Lucas-TVS Ltd.

, Padi, Chennai

Team Members – M Mohanraj

S Sasikumar
A Arumuga Nainar

1
 COMPANY PROFILE
An Overview Lucas TVS was established in 1962 as a Joint Venture between Lucas Plc.
UK and TVS Group, India. Five decades of leadership on Indian Auto
Electrical Market. 7 plants in India, main plant in Chennai. Product
development capability - 75% of revenue from In-house developed products

Awards & Recognitions

Products

Alternator, Starters, Wiper Motor, Two Wheeler Starter Motors, Wiping System, Compressor Motor, Stick coil

Our Customers
MAJOR PROCESSES

Single Piece Flow

Line Assembly
 ENERGY MANAGEMENT
ISO50001 Certification Energy Policy Corporate Objectives

Reduction
in Energy
by 10%

GHG
Reduction
by 5%
 APPROACH ON ENERGY CONSERVATION
1
Distribution loss
Technology / Engineering Improvements
Right sizing of Motors
LED Lighting
Air leak audit &
IE3 Motors

Waste Elimination
correction
2

Renewable Energy
Thyristor Controls Solar
BLDC Fans Wind
Conversion
VF Drive
Sleep Timers 3
Bio-Gas
Harmonic Filters Lux Level Optimiz. Bio-Mass
Heat Pumps
Natural Lighting
Demand Control /
Lean Electricals Load Sharing
Air Managers
Insulation improv.
 ENCON PROCESS
Significant Energy
consuming Equipments Obsolete Model
& Replacements
Waste Identification
Continuous Monitoring Energy
& Control Audits
System Adherence Technology Upgradation
& Deviations
Need for Training & Awareness System
Statutory Compliances
Evaluation &
Improvements
Work Efficiency improvement
Internal Audit (Yearly) External Audit (Once in 2 years)

Audit Identification Proposal & Execution Result

of Projects Evaluation Approvals Verification
Implementation on ISO 50001 & GreenCo rating
Energy Monitoring &
Management

Percentage Investment on Energy conservation Projects with respect

to turnover FY 2017-18 – 0.25%

7
 Specific Energy Consumption Trend
Year wise Energy Consumption Production Volume Better
Better
29
295 30 28
300 266 267 266 275 278 277 25 26 25 25
240 248 25 24
250 220 230 21
193 203 204
20

Nos. in Lacs
Units in Lacs

200 172 163 162 163 180 16 16 16

14 15
150 15 13
11
9 10
10 8 9
100
50 5

0 0
98-99 99-00 00-01 02-03 03-04 04-05 05-06 06-07 07-08 08-09 09-10 10-11 11-12 12-13 13-14 14-15 15-16 16-17 17-18 98-99 99-00 00-01 02-03 03-04 04-05 05-06 06-07 07-08 08-09 09-10 10-11 11-12 12-13 13-14 14-15 15-16 16-17 17-18

25.00
Energy Units Per Product Total Power Cost
21.00 Better Better

20.00 19.00
18.00 2500 2317
16.00 16.50 2157 2150
Units in kWh

1952 2033 2021 1955

15.00 1855
15.00 13.40 13.30 13.10 13.97 12.74 2000
1476

Rs.in Lacs
10.56 10.35 10.31 9.90 9.95 9.89
9.73
1500
10.00 8.42 983 1011
1000

5.00 500

0
0.00 07-08 08-09 09-10 10-11 11-12 12-13 13-14 14-15 15-16 16-17 17-18
98-99 99-00 00-01 02-03 03-04 04-05 05-06 06-07 07-08 08-09 09-10 10-11 11-12 12-13 13-14 14-15 15-16 16-17 17-18
 Specific Energy Consumption Trend 2017-18

