National Award

for
Excellence in Energy Management 2019

Category Excellent Energy Efficient Unit

Sector Automobile
Unit CVBU - Lucknow, Tata Motors Limited
ISO 50001:2011
OHSAS 18001:2007
ISO 14001:2015
IATF 16949:2016
Represented By : Dr. Srinu Babu. Matta - Energy Lead Auditor
Head- Central Plant Engineering Department

Mr. Mohd. Amir - Energy Lead Auditor

© Copyright, Confidential, Tata Motors Ltd 1

Company Profile:- Lucknow Plant

❖Tata Motors Limited is
➢India’s largest automobile company,
➢Consolidated revenues of Rs.3,01,938 crore’s (44 Billion USD) in 2018-19
➢We are the leader in commercial vehicles in each segment,
➢The company is world’s fourth largest truck manufacturer,
➢ World’s fourth largest bus manufacturer.

❖Tata 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 , MSRTC, KSRTC, APSRTC, TSRTC, JnNURM, UPSRTC and
other STUs.

Lake View Within the

Plant
© Copyright, Confidential, Tata Motors Ltd 2
Plant Greenery

1
 Who areon
Brief introduction we…
Company/Unit

Lucknow Works Facilities @ Lucknow

278 Acre land area 303 Acre land area
EASTERN COMPLEX LUCKNOW WORKS

Bus
Focused
ERC setup

Prolife TCF &

Weld Shop Paint Shop
Vehicle PE & Axle Integral Bus Rear Axle
Factory Shop Factory
Cowl &
Module Fully Build Cabin
Frame Front Axle Fabrication Vehicle Vehicle
Production Module Assembly
Cowl
Engineering Assembly Tata
Marcopolo Rear Axle
Vehicle
Assembly Motors
Limited

Service
Training
center

© Copyright, Confidential, Tata Motors Ltd 3

Brief introduction on Company/Unit

Plant Process

Drive Axle Front Axle Engine

Assembly Assembly Assembly
SUPPLY
CHAIN Vehicle Assembly Line DTC*
DISPATCH

Western Complex
Material Bus Assembly Line
from TMML STU**
Vendor
base - Vehicle Assembly Line
Local, Eastern Complex
Private
Pune & Operator
Jamshedpur Chassis Cowl Paint BIW
Assembly Assembly Shop Shop

* Delhi Transport Corporation

**State Transport Unit
© Copyright, Confidential, Tata Motors Ltd 4

2
 1. Energy Consumption Overview- Electrical

2016-17 ELECTRICAL Purchase & Supply 2017-18 ELECTRICAL

Purchase & (KWH) Chain (KWH)
Supply Chain PlanningAxle Line 0% Planning
1% 1% Plant Services 1%
Plant Services 2% Axle Line
IBF 3% 2%
3%
3% IBF…
HR
3% Paint Shop HR
Paint Shop
41% 3%
BIW 42%
BIW
6%
TCF 7%
17% Heat &
TCF Heat &
Transmission Shop
Transmission
Asly line 1 9% 22%
Asly line 1 Shop
14%
14% 4%
More than 80% energy is consumed in Paint Shop, TCF, PE & Front Axle and Assy. Line 1
Purchase & 2018-19 ELECTRICAL
Supply Chain
0% (KWH)
Planning Axle Line
Plant Services 4%
IBF 1%
3%
1%
HR
3%
Paint Shop
BIW 45%
9%

TCF PE & Front

21% Axle
Asly line 1
0.26%
13%

© Copyright, Confidential, Tata Motors Ltd ❖ Specific Energy consumption reduced by 34.3% in three years 5

1. Energy Consumption Overview- Thermal

Fuels are used in Shops :Paint Shop: Propane gas ; Heat & Transmission: LPG & Assembly Line1 : LPG
Heat & 2018-19 THERMAL
2016-17 THERMAL
Transmission
Asly line 1 (MTOE)
Heat & Asly line 1 (MTOE) Shop stopped in 2%
Transmissi 6% mid of the year
on Shop 2017-18
5%

Paint Shop
98%
Paint Shop
89%
THERMAL CONSUMPTION
3000 0.019 0.020
MTOE/ Plant Eq. Veh

0.016 0.015 0.018

2500 0.016
2000 0.014
MTOE

0.012
1500 0.010
2455 0.008
1000
1841 2028 0.006
500 0.004
0.002
0 0.000
2016-17 2017-18 2018-19
❖ High propane consumption for double coat painting of Orange cabs in 2017 and Yellow cabs in 2018. Still Specific
Thermal
© Copyright, consumption
Confidential, was
Tata Motors Ltdreduced by 28.96% in three years 6

3
 2. Specific Energy Consumption in last 3 years

Key Initiatives for Energy Saving

➢ Monocoat Sunrise Orange Painting process of cabs
➢ LED lighting migration in Line-1 through OPEX model
➢ Replacement of conventional sodium vapour street lights by LED lights
23% ➢ Empty skid storage facility in Paint shop
15% ➢ Optimization of FDV and HVAC operations
➢ Conducting energy audits and compressed air leakage audits across
the plant
➢ Phosphating heat exchanger hot water pump running hours
optimization done through interlocking in PLC.
➢ Optimization of B and C shift lighting consumption
➢ Conversion of shop and office lighting to LEDs

Thermal (MTOE/Eq. veh.) Overall Energy (MTOE/Eq. veh.)

0.020 0.019 0.057 0.060
0.060 0.055 0.052
0.055 14% 0.016
0.055
0.016 6% 0.015 0.050
20% 0.042
0.040 0.037
0.050 11%
0.012
0.045 0.030
0.008
0.040 0.020
0.035
0.004 0.010
0.030 -
0.000
0.025 2016-17 2017-18 2018-19 2016-17 2017-18 2018-19
0.020
❖ Overall specific
2016-17
Energy consumption
2017-18 2018-19
reduced by 29% in last 3 year.
c Copyright, Confidential, Tata Motors Limited Reduction %

3. Information on Competitors, National & Global

Benchmark

NATIONAL AWARD FOR EXCELLENCE IN ENERGY MANAGEMENT

(Year - 2019) -AUTOMOBILE SECTOR

National Benchmarking
Electrical Specific Energy
Thermal Specific Energy Consumption
Parameters Consumption
kWh/Eq. vehicle GJ/Eq. Vehicle
TML Lucknow CVBU 250 640
TML Pune CVBU 426 782
TML Jamshedpur CVBU 574 1204
TML Pantnagar CVBU 199 584
TML Dharwad CVBU 198 402
Mahindra & Mahindra, Kandivli (2017-18) 268 --
Mahindra & Mahindra, Nashik (2017-18) 181 --
Mahindra & Mahindra, Zaheerabad (2017-18) 460 --

International Benchmarking
Electrical Specific Energy
Thermal Specific Energy Consumption
Parameters Parameters Consumption
kWh/Vehicle GJ/Eq. Vehicle
Scania (Kwh/Veh.) 7200 --
Volvo (Kwh/Veh.) 6400 --
Daimler (Kwh/Veh.) 6870 --
National Benchmark for SEC 181 --

SEC Target for FY Year 2019 - 2020 220 563

Sources / References for the furnished data www.greenbusinesscentre.com;

