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IIT - Kanpur- CVBU LUCKNOW
Lucknow Plant
Bombay Chamber of Commerce and Industry
The Ruby || 4th Floor NW 29 || Senapati Bapat Marg (Tulsi Pipe Road)Dadar (W) || MUMBAI ndash 400 028 || INDIA
Tel (D) + 91 22 6120 0227 (B) 6120 0200 Ext- 227 Fax 6120 0213
Email csrbombaychambercom Website wwwbombaychambercom
IIT - Kanpur- CVBU LUCKNOW
Dr Matta Srinu BabuDy General Manager amp Energy AuditorTata Motors Ltdsrinubabumattatatamotorscom97940 52525
Professional experience 23+ years Larsen amp Toubro Ltd Aditya Birla Group Mahindra amp Mahindra Ltd General Motors and Tata Motors Ltd
Academic qualifications PhD in Smart Grid ApplicationsM Tech in Power SystemsB Tech in Electrical amp Electronics Engineering
MBA in Sales amp ServicesSix Sigma ndash Black Belt
Energy Auditor EA 5021 ISO 50001 Lead Auditor
Profile
Energy Efficiency related recognitions National Energy Conservation Awards from BEE India CII Energy Excellence award from CII GBCBest Energy Efficiency Award from UPNEDA Govt of UP
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Sources of Energy
Sources of Renewable Energy
Sun
Wind
Hydro-electricity
Geothermal
Ocean currents
Biomass
Sources of Non Renewable Energy
Coal
Oil
Natural Gas
Nuclear
IIT - Kanpur- CVBU LUCKNOW
Many villages still need remain un-electrified Quality power not available
Energy shortage ndash Capacity Vs Deficit
httpswwwibeforgindustrypower-sector-
indiainfographic
Source of data
IIT - Kanpur- CVBU LUCKNOW
Energy Dilemma
IIT - Kanpur- CVBU LUCKNOW
Energy Deficit Solution
IIT - Kanpur- CVBU LUCKNOW
Energy Consumption
IIT - Kanpur- CVBU LUCKNOW
55 units
Energy Consumption
IIT - Kanpur- CVBU LUCKNOW
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
4
6
8
10
12
14
16
18
2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021
Year
Tariff (
Rs kW
h)
Tariff
Disruptive technology advancements
Indigenisation
Materiality Scale
Feed in Tariffs
0020406080
100120140160180
2008
2009
2010
2011
2012
2013
2014
2015
2016
2017
2018
2019
2020
Timeline
RsK
Wh RsKWh from
grid(Commercial))RsKWh fromgrid(Residential))RsKWh fromgrid (Industrial)
RsKWh fromsolar
Grid parity for commercial consumption as well
Source of data MNRE Assuming an yearly reduction of cost of solar power by 5 and increase in retail prices for grid electricity by 3
IIT - Kanpur- CVBU LUCKNOW
Dr Matta Srinu BabuDy General Manager amp Energy AuditorTata Motors Ltdsrinubabumattatatamotorscom97940 52525
Professional experience 23+ years Larsen amp Toubro Ltd Aditya Birla Group Mahindra amp Mahindra Ltd General Motors and Tata Motors Ltd
Academic qualifications PhD in Smart Grid ApplicationsM Tech in Power SystemsB Tech in Electrical amp Electronics Engineering
MBA in Sales amp ServicesSix Sigma ndash Black Belt
Energy Auditor EA 5021 ISO 50001 Lead Auditor
Profile
Energy Efficiency related recognitions National Energy Conservation Awards from BEE India CII Energy Excellence award from CII GBCBest Energy Efficiency Award from UPNEDA Govt of UP
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Sources of Energy
Sources of Renewable Energy
Sun
Wind
Hydro-electricity
Geothermal
Ocean currents
Biomass
Sources of Non Renewable Energy
Coal
Oil
Natural Gas
Nuclear
IIT - Kanpur- CVBU LUCKNOW
Many villages still need remain un-electrified Quality power not available
Energy shortage ndash Capacity Vs Deficit
httpswwwibeforgindustrypower-sector-
indiainfographic
Source of data
IIT - Kanpur- CVBU LUCKNOW
Energy Dilemma
IIT - Kanpur- CVBU LUCKNOW
Energy Deficit Solution
IIT - Kanpur- CVBU LUCKNOW
Energy Consumption
IIT - Kanpur- CVBU LUCKNOW
55 units
Energy Consumption
IIT - Kanpur- CVBU LUCKNOW
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
4
6
8
10
12
14
16
18
2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021
Year
Tariff (
Rs kW
h)
Tariff
Disruptive technology advancements
Indigenisation
Materiality Scale
Feed in Tariffs
0020406080
100120140160180
2008
2009
2010
2011
2012
2013
2014
2015
2016
2017
2018
2019
2020
Timeline
RsK
Wh RsKWh from
grid(Commercial))RsKWh fromgrid(Residential))RsKWh fromgrid (Industrial)
RsKWh fromsolar
Grid parity for commercial consumption as well
Source of data MNRE Assuming an yearly reduction of cost of solar power by 5 and increase in retail prices for grid electricity by 3
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Sources of Energy
Sources of Renewable Energy
Sun
Wind
Hydro-electricity
Geothermal
Ocean currents
Biomass
Sources of Non Renewable Energy
Coal
Oil
Natural Gas
Nuclear
IIT - Kanpur- CVBU LUCKNOW
Many villages still need remain un-electrified Quality power not available
Energy shortage ndash Capacity Vs Deficit
httpswwwibeforgindustrypower-sector-
indiainfographic
Source of data
IIT - Kanpur- CVBU LUCKNOW
Energy Dilemma
IIT - Kanpur- CVBU LUCKNOW
Energy Deficit Solution
IIT - Kanpur- CVBU LUCKNOW
Energy Consumption
IIT - Kanpur- CVBU LUCKNOW
55 units
Energy Consumption
IIT - Kanpur- CVBU LUCKNOW
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
4
6
8
10
12
14
16
18
2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021
Year
Tariff (
Rs kW
h)
Tariff
Disruptive technology advancements
Indigenisation
Materiality Scale
Feed in Tariffs
0020406080
100120140160180
2008
2009
2010
2011
2012
2013
2014
2015
2016
2017
2018
2019
2020
Timeline
RsK
Wh RsKWh from
grid(Commercial))RsKWh fromgrid(Residential))RsKWh fromgrid (Industrial)
RsKWh fromsolar
Grid parity for commercial consumption as well
Source of data MNRE Assuming an yearly reduction of cost of solar power by 5 and increase in retail prices for grid electricity by 3
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Sources of Energy
Sources of Renewable Energy
Sun
Wind
Hydro-electricity
Geothermal
Ocean currents
Biomass
Sources of Non Renewable Energy
Coal
Oil
Natural Gas
Nuclear
IIT - Kanpur- CVBU LUCKNOW
Many villages still need remain un-electrified Quality power not available
Energy shortage ndash Capacity Vs Deficit
httpswwwibeforgindustrypower-sector-
indiainfographic
Source of data
IIT - Kanpur- CVBU LUCKNOW
Energy Dilemma
IIT - Kanpur- CVBU LUCKNOW
Energy Deficit Solution
IIT - Kanpur- CVBU LUCKNOW
Energy Consumption
IIT - Kanpur- CVBU LUCKNOW
55 units
Energy Consumption
IIT - Kanpur- CVBU LUCKNOW
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
4
6
8
10
12
14
16
18
2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021
Year
Tariff (
Rs kW
h)
Tariff
Disruptive technology advancements
Indigenisation
Materiality Scale
Feed in Tariffs
0020406080
100120140160180
2008
2009
2010
2011
2012
2013
2014
2015
2016
2017
2018
2019
2020
Timeline
RsK
Wh RsKWh from
grid(Commercial))RsKWh fromgrid(Residential))RsKWh fromgrid (Industrial)
RsKWh fromsolar
Grid parity for commercial consumption as well
Source of data MNRE Assuming an yearly reduction of cost of solar power by 5 and increase in retail prices for grid electricity by 3
IIT - Kanpur- CVBU LUCKNOW
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Sources of Energy
Sources of Renewable Energy
Sun
Wind
Hydro-electricity
Geothermal
Ocean currents
Biomass
Sources of Non Renewable Energy
Coal
Oil
Natural Gas
Nuclear
IIT - Kanpur- CVBU LUCKNOW
Many villages still need remain un-electrified Quality power not available
Energy shortage ndash Capacity Vs Deficit
httpswwwibeforgindustrypower-sector-
indiainfographic
Source of data
IIT - Kanpur- CVBU LUCKNOW
Energy Dilemma
IIT - Kanpur- CVBU LUCKNOW
Energy Deficit Solution
IIT - Kanpur- CVBU LUCKNOW
Energy Consumption
IIT - Kanpur- CVBU LUCKNOW
55 units
Energy Consumption
IIT - Kanpur- CVBU LUCKNOW
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
4
6
8
10
12
14
16
18
2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021
Year
Tariff (
Rs kW
h)
Tariff
Disruptive technology advancements
Indigenisation
Materiality Scale
Feed in Tariffs
0020406080
100120140160180
2008
2009
2010
2011
2012
2013
2014
2015
2016
2017
2018
2019
2020
Timeline
RsK
Wh RsKWh from
grid(Commercial))RsKWh fromgrid(Residential))RsKWh fromgrid (Industrial)
RsKWh fromsolar
Grid parity for commercial consumption as well
Source of data MNRE Assuming an yearly reduction of cost of solar power by 5 and increase in retail prices for grid electricity by 3
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Sources of Energy
Sources of Renewable Energy
Sun
Wind
Hydro-electricity
Geothermal
Ocean currents
Biomass
Sources of Non Renewable Energy
Coal
Oil
Natural Gas
Nuclear
IIT - Kanpur- CVBU LUCKNOW
Many villages still need remain un-electrified Quality power not available
Energy shortage ndash Capacity Vs Deficit
httpswwwibeforgindustrypower-sector-
indiainfographic
Source of data
IIT - Kanpur- CVBU LUCKNOW
Energy Dilemma
IIT - Kanpur- CVBU LUCKNOW
Energy Deficit Solution
IIT - Kanpur- CVBU LUCKNOW
Energy Consumption
IIT - Kanpur- CVBU LUCKNOW
55 units
Energy Consumption
IIT - Kanpur- CVBU LUCKNOW
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
4
6
8
10
12
14
16
18
2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021
Year
Tariff (
Rs kW
h)
Tariff
Disruptive technology advancements
Indigenisation
Materiality Scale
Feed in Tariffs
0020406080
100120140160180
2008
2009
2010
2011
2012
2013
2014
2015
2016
2017
2018
2019
2020
Timeline
RsK
Wh RsKWh from
grid(Commercial))RsKWh fromgrid(Residential))RsKWh fromgrid (Industrial)
RsKWh fromsolar
Grid parity for commercial consumption as well
Source of data MNRE Assuming an yearly reduction of cost of solar power by 5 and increase in retail prices for grid electricity by 3
IIT - Kanpur- CVBU LUCKNOW
Sources of Energy
Sources of Renewable Energy
Sun
Wind
Hydro-electricity
Geothermal
Ocean currents
Biomass
Sources of Non Renewable Energy
Coal
Oil
Natural Gas
Nuclear
IIT - Kanpur- CVBU LUCKNOW
Many villages still need remain un-electrified Quality power not available
Energy shortage ndash Capacity Vs Deficit
httpswwwibeforgindustrypower-sector-
indiainfographic
Source of data
IIT - Kanpur- CVBU LUCKNOW
Energy Dilemma
IIT - Kanpur- CVBU LUCKNOW
Energy Deficit Solution
IIT - Kanpur- CVBU LUCKNOW
Energy Consumption
IIT - Kanpur- CVBU LUCKNOW
55 units
Energy Consumption
IIT - Kanpur- CVBU LUCKNOW
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
4
6
8
10
12
14
16
18
2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021
Year
Tariff (
Rs kW
h)
Tariff
Disruptive technology advancements
Indigenisation
Materiality Scale
Feed in Tariffs
0020406080
100120140160180
2008
2009
2010
2011
2012
2013
2014
2015
2016
2017
2018
2019
2020
Timeline
RsK
Wh RsKWh from
grid(Commercial))RsKWh fromgrid(Residential))RsKWh fromgrid (Industrial)
RsKWh fromsolar
Grid parity for commercial consumption as well
Source of data MNRE Assuming an yearly reduction of cost of solar power by 5 and increase in retail prices for grid electricity by 3
IIT - Kanpur- CVBU LUCKNOW
Many villages still need remain un-electrified Quality power not available
Energy shortage ndash Capacity Vs Deficit
httpswwwibeforgindustrypower-sector-
indiainfographic
Source of data
IIT - Kanpur- CVBU LUCKNOW
Energy Dilemma
IIT - Kanpur- CVBU LUCKNOW
Energy Deficit Solution
IIT - Kanpur- CVBU LUCKNOW
Energy Consumption
IIT - Kanpur- CVBU LUCKNOW
55 units
Energy Consumption
IIT - Kanpur- CVBU LUCKNOW
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
4
6
8
10
12
14
16
18
2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021
Year
Tariff (
Rs kW
h)
Tariff
Disruptive technology advancements
Indigenisation
Materiality Scale
Feed in Tariffs
0020406080
100120140160180
2008
2009
2010
2011
2012
2013
2014
2015
2016
2017
2018
2019
2020
Timeline
RsK
Wh RsKWh from
grid(Commercial))RsKWh fromgrid(Residential))RsKWh fromgrid (Industrial)
RsKWh fromsolar
Grid parity for commercial consumption as well
Source of data MNRE Assuming an yearly reduction of cost of solar power by 5 and increase in retail prices for grid electricity by 3
IIT - Kanpur- CVBU LUCKNOW
Energy Dilemma
IIT - Kanpur- CVBU LUCKNOW
Energy Deficit Solution
IIT - Kanpur- CVBU LUCKNOW
Energy Consumption
IIT - Kanpur- CVBU LUCKNOW
55 units
Energy Consumption
IIT - Kanpur- CVBU LUCKNOW
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
4
6
8
10
12
14
16
18
2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021
Year
Tariff (
Rs kW
h)
Tariff
Disruptive technology advancements
Indigenisation
Materiality Scale
Feed in Tariffs
0020406080
100120140160180
2008
2009
2010
2011
2012
2013
2014
2015
2016
2017
2018
2019
2020
Timeline
RsK
Wh RsKWh from
grid(Commercial))RsKWh fromgrid(Residential))RsKWh fromgrid (Industrial)
RsKWh fromsolar
Grid parity for commercial consumption as well
Source of data MNRE Assuming an yearly reduction of cost of solar power by 5 and increase in retail prices for grid electricity by 3
IIT - Kanpur- CVBU LUCKNOW
Energy Deficit Solution
IIT - Kanpur- CVBU LUCKNOW
Energy Consumption
IIT - Kanpur- CVBU LUCKNOW
55 units
Energy Consumption
IIT - Kanpur- CVBU LUCKNOW
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
4
6
8
10
12
14
16
18
2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021
Year
Tariff (
Rs kW
h)
Tariff
Disruptive technology advancements
Indigenisation
Materiality Scale
Feed in Tariffs
0020406080
100120140160180
2008
2009
2010
2011
2012
2013
2014
2015
2016
2017
2018
2019
2020
Timeline
RsK
Wh RsKWh from
grid(Commercial))RsKWh fromgrid(Residential))RsKWh fromgrid (Industrial)
RsKWh fromsolar
Grid parity for commercial consumption as well
Source of data MNRE Assuming an yearly reduction of cost of solar power by 5 and increase in retail prices for grid electricity by 3
IIT - Kanpur- CVBU LUCKNOW
Energy Consumption
IIT - Kanpur- CVBU LUCKNOW
55 units
Energy Consumption
IIT - Kanpur- CVBU LUCKNOW
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
4
6
8
10
12
14
16
18
2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021
Year
Tariff (
Rs kW
h)
Tariff
Disruptive technology advancements
Indigenisation
Materiality Scale
Feed in Tariffs
0020406080
100120140160180
2008
2009
2010
2011
2012
2013
2014
2015
2016
2017
2018
2019
2020
Timeline
RsK
Wh RsKWh from
grid(Commercial))RsKWh fromgrid(Residential))RsKWh fromgrid (Industrial)
RsKWh fromsolar
Grid parity for commercial consumption as well
Source of data MNRE Assuming an yearly reduction of cost of solar power by 5 and increase in retail prices for grid electricity by 3
IIT - Kanpur- CVBU LUCKNOW
55 units
Energy Consumption
IIT - Kanpur- CVBU LUCKNOW
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
4
6
8
10
12
14
16
18
2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021
Year
Tariff (
Rs kW
h)
Tariff
Disruptive technology advancements
Indigenisation
Materiality Scale
Feed in Tariffs
0020406080
100120140160180
2008
2009
2010
2011
2012
2013
2014
2015
2016
2017
2018
2019
2020
Timeline
RsK
Wh RsKWh from
grid(Commercial))RsKWh fromgrid(Residential))RsKWh fromgrid (Industrial)
RsKWh fromsolar
Grid parity for commercial consumption as well
Source of data MNRE Assuming an yearly reduction of cost of solar power by 5 and increase in retail prices for grid electricity by 3
IIT - Kanpur- CVBU LUCKNOW
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
4
6
8
10
12
14
16
18
2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021
Year
Tariff (
Rs kW
h)
Tariff
Disruptive technology advancements
Indigenisation
Materiality Scale
Feed in Tariffs
0020406080
100120140160180
2008
2009
2010
2011
2012
2013
2014
2015
2016
2017
2018
2019
2020
Timeline
RsK
Wh RsKWh from
grid(Commercial))RsKWh fromgrid(Residential))RsKWh fromgrid (Industrial)
RsKWh fromsolar
Grid parity for commercial consumption as well
