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National Award In

Excellence in Energy Management 2010


Category
Sector

Excellent Energy Efficient Unit


Automobile

Unit

Tata Motors Limited ,CVBU


,CVBU - Lucknow

Results

Best in class
Sp. Energy consumption
- Sp. Water consumption &
- Sp. Fuel consumption

Lake View Within the Plant

Plant Greenery

- CVBU LUCKNOW

Sohrabji Godrej Green Business Centre

National Award In
Excellence in Energy Management 2010

Tata Motors Limited


CVBU - Lucknow
Presented By:Srinu Babu . Matta

Div Manager

Energy Auditor

Nitansh . Kamboj

Manager

Energy Manager

Md. Amir

Manager

- CVBU LUCKNOW

Sohrabji Godrej Green Business Centre

Company Profile:- Lucknow Plant


vTata Motors Limited is
Indias largest automobile company,
Consolidated revenues of Rs. 92,519.25 crores in 2009-10.
(US $ 18.3 billion)

We are the leader in commercial vehicles in each segment,


The company is worlds fourth largest truck manufacturer,
Worlds second largest bus manufacturer.
vTata Motors -CVBU Lucknow is
Established in 1992 to meet the demand of Commercial
Vehicles in Indian & overseas market.
Specialized in the designing and manufacturing of a range
of modern buses Low floor, Ultra Low floor, CNG &
RE Buses.
Prominent customers include DTC & STU.

Lake View Within the Plant

TML - Lucknow
- CVBU LUCKNOW

Plant Greenery
Sohrabji Godrej Green Business Centre

Facilities @ Lucknow

Who are we
Lucknow Works

EASTERN COMPLEX LUCKNOW WORKS

Bus
Focused
ERC setup
Recon
Vehicle
Factory

Transmission
Factory

Integral Bus
Factory

Frame

Heat
Treatment

Module
Fabrication

Cowl

Machining

Module
Assembly

FBV
Head
Quarter

Weld Shop

Paint Shop

TCF

Cowl &
Cabin
Vehicle
Assembly

TMML

Vehicle
Assembly

Service
Training
center

- CVBU LUCKNOW

Sohrabji Godrej Green Business Centre

Plant Process
Transmission
Assembly

Engine
Assembly

Vehicle Assembly Line


Western Complex
Bus Assembly Line
TMML
Vehicle Assembly Line
Eastern Complex

Material
from
Vendor base -

Local,
Pune &
Jamshedpur

Chassis
Assembly

Cowl
Assembly

Paint
Shop

DISPATCH

SUPPLY
CHAIN

Axle
Assembly

DTC*

STU**

Private
Operator

BIW
Shop

* Delhi Transport Corporation


**State Transport Unit
- CVBU LUCKNOW

Sohrabji Godrej Green Business Centre

Sohrabji Godrej Green Business Centre

Plant Energy Policy

- CVBU LUCKNOW

Energy Management Cell


We have Energy Management Cell in our
Plant, Which initiates & Manages all sorts
of Energy Conservation measures across
the Plant. The structure of the Energy
Management Cell is,

- CVBU LUCKNOW

Sohrabji Godrej Green Business Centre

ENCON Summary

Low Investment < Rs 10,000/-

- CVBU LUCKNOW

Sohrabji Godrej Green Business Centre

ENCON Projects

2006-2007

- CVBU LUCKNOW

ENCON Projects

Sohrabji Godrej Green Business Centre

2006-2007

- CVBU LUCKNOW

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Sohrabji Godrej Green Business Centre

ENCON Projects

2006-2007

- CVBU LUCKNOW

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ENCON Projects

Sohrabji Godrej Green Business Centre

2006-2007

- CVBU LUCKNOW

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Sohrabji Godrej Green Business Centre

ENCON Projects

2006-2007

- CVBU LUCKNOW

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ENCON Projects

Sohrabji Godrej Green Business Centre

2006-2007

- CVBU LUCKNOW

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Sohrabji Godrej Green Business Centre

ENCON Projects

2006-2007

- CVBU LUCKNOW

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ENCON Projects

Sohrabji Godrej Green Business Centre

2007-2008

- CVBU LUCKNOW

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Sohrabji Godrej Green Business Centre

ENCON Projects

2007-2008

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ENCON Projects

Sohrabji Godrej Green Business Centre

2007-2008

- CVBU LUCKNOW

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Sohrabji Godrej Green Business Centre

ENCON Projects

2007-2008

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ENCON Projects

Sohrabji Godrej Green Business Centre

2007-2008

- CVBU LUCKNOW

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Sohrabji Godrej Green Business Centre

ENCON Projects

2007-2008

- CVBU LUCKNOW

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ENCON Projects

Sohrabji Godrej Green Business Centre

2007-2008

- CVBU LUCKNOW

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Sohrabji Godrej Green Business Centre

ENCON Projects

2007-2008

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ENCON Projects

Sohrabji Godrej Green Business Centre

2008-2009

- CVBU LUCKNOW

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Sohrabji Godrej Green Business Centre

ENCON Projects

2008-2009

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ENCON Projects

Sohrabji Godrej Green Business Centre

2008-2009

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Sohrabji Godrej Green Business Centre

ENCON Projects

2008-2009

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ENCON Projects

Sohrabji Godrej Green Business Centre

2008-2009

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Sohrabji Godrej Green Business Centre

ENCON Projects

2008-2009

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ENCON Projects

Sohrabji Godrej Green Business Centre

2008-2009

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Sohrabji Godrej Green Business Centre

ENCON Projects

2008-2009

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ENCON Projects

Sohrabji Godrej Green Business Centre

2008-2009

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Sohrabji Godrej Green Business Centre

ENCON Projects

2008-2009

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ENCON Projects

Sohrabji Godrej Green Business Centre

2008-2009

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Sohrabji Godrej Green Business Centre

ENCON Projects

2008-2009

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ENCON Projects

Sohrabji Godrej Green Business Centre

2008-2009

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Sohrabji Godrej Green Business Centre

ENCON Projects

2008-2009

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ENCON Projects

Sohrabji Godrej Green Business Centre

2008-2009

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Sohrabji Godrej Green Business Centre

ENCON Projects

2008-2009

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Sohrabji Godrej Green Business Centre

2008-2009

ENCON Projects

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Sohrabji Godrej Green Business Centre

ENCON Projects

2009-2010

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ENCON Projects

Sohrabji Godrej Green Business Centre

2009-2010

- CVBU LUCKNOW

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Sohrabji Godrej Green Business Centre

ENCON Projects

2009-2010

- CVBU LUCKNOW

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ENCON Projects

Sohrabji Godrej Green Business Centre

2009-2010

- CVBU LUCKNOW

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Sohrabji Godrej Green Business Centre

ENCON Projects

2009-2010

- CVBU LUCKNOW

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ENCON Projects

Sohrabji Godrej Green Business Centre

2009-2010

- CVBU LUCKNOW

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Sohrabji Godrej Green Business Centre

ENCON Projects

2009-2010

- CVBU LUCKNOW

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ENCON Projects

Sohrabji Godrej Green Business Centre

2009-2010

- CVBU LUCKNOW

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Sohrabji Godrej Green Business Centre

ENCON Projects

Zero Investment

Optimisation of Sealer Oven- Cowl Baking in Paint Shop


After CED process , Seam Sealant and Under body sealant is applied on body. After Sealant application it goes
for baking in sealant Oven at 150 C. After Baking body goes for sanding , top coat application and again baking
up to 150C. So sealant gets baked twice in one cycle.
Before: Top mounted three burners oven maintains inside oven temperature i.e. 150 0 C for full baking of Cowl
body.
Air

Air
Blower

Burner

Air
Blower

Burner

Blower

Burner

Make:Maxon-Oven Pak400
Burner

Thermal O/p-426 KW

Temp 150 0 C

Vol-60,000 M3/Hr

After:

SEALER OVEN

After Consultation with OEM and Internal Quality controller, we found baking of Cowl after sealant paint at 110 0
C at its pregel stage, which fulfills the requirement. Accordingly one Burner out of three Burners has been
stopped.
Air