(National & International Data) Energy consumption data from Tata Motors plants

c Copyright, Confidential, Tata Motors Limited

4
4. A. ENergy CONserving (ENCON) projects
B. Innovatiion Projects

c Copyright, Confidential, Tata Motors Limited

4.A. Energy saving projects implemented in for last 3

years

Encon’s Summary
Annual Annual Thermal
Annual Electrical Saving Annual Thermal Total Annual Investment
Electrical Payback
Year Cost Saving Cost Saving Savings Made
Saving Quantity (Months)
(Rs million) (Rs million) (Rs million) (Rs million)
(Lac. kWh) (MT)
2016~17 17.06 13.99 331.10 9.93 38.12 9.51 3.0
2017~18 34.48 26.90 81.90 3.11 30.70 14.58 5.7
2018~19 59.05 47.24 73.00 7.07 54.31 15.30 3.4

123.13

2018-19
68.82
38.12 2017-18

2016-17 Total Annual cumulative saving from

2016-17 in Rs Million

c Copyright, Confidential, Tata Motors Limited

5
 4.A.1 ENCON Project in Paint shop – Wet on Wet (2C-1B)
and 1C – 1B Technology
Before
• New Model
Signa Cab was
Electro
Electro Deposition
introduced in Pre Treatment
Process Process
Process
Deposition Baking Oven

2017.
• It requires two
coat painting Sealant Line 1
application for Sealer Oven Underbody CED Inspection
the required
finish of the Sealant Line 2

paint process.
• So it was twice Baking
Moist Sanding Top Coat Line 2
Coated and Oven

twice baked (2C

2B), So it was Top Coat Line 1 Baking
Oven
consuming 3C-1B

double energy
in this process. Dispatch Wax Application Touch Inspection &
Up Polishing

4.A.1 ENCON Project in Paint shop – Wet on Wet (2C-1B)

and 1C – 1B Technology
Important ENCON Project in Paint shop Wet – on – wet technology

Proposed Changes

❑ 1. Orange paint (Base and Top coat) on wet on wet technology.

2 Coat +1 Bake

❑ 2. Developing mono coat paint along with the paint manufacturer

1Coat+1 Bake

6
 4.A.1 ENCON Project in Paint shop – Wet on Wet (2C-1B)
and 1C – 1B Technology
After : First Phase:
Important ENCON Project in Paint shop Wet – on – wet technology
New paint developed in consultation of Paint technology OEM. It does not require to bake primer coat before applying top coat
paint. It allows wet on wet painting. So resulted energy saving by eliminating one baking process.
Second phase:
For Orange & Yellow Cab, it requires baking in-between
Primer & Top coat. So new paint has been developed after working along with Paint OEM so that single coat can give the desired
quality of the cab painting. Therefore in-between baking requirement has been completely eliminated by mono coat.

Pre Treatment Electro

Electro Deposition
Deposition
Process Baking Oven
Process Process

Sealant Line 1

Sealer Oven Underbody CED Inspection

Sealant Line 2

Baking
Moist Sanding Top Coat Line 2 ( 3C -1B Primer implemented) Oven

Top Coat Line 1 Baking

Oven
3C-1B

Dispatch Wax Application Touch Inspection &

Up Polishing

Energy Saving : 11.2 Lakhs KWH/Year

4.A.2 ENCON Project in Paint shop - VFD provision in

Paint resin circulatory Pumps of
Cathodic ElectroDeposition (CED) System
Paint shop gets the Cab from BIW Shop (Weld shop) for painting. In Paint shop, it passes first from Pretreatment stage,
where oil, grease, dust & dirt are 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 applied over the surface of cab by CED (cathodic electro deposition) process and follows subsequent
painting processes .
Before:
The CED Tank having capacity of 300 KL which holds Positive charged paint resin and negative charged Cab passes
through it and gets painted due to CED process. There are three circulatory pumps capacity(1X45 KW and 2X 30 KW) runs
on continuous basis i.e. 24X7 even during non production time as well.
Pretreatment(PT)
Oven Zone
Cathode Electro
deposition
Hot Air
Hot
water + + + + Cooling Zone
Spray Phosphating + + +
Air
LHS Pump RHS
30 KW Blower
Pump Burner

Bottom
45 KW 30 KW
Pump
Chilled
VFD Drive Heat water
Exchanger IN/Out

After:
After study and consultation with paint technology OEM, we have provided VFD’s in paint circulation
pumps of CED system. We reduced pump speed optimally during non production time like lunch break,
tea breaks, Sundays and public holidays etc while meeting the system circulation requirements, saved
energy substantially.
c Copyright, Confidential, Tata Motors Limited
Energy Saving : 1.3 Lakhs KWH/Year

7
 4.A.3 ENCON Project in Assembly Line #01 – Thermal
Energy reduction in the Baking Oven

ENCON : Baking oven energy consumption is significant in the Line #01. An ENCON on Reducing
thermal energy in baking oven at Assembly Line 1 by 10 % was taken.
Input Energy : LPG, Consumption- 22.5 Kg/ Eq. Vehicle

Baking Oven- Frame shop

Frames are fed into

baking oven

4.A.3 ENCON Project in Assembly Line #01 – Thermal

Energy reduction in the Baking Oven
Analysed Current Condition of Baking oven

Loading Vehicle:
Hump (Low floor bus), Loading qty per cycle- 2
Nos Can we increase number of
MCV Model: Loading qty per cycle- 3 Nos., LCV loading vehicle in each cycle
Model: Loading qty per cycle- 4 Nos.

Temperature to be maintained- 140 ° C Can we decrease baking temperature

Time for baking- 40-45 mints Questions – Can we decrease baking time
Three stations – Loading, Baking and
Unloading. (Length of each station of three15 Opportunities
Mtrs) of
improvements Can we reduce heat loss through Air curtain
Air curtain
Heat loss through air curtain Can we optimise conveyor speed

Conveyor operation for transferring frame

c Copyright, Confidential, Tata Motors Limited

8
 4.A.3 ENCON Project in Assembly Line #01 – Thermal
Energy reduction in the Baking Oven
A. Increased number of frame baked per cycle by increasing the
Can we increase number of
stack size
loading vehicle in each cycle
1. For LCV model stack size is increased from 4 to 6, Frames
2. For hump increased from 2 to 3 and stack to
3. For rest other model the stack size is of 4 be
loaded
4. For Multi model
i. 1 Hump & 4 LCV
ii. 1 Hump & 3 MCV (LPO55, LP52, LP42 & LP48)
iii. 1MCV& 4 LCV

Can we optimise conveyor speed Three stations – Loading, Baking and Unloading. (Length of each station of three15
Mtrs)
Increased conveyor speed (5.7 to 7.57 mts/min i.e. 7.89 mints to 5.25 mnts)
Time of Cycle reduced by 2.64 Minutes

Can we reduce heat loss through Air

curtain

Open Actuated shutter at

suction end suction end of
of Blower Blower

There was heat loss during baking operation through air curtain
blower suction opening.
Solution: We have provided a pneumatic actuated shutter for
closing blower suction opening while baking process in progress.