12.00
Better
11.00
10.60
10.31
10.00 10.00 9.90 9.89
10.00 9.90 9.73 9.50 9.30 9.20
8.97 9.00 8.90 8.80
8.91 8.90 8.76 8.70 8.60 8.50 8.30
8.42 9.46 9.41 8.20 8.10
8.83 8.76
8.00 8.56
8.33 8.25 8.17
7.99 7.82
7.78
Units Per ESU

7.73

6.00 Achieved – 8.42 Units / ESU (Avg.)

4.00

2.00

0.00
11-12 12-13 13-14 14-15 15-16 16-17 17-18 Apr-17 May-17 Jun-17 Jul-17 Aug-17 Sep-17 Oct-17 Nov-17 Dec-17 Jan-18 Feb-18 Mar-18

Plan Achieved Plan Actual

ESU – Equivalent Standard Unit

 Specific Energy Consumption Trend 2018-19

12.00
11.00
10.60 Better
10.31
10.00 10.00 9.90 9.89
10.00 9.90 9.73
8.97 8.90 8.75 8.94
8.91 8.76 8.41
8.42
8.00
8.00
8.30 8.30 8.15 8.10 8.05 8.05 8.00 8.00 7.90 7.90 7.80 7.80
Units Per ESU

6.00
Target – 8.00 Units / ESU (Avg.)

4.00

2.00

0.00
11-12 12-13 13-14 14-15 15-16 16-17 17-18 18-19 Apr-18 May-18 Jun-18 Jul-18 Aug-18 Sep-18 Oct-18 Nov-18 Dec-18 Jan-19 Feb-19 Mar-19

Plan Achieved Plan Actual

ESU – Equivalent Standard Unit

 ENCON Projects for last 4 years
2015-16
•Campaign on Heat Loss elimination
• Replacement of conv. AC by new AC
• VRF Airconditioners 2017-18
2014-15 • Replacement of motors-3 times rewinding • LED Lighting
• VFDs • BLDC Fans
12.00 16
• Induction Lighting 2016-17 • IE3 Motors
• BMS
10.41 • Thyristor Controls • Transformer No Load Loss • Energy Saver for AC 14
10.00 • Day Light optimization
9.00 9.00 9.00 9.00 • Air Manager
12
• AC Tonnage Timer control
8.00
9.00 10
Units in Lacs

Units in Lacs
6.50
6.03 8.00
6.00 8
5.00 5.20
6.00
6
4.00
4.00
3.00 4
2.50
2.00 2.00
1.25 1.50
1.00 2
0.50 0.75
1.10
0.56 0.89
0.00 0.20 0
14-15 15-16 16-17 17-18 18-19 Apr-18 May-18 Jun-18 Jul-18 Aug-18 Sep-18 Oct-18 Nov-18 Dec-18 Jan-19 Feb-19 Mar-19

Plan Achieved Plan Actual

 Energy Conservation Plan vs Actual 2017-18
Energy Saving Cost Saving Investment
Project Title
0.00 5.00 10.00 0.0 20.0 40.0 60.0 0.0 50.0 100.0

1 1 2.0
Thyristor for Induction Hardening Machine 1 0.05 0.4

Replacement of conventional Ceiling Fan with BLDC ceiling fan 2 0.18 2 1.3 2 4.2

Investment
Day light optimization by introducing Sola Tube in Warehouse 3 0.24 3 1.7 3 10.0 in Lacs

Introduction of IE3 Motor for Compressor by replacing IE1 motor 4 1.8 4 10.0
4 0.25

Elimination of Transformer no load loss by replacing 40 years Energy

5 5.4 5 15.0
old Transformer with Oil type Transformer 5 0.78 saving in
lac kWh Cost
6 5.4 6 11.3
Introduction of energy efficient ACs by replacing old ACs 6 0.78 saving