Source of data MNRE Assuming an yearly reduction of cost of solar power by 5 and increase in retail prices for grid electricity by 3
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
4
6
8
10
12
14
16
18
2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021
Year
Tariff (
Rs kW
h)
Tariff
Disruptive technology advancements
Indigenisation
Materiality Scale
Feed in Tariffs
0020406080
100120140160180
2008
2009
2010
2011
2012
2013
2014
2015
2016
2017
2018
2019
2020
Timeline
RsK
Wh RsKWh from
grid(Commercial))RsKWh fromgrid(Residential))RsKWh fromgrid (Industrial)
RsKWh fromsolar
Grid parity for commercial consumption as well
Source of data MNRE Assuming an yearly reduction of cost of solar power by 5 and increase in retail prices for grid electricity by 3
IIT - Kanpur- CVBU LUCKNOW
4
6
8
10
12
14
16
18
2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021
Year
Tariff (
Rs kW
h)
Tariff
Disruptive technology advancements
Indigenisation
Materiality Scale
Feed in Tariffs
0020406080
100120140160180
2008
2009
2010
2011
2012
2013
2014
2015
2016
2017
2018
2019
2020
Timeline
RsK
Wh RsKWh from
grid(Commercial))RsKWh fromgrid(Residential))RsKWh fromgrid (Industrial)
RsKWh fromsolar
Grid parity for commercial consumption as well
Source of data MNRE Assuming an yearly reduction of cost of solar power by 5 and increase in retail prices for grid electricity by 3
Chart2
Sheet1
Sheet1
Sheet2
Sheet3
PLF | 25 | ||||||||||||||||
Subsidy | 125 | Rs kWh | |||||||||||||||
Year | MW Com | Cum MW | Annual Energy Mus | Annual Subsidy (Crores) | |||||||||||||
2011 | 350 | 350 | 7665 | 958125 | |||||||||||||
2012 | 400 | 750 | 16425 | 2053125 | |||||||||||||
2013 | 500 | 1250 | 27375 | 3421875 | |||||||||||||
2014 | 500 | 1750 | 38325 | 4790625 | |||||||||||||
Total Subsidy | 1122375 | ||||||||||||||||
458 | of annual fuel subsidy | ||||||||||||||||
Normal Tariff | 4 | PLF | 25 | ||||||||||||||
Year | Annual Subsidy | Net Tariff | MW Added | Cumulative MW | New Energy Mus | New Subsidy | Tariff | ||||||||||
2010 | 5256 | 12 | 200 | 0 | 438 | 5256 | 16 | ||||||||||
2011 | 10512 | 12 | 200 | 0 | 438 | 5256 | 16 | ||||||||||
2012 | 23652 | 12 | 500 | 0 | 1095 | 1314 | 16 | ||||||||||
2013 | 36792 | 12 | 500 | 0 | 1095 | 1314 | 16 | ||||||||||
2014 | 45552 | 8 | 500 | 0 | 1095 | 876 | 12 | ||||||||||
2015 | 54312 | 8 | 500 | 0 | 1095 | 876 | 12 | ||||||||||
2016 | 60882 | 6 | 500 | 0 | 1095 | 657 | 10 | ||||||||||
2017 | 67452 | 6 | 500 | 0 | 1095 | 657 | 10 | ||||||||||
2018 | 712845 | 35 | 500 | 0 | 1095 | 38325 | 75 | ||||||||||
2019 | 75117 | 35 | 500 | 0 | 1095 | 38325 | 75 | ||||||||||
2020 | 77307 | 2 | 500 | 0 | 1095 | 219 | 6 | ||||||||||
2021 | 79497 | 2 | 500 | 0 | 1095 | 219 | 6 | ||||||||||
6076155 |
2010 | 2010 | |||||||
2011 | 2011 | |||||||
2012 | 2012 | |||||||
2013 | 2013 | |||||||
2014 | 2014 | |||||||
2015 | 2015 | |||||||
2016 | 2016 | |||||||
2017 | 2017 | |||||||
2018 | 2018 | |||||||
2019 | 2019 | |||||||
2020 | 2020 | |||||||
2021 | 2021 |
Sheet1
Sheet1
Sheet2
Sheet3
PLF | 25 | ||||||||||||||||
Subsidy | 125 | Rs kWh | |||||||||||||||
Year | MW Com | Cum MW | Annual Energy Mus | Annual Subsidy (Crores) | |||||||||||||
2011 | 350 | 350 | 7665 | 958125 | |||||||||||||
2012 | 400 | 750 | 16425 | 2053125 | |||||||||||||
2013 | 500 | 1250 | 27375 | 3421875 | |||||||||||||
2014 | 500 | 1750 | 38325 | 4790625 | |||||||||||||
Total Subsidy | 1122375 | ||||||||||||||||
458 | of annual fuel subsidy | ||||||||||||||||
Normal Tariff | 4 | PLF | 25 | ||||||||||||||
Year | Annual Subsidy | Net Tariff | MW Added | Cumulative MW | New Energy Mus | New Subsidy | Tariff | ||||||||||
2010 | 5256 | 12 | 200 | 0 | 438 | 5256 | 16 | ||||||||||
2011 | 10512 | 12 | 200 | 0 | 438 | 5256 | 16 | ||||||||||
2012 | 23652 | 12 | 500 | 0 | 1095 | 1314 | 16 | ||||||||||
2013 | 36792 | 12 | 500 | 0 | 1095 | 1314 | 16 | ||||||||||
2014 | 45552 | 8 | 500 | 0 | 1095 | 876 | 12 | ||||||||||
2015 | 54312 | 8 | 500 | 0 | 1095 | 876 | 12 | ||||||||||
2016 | 60882 | 6 | 500 | 0 | 1095 | 657 | 10 | ||||||||||
2017 | 67452 | 6 | 500 | 0 | 1095 | 657 | 10 | ||||||||||
2018 | 712845 | 35 | 500 | 0 | 1095 | 38325 | 75 | ||||||||||
2019 | 75117 | 35 | 500 | 0 | 1095 | 38325 | 75 | ||||||||||
2020 | 77307 | 2 | 500 | 0 | 1095 | 219 | 6 | ||||||||||
2021 | 79497 | 2 | 500 | 0 | 1095 | 219 | 6 | ||||||||||
6076155 |
Sheet1
Sheet2
Sheet3
Sheet2
Sheet3
Sheet3
Chart2
CAGR
NPV
IRR
EMI
Sheet2
Sheet2
Sheet1
World energy by fuel type
Grid Parity in India
Grid Parity in India
Sheet3
IIT - Kanpur- CVBU LUCKNOW
Wind Power
IIT - Kanpur- CVBU LUCKNOW
bull A report on the Solar power says that the utilization of just 5of existing solar energy would suffice the Global energyrequirement
bull Technology is readily available for generation of Power heating cooking etc applications For industries an immediate thoughtof putting up solar power plant of rated capacity and solarconcentrator for Canteen Guest houses offices remotelylocated load centers would reduce the energy bill besidesprotecting the environment
Solar Power
IIT - Kanpur- CVBU LUCKNOW
Bio-Gas
Wastersquos of animals trees rice husk etc can be utilizedfor the generation of gases which inturn utilized forheating cooking applications
Bio-Diesel
As the cost of petroleum products touching the sky an immediate thought on alternate fuels is the top most order of demand today Proven technology for Bio-diesel from Jetropa amp Pengenia etc is readily available With these in line the demand on Petroleum product would come down by 25-35 In APCW premises all unused area can be utilized for Jetropa amp Pengenia cultivation inturn to sell in the market or for mines-vehicle like Dozer Dumper shovel etc application
Bio Fuels
IIT - Kanpur- CVBU LUCKNOW
Simple schematic
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustriesIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
We have Energy Management Cell in our Plant Which initiates amp Manages all sorts of Energy Conservation measuresacross the Plant
Energy Management System
Mr Pramod ChoudharyPlant Head Lucknow
DH ndash Mr S B MattaPlant services
MR -Lko Works Dr SB Matta
DH ndash Mr V AgrawalPaint shop
DH ndash Mr S N VermaTCF
DH ndash Mr U TauheedBIW
DH ndash Mr R K SinghIBF
DH ndash Mr R K SinghAxle Shop
DH ndashMr G V JoshiPlanning
DH ndash Mr A ChhariaMaterials amp ADD
DH ndash Mr Ankush GourHR
DH ndash Mr R K SinghCV- CX
Team Structure ndash ISO 50001
DH ndash Divisional Head
ISO 50001 CertificateEnergy Policy
2013 2016 2019
IIT - Kanpur- CVBU LUCKNOW
ENERGY MANAGEMENT SYSTEM ndash An Overview
TOP MANAGEMENT COMMITMENT
STAFF COMMITMENT
ENERGY AUDIT
ACTION PLAN
MONITORING amp TARGET SETTING
REVIEW amp DEVELOP PROFILE
LONG PAY BACK PROJECTS
IIT - Kanpur- CVBU LUCKNOW
Preliminary Energy audit
Detailed Energy audit
Plant Coordinator
GO AHEAD
Energy savings discussion and presentation
GO AHEAD for Implementation
Energy savings monitoring and interim report to Energy Mgmt Cell
Acceptance of Proposal
Submission of Techno commercial proposal
Team formation
Energy Management CellEnCon Implementation Methodology
copy Copyright Confidential Tata Motors Limited
Innovation Digital Transformation Project Planning amp Operation
3D layout of Manufacturing Line Process flow for Digital transformation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
44
Collaboration
Training
Layout
Maintenance
2D drawings using Auto Cad 3D digital Factory
No single platform for discussions and decision making among various stake-holder
Virtual Factory encouraged different agencies to work in more collaborate manner
Traditional training methods such as classroom teaching using PPTs and OJT
3D Digital Work-Instruction videos along with Quality and Safety awareness
Maintenance based on Real time data
Preventive Maintenance Breakdown Maintenance based on schedule
Collection of information from individual machines and preparing reports
Connected Machines IPMS Mobile App online quality parameter monitoring
Traditional Method Digital Method
Technology Landscape ndash before and after implementation
Factory Set-up time reduced
Issue identified and resolved before physical installationconstruction
Better Visualization of the process enables operator to learn fast
Down-time of machines reduced thusimproving OEE
Better tracking and control quality and Mc parameters Faster information exchange
Transformation Impact
No Virtual Simulation Expensive Physicals only for very critical processes
Virtual Simulation of Critical Processes helped to identified Potential issues
Short Project Lead time Saving on rework cost and time
Simulation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
Sales~10 Increase throughbull Levelled Productionbull Improvement in Customer Experience
Cost
Customer Complaint
Project Time
Quality
Employee Engagement
~15 Reduction through bull Inventory Optimizationbull Warranty Cost reductionbull COPQ Reduction
~15 Reduction through bull Robust Process Designbull Resulting Reliability of Product
~25 Reduction throughbull Better Project
ManagementWith Use of Simulations Avoided Rework
~25 Improvement throughbull Connected Equipment
bull Avoiding Defect Passing
~10 Improvement throughbull Layout Improvementbull Process Automation
bull Ergonomics amp Safety improvement
Quantitative Benefits and Awarded in CII Digital Transformation Meet
Innovation Digital Transformation Project Planning amp Operation
IIT - Kanpur- CVBU LUCKNOW
Teamwork Employee involvement amp MonitoringDaily Consumption Report
Daily Energy Audit Report
Daily Shopwise Report
Daily Solar Generation Report
Hourly Consumption Report-Plant
Hourly Consumption Report-Shop
Monthly Energy Consumption Report
Awar
enes
sle
vel
2017-18
Reporting of energy consumption of the plant and
individual shops on fortnightly and monthly
basis
2018-19
H1 Reporting of entire plantrsquos energy consumption on daily basis
Daily Energy Audit Report (DEAR) circulated across the plant to minimize
energy wastageH2 Reporting of entire plantrsquos and shop-wise energy consumption on
daily basis
2019-20
H1 Reporting of shop-wise energy consumption started on hourly
basisH1 Reporting of working dayrsquos
and non-working dayrsquos consumption separately for
identification of areasprocesses 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
ENERGY CONSUMPTION 2019-20Figures in KWH
FACTORY Dec-19 Jan-20 Feb-20 Mar-20EASTERN COMPLEXBIWBIW Cab 30103 29885 42825 7097BIW Cowl 17657 16650 20104 7438FDV 0 0 0 0COMP 13691 12555 15960 4155BIW Office others 3459 2845 3824 599Distribution Losses 5737 5686 8235 3398Total 70648 67620 90949 22688PAINT SHOPPTED 276243 270240 58056 125761Paint 199896 182651 252332 55852COMP 69201 71042 191305 32740Paint others 33456 34243 71892 16336Distribution Losses 52586 55324 32462 45001Total 631382 613501 606048 275690TCFAssly 84210 101803 92831 23993Trim Assly 12468 17988 15117 4219FDV 0 0 0 0Compressor 38154 41387 42232 13080TCF officeothers 19581 18255 15958 13560Distribution Losses 14262 16490 17609 10428Total 168676 195923 183747 65281
Rear Axle and Line-45 17252 16260 4125 1830Logistics Centre 14904 25247 20629 9615RSO 5597 9370 8390 8445
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
GSM Based Smart Control of Shop Floor Ventilation System
Concerns in present method bull One operator has to travel around 1 Km for manually switching off all FDVs in western complex due to control panel given at that particular
location and hence there is electrical energy wastage of 5137 KWHmonth due to travel time of around 20 mins
Present process Moving to
switching off SB1 FDV
(0 mins)
Moving to switching off SB2 FDV
(5 mins)
Moving to switching off F Block FDV
(15 mins)
Moving to switching off
SB4 FDV(20 mins)
Moving to switching off SB3 FDV
(10 mins)
Blower amp Control panel
FDV Locations in Line 1
EnCon Projects
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
LCA Solution
bull Remote switching off FDVs by integrating off operation of FDV with GSMmodem from one location Also message will be delivered to user thatwhich FDV has been switched off (wireless switching off operation is donethrough GSM modem to avoid cable cost and laying of cable line)
Benefits amp Horizontal Scope 1Energy saving - Energy saving of 41096 KWHannum by providing remote switching off FDVs
2 Cost Saving - Recurring cost saving of Rs 328 lakhsannum3 Environment- Reduction in carbon footprint (reduction of 337 tonne of CO2annum by energy saving)
4 SMS escalation to user for information of FDV switch off5No laying out of wire is required as it is wireless communication with help of GSM modem6 Horizontal deployment of GSM based control for other process machines of assembly line 12 and 3
Solution Cost-Rs 328 Lacs for all 5 FDVs
Remote switching off SB3 FDV (Instantly)
Control panel- Remote Switching off SB1 FDV
Remote switching off SB2 FDV (Instantly)
Remote switching off F Block FDV (Instantly)
Remote switching off SB4 FDV (Instantly)
GSM Based Smart Control of Shop Floor Ventilation System
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Innovative Projects LED Migration Project
Evolution of Lighting
LEDification Project
No expenses in LED- migration
OPEX model Lights Installation Testing amp
Commissioning of LED lights 5 yrs extended warranty
Scope amp Savings
Phase wise LEDification project
Entire plant in phases Better control schemes Reduction in consumption by
50 (Minimum)
Optimal design amp execution
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
Why LED for lighting
LED the best lighting option today
Energy efficient higher Lumens per Watts
No Mercury-Environmental friendly
No IR amp UV emissions Reduced heat generation
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Conventional Lighting system After LED Migration
Power Consumption 14 KW Lux level 125~200
Energy Cons-Monthly 6300 KWH 50400 INR-Annually 75600 KWH 604800 INR
65 KW (Red 464) 250~450 (Inc 250 )
2925 KWH 23400 INR (Red 464 )
35100 KWH 280800 INR
65 KW (Red 464) 250~450 (Inc 250 )
1312 KWH 10400 INR (Red 782 ) 15744 KWH 125952 INR
Occupancy Sensor
After Sensor installation
Occupancy sensor
Sensor Controlled
lightingGroup
Manual Controlled
Lighting group
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Slide Number 55
- Slide Number 56
- Slide Number 57
- Slide Number 58
- Slide Number 59
- Slide Number 60
- Slide Number 61
- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
Total cost | 55177211 | 14176846 | 107850 | 184319 | ||||||||||||||||||
World Resi | 485 | 46 | Profit Margin | 15 | 1530 | 19 | 360 | |||||||||||||||
OECD Resi | 286 | 27 | Sales Tax | 2505507 | 685912 | 5024 | 8654 | |||||||||||||||
144 | 65143189 | 17429501 | 137703 | 225000 | ||||||||||||||||||
57 | ||||||||||||||||||||||
43 | Selling price to Customer | 62637682 | 16743589 | 132679 | 216346 | |||||||||||||||||
14 | ||||||||||||||||||||||
14 | 1191 | 1533 | 1871 | 1480 | ||||||||||||||||||
Total cost | 11863 | 22545 | 3104 | 05896907216 | ||||||||||||||||||
Sales Tax | 526 | 951 | 161 | 1971 | ||||||||||||||||||
Profit Margin | 1480 | 1020 | 1575 | 729 | ||||||||||||||||||
Selling price to Customer | 14500 | 26026 | 3860 | |||||||||||||||||||
New SP | 13974 | 25075 | 3699 | |||||||||||||||||||
Margin | 15 | 10 | 16 | |||||||||||||||||||
Margin | 1 ton of oil equivalent | 418 Giga Joule | ||||||||||||||||||||
10^6 | 181 | 201 | 218 | 234 | 249 | |||||||||||||||||
27 | 30 | 32 | 35 | 38 | ||||||||||||||||||
50 | 55 | 58 | 61 | 64 | ||||||||||||||||||