4.A.3 ENCON Project in Assembly Line #01 – Thermal

Energy reduction in the Baking Oven

Before After
LPG Consumption in FY 2017-18 LPG Comsumption in FY 2017-18
(Kg/Equivalent Vehicle) (Kg/Equivalent Vehicle)
24.4 24.8 30 24.423.524.2 28 % LPG Consumption
26 22.6 23.1 23.5 22.8 21.8
LPG (Kg/EQV)

21.922.121.121.6 reduction
25
LPG (Kg/EQV)

21.2 20.6 18.7

20 16.315.815.415.715.616.115.5
21
15
16 10
Oct-18
Sep-18

Nov-18

Jan-19
Feb-19
Mar-19
May-18
Apr-18

Jun-18
Jul-18
Aug-18

Dec-18

Months Months

Avg. Cons:- 22.5Kg/Equ. veh Avg. Cons:- 16.18 Kg/Equ. veh

Saving:-
The LPG consumption per Equi. veh. before improvement : Rs 1152 (22.43*51.36 )
The LPG consumption per Equi. veh. after improvements : Rs 831 (16.18*51.36)
Saving Per equivalent vehicle : Rs 321
Saving per annum (at rate of 9.5 Equ. frame per day) : Rs. 9,14,850 (321*9.5*25*12)

28 % LPG (Kg/EQV) Consumption reduction achieved against 10% target

9
 4.A. Energy saving projects implemented
in for last 3 years : 2016-17
Annual Annual Annual Thermal Saving Annual
Total Annual Investment
Electrical Electrical Thermal Cost Payback
No Title of Project Year Unit of Savings (Rs Made (Rs
Saving Cost Saving Saving (Rs (Months)
Quantity Measureme million) million)
(kWh) (Rs million) million)
nt
1 Reduction of Specific power consumption in CV-Cx & 2016-2017 18000 0.14 0 kgs 0 0.14 0.1 9
TCF line
2 Optimising use of Recon Interconnection 2016-2017 18000 0.14 0 kgs 0 0.14 0.45 39
3 Reduction of Specific power consumption through 2016-2017 18000 0.14 0 kgs 0 0.14 0.3 26
optimized running of compressors (mix)
4 Pressure optimisation in shops 2016-2017 27000 0.22 0 kgs 0 0.22 0.5 27
5 Optimised operation of FDV in F Block(Trim Line-1) 2016-2017 14000 0.11 0 kgs 0 0.11 0.3 33
6 Optimised running of service bay FDV blowers 2016-2017 30000 0.24 0 kgs 0 0.24 0 0
7 Optimised running hours of Eastern complex FDV 2016-2017 30358 0.24 0 kgs 0 0.24 0 0
blower.
8 Replacing of old celdac pads at Eastern Complex 2016-2017 8527 0.07 0 kgs 0 0.07 0.06 10
9 Reduction in slip % 2016-2017 10272 0.08 0 kgs 0 0.08 0.15 23
10 Optimising the capacity of AC system by giving 2016-2017 22491 0.18 0 kgs 0 0.18 0.15 10
alternate solution of cooling.
11 Running hours optimisation of AC plants 2016-2017 44660 0.36 0 kgs 0 0.36 0 0
12 Enhancing efficiency of AC System 2016-2017 9000 0.07 0 kgs 0 0.07 0.05 9
13 Stoppage of production on Saturdays 2016-2017 180000 1.44 0 kgs 0 1.44 0 0
14 Elimination of production activity in C shift 2016-2017 202500 1.62 0 kgs 0 1.62 0 0
15 Avoid Chain running of floor conveyors during idle 2016-2017 26460 0.21 0 kgs 0 0.21 0 0
time
16 Control of Building lights operation 2016-2017 200000 1.6 0 kgs 0 1.6 0.1 1
17 Control of process light in Work Areas 2016-2017 10000 0.08 0 kgs 0 0.08 0 0
18 Control of Overhead lights in the Coagulation area 2016-2017 13824 0.11 0 kgs 0 0.11 0 0
19 Optimization of 3 nos AC operation at PTED 2016-2017 43800 0.35 0 kgs 0 0.35 0 0
chemical Room
c Copyright, Confidential, Tata Motors Limited

4.A Energy saving projects implemented

in for last 3 years : 2016-17 37 Projects
Annual Annual Thermal Saving Annual
Annual Total Annual Investment
Electrical Cost Thermal Cost Payback
No Title of Project Year Electrical Saving Savings (Rs Made (Rs
Saving (Rs Unit of Saving (Rs (Months)
(kWh) million) million)
million) Quantity Measuremen million)
t
20 PT/ED line Batch Production 2016-2017 250000 2 0 kgs 0 2 0 0
21 No Production activity on Saturday-Paint Shop 2016-2017 150000 1.2 0 kgs 0 1.2 0 0
22 Optimization of pumps operation in PTED 2016-2017 235000 1.88 0 kgs 0 1.88 0 0
23 Empty skid storage system 2016-2017 38640 0.31 36083.33 kgs 1.08 2.98 2.2 9
24 Operational control of office air conditioner 2016-2017 32536 0.26 0 kgs 0 0.26 0 0
25 Optimize usage of lighting and man-coolers 2016-2017 12637 0.1 0 kgs 0 0.1 0 0
26 Optimize usage of lighting and man-coolers 2016-2017 10139 0.08 0 kgs 0 0.08 0 0
27 To optimize usage of air conditioning 2016-2017 6754 0.05 0 kgs 0 0.05 0 0
28 Optimize usage of compressed air on shop floor 2016-2017 7245 0.06 0 kgs 0 0.06 0 0
29 Power cost reduction thourgh various idea (like motor 2016-2017 18024 0.14 0 kgs 0 0.14 0.1 9
KW/Hr rating etc.)

30 Implementation of Magnetic Inductor System in the 2016-2017 0 0 33,000 kgs 1.0 2.45 0.07 0
Gas burner units

31 Installation of Heat Recovery System 2016-2017 0 0 1,88,417 kgs 5.7 13.93 5 4

32 Low Temperature Phosphate Chemical introduction 2016-2017 0 0 73,583 kgs 2.2 5.44 0 0
33 Pinion loading in modified pinion grids 2016-2017 0 0 19 kgs 0.00057 0.0005 0 0
34 Control of Overhead lights in the Booster Compressor 2016-2017 4380 0.03 0 kgs 0 0.03 0 0
35 To reduce power consumption of man coolers by 2016-2017 4500 0.04 0 kgs 0 0.04 0 0
optimizing the controls

36 To reduce power consumption of lighting by optimizing 2016-2017 4528 0.04 0 kgs 0 0.04 0 0
the controls

37 Pinion loading with new motified grid 2016-2017 4770 0.04 0 kgs 0 0.04 0 0

Total 13.63 331102 9.93 38.12 10 3.00

17,06,045
c Copyright, Confidential, Tata Motors Limited

10
 4.A Energy saving projects implemented
in for last 3 years : 2017-18
Annual Annual Thermal Saving
Annual Thermal Total Annual Investment
Annual Electrical Electrical Cost Payback
No Title of Project Year Cost Saving (Rs Savings (Rs Made (Rs
Saving (kWh) Saving (Rs (Months)
Unit of million) million) million)
million) Quantity
Measurement

To reduce the electrical energy consumption by 5% 1. 200 Kg

1 2017-2018 124379 0.995 0 kgs 0 0.995 0 0
CCHF/Eq. Veh by 5% 2. CWP machine by 5%
Reduction of energy consumption by minimising rework
2 2017-2018 9530 0.08 0 kgs 0 0.076 0 0
activities.
To reduce the energy consumption of office power
3 2017-2018 115.41 0.00 0 kgs 0 0.001 0 0
consumption by 5%

4 Reduction in trim assy. Line consumption by 5% 2017-2018 53.27 0.00 0 kgs 0 0.000 0 0

To reduce the energy consumption of manufacturing by 5% at

5 2017-2018 50.33 0.00 0 kgs 0 0.000 0 0
TCF line 2 & 3

6 Low Temperature Phosphate Chemical introduction 2017-2018 0 0.00 1901.524 kgs 0.072 0.072 0 0

7 Installation of Heat Recovery System 2017-2018 0 0.00 44000 kgs 1.672 1.672 5 35.9

Implementation of Magnetic Inductor System in the Gas

8 2017-2018 0 0.00 36000 kgs 1.368 1.368 1 8.8
burner units

9 Empty skid storage system 2017-2018 386400 3.09 0 kgs 0 3.091 8 31.1
10 Optimization of pumps operation in PTED 2017-2018 235000 1.88 0 kgs 0 1.880 0 0

