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COMPANY PROFILE
CII 18th National Award for Excellence in Energy Management 2017 Products
Light Commercial Vehicles Power Solution
Ashokleyland Seven
Manufacturing Plants in India
6000 kVA
Demand
Manpower (Associates +Exe) 832
Trees (no's) 4592
CII 2017 Energy Award 1 2
CII 2017 Energy Award
AL Energy Policy Hosur, Unit1 - Key Mile stone Energy Improvement National Bench marking - Kwh per Eq Vehicle National Bench Marking % Power cost to Mfg cost
1100 995 1042 1.00
963 962 0.93
905 909 953 0.82 0.83 0.83
Kwh per HECU - Hosur, Unit1 900 0.80 0.73
0.77
1300 0.67
Kwh /vehicle
700 0.60
1100
500 0.40
Horizontal deployment
Best practices
Waste elimination
Plant wise: Reviewed daily Shopwise wise: Reviewed daily Shift wise / Component wise (Daily) 2014-15 2015-16 2016-17
• Best among the best 70 projects selected from • Best among the best 70 projects selected from all
Plants and Corporate functions Plants.
• Hosur 1 team won One ‘Gold’ award in support • Hosur 1 won One ‘Bronze’ award in
Service category , One ‘Silver ’ award in support Manufacturing support services category & One
services category and Two ‘Merit’ awards ‘Super Merit’ awards and Four ‘Merit’ awards • Best among the best 72 projects selected from
Plants and Corporate functions
Current Power consumption pattern • Plant-wise, Aggregate-wise reports circulated to Line Executives & Section Heads
Daily
Weekly • Power cost discussed weekly with the respective Sponsors and Process owners.
Significant Energy saving Projects – FY14-15 Significant Energy saving Projects – FY15-16
Energy saving through Energy saving through Kwh Cost reduction through
Energy saving through air circuit
5 0.70 2.60 3 10 introduction LED/CFL/T5 lamps 10.70 6.40 20 5 introduction LED/CFL/T5 lamps 1.00 1.10 11.2 10 introduction of alternate power 1.00 1.10 11.2
modification in 2areas.
in 13areas/650nos. in 9areas/132nos. source.
Rs In Lakhs
ROI
Rs In Lakhs
ROI Elimination of Stress Relieving Process in Cylinder Head by introduction of multi-stage milling
S.no Project Description S.no Project Description Saving
Saving Month Investment Month
Investment
/Annum /Annum Before : After:
Stress Relieving in Stress Relieving in By modifying the milling
Energy regeneration during 6
Turbo Ventilator for shop
7.50 13.00 7 Muffle Furnace Muffle Furnace process and introducing
1 0.00 10.00 0 ventilation
Engine testing .
semi-finish milling, furnace
1
operation is eliminated.
Rocker Face Rough Milling Rocker Face Rough Milling
2 1
Energy saving through rough Daylight improvement in
2 0.00 0.04 0 7 8.00 19.50 5
Block weight reduction Machine shops Combustion Face Rough Milling Combustion Face Rough Milling
3 2 Number of
head / year 41,209
Rocker Face Finish Milling
4 Combustion Face Semi finish Milling
Energy saving through 3
8 introduction LED/CFL/T5 lamps 9.70 9.10 13 Combustion Face Finish Milling 1 Reduction
3 Rainwater for Process 0.50 1.70 4
in shop floor/Office/Street light
5
4
Combustion Face Finish Milling 1 Kwh / Cy 13
Valve Guide Valve Seat Parent Bore head
6
Rocker Face Finish Milling
5
Energy saving through Injector mouth profile forming Savings in
4 introduction of VFD and 2.50 6.00 5 9
Derating of Man cooler to air
11.30 8.10 17 7
Combustion Face Finish Milling 1 & Valve Kwh / year 5.33 lakhs
circulator 6 Guide Valve Seat Parent Bore
Derating of Motors 8
Valve Guide Valve Seat Insitu Bore
Injector mouth profile forming , Valve Guide
Cost Saving
Energy saving through Heat
Introduction of Heat pumps 9
Combustion Face Dowel 7 valve seat insitu bore & Combustion dowel
Rs. In lakhs 37.50
5 3.80 4.40 10 10 instead of Electrical heaters in 24.90 18.90 16
recovery in screw compressor
High intensive washing M/Cs Power consumed 38 Kwh / Cy head Power consumed 25 Kwh / Cy head
CII 2017 Energy Award 11 CII 2017 Energy Award 12
8/30/2017
Introduction of General purpose CNC route machining using guide pad tooling and multi spindle Honing SPM by
Introduction of Tempering in Induction Hardening SPM and eliminated conventional tempering furnace
replacing conventional SPM route machining.