95 | 104 | 113 | 119 | 128 | ||||||||||||||||||
14 | 195 | 217 | 238 | 258 | 278 | |||||||||||||||||
14 | 450 | 548 | 607 | 659 | 707 | 757 | ||||||||||||||||
43 | ||||||||||||||||||||||
57 | ||||||||||||||||||||||
144 |
Years | 2008 | 2009 | 2010 | 2011 | 2012 | 2013 | 2014 | 2015 | 2016 | 2017 | 2018 | 2019 | 2020 | |||||||||||||||
RsKWh from grid (Commercial)) | 110 | 113 | 117 | 120 | 124 | 128 | 131 | 135 | 139 | 144 | 148 | 152 | 157 | |||||||||||||||
RsKWh from grid (Residential)) | 40 | 41 | 42 | 44 | 45 | 46 | 48 | 49 | 51 | 52 | 54 | 55 | 57 | |||||||||||||||
RsKWh from grid (Industrial) | 60 | 62 | 64 | 66 | 68 | 70 | 72 | 74 | 76 | 78 | 81 | 83 | 86 | |||||||||||||||
RsKWh from solar | 140 | 133 | 127 | 121 | 115 | 110 | 104 | 99 | 95 | 90 | 86 | 82 | 78 |
Australia | 300000 | 1200000 | 2500 | ||||||||
India | 290000 | 1200000 | 2417 | ||||||||
Norway | 170000 | 1200000 | 1417 | ||||||||
United States | 160000 | 1200000 | 1333 | ||||||||
Canada | 100000 | 1200000 | 833 | ||||||||
South Africa | 35000 | 1200000 | 292 | ||||||||
Brazil | 16000 | 1200000 | 133 | ||||||||
Malaysia | 4500 | 1200000 | 038 | ||||||||
Other Countries | 95000 | 1200000 | 792 | ||||||||
World Total |
23 | 8 | 6 | 34 | 2 | |||||||||||||||||||
43 | |||||||||||||||||||||||
Orders | |||||||||||||||||||||||
Arushi | |||||||||||||||||||||||
No | KWp | Rs | |||||||||||||||||||||
FAG | 2875 | 949 | 69 | ||||||||||||||||||||
rest | 1000 | 33 | 24 | ||||||||||||||||||||
116 | 8200 | 27 | 75 | 132 | 500 | 165 | 12 | ||||||||||||||||
100 | 033 | 24 | |||||||||||||||||||||
100 | 033 | 24 | |||||||||||||||||||||
53 | 5800 | 61 | 64 | 68 | 100 | 033 | 24 | ||||||||||||||||
Resi | 50 | 55 | 58 | 61 | 64 | 400 | 132 | 96 | |||||||||||||||
150 | 05 | 36 | |||||||||||||||||||||
Ind | 19100 | 21200 | 230 | 247 | 263 | 100 | 033 | 24 | |||||||||||||||
181 | 201 | 218 | 234 | 249 | 50 | 017 | 12 | ||||||||||||||||
Comm | 28 | 32 | 34 | 37 | 40 | ||||||||||||||||||
27 | 30 | 32 | 35 | 38 | R Lite | 200 | 2 | 1412 | |||||||||||||||
15 | 015 | 106 | |||||||||||||||||||||
Trans | 100 | 110 | 119 | 126 | 135 | 100 | 1 | 706 | |||||||||||||||
95 | 104 | 113 | 119 | 128 | 25 | 025 | 176 | ||||||||||||||||
100 | 1 | 706 | |||||||||||||||||||||
Elec | 206 | 229 | 251 | 272 | 293 | 30 | 03 | 21 | |||||||||||||||
195 | 217 | 238 | 258 | 278 | 25 | 025 | 176 |
Module | 1821 | |||||
Battery | 556 | |||||
Structure Assembly | 212 | |||||
Luminaire amp Charge Controller | 309 | |||||
Cables | 48 | |||||
Freight | 159 | |||||
I ampC | 90 | |||||
Service and Maintenance | 134 | |||||
Logistics and Inventory Holding | 50 | |||||
Sales and Service Tax | 142 |
Loan | Amounts in Rs lac | |||||||||||||
Total Invst | 1000000 | |||||||||||||
Equity | 260000 | |||||||||||||
Debt | 740000 | |||||||||||||
Principal Loan | 740000 | |||||||||||||
Rate of Int | 9 | |||||||||||||
Period | 10 | Years | ||||||||||||
EYI | 1153 | |||||||||||||
Amounts in Rs lac | ||||||||||||||
Op Principal | Interest | Principal | EYI | Cl Principal | Formula for EMI =(pr)(1-(1(1+r)^n)) | |||||||||
1 | 740000 | 66600 | 48707 | 115307 | 691293 | |||||||||
2 | 691293 | 62216 | 53090 | 115307 | 638203 | |||||||||
3 | 638203 | 57438 | 57869 | 115307 | 580334 | |||||||||
4 | 580334 | 52230 | 63077 | 115307 | 517257 | |||||||||
5 | 517257 | 46553 | 68754 | 115307 | 448503 | |||||||||
6 | 448503 | 40365 | 74942 | 115307 | 373562 | |||||||||
7 | 373562 | 33621 | 81686 | 115307 | 291876 | |||||||||
8 | 291876 | 26269 | 89038 | 115307 | 202838 | |||||||||
9 | 202838 | 18255 | 97051 | 115307 | 105786 | |||||||||
10 | 105786 | 9521 | 105786 | 115307 | 000 |
IRR RULE | |||||||||||||||||||||||
For a standard project | NPV gt 0 | if and only if | IRR gt Cost of Capital | ||||||||||||||||||||
IRR Rule Choose a project | if and only if | IRR gt Cost of Capital | |||||||||||||||||||||
Standard means | |||||||||||||||||||||||
- cash outflows occur in early years and cash inflows in later years | |||||||||||||||||||||||
- the alternative to the project is the status quo | |||||||||||||||||||||||
Year | 0 | 1 | 2 | 3 | 4 | 5 | 6 | Interest rate | 547 | ||||||||||||||
Income amounts | ($1000) | $200 | $200 | $200 | $200 | $200 | $200 | ||||||||||||||||
Discounted | -1000 | 189627382194 | 1797927203887 | 1704681145242 | 1616271115239 | 1532446302493 | 1452968903473 | 0 | |||||||||||||||
NPV | 0 | ||||||||||||||||||||||
Thus 547 is the Internal Rate of Return ie IRR | |||||||||||||||||||||||
IRR is the interest rate at which the NPV is equal to zero | |||||||||||||||||||||||
Therefore using Goal seek method |
Year | 0 | 1 | 2 | 3 | 4 | 5 | 6 | Interest rate | 100 | |||||||||||||
Income amounts | ($1000) | $200 | $200 | $200 | $200 | $200 | $200 | |||||||||||||||
Discounted | -1000 | 1818181818182 | 1652892561983 | 1502629601803 | 136602691073 | 1241842646118 | 1128947860108 | -129 | ||||||||||||||
NPV | -129 | |||||||||||||||||||||
If the returns are in Initial years the NPV will be high |
value | year | ||||||||||
200 | 1 | ||||||||||
700 | 10 | CAGR =((End ValueStart Value)^(1(Periods - 1)) -1 | |||||||||
Year 1 | 11006 | ||||||||||
CAGR | Year 10 | 26083 | |||||||||
=((B3B2)^(19))-1 | 1006 |
2008 | 2008 | 2008 | 2008 | ||||
2009 | 2009 | 2009 | 2009 | ||||
2010 | 2010 | 2010 | 2010 | ||||
2011 | 2011 | 2011 | 2011 | ||||
2012 | 2012 | 2012 | 2012 | ||||
2013 | 2013 | 2013 | 2013 | ||||
2014 | 2014 | 2014 | 2014 | ||||
2015 | 2015 | 2015 | 2015 | ||||
2016 | 2016 | 2016 | 2016 | ||||
2017 | 2017 | 2017 | 2017 | ||||
2018 | 2018 | 2018 | 2018 | ||||
2019 | 2019 | 2019 | 2019 | ||||
2020 | 2020 | 2020 | 2020 |
CAGR
NPV
IRR
EMI
Sheet2
Sheet2
Sheet1
World energy by fuel type
Grid Parity in India
Grid Parity in India
Sheet3
IIT - Kanpur- CVBU LUCKNOW
Wind Power
IIT - Kanpur- CVBU LUCKNOW
bull A report on the Solar power says that the utilization of just 5of existing solar energy would suffice the Global energyrequirement
bull Technology is readily available for generation of Power heating cooking etc applications For industries an immediate thoughtof putting up solar power plant of rated capacity and solarconcentrator for Canteen Guest houses offices remotelylocated load centers would reduce the energy bill besidesprotecting the environment
Solar Power
IIT - Kanpur- CVBU LUCKNOW
Bio-Gas
Wastersquos of animals trees rice husk etc can be utilizedfor the generation of gases which inturn utilized forheating cooking applications
Bio-Diesel
As the cost of petroleum products touching the sky an immediate thought on alternate fuels is the top most order of demand today Proven technology for Bio-diesel from Jetropa amp Pengenia etc is readily available With these in line the demand on Petroleum product would come down by 25-35 In APCW premises all unused area can be utilized for Jetropa amp Pengenia cultivation inturn to sell in the market or for mines-vehicle like Dozer Dumper shovel etc application
Bio Fuels
IIT - Kanpur- CVBU LUCKNOW
Simple schematic
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustriesIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
We have Energy Management Cell in our Plant Which initiates amp Manages all sorts of Energy Conservation measuresacross the Plant
Energy Management System
Mr Pramod ChoudharyPlant Head Lucknow
DH ndash Mr S B MattaPlant services
MR -Lko Works Dr SB Matta
DH ndash Mr V AgrawalPaint shop
DH ndash Mr S N VermaTCF
DH ndash Mr U TauheedBIW
DH ndash Mr R K SinghIBF
DH ndash Mr R K SinghAxle Shop
DH ndashMr G V JoshiPlanning
DH ndash Mr A ChhariaMaterials amp ADD
DH ndash Mr Ankush GourHR
DH ndash Mr R K SinghCV- CX
Team Structure ndash ISO 50001
DH ndash Divisional Head
ISO 50001 CertificateEnergy Policy
2013 2016 2019
IIT - Kanpur- CVBU LUCKNOW
ENERGY MANAGEMENT SYSTEM ndash An Overview
TOP MANAGEMENT COMMITMENT
STAFF COMMITMENT
ENERGY AUDIT
ACTION PLAN
MONITORING amp TARGET SETTING
REVIEW amp DEVELOP PROFILE
LONG PAY BACK PROJECTS
IIT - Kanpur- CVBU LUCKNOW
Preliminary Energy audit
Detailed Energy audit
Plant Coordinator
GO AHEAD
Energy savings discussion and presentation
GO AHEAD for Implementation
Energy savings monitoring and interim report to Energy Mgmt Cell
Acceptance of Proposal
Submission of Techno commercial proposal
Team formation
Energy Management CellEnCon Implementation Methodology
copy Copyright Confidential Tata Motors Limited
Innovation Digital Transformation Project Planning amp Operation
3D layout of Manufacturing Line Process flow for Digital transformation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
44
Collaboration
Training
Layout
Maintenance
2D drawings using Auto Cad 3D digital Factory
No single platform for discussions and decision making among various stake-holder
Virtual Factory encouraged different agencies to work in more collaborate manner
Traditional training methods such as classroom teaching using PPTs and OJT
3D Digital Work-Instruction videos along with Quality and Safety awareness
Maintenance based on Real time data
Preventive Maintenance Breakdown Maintenance based on schedule
Collection of information from individual machines and preparing reports
Connected Machines IPMS Mobile App online quality parameter monitoring
Traditional Method Digital Method
Technology Landscape ndash before and after implementation
Factory Set-up time reduced
Issue identified and resolved before physical installationconstruction
Better Visualization of the process enables operator to learn fast
Down-time of machines reduced thusimproving OEE
Better tracking and control quality and Mc parameters Faster information exchange
Transformation Impact
No Virtual Simulation Expensive Physicals only for very critical processes
Virtual Simulation of Critical Processes helped to identified Potential issues
Short Project Lead time Saving on rework cost and time
Simulation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
Sales~10 Increase throughbull Levelled Productionbull Improvement in Customer Experience
Cost
Customer Complaint
Project Time
Quality
Employee Engagement
~15 Reduction through bull Inventory Optimizationbull Warranty Cost reductionbull COPQ Reduction
~15 Reduction through bull Robust Process Designbull Resulting Reliability of Product
~25 Reduction throughbull Better Project
ManagementWith Use of Simulations Avoided Rework
~25 Improvement throughbull Connected Equipment
bull Avoiding Defect Passing
~10 Improvement throughbull Layout Improvementbull Process Automation
bull Ergonomics amp Safety improvement
Quantitative Benefits and Awarded in CII Digital Transformation Meet
Innovation Digital Transformation Project Planning amp Operation
IIT - Kanpur- CVBU LUCKNOW
Teamwork Employee involvement amp MonitoringDaily Consumption Report
Daily Energy Audit Report
Daily Shopwise Report
Daily Solar Generation Report
Hourly Consumption Report-Plant
Hourly Consumption Report-Shop
Monthly Energy Consumption Report
Awar
enes
sle
vel
2017-18
Reporting of energy consumption of the plant and
individual shops on fortnightly and monthly
basis
2018-19
H1 Reporting of entire plantrsquos energy consumption on daily basis
Daily Energy Audit Report (DEAR) circulated across the plant to minimize
energy wastageH2 Reporting of entire plantrsquos and shop-wise energy consumption on
daily basis
2019-20
H1 Reporting of shop-wise energy consumption started on hourly
basisH1 Reporting of working dayrsquos
and non-working dayrsquos consumption separately for
identification of areasprocesses 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
ENERGY CONSUMPTION 2019-20Figures in KWH
FACTORY Dec-19 Jan-20 Feb-20 Mar-20EASTERN COMPLEXBIWBIW Cab 30103 29885 42825 7097BIW Cowl 17657 16650 20104 7438FDV 0 0 0 0COMP 13691 12555 15960 4155BIW Office others 3459 2845 3824 599Distribution Losses 5737 5686 8235 3398Total 70648 67620 90949 22688PAINT SHOPPTED 276243 270240 58056 125761Paint 199896 182651 252332 55852COMP 69201 71042 191305 32740Paint others 33456 34243 71892 16336Distribution Losses 52586 55324 32462 45001Total 631382 613501 606048 275690TCFAssly 84210 101803 92831 23993Trim Assly 12468 17988 15117 4219FDV 0 0 0 0Compressor 38154 41387 42232 13080TCF officeothers 19581 18255 15958 13560Distribution Losses 14262 16490 17609 10428Total 168676 195923 183747 65281
Rear Axle and Line-45 17252 16260 4125 1830Logistics Centre 14904 25247 20629 9615RSO 5597 9370 8390 8445
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
GSM Based Smart Control of Shop Floor Ventilation System
Concerns in present method bull One operator has to travel around 1 Km for manually switching off all FDVs in western complex due to control panel given at that particular
location and hence there is electrical energy wastage of 5137 KWHmonth due to travel time of around 20 mins
Present process Moving to
switching off SB1 FDV
(0 mins)
Moving to switching off SB2 FDV
(5 mins)
Moving to switching off F Block FDV
(15 mins)
Moving to switching off
SB4 FDV(20 mins)
Moving to switching off SB3 FDV
(10 mins)
Blower amp Control panel
FDV Locations in Line 1
EnCon Projects
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
LCA Solution
bull Remote switching off FDVs by integrating off operation of FDV with GSMmodem from one location Also message will be delivered to user thatwhich FDV has been switched off (wireless switching off operation is donethrough GSM modem to avoid cable cost and laying of cable line)
Benefits amp Horizontal Scope 1Energy saving - Energy saving of 41096 KWHannum by providing remote switching off FDVs
2 Cost Saving - Recurring cost saving of Rs 328 lakhsannum3 Environment- Reduction in carbon footprint (reduction of 337 tonne of CO2annum by energy saving)
4 SMS escalation to user for information of FDV switch off5No laying out of wire is required as it is wireless communication with help of GSM modem6 Horizontal deployment of GSM based control for other process machines of assembly line 12 and 3
Solution Cost-Rs 328 Lacs for all 5 FDVs
Remote switching off SB3 FDV (Instantly)
Control panel- Remote Switching off SB1 FDV
Remote switching off SB2 FDV (Instantly)
Remote switching off F Block FDV (Instantly)
Remote switching off SB4 FDV (Instantly)
GSM Based Smart Control of Shop Floor Ventilation System
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Innovative Projects LED Migration Project
Evolution of Lighting
LEDification Project
No expenses in LED- migration
OPEX model Lights Installation Testing amp
Commissioning of LED lights 5 yrs extended warranty
Scope amp Savings
Phase wise LEDification project
Entire plant in phases Better control schemes Reduction in consumption by
50 (Minimum)
Optimal design amp execution
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
Why LED for lighting
LED the best lighting option today
Energy efficient higher Lumens per Watts
No Mercury-Environmental friendly
No IR amp UV emissions Reduced heat generation
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Conventional Lighting system After LED Migration
Power Consumption 14 KW Lux level 125~200
Energy Cons-Monthly 6300 KWH 50400 INR-Annually 75600 KWH 604800 INR
65 KW (Red 464) 250~450 (Inc 250 )
2925 KWH 23400 INR (Red 464 )
35100 KWH 280800 INR
65 KW (Red 464) 250~450 (Inc 250 )
1312 KWH 10400 INR (Red 782 ) 15744 KWH 125952 INR
Occupancy Sensor
After Sensor installation
Occupancy sensor
Sensor Controlled
lightingGroup
Manual Controlled
Lighting group
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
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- Slide Number 11
- Slide Number 12