11 PT/ED line Batch Production 2017-2018 250000 2.00 0 kgs 0 2.000 0 0

12 Control of Overhead lights in the Coagulation area 2017-2018 400000 3.20 0 kgs 0 3.200 0 0

13 Control of process light in Work Areas 2017-2018 10000 0.08 0 kgs 0 0.080 0 0

14 Control of Building lights operation 2017-2018 280000 2.24 0 kgs 0 2.240 0 0

15 Avoid Chain running of floor conveyors during idle time 2017-2018 26460 0.21 0 kgs 0 0.212 0 0

16 Elimination of production activity in C shift 2017-2018 225000 1.80 0 kgs 0 1.800 0 0

17 Stoppage of production on Saturdays. 2017-2018 200000 1.60 0 kgs 0 1.600 0 0

To reduce the energy consumption of office power
18 2017-2018 115.41 0.00 0 kgs 0 0.001 0 0
consumption by 5%
19 Reduction in trim assy. Line consumption by 5% 2017-2018 53.27 0.00 0 kgs 0 0.000 0 0
c Copyright, Confidential, Tata Motors Limited

4.A Energy saving projects implemented

in for last 3 years : 2017-18 38 Projects
Annual Annual Thermal Saving Annual Thermal Total Annual Investment
Annual Electrical Electrical Cost Payback
No Title of Project Year Cost Saving (Rs Savings (Rs Made (Rs
Saving (kWh) Saving (Rs Unit of (Months)
Quantity million) million) million)
million) Measurement
To reduce the energy consumption of manufacturing by 5% at
20 2017-2018 50.33 0.00 0 kgs 0 0.000 0 0
TCF line 2 & 3

21 Optimize usage of compressed air on shop floor 2017-2018 71535 0.57 0 kgs 0 0.572 0 0

22 Optimizing line running hours 2017-2018 220260 1.76 0 kgs 0 1.762 0 0

23 To optimize usage of air conditioning 2017-2018 104057 0.83 0 kgs 0 0.832 0 0

24 Optimize usage of lighting and man-coolers 2017-2018 392814 3.14 0 kgs 0 3.143 0 0

LED Street light replacement of 250W to 100W LED for load

25 2017-2018 48040 0.38 0 kgs 0 0.384 0.378 11.80
reduction.

26 Optimization of street lighting 2017-2018 9550 0.08 0 kgs 0 0.076 0 0

27 Astronomical Timer ON/OFF operation control of street light. 2017-2018 12525 0.10 0 kgs 0 0.100 0 0

28 Temperature Optimisation in Air conditioning system 2017-2018 25000 0.20 0 kgs 0 0.200 0 0

29 Running hours optimisation of AC plants 2017-2018 45000 0.36 0 kgs 0 0.360 0 0

Optimising the capacity of AC system by giving alternate

30 2017-2018 15000 0.12 0 kgs 0 0.120 0 0
solution of cooling.

31 Reduction in slip % 2017-2018 15000 0.12 0 kgs 0 0.120 0 0

32 Replacing of old celdac pads at Eastern Complex 2017-2018 35000 0.28 0 kgs 0 0.280 0.2 8.6

33 Optimised running hours of Eastern complex FDV blower. 2017-2018 25000 0.20 0 kgs 0 0.200 0 0

34 Optimised running of service bay FDV blowers 2017-2018 50000 0.40 0 kgs 0 0.400 0 0

35 Optimised operation of FDV in F Block(Trim Line-1) 2017-2018 15000 0.12 0 kgs 0 0.120 0 0

36 Pressure optimisation in shops 2017-2018 78982 0.63 0 kgs 0 0.632 0 0

Reduction of Specific power consumption through optimized

37 2017-2018 75000 0.60 0 kgs 0 0.600 0 0
running of compressors (mix)

38 Reduction of Specific power consumption in CV-Cx & TCF line 2017-2018 63437 0.51 0 kgs 0 0.507 0 0

Totalc Copyright, Confidential, Tata Motors Limited 3448407 27.6 81901.5 3.11 30.70 14.58 5.70

11
 4.A Energy saving projects implemented
in for last 3 years : 2018-19
Annual Annual Thermal Saving Annual
Annual Total Annual Investment
Electrical Thermal Cost Payback
No Title of Project Year Electrical Savings (Rs Made (Rs
Cost Saving Unit of Saving (Rs (Months)
Saving (kWh) million) million)
(Rs million) Quantity Measureme million)
nt
2018-
1 LED Migration project for Phase-01 2460000 19.7 0 kgs 0 19.7 12.60 7.7
2019
2018-
2 Optimization of compressed air energy 400000 3.2 0 kgs 0 3.2 0.2 0.8
2019
2018-
3 Elimination of C-Shift production 500000 4.0 0 kgs 4 8.0 0.5 0.8
2019
Low Temperature Phosphate Chemical 2018-
4 0 0.0 10000 kgs 0.42 0.4 0 0.0
introduction 2019
2018-
5 Empty Skid storage installation 0 0.0 25000 kgs 1.05 1.1 2 0.0
2019
2018-
6 Installation of Heat Recovery System 0 0.0 35000 kgs 1.47 1.5 0 0.0
2019
Implementation of Magnetic Inductor System in 2018-
7 0 0.0 3000 kgs 0.13 0.1 0 0.0
the Gas burner units 2019
2018-
8 Empty skid storage system 236400 1.9 0 kgs 0 1.9 0 0.0
2019
2018-
9 Optimization of pumps operation in PTED 200000 1.6 0 kgs 0 1.6 0 0.0
2019
2018-
10 PT/ED line Batch Production 200000 1.6 0 kgs 0 1.6 0 0.0
2019
Avoid Chain running of floor conveyors during idle 2018-
11 75000 0.6 0 kgs 0 0.6 0 0.0
time 2019
2018-
12 Stoppage of production on Saturdays. 100000 0.8 0 kgs 0 0.8 0 0.0
2019
To reduce the energy consumption of FDV in BIW 2018-
13 6832 0.1 0 kgs 0 0.1 0 0.0
by 5% 2019
To reduce the energy consumption of compressed 2018-
14 24075 0.2 0 kgs 0 0.2 0 0.0
air in BIW by 5% 2019
To reduce the energy consumption of CAB line in 2018-
15 148277 1.2 0 kgs 0 1.2 0 0.0
BIW by 5% 2019
To reduce the energy consumption of office 2018-
16 830489 6.6 0 kgs 0 6.6 0 0.0
power consumption by 5%
c Copyright, Confidential, Tata Motors Limited
2019
2018-
17 Reduction in trim assy. Line consumption by 5% 49462 0.4 0 kgs 0 0.4 0 0.0
2019

4.A Energy saving projects implemented

in for last 3 years : 2018-19 34 Projects
Annual Annual Thermal Saving Annual
Annual Total Annual Investment
Electrical Cost Thermal Cost Payback
No Title of Project Year Electrical Saving Savings (Rs Made (Rs
Saving (Rs Unit of Saving (Rs (Months)
(kWh) Quantity million) million)
million) Measurement million)
To reduce the energy consumption of manufacturing by
18 2018-2019 212140 1.7 0 kgs 0 1.7 0 0.0
5%
To reduce the energy consumption of office power
19 2018-2019 27 0.0 0 kgs 0 0.0 0 0.0
consumption by 5%
20 Reduction in trim assy. Line consumption by 5% 2018-2019 48 0.0 0 kgs 0 0.0 0 0.0
To reduce the energy consumption of manufacturing by
21 2018-2019 91 0.0 0 kgs 0 0.0 0 0.0
5% at TCF line 2 & 3
22 Reduction in power consumption of PE shop 2018-2019 32083 0.3 0 kgs 0 0.3 0 0.0
LED Street light replacement of 250W to 100W LED for
23 2018-2019 48000 0.4 0 kgs 0 0.4 0 0.0
load reduction.
24 Optimization of street lighting 2018-2019 9500 0.1 0 kgs 0 0.1 0 0.0
Astronomical Timer ON/OFF operation control of street
25 2018-2019 12500 0.1 0 kgs 0 0.1 0 0.0
light.
26 Temperature Optimisation 2018-2019 25000 0.2 0 kgs 0 0.2 0 0.0