Before : Line Bore
After : Before : After :
Finish Boring
Honing By introducing multi-spindle By combining tempering
machines and combining operation along with
Line Bore Induction Tempering Straightening
Head
Finish Boring
Honing processes in a single Induction
Straightening hardening process,
Head face Hardening Furnace Operation Hardening Tempering
Dowel
finish
Line Bore machine, energy per Furnace Operation Eliminated tempering
Milling Head Face Tempering
Finish Boring Honing Dowel & Finish
Line Bore Multistage
component reduced. furnace.
Finish Boring Honing
Milling
Number of CS
/ year 50,587
Number of
block / year 44,267
Reduction in
Reduction in Kwh per CS 1.00
Kwh / Cy 6.90
block
Savings / year
Total Units Kwh in lakhs 0.51
saved / year 3.05
in lakhs
Power consumed 2.6 units Per Camshaft Power consumed 1.6 units Per Camshaft Cost Saving
Rs. in lakhs 3.54
Power consumed 16.4 units Per Block Power consumed 9.5 units Per Block Cost Saving
Rs. In Lakhs 21.38
CII 2017 Energy Award 13 CII 2017 Energy Award 14
HEAT PUMP for Power Intensive washing machines: Waste HEAT RECOVERY from Rotary Screw Compressor
Before : After : Before : After :
Electric heaters replaced Recovered heat utilized
by HEAT PUMP in four in two washing
washing machines & Heat Exchanger machines at P15 Engine
realized 60% reduction in Retrofit unit fixed with
Assembly
existing air
fluid heating by maintain Compressor + piping
same tempt & Quality
parameters Number /
year
31,410
Heating load in KW 72 x 4 = 288 Heat pump load in KW 10 X 4 = 40 Reduction / year Kwh 6.34 L
Savings Rs in lakhs 44.39 Units saved
Fluid Tempt in Deg C 52 Fluid Tempt in Deg C 52 / year
Kwh 0.19 in L
Investment Rs in lakhs 32.50
Kwh per Engine 38.83 Kwh per Engine 25.50 Washing Tempt : 55 Deg C Washing Tempt : 55 Deg C
Payback in years 1.37 Electrical heaters : 48 KW Cost Rs 1.30 L / Yr
Reduction in Kwh NIL Reduction in Kwh 13.33 Pump : 1 KW Savings ROI – 2.5 years
Units / per Aggregate : 2.01 Units / per Aggregate : 1.42
CII 2017 Energy Award 15 CII 2017 Energy Award 16
8/30/2017
SMED Set-up change time reduction in Cy block machining to minimize idle running
Cylinder Block Casting modifications to optimize casting weight and machining allowance in rough machining
Before : After :
Before : After : Idle running of auxiliary
Rough casting weight equipment minimized
optimized 3% by reducing during setup change
the stock in specified areas. through single minute die
change concept (SMED).
Number of
block / year
8,200 No of setup
24
change / Year
Guide for B-platform Guide for A-platform Position for B-platform Position for A- platform
Reduction
Kwh / Cy block 1.57 knob Reduction in
259
Kwh / Change
Movable
guide
Savings Kwh
in lakhs / Yr
0.13 Kwh savings /
6,216
Fixed guide year
Power consumption in rough Power consumption in rough
machining (13 m/cs) per Cy Block machining (13 m/cs) per Cy block Savings Rs in Savings Rs in
lakhs
0.90 Setup change time in 12 m/cs : 300 Min Setup change time in 12 m/cs : 12 Min 0.44
: 12.48 Kwh : 10.91 Kwh Consumption : 270 Kwh Consumption : 11 Kwh lakhs
Energy saving through Pressure regulating valve Energy saving by interconnecting two production lines through ring main distribution
Before : After : Before : After :
High Pressure air converted
to low pressure air through Two Engine Assembly &
pressure regulating valve & Machine interconnected with
unloading of compressors ring main & avoided running
hours minimized. of dedicated Air compressor
No of working
days 300 No of Working
days 300
Reduction in
Kwh / WD 200 Reduction in
Kwh / WD 300
Savings in Kwh
/ year in lakhs 0.60 Savings in
Kwh / year 0.9 lakh
Savings Rs in
lakhs / year
4.20 Savings per
year Rs 6.30 L
Power consumption / day = 3000 units Power consumption / day = 2700 units
CII 2017 Energy Award 19 CII 2017 Energy Award 20
8/30/2017
Elimination of Painting in Engine Assembly by introduction of pre-painted casting without Heat treatment H Engine: SEC – kWh/HECU P15: Engine SEC – kWh/HECU
Before : After : 9.1 % 15.9%
The increase in FY 15-16 is due to
In line with change in heat 1329
MS 1 renovation , decrease in 1152
Casting Red Oxide Casting Enamel volume, increase in Engine R&D 1000 1026
Painting Painting
treatment process, Painting 1207 863
1013 966 activity (BS4) & introduction of
operation Eliminated in Spare parts warehouse.