- Slide Number 13
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- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
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- Slide Number 60
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- Slide Number 62
- Slide Number 63
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- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
Total cost | 55177211 | 14176846 | 107850 | 184319 | ||||||||||||||||||
World Resi | 485 | 46 | Profit Margin | 15 | 1530 | 19 | 360 | |||||||||||||||
OECD Resi | 286 | 27 | Sales Tax | 2505507 | 685912 | 5024 | 8654 | |||||||||||||||
144 | 65143189 | 17429501 | 137703 | 225000 | ||||||||||||||||||
57 | ||||||||||||||||||||||
43 | Selling price to Customer | 62637682 | 16743589 | 132679 | 216346 | |||||||||||||||||
14 | ||||||||||||||||||||||
14 | 1191 | 1533 | 1871 | 1480 | ||||||||||||||||||
Total cost | 11863 | 22545 | 3104 | 05896907216 | ||||||||||||||||||
Sales Tax | 526 | 951 | 161 | 1971 | ||||||||||||||||||
Profit Margin | 1480 | 1020 | 1575 | 729 | ||||||||||||||||||
Selling price to Customer | 14500 | 26026 | 3860 | |||||||||||||||||||
New SP | 13974 | 25075 | 3699 | |||||||||||||||||||
Margin | 15 | 10 | 16 | |||||||||||||||||||
Margin | 1 ton of oil equivalent | 418 Giga Joule | ||||||||||||||||||||
10^6 | 181 | 201 | 218 | 234 | 249 | |||||||||||||||||
27 | 30 | 32 | 35 | 38 | ||||||||||||||||||
50 | 55 | 58 | 61 | 64 | ||||||||||||||||||
95 | 104 | 113 | 119 | 128 | ||||||||||||||||||
14 | 195 | 217 | 238 | 258 | 278 | |||||||||||||||||
14 | 450 | 548 | 607 | 659 | 707 | 757 | ||||||||||||||||
43 | ||||||||||||||||||||||
57 | ||||||||||||||||||||||
144 |
Years | 2008 | 2009 | 2010 | 2011 | 2012 | 2013 | 2014 | 2015 | 2016 | 2017 | 2018 | 2019 | 2020 | |||||||||||||||
RsKWh from grid (Commercial)) | 110 | 113 | 117 | 120 | 124 | 128 | 131 | 135 | 139 | 144 | 148 | 152 | 157 | |||||||||||||||
RsKWh from grid (Residential)) | 40 | 41 | 42 | 44 | 45 | 46 | 48 | 49 | 51 | 52 | 54 | 55 | 57 | |||||||||||||||
RsKWh from grid (Industrial) | 60 | 62 | 64 | 66 | 68 | 70 | 72 | 74 | 76 | 78 | 81 | 83 | 86 | |||||||||||||||
RsKWh from solar | 140 | 133 | 127 | 121 | 115 | 110 | 104 | 99 | 95 | 90 | 86 | 82 | 78 |
Australia | 300000 | 1200000 | 2500 | ||||||||
India | 290000 | 1200000 | 2417 | ||||||||
Norway | 170000 | 1200000 | 1417 | ||||||||
United States | 160000 | 1200000 | 1333 | ||||||||
Canada | 100000 | 1200000 | 833 | ||||||||
South Africa | 35000 | 1200000 | 292 | ||||||||
Brazil | 16000 | 1200000 | 133 | ||||||||
Malaysia | 4500 | 1200000 | 038 | ||||||||
Other Countries | 95000 | 1200000 | 792 | ||||||||
World Total |
23 | 8 | 6 | 34 | 2 | |||||||||||||||||||
43 | |||||||||||||||||||||||
Orders | |||||||||||||||||||||||
Arushi | |||||||||||||||||||||||
No | KWp | Rs | |||||||||||||||||||||
FAG | 2875 | 949 | 69 | ||||||||||||||||||||
rest | 1000 | 33 | 24 | ||||||||||||||||||||
116 | 8200 | 27 | 75 | 132 | 500 | 165 | 12 | ||||||||||||||||
100 | 033 | 24 | |||||||||||||||||||||
100 | 033 | 24 | |||||||||||||||||||||
53 | 5800 | 61 | 64 | 68 | 100 | 033 | 24 | ||||||||||||||||
Resi | 50 | 55 | 58 | 61 | 64 | 400 | 132 | 96 | |||||||||||||||
150 | 05 | 36 | |||||||||||||||||||||
Ind | 19100 | 21200 | 230 | 247 | 263 | 100 | 033 | 24 | |||||||||||||||
181 | 201 | 218 | 234 | 249 | 50 | 017 | 12 | ||||||||||||||||
Comm | 28 | 32 | 34 | 37 | 40 | ||||||||||||||||||
27 | 30 | 32 | 35 | 38 | R Lite | 200 | 2 | 1412 | |||||||||||||||
15 | 015 | 106 | |||||||||||||||||||||
Trans | 100 | 110 | 119 | 126 | 135 | 100 | 1 | 706 | |||||||||||||||
95 | 104 | 113 | 119 | 128 | 25 | 025 | 176 | ||||||||||||||||
100 | 1 | 706 | |||||||||||||||||||||
Elec | 206 | 229 | 251 | 272 | 293 | 30 | 03 | 21 | |||||||||||||||
195 | 217 | 238 | 258 | 278 | 25 | 025 | 176 |
Module | 1821 | |||||
Battery | 556 | |||||
Structure Assembly | 212 | |||||
Luminaire amp Charge Controller | 309 | |||||
Cables | 48 | |||||
Freight | 159 | |||||
I ampC | 90 | |||||
Service and Maintenance | 134 | |||||
Logistics and Inventory Holding | 50 | |||||
Sales and Service Tax | 142 |
Loan | Amounts in Rs lac | |||||||||||||
Total Invst | 1000000 | |||||||||||||
Equity | 260000 | |||||||||||||
Debt | 740000 | |||||||||||||
Principal Loan | 740000 | |||||||||||||
Rate of Int | 9 | |||||||||||||
Period | 10 | Years | ||||||||||||
EYI | 1153 | |||||||||||||
Amounts in Rs lac | ||||||||||||||
Op Principal | Interest | Principal | EYI | Cl Principal | Formula for EMI =(pr)(1-(1(1+r)^n)) | |||||||||
1 | 740000 | 66600 | 48707 | 115307 | 691293 | |||||||||
2 | 691293 | 62216 | 53090 | 115307 | 638203 | |||||||||
3 | 638203 | 57438 | 57869 | 115307 | 580334 | |||||||||
4 | 580334 | 52230 | 63077 | 115307 | 517257 | |||||||||
5 | 517257 | 46553 | 68754 | 115307 | 448503 | |||||||||
6 | 448503 | 40365 | 74942 | 115307 | 373562 | |||||||||
7 | 373562 | 33621 | 81686 | 115307 | 291876 | |||||||||
8 | 291876 | 26269 | 89038 | 115307 | 202838 | |||||||||
9 | 202838 | 18255 | 97051 | 115307 | 105786 | |||||||||
10 | 105786 | 9521 | 105786 | 115307 | 000 |
IRR RULE | |||||||||||||||||||||||
For a standard project | NPV gt 0 | if and only if | IRR gt Cost of Capital | ||||||||||||||||||||
IRR Rule Choose a project | if and only if | IRR gt Cost of Capital | |||||||||||||||||||||
Standard means | |||||||||||||||||||||||
- cash outflows occur in early years and cash inflows in later years | |||||||||||||||||||||||
- the alternative to the project is the status quo | |||||||||||||||||||||||
Year | 0 | 1 | 2 | 3 | 4 | 5 | 6 | Interest rate | 547 | ||||||||||||||
Income amounts | ($1000) | $200 | $200 | $200 | $200 | $200 | $200 | ||||||||||||||||
Discounted | -1000 | 189627382194 | 1797927203887 | 1704681145242 | 1616271115239 | 1532446302493 | 1452968903473 | 0 | |||||||||||||||
NPV | 0 | ||||||||||||||||||||||
Thus 547 is the Internal Rate of Return ie IRR | |||||||||||||||||||||||
IRR is the interest rate at which the NPV is equal to zero | |||||||||||||||||||||||
Therefore using Goal seek method |
Year | 0 | 1 | 2 | 3 | 4 | 5 | 6 | Interest rate | 100 | |||||||||||||
Income amounts | ($1000) | $200 | $200 | $200 | $200 | $200 | $200 | |||||||||||||||
Discounted | -1000 | 1818181818182 | 1652892561983 | 1502629601803 | 136602691073 | 1241842646118 | 1128947860108 | -129 | ||||||||||||||
NPV | -129 | |||||||||||||||||||||
If the returns are in Initial years the NPV will be high |
value | year | ||||||||||
200 | 1 | ||||||||||
700 | 10 | CAGR =((End ValueStart Value)^(1(Periods - 1)) -1 | |||||||||
Year 1 | 11006 | ||||||||||
CAGR | Year 10 | 26083 | |||||||||
=((B3B2)^(19))-1 | 1006 |
NPV
IRR
EMI
Sheet2
Sheet2
Sheet1
World energy by fuel type
Grid Parity in India
Grid Parity in India
Sheet3
IIT - Kanpur- CVBU LUCKNOW
Wind Power
IIT - Kanpur- CVBU LUCKNOW
bull A report on the Solar power says that the utilization of just 5of existing solar energy would suffice the Global energyrequirement
bull Technology is readily available for generation of Power heating cooking etc applications For industries an immediate thoughtof putting up solar power plant of rated capacity and solarconcentrator for Canteen Guest houses offices remotelylocated load centers would reduce the energy bill besidesprotecting the environment
Solar Power
IIT - Kanpur- CVBU LUCKNOW
Bio-Gas
Wastersquos of animals trees rice husk etc can be utilizedfor the generation of gases which inturn utilized forheating cooking applications
Bio-Diesel
As the cost of petroleum products touching the sky an immediate thought on alternate fuels is the top most order of demand today Proven technology for Bio-diesel from Jetropa amp Pengenia etc is readily available With these in line the demand on Petroleum product would come down by 25-35 In APCW premises all unused area can be utilized for Jetropa amp Pengenia cultivation inturn to sell in the market or for mines-vehicle like Dozer Dumper shovel etc application
Bio Fuels
IIT - Kanpur- CVBU LUCKNOW
Simple schematic
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustriesIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
We have Energy Management Cell in our Plant Which initiates amp Manages all sorts of Energy Conservation measuresacross the Plant
Energy Management System
Mr Pramod ChoudharyPlant Head Lucknow
DH ndash Mr S B MattaPlant services
MR -Lko Works Dr SB Matta
DH ndash Mr V AgrawalPaint shop
DH ndash Mr S N VermaTCF
DH ndash Mr U TauheedBIW
DH ndash Mr R K SinghIBF
DH ndash Mr R K SinghAxle Shop
DH ndashMr G V JoshiPlanning
DH ndash Mr A ChhariaMaterials amp ADD
DH ndash Mr Ankush GourHR
DH ndash Mr R K SinghCV- CX
Team Structure ndash ISO 50001
DH ndash Divisional Head
ISO 50001 CertificateEnergy Policy
2013 2016 2019
IIT - Kanpur- CVBU LUCKNOW
ENERGY MANAGEMENT SYSTEM ndash An Overview
TOP MANAGEMENT COMMITMENT
STAFF COMMITMENT
ENERGY AUDIT
ACTION PLAN
MONITORING amp TARGET SETTING
REVIEW amp DEVELOP PROFILE
LONG PAY BACK PROJECTS
IIT - Kanpur- CVBU LUCKNOW
Preliminary Energy audit
Detailed Energy audit
Plant Coordinator
GO AHEAD
Energy savings discussion and presentation
GO AHEAD for Implementation
Energy savings monitoring and interim report to Energy Mgmt Cell
Acceptance of Proposal
Submission of Techno commercial proposal
Team formation
Energy Management CellEnCon Implementation Methodology
copy Copyright Confidential Tata Motors Limited
Innovation Digital Transformation Project Planning amp Operation
3D layout of Manufacturing Line Process flow for Digital transformation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
44
Collaboration
Training
Layout
Maintenance
2D drawings using Auto Cad 3D digital Factory
No single platform for discussions and decision making among various stake-holder
Virtual Factory encouraged different agencies to work in more collaborate manner
Traditional training methods such as classroom teaching using PPTs and OJT
3D Digital Work-Instruction videos along with Quality and Safety awareness
Maintenance based on Real time data
Preventive Maintenance Breakdown Maintenance based on schedule
Collection of information from individual machines and preparing reports
Connected Machines IPMS Mobile App online quality parameter monitoring
Traditional Method Digital Method
Technology Landscape ndash before and after implementation
Factory Set-up time reduced
Issue identified and resolved before physical installationconstruction
Better Visualization of the process enables operator to learn fast
Down-time of machines reduced thusimproving OEE
Better tracking and control quality and Mc parameters Faster information exchange
Transformation Impact
No Virtual Simulation Expensive Physicals only for very critical processes
Virtual Simulation of Critical Processes helped to identified Potential issues
Short Project Lead time Saving on rework cost and time
Simulation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
Sales~10 Increase throughbull Levelled Productionbull Improvement in Customer Experience
Cost
Customer Complaint
Project Time
Quality
Employee Engagement
~15 Reduction through bull Inventory Optimizationbull Warranty Cost reductionbull COPQ Reduction
~15 Reduction through bull Robust Process Designbull Resulting Reliability of Product
~25 Reduction throughbull Better Project
ManagementWith Use of Simulations Avoided Rework
~25 Improvement throughbull Connected Equipment
bull Avoiding Defect Passing
~10 Improvement throughbull Layout Improvementbull Process Automation
bull Ergonomics amp Safety improvement
Quantitative Benefits and Awarded in CII Digital Transformation Meet
Innovation Digital Transformation Project Planning amp Operation
IIT - Kanpur- CVBU LUCKNOW
Teamwork Employee involvement amp MonitoringDaily Consumption Report
Daily Energy Audit Report
Daily Shopwise Report
Daily Solar Generation Report
Hourly Consumption Report-Plant
Hourly Consumption Report-Shop
Monthly Energy Consumption Report
Awar
enes
sle
vel
2017-18
Reporting of energy consumption of the plant and
individual shops on fortnightly and monthly
basis
2018-19
H1 Reporting of entire plantrsquos energy consumption on daily basis
Daily Energy Audit Report (DEAR) circulated across the plant to minimize
energy wastageH2 Reporting of entire plantrsquos and shop-wise energy consumption on
daily basis
2019-20
H1 Reporting of shop-wise energy consumption started on hourly
basisH1 Reporting of working dayrsquos
and non-working dayrsquos consumption separately for
identification of areasprocesses 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
ENERGY CONSUMPTION 2019-20Figures in KWH
FACTORY Dec-19 Jan-20 Feb-20 Mar-20EASTERN COMPLEXBIWBIW Cab 30103 29885 42825 7097BIW Cowl 17657 16650 20104 7438FDV 0 0 0 0COMP 13691 12555 15960 4155BIW Office others 3459 2845 3824 599Distribution Losses 5737 5686 8235 3398Total 70648 67620 90949 22688PAINT SHOPPTED 276243 270240 58056 125761Paint 199896 182651 252332 55852COMP 69201 71042 191305 32740Paint others 33456 34243 71892 16336Distribution Losses 52586 55324 32462 45001Total 631382 613501 606048 275690TCFAssly 84210 101803 92831 23993Trim Assly 12468 17988 15117 4219FDV 0 0 0 0Compressor 38154 41387 42232 13080TCF officeothers 19581 18255 15958 13560Distribution Losses 14262 16490 17609 10428Total 168676 195923 183747 65281
Rear Axle and Line-45 17252 16260 4125 1830Logistics Centre 14904 25247 20629 9615RSO 5597 9370 8390 8445
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
GSM Based Smart Control of Shop Floor Ventilation System
Concerns in present method bull One operator has to travel around 1 Km for manually switching off all FDVs in western complex due to control panel given at that particular
location and hence there is electrical energy wastage of 5137 KWHmonth due to travel time of around 20 mins
Present process Moving to
switching off SB1 FDV
(0 mins)
Moving to switching off SB2 FDV
(5 mins)
Moving to switching off F Block FDV
(15 mins)
Moving to switching off
SB4 FDV(20 mins)
Moving to switching off SB3 FDV
(10 mins)
Blower amp Control panel
FDV Locations in Line 1
EnCon Projects
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
LCA Solution
bull Remote switching off FDVs by integrating off operation of FDV with GSMmodem from one location Also message will be delivered to user thatwhich FDV has been switched off (wireless switching off operation is donethrough GSM modem to avoid cable cost and laying of cable line)
Benefits amp Horizontal Scope 1Energy saving - Energy saving of 41096 KWHannum by providing remote switching off FDVs
2 Cost Saving - Recurring cost saving of Rs 328 lakhsannum3 Environment- Reduction in carbon footprint (reduction of 337 tonne of CO2annum by energy saving)
4 SMS escalation to user for information of FDV switch off5No laying out of wire is required as it is wireless communication with help of GSM modem6 Horizontal deployment of GSM based control for other process machines of assembly line 12 and 3
Solution Cost-Rs 328 Lacs for all 5 FDVs
Remote switching off SB3 FDV (Instantly)
Control panel- Remote Switching off SB1 FDV
Remote switching off SB2 FDV (Instantly)
Remote switching off F Block FDV (Instantly)
Remote switching off SB4 FDV (Instantly)
GSM Based Smart Control of Shop Floor Ventilation System
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Innovative Projects LED Migration Project
Evolution of Lighting
LEDification Project
No expenses in LED- migration
OPEX model Lights Installation Testing amp
Commissioning of LED lights 5 yrs extended warranty
Scope amp Savings