Burner

Air
Blower

Temp 110 0 C

Burner

No Flame
Blower

SEALER OVEN

Total Investment : 0 Lakh


Total Savings
Payback :Immediate
- CVBU LUCKNOW

Blower

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ENCON Projects

: 43.84 T CO2/annum
Sohrabji Godrej Green Business Centre

Zero Investment

Optimizing the Compressor Pressure


In Phase 1 : 2008-09 : The compressed air pr. of 6.2 bar was under usage earlier. The
Line pressure of the Compressed air reduced to 5.9 bar with no effect on the pressure
delivered at the end user.
In Phase 2 :2009-10: After detailed study and agreement from end user, further
reduced the pressure setting optimally at 5.7 bar.
Compressor House
Before Condition
Phase 1
Phase 2

6.2 bar

5.9 bar

5.7 bar

Total Investment : 0 Lakh


Total Savings
Payback :Immediate
- CVBU LUCKNOW

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: 0.92 Lakh/annum
Sohrabji Godrej Green Business Centre

ENCON Projects

Low Investment

Optimisation of Cooling Zone- Roller Belt operation in Paint Shop


In Paint shop, after Top Coat & Sealer Oven ,cowl passes through the cooling Zone on roller bed conveyor for
cooling the cowl body by forced draft blower.
Before:
Roller bed conveyor operates with three motor which connected with
roller operated conveyor belt.
Sensor
M3
M2
M1

3 Motors
Cooling Zone

L2

L1

After :
Process improvement-Removed one motor after evaluate the
prime mover capacity to operate the roller bed conveyor
M3

Sensor

Long belt

M1

Cooling Zone

L1

Total Investment : 0 Lakh


Total Savings
Payback : 5 Months
- CVBU LUCKNOW

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: 1,085 KWH/annum
Sohrabji Godrej Green Business Centre

Energy Conservation Achievements


Innovative approach with Zero & Low Investment

Total ENCONs in last 4 years: 331

Total Savings: Rs. 72.734 Million

Total zero investment ENCONs : 38

Total Savings thru. Zero investment


ENCONs : Rs. 6.32 Millions
Total Savings thru. Low Investment
ENCONs : Rs. 21.22 Million
Savings

Total Low Investment ENCONs : 71


ENCONs
71
38

21
48

222

Total ENCONs
Zero Investments ENCONs
Low Investment ENCONs

Total ENCONS
Zero Investments ENCONs
Low Investment ENCONs

Low Investments mean < Rs. 10,000 /- of investment


- CVBU LUCKNOW

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Sohrabji Godrej Green Business Centre

Specific Energy Consumption


Year
(April
March)

Annual Energy consumption

Electrical

Prodn. in
tons or any
other unit of
prodn.

Thermal

Rs Million

Eq. Veh.

Specific Energy
Consumption
Electrical
KWH / Ton
or unit of
prodn

Thermal
tons or kL
per ton or
unit of
prodn
KWH/Eq.Veh KL/Eq.Veh.
.

Redn. in Specific Energy


consn. Over previous year
**
Electrical
Thermal

KWH *
Million

Rs Million

Type of
fuel

Tons/KL
(KL)

% redn.

% redn.

200506

13.81

55.45

HSD

600

--

31,049

445

0.0193

--

--

200607

15.52

62.49

HSD

720

24.85

43,073

360

0.0167

18.962

13.498

200708

15.77

64.30

HSD

768

25.52

46,725

337

0.0164

6.343

1.670

200809

12.02

50.64

HSD

612

20.31

33,366

359

0.0183

-6.379

-11.593

200910

14.27

60.93

HSD

715

27.30

65,495

218

0.0109

39.276

40.451

Best in Class

Specific Energy Consumption per Equivalent Vehicle produced


Copper

- G Cal / Ton

TML-LKO

- CVBU LUCKNOW

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20
09
1
0

200
20
08
0
9

60 %

G Cal / Ton
kWh/MT & KL or MT/MT of Product
kWh/Tone of Cane & % of Steam on
% Aux iliary power consumption & Heat Rate (kCals/kWh)

Exa mple
** Specific energy cons umption during 2008 - 09 = (A)
Specific energy consumpt ion during 2007 - 08 = (B)
Reduct ion in Sp. Energy Consumption = B A x 100 = %

20
07
0
8

Tata Motors Lucknow :

300

20
03
0
4

Mahindra & Mahindra Ltd : 35 %

400

20
06
0
7

Benchmark data : Reduction over 6 yrs

500

- kWh / kg
- kJ / kg

Fertilizer
Foundry
Sugar
Power Plant

20
05
0
6

& International Bench mark across the class.

600

Text ile
Ceramic

20
04
0
5

Sp Energy consumption at 218 KWH/Eq Vehicle. This is National

KWH/Eq. Vehicle

The Energy conservation measures resulted in managing the

Sohrabji Godrej Green Business Centre

SEC Comparison data


Specific Energy Consumption ( KWH / Eq Vehicle) &
Specific Water Consumption ( M3/Eq. Vehicle) details

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- CVBU LUCKNOW

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Sohrabji Godrej Green Business Centre

SEC Comparison data


Specific Fuel Consumption ( M Kcal / Eq Vehicle) details :

Ultimate Object :
Based on above comparative SEC data of various companies, TATA Motors CVBU Lucknow plant is the
Most Energy Efficient Automobile company. As part of continual improvement we would further
reinvestigate all our processes to achieve further cost reduction by reducing Energy consumptions at
all levels.
To sustain the best achieved level :We are following robust process of assessment of performance vis-a-vis comparative information / benchmark
from different organisation & standards.
Our emphasis is on:
To optimise the use of Resources while using appropriate and innovative method to reduce the energy
consumption in all the areas of operation on the continuous basis through evaluation and improvement.

Use of Latest technologies wherever possible.

Maximize the use of non-conventional Energy resources wherever possible.


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- CVBU LUCKNOW

Sohrabji Godrej Green Business Centre

Road Map for Sustaining Benchmark


Road Map set for 2010-11 ::
15%
Reduction

Feb11

y
rg ell
e
C
En mt
g
M

Jan11

Nov10

Aug10
Jul10
Jun10
May10
Apr10

Sp. Suggestion campaign, Energy Audit & Review

Dec10

Oct10

Bench Marking with other Plants

Assessment of CDM project; Energy Week Celebrations.


Carbon Foot printing of Lucknow Plant External

Assessment of CDM project ; Energy Audit & Review


Energy Mgmt Trg -CII; Energy Audit,Review & Sugg. scheme
CII Energy Exim Award; TQMS Trg; Energy Audit & Review

WED Celebrations; Energy Audit & ENCON Implementation

Energy Audit & review ; TBEM ; ENCON Implementation


Energy Audit & Review ; Put up ENCONs thru Capex10-11

Planned
In progress
Completed

- CVBU LUCKNOW

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Sohrabji Godrej Green Business Centre

Innovation:- Way of Life at TML


Introducing New Products becomes more
essential in the situation where the market is
keen about fuel efficiency & alternate fuels
with least impact on the environment.

New Products Introduced


120

Better

98

100
80

Lucknow Plant constantly focuses on NPI


(New Product Introduction) to a great extent.

60

The number of NPI rose to 98 from 62 nos


till last year. We also monitor the Percentage
contribution of the New Products in terms of
Performance, Volume & Revenue to ensure
effectiveness in addition to the NPI index.

