Lucas-TVS Limited Padi (Chennai

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UNIT PROFILE Lucas-TVS is a part of the TVS group. It was setup in 1961 as a joint venture of Lucas Industries plc, UK and TV Sundaram Iyengar and Sons at Chennai to manufacture automotive electrical systems.

Lucas-TVS has since inception has been maintaining its leadership as an automobile electrical systems supplier. Lucas-TVS manufactures a complete range of auto electrical products consisting of direct drive and gear reduction Starters, internal and external fan alternators, wipers, fan motors, blower motors, window lift motors, mechanical and electronic distributors, cam sensors, headlamps etc. The Auto Electricals division now has three plants situated in Padi, Pondicherry and Rewari. The Padi plant, which is the mother plant, manufactures all range of electrical automobile products. “ ENERGY MANAGEMENT POLICY “ We are committed to reduce the Specific Energy consumption (Electrical units per Equivalent Starter Unit) for our products comparing to the previous year consumption THROUGH 1. Maximize the Capacity utilization. 2. Fine tuning our Operations and Maintenance continuously to achieve the above goal. 3. Technology up-gradation with energy efficient processes and equipment’s. 4. People involvement – suggestion, Small group activities, quality improvement team and work team. 5. Waste elimination – reduce, reuse and recycling. 6. Promote awareness in every employee through training, competition and factory visit. 7. Large cell formation. 8. Process changes. 9. Setting up a system to continuously monitor the progress. 10. Comply with Energy legislation and Environment regulation. APPROACH • Training • Formation of Task force team • Cross functional Team • QC story • Employees involvement through 1. S.G.A. (Small Group Activities) – 60 2. Suggestion Scheme & Voluntary – 1200 / year 3. Work Teams (5S, TPM, ENVIRO, SAFETY) – 520 members 4. Energy Audits (Internal & External) 5. Quality Improvement Team (QIT).

Acts as a Facilitator in implementing the Encon Projects Interacts with core team members / cross functional team periodically to review the progress Constitutes a team of Auditors to monitor the Retainment of Improvements Presents the achievements to Top Management MONITORING AND REPORTING SYSTEM AWARENESS OF POTENTIAL SAVINGS TOP MANAGEMENT COMMITMENT TEAM FORMATION BY ENERGY MANAGER PRELIMINARY ENERGY AUDIT DETAILED ENERGY AUDIT IMPLEMENT QUICK HITS HIGH COST PROJECTS TRAINING MONITOR FEASIBILITY STUDIES Feed back to top management IMPLEMENT HIGHER COST MEASURES ENERGY CONSERVATION ORGANISATION .STRUCTURE ENERGY CONSERVATION ACHIEVEMENTS .ROLE OF ENERGY MANAGER • • • • • • Prepares Annual Plan with Targets and Budget Establish an Energy conservation cell within the firm with managements concern about the mandate and task of the cell.

23 Lacs with an investment of Rs.9 1.7 1.4 1.5 0.Energy Consumption per product (ESU) 3. 78 Lacs.0 0.3 1. ELECTRICAL SAVINGS.0 1.3 1 .5 2.During the period 2004 – 2006 Lucas – TVS Ltd has implemented around 33 projects through Engineering initiatives and workman’s suggestion schemes resulting into total saving of Rs.0 2.0 Plan 2. A.6 1.4 units per product in specific electrical energy consumption. 103. Screw compressor with variable frequency drive Compressor .5 1.0 ESU 1. This has been resulted in a reduction from 15 units per product to 13.

8.Saving = Rs. Replacing high consumption Air conditioners 15 Nos. BEFORE AFTER .37 Lakhs / Annum C.

Power consumption per annum = 0.BEFORE AFTER efore nstallation: B i Forced cooling tower with 15 HP jack water pump and 10HP blower motor for cooling the engine.90 Lakhs .