Phase wise LEDification project
Entire plant in phases Better control schemes Reduction in consumption by
50 (Minimum)
Optimal design amp execution
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
Why LED for lighting
LED the best lighting option today
Energy efficient higher Lumens per Watts
No Mercury-Environmental friendly
No IR amp UV emissions Reduced heat generation
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Conventional Lighting system After LED Migration
Power Consumption 14 KW Lux level 125~200
Energy Cons-Monthly 6300 KWH 50400 INR-Annually 75600 KWH 604800 INR
65 KW (Red 464) 250~450 (Inc 250 )
2925 KWH 23400 INR (Red 464 )
35100 KWH 280800 INR
65 KW (Red 464) 250~450 (Inc 250 )
1312 KWH 10400 INR (Red 782 ) 15744 KWH 125952 INR
Occupancy Sensor
After Sensor installation
Occupancy sensor
Sensor Controlled
lightingGroup
Manual Controlled
Lighting group
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
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- Bio-Gas
- Slide Number 21
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- Thank You
-
Total cost | 55177211 | 14176846 | 107850 | 184319 | ||||||||||||||||||
World Resi | 485 | 46 | Profit Margin | 15 | 1530 | 19 | 360 | |||||||||||||||
OECD Resi | 286 | 27 | Sales Tax | 2505507 | 685912 | 5024 | 8654 | |||||||||||||||
144 | 65143189 | 17429501 | 137703 | 225000 | ||||||||||||||||||
57 | ||||||||||||||||||||||
43 | Selling price to Customer | 62637682 | 16743589 | 132679 | 216346 | |||||||||||||||||
14 | ||||||||||||||||||||||
14 | 1191 | 1533 | 1871 | 1480 | ||||||||||||||||||
Total cost | 11863 | 22545 | 3104 | 05896907216 | ||||||||||||||||||
Sales Tax | 526 | 951 | 161 | 1971 | ||||||||||||||||||
Profit Margin | 1480 | 1020 | 1575 | 729 | ||||||||||||||||||
Selling price to Customer | 14500 | 26026 | 3860 | |||||||||||||||||||
New SP | 13974 | 25075 | 3699 | |||||||||||||||||||
Margin | 15 | 10 | 16 | |||||||||||||||||||
Margin | 1 ton of oil equivalent | 418 Giga Joule | ||||||||||||||||||||
10^6 | 181 | 201 | 218 | 234 | 249 | |||||||||||||||||
27 | 30 | 32 | 35 | 38 | ||||||||||||||||||
50 | 55 | 58 | 61 | 64 | ||||||||||||||||||
95 | 104 | 113 | 119 | 128 | ||||||||||||||||||
14 | 195 | 217 | 238 | 258 | 278 | |||||||||||||||||
14 | 450 | 548 | 607 | 659 | 707 | 757 | ||||||||||||||||
43 | ||||||||||||||||||||||
57 | ||||||||||||||||||||||
144 |
Years | 2008 | 2009 | 2010 | 2011 | 2012 | 2013 | 2014 | 2015 | 2016 | 2017 | 2018 | 2019 | 2020 | |||||||||||||||
RsKWh from grid (Commercial)) | 110 | 113 | 117 | 120 | 124 | 128 | 131 | 135 | 139 | 144 | 148 | 152 | 157 | |||||||||||||||
RsKWh from grid (Residential)) | 40 | 41 | 42 | 44 | 45 | 46 | 48 | 49 | 51 | 52 | 54 | 55 | 57 | |||||||||||||||
RsKWh from grid (Industrial) | 60 | 62 | 64 | 66 | 68 | 70 | 72 | 74 | 76 | 78 | 81 | 83 | 86 | |||||||||||||||
RsKWh from solar | 140 | 133 | 127 | 121 | 115 | 110 | 104 | 99 | 95 | 90 | 86 | 82 | 78 |
Australia | 300000 | 1200000 | 2500 | ||||||||
India | 290000 | 1200000 | 2417 | ||||||||
Norway | 170000 | 1200000 | 1417 | ||||||||
United States | 160000 | 1200000 | 1333 | ||||||||
Canada | 100000 | 1200000 | 833 | ||||||||
South Africa | 35000 | 1200000 | 292 | ||||||||
Brazil | 16000 | 1200000 | 133 | ||||||||
Malaysia | 4500 | 1200000 | 038 | ||||||||
Other Countries | 95000 | 1200000 | 792 | ||||||||
World Total |
23 | 8 | 6 | 34 | 2 | |||||||||||||||||||
43 | |||||||||||||||||||||||
Orders | |||||||||||||||||||||||
Arushi | |||||||||||||||||||||||
No | KWp | Rs | |||||||||||||||||||||
FAG | 2875 | 949 | 69 | ||||||||||||||||||||
rest | 1000 | 33 | 24 | ||||||||||||||||||||
116 | 8200 | 27 | 75 | 132 | 500 | 165 | 12 | ||||||||||||||||
100 | 033 | 24 | |||||||||||||||||||||
100 | 033 | 24 | |||||||||||||||||||||
53 | 5800 | 61 | 64 | 68 | 100 | 033 | 24 | ||||||||||||||||
Resi | 50 | 55 | 58 | 61 | 64 | 400 | 132 | 96 | |||||||||||||||
150 | 05 | 36 | |||||||||||||||||||||
Ind | 19100 | 21200 | 230 | 247 | 263 | 100 | 033 | 24 | |||||||||||||||
181 | 201 | 218 | 234 | 249 | 50 | 017 | 12 | ||||||||||||||||
Comm | 28 | 32 | 34 | 37 | 40 | ||||||||||||||||||
27 | 30 | 32 | 35 | 38 | R Lite | 200 | 2 | 1412 | |||||||||||||||
15 | 015 | 106 | |||||||||||||||||||||
Trans | 100 | 110 | 119 | 126 | 135 | 100 | 1 | 706 | |||||||||||||||
95 | 104 | 113 | 119 | 128 | 25 | 025 | 176 | ||||||||||||||||
100 | 1 | 706 | |||||||||||||||||||||
Elec | 206 | 229 | 251 | 272 | 293 | 30 | 03 | 21 | |||||||||||||||
195 | 217 | 238 | 258 | 278 | 25 | 025 | 176 |
Module | 1821 | |||||
Battery | 556 | |||||
Structure Assembly | 212 | |||||
Luminaire amp Charge Controller | 309 | |||||
Cables | 48 | |||||
Freight | 159 | |||||
I ampC | 90 | |||||
Service and Maintenance | 134 | |||||
Logistics and Inventory Holding | 50 | |||||
Sales and Service Tax | 142 |
Loan | Amounts in Rs lac | |||||||||||||
Total Invst | 1000000 | |||||||||||||
Equity | 260000 | |||||||||||||
Debt | 740000 | |||||||||||||
Principal Loan | 740000 | |||||||||||||
Rate of Int | 9 | |||||||||||||
Period | 10 | Years | ||||||||||||
EYI | 1153 | |||||||||||||
Amounts in Rs lac | ||||||||||||||
Op Principal | Interest | Principal | EYI | Cl Principal | Formula for EMI =(pr)(1-(1(1+r)^n)) | |||||||||
1 | 740000 | 66600 | 48707 | 115307 | 691293 | |||||||||
2 | 691293 | 62216 | 53090 | 115307 | 638203 | |||||||||
3 | 638203 | 57438 | 57869 | 115307 | 580334 | |||||||||
4 | 580334 | 52230 | 63077 | 115307 | 517257 | |||||||||
5 | 517257 | 46553 | 68754 | 115307 | 448503 | |||||||||
6 | 448503 | 40365 | 74942 | 115307 | 373562 | |||||||||
7 | 373562 | 33621 | 81686 | 115307 | 291876 | |||||||||
8 | 291876 | 26269 | 89038 | 115307 | 202838 | |||||||||
9 | 202838 | 18255 | 97051 | 115307 | 105786 | |||||||||
10 | 105786 | 9521 | 105786 | 115307 | 000 |
IRR RULE | |||||||||||||||||||||||
For a standard project | NPV gt 0 | if and only if | IRR gt Cost of Capital | ||||||||||||||||||||
IRR Rule Choose a project | if and only if | IRR gt Cost of Capital | |||||||||||||||||||||
Standard means | |||||||||||||||||||||||
- cash outflows occur in early years and cash inflows in later years | |||||||||||||||||||||||
- the alternative to the project is the status quo | |||||||||||||||||||||||
Year | 0 | 1 | 2 | 3 | 4 | 5 | 6 | Interest rate | 547 | ||||||||||||||
Income amounts | ($1000) | $200 | $200 | $200 | $200 | $200 | $200 | ||||||||||||||||
Discounted | -1000 | 189627382194 | 1797927203887 | 1704681145242 | 1616271115239 | 1532446302493 | 1452968903473 | 0 | |||||||||||||||
NPV | 0 | ||||||||||||||||||||||
Thus 547 is the Internal Rate of Return ie IRR | |||||||||||||||||||||||
IRR is the interest rate at which the NPV is equal to zero | |||||||||||||||||||||||
Therefore using Goal seek method |
Year | 0 | 1 | 2 | 3 | 4 | 5 | 6 | Interest rate | 100 | |||||||||||||
Income amounts | ($1000) | $200 | $200 | $200 | $200 | $200 | $200 | |||||||||||||||
Discounted | -1000 | 1818181818182 | 1652892561983 | 1502629601803 | 136602691073 | 1241842646118 | 1128947860108 | -129 | ||||||||||||||
NPV | -129 | |||||||||||||||||||||
If the returns are in Initial years the NPV will be high |
IRR
EMI
Sheet2
Sheet2
Sheet1
World energy by fuel type
Grid Parity in India
Grid Parity in India
Sheet3
IIT - Kanpur- CVBU LUCKNOW
Wind Power
IIT - Kanpur- CVBU LUCKNOW
bull A report on the Solar power says that the utilization of just 5of existing solar energy would suffice the Global energyrequirement
bull Technology is readily available for generation of Power heating cooking etc applications For industries an immediate thoughtof putting up solar power plant of rated capacity and solarconcentrator for Canteen Guest houses offices remotelylocated load centers would reduce the energy bill besidesprotecting the environment
Solar Power
IIT - Kanpur- CVBU LUCKNOW
Bio-Gas
Wastersquos of animals trees rice husk etc can be utilizedfor the generation of gases which inturn utilized forheating cooking applications
Bio-Diesel
As the cost of petroleum products touching the sky an immediate thought on alternate fuels is the top most order of demand today Proven technology for Bio-diesel from Jetropa amp Pengenia etc is readily available With these in line the demand on Petroleum product would come down by 25-35 In APCW premises all unused area can be utilized for Jetropa amp Pengenia cultivation inturn to sell in the market or for mines-vehicle like Dozer Dumper shovel etc application
Bio Fuels
IIT - Kanpur- CVBU LUCKNOW
Simple schematic
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustriesIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
We have Energy Management Cell in our Plant Which initiates amp Manages all sorts of Energy Conservation measuresacross the Plant
Energy Management System
Mr Pramod ChoudharyPlant Head Lucknow
DH ndash Mr S B MattaPlant services
MR -Lko Works Dr SB Matta
DH ndash Mr V AgrawalPaint shop
DH ndash Mr S N VermaTCF
DH ndash Mr U TauheedBIW
DH ndash Mr R K SinghIBF
DH ndash Mr R K SinghAxle Shop
DH ndashMr G V JoshiPlanning
DH ndash Mr A ChhariaMaterials amp ADD
DH ndash Mr Ankush GourHR
DH ndash Mr R K SinghCV- CX
Team Structure ndash ISO 50001
DH ndash Divisional Head
ISO 50001 CertificateEnergy Policy
2013 2016 2019
IIT - Kanpur- CVBU LUCKNOW
ENERGY MANAGEMENT SYSTEM ndash An Overview
TOP MANAGEMENT COMMITMENT
STAFF COMMITMENT
ENERGY AUDIT
ACTION PLAN
MONITORING amp TARGET SETTING
REVIEW amp DEVELOP PROFILE
LONG PAY BACK PROJECTS
IIT - Kanpur- CVBU LUCKNOW
Preliminary Energy audit
Detailed Energy audit
Plant Coordinator
GO AHEAD
Energy savings discussion and presentation
GO AHEAD for Implementation
Energy savings monitoring and interim report to Energy Mgmt Cell
Acceptance of Proposal
Submission of Techno commercial proposal
Team formation
Energy Management CellEnCon Implementation Methodology
copy Copyright Confidential Tata Motors Limited
Innovation Digital Transformation Project Planning amp Operation
3D layout of Manufacturing Line Process flow for Digital transformation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
44
Collaboration
Training
Layout
Maintenance
2D drawings using Auto Cad 3D digital Factory
No single platform for discussions and decision making among various stake-holder
Virtual Factory encouraged different agencies to work in more collaborate manner
Traditional training methods such as classroom teaching using PPTs and OJT
3D Digital Work-Instruction videos along with Quality and Safety awareness
Maintenance based on Real time data
Preventive Maintenance Breakdown Maintenance based on schedule
Collection of information from individual machines and preparing reports
Connected Machines IPMS Mobile App online quality parameter monitoring
Traditional Method Digital Method
Technology Landscape ndash before and after implementation
Factory Set-up time reduced
Issue identified and resolved before physical installationconstruction
Better Visualization of the process enables operator to learn fast
Down-time of machines reduced thusimproving OEE
Better tracking and control quality and Mc parameters Faster information exchange
Transformation Impact
No Virtual Simulation Expensive Physicals only for very critical processes
Virtual Simulation of Critical Processes helped to identified Potential issues
Short Project Lead time Saving on rework cost and time
Simulation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
Sales~10 Increase throughbull Levelled Productionbull Improvement in Customer Experience
Cost
Customer Complaint
Project Time
Quality
Employee Engagement
~15 Reduction through bull Inventory Optimizationbull Warranty Cost reductionbull COPQ Reduction
~15 Reduction through bull Robust Process Designbull Resulting Reliability of Product
~25 Reduction throughbull Better Project
ManagementWith Use of Simulations Avoided Rework
~25 Improvement throughbull Connected Equipment
bull Avoiding Defect Passing
~10 Improvement throughbull Layout Improvementbull Process Automation
bull Ergonomics amp Safety improvement
Quantitative Benefits and Awarded in CII Digital Transformation Meet
Innovation Digital Transformation Project Planning amp Operation
IIT - Kanpur- CVBU LUCKNOW
Teamwork Employee involvement amp MonitoringDaily Consumption Report
Daily Energy Audit Report
Daily Shopwise Report
Daily Solar Generation Report
Hourly Consumption Report-Plant
Hourly Consumption Report-Shop
Monthly Energy Consumption Report
Awar
enes
sle
vel
2017-18
Reporting of energy consumption of the plant and
individual shops on fortnightly and monthly
basis
2018-19
H1 Reporting of entire plantrsquos energy consumption on daily basis
Daily Energy Audit Report (DEAR) circulated across the plant to minimize
energy wastageH2 Reporting of entire plantrsquos and shop-wise energy consumption on
daily basis
2019-20
H1 Reporting of shop-wise energy consumption started on hourly
basisH1 Reporting of working dayrsquos
and non-working dayrsquos consumption separately for
identification of areasprocesses 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
ENERGY CONSUMPTION 2019-20Figures in KWH
FACTORY Dec-19 Jan-20 Feb-20 Mar-20EASTERN COMPLEXBIWBIW Cab 30103 29885 42825 7097BIW Cowl 17657 16650 20104 7438FDV 0 0 0 0COMP 13691 12555 15960 4155BIW Office others 3459 2845 3824 599Distribution Losses 5737 5686 8235 3398Total 70648 67620 90949 22688PAINT SHOPPTED 276243 270240 58056 125761Paint 199896 182651 252332 55852COMP 69201 71042 191305 32740Paint others 33456 34243 71892 16336Distribution Losses 52586 55324 32462 45001Total 631382 613501 606048 275690TCFAssly 84210 101803 92831 23993Trim Assly 12468 17988 15117 4219FDV 0 0 0 0Compressor 38154 41387 42232 13080TCF officeothers 19581 18255 15958 13560Distribution Losses 14262 16490 17609 10428Total 168676 195923 183747 65281
Rear Axle and Line-45 17252 16260 4125 1830Logistics Centre 14904 25247 20629 9615RSO 5597 9370 8390 8445
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
GSM Based Smart Control of Shop Floor Ventilation System
Concerns in present method bull One operator has to travel around 1 Km for manually switching off all FDVs in western complex due to control panel given at that particular
location and hence there is electrical energy wastage of 5137 KWHmonth due to travel time of around 20 mins
Present process Moving to
switching off SB1 FDV
(0 mins)
Moving to switching off SB2 FDV
(5 mins)
Moving to switching off F Block FDV
(15 mins)
Moving to switching off
SB4 FDV(20 mins)
Moving to switching off SB3 FDV
(10 mins)
Blower amp Control panel
FDV Locations in Line 1
EnCon Projects
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
LCA Solution
bull Remote switching off FDVs by integrating off operation of FDV with GSMmodem from one location Also message will be delivered to user thatwhich FDV has been switched off (wireless switching off operation is donethrough GSM modem to avoid cable cost and laying of cable line)
Benefits amp Horizontal Scope 1Energy saving - Energy saving of 41096 KWHannum by providing remote switching off FDVs
2 Cost Saving - Recurring cost saving of Rs 328 lakhsannum3 Environment- Reduction in carbon footprint (reduction of 337 tonne of CO2annum by energy saving)
4 SMS escalation to user for information of FDV switch off5No laying out of wire is required as it is wireless communication with help of GSM modem6 Horizontal deployment of GSM based control for other process machines of assembly line 12 and 3
Solution Cost-Rs 328 Lacs for all 5 FDVs
Remote switching off SB3 FDV (Instantly)