Installation of LSHV Ceiling Fan instead of Almonard fans 7 0.90

7 6.3 7 80.0

Introduction of Energy Saver Unit for Airconditioners 8 1.20

8 8.4 8 1.8

IE3 Motor for Manufacturing Machines in Shopfloor 9

9 12.6 9 6.0
1.80

Introduction of Energy Efficient Lighting across factory 10 54.6 10 40.0

10 7.80
 Energy conservation Plan 2018 - 19
Project Title Energy saving in Lacs

Replacement of motors to IE3 0.29 kWh

Expected
Elimination of Transformer No load loss 0.4 kWh Savings of
by replacing with dry type
Around
9.0 Lac
Introduction of BLDC HVLS fans 3.36 kWh Units in
2018-19
Day light optimization by introducing Sola 0.24 kWh
Tube in Claw and EOU Ware House Investment
on Energy
Power Quality improvement by installing 2.1 kWh conserving
passive Harmonic Filters
Projects
1.97 Crores
Downsizing of Motors in Manufacturing 1.50 kWh
machineries in shop floor
 Energy Conservation Projects
Before After

After installation of Sola tubes, Usage of Light fittings were

Previously, Warehouse had high wattage light fittings and
reduced to only 12 hours in the night as Natural lighting
was in operating condition day and night(24 hrs)
was used during the day.
Financials ( in Lakhs )
12.5
0.24 TCO2e
₹10 ₹ 1.68
kWh
 Energy Conservation Projects
Before After

35W BLDC type Ceiling fans are being introduced in main

Conventional 75W ceiling fans were being used
offices to reduce energy consumption by 53%
throughout the company.
- 490 Nos replaced so far
Financials ( in Lakhs )
66
1.27 TCO2e
₹1.8 ₹8.9
kWh
 Energy Conservation Projects
Before After

The transformer was replaced with 1000 kVA Oil cooled

We had a 40 year old transformer 750 kVA Transformer in
Transformer with On-Load Tap Changer which results in
substation.
reduction of no load losses by 5%
Financials ( in Lakhs )
41
0.78 TCO2e
₹15 ₹ 5.44
kWh
 Energy Conservation Projects
Before After

9 Ltrs per 6 Ltrs per

panel panel

Solar panel cleaning is carried out every month. High pressure nozzle was introduced to the hose & water
Avg. water consump. to clean 3820 panels is 37000 litres/month. pressure was improved and 20200 litres to clean 3820
Low pressure water hose was used to clean solar panel solar panels.
Financials ( in Lakhs )
0.3
200 TCO2e
₹0.010 ₹0.24
kL
 Energy Conservation Projects
Before After

Previously, In office areas ACs were continuously running

Now, an energy saver is used to optimize usage of ACs
without a timer based system which resulted in wastage
depending on the ambient temperature
of energy.
Financials ( in Lakhs )
63
1.20 TCO2e
₹1.8 ₹8.43
kWh
 Energy Conservation Projects
Before After

18W 36W 75W

The conventional light fittings were replaced with energy
We were equipped with 36W Tube-lights, 72W recess
efficient LED Lights – 3507 / 5358 Nos.
mounted fittings & 150 W high bay lights.
Reduction in Energy by 50% .
Financials ( in Lakhs )
409
7.80 TCO2e
₹40 ₹ 54.6
kWh
 Energy Conservation Projects
Before After
180 W
HVLS fans proposed
Industrial
type fan

Almonard fans

631Nos x 180W 61Nos x 750W

=113kW =45 kW

Introduction of HVLS fans by replacing Almonard fans in

180W Almonard fans were being used in Main Assembly
shop-floor. 750W x 1 No. = 750W per Assembly.
lines. 180W x 10 Nos – 1800W per Assembly
Effective air coverage Area – 24000 Sq.ft
Financials ( in Lakhs )
47.2
0.90 TCO2e
₹80 ₹ 6.30
kWh
 Energy Conservation Projects
Before After

ITA 0004, Thread rolling Machine in Manufacturing line This motor was replaced with higher efficiency IE3 motor
had IE1 motor of 30HP capacity resulting in 5% reduction of energy consumption.