20

40

62
26

2007-08

2008-09

2009-10

35% of the
volumes are
from New
Models

- CVBU LUCKNOW

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Sohrabji Godrej Green Business Centre

Innovation and Technology Fest


Tata Motors, Lucknow celebrated its first Innovation and Technology festival- Mastishkotsav
from 18th to 20th September 2008 with the following objective
Creating awareness amongst employees on the Innovation initiative taken at Tata Motors,
Lucknow in line with group initiative
Encourage employee participation in generating new ideas
Exposure on new technologies

Implementation campaign
6 Task forces constituted for execution of ideas
generated in campaign (low hanging fruits)
Around 80 Lacs has been realized rest are in
pipeline for execution

I.P.R
Trial
Execution

Campaigns Launched
Opportunity Identification Campaign
Posting to "Innovation Council"

Tata Innovation Day

Ideas campaign launched for all grades


Participation promoted through multiple
communication

Novel Ideas in
Suggestion
Scheme

- CVBU LUCKNOW

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Novel Ideas in
Kaizen & CFT

Special
Campaigns on
"Innovation"

Sohrabji Godrej Green Business Centre

Innovation Project :
Conservation of electricity through utilization of temperature from heated waste gases to
heat water in post wash chamber
MACHINE : 200 Kg/Hr CCHF

Before :
Post Wash operation:After the quenching process the metaquench42 oil layers needs to be cleaned from
the components. To remove this oil layer we perform the post wash operation in
which the components are dipped and wash with the spray of warm water which is
maintained at the temperature of 60C.
Post Wash Tank

LPG
Burners

Method used to raise the water temperature:LPG burner were used to raise the temperature of water to 60C.
59

- CVBU LUCKNOW

Sohrabji Godrej Green Business Centre

Innovation Project :
After :
Copper coil

Post Wash
Tank

Furnace

LPG Burners
(Partial Load)

Method used to raise the water temperature:Now a modification is made in the system in which the heat of the flue gases are extracted
and used to raise the temperature of water used for post wash.
The temperature of flue gases when burnt is 275C and with the help of heat exchanger we
recovered the heat. And this extracted heat is used to raise the water temperature of post
wash to the required level.
Benefits :
Total Carbon emission reductions per annum : 45
- CVBU LUCKNOW

T CO2
60

Sohrabji Godrej Green Business Centre

Innovation Project :
Optimisation of Cooling Zone Fans operation at Paint Shop

Paint shop gets the Cowl from BIW Shop (Weld shop) for painting. In Paint shop, it passes first from
Pretreatment stage, where oil, grease, dust & dirt is removed by hot water spray. Next, the Cowl body
passes from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition).
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for baking
& drying at defined temperature i.e. 150C. This oven is horizontally connected with cooling zone, where
cowls gets cooled by two axial flow fans i.e.. 22KW & 30 KW.

Before:
The Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown below.
The Cooling fans automatically comes into operation as soon as the conveyor starts. It is found always in
running mode once the line gets started. Cowl takes almost 2 hrs time to reach the oven from
Pretreatment stage.
Pretreatment(PT)

Hot water
Spray

+
Phosphating

Traveling time till


Cooling Zone is 2
Hrs

22KW

CED

30KW
Oven Zone

Hot Air
Cooling Zone
Burner

Air Blower

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- CVBU LUCKNOW

Sohrabji Godrej Green Business Centre

Innovation Project :
After :
A Position sensor has been provided at the starting end of cooling zone, which senses the entry of
cowl into oven subsequently it gives the start signal to the axial flow fan to run.
Pretreatment(PT)

Hot water
Spray

+
Phosphating

CED

Sensor
Oven Zone

Hot Air
Cooling Zone
Air Blower

Burner

Benefits :
Total Carbon emission reductions per annum : 112
- CVBU LUCKNOW

T CO2
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Sohrabji Godrej Green Business Centre

Innovation Project :

Innovation Project:
Energy & Cost Optimisation
for transportation of modules
from Lucknow to Dharwad

Scope & Objective


To identify most energy & cost effective solution for
transportation of modules from TML, Lucknow to TMML,
Dharwad
Trials and proving of best solution
Models to be covered: LPO-1618 RE LE- CNG & Diesel
- CVBU LUCKNOW

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Sohrabji Godrej Green Business Centre

Innovation Project :

Despatch of
Modules from
TML Lucknow to
TMML Dharwad

Options
By Road - DAC

Scenario-III

By Road On 40 Ft Trailer

Scenario-II

By Road On HCV Truck

By Road On MCV Truck

By Train

Scenario- I : Transportation of 1.5 Chassis through Trailer


Scenario-II : Transportation of 2 Chassis through Trailer
Scenario-III : Transportation of Chassis through road (DAC)
- CVBU LUCKNOW

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Sohrabji Godrej Green Business Centre

Innovation Project :
Transportation of 1 Chassis ( 1 Front & 1 Rear module) in 28 ft Trailer ( Existing Practice)

Existing Practice

Front module

Rear module
Trailer Bed

- CVBU LUCKNOW

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Sohrabji Godrej Green Business Centre

Innovation Project :
Transportation of 1.5 Chassis ( 1 Front & 2 Rear module ) in 40 ft Trailer (Existing Practice)

Scenario -I
2
Front module
3
Rear module

Trailer Bed

- CVBU LUCKNOW

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Sohrabji Godrej Green Business Centre

Innovation Project :
Transportation of 1.5 Chassis ( 2 Front & 1 Rear module ) in 40 ft Trailer (Existing Practice)

Scenario -I
2

Front module

Rear module
Trailer Bed

- CVBU LUCKNOW

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Sohrabji Godrej Green Business Centre

Innovation Project :

Improved method of
module transportation

Scenario-II
Improvement in stacking of modules and maximizing
trailer utilisation
Transportation trials of 2 Chassis (2 Front & 2 Rear)
in a 40 ft Flat Bed Trailer

- CVBU LUCKNOW

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Sohrabji Godrej Green Business Centre

Innovation Project :
2 Front & 2 Rear
modules loaded on
40 ft flat bed trailer

Front module
1
3

Space created on trailer


bed for storage of CNG
cylinders and other spares

Rear module

Scenario -II
- CVBU LUCKNOW

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Innovation Project :

Sohrabji Godrej Green Business Centre

Arrangement for Rear module

Engine side

Stand welded with trailer bed

Wheel movement arrested


by wheel chock
Stand welded with trailer bed
- CVBU LUCKNOW

Suspension side
70

Scenario -II
Sohrabji Godrej Green Business Centre

Innovation Project :
Rear end
Supported on stand

Arrangement for Front module


Provisions for Front module

Front Module

Front module tyres


supported on stand
a
Front end of front module
rested on rear module frame
and clamped by U-bolt
Rear Module
b

Scenario -II
- CVBU LUCKNOW

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Innovation Project :
c

Sohrabji Godrej Green Business Centre

Arrangement for Front module


b

Engine side
U BOLT

Both the front modules


rested on common
stand

Front module rested


on rear module and
clamped with the
help of U-bolt

- CVBU LUCKNOW

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Resting at front
side

Supporting stand for


tyres
Sohrabji Godrej Green Business Centre

Innovation Project :

Results of transportation trial conducted


in August09 (Scenario-II)

Scenario -II
- CVBU LUCKNOW

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Sohrabji Godrej Green Business Centre

Innovation Project :
Transportation Trial

Trailer on the way to Dharwad

Front module unloaded at


Dharwad

Rear module

Rear module unloaded at


Dharwad
- CVBU LUCKNOW

Scenario -II
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Sohrabji Godrej Green Business Centre

Innovation Project :

Improved method of
chassis transportation
Drive Away Chassis- Transportation of LPO-1618 RE LE
Chassis through road

Scenario-III

- CVBU LUCKNOW

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Sohrabji Godrej Green Business Centre

Innovation Project :
Objective
To integrate the front and rear module so that complete chassis can be
driven down to Dharwad as a Drive away chassis for Bus body building.

Front Module

Rear Module
Integrated Chassis

- CVBU LUCKNOW

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Sohrabji Godrej Green Business Centre

Innovation Project :
Requirements for Drive Away Chassis

Proper ground clearance

6300 mm

at engine side

Wheel
base

Temporary Support Structure to be used


for connecting Front & Rear Modules
- CVBU LUCKNOW

Innovation Project :

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Sohrabji Godrej Green Business Centre

Details of Temporary Support Structure

Rear Module

Temporary Support
Structure

Box section support with pre-tensioning members to arrest the sagging


of rear module
- CVBU LUCKNOW

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Sohrabji Godrej Green Business Centre

Innovation Project :

In-house Trial Results


Ground ClearanceBefore Improvement
(Bellows in fully inflated condition)

320mm

220mm

Ground ClearanceAfter Improvement


(Bellows in fully
inflated condition)
530mm

- CVBU LUCKNOW

390mm

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Sohrabji Godrej Green Business Centre

Innovation Project :

IN-HOUSE TRIAL RESULTS OF LPO-1618 RE LE

- CVBU LUCKNOW

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Sohrabji Godrej Green Business Centre

Innovation Project :

Transportation trial-DAC

Status of chassis
at Jhansi

Status of chassis
at Dewas

- CVBU LUCKNOW

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Sohrabji Godrej Green Business Centre

Innovation Project :

Improved method of
chassis transportation
2-Tier Drive Away Chassis- Transportation of
LPO-1624 RE LE Chassis through road.