Machining Machining Engine Assembly
Operation Operation
FY13-14 FY14-15 FY15-16 FY16-17
FY13-14 FY14-15 FY15-16 FY16-17
No of Engines /
Painting Painting Year 54,000 Energy Conservation @ Hosur 1 (Approach adopted)
Fixed Power: kWh/month in lacs
Reduction in Kwh • More focus on renovation of process manufacturing
Engine Assembly Engine Assembly / Engine 0.60 3.20 3.19
2.90 • Introduction of Energy Efficient Products
2.55
Reduction / year • Lean manufacturing
Kwh in lakhs
0.32
• Synergy between Production plan & Energy Management
Power consumption by paint booth Painting Eliminated
Cost Saving Rs.
: 0.60 Kwh / Engine In lakhs / Yr
2.27 • Total Employee involvement
FY13-14 FY14-15 FY15-16 FY16-17
CII 2017 Energy Award 21 CII 2017 Energy Award
• Energy cross audits by other plants (Horizontal deployment) 22
Reduction of SEC – H Engine & P15 Engine Specific Energy Reduction Trend
H-Block SEC – kWh/HECU H-Head SEC – kWh/HECU H-Engine Assy SEC – kWh/HECU Diesel Litre / HECU Water KL / HECU
30 26 12 11 20%
1013 23% 15% 16% 20
37% 10 9
10
918 785 1467 1441 20 16 8
10 Good 8
784 619 669
H Engine 1207 10 6
4
Production 0
2
2013-14 2014-15 2015-16 2016-17
Lines 0
2013-14 2014-15 2015-16 2016-17
Cutting & Hyd Fluids Litre / HECU
15 13 13 12
FY14-15 FY15-16 FY16-17 FY14-15 FY15-16 FY16-17 FY14-15 FY15-16 FY16-17 33%
10 8 Good
5
P15-Block SEC – kWh/HECU P15-Head SEC – kWh/HECU P15-Engine Assy SEC – kWh/HECU
0
932 933
13% 670 669 22% 17% 2013-14 2014-15 2015-16 2016-17
741
691
523 614 Compressed Air Unit / HECU
P15 Engine
200
Production 156 166
816 130
Lines 150
109
100
Turbo Ventilators in M/C shop – 150 numbers installed Natural light through transparent sheets in M/C shop Common Pooling arrangement for Associates Bio Diesel for Canteen Boiler Carbon foot print
enabled the reduction of number of people
coming in bikes • HSD procurement
Base Line 13-14 FY14-15 FY15-16 FY16-17
minimized
Rainwater Harvesting - 500 KL Utilized for Process 9 KL Solar Water Heater for canteen dish washing Diesel Consumption reduction in Forklift by introducing a Tractor-Trailer arrangement which can hold up to 10 engines & by bringing stores and
Shop2 E Assy dispatch areas near to the shop floor
Consumption in KL
SH-1 M/C shop 54.0 6.7%
54.7
52.0
Re use in KL
7,467
In M tonne
3.0 7500
Reuse in kL
Effluent Treatment Plant : Treated water to RO, 25 KLD Per 55000
7,260
54,339 54,188 6,900
day for Industrial use. 2.0 1.5 1.6
54000
7000
Coolant / Cutting Oil Recovery Oil Soaked Waste Industrial RO Reject Reuse
6 100 82 4500 4,440
81
4.00 4400 4,350
Re use in KL
Sewage treatment Plant : Treated water to Garden 180 KLD 4
Reuse in kL
2.80 48
In MT
50 4300 4,260
Per day. 2 1.48
4200
0 0 4100
2014-15 2015-16 2016-17 2014-15 2015-16 2016-17 2014-15 2015-16 2016-17
Canteen Food
Waste Coolant Recovery : Recovery, Recycle & Reuse of wastage to
3 KL of coolant per month. Biogas
Food Waste Crusher Digester Cooking
CII 2017 Energy Award 31 CII 2017 Energy Award 32
8/30/2017
Capex Payback
Sl.no Description PDC Remarks
Regeneration of Energy during Engine testing – Implemented at PNR & Technical (Rs in L) in years
Center (nine test beds completed & six in pipe line). 1
Replace Reciprocating air comp by Energy efficient
13.75 1 Jul'17 Completed
screw comp.
Introduce on line MOTOR ANALYTICS in power System improvement , Completed in air
2 0.75 … Jul'17
4.12 MW Roof top solar power plant Horizontally deployed at other four plants & intensive motors like Air comp, blowers & pumps compressors
Hosur Management development center. Implementation of energy saving products in
3 10.00 8 Jun'17 Completed
works office renovation.
4 Eliminate CH stress relieving process in line 1 60.00 3.50 Sep'17 Work in progress
Heat pumps for power intensive washing machines implemented at other three
plants (six no completed & nine no in pipe line). 5 Heat Pump for P15 two ROBO washing machines 18.00 1 Dec'17 Horizontal deployment
Journey from …