27 Running hours optimisation of AC plants 2018-2019 50000 0.4 0 kgs 0 0.4 0 0.0
Optimising the capacity of AC system by giving alternate
28 2018-2019 15000 0.1 0 kgs 0 0.1 0 0.0
solution of cooling.
29 Replacing of old celdac pads at Eastern Complex 2018-2019 50000 0.4 0 kgs 0 0.4 0 0.0
Optimised running hours of Eastern complex FDV
30 2018-2019 25000 0.2 0 kgs 0 0.2 0 0.0
blower.
31 Optimised running of service bay FDV blowers 2018-2019 50000 0.4 0 kgs 0 0.4 0 0.0

32 Optimised operation of FDV in F Block(Trim Line-1) 2018-2019 15000 0.1 0 kgs 0 0.1 0 0.0
Reduction of Specific power consumption through
33 2018-2019 80000 0.6 0 kgs 0 0.6 0 0.0
optimized running of compressors (mix)
Reduction of Specific power consumption in CV-Cx & TCF
34 2018-2019 50000 0.4 0 kgs 0 0.4 0 0.0
line
Total 5904924 47.2 7.066 54.31 15.30 3.38

c Copyright, Confidential, Tata Motors Limited

12
 4.B.1 Innovation Project : Remote Switching of Forced
Draft Ventilation System (FDV) via Mobile GSM System

Back ground and Current Situation

Currently, utility services consume more than 30% of total power consumption of plant. And out of that a
major portion of it is consumed by shopfloor ventilation system i.e. FDV’ (Forced Draft Ventilation). Hence,
we worked out to find out the areas having maximum scope of optimisation of energy consumption and we
singled out Assembly Line 1 FDV system for energy optimisation.
Consumption Distribution of FDV's (KWh)
BIW Shop,
1,80,727 ,
7%

TCF Line 2 &

Cooled air is 3, 9,87,802
Blowers for forcing distributed inside , 38% Line 1 Shop,
Pre-filter Cooling
section media: Spray
cooled air in the shopfloor via 13,97,715 , 54%
shopfloor. ducts
System/
Cooling Pads

2018-19
Forced draft Ventilation Units 2016-17 2017-18
Till Feb’19
Plant KWh/Eq Vehicle 21 17 18
Line 2 & 3 KWh/Eq Vehicle 16 12 12
BIW Shop KWh/Eq Vehicle 14 11 12
Assembly Line 1 Shop KWh/Eq Vehicle 40 38 46

4.B.1 Innovation Project : Remote Switching of Forced

Draft Ventilation System (FDV) via Mobile GSM System

Concerns in present method : FDV Locations in Line 1

• One operator had to travel around 1
Km. for manually switching off all
FDVs(forced draft ventilations) in
western complex due to control panel
given at that particular location and
hence there is electrical energy
wastage due to travel time of around
20 mins.
ROOT CAUSE ANALYSIS
FDV’s run during non-
Why? production timings

Because there is a long delay in

Why? switching off all FDV’s

FDV’s are situated remotely and

operator has to walk around 1
Why?
km to switch off all FDV’s
Because all FDV’s have only
Why? localized operation facility and
no remote operation facility
Operator movement
• Total load of these FDV’s on our electrical system is about 1200 KW. This leads
to a wastage of electricity during non-production times (during lunch time and
shift over time)
• A robust operational control compatible with our operating schedule was
needed to avoid this wastage.

13
 4.B.1 Innovation Project : Remote Switching of Forced
Draft Ventilation System (FDV) via Mobile GSM System
Remote Switching FDVs
•This system is based on GSM (SMS based)
•It consists of 1 master block and 5 slave blocks (one at each electrical panel). SB 2 Switched off
•Slave blocks is installed at motor panel side while the master block is at control SB 2 Acknowledgement
room. (using authentication SIM only) Sent

SB 3 Switched off
SB 3
Acknowledgement
Sent
SB 4 Switched off
SB 4
Acknowledgement
Sent
F Block 1-5
Master Controller GSM modem F Block 1-5 Switched off
Slave controller
Acknowledgement
Sent
F Block 6-10
F Block 6-10 Switched off
Acknowledgement
Sent
1 Network Indicator:
Shows if mobile network
1 for operation is available
2 or not
2 FDV Status: Switched
on/off
3
3 Pushbutton for operation

4.B.1 Innovation Project : Remote Switching of Forced

Draft Ventilation System (FDV) via Mobile GSM System

Before After

Master Controller GSM modem Receiver controller

Issue: Action Taken:

Delay in switching off FDVs of SB2, SB3, SB4 & F block as Remote switching off FDVs by integrating off operation of FDV
operator has to travel around distance of one kilometer with GSM modem for switching off FDVs remotely from one
for switching off FDVs as switch off function is available at location and also message will be delivered to user that which
defined location only. This excess working of FDVs can be FDV has been switched off (wireless switching off operation is
avoided through remote switching off FDVs done through GSM modem to avoid cable cost and laying of
cable line)

Concerns:
1. Energy Loss:-Energy loss of 1.5lakh KWH/annum due to
running of FDV's during non-production hours.
2. Environment:- Increase in carbon footprint due to
energy loss
Benefits:
1.Energy saving :- Energy saving of 1.5lakh KWH/annum by
providing remote switching off FDVs
2. Cost Saving :- Recurring cost saving of Rs. 10.7 Lakhs/annum
3. Environment:- Reduction in carbon footprint
4. SMS escalation to user for information of FDV switch off

14
 4.B.2 Innovation Project : LED Migration Project - Solution
based design and World Class Quality Standards compliance

Innovative Projects: LED Migration Project

Evolution of Lighting

Why LED for LEDification Scope & Optimal design &

lighting Project Savings execution

LED, the best lighting option No expenses in
today LED- migration
▪ Energy efficient, higher
▪ OPEX model with M/s.
Lumens per Watts
Philips
▪ No Mercury-Environmental
▪ Supply of LED Lights,
friendly
Installation, Testing &
▪ No IR & UV emissions
Commissioning of LED lights
▪ Reduced heat generation
▪ 5 yrs extended warranty
Phase wise LEDification
project
▪ Entire plant in phases
▪ Better control schemes
▪ Reduction in consumption by
50% (Minimum)
WCQ- Lighting Standard
compliance
▪ Designed lighting wrt WCQ
Lighting standard
▪ Modifications - New wiring /
removal as per conditions
▪ Execution of the project without
disturbing the production
▪ Compliance to Safety standards

4.B.2 Innovation Project : LED Migration Project - Solution

based design and World Class Quality Standards compliance

Implementation Roadmap:
Innovative Projects: LED Migration Project Cowl shop
Before: 200-250 Lux After: 450-500 Lux
Phase-I Phase-II Phase-III 23 KW 8 KW
• Line-1 • TCF • Paint shop
• Street Lighting (EC • Other shops
& WC)
• BIW

2018-19 H2 2019-20 H1 2019-20 Q4

Annual Saving: INR 2.1 Cr Annual Saving: INR 1.4 Cr
Phase-I Delivered:
Before LED migration
969 KW (100%)
Expenses per annum :
36 Lac KWH & ₹ 287 Lac’s
Lighting : < WCQ Std.
Annual Saving : INR 0.7 Cr
After LED migration
372 KW (38%)
Expenses per annum:
11.6 Lac KWH & ₹ 93 Lac’s
Lighting : >/= WCQ Std.
Lighting simulations
Savings
Completed : Line#1,
597 KW (62%)
Street lights across
Savings per annum :
the plant,
24.3 Lac KWH & ₹ 200 Lac’s
WCQ - Lux Compliance
Lighting Consumption in KWH

Key Improvements Planned in Phase-II w.r.t. Phase-I:

Lighting Load in KW

✓ Occupancy sensor-based lighting design.