Scenario -IV
- CVBU LUCKNOW

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Sohrabji Godrej Green Business Centre

Innovation Project :
Objectives:

To monitor the performance of 2-Tier Drive Away Chassis and collect transit
observations for further improvement in design of temporary support
structure and other accessories
To establish the process of dismantling LPO 1624 RE LE front & rear
modules which is loaded on the DAC along with temporary support structure
at TMML, Dharwad
To establish the process of recycling of temporary support structure and
other accessories.

- CVBU LUCKNOW

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Sohrabji Godrej Green Business Centre

Innovation Project :
LPOLPO-16181618-RELE CHASSIS AT LUCKNOW BEFORE
DISPATCH.

- CVBU LUCKNOW

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Sohrabji Godrej Green Business Centre

Innovation Project :

No sagging of Rear module

Status of chassis at Dewas

No sagging of Front module


- CVBU LUCKNOW

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Sohrabji Godrej Green Business Centre

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Sohrabji Godrej Green Business Centre

Innovation Project :

Status of Chassis at Pune

- CVBU LUCKNOW

Innovation Project :

Transit Observations
checklist:

- CVBU LUCKNOW

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Innovation Project :

Sohrabji Godrej Green Business Centre

Transit Observation Photographs.

Complete module at a glance at TMML


Dharwad

Rear End side


- CVBU LUCKNOW

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Front End
side
Sohrabji Godrej Green Business Centre

Innovation Project :

Information shared with Dharwad

Process of Dismantling

Front module U bolt


unfastening

U bolt unfastening of Middle cross-member

Unfastening of additional plate at rear end of rear module and


re-bolting after removing both the additional plate.

Unfastening of rear module mtg. bolts from middle


stand.

Unfastening of bolts from rear


stand.

Lift Rear module &


keep on stand.

Lift Front module &


keep on stand.

- CVBU LUCKNOW

89

Innovation Project :

Unfastening of tension rod from rear module.

Upper tear is unloaded and kept


aside.

Sohrabji Godrej Green Business Centre

Information shared with Dharwad

Process of Dismantling

Rear Module
resting on stand

Front Module
resting on stand

Rear module
dismantling. From
outside

Spare wheel
removal

Rear module
dismantling from
inside

Front module
dismantling.

Place jack at the


base of middle
structure.

Middle pillar
dismantling

Unfastening from
inside of Front
module.

Unfastening of U
bolts front mod. side.

Front module
unfastened from
middle structure.

- CVBU LUCKNOW

U-bolt dismantling
on rear module

Additional structure
Unfastening

Middle structure removed

90

Wiring harness
removal

Air pipe
unfastening

Rear and Front module


separated.

Sohrabji Godrej Green Business Centre

Innovation Project :
v TML Quality Check points:

Mounting of rear and front modules to be checked thoroughly.


All the bolts to be tightened with nyloc nut and properly torqued.
All the quality checkpoints e.g PDI, Dynamometer testing, road testing
etc to be assured before dispatch.

TMML Quality Check points:

Check for module sagging by measuring heights from ground level at predefined positions on front and rear module
Check for tyre wear
Functional testing of chassis to be done prior to dismantling of modules
Hole elongations to be checked after dismantling of modules
- CVBU LUCKNOW

91

Sohrabji Godrej Green Business Centre

Observation after Dismantling

Innovation Project :

No elongation of mounting holes at front and rear module mounting


locations
Uniform rear module height from ground level .
No prominent tyre wear

- CVBU LUCKNOW

92

Sohrabji Godrej Green Business Centre

Innovation Project :

Summary

Scenario-I -1.5 Chassis/Trailer II - 3 Chassis/Trailer

Jun09 July09

III Drive away Chassis IV2 Tier Drive away Chassis

Aug09

Sep09 Nov09

Dec09 Feb10

Results :
Freight - Rs/Chassis or module set

Carbon emission in T CO2 per


Chassis transportation

48000

3.75

36000

Reduction by 75%

1.91

Experiment & experiment and


don't let the idea fail.

IV

Scenario

Keep on exploring newer ways of


solving the problem till you
succeed.

III

II

0.94

IV

III

II

12000

Learning
from
successful
implementation of this Project :
Raise the bar when the solution is
too obvious.

2.81

24000

Scenario

Learnings

93

- CVBU LUCKNOW

Sohrabji Godrej Green Business Centre

Involvement of Employees & Extent of team work in Encon


S.No

Name of EnCon idea *

Ins tallation of VFD in AHU of CAB office


block at Metrology and Plant Head
building

Replaced all the conventional cu


ballas t us ed in tube lights with the
energy efficient electronic choke
Ins tallation of energy s aver at ETP & HT
s hop to reduce the energy
cons umption by without effecting the
required lux level
Ins tallation of cpacitor bank at
Trans mis s ion factory to im prove the PF

Source of EnCON
idea*

Idea
Extent of man-power involved
originated in
***
FY **
Middle Management &
2007-08
Top Managem ent, corporate
Maintenance Engineer
office, Middle Managem ent,
Energy Cell, Project Execution
Group, Maintenance Team .
Workmen & Supervis or
2007-08
Workm en, Supervis or, Sectional
Head, Energy Cell & Divis ional
Head
Middle Management &
2008-09
Top Managem ent, corporate
Maintenance Engineer
office, Middle Managem ent,
Energy Cell, Project Execution
Group, Maintenance Team .
Middle Management &
2008-09
Top Managem ent, corporate
Maintenance Engineer
office, Middle Managem ent,
Energy Cell, Project Execution
Group, Maintenance Team .
Workmen & Supervis or
2009-10
Workm en, Supervis or, Sectional
Head, Energy Cell & Divis ional
Head

In HT s hop previous ly the whole


cooling plant us ed to be put ON
through out the year now cold s ump
pum p and cooling tower fan s witched
off during winters (approx 120 days ).
And the pipe line of Hot s um p is directly
connected to the feeder in which
cooling
Fram e Shop: Previous ly the long
Middle Management &
mem ber trans fer roller conveyors were
Maintenance Engineer
running continious ly whether the
mem ber is pres ent over it or not. Now
the provis ion is provided in which once
the m em ber is reached its des ired
location the motors of the conveyors get

2009-10

Top Managem ent, corporate


office, Middle Managem ent,
Energy Cell, Project Execution
Group, Maintenance Team .

Progress of
implementation
Idea Implem ented

Idea Implem ented

Idea Implem ented

Idea Implem ented

Idea Implem ented

Idea Implem ented

Towards Excellence
94
- CVBU LUCKNOW

94

Sohrabji Godrej Green Business Centre

Energy Management Cell

Implementation Methodology

Plant Coordinator

Preliminary Energy audit

Submission of Techno
commercial proposal

Acceptance of Proposal

GO AHEAD

Detailed Energy audit

Team formation

Energy savings discussion and


presentation

GO AHEAD for
Implementation

Energy savings monitoring and


interim report to
Energy Mgmt Cell

- CVBU LUCKNOW

95

Sohrabji Godrej Green Business Centre

Monitoring & reporting


Frequency of review of energy consumption and energy conservation projects:
Daily, Weekly, Monthly Quarterly, Half-yearly & Annually
Review by : Energy Auditor & Managers
Daily Energy Consumption Performance Report: Daily monitoring, analyzing and reporting of various key energy resources such as Electricity, Water, Compressed Air,
Fuels. The Report is analyzed in detail at each shop Level in-charge w r t to production activity on daily basis. The daily Energy
Performance vis--vis target is also displayed at shop floor to increase the awareness within entire teams in the shop.
Review by : Energy Auditor & Asst GM
Monthly Performance Report: Monthly report is generated on the basis of data from monthly consumption along with data of production and indicates
the Monthly and cumulative Performance Ratios of major areas like CV,IBF,TMML,HT shop. All the Sp. energy, Sp. Compressed air,
Sp. Compressed air is reported to the individual departmental heads.