Financials ( in Lakhs )
94
1.80 TCO2e
₹6.0 ₹12.6
kWh
 Energy Conservation Projects
Before After

Window type ACs were replaced with VRF type ACs in Engg
Previously, Window type ACs were installed in offices,
centre & Advanced Engg., HR dept & Quality office
standards room & labs consuming high energy.
resulting in a reduction of energy consumption by 32%.
Financials ( in Lakhs )
41
0.78 TCO2e
₹11.3 ₹ 5.44
kWh
 Energy Conservation Projects
Before After

In Previous control systems, Heaters were continuously

Thyristor control was introduced in Pre-heat & baking zone
running in ITA 0073 Armature Gel coating plant, ITA 0074,
resulting in 6% reduction of energy consumption.
ITA 0076 Stator varnishing plant, even in ideal condition
Financials ( in Lakhs )
2.6
0.05 TCO2e
₹2.0 ₹ 0.35
kWh
 Energy Conservation Projects
Before After

EOU M/C's EOU M/C's

SS 10HP
SS
Cooling Cooling 10HP
tower 10HP
tower GRS M/C's
GRS M/C's

However, it was identified that both EOU & GRS

Two different 10HP motors were being used to feed EOU
requirements can be fed with a single 10 HP motor & the
& GRS requirements individually.
other motor has been removed from the circuit.
Financials ( in Lakhs )
22.5
0.43 TCO2e
₹0.15 ₹3.01
kWh
 INNOVATIVE PROJECT - HEAT PUMP SYSTEM
Before After

Thermopac Plating shop Phospating shop

Thermopacs were being used for Phospating and Plating Heat Pump System were introduced by eliminating
application. SKO consumption per day -540 Litres Thermopacs for Phospating and Plating application.
Avg. Expense – Rs.7.74 per K Cal. Avg. Expense – Rs.5.50 per K Cal.
Financials ( in Lakhs )
442
185KL TCO2e
Zero ₹20.76
of SKO
 Innovative Project – Heat Pump
Existing Heating Application in LTVS

26
 HEAT PUMP

Thermal Energy Requirement

27
 INNOVATIVE PROJECT - HEAT PUMP SYSTEM

Description Value Description Value

Heat kW to Plating shop 90 kW Heat kW to Plating shop 70 kW
Temperature delivered to Process tanks 70 – 80 ◦c Temperature delivered to Process tanks 80 – 90 ◦c
Energy consumed by heat Pump 30 kW Energy consumed by heat Pump 23 kW
28
Innovative Project - Phospating Plant – Heat Pump Layout

Air Vent

Expansion
Tank

Input temperature
Output Temperature
Heat pump input

29
 RENEWABLE ENERGY SOURCES

OGP - Wind OWN WIND POWERPLANT Fossil

POWER SOURCES EB
9%
Fuel
29% DG
2%

Green
power
60%

Purchase quantum : 1.80 MW (Wind Power) Windmill Capacity : 1 MW (4 nos. x 250 KW)

Contract Agency : M/s Orient Green Power Installed Location : Tirunelveli

Purpose : Use of Renewable Energy Purpose : Use of Renewable Energy

Energy Unit Generation : 13,00,000 Units per Month Energy Unit Generation : 15 Lacs Units / Annum

Benefit : Off setting by 60% Benefit : Off setting by 4%

 RENEWABLE ENERGY SOURCES
BBefore BAfter 6000
10.50AM - 5468 KVA 2.00 PM - 5501 KVA 6.20 PM - 5255 KVA Solar
Non-Solar
6.50 PM - 5046 KVA

5000

4000

Demand in KVA
3000 10.50AM - 4755 KVA 6.20 PM - 5223 KVA
2.00 PM - 5134 KVA 6.50 PM - 5408 KVA
2000