68%
✓ Circuit segregation area-wise and application-wise.
✓ Reduced project execution time period using off days & night
shifts .
✓ Dedicated on-site Safety Manager and Supervisors
✓ More quantity of cherry pickers for faster execution of Work-at-
height jobs.
✓ Two contractors deputed for site execution.

15
 4.B.2 Innovation Project : LED Migration Project - Solution
based design and World Class Quality Standards compliance
Conventional After Sensor installation
After LED Migration
Lighting system

Lighting Consumption in KWH

Lighting Load in KW
Occupancy
sensor

Sensor
Controlled
lighting
Group

Manual
Controlled
Lighting group

Horizontal
Deployment of
this innovation
Occupancy Sensor project across Tata
Power Consumption : 14 KW : 6.5 KW (Red 46.4%) : 6.5 KW (Red 46.4%) Motors Plants is in
Lux level : 125~200 : 250~450 (Inc 250% ) : 250~450 (Inc 250% )
Energy Cons.-Monthly: 6,300 : 2,925 KWH / 23,400 INR : 1,312 KWH / 10,400 INR (Red 78.2% ) progress
KWH / 50,400 INR-Annually : (Red 46.4% )
: 15,744 KWH / 1,25,952 INR
75,600 KWH / 6,04,800 INR : 35,100 KWH / 2,80,800 INR

5. Utilization of Renewable Energy Sources

➢ Compliance to RE 100 road map of Tata Group & Tata Motors
➢ RE Contribution road map

Annual Saving: Annual Saving: Annual Saving:

INR 68 Lacs INR 77 Lacs INR 430 Lacs

Power cost reduction

Inauguration of Phase-1 of Solar Power Plant Inauguration of 644 kWp Solar Power Plant in Tyre Yard-
2 MWp in Paint Shop on 8th Jan’ 2018 by Plant Head E.C. on 4th Mar 2019 by COO, Tata Motors
c Copyright, Confidential, Tata Motors Limited

16
 5. Utilization of Renewable Energy Sources

Installed Generation
Type of Onsite / % of Overall
Year Technology Capacity (Million
Energy Offsite Electrical Energy
(MWp) kWh)
2016-17 Solar PV Electrical Onsite 0.025 0.023822 0.058
2017-18 Solar PV Electrical Onsite 2.025 0.313893 0.714
2018-19 Solar PV Electrical Onsite 4.025 2.496101 5.412
Roof-top Locations Planned for Solar Plant Installation in Eastern Complex

Rear Axle Shop

Tyre Yard)
Trim Line-2&3) TCF Line-2&3 (South roof)
Paint Shop

TCF Line-2&3 (South roof)

BIW

Solar plant Locations completed in Phase-I: BIW, Paint Shop and TCF Line-2&3
Solar plant Locations completed in Phase-II: Tyre Yard, Rear Axle shop, TCF-2&3 (south roof) and Trim Line-2&3
c Copyright, Confidential, Tata Motors Limited

5. Utilization of Renewable Energy Sources

Key Features of Phase-II Solar Project

• Solar Modules of 330 Wp each instead

of 325 Wp used in Ph-I
• String inverters of capacity 60 kW
each instead of 40 kW used in Ph-I
• Safety Lifelines, Walkways and
Lightning Arrestors have been installed
on all solar roof-tops
Solar Modules on TCF roof top # Phase-I Solar Modules on Tyre Yard oof top
Solar Power Generation & Cost Saving : 4 MWp # Phase-II
80 (Ph-I & II)

70
57.03

69.91

Annual Saving Potential : FY 2019-20

67.87

60 Phase I & II : 4 MWp Solar power plant

44.41

50 Energy Generation : kWh 48 Lac's

Cost Saving : INR 145 Lac‘s
30.18

40
25.04

24.03
19.60

30
15.26
14.04

Annual Carbon
10.37

20
8.51

abatement
4.82
3.14

10 (Ph-I & II)

0 3,936
c Copyright, Confidential, Tata Motors Limited T CO2e

17
 6. Utilization of Waste Material as Fuel

Total Waste Generated

❖ Specific Waste Generation reduced by 14% in three years

6. Utilization of Waste Material as Fuel

Type of ETP Waste

Waste Carton Wood Plastic Used Oil
Sludge Thinner
Material

Utilization of waste as fuel (Alternative fuel utilization )

16-17 17-18 18-19
Name of the Quantity of Heat Value Name of the Quantity of Heat Value Name of the Quantity of Heat Value Waste fuel as %
Fuel Waste fuel (million kcal Fuel Waste fuel (million kcal Fuel Waste fuel (million kcal of total Energy
Used /Year) Used /Year) Used /Year) used
Carton 1450 5122.85 Carton 1890 6677 Carton 2157 7621 12.97
Wood 1100 3885 Wood 1315 4645 Wood 1361 4807 8.18
Plastic 72 773 Plastic 35 376 Plastic 97 1041 1.77
Waste thinner 4.3 27 Waste thinner 7.6 49 Waste thinner 6 38 0.07
Used Oil 51.4 442 Used Oil 45.5 391 Used Oil 56 482 0.82
ETP Sludge 69.7 263 ETP Sludge 72.5 273 ETP Sludge 86.5 326 0.56
Total
2747 732 3366 713 3764 846 24.36
Consumption

18
 7. Specific GHG Emission

GHG Emission Inventorization (Scope 1 + Scope 2)

Mitigation
Scope 2 GHG Intensity Total Reduction in
Scope 1 emissions Total Emission Production
Year emissions (T CO2 e/Eq. emission intensity
T CO2e T CO2e (Eq. Vehicle)
T CO2e Vehicle) since baseline year
T CO2e
2016-17 5579 30177 35756 96704 0.37 Baseline Year
2017-18 5765 33933 39698 124086 0.32 13%
2018-19 6499 34363 40862 159086 0.26 31%

Specific GHG Emission (Scope 1 + Scope 2)

The GHG emission sources considered in TCO2e / Eq. vehicle
each scope of the Carbon Inventory

Scope 1 Emissions Propane, LPG, Petrol and Diesel

Scope 2 Emissions Electricity
13%
19%

❖ Specific GHG emission reduced

by 31% in three years

c Copyright, Confidential, Tata Motors Limited

8. Green Supply Chain

Environmental Policy

Climate Change Policy

Environmental Procurement Policy

c Copyright, Confidential, Tata Motors Limited

19
 8. Green Supply Chain

Initiatives taken to reduce energy Consumption and carbon emissions reductions:

Saving in Q4 2017-18 Saving in FY 2018-19

S.No. Project description
(in Lakhs) (in Lakhs)

