacs/ Annum
74

BAL-Waluj

Waste utilization
Reuse of Quenching Salt

Heat treatment
After

Before
Washer

Salt water inlet


from Shop

components

Hot water
Salt +water

Burner

To ETP.

Kulfi Pots for


salt collection

Weekly Draining to ETP.


No provision of Salt recovery
Wastage of Quenching Salt
during Washing of components.

Salt recovery by evaporation of water.

Investment Rs. 35 Lacs


75

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 %

Reduction in Carbon Emission Total


77

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

Under Companys Control

Distance Reduction

Fuel Consumption Reduction


78

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

Reduce No. of Trips

Increase Loadability

Eliminate Movements

Increase occupancy

Eliminate Multi-handling
Use of Alternate equipment ( e g. Use
of BOPT )
Use of Belt for material movement

Milk Run Route


Reduce distance ( bring vendor
near to BAL)
Increase vehicle cube capacity

5
6

5
6
79

Carbon Reduction

Carbon Reduction through - Logistics Improvement


M/s. BAL & M/s. Skoda Joint Initiative

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

Trip Distance Reduction - Container Transport


After Condition

JNPT PORT

Skoda
Filled
Containe
r

BAL
Empty
Containe
r

82

JNPT PORT
Filled
Containe
r

BAL-Waluj

Carbon Reduction

Trip Distance Reduction - Container Transport


Carbon Reduction through Logistics Improvement
960 Km

Saving in travelling Distance per Trip


Net reduction in Diesel per Trip
Total Carbon Reduction per Trip
No. of Trips per Year

192 Lit.
509 Kg.
3600 Nos.

1832 Tons / Year

Net Carbon Reduction

Next objective Explore use of import containers from local industries


83

Methodology - Implementation of ENCON initiatives at


Vendors end
Formation of
Vendor TPM Cell

Handholding on
Loss Reduction

Inputs to Vendor
on TPM Philosophy

(16 type of Losses)

Practical Training at
Learning Centre BAL

Help to Identify
Improvement
Projects

Promoting Renewed Partnership

Appreciate the
Improvements

BAL-Waluj

Sharing of Improvements
across the Bajaj Auto
Vendor Association

84

Consultation from
Company Experts
for Implementation

Implementation of ENCON initiatives at Vendors end


Name of
vendor

Sr

Product

Per unit Energy


consumed
Before

BAL-Waluj

%
Inputs / projects provided to the
improvement
vendor/ associate

After

M/s Duro valve


Valves
(I) Pvt Ltd,
production
Aurangabad

0.20Kwh/
Valve

0.17Kwh/Val
ve

33 %

Training , Visit to our plant , Help in


Energy Audit & Implementation of
projects

M/s
Badve
Engineering
Silencer
Unit
2, production
Aurangabad

3.6Kwh/Sile
ncer

3.3
Kwh/
Silencer

8.33 %

Training , Visit to our plant , Waste


elimination, Timed control operation

M/s
Varroc
Mirror
Polymers Pvt
production
Ltd. Pl. 2

0.32
Kwh/Unit

0.0.2
Kwh/Unit

37.5 %

Training , Visit to our plant , Waste


elimination,
Renewable
energy
usages, Efficient equipments ,
Optimized heat utilization.

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

Loss reduction by Power Factor Improvement


Elimination of compressed air leakages through cell wise shutoff
valves & replcement of fittings type .
Lighting/cooling
Induction Lighting for shops - 490 nos

Utilities

Installation of LED lights for Offices & shops

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

Installation of transparrent roof sheets for Shops


Installation of Occupancy sensors for Shop work places
Roof top garden for reduction of temperature inside offices by 10
deg c
Installation Of Breez air cooling system in place of ARP
Installation of Galvalume sheeting with insulation for temperature
reduction by 3 Deg c
Installation of Water cooled scrol chiller for paint shop -60 TR
Method Change
Use of Heat pumps for Washing machine water heating
Pumps /AHU
Installation of energy efficient pumps for coolant system (
downsizining) -3 Nos.
Installation of VFD s for air handeling system

15

Utilities

Installation of energy efficient pumps- 15 no.

0.9

6.31

7.50

16

Machine shop

Installation of energy efficient motors- 7 no.


Renewable Energy

0.42

2.94
0.00

6.00

17

Utilities

Installation of off grid solar power system-100 Kwp( Upto 10 MW)

1.5

10.52

80.00

18

Utilities

Solar Air conditioners unit ( 30 TR)

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

Variale speed compressor -NIRVAN- 2 Nos. 1000CFM


in place of Reciprocating compressors

6.6

36.3

48.00

23

Utilities

Installation of scroll compresor air dryers for


compressed air -2 Nos.

0.5

2.75

6.00

24

MCD shop

Use of Air boosters for high pressure compressed air


instead of localised compressors -2 No.

Magnetic Resonanse for LPG lines for improving


combustion
Installtion of heat recovery for system for washing
stage water heating
Direct heating for phosphate tank
Air & Chillers

0.45
34.64

2.25

2.00

235.8

465.7

Total Projets : 24 No.s


Total Saving Expected : 235 Lakhs
Total Investment Expected : 465 Lakhs

87

Awards & Accolades

BAL-Waluj

MEDA- Excellence in Energy


Conservation & Management
Award 2012
CII- Efficient Unit Award 2012

88

Awards & Accolades

BAL-Waluj

89

Awards & Accolades


Award

BAL-Waluj

Sr

Year

2012

State Level award for Excellence in Energy conservation & Management

2012

Energy Efficient unit award at National Level

2012

Green Manufacturing Excellence Award Challenger category

2009

State Level award for Excellence in Energy conservation & Management

2008

Energy Efficient unit award at National Level

CII- GBC

2008

Excellent water efficient unit award at National level

CII- GBC

2007

Excellent energy efficient unit award at National Level

CII- GBC

2006

Excellent energy efficient unit award at National Level

CII- GBC

2006

State Level award for Excellence in Energy conservation & Management

10

2006

Excellent water efficient unit award at National level

CII-GBC

11

2005

Energy Efficient unit award at National Level

CII- GBC

12

2005

Excellent water efficient unit award at National level

CII- GBC

13

2004

State Level award for Excellence in Energy conservation & Management

14 2003/2004 Excellent energy efficient unit award at National Level


90

Agency
MEDA
CII- GBC
Frost & Sullivan
MEDA

MEDA

MEDA
CII- GBC

BAL-Waluj

Conserve for Today


Today
Preserve for Tomorrow
Tomorrow.
Reserve for future Generation
Generation.Also
Reduce + Reuse + Recycle

91