Monthly Report To Plant Head & Divisions: -

Review by : Energy Auditor ,Asst GM, GM & Plant Head


Executive summary Report giving monthly and cumulative performance and the variance with respect to targets set ,
previous year's performance, etc for the whole year and the corresponding period is sent to respective Divisional Heads for
information & initiating necessary improvement actions. The report is also send to Plant Head for his perusal & information. Plant
Head also reviews the Monthly report in the monthly Variable Conversion Cost (VCC) review meeting.

Quarterly Performance Report:-

Review by : Energy Auditor ,Asst GM, GM, Plant Head, Sr. VP &MD
This report gives the consumption, Monthly and cumulative, performance trends, and efforts taken. This report is sent
to Plant Head (CVBU - Pune) & respective Divisional Heads.

Half yearly Performance Feed back to Plant Head & Divisions: -

Review by : Energy Auditor ,Asst GM, GM, Plant Head, Sr. VP &MD
The performance of the Divisions with reference to the target both monthly and cumulative along with the performance
expected to achieve w r t the Target.

Annual Performance Report: -

Review by : Energy Auditor ,Asst GM, GM, Plant Head, Sr. VP &MD
This report giving consumption performance of various areas along with the efforts taken by various Divisions. This
report is released to - Finance Division as Input for disclosures for Director's Report.
Energy Management Cell Prepares the Energy report Daily, Monthly( M), Quarterly (Q), Half-yearly (H) & Annual reports.
Plant Head & MD reviews M, QY, HY, Annual reports

- CVBU LUCKNOW

96

Sohrabji Godrej Green Business Centre

Monthly Energy Report to Top Management


To Plant Head
Area

Ist Jan 10
Prev Yr
Consp
08-09
Units

Prev Yr
Eq. Veh
08-09
Nos.

Specific
Energy
08-09
KWH/Eq. Veh

Consp till
Dec
08-09
Units

Eq. veh till


Dec
08-09
Nos

Specific
Energy
till Dec 08
KWH/Eq. veh

Consp till Dec


09-10
Units

Eq. Veh till


Dec
09-10
Nos.

Specific
Energy
till Dec 09
KW H/Eq. veh

CV + IB Fact

5707472

29,101

196

4,479,432

22,069

203

5,408,501

36,580

148

Trans Fact

3834062

4,265

899

3,026,580

3,251

931

2,905,410

2,833

1,026

Others

2453210

33,366

74

2,202,250

25,320

87

2,157,571

39,412

55

11994744

33,366

359

9,708,262

25,320

383

10,471,482

39,412

266

Total

From
Energy Auditor
Energy Auditor Cell

YTD
Status

Asst General Manager


Central Maint & Plant Services

Q,H & Annual Energy Report to Top Management


VARIABLE CONV COST (Rs. /Eq. Veh. ) 09-10

3920

Shop wise Energy consumption


IBF
6%

747

890

701

885

662

863

840

639

790

610

584

VARIABLE CONV COST (Rs. /Eq. Veh. ) 09-109


Actual 09-10

CV FACT
11%

MARCOPLO
16%

916

772

774

3794

Feb-10

3919

Dec-09

Oct-09

Nov-09

Sept-09

Aug-09

Jun-09

July-09

Apr-09

May-09

3733

856

March-10

3677

Actual 08-09

933

937

925

Jan-10

3611

Jan-10

3689

Actu al 09-10

935
885

3840

Feb-10

3605

4001
3820

Dec-09

4098

951

863

869

4145

Oct-09

4409

Aug-09

4600

Jun-09

4621
3705

Nov-09

Transmission Factory
963

4811

July-09

5011

May-09

4717
3890

4671

Apr-09

5083
4740

VARIABLE CONV COST (Rs. /Eq. Veh. ) 09-10

Actu al 08-09

Sept-09

Actual 09-10

March-10

CV Factory

1794

1757

1724

1472
1424

1434

1427

TGT 09-10

1618

TRAN FACT
12%

1426

1409

1343

1346

1305

1274

1249

1231

1219

1395
1259
1074

942

8 63

March-10

Jan-10

Dec-09

Nov-09

Oct-09

Sept-09

Aug-09

July-09

Jun-09

Apr-09

OT HERS
7%
RECON
2%

May-09

1011

Feb-10

1167

EAST COM P
46%

97

- CVBU LUCKNOW

Sohrabji Godrej Green Business Centre

Afforestation
Environmental Projects

Cum. No. of trees planted

Tata Motors CVBU Lucknow is plant is having plot area of 600 Acres. We have Green cover of 52%. We
celebrate World Environment Day, Earth Hour etc every year in the plant, at Vendor end and also at Villages
through CSR teams ( Corporate Social Responsibility ). Utilise every opportunity for tree plantation & spreading the
awareness on its importance across all the stake holders i.e. Community, Employees, Vendors & Business
associates
57436

60000
45436

50000
37836

40000
29236

30000
20686
20000
10686
10000
0
2004-05

2005-06

2006-07

2007-08

2008-09

2009-10

Tress Planned for plantation in 2009-10


In the Plant Premises

: 12,000 nos

Thru. CSR & at Vendor end (Through Associates) : 1 Lakh no.s

Lucknow Plant Lake View


- CVBU LUCKNOW

98

Sohrabji Godrej Green Business Centre

2006-07

Environmental Projects

- CVBU LUCKNOW

99

Sohrabji Godrej Green Business Centre

2007-08

Environmental Projects

100
- CVBU LUCKNOW

100

Sohrabji Godrej Green Business Centre

2008-09

Environmental Projects
S.No

Year

200809

200809

Area

Whole Plant

CTP site

200809

STP Site in
Eastern
Complex

200809

W.complex &
Eastern
complex

200809

STP Site in
Western
Complex

Trigger for
improvement

Process
improvement

Facility required at
the bore well site to
monitor the frequency
variation in ground
water level

Installation of
Peizometer well at
different location
both in E.complex &
W. complex to
monitor th level of
ground water aquifer
& thereby complying
consent conditions

Tracking/ mainting
records for the
depletion or incres
in ground water
table

Waste coolant is
having very different
coplex chemical
property & needs
separte treatment
otherwise it
contaminates th
wholw homogenous
mixture & hinders in
treatment process
Facilitates the
provisions for heavy
load of domestic
effluent

Instllation of Coolant
treatment plant for
the effective
treatment of waste
coolant as
discharged from
grinding machine at
HT & Gear shop

Coolant is being
treated to crack the
heavy emulsion &
attain a level of
parameters which
doesn't disrupt after
mixing with the
quality of industrial
effluent

Installation of one
1200 KLD FAB
based STP for
treating the effluent
load generated from
different process &
activity & meeting
statutory
environmental
norms
Dedicated
Environmental
Laboratory for
undertaking testing
of essential
parameters & also
regulating the
dosing of chemicals
Enhancement of two
no. of 400 KLD
Fludized bed
reactor (FAB)
based STP to cater
the enhanced
domestic sewage
load & meeting
statutory
environmental
norms

Complete treatment
of sewage for
achieving the
parameters well
below the statutory
specified limiting
value

Analysis required for


the quality of influent
& & treated effleunt

Inadequate provision
for chemical &
bilogical treatment of
the increased
sewage load

- CVBU LUCKNOW

Result achieved

Photographs

- -

Determination of
chemical dosing
quantity as per
influent quality for
effective treatment

- -

Complete treatment
of sewage for
achieving the
parameters well
below the statutory
specified limiting
value

101

101

Sohrabji Godrej Green Business Centre

2009-10

Environmental Projects
S.No

Year

200910

Area

Primary ETP
Site in Eastern
Complex

200910

Western
Complex

200910

Eastern
Complex

200910

Weatern
Complex

Trigger for
improvement
Waste water
generated from P ai nt
shop contains very
complex orgnic paint
resins which
essentially requires
prior physi cal &
chemical treatment
before sending i t to
secondary treatment
Uncontrolled use of
fresh water resource
at the major point
sources

200910

2009200809
10

Reducti on &
prci pitation of heavy
organi c particulates,
heavy metals etc.