1000 Shift-A Shift-B Shift-C

06:…

08:…

09:…
10:…
10:…
11:…
12:…
12:…
13:…
14:…
14:…
15:…
16:…
16:…
17:…
18:…
18:…
19:…
20:…
20:…
21:…
22:…
22:…
23:…
00:…
00:…
01:…
02:…
02:…
03:…
04:…
04:…
05:…
06:…

07:…

08:…
Ref. data : 31.05.2016 (Total consumption-96,786) • Reduce Peak demand with help of solar power
• Cost saving of Rs.0.98 Lacs per month for Demand charges
Project : Installation of Roof Top Solar Power Plant
Plant Capacity : 1.22 MWp
Satellite of
Project Cost : Zero investment – BOOT concept L-TVS Padi
Power generation : 5000 Units / day (Avg.) Roof top.
Benefit : Cost Saving @ 1.72 Lakhs / Month
: 100% Compliance with TNREC regulation (RPO)
 Renewable Power Utilization Trend – 9 years
100% 1 0 0
0 4
0 10 8
12
0
90% 18
0 22
6 29
6
0
31 Plan to enhance
80%
0 renewable power
42
70% 25
purchase from 55%
0 6
22
71 to 84%
31
60% 77
Percentage %

1 62
50% 84
47
29
40%
55
28
30% 60 2
52 Fossil Fuel
20% Solar Power
8 2
28 16 Green power
27
10% 19 20 2 DG
14 2
9 EB
6 6
0%
2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 2018-19

32
 Utilization of Waste Material as Fuel

Generation of 8 – 10
kg of Methane gas per
day of LP for every 50
kg of food waste

Canteen Area

Pre-Digester

Digester Waste Material Used – Canteen Food waste

Crusher

Financials ( in Lakhs )

9.68
₹5.0 1825 kg ₹0.91 TCO2e

33
 GHG Inventorisation
Scope 1 emissions 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18
LPG consumption MT 189645 168249 171052 163837 165963 179295
Emissions from LPG consumption t CO2 565142 501382 509735 488234 494569 534299
HSD & SKO consumption KL 1859 1097 747 748 832 725

Emissions from HSD & SKO consumption t CO2 4862934 2853329 1916618 1915326 2130545 1856544

Scope 2 emissions
Purchased electricity MWh 10529 3745 7299 15249 8427 10548
Emissions from purchased electricity t CO2 8634 3071 5985 12504 6910 8649

Total emissions t CO2 5436711 3357782 2432337 2416064 2632024 2399492

Annual production ESU 2500000 2550000 2540000 2538000 2792000 2931000

Specific intensity (tonne of CO2/ESU) 2.17 1.32 0.96 0.95 0.94 0.82

34
 GHG Inventorisation
Scope – 1 Emission Scope – 1 Consumption
6000000
195000
5000000 4862934 Avg-18.5 Million 190000
189645
LPG-175 Ton
185000
4000000 Ton Avg.
180000
175000 179295
t CO2e

3000000 2853329
170000
2000000 2130545 165000 171052
1916618 1915326 1856544 168249
160000 165963
1000000 163837
155000
0 150000
2012-13 2013-14 2014-15 2015-16 2016-17 2017-18
2012-13 2013-14 2014-15 2015-16 2016-17 2017-18
Emissions from HSD & SKO consumption t CO2 HSD & SKO consumption LPG consumption
Emissions from LPG consumption t CO2

Scope – 2 Emission Scope – 2 Consumption

14000 18000
12000 16000 kWh-264 Lacs
12504
Avg-7500 Ton
14000 15249
10000
12000
tCO2e

8000 10000
8634 8649 10529 10548
6000 6910 8000
5985 8427
4000 6000 7299
4000
2000 3071 2000 3745
0 0
2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18