1 Manufacturing LPT 1615 frames at WC Frame Shop 19 77

2 Speed up Localization & SOB of BIW for 100% Parts 39 150

2 way strategy for Transportation of aggregates from
3 20 247
Pune
4 Axle Storage in Axle Shop 6.3 39
5 Local Manufacturing of FA Beams 30 180
6 Rear Axle manufacturing in Lucknow - 70
Tractor Trolley Instead of Trailers for Aggregate
7 4 48
Movement (Frames/Cowls)
Total Savings 118.3 811

❖ Abated carbon emissions by

14,286 TCO2 e in last two years

c Copyright, Confidential, Tata Motors Limited

8. Green Supply Chain

Proposals for Evaluation by Evaluation Committee

- Summary of evaluation committee meeting
S.No. Activity description Responsible Agency Remarks

Mr. Gunjan Choudhary Better Inventory Management & cost/

Consolidation Centre to be converted to
1 Mr. Umesh Tambolkar space optimization. Internal resources
3PL contracts
Mr. Vivek Saxena freed for higher value work

Average Rs. 1750/ axle in As Is

Rear Axle Manufacturing at Lucknow condition.
2 Mr. Gururaj Joshi
Plant Current cost Rs. 1000/ Axle (w/o wheel
hubs)

Local development at Lucknow for Front

Potential of approx. Rs. 300/ veh cost
3 Axle Beams through a dedicated Mr. Manish Goyal
reduction
supplier

Mr. Gunjan Choudhary/Mr.

Re-negotaition of rates for Annual Potential Reduction In VCC of
4 Umesh Tambolkar/ Mr. Vineet
Transportation of aggregates from Pune Approx Rs.88 lakhs
Bansal
+ BIW Parts
Marine Insurance for Tranportation to be
5 Management Decision
owned by the transporters

Discontinution of CNG models at Annual Potential Reduction In VCC of

6 Management Decision
Lucknow Approx Rs.716.06 Lakhs
c Copyright, Confidential, Tata Motors Limited

20
 8. Green Supply Chain

Environment friendly initiatives taken by Supply Chain team along with vendors & Suppliers
Idea Value Realized value Status of Cost &
S. NO Projects on Energy conservation (in Rs. Cr) (in Rs. Cr) Energy Audit by
2018-19 Energy Cell
1 Small Urea Solution packaging replaced with bulk storage tanks near filling
station to reduce HW and eliminate Plastic. 1.79 1.39 Done

2 Thinner reuse by replacing black paint thinner with Paint Shop Recycled Thinner
in Frame Painting 0.12 0.04 Done

3 Implementation of liquid activation which will reduce drainage of bath from 15

days to 6 months. 0.06 0.01 Done

4 Packaged Drinking water is replaced by own purified water 0.04 0.04 Done
5 Plastic Cups replaced with steel cups and paper cups 0.08 0.08 Done
6 Sand Paper optimization 0.01 0 Done
7 Thermocol replaced by recyclable material in battery packaging 0.05 0.03 Done
8 Elimination of plastic wrapping waste from door Post 0.15 0.9 Done
9 Paint tins being disposed through scrap Sell after cleaning. 0.2 0.1 Done
Total annual value of implemented ideas 4 2.6

S N0.: 1
❖ Abated carbon emissions by 2,632 TCO2 e in last two years

8. Green Supply Chain

Plastic Elimination & Thermocol Elimination
8.1 Plastic Elimination by replacing of Urea 1 KL Plastic Barrels with Bulk storage Tank
Earlier Condition - Implemented condition
1. Urea Solution was coming in 1000 lts plastic tank . 1.Urea Bulk Storage tank is established to eliminate plastic
2. 10 lts wastage noted every 1000 lts . barrels .
3. Polythene was used for wrapping of barrels. 2. Storage tank is refilled with tanker .
4. Empty plastic Barrels was disposed through 3.10 lts urea wastage is eliminated and having potential
hazardous waste disposal Process. saving of 10.8 lacs/annum
4. Use of Plastic barrel& polythene wrapper is eliminated
Urea coming in 1000 Lts plastic tank and having potential savings of 22 lacs/annum

Urea Bulk
Storage Tank
50 KL

8.2 Thermocol Elimination by replacing Thermocoal separator between battery stack layers
with recyclable separator Implemented condition
Earlier Condition – 1.Thermocol is replaced by
1. Thermocol was used as a separator recyclable separator
between layers of batteries in a battery 2. Thermocol usage in battery
stack. stack is eliminated.
2. Generation of waste Thermocol was not 3. Apart from being an ecofriendly
best environment practice . initiatives this project having
3. Lot of hip of Thermocol was accumulated potential saving of 5 lacs/annum Batteries package with
Batteries package with
c Copyright, Confidential, Tata Motors Limited Recyclable Separator
Thermocol Separator

21
 9. Teamwork, Employee involvement & Monitoring

Monthly Energy Consumption Daily Consumption Report Daily Shopwise Report Hourly Consumption Report-Plant
Report

Daily Energy Audit Report Daily Solar Generation Report Hourly Consumption Report-Shop

2019-20

2018-19
H1: Reporting of shop-wise energy
2017-18 consumption started on hourly basis.
H1: Reporting of entire plant’s energy H1: Reporting of working day’s and
Reporting of energy consumption on daily basis non-working day’s consumption
consumption of the plant and Daily Energy Audit Report (DEAR) separately for identification of
Awareness level

individual shops on fortnightly
and monthly basis
circulated across the plant to minimize
energy wastage.
H2: Reporting of entire plant’s and shop-
wise energy consumption on daily basis.
areas/processes of energy wastage.
H2: Automatic recording and reporting
of energy consumption through SCADA
for eliminating manual errors and
minimizing the time required for report
preparation. → WIP

9. Teamwork, Employee involvement & Monitoring

Review Frequency for Energy Monitoring
Hourly, Daily, Weekly, Monthly Quarterly, Half-yearly & Annually
➢ Daily Energy Consumption Performance Report: -Review by : Energy Auditors & EnMS Divisional Coordinators
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-à-vis target is also displayed at shop floor to increase the awareness within entire teams in the shop.
➢ Monthly Performance Report: - Review by : Energy Auditor & Dy GM
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.
Review by : Energy Auditor ,GM - Plant Head
➢ Monthly Report To Plant Head & Divisions: -
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 , 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.
Review by : Energy Auditor GM , Plant Head, Sr.
➢ Half yearly Performance Feed back to Plant Head & Divisions: - 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 , 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

22
 9. Teamwork, Employee involvement & Monitoring
Projects implemented through Kaizen

• Kaizens
• Suggestion
schemes
• Workshops
• Vendor meets
• Expo’s
• Challenging
projects
c Copyright, Confidential, Tata Motors Limited

10. Implementation of ISO 50001/Green Co/IGBC rating

We have Energy Management Cell in our Plant, Which initiates & Manages all sorts of Energy Conservation measures
across the Plant.
Energy Policy ISO 50001 Certificate

Team Structure – ISO 50001

Mr. Pramod Choudhary

Plant Head Lucknow 2013 2016 2019

BEE Certified Manager & Auditors : 4

MR -Lko Works ISO 50001 Certified Lead Auditors : 15
Mr. S.B. Matta

DH – Mr. S. B. Matta DH – Mr. V. Agrawal DH – Mr. S. N. Verma DH – Mr. U. Tauheed DH – Mr. R. K. Singh
Plant services Paint shop TCF BIW IBF