Installation of water
flow meter at
canteen, Recon
shop, frame paint
booth & cowl shop
for tracking &
regulating fresh
water consumpti on

Tracking &
regulating the water
consumption rate

Installtion of 6 nos.
of new borewells in
E. Complex to cater
the hi gh water
demand for
domestic, industrial,
process, fire service
etc.

Fullfillment of water
demand for
manufacturing
process

Earli er we had no
recirculation system
for the wash water
generated due to
washing of cowls

Greater concern for


water conservati on
has prompted us to
i nstall recirculation
system

Fresh Water
resource
Conservati on

Inadequate provision
for chemical &
bilogical treatment of
the increased effluent
load

Enhancement of
one 400 KLD hitech E TP for treating
the enhanced
effluent load
generated from
different process &
activity & meeting
statutory
environmental
norms

Complete treatment
of effluent for
achieving the
parameters well
below the statutory
specifi ed li miting
value

Heavy load of effluent


discharged during the
process & operation
containg
homogenous
mixuture of di fferent
type of complex
contaminants

Installation of one
1800 KLD hi-tech
secondary ETP for
treati ng the effluent
load generated from
different process &
activity & meeting
statutory
environmental
norms

Complete treatment
of effluent for
achieving the
parameters well
below the statutory
specifi ed li miting
value

ETP Si te in
Western
complex

ETP Si te in
Eastern
complex

Result achieved

Installation of one
450 KLD primary
ETP at paint booth
meeting for
undertaki ng batch
process treatment

Expansion project

Process
improvement

- CVBU LUCKNOW

102

Photographs

- -

Paint
Shop

TCF
- -

102
Sohrabji Godrej Green Business Centre

World Environmental Day Celebrations In the Plant & at Vendors end


Greenathon : Flag off by Mr.MC Pandey

Winners

Senior Leaders

Union Leaders

Service providers

Vendor end

Mr. A Chharia and U Tauheed


planting a tree

Gather for tree plantation

team planting trees at Eastern


complex

team planting trees at


vendor end

Display of various posters and Paintings at the Service


Provider site

Winners

CSR
plantation at Jainabad
village

- CVBU LUCKNOW

103

Environmental Projects : Few Examples

Sohrabji Godrej Green Business Centre

Linking with Reduction in t CO2

D . Projects linking with Carbon Emission Reduction

- CVBU LUCKNOW

104

Sohrabji Godrej Green Business Centre

Environmental Projects : Few Examples

Linking with Reduction in t CO2

D . Projects linking with Carbon Emission Reduction

- CVBU LUCKNOW

105

Environmental Projects : Few Examples

Sohrabji Godrej Green Business Centre

Linking with Reduction in t CO2

D . Projects linking with Carbon Emission Reduction

- CVBU LUCKNOW

106

Sohrabji Godrej Green Business Centre

Environmental Projects : Few Examples

Linking with Reduction in t CO2

D . Projects linking with Carbon Emission Reduction

107

- CVBU LUCKNOW

Sohrabji Godrej Green Business Centre

Switching to Renewable energy Source


Replacement of Electrical Energy with RES
Type of RES

Wind
Solar photovoltaic
Turbo ventillators

Installed Capacity

2007-08
Energy
Annual
Generated
Savings
(Lac kWh)
(Rs. In
Millions)

24.5 MW

2009-10
Energy
Annual Savings
Generated (Rs. In Millions)
(Lac kW h)

559

167

576

227

529

175

1,318

0.005

1,318

0.005

1,318

0.005

619,488

2.48

495,590

2.12

650,462

2.78

110 W
1,403,663 CFM

2008-09
Energy
Annual
Generated
Savings
(Lac kW h)
(Rs. In
Millions)

Replacement of Thermal Energy with RES


Type of RES

Solar The rmal

Installed
Capacity

700 LPD

2007-08
Equ Fuel
Annual
Savings
Savings
(kL)
(Rs.)
0.53

2008-09
Equ Fuel
Annual
Savings
Savings (Rs.)
(kL)

16,960

0.53

19,080

2009-10
Equ Fuel
Annual
Savings
Savings (Rs.)
(kL)
0.73

26,280

Other Renewable Projects in pipe line for 2010-11 :

Solar Power Plant 25KW x

Solar Garden lights for

4 nos - Grid connect type

Lake lighting

- CVBU LUCKNOW

Solar Traffic controlling Road Wind driven turbines-1200 nos


Flasher for Plant premises
Total Capacity 39 Lakh CFM

108

Light Pipes 500 Nos

Sohrabji Godrej Green Business Centre

Technology Absorption
Technology Absorption Details of year wise efforts made in technology absorption relating to energy
SN

Details of Technology
absorption

1 Celltec Pad Instead of Water Jet


Nozzle

2 VSD Air screw Compressor for


compressed air

3 Energy saver in street lights

Saving
Capital
Potential investment

Absorbed/Learnt
from

KWH
Rs in Lakhs
388800 Less than jet ISHRAE - Indian
Society of Heating
nozzles
Refregirating &
Airconditioning
Engineers
300000 45Lakhs/eac Atals copco,
h
Sweden

109500

Implemented in
Plant / Sub
location

year of
Photograph
implementati
on

MARCOPOLO, E.C

2007-08

Eastern Complex

2007-08

200000 CII Seminar,


Chandigarh

Eastern Complex

2007-08

4 LPG gas heating

20000

500000 BEE Seminar,


Kanpur

Western Complex

2007-08

5 VFD for AHU

10000

125000 CII Seminar


Chennai

Eastern Complex

2007-08

All over E.C

2008-09

6 Insulation of Closed cell


polyethylene with metalized
layer in FDV ducting

14256

8.5

- CVBU LUCKNOW

ISHRE SEMINAR

109

Sohrabji Godrej Green Business Centre

Technology Absorption
Technology Absorption Details of year wise efforts made in technology absorption relating to energy
SN

Details of Technology
absorption

Saving
Potential
KWH
1069200

Capital
Absorbed/Learnt
investment
from
Rs in Lakhs
Almost same KRUGER ,
as backward Germany
curve

Backward curve centrifugal


Blower instead of forward curve

Centrifigual compressor for


catering of air CFM base load.

200000

75
Lkhs/each

Microprocessor based ES
system for centralised
controlling of compressors as
per air CFM demand.

180000

10 Energy efficient air circuit


breakers

Implemented in
Plant / Sub
location
All over E.C

year of
Photograph
implementati
on
2008-09

Atals copco,
Sweden

Eastern Complex

2008-09

12 Lakh

Chicago
Pneumatic, US

Eastern Complex

2008-09

7884

4500000

CII Seminar,
Chandigarh

Tata Motors Plant

2008-09

11 LED type street lights

52560

1500000

CII Seminar, Delhi

Tata Motors Plant

2009-10

12 Emergency lights through solar


panels

2000

160000

Seminar
orgainised by
TATA BP solar

Western Complex

2009-10

225000

7500000

Renewable Energy Western Complex


Work shop by
MNRE-India at
New Delhi

13 Solar based Power Plant

- CVBU LUCKNOW

110

2010-11
(Work in
progress)

Sohrabji Godrej Green Business Centre

Carbon Emission Reduction

Summary

Targets 20011-12 :: Reduction in total carbon emissions : 60 %


20000
18000

60%
16579
15114

16000

T CO 2

14000
11247

12000
10000

8500

8000

6632

6000
4000
2000
2007-08

2008-09

2009-10

2010-11

2011-12

Upto July10
Total Carbon reduction : T CO2 : 913
- CVBU LUCKNOW

111

Impact on Plant Production

Sohrabji Godrej Green Business Centre

Summary

Impact of ENCON, Innovation & Carbon emission reduction measures on reduction of cost
of production goods.

- CVBU LUCKNOW

112

Sohrabji Godrej Green Business Centre

Waste Management

Input Waste

Recycle

Process Waste

Reuse

Output Waste

Incinerate

Plant Internal
&
External Authorized Agency

External Authorized Agency

Nothing is Waste in this world !!!