Control panel- Remote Switching off SB1 FDV
Remote switching off SB2 FDV (Instantly)
Remote switching off F Block FDV (Instantly)
Remote switching off SB4 FDV (Instantly)
GSM Based Smart Control of Shop Floor Ventilation System
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Innovative Projects LED Migration Project
Evolution of Lighting
LEDification Project
No expenses in LED- migration
OPEX model Lights Installation Testing amp
Commissioning of LED lights 5 yrs extended warranty
Scope amp Savings
Phase wise LEDification project
Entire plant in phases Better control schemes Reduction in consumption by
50 (Minimum)
Optimal design amp execution
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
Why LED for lighting
LED the best lighting option today
Energy efficient higher Lumens per Watts
No Mercury-Environmental friendly
No IR amp UV emissions Reduced heat generation
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Conventional Lighting system After LED Migration
Power Consumption 14 KW Lux level 125~200
Energy Cons-Monthly 6300 KWH 50400 INR-Annually 75600 KWH 604800 INR
65 KW (Red 464) 250~450 (Inc 250 )
2925 KWH 23400 INR (Red 464 )
35100 KWH 280800 INR
65 KW (Red 464) 250~450 (Inc 250 )
1312 KWH 10400 INR (Red 782 ) 15744 KWH 125952 INR
Occupancy Sensor
After Sensor installation
Occupancy sensor
Sensor Controlled
lightingGroup
Manual Controlled
Lighting group
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
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- Bio-Gas
- Slide Number 21
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- Slide Number 69
- Thank You
-
Total cost | 55177211 | 14176846 | 107850 | 184319 | ||||||||||||||||||
World Resi | 485 | 46 | Profit Margin | 15 | 1530 | 19 | 360 | |||||||||||||||
OECD Resi | 286 | 27 | Sales Tax | 2505507 | 685912 | 5024 | 8654 | |||||||||||||||
144 | 65143189 | 17429501 | 137703 | 225000 | ||||||||||||||||||
57 | ||||||||||||||||||||||
43 | Selling price to Customer | 62637682 | 16743589 | 132679 | 216346 | |||||||||||||||||
14 | ||||||||||||||||||||||
14 | 1191 | 1533 | 1871 | 1480 | ||||||||||||||||||
Total cost | 11863 | 22545 | 3104 | 05896907216 | ||||||||||||||||||
Sales Tax | 526 | 951 | 161 | 1971 | ||||||||||||||||||
Profit Margin | 1480 | 1020 | 1575 | 729 | ||||||||||||||||||
Selling price to Customer | 14500 | 26026 | 3860 | |||||||||||||||||||
New SP | 13974 | 25075 | 3699 | |||||||||||||||||||
Margin | 15 | 10 | 16 | |||||||||||||||||||
Margin | 1 ton of oil equivalent | 418 Giga Joule | ||||||||||||||||||||
10^6 | 181 | 201 | 218 | 234 | 249 | |||||||||||||||||
27 | 30 | 32 | 35 | 38 | ||||||||||||||||||
50 | 55 | 58 | 61 | 64 | ||||||||||||||||||
95 | 104 | 113 | 119 | 128 | ||||||||||||||||||
14 | 195 | 217 | 238 | 258 | 278 | |||||||||||||||||
14 | 450 | 548 | 607 | 659 | 707 | 757 | ||||||||||||||||
43 | ||||||||||||||||||||||
57 | ||||||||||||||||||||||
144 |
Years | 2008 | 2009 | 2010 | 2011 | 2012 | 2013 | 2014 | 2015 | 2016 | 2017 | 2018 | 2019 | 2020 | |||||||||||||||
RsKWh from grid (Commercial)) | 110 | 113 | 117 | 120 | 124 | 128 | 131 | 135 | 139 | 144 | 148 | 152 | 157 | |||||||||||||||
RsKWh from grid (Residential)) | 40 | 41 | 42 | 44 | 45 | 46 | 48 | 49 | 51 | 52 | 54 | 55 | 57 | |||||||||||||||
RsKWh from grid (Industrial) | 60 | 62 | 64 | 66 | 68 | 70 | 72 | 74 | 76 | 78 | 81 | 83 | 86 | |||||||||||||||
RsKWh from solar | 140 | 133 | 127 | 121 | 115 | 110 | 104 | 99 | 95 | 90 | 86 | 82 | 78 |
Australia | 300000 | 1200000 | 2500 | ||||||||
India | 290000 | 1200000 | 2417 | ||||||||
Norway | 170000 | 1200000 | 1417 | ||||||||
United States | 160000 | 1200000 | 1333 | ||||||||
Canada | 100000 | 1200000 | 833 | ||||||||
South Africa | 35000 | 1200000 | 292 | ||||||||
Brazil | 16000 | 1200000 | 133 | ||||||||
Malaysia | 4500 | 1200000 | 038 | ||||||||
Other Countries | 95000 | 1200000 | 792 | ||||||||
World Total |
23 | 8 | 6 | 34 | 2 | |||||||||||||||||||
43 | |||||||||||||||||||||||
Orders | |||||||||||||||||||||||
Arushi | |||||||||||||||||||||||
No | KWp | Rs | |||||||||||||||||||||
FAG | 2875 | 949 | 69 | ||||||||||||||||||||
rest | 1000 | 33 | 24 | ||||||||||||||||||||
116 | 8200 | 27 | 75 | 132 | 500 | 165 | 12 | ||||||||||||||||
100 | 033 | 24 | |||||||||||||||||||||
100 | 033 | 24 | |||||||||||||||||||||
53 | 5800 | 61 | 64 | 68 | 100 | 033 | 24 | ||||||||||||||||
Resi | 50 | 55 | 58 | 61 | 64 | 400 | 132 | 96 | |||||||||||||||
150 | 05 | 36 | |||||||||||||||||||||
Ind | 19100 | 21200 | 230 | 247 | 263 | 100 | 033 | 24 | |||||||||||||||
181 | 201 | 218 | 234 | 249 | 50 | 017 | 12 | ||||||||||||||||
Comm | 28 | 32 | 34 | 37 | 40 | ||||||||||||||||||
27 | 30 | 32 | 35 | 38 | R Lite | 200 | 2 | 1412 | |||||||||||||||
15 | 015 | 106 | |||||||||||||||||||||
Trans | 100 | 110 | 119 | 126 | 135 | 100 | 1 | 706 | |||||||||||||||
95 | 104 | 113 | 119 | 128 | 25 | 025 | 176 | ||||||||||||||||
100 | 1 | 706 | |||||||||||||||||||||
Elec | 206 | 229 | 251 | 272 | 293 | 30 | 03 | 21 | |||||||||||||||
195 | 217 | 238 | 258 | 278 | 25 | 025 | 176 |
Module | 1821 | |||||
Battery | 556 | |||||
Structure Assembly | 212 | |||||
Luminaire amp Charge Controller | 309 | |||||
Cables | 48 | |||||
Freight | 159 | |||||
I ampC | 90 | |||||
Service and Maintenance | 134 | |||||
Logistics and Inventory Holding | 50 | |||||
Sales and Service Tax | 142 |
Loan | Amounts in Rs lac | |||||||||||||
Total Invst | 1000000 | |||||||||||||
Equity | 260000 | |||||||||||||
Debt | 740000 | |||||||||||||
Principal Loan | 740000 | |||||||||||||
Rate of Int | 9 | |||||||||||||
Period | 10 | Years | ||||||||||||
EYI | 1153 | |||||||||||||
Amounts in Rs lac | ||||||||||||||
Op Principal | Interest | Principal | EYI | Cl Principal | Formula for EMI =(pr)(1-(1(1+r)^n)) | |||||||||
1 | 740000 | 66600 | 48707 | 115307 | 691293 | |||||||||
2 | 691293 | 62216 | 53090 | 115307 | 638203 | |||||||||
3 | 638203 | 57438 | 57869 | 115307 | 580334 | |||||||||
4 | 580334 | 52230 | 63077 | 115307 | 517257 | |||||||||
5 | 517257 | 46553 | 68754 | 115307 | 448503 | |||||||||
6 | 448503 | 40365 | 74942 | 115307 | 373562 | |||||||||
7 | 373562 | 33621 | 81686 | 115307 | 291876 | |||||||||
8 | 291876 | 26269 | 89038 | 115307 | 202838 | |||||||||
9 | 202838 | 18255 | 97051 | 115307 | 105786 | |||||||||
10 | 105786 | 9521 | 105786 | 115307 | 000 |
IRR RULE | |||||||||||||||||||||||
For a standard project | NPV gt 0 | if and only if | IRR gt Cost of Capital | ||||||||||||||||||||
IRR Rule Choose a project | if and only if | IRR gt Cost of Capital | |||||||||||||||||||||
Standard means | |||||||||||||||||||||||
- cash outflows occur in early years and cash inflows in later years | |||||||||||||||||||||||
- the alternative to the project is the status quo | |||||||||||||||||||||||
Year | 0 | 1 | 2 | 3 | 4 | 5 | 6 | Interest rate | 547 | ||||||||||||||
Income amounts | ($1000) | $200 | $200 | $200 | $200 | $200 | $200 | ||||||||||||||||
Discounted | -1000 | 189627382194 | 1797927203887 | 1704681145242 | 1616271115239 | 1532446302493 | 1452968903473 | 0 | |||||||||||||||
NPV | 0 | ||||||||||||||||||||||
Thus 547 is the Internal Rate of Return ie IRR | |||||||||||||||||||||||
IRR is the interest rate at which the NPV is equal to zero | |||||||||||||||||||||||
Therefore using Goal seek method |
EMI
Sheet2
Sheet2
Sheet1
World energy by fuel type
Grid Parity in India
Grid Parity in India
Sheet3
IIT - Kanpur- CVBU LUCKNOW
Wind Power
IIT - Kanpur- CVBU LUCKNOW
bull A report on the Solar power says that the utilization of just 5of existing solar energy would suffice the Global energyrequirement
bull Technology is readily available for generation of Power heating cooking etc applications For industries an immediate thoughtof putting up solar power plant of rated capacity and solarconcentrator for Canteen Guest houses offices remotelylocated load centers would reduce the energy bill besidesprotecting the environment
Solar Power
IIT - Kanpur- CVBU LUCKNOW
Bio-Gas
Wastersquos of animals trees rice husk etc can be utilizedfor the generation of gases which inturn utilized forheating cooking applications
Bio-Diesel
As the cost of petroleum products touching the sky an immediate thought on alternate fuels is the top most order of demand today Proven technology for Bio-diesel from Jetropa amp Pengenia etc is readily available With these in line the demand on Petroleum product would come down by 25-35 In APCW premises all unused area can be utilized for Jetropa amp Pengenia cultivation inturn to sell in the market or for mines-vehicle like Dozer Dumper shovel etc application
Bio Fuels
IIT - Kanpur- CVBU LUCKNOW
Simple schematic
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustriesIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
We have Energy Management Cell in our Plant Which initiates amp Manages all sorts of Energy Conservation measuresacross the Plant
Energy Management System
Mr Pramod ChoudharyPlant Head Lucknow
DH ndash Mr S B MattaPlant services
MR -Lko Works Dr SB Matta
DH ndash Mr V AgrawalPaint shop
DH ndash Mr S N VermaTCF
DH ndash Mr U TauheedBIW
DH ndash Mr R K SinghIBF
DH ndash Mr R K SinghAxle Shop
DH ndashMr G V JoshiPlanning
DH ndash Mr A ChhariaMaterials amp ADD
DH ndash Mr Ankush GourHR
DH ndash Mr R K SinghCV- CX
Team Structure ndash ISO 50001
DH ndash Divisional Head
ISO 50001 CertificateEnergy Policy
2013 2016 2019
IIT - Kanpur- CVBU LUCKNOW
ENERGY MANAGEMENT SYSTEM ndash An Overview
TOP MANAGEMENT COMMITMENT
STAFF COMMITMENT
ENERGY AUDIT
ACTION PLAN
MONITORING amp TARGET SETTING
REVIEW amp DEVELOP PROFILE
LONG PAY BACK PROJECTS
IIT - Kanpur- CVBU LUCKNOW
Preliminary Energy audit
Detailed Energy audit
Plant Coordinator
GO AHEAD
Energy savings discussion and presentation
GO AHEAD for Implementation
Energy savings monitoring and interim report to Energy Mgmt Cell
Acceptance of Proposal
Submission of Techno commercial proposal
Team formation
Energy Management CellEnCon Implementation Methodology
copy Copyright Confidential Tata Motors Limited
Innovation Digital Transformation Project Planning amp Operation
3D layout of Manufacturing Line Process flow for Digital transformation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
44
Collaboration
Training
Layout
Maintenance
2D drawings using Auto Cad 3D digital Factory
No single platform for discussions and decision making among various stake-holder
Virtual Factory encouraged different agencies to work in more collaborate manner
Traditional training methods such as classroom teaching using PPTs and OJT
3D Digital Work-Instruction videos along with Quality and Safety awareness
Maintenance based on Real time data
Preventive Maintenance Breakdown Maintenance based on schedule
Collection of information from individual machines and preparing reports
Connected Machines IPMS Mobile App online quality parameter monitoring
Traditional Method Digital Method
Technology Landscape ndash before and after implementation
Factory Set-up time reduced
Issue identified and resolved before physical installationconstruction
Better Visualization of the process enables operator to learn fast
Down-time of machines reduced thusimproving OEE
Better tracking and control quality and Mc parameters Faster information exchange
Transformation Impact
No Virtual Simulation Expensive Physicals only for very critical processes
Virtual Simulation of Critical Processes helped to identified Potential issues
Short Project Lead time Saving on rework cost and time
Simulation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
Sales~10 Increase throughbull Levelled Productionbull Improvement in Customer Experience
Cost
Customer Complaint
Project Time
Quality
Employee Engagement
~15 Reduction through bull Inventory Optimizationbull Warranty Cost reductionbull COPQ Reduction
~15 Reduction through bull Robust Process Designbull Resulting Reliability of Product
~25 Reduction throughbull Better Project
ManagementWith Use of Simulations Avoided Rework
~25 Improvement throughbull Connected Equipment
bull Avoiding Defect Passing
~10 Improvement throughbull Layout Improvementbull Process Automation
bull Ergonomics amp Safety improvement
Quantitative Benefits and Awarded in CII Digital Transformation Meet
Innovation Digital Transformation Project Planning amp Operation
IIT - Kanpur- CVBU LUCKNOW
Teamwork Employee involvement amp MonitoringDaily Consumption Report
Daily Energy Audit Report
Daily Shopwise Report
Daily Solar Generation Report
Hourly Consumption Report-Plant
Hourly Consumption Report-Shop
Monthly Energy Consumption Report
Awar
enes
sle
vel
2017-18
Reporting of energy consumption of the plant and
individual shops on fortnightly and monthly
basis
2018-19
H1 Reporting of entire plantrsquos energy consumption on daily basis
Daily Energy Audit Report (DEAR) circulated across the plant to minimize
energy wastageH2 Reporting of entire plantrsquos and shop-wise energy consumption on
daily basis
2019-20
H1 Reporting of shop-wise energy consumption started on hourly
basisH1 Reporting of working dayrsquos
and non-working dayrsquos consumption separately for
identification of areasprocesses 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
ENERGY CONSUMPTION 2019-20Figures in KWH
FACTORY Dec-19 Jan-20 Feb-20 Mar-20EASTERN COMPLEXBIWBIW Cab 30103 29885 42825 7097BIW Cowl 17657 16650 20104 7438FDV 0 0 0 0COMP 13691 12555 15960 4155BIW Office others 3459 2845 3824 599Distribution Losses 5737 5686 8235 3398Total 70648 67620 90949 22688PAINT SHOPPTED 276243 270240 58056 125761Paint 199896 182651 252332 55852COMP 69201 71042 191305 32740Paint others 33456 34243 71892 16336Distribution Losses 52586 55324 32462 45001Total 631382 613501 606048 275690TCFAssly 84210 101803 92831 23993Trim Assly 12468 17988 15117 4219FDV 0 0 0 0Compressor 38154 41387 42232 13080TCF officeothers 19581 18255 15958 13560Distribution Losses 14262 16490 17609 10428Total 168676 195923 183747 65281
Rear Axle and Line-45 17252 16260 4125 1830Logistics Centre 14904 25247 20629 9615RSO 5597 9370 8390 8445
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
GSM Based Smart Control of Shop Floor Ventilation System
Concerns in present method bull One operator has to travel around 1 Km for manually switching off all FDVs in western complex due to control panel given at that particular
location and hence there is electrical energy wastage of 5137 KWHmonth due to travel time of around 20 mins
Present process Moving to
switching off SB1 FDV
(0 mins)
Moving to switching off SB2 FDV
(5 mins)
Moving to switching off F Block FDV
(15 mins)
Moving to switching off
SB4 FDV(20 mins)
Moving to switching off SB3 FDV
(10 mins)
Blower amp Control panel
FDV Locations in Line 1
EnCon Projects
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
LCA Solution
bull Remote switching off FDVs by integrating off operation of FDV with GSMmodem from one location Also message will be delivered to user thatwhich FDV has been switched off (wireless switching off operation is donethrough GSM modem to avoid cable cost and laying of cable line)
Benefits amp Horizontal Scope 1Energy saving - Energy saving of 41096 KWHannum by providing remote switching off FDVs
2 Cost Saving - Recurring cost saving of Rs 328 lakhsannum3 Environment- Reduction in carbon footprint (reduction of 337 tonne of CO2annum by energy saving)
4 SMS escalation to user for information of FDV switch off5No laying out of wire is required as it is wireless communication with help of GSM modem6 Horizontal deployment of GSM based control for other process machines of assembly line 12 and 3