# DH – Divisional Head

DH – Mr. R. K. Singh DH –Mr. G. V. Joshi DH – Mr. A Chharia DH – Mr. Ankush Gour DH – Mr. R. K. Singh
Axle Shop Planning Materials & ADD HR CV- CX

c Copyright, Confidential, Tata Motors Limited

23
 10. Implementation of ISO 50001/Green Co/IGBC
rating
Events Planned for Energy Conservation Month Celebrations
➢ Energy Conservation Flag Hoisting
➢ Energy Conservation Pledge
➢ Slogan & Essay writing
➢Poster designing
➢Technical Seminars & Product Display
➢Energy Conservation Workshops
TARG
➢Expert Hour sessions
➢Energy Conservation Projects
➢Kaizen Events
➢Best Energy efficient shop competition
➢Best Energy efficient office competition
➢Energy Nuggets
➢Energy Conservation Competitions at schools
➢Awareness programs

10. Implementation of ISO 50001/Green Co/IGBC rating

Flag Hoisting Ceremony

Motivational speech on Energy Conservation by Plant head Introductory speech by Head-CPED

Motivational speech on Energy Conservation by Head- Signing Energy pledge by the employees
Technical Services

24
 10. Implementation of ISO 50001/Green Co/IGBC rating

Awareness Session at Vendor’s area

Location- M/s Gloria Engineering, Lucknow

10. Implementation of ISO 50001/Green Co/IGBC rating

c Copyright, Confidential, Tata Motors Limited

25
 10. Implementation of ISO 50001/Green Co/IGBC rating

Atlas Copco MD Surya ABB

international

Philips lighting Panama Solaire Encon

Foot fall of 915+ had in the workshop including, Employees, Vendors, Contractual work force, Service
providers, Deligates from NEDA etc. and learnt about energy conserving products and Renewable
energy related products.
c Copyright, Confidential, Tata Motors Limited

11. Other innovative Technologies implemented

Capital
Saving Potential Year of
Investment
S.No Details of Technology Absorption implementatio Photographs
n
KWH Rs. In Lakh

LED Migration of Line-01 & Street Lights 2430000 37 Million 2018-19

1

LED based down lights in offices corridores. 1500 0.36 2018-19

2

Solar Power Plant installation of 2MWP 300000 OPEX 2018-19

3

Use of Astro/Digital timers for street Lighting 28080 1.92 2018-19

4 optimization.

Smart Lighting project for Rear axle store area. 15744 0.05 2018-19
5

Development of Low cost automation for remote 133750 2.5 2018-19

switching of FDV's
6

Development of SCADA based Energy NA NA 2018-19

management system for better Energy
7
monitoring.

VFD & PID based operation of Cooling Towers. 2160 2.5 2018-19
8

26
 11. Other innovative Technologies implemented

Capital Year of
Saving Potential
S. No. Details of Technology absorption investment (Rs. Implementatio Photographs
(KWH)
In Lakhs) n

Use of Pneumatic shut off valve for controlling 79200 5.544 2017-18
1 leakage

Use of CSU for individual offices to comensate for 10800 0.756 2017-18
2
flexible work hours

Use of RTPFC panel for power factor correction 3142857 22 2017-18

3

Use of pump coro coat for improving pump 35200 2.464 2017-18
4 efficiency

Treated fresh air unit for SB-5 ofice 2720 0.1904 2017-18
5

11. Other innovative Technologies implemented

Capital Year of
S.No Details of Technology Absorption Saving Potential investment (Rs. implementatio Photographs
In Lakhs) n
Precision units in network and server rooms. 35000 6.2 2016-17
1

Use of Energy efficient motors in old AC and FDV 170000 22 2016-17

2
system.

Diode based Laser marking machine 130000 16.5 2016-17

3

Solar based power plant 225000 75 2016-17

4

FRP based Mancoolers at TCF & BIW 432000 1.8 2016-17

5

Solar Based Street lights and flashers. 4336.2 15.2 2016-17

6

Use of Energy efficient motors in old cooling 12600 1.5 2016-17

7
towers.

27
 12. Long term Vision on EE

Vision towards Energy Conservation by FY 2024-25 (5 years) Specific Power Consumption ( kWh/Eq. Veh.)
Focused areas for reducing SPC: 400 381 Target of SPC reduction Better
➢ Optimization of Production processes. by 50% in 5 years.
➢ Periodic Energy audits.
➢ Heat Pumps installation for Axle Shop. 300 294
SPC-Actual
➢ Optimization Operation for HVAC system, Street 250

kWh.Eq. veh
SPC-Target
Lighting & other utilities. 220
➢ Adopting new technologies such as Smart 200 194
Lighting,LED migration, VFD’s for Paint shop, ASU & 166
138
Chiller Units, Energy Efficient motors, Star rated 110
equipments etc. 100
➢ Implementation of IOT in Energy
Management system.
0
Renewable Energy Contribution ( % )
Target of achieving RE
100
100 contribution by 100% in 5 years.
Better
90 85
80
Focused areas for increasing
RE Share-Target 65 RE contribution:
70
60 RE Share-Actual 52
50 ➢ Open Access Solar Power Plant of 14 MWp.
%

40 ➢ Installation of 2MWp Roof Top Solar Power Plant in

30 Western Complex.
20 14 ➢ Solar Showcase projects like Solar walkways of 100KW in
10 5.2 various locations of Plant.
0.7
0 ➢ Adopting new Solar Equipment’s to reduce Fixed Utility
cost.

List of Awards and Recognitions

1) Tata Motors Lucknow won the have bagged “FIRST PRIZE” in
the Industrial Category of UP State Energy Conservation Award –
2018 competition
2) Tata Motors CVBU-Lucknow Plant bagged the prestigious
‘1st Runner-Up Prize’ – State Energy Conservation Award-2017
conducted by UP NEDA on 14th December at Lucknow
3) TATA Motors Lucknow Works has been awarded Second Prize NECA- 2016 UPSECA- 2017
in Automobile Sector at the prestigious National Energy
Conservation Award (NECA-2016) for the Excellence in
Energy conservation and its Management
4) Tata Motors Lucknow won the CII Excellent energy efficient award
2012 for the forth consecutive years. UPSECA
5) Tata Motors was awarded the Certificate of Commendation for
6) Significant Achievement 2018
at the CII-ITC Sustainability Awards 2011, BEE- 2011
for demonstrating excellent performance in
the area of sustainable development
7) Tata Motors Lucknow was conferred the
Second prize of National Energy Conservation
Award 2011 by BEE, Ministry of Power
8) Tata Motors CVBU-Lucknow Plant bagged
the most prestigious “ Excellent Energy Efficient
Unit Award-2009” conducted by CII on 19th & 20th of
Nov’2009 at Chennai.
9) Tata Motors CVBU-Lucknow Plant CII- SA-2011 CII- 2012
bagged the most prestigious
“ Excellent Energy Efficient Unit
Award-2010” conducted by CII
on 01st & 2nd Nov’2010 at Chennai
10) Tata Motors CVBU-Lucknow Plant
has bagged 1st Prize in National
Energy Conservation Award (NECA)-2010
under Automobile sector at New Delhi
on 14th Dec 2010
11) Tata Motors CVBU-Lucknow Plant
has received Silver award in automobile

BEE- 10,11,12 & 16 Sustainability Award – 2011

sector in 11th Global Tech 2010 Excellence
Award at Hyderabad on 12th Dec 2010.
UPSECA- 16,17 & 18 CII – 09,10,11,12,14, 16 GreenTech -09,10,11,12,13 & 14

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 Our Message through this presentation is
“Systematic, Sustainable, Continual improvements,
Knowledge sharing, Innovation, customer delight,
society centric and Team Work”
are the core pillars to make a plant as an

“Excellent Energy Efficient unit “

Thank You ! ! !

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