113

- CVBU LUCKNOW

Sohrabji Godrej Green Business Centre

Waste Management
Waste generated = Waste utilised
SN

Type of
the
Waste
used

Name of the
Waste generated

Details of the
Waste
generated

UO
M

Qty of waste
generated
2009-10

Qty of waste
generated and
utilised
2009-10

Waste fuel as Present usage of


% of total
the waste
energy

Snap shots

For Tool Boxes, with


Drive away Chassis,

Packing

Wood

From Packing

Kg

3,079,418

3,079,418

13 Stand or pallet for

Packing

Carton

From Packing

Kg

800,240

800,240

Packing

Polythene

From Packing

Kg

79,210

71,289

Packing

Jute Cartons

From Packing

Kg

167,310

158,945

11

Process

Used Cutting oil

From Machining
& Grinding

Lt

8,610

6,027

22 filteration and resale

Process

Used Engine oil

From Engine
Reconditioning

Kg

2,730

1,911

7 filteration and resale

Process

Paint Sludge

From Paint
Booths

Kg

30,000

30,000

9 incinerable waste

Used Coolant

From Machining
& Grinding

Kg

100,000

100,000

2 incinerable waste

storing material

8
9

Process
Process

ETP Sludge

10 Process

Paint Drums - MS

11 Process

Plastic Drums Coolant/ Oil

From ETP
Drying Bed
From Painting
Process
From Oil
Process

12 Process

Chips

From Gear
Cutting

13 Process

MS Offcuts

From
Construction &
Fabrication

Kg

30,000

30,000

Nos.

35,000

35,000

Nos.

3,000

2,100

Sold to recycler for


reuse of the same.
Sold to recycler for
reuse of the same.

Sold to recycler for

Sold to recycler for

Disposed as

Disposed as

Disposed as

0.05 incinerable waste


--

Sold to recycler for reuse after cleaning


Sold to recycler for re-

0.002 use after cleaning

Kg

60,000

39,000

--

Sold to recycler for


secondary use of
steel

Kg

100,000

77,000

--

Sold to recycler
forsecondary use of
steel, for fabrication
of stands and fixtures
for internal use

Total Waste fuel is 70% of the total energy consumption


- CVBU LUCKNOW

114

Sohrabji Godrej Green Business Centre

Certifications for Lucknow

Implementation from TS/ISO/OHSAS

All Energy &


Environment
certifications
from regulatory
bodies.

NABL certification
OHSAS 18001:2007
ISO/TS certification
ISO 14001 certification

2003-04

2007-08

2009-10

115

- CVBU LUCKNOW

2011-12
Sohrabji Godrej Green Business Centre

Certifications for Channel partners

Implementation from TS/ISO/OHSAS

Aim: 100% vendors


ISO/TS certified

ISO certified : 268


TS certified: 195
ISO 14001 - 30
ISO journey for
vendors
2005-06

2009-10

- CVBU LUCKNOW

116

2011-12

Sohrabji Godrej Green Business Centre

Corrective actions & Status Report

TS 16949, ISO 14001 & ISO 18001


TS16949
S.N
o

Clause

4.5.2

4.3.2

4.3.1

NCR Description

Correction

Corrective Action

Environmental board
displayed outside the main
entrance does not have
updated information on Air &
water consent with validity &
analysis of treated effluent
There is no evidence of
analysis of used oil before
disposal to authorised recyler

Updated information on Air


and Water consent with validity
& analysis report of treated
effluent have been mentioned
on the Environmental
information board.
Used oil to be disposed has
been analysed.

Di splay of updated
information on Air and Water
consent, analysis report of
treated effluent & analysis of
used oil as per requirement
will be reviewed in MR
meeting in order to maintain
continuity.
Henceforth, used oil will be
analysed before di sposa

Following changes in
applicable legal requirements
not i dentified in Legal
Register
Hazardous Waste
Management & Handling
Rules amendments -2008
Petroleum rules 2002
Indian Electricity rules
amendments-2002

The changes in applicable legal


requirements have been
identified in the Legal register
and the register has been
revised.

Subscription to legal update


has been renewed and
updates are bei ng received.
Moreover, henceforth,
alongwith review of legal
compliance ; updation of
Legal register also will be
reviewed in MR meeting.

Aspect-Impact related to the


following activities not
identified
Storage and usage of C O2
Cylinders in Frame Shop
Leakage of Compressed
Ai r
Generation of used oil filter

Use (in welding) and storage


of CO2 cylinders in Frame
shop has been identified in IER
of Frame CX
Leakage of compressed air
has been identified in IER of
Engg. Services dept.
Generation of used oil filter
has been identified in IER.s of
HT shop.

Status

Closed

Closed

Review of IER will be


discussed in MR meeting as
a regular review mechanism.
Closed

OSHAS 18001 : 2007


S.No

Cla use

4.5.2

NCR De scription

Ambient air monitoring


doesnt include all the
parameters i.e.Pb is not
being monitored
as per the Enviornmental
Protection Rule 1986 clause
3(3B) and schedule VII.

Correction

Corrective Action

Monitoring of Lead (Pb)


concentration in ambient air
quality has been started.

- CVBU LUCKNOW

117

Identified legal and other


requirements will be
complied
with in an unbiased
manner

Status

Closed

Sohrabji Godrej Green Business Centre

Corrective actions & Status Report

TS 16949, ISO 14001 & ISO 18001


ISO 14001 : 2004
S.No

Cla use

8.2.3.1

NCR De scription

System made to establish and


monitor targets for process
capability, reliability,
maintainability and availability.
RFQ will capture all the
requirements and in machine
acceptance criteria form it will
be communicated to the user

Understanding on basic
statistical concepts and
utilization of control charts is
inadequate.

(1) 1. Control limits established.


UCL = 0.05, LCL = 0
2. Sample size increase 10 per
day i.e 5 / shift
(2) Cpk observed 3.87 was for
ratio 41/6 pinion whereas during
audit ratio running was 45/7
pinion. CpK study carried out for
this ratio and found 0.7.

8.1.2

7.3.3

Correction

A systematic approach of
performing process studies
on new assembly processes
to establish the objectives for
process capability, reliability,
maintainability and availability
is not in place.

Out put of manufacturing


process design is not
adequately addressed to
facilitate effective process
control. Ex. Control plan for
machining for pinion 41/6
does not include surface
finish and the process
parameters such as speed,
feed rate etc.

Control plan for pinion 41/6


revisited.

Corrective Action

Procedure for product


transfer process (LAPRP02A) covering process
design and development
revised including targets
for productivity, process
capability, reliability,
maintainability,
availability.
1. Training for SPC
planned in 3rd week of
Dec' 09
2. Ratio wise CpK will be
calculated
3. Inspection frequency
will be decided based on
the CpK results

Status

Closed

Closed

1. Training on control plan


completed

Closed

All NCRs closed

FORMAT OF Non-Conformity Reports


- CVBU LUCKNOW

118

Sohrabji Godrej Green Business Centre

Replication of Best Practices

Knowledge through Learning & Sharing


TKC-Tata Knowledge Chain

All TATA Group companies can access the TKC internet based portal.
Every one can learn & share the knowledge
Vibes- Tata Motors Intranet
All TATA Motors employees can access the VIBES-the Intra net portal through which knowledge can be
enhanced through learning & sharing.
Knowledge through Learning (KTL) of CVBU
Lucknow Plant, in 2009-10 year contributed 3680 numbers of knowledge pieces in the KTL Book of CVBU.
Also a CD comprising of all the improvements were released. The divisions /departments who contributed
significantly were also felicitated subsequently.
Plant head inaugurating the KTL CD
Divisions / Departments
which contributed
significantly were
Planning,
Manufacturing, Central
Quality, Transmission
Factory, Assembly Line
planning, Sourcing,
Vehicle Factory, Lean
Manufacturing, PTPA,
PE, Integral Bus
Factory, Sustenance &
Training Centre

In-house/External training
program
Knowledge sharing through
Plant visits
Sharing of the best practices
implemented though
Video Conferencing

Yugandhara Is the thought at the core of the Tata Motors Climate


Change web site. It brings together information and experiences
regarding Climate Change & Energy Conservation initiatives across
the Tata Motors. Every employee across the Tata Motors is having the
access this web site.