Introduction of Solid State Power source in place of MG set in Starter Performance testing rig efore nstallation: B i 25 HP motor is used as prime mover for DC Generator which produces 0 – 30 VDC for a load upto 2000 Amperes. Total heater capacity = 90 KW Power consumption per annum = 2.0 Lakhs / Annum Saving = Rs. Present heater capacity = 70 KW Power consumption per annum = 2.70 Lakhs units Operating cost = Rs 13.0 Lakhs / Annum After modifcation: i The utilized capacity is 50 Ton. The motor runs throughout the day. 4. efore modifcation: B i MG set power consumption per annum = 789900 units Operating cost = Rs.048 Lakhs units Operating cost = Rs 0. 36. 3.10 Lakhs units Operating cost = Rs 10.5 Lakhs / Annum After modifcation: i The IR Heater array was re-positioned to optimise heat radiation and 40 Heaters were removed retaining the operating efficiency of the plant. Motor capacity = 25 HP Power consumption per annum = 0. MG set to static high current power source.J.9 Lakhs / Annum After nstallation: i Solid State electronics controlled power supply that consumes power only during Testing is used. of heaters is 140 only.0 Lakhs / Annum L. Present motor capacity = 75 HP Power consumption per annum = 2. There is no increase in cycle time. Motor capacity = 100 HP Power consumption per annum = 3.66 Lakhs / Annum K. which is 20 seconds. Idle power consumption = 150 Watts Power consumption per annum = 0. Modification of Infra Red Heater array in Armature varnishing plant efore modifcation: B i The armatures are pre heated and cured in the conveyorised plant.73 Lakhs . Each heater is of 500 Watts.0 Lakhs units Operating cost = Rs 15. The actual load requirement is 50 Ton.78 Lakhs units Operating cost = Rs 3. The idle time power consumption is reduced by cutting off the 25HP motor and running only the 75HP motor. which has 180 IR heaters installed in the sides.0 Lakhs / Annum (For 2 machines) M. The power consumption during idle time is 150 Watts.5 Lakhs / Annum Saving = Rs.24 Lakhs / Annum Saving = Rs. Now the no. 3. The actual usage time is 10 Hours (900 yokes X 20 seconds X 2 shifts) the idle power consumption is 400 KWH. Elimination of ONE pump in 150 Ton Yoke Sizing Presses (two machines) efore modifcation: B i One 75 HP and One 25 HP motors are used to drive 3 Pumps for a capacity of 150 Ton operation.6 Lakhs units Operating cost = Rs 13. The average testing time per starter is 10 seconds and daily production per line is 400 nos.

Fuel savings Through solar water heater.06 Lakhs.25 Lakhs Savings = 0. 1. 36.67 Lakhs Savings = Rs.88 Lakhs After nstallation I After Power consumed by the compressor = 27000 units / annum Operating cost = Rs.After modification: Power consumed by Static power source = 14400 units / annum Operating cost per annum = Rs. N. 0. Elimination of High pressure compressed air for agitation by using High Volume Low Pressure blower at auto plating Before efore nstallation: B I Power consumed per annum = 40500 units Operating cost = 1.63 Lakhs / annum. LPG to SKO conversion .

37 •1999 •2004 SOLAR PLATE HEATING FOR CANTEEN 20 PLATES-2000 LTS.SKO RUN CANTEEN BOILERS •14 STEP CHANGES IN CANTEEN BOILER FUEL CONSERVATION •12 Work In Progress •12. CAPACITY FUEL (LPG)CONSERVATION • CONVERSION OF LPG FIRED BOILER INTO HSD FIRED REVOMAX BOILER. • PURPOSE : ENERGY SAVING HAZARD MINIMIZATION & OPERATIONAL .5.400 Lts/Annum •4 •2 LPG to HSD Conversion: • LPG:396 Kg/Day * Rs.89 •Savings / Annum .16.4 / Ltr.71 •6 PRE-HEATING THE FEED WATER BY SOLAR PLATES Savings: 32. •8 •7.in Rs.20/Kg • HSD:432 Lts/Day * Rs.50/Lt •0 •1997 •2.18 Lacs/Annum @ Rs.Lacs HSD to SKO CONVERTION •10 Savings: Rs.

Improvements: Exhaust system straight outlet chimney modified from canopy outlet.36 units per litre of Diesel After improvement SFC – 3. To reduce the suction air temperature the air inlet pipes were extended to three metres away from the engine where the air had nearly ambient temperature The return fuelTd8ooled through heat exchanger to reduce the temperature Before impr8oovement SFC – 3.9 units per litre of Diesel .

18 16 15 14.5 .