Emissions from purchased electricity 35 Purchased electricity

 GHG Inventorisation

6000000 5428077
Total emissions (tCo2e) % Reduction in CO2
5000000 emission over last 4
4000000 3354711 years – 38%
3000000 2426353
2403561
2625114
2390843
2000000
1000000
0
2012-13 2013-14 2014-15 2015-16 2016-17 2017-18

Total emissions

Specific intensity (tCO2e / ESU) Specific intensity

0.10 of CO2 - %
0.08
0.08
0.07 0.07
Reduction over
0.06 0.06
0.06
0.06 last 4 years - 38%
0.04

0.02

0.00
2012-13 2013-14 2014-15 2015-16 2016-17 2017-18

Specific intensity (kg of CO2/ESU)

36
 CARBON NEUTRALITY TREND

15000000 Offset with Green powerunits TNEB units (Fossil Fuel)

11803950
10480124
Net Zero
10000000 7328358 7658438
5952991 Carbon
5759154
4133781 4049518 4669474 Footprint by
5000000
0 end of
March ‘19
kgCO2e

0
2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18 2018-19

-5000000 -786930 -3474768.108 -3292450.833

-6876460.105 -6059601.278
-10000000 -7344680 -8790673.843
-9808145.322 -9869935.747

-15000000 -14549828

-20000000

37
 GREEN SUPPLY CHAIN – Vehicle Route Optimization
Routes optimized while vehicle allotment for reducing lead time, reduce cost of logistics
and improve fuel efficiency. CO2 Emission
reduced by 60 %
Route 1 – Ambattur Zone – 5 Vehicles – 20 Suppliers Covered - 107 T CO2 e

Route 2 – Porur Zone – 2 Vehicles – 6 Suppliers Covered

Route 3 – Arumbakkam Zone – 2 Vehicles – 3 Suppliers Covered
Route 4 – Tambaram Zone – 3 Vehicles – 4 Suppliers Covered
Route 5 – Thirumazhisai & Thirumudivakkam Zone – 2 Vehicles – 6
Before
After
Suppliers – Suppliers Suppliers –
60 60
Vehicles - Route 6 – Perungudi Zone – 1 Vehicle – 6 Suppliers
Vehicles - 20
50
Route 7 – Guindy / Villivakkam Zone – 4 Vehicles – 11 Suppliers
Covered
Route 8 – Other Zones – 2 Vehicles38– 4 Suppliers
Green Supply Chain - Carton Box Elimination in Incoming Supplies
Total Parts Identified 801 Nos Proposed use of Polythene bags of thickness > 50microns for;
 Parts prone to oxidation / white rust
Completed 487 Nos
 Parts from outstation suppliers
Balance To Complete 314 Nos  Smaller parts like bushes, washers, fasteners,etc.

Existing Method Present Method

Larger Parts 174 Nos Carton PVC tray

box

Existing Method Present Method

Smaller Parts 517 Nos

Polythene
Polythene
bags > 50
bags < 50
Microns
Microns

39
 Total Employee Involvement

SGA
Voluntary
Work Suggestions
Teams

Awareness Campaign &

Programs Competitions
for
Contractors

Training &
Awareness
Audit at Program for
Vendor Employee
plants Families

40
 Total Employee Involvement
Campaign & CompetitionsCampaign & Competitio
National Energy Management Award 2017 - CII
Training Programme for Training
Training Programme forProgramme for Programme
Training TrainingforProgramme for Programme
Training Training
forProgra
Contractor Trainee Contractor Vendor Trainee Family Vendo

Campaign & Competitions

ABK-AOTS Competition
Training Programme for for EnergyTraining
Policy - Programme
Pledge for Energy Policy - Pledge
Training Programme for Mtce personnel
Contractor
Training Programme for Training Programme for Contractor
Training Programme for
Contractor Trainee Vendor Family

No. of campaign - 12 nos. N

No. of competitions - 10 nos. N

Training Programme for Energy Policy - Pledge

Contractor

No. of campaign - 12 nos.

No. of competitions - 10 nos.
41
Thank you…