119

- CVBU LUCKNOW

Sohrabji Godrej Green Business Centre

Replication of the Best Practices implemented on Energy conservation

Through Associates

TATA Motors Ltd. - CVBU Lucknow has conducted special drives at business associates /Vendor end to
optimise the over all vendor management process. We have conduced KAIZENs AT VENDORs END. The
results of this special drive are,
KAIZEN Exercises within Plant & at TMLs Vendors

108

82

88

60

84

84

48

70

40

09-10

60

IInd Qtr

Ist Qtr

08-09

09-10

IVth Qtr

IInd Qtr

Ist Qtr

08-09

IIIrd Qtr

21

20
0

84
81
78

80

80

IVth Qtr

108

103

100

Better

Target : 80

90

IIIrd Qtr

Target : 100

Sustenance (%)
KaizenKaizen
Sustenance
in %

Better

No of Kaiz en Events

No. of Kaizen events


120

Major Kaizen
TM & LS Participation ( % )
Employee
Participation in %

80

Process streamlining to achieve single piece flow at M/s.


Narayan Engg. (Recon)

40

81

76

82

82

09-10

Installation and layout finalization at M/s. Lucknow


Grinding (Recon)

Better

Target : 80

100

60
40

IIIrd Qtr

Re-arrangement of fastener store

IInd Qtr

3P for cost economic shedding for tyre yard

Ist Qtr

21

20
08-09

Productivity improvement kaizen at BIW

IVth Qtr

Vendor Kaizen at M/s. Suprabha Industries

Kanban implementation in Frame CX

- CVBU LUCKNOW

120

Sohrabji Godrej Green Business Centre

Aligning associates to Changing Market Scenario & Optimising overall productivity process
TATA Motors Ltd. - CVBU Lucknow has conducted special drives at business associates /Vendor to optimise
the over all vendor management process. We have conduced QUALITY AT SOURCE event in November09
& December09. The results of this special drive are,

- CVBU LUCKNOW

121

Replication of the Best Practices implemented on energy

Sohrabji Godrej Green Business Centre

Through Associates

TATA Motors Ltd. - CVBU Lucknow has conducted various programs like Technology Up gradation awareness
program, Modern trend in vehicle assembly system, Green Initiatives, Energy Conservation measures etc to
business associates / vendor to enhance the productivity & quality of material they supply inturn reduce the cost
of poor quality.
The Quality Month communication has been conducted in December2009 at Tata Motors-Lucknow plant and all
the associates/vendors participated the event. Various rewards been given to vendors for their good quality of
product. Couple of snap shots are,

- CVBU LUCKNOW

122

Sohrabji Godrej Green Business Centre

Replication of the Best Practices implemented on energy Through Associates


Senior Management team of TATA Motors Ltd. - CVBU Lucknow regularly visits the Associates/Vendors
plant to constantly motivate their employees on Safety, Energy conservation, Quality, Cost, Deliverability &
Environment. Here are couple of snap shots of sr. mgmt visit to neighboring Vendor plants.

- CVBU LUCKNOW

Tata Motors
Jamshedpur

123

Sohrabji Godrej Green Business Centre

CII
ISHRAE

BEE

Tata Motors
Lucknow

Earnst & Young


Mckensy

ISO 9001
Vendors
Associates

KNOME
Yugandhara
Tata Motors
Pune

Knowledge Pond

OSHAS

Enterprise
System Manual

TKC
Innovista

Climate
Change

Safety
TQMS

CSR

Tata Daewoo
Hispano

Vibes

Tata Motors
Pantnagar

Jagaur
&
LandRover

Tata Motors
Sanand

- CVBU LUCKNOW

124

Sohrabji Godrej Green Business Centre

Results of the replication arising out of Best Practices implemented on energy front through
associates are
Process has been institutionalized at Lucknow

Vendor Quality Incoming PPM level


Better

Direct Material Cost reduction

Rs in Crores

Better

Energy Cost as a % of manufacturing cost


0.35

Better

0.31

0.3

0.27

0.25
0.19

0.2
0.15
0.1

2007-08

2008-09

2009-10

- CVBU LUCKNOW

2006-07

Energy Cost as a
% of
manufacturing
cost in 2009-10 is
0.192 %
Best in Class

125

Sohrabji Godrej Green Business Centre

2007-2009

Rewards & Recognitions


List of Certifications:1)

Quality Certification: ISO/TS -16949.

2)

Environment Certification: ISO -14001 : 2004

3)

Occupational Health & Safety Management SYSTEM Certification: OHSAS - 18001

List of Awards
1)

Tata Motors CVBU-Lucknow Plant bagged the most prestigious


Excellent Energy Efficient Unit Award-2009 conducted by CII
on 19th & 20th of Nov2009 at Chennai.

2)

CVBU Lucknow won the second prize in the prestigious


INSSAN Award for Excellence in Suggestion Scheme at

1)

the Annual Regional Convention 2010 of INSSAN


(Indian National Suggestion Schemes'' Association)
- Eastern India Chapter.
3)

Tata Motors CVBU-Lucknow Plant received the IME Award 2008.


(IMEA-Indian Manufacturers Excellence Award)

2)

4)

Tata Motors bags the NDTV Profit Business Leadership Award 2008

5)

Tata Motors has been ranked First in India in Investor Relations, in the Thomson Reuters

6)

Tata Motors has been awarded the 'Top Exporter Gold Trophy in the Large Enterprise category by the Engineering

Extel Asia (ex-Japan) Survey 2008.

3)

Export Promotion Council (EEPC) for the year 2006-07.


7)

Tata Motors has received the Emerson Network Power and Express Computer Uptime Champion Award 2007

The Aggregates Business of Tata Motors' Commercial Vehicle Business Unit has won the 'Best Supplier Award 2007
from Escorts Construction Equipment Ltd (ECEL).

- CVBU LUCKNOW

126

Sohrabji Godrej Green Business Centre

Our Message through this presentation is


Systematic, Sustainable, Continual improvements,
Knowledge sharing, Innovation, and Team Work
are the core pillars to make a plant an

Excellent Energy Efficient unit

Thank You ! ! !
127

- CVBU LUCKNOW

Sohrabji Godrej Green Business Centre

Innovation Project : Optimisation of Energy & Cost of Bus Module - transportation


SN

Mode of transportation

1 TRAILER-28 FT

Load
Carrying
Capacity
48000 15T

2 TRAILER-40 FT-3516

72000 20T

1.5

3 Two Chassis Transportation thru Trailer 40FT

72000 20T

4 Drive Away Chassis


Distance from LKO to Dharwad 1900KM,
Milleage 4KMPL.
Cost of fuel
Driver - Daily allowance - Rs 250 for 6 days
Return charges for driver
Road Toll tax

Rate

No of
chassis per
Trailer
1

17100
1500
750
4550

Fuel cost Driver - Daily allowance - Rs 250 for 6 days


Return charges for driver
Road Toll tax - Consolidated rebate

2
17100
1500
750
2799

Scenario

48000 Existing Scenario


48000 Scenario - I
36000 Scenario - II
Scenario - III

17100
1500
750
4550
23900
24000 Scenario - III

Cost of Drive away Chassis transportation


5 2 Tier - Drive away Chassis

Cost per
Chassis

Scenario - IV
9500
750
375
1400
12025
12000 Scenario - IV

Assumptions :
Cost of temporary support recycling is not considered.

- CVBU LUCKNOW

128

Sohrabji Godrej Green Business Centre

Heat contained in Flue Gas=Q g= m x Cp x Tg


Flow rate of flue gas=180 M3/hr
Density=(MW/359)x(492/(460+Tg)
Qg= 208 kcal/sec
Amount of heat required for heating the water=m x Cp x (T2-T1)
Where (T2-T1)=(65-40)=25 0 C ; m(flow rate)= 5.5 Kg/sec; Cp =1Kcal/kg c
=137.5 Kcal/ sec
Heat exchanger
Q=137.5=U A (LMTD)
U=Overall heat transfer Coeff
A= surface area
LMTD=Log Mean Temp difference

A=Q/(U x LMTD)= 0.95 M2


we selected GI coil with surface area of 1 M 2

- CVBU LUCKNOW

129

Sohrabji Godrej Green Business Centre