Solution Cost-Rs 328 Lacs for all 5 FDVs
Remote switching off SB3 FDV (Instantly)
Control panel- Remote Switching off SB1 FDV
Remote switching off SB2 FDV (Instantly)
Remote switching off F Block FDV (Instantly)
Remote switching off SB4 FDV (Instantly)
GSM Based Smart Control of Shop Floor Ventilation System
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Innovative Projects LED Migration Project
Evolution of Lighting
LEDification Project
No expenses in LED- migration
OPEX model Lights Installation Testing amp
Commissioning of LED lights 5 yrs extended warranty
Scope amp Savings
Phase wise LEDification project
Entire plant in phases Better control schemes Reduction in consumption by
50 (Minimum)
Optimal design amp execution
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
Why LED for lighting
LED the best lighting option today
Energy efficient higher Lumens per Watts
No Mercury-Environmental friendly
No IR amp UV emissions Reduced heat generation
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Conventional Lighting system After LED Migration
Power Consumption 14 KW Lux level 125~200
Energy Cons-Monthly 6300 KWH 50400 INR-Annually 75600 KWH 604800 INR
65 KW (Red 464) 250~450 (Inc 250 )
2925 KWH 23400 INR (Red 464 )
35100 KWH 280800 INR
65 KW (Red 464) 250~450 (Inc 250 )
1312 KWH 10400 INR (Red 782 ) 15744 KWH 125952 INR
Occupancy Sensor
After Sensor installation
Occupancy sensor
Sensor Controlled
lightingGroup
Manual Controlled
Lighting group
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
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- Slide Number 7
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- Bio-Gas
- Slide Number 21
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- Thank You
-
Total cost | 55177211 | 14176846 | 107850 | 184319 | ||||||||||||||||||
World Resi | 485 | 46 | Profit Margin | 15 | 1530 | 19 | 360 | |||||||||||||||
OECD Resi | 286 | 27 | Sales Tax | 2505507 | 685912 | 5024 | 8654 | |||||||||||||||
144 | 65143189 | 17429501 | 137703 | 225000 | ||||||||||||||||||
57 | ||||||||||||||||||||||
43 | Selling price to Customer | 62637682 | 16743589 | 132679 | 216346 | |||||||||||||||||
14 | ||||||||||||||||||||||
14 | 1191 | 1533 | 1871 | 1480 | ||||||||||||||||||
Total cost | 11863 | 22545 | 3104 | 05896907216 | ||||||||||||||||||
Sales Tax | 526 | 951 | 161 | 1971 | ||||||||||||||||||
Profit Margin | 1480 | 1020 | 1575 | 729 | ||||||||||||||||||
Selling price to Customer | 14500 | 26026 | 3860 | |||||||||||||||||||
New SP | 13974 | 25075 | 3699 | |||||||||||||||||||
Margin | 15 | 10 | 16 | |||||||||||||||||||
Margin | 1 ton of oil equivalent | 418 Giga Joule | ||||||||||||||||||||
10^6 | 181 | 201 | 218 | 234 | 249 | |||||||||||||||||
27 | 30 | 32 | 35 | 38 | ||||||||||||||||||
50 | 55 | 58 | 61 | 64 | ||||||||||||||||||
95 | 104 | 113 | 119 | 128 | ||||||||||||||||||
14 | 195 | 217 | 238 | 258 | 278 | |||||||||||||||||
14 | 450 | 548 | 607 | 659 | 707 | 757 | ||||||||||||||||
43 | ||||||||||||||||||||||
57 | ||||||||||||||||||||||
144 |
Years | 2008 | 2009 | 2010 | 2011 | 2012 | 2013 | 2014 | 2015 | 2016 | 2017 | 2018 | 2019 | 2020 | |||||||||||||||
RsKWh from grid (Commercial)) | 110 | 113 | 117 | 120 | 124 | 128 | 131 | 135 | 139 | 144 | 148 | 152 | 157 | |||||||||||||||
RsKWh from grid (Residential)) | 40 | 41 | 42 | 44 | 45 | 46 | 48 | 49 | 51 | 52 | 54 | 55 | 57 | |||||||||||||||
RsKWh from grid (Industrial) | 60 | 62 | 64 | 66 | 68 | 70 | 72 | 74 | 76 | 78 | 81 | 83 | 86 | |||||||||||||||
RsKWh from solar | 140 | 133 | 127 | 121 | 115 | 110 | 104 | 99 | 95 | 90 | 86 | 82 | 78 |
Australia | 300000 | 1200000 | 2500 | ||||||||
India | 290000 | 1200000 | 2417 | ||||||||
Norway | 170000 | 1200000 | 1417 | ||||||||
United States | 160000 | 1200000 | 1333 | ||||||||
Canada | 100000 | 1200000 | 833 | ||||||||
South Africa | 35000 | 1200000 | 292 | ||||||||
Brazil | 16000 | 1200000 | 133 | ||||||||
Malaysia | 4500 | 1200000 | 038 | ||||||||
Other Countries | 95000 | 1200000 | 792 | ||||||||
World Total |
23 | 8 | 6 | 34 | 2 | |||||||||||||||||||
43 | |||||||||||||||||||||||
Orders | |||||||||||||||||||||||
Arushi | |||||||||||||||||||||||
No | KWp | Rs | |||||||||||||||||||||
FAG | 2875 | 949 | 69 | ||||||||||||||||||||
rest | 1000 | 33 | 24 | ||||||||||||||||||||
116 | 8200 | 27 | 75 | 132 | 500 | 165 | 12 | ||||||||||||||||
100 | 033 | 24 | |||||||||||||||||||||
100 | 033 | 24 | |||||||||||||||||||||
53 | 5800 | 61 | 64 | 68 | 100 | 033 | 24 | ||||||||||||||||
Resi | 50 | 55 | 58 | 61 | 64 | 400 | 132 | 96 | |||||||||||||||
150 | 05 | 36 | |||||||||||||||||||||
Ind | 19100 | 21200 | 230 | 247 | 263 | 100 | 033 | 24 | |||||||||||||||
181 | 201 | 218 | 234 | 249 | 50 | 017 | 12 | ||||||||||||||||
Comm | 28 | 32 | 34 | 37 | 40 | ||||||||||||||||||
27 | 30 | 32 | 35 | 38 | R Lite | 200 | 2 | 1412 | |||||||||||||||
15 | 015 | 106 | |||||||||||||||||||||
Trans | 100 | 110 | 119 | 126 | 135 | 100 | 1 | 706 | |||||||||||||||
95 | 104 | 113 | 119 | 128 | 25 | 025 | 176 | ||||||||||||||||
100 | 1 | 706 | |||||||||||||||||||||
Elec | 206 | 229 | 251 | 272 | 293 | 30 | 03 | 21 | |||||||||||||||
195 | 217 | 238 | 258 | 278 | 25 | 025 | 176 |
Module | 1821 | |||||
Battery | 556 | |||||
Structure Assembly | 212 | |||||
Luminaire amp Charge Controller | 309 | |||||
Cables | 48 | |||||
Freight | 159 | |||||
I ampC | 90 | |||||
Service and Maintenance | 134 | |||||
Logistics and Inventory Holding | 50 | |||||
Sales and Service Tax | 142 |
Loan | Amounts in Rs lac | |||||||||||||
Total Invst | 1000000 | |||||||||||||
Equity | 260000 | |||||||||||||
Debt | 740000 | |||||||||||||
Principal Loan | 740000 | |||||||||||||
Rate of Int | 9 | |||||||||||||
Period | 10 | Years | ||||||||||||
EYI | 1153 | |||||||||||||
Amounts in Rs lac | ||||||||||||||
Op Principal | Interest | Principal | EYI | Cl Principal | Formula for EMI =(pr)(1-(1(1+r)^n)) | |||||||||
1 | 740000 | 66600 | 48707 | 115307 | 691293 | |||||||||
2 | 691293 | 62216 | 53090 | 115307 | 638203 | |||||||||
3 | 638203 | 57438 | 57869 | 115307 | 580334 | |||||||||
4 | 580334 | 52230 | 63077 | 115307 | 517257 | |||||||||
5 | 517257 | 46553 | 68754 | 115307 | 448503 | |||||||||
6 | 448503 | 40365 | 74942 | 115307 | 373562 | |||||||||
7 | 373562 | 33621 | 81686 | 115307 | 291876 | |||||||||
8 | 291876 | 26269 | 89038 | 115307 | 202838 | |||||||||
9 | 202838 | 18255 | 97051 | 115307 | 105786 | |||||||||
10 | 105786 | 9521 | 105786 | 115307 | 000 |
Sheet2
Sheet2
Sheet1
World energy by fuel type
Grid Parity in India
Grid Parity in India
Sheet3
IIT - Kanpur- CVBU LUCKNOW
Wind Power
IIT - Kanpur- CVBU LUCKNOW
bull A report on the Solar power says that the utilization of just 5of existing solar energy would suffice the Global energyrequirement
bull Technology is readily available for generation of Power heating cooking etc applications For industries an immediate thoughtof putting up solar power plant of rated capacity and solarconcentrator for Canteen Guest houses offices remotelylocated load centers would reduce the energy bill besidesprotecting the environment
Solar Power
IIT - Kanpur- CVBU LUCKNOW
Bio-Gas
Wastersquos of animals trees rice husk etc can be utilizedfor the generation of gases which inturn utilized forheating cooking applications
Bio-Diesel
As the cost of petroleum products touching the sky an immediate thought on alternate fuels is the top most order of demand today Proven technology for Bio-diesel from Jetropa amp Pengenia etc is readily available With these in line the demand on Petroleum product would come down by 25-35 In APCW premises all unused area can be utilized for Jetropa amp Pengenia cultivation inturn to sell in the market or for mines-vehicle like Dozer Dumper shovel etc application
Bio Fuels
IIT - Kanpur- CVBU LUCKNOW
Simple schematic
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustriesIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
We have Energy Management Cell in our Plant Which initiates amp Manages all sorts of Energy Conservation measuresacross the Plant
Energy Management System
Mr Pramod ChoudharyPlant Head Lucknow
DH ndash Mr S B MattaPlant services
MR -Lko Works Dr SB Matta
DH ndash Mr V AgrawalPaint shop
DH ndash Mr S N VermaTCF
DH ndash Mr U TauheedBIW
DH ndash Mr R K SinghIBF
DH ndash Mr R K SinghAxle Shop
DH ndashMr G V JoshiPlanning
DH ndash Mr A ChhariaMaterials amp ADD
DH ndash Mr Ankush GourHR
DH ndash Mr R K SinghCV- CX
Team Structure ndash ISO 50001
DH ndash Divisional Head
ISO 50001 CertificateEnergy Policy
2013 2016 2019
IIT - Kanpur- CVBU LUCKNOW
ENERGY MANAGEMENT SYSTEM ndash An Overview
TOP MANAGEMENT COMMITMENT
STAFF COMMITMENT
ENERGY AUDIT
ACTION PLAN
MONITORING amp TARGET SETTING
REVIEW amp DEVELOP PROFILE
LONG PAY BACK PROJECTS
IIT - Kanpur- CVBU LUCKNOW
Preliminary Energy audit
Detailed Energy audit
Plant Coordinator
GO AHEAD
Energy savings discussion and presentation
GO AHEAD for Implementation
Energy savings monitoring and interim report to Energy Mgmt Cell
Acceptance of Proposal
Submission of Techno commercial proposal
Team formation
Energy Management CellEnCon Implementation Methodology
copy Copyright Confidential Tata Motors Limited
Innovation Digital Transformation Project Planning amp Operation
3D layout of Manufacturing Line Process flow for Digital transformation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
44
Collaboration
Training
Layout
Maintenance
2D drawings using Auto Cad 3D digital Factory
No single platform for discussions and decision making among various stake-holder
Virtual Factory encouraged different agencies to work in more collaborate manner
Traditional training methods such as classroom teaching using PPTs and OJT
3D Digital Work-Instruction videos along with Quality and Safety awareness
Maintenance based on Real time data
Preventive Maintenance Breakdown Maintenance based on schedule
Collection of information from individual machines and preparing reports
Connected Machines IPMS Mobile App online quality parameter monitoring
Traditional Method Digital Method
Technology Landscape ndash before and after implementation
Factory Set-up time reduced
Issue identified and resolved before physical installationconstruction
Better Visualization of the process enables operator to learn fast
Down-time of machines reduced thusimproving OEE
Better tracking and control quality and Mc parameters Faster information exchange
Transformation Impact
No Virtual Simulation Expensive Physicals only for very critical processes
Virtual Simulation of Critical Processes helped to identified Potential issues
Short Project Lead time Saving on rework cost and time
Simulation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
Sales~10 Increase throughbull Levelled Productionbull Improvement in Customer Experience
Cost
Customer Complaint
Project Time
Quality
Employee Engagement
~15 Reduction through bull Inventory Optimizationbull Warranty Cost reductionbull COPQ Reduction
~15 Reduction through bull Robust Process Designbull Resulting Reliability of Product
~25 Reduction throughbull Better Project
ManagementWith Use of Simulations Avoided Rework
~25 Improvement throughbull Connected Equipment
bull Avoiding Defect Passing
~10 Improvement throughbull Layout Improvementbull Process Automation
bull Ergonomics amp Safety improvement
Quantitative Benefits and Awarded in CII Digital Transformation Meet
Innovation Digital Transformation Project Planning amp Operation
IIT - Kanpur- CVBU LUCKNOW
Teamwork Employee involvement amp MonitoringDaily Consumption Report
Daily Energy Audit Report
Daily Shopwise Report
Daily Solar Generation Report
Hourly Consumption Report-Plant
Hourly Consumption Report-Shop
Monthly Energy Consumption Report
Awar
enes
sle
vel
2017-18
Reporting of energy consumption of the plant and
individual shops on fortnightly and monthly
basis
2018-19
H1 Reporting of entire plantrsquos energy consumption on daily basis
Daily Energy Audit Report (DEAR) circulated across the plant to minimize
energy wastageH2 Reporting of entire plantrsquos and shop-wise energy consumption on
daily basis
2019-20
H1 Reporting of shop-wise energy consumption started on hourly
basisH1 Reporting of working dayrsquos
and non-working dayrsquos consumption separately for
identification of areasprocesses 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
ENERGY CONSUMPTION 2019-20Figures in KWH
FACTORY Dec-19 Jan-20 Feb-20 Mar-20EASTERN COMPLEXBIWBIW Cab 30103 29885 42825 7097BIW Cowl 17657 16650 20104 7438FDV 0 0 0 0COMP 13691 12555 15960 4155BIW Office others 3459 2845 3824 599Distribution Losses 5737 5686 8235 3398Total 70648 67620 90949 22688PAINT SHOPPTED 276243 270240 58056 125761Paint 199896 182651 252332 55852COMP 69201 71042 191305 32740Paint others 33456 34243 71892 16336Distribution Losses 52586 55324 32462 45001Total 631382 613501 606048 275690TCFAssly 84210 101803 92831 23993Trim Assly 12468 17988 15117 4219FDV 0 0 0 0Compressor 38154 41387 42232 13080TCF officeothers 19581 18255 15958 13560Distribution Losses 14262 16490 17609 10428Total 168676 195923 183747 65281
Rear Axle and Line-45 17252 16260 4125 1830Logistics Centre 14904 25247 20629 9615RSO 5597 9370 8390 8445
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
GSM Based Smart Control of Shop Floor Ventilation System
Concerns in present method bull One operator has to travel around 1 Km for manually switching off all FDVs in western complex due to control panel given at that particular
location and hence there is electrical energy wastage of 5137 KWHmonth due to travel time of around 20 mins
Present process Moving to
switching off SB1 FDV
(0 mins)
Moving to switching off SB2 FDV
(5 mins)
Moving to switching off F Block FDV
(15 mins)
Moving to switching off
SB4 FDV(20 mins)
Moving to switching off SB3 FDV
(10 mins)
Blower amp Control panel
FDV Locations in Line 1
EnCon Projects
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
LCA Solution
bull Remote switching off FDVs by integrating off operation of FDV with GSMmodem from one location Also message will be delivered to user thatwhich FDV has been switched off (wireless switching off operation is donethrough GSM modem to avoid cable cost and laying of cable line)
Benefits amp Horizontal Scope 1Energy saving - Energy saving of 41096 KWHannum by providing remote switching off FDVs
2 Cost Saving - Recurring cost saving of Rs 328 lakhsannum3 Environment- Reduction in carbon footprint (reduction of 337 tonne of CO2annum by energy saving)
4 SMS escalation to user for information of FDV switch off5No laying out of wire is required as it is wireless communication with help of GSM modem6 Horizontal deployment of GSM based control for other process machines of assembly line 12 and 3
Solution Cost-Rs 328 Lacs for all 5 FDVs
Remote switching off SB3 FDV (Instantly)
Control panel- Remote Switching off SB1 FDV
Remote switching off SB2 FDV (Instantly)
Remote switching off F Block FDV (Instantly)
Remote switching off SB4 FDV (Instantly)
GSM Based Smart Control of Shop Floor Ventilation System
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Innovative Projects LED Migration Project
Evolution of Lighting
LEDification Project
No expenses in LED- migration
OPEX model Lights Installation Testing amp
Commissioning of LED lights 5 yrs extended warranty
Scope amp Savings
Phase wise LEDification project
Entire plant in phases Better control schemes Reduction in consumption by
50 (Minimum)
Optimal design amp execution