7 19 Specific Energy Consumption Trend 26 25 24 2 3 2 3 .5 13.4 14.5 1 3 .5 22 21 20 19 18 17 16 15 14 13 12 11 10 95-96 22 2 1 .0 5 18 0 2 '-0 3 163 9 .05 U N IT IN L AC S P R O D .3 4 15 0 4 '-0 5 193 1 3 .4 163 9.5 1 3 .34 9.5 170 163 162 160 8.5 180 13.7 150 0 0 '-0 1 0 1 '-0 2 162 9 .4 13 KWHR / ESU 96-97 97-98 98-99 99-00 00-01 01-02 02-03 03-04 04-05 05-06 Y E AR 06-07 .5 1 4 .E S U IN L AC S U N ITS /P R O D U C T 163 8 .5 20 19 SELF BENCH MARK (06 – 07) 18 17 16 15 1 4 .87 11.O VE R A L L E L E C T R IC A L E S U T R E ND 210 203 200 19 193 18 16 180 15 U N ITS in lacs 190 14.5 0 5 -'0 6 203 1 4 .8 7 16 0 3 '-0 4 180 1 1 .

2 5 K V A R B A N K S P o w e r Factor C a p acito r B an ks * Fix ed cap acito r b anks at su p p ly en d * M o re En erg y 1 8 N o s. 2.0 8.00 10.00 .F 1 9 95 . 1. 10 0 K V A R B A N K S 0.F 0.IM P R O V E M E N T IN P o w e r Facto r er IM P VE RO M EN TS P o w e r facto r C a p a cito r B an k s * C ap acito rs b an k d istrib b ased o n the lo ad cen ter.1 99 8 1 9 98 .2 00 3 2 0 03 . Tw K V A R B A N K S 2 N o s.97 P. Title of Energy saving project Implemented Introduction of VFD for compressor Replacement of in-efficient compressor Blower less cooling tower Savings In Lakhs 18.2 00 5 w 3 W ED ENERGY CONSERVATION FOR THE YEAR 2005 –2006 Sen.F 0. 3.00 9.37 Investment in Lacs 12. * C ap acito rs b an k p ro vid ed for th e lig hting * C ap acito rs p ro vid ed for the hig h p o w er m ach ines .995 P. 95 P. * A u to m atic P o w er facto r correctio n b ank in d ifferent lo catio ns * G a s filled cap acito rs/ N o los s 26 N os.0 10.

00 2.00 9. 5. .38 0.46 735. 6.2 1.00 4.00 . Ring main system for compressed Air system Replacement of in-1 ref479.6 7.4. Replacement of in-efficient A/C units Solar water heater for canteen Replacement of in-efficient transformer 1.50 4.

which involves recovering waste oil from waste coolant.2% oil against PCB norms of 15 % water & 85% Oil) Cost saving Rs 6. roducts and servces iv i p i . reservation and mrovement of the envronment by W L T P p i p i continually orienting our actites. High TDS water (RO Reject) disposal problem is solved.e at ucas VS are committed to rotection.TVS WASTE COOLANT WITH OIL FACTORY USED COOLANT OIL FROM FACTORY UNLOADING WATER TREATMENT PLANT LUCAS . It uses RO Rejection water & solar evaporation for coolant oil treatment process. No Chemical treatment is involved in this process whereas other companies are using chemicals & Electrolysis for treatment.8% water & 99. Meeting out the PCB standard to sell the oil for recycling (0.TVS WATER VALUE YARD OIL BARREL DISPOSAL TO RECYCLER WITH PAYMENT CPCB & TNPCB COOLANT OIL STORAGE AREA STORAGE TANK ( 2 LAKH LITRE CAPACITY ) STOPPED HAZARDOUS WASTE STORAGE AREA SOLID & POWDER SOLAR POND VALUE YARD ( FOR SALE OF OIL ) BEFORE IMPROVEMENT AFTER IMPROVEMENT . INNOVATIVE TECHNOLOGY FOR ENERGY AND ENVIRONMENT One of the remarkable contributions this year was the establishment of indigenous waste coolant treatment system.52 lacs per annum. Energy Consumption is very less SUN RO REJECTION WITH HIGH TDS OF 5000 RO PLANT FACTORY LUCAS . ENVIRONMENTAL AND ENERGY BENEFITS This process is unique one. thereby the quantity of waste disposed has reduced by 55% compared to last year. which was not done before by any of the industries in the world.

and also a new system for solder recovery from waste lead solder dross where by we can able to reduce the .Next to this the reduction of lead soldering stations for armatures by the introduction of brazing method.

Even though the production has increased by 1.Development of greenery. water conservation are our routine activites. rainwater harvesting.08 times compared to last we can able to reduce the water consumption .

ENERGY SAVINGS DUE TO THE SOLAR EVAOPARTION OF POND IN PLACE OF ELECTRICAL HEATING SYSTEM .

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