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
Why LED for lighting
LED the best lighting option today
Energy efficient higher Lumens per Watts
No Mercury-Environmental friendly
No IR amp UV emissions Reduced heat generation
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Conventional Lighting system After LED Migration
Power Consumption 14 KW Lux level 125~200
Energy Cons-Monthly 6300 KWH 50400 INR-Annually 75600 KWH 604800 INR
65 KW (Red 464) 250~450 (Inc 250 )
2925 KWH 23400 INR (Red 464 )
35100 KWH 280800 INR
65 KW (Red 464) 250~450 (Inc 250 )
1312 KWH 10400 INR (Red 782 ) 15744 KWH 125952 INR
Occupancy Sensor
After Sensor installation
Occupancy sensor
Sensor Controlled
lightingGroup
Manual Controlled
Lighting group
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
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- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
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- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
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- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Slide Number 55
- Slide Number 56
- Slide Number 57
- Slide Number 58
- Slide Number 59
- Slide Number 60
- Slide Number 61
- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
Total cost | 55177211 | 14176846 | 107850 | 184319 | ||||||||||||||||||
World Resi | 485 | 46 | Profit Margin | 15 | 1530 | 19 | 360 | |||||||||||||||
OECD Resi | 286 | 27 | Sales Tax | 2505507 | 685912 | 5024 | 8654 | |||||||||||||||
144 | 65143189 | 17429501 | 137703 | 225000 | ||||||||||||||||||
57 | ||||||||||||||||||||||
43 | Selling price to Customer | 62637682 | 16743589 | 132679 | 216346 | |||||||||||||||||
14 | ||||||||||||||||||||||
14 | 1191 | 1533 | 1871 | 1480 | ||||||||||||||||||
Total cost | 11863 | 22545 | 3104 | 05896907216 | ||||||||||||||||||
Sales Tax | 526 | 951 | 161 | 1971 | ||||||||||||||||||
Profit Margin | 1480 | 1020 | 1575 | 729 | ||||||||||||||||||
Selling price to Customer | 14500 | 26026 | 3860 | |||||||||||||||||||
New SP | 13974 | 25075 | 3699 | |||||||||||||||||||
Margin | 15 | 10 | 16 | |||||||||||||||||||
Margin | 1 ton of oil equivalent | 418 Giga Joule | ||||||||||||||||||||
10^6 | 181 | 201 | 218 | 234 | 249 | |||||||||||||||||
27 | 30 | 32 | 35 | 38 | ||||||||||||||||||
50 | 55 | 58 | 61 | 64 | ||||||||||||||||||
95 | 104 | 113 | 119 | 128 | ||||||||||||||||||
14 | 195 | 217 | 238 | 258 | 278 | |||||||||||||||||
14 | 450 | 548 | 607 | 659 | 707 | 757 | ||||||||||||||||
43 | ||||||||||||||||||||||
57 | ||||||||||||||||||||||
144 |
Years | 2008 | 2009 | 2010 | 2011 | 2012 | 2013 | 2014 | 2015 | 2016 | 2017 | 2018 | 2019 | 2020 | |||||||||||||||
RsKWh from grid (Commercial)) | 110 | 113 | 117 | 120 | 124 | 128 | 131 | 135 | 139 | 144 | 148 | 152 | 157 | |||||||||||||||
RsKWh from grid (Residential)) | 40 | 41 | 42 | 44 | 45 | 46 | 48 | 49 | 51 | 52 | 54 | 55 | 57 | |||||||||||||||
RsKWh from grid (Industrial) | 60 | 62 | 64 | 66 | 68 | 70 | 72 | 74 | 76 | 78 | 81 | 83 | 86 | |||||||||||||||
RsKWh from solar | 140 | 133 | 127 | 121 | 115 | 110 | 104 | 99 | 95 | 90 | 86 | 82 | 78 |
Australia | 300000 | 1200000 | 2500 | ||||||||
India | 290000 | 1200000 | 2417 | ||||||||
Norway | 170000 | 1200000 | 1417 | ||||||||
United States | 160000 | 1200000 | 1333 | ||||||||
Canada | 100000 | 1200000 | 833 | ||||||||
South Africa | 35000 | 1200000 | 292 | ||||||||
Brazil | 16000 | 1200000 | 133 | ||||||||
Malaysia | 4500 | 1200000 | 038 | ||||||||
Other Countries | 95000 | 1200000 | 792 | ||||||||
World Total |
23 | 8 | 6 | 34 | 2 | |||||||||||||||||||
43 | |||||||||||||||||||||||
Orders | |||||||||||||||||||||||
Arushi | |||||||||||||||||||||||
No | KWp | Rs | |||||||||||||||||||||
FAG | 2875 | 949 | 69 | ||||||||||||||||||||
rest | 1000 | 33 | 24 | ||||||||||||||||||||
116 | 8200 | 27 | 75 | 132 | 500 | 165 | 12 | ||||||||||||||||
100 | 033 | 24 | |||||||||||||||||||||
100 | 033 | 24 | |||||||||||||||||||||
53 | 5800 | 61 | 64 | 68 | 100 | 033 | 24 | ||||||||||||||||
Resi | 50 | 55 | 58 | 61 | 64 | 400 | 132 | 96 | |||||||||||||||
150 | 05 | 36 | |||||||||||||||||||||
Ind | 19100 | 21200 | 230 | 247 | 263 | 100 | 033 | 24 | |||||||||||||||
181 | 201 | 218 | 234 | 249 | 50 | 017 | 12 | ||||||||||||||||
Comm | 28 | 32 | 34 | 37 | 40 | ||||||||||||||||||
27 | 30 | 32 | 35 | 38 | R Lite | 200 | 2 | 1412 | |||||||||||||||
15 | 015 | 106 | |||||||||||||||||||||
Trans | 100 | 110 | 119 | 126 | 135 | 100 | 1 | 706 | |||||||||||||||
95 | 104 | 113 | 119 | 128 | 25 | 025 | 176 | ||||||||||||||||
100 | 1 | 706 | |||||||||||||||||||||
Elec | 206 | 229 | 251 | 272 | 293 | 30 | 03 | 21 | |||||||||||||||
195 | 217 | 238 | 258 | 278 | 25 | 025 | 176 |
Module | 1821 | |||||
Battery | 556 | |||||
Structure Assembly | 212 | |||||
Luminaire amp Charge Controller | 309 | |||||
Cables | 48 | |||||
Freight | 159 | |||||
I ampC | 90 | |||||
Service and Maintenance | 134 | |||||
Logistics and Inventory Holding | 50 | |||||
Sales and Service Tax | 142 |
Sheet2
Sheet1
World energy by fuel type
Grid Parity in India
Grid Parity in India
Sheet3
IIT - Kanpur- CVBU LUCKNOW
Wind Power
IIT - Kanpur- CVBU LUCKNOW
bull A report on the Solar power says that the utilization of just 5of existing solar energy would suffice the Global energyrequirement
bull Technology is readily available for generation of Power heating cooking etc applications For industries an immediate thoughtof putting up solar power plant of rated capacity and solarconcentrator for Canteen Guest houses offices remotelylocated load centers would reduce the energy bill besidesprotecting the environment
Solar Power
IIT - Kanpur- CVBU LUCKNOW
Bio-Gas
Wastersquos of animals trees rice husk etc can be utilizedfor the generation of gases which inturn utilized forheating cooking applications
Bio-Diesel
As the cost of petroleum products touching the sky an immediate thought on alternate fuels is the top most order of demand today Proven technology for Bio-diesel from Jetropa amp Pengenia etc is readily available With these in line the demand on Petroleum product would come down by 25-35 In APCW premises all unused area can be utilized for Jetropa amp Pengenia cultivation inturn to sell in the market or for mines-vehicle like Dozer Dumper shovel etc application
Bio Fuels
IIT - Kanpur- CVBU LUCKNOW
Simple schematic
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustriesIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
We have Energy Management Cell in our Plant Which initiates amp Manages all sorts of Energy Conservation measuresacross the Plant
Energy Management System
Mr Pramod ChoudharyPlant Head Lucknow
DH ndash Mr S B MattaPlant services
MR -Lko Works Dr SB Matta
DH ndash Mr V AgrawalPaint shop
DH ndash Mr S N VermaTCF
DH ndash Mr U TauheedBIW
DH ndash Mr R K SinghIBF
DH ndash Mr R K SinghAxle Shop
DH ndashMr G V JoshiPlanning
DH ndash Mr A ChhariaMaterials amp ADD
DH ndash Mr Ankush GourHR
DH ndash Mr R K SinghCV- CX
Team Structure ndash ISO 50001
DH ndash Divisional Head
ISO 50001 CertificateEnergy Policy
2013 2016 2019
IIT - Kanpur- CVBU LUCKNOW
ENERGY MANAGEMENT SYSTEM ndash An Overview
TOP MANAGEMENT COMMITMENT
STAFF COMMITMENT
ENERGY AUDIT
ACTION PLAN
MONITORING amp TARGET SETTING
REVIEW amp DEVELOP PROFILE
LONG PAY BACK PROJECTS
IIT - Kanpur- CVBU LUCKNOW
Preliminary Energy audit
Detailed Energy audit
Plant Coordinator
GO AHEAD
Energy savings discussion and presentation
GO AHEAD for Implementation
Energy savings monitoring and interim report to Energy Mgmt Cell
Acceptance of Proposal
Submission of Techno commercial proposal
Team formation
Energy Management CellEnCon Implementation Methodology
copy Copyright Confidential Tata Motors Limited
Innovation Digital Transformation Project Planning amp Operation
3D layout of Manufacturing Line Process flow for Digital transformation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
44
Collaboration
Training
Layout
Maintenance
2D drawings using Auto Cad 3D digital Factory
No single platform for discussions and decision making among various stake-holder
Virtual Factory encouraged different agencies to work in more collaborate manner
Traditional training methods such as classroom teaching using PPTs and OJT
3D Digital Work-Instruction videos along with Quality and Safety awareness
Maintenance based on Real time data
Preventive Maintenance Breakdown Maintenance based on schedule
Collection of information from individual machines and preparing reports
Connected Machines IPMS Mobile App online quality parameter monitoring
Traditional Method Digital Method
Technology Landscape ndash before and after implementation
Factory Set-up time reduced
Issue identified and resolved before physical installationconstruction
Better Visualization of the process enables operator to learn fast
Down-time of machines reduced thusimproving OEE
Better tracking and control quality and Mc parameters Faster information exchange
Transformation Impact
No Virtual Simulation Expensive Physicals only for very critical processes
Virtual Simulation of Critical Processes helped to identified Potential issues
Short Project Lead time Saving on rework cost and time
Simulation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
Sales~10 Increase throughbull Levelled Productionbull Improvement in Customer Experience
Cost
Customer Complaint
Project Time
Quality
Employee Engagement
~15 Reduction through bull Inventory Optimizationbull Warranty Cost reductionbull COPQ Reduction
~15 Reduction through bull Robust Process Designbull Resulting Reliability of Product
~25 Reduction throughbull Better Project
ManagementWith Use of Simulations Avoided Rework
~25 Improvement throughbull Connected Equipment
bull Avoiding Defect Passing
~10 Improvement throughbull Layout Improvementbull Process Automation
bull Ergonomics amp Safety improvement
Quantitative Benefits and Awarded in CII Digital Transformation Meet
Innovation Digital Transformation Project Planning amp Operation
IIT - Kanpur- CVBU LUCKNOW
Teamwork Employee involvement amp MonitoringDaily Consumption Report
Daily Energy Audit Report
Daily Shopwise Report
Daily Solar Generation Report
Hourly Consumption Report-Plant
Hourly Consumption Report-Shop
Monthly Energy Consumption Report
Awar
enes
sle
vel
2017-18
Reporting of energy consumption of the plant and
individual shops on fortnightly and monthly
basis
2018-19
H1 Reporting of entire plantrsquos energy consumption on daily basis
Daily Energy Audit Report (DEAR) circulated across the plant to minimize
energy wastageH2 Reporting of entire plantrsquos and shop-wise energy consumption on
daily basis
2019-20
H1 Reporting of shop-wise energy consumption started on hourly
basisH1 Reporting of working dayrsquos
and non-working dayrsquos consumption separately for
identification of areasprocesses 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
ENERGY CONSUMPTION 2019-20Figures in KWH
FACTORY Dec-19 Jan-20 Feb-20 Mar-20EASTERN COMPLEXBIWBIW Cab 30103 29885 42825 7097BIW Cowl 17657 16650 20104 7438FDV 0 0 0 0COMP 13691 12555 15960 4155BIW Office others 3459 2845 3824 599Distribution Losses 5737 5686 8235 3398Total 70648 67620 90949 22688PAINT SHOPPTED 276243 270240 58056 125761Paint 199896 182651 252332 55852COMP 69201 71042 191305 32740Paint others 33456 34243 71892 16336Distribution Losses 52586 55324 32462 45001Total 631382 613501 606048 275690TCFAssly 84210 101803 92831 23993Trim Assly 12468 17988 15117 4219FDV 0 0 0 0Compressor 38154 41387 42232 13080TCF officeothers 19581 18255 15958 13560Distribution Losses 14262 16490 17609 10428Total 168676 195923 183747 65281
Rear Axle and Line-45 17252 16260 4125 1830Logistics Centre 14904 25247 20629 9615RSO 5597 9370 8390 8445
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
GSM Based Smart Control of Shop Floor Ventilation System
Concerns in present method bull One operator has to travel around 1 Km for manually switching off all FDVs in western complex due to control panel given at that particular
location and hence there is electrical energy wastage of 5137 KWHmonth due to travel time of around 20 mins
Present process Moving to
switching off SB1 FDV
(0 mins)
Moving to switching off SB2 FDV
(5 mins)
Moving to switching off F Block FDV
(15 mins)
Moving to switching off
SB4 FDV(20 mins)
Moving to switching off SB3 FDV
(10 mins)
Blower amp Control panel
FDV Locations in Line 1
EnCon Projects
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
LCA Solution
bull Remote switching off FDVs by integrating off operation of FDV with GSMmodem from one location Also message will be delivered to user thatwhich FDV has been switched off (wireless switching off operation is donethrough GSM modem to avoid cable cost and laying of cable line)
Benefits amp Horizontal Scope 1Energy saving - Energy saving of 41096 KWHannum by providing remote switching off FDVs
2 Cost Saving - Recurring cost saving of Rs 328 lakhsannum3 Environment- Reduction in carbon footprint (reduction of 337 tonne of CO2annum by energy saving)
4 SMS escalation to user for information of FDV switch off5No laying out of wire is required as it is wireless communication with help of GSM modem6 Horizontal deployment of GSM based control for other process machines of assembly line 12 and 3
Solution Cost-Rs 328 Lacs for all 5 FDVs
Remote switching off SB3 FDV (Instantly)
Control panel- Remote Switching off SB1 FDV
Remote switching off SB2 FDV (Instantly)
Remote switching off F Block FDV (Instantly)
Remote switching off SB4 FDV (Instantly)
GSM Based Smart Control of Shop Floor Ventilation System
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Innovative Projects LED Migration Project
Evolution of Lighting
LEDification Project
No expenses in LED- migration
OPEX model Lights Installation Testing amp
Commissioning of LED lights 5 yrs extended warranty
Scope amp Savings
Phase wise LEDification project
Entire plant in phases Better control schemes Reduction in consumption by
50 (Minimum)
Optimal design amp execution
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
Why LED for lighting
LED the best lighting option today
Energy efficient higher Lumens per Watts
No Mercury-Environmental friendly
No IR amp UV emissions Reduced heat generation
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Conventional Lighting system After LED Migration
Power Consumption 14 KW Lux level 125~200
Energy Cons-Monthly 6300 KWH 50400 INR-Annually 75600 KWH 604800 INR
65 KW (Red 464) 250~450 (Inc 250 )
2925 KWH 23400 INR (Red 464 )
35100 KWH 280800 INR
65 KW (Red 464) 250~450 (Inc 250 )
1312 KWH 10400 INR (Red 782 ) 15744 KWH 125952 INR
Occupancy Sensor
After Sensor installation
Occupancy sensor
Sensor Controlled
lightingGroup
Manual Controlled
Lighting group
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
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- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
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- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
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- Slide Number 49
- Slide Number 50
- Slide Number 51
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- Slide Number 53
- Slide Number 54
- Slide Number 55
- Slide Number 56
- Slide Number 57
- Slide Number 58
- Slide Number 59
- Slide Number 60
- Slide Number 61
- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
Total cost | 55177211 | 14176846 | 107850 | 184319 | ||||||||||||||||||
World Resi | 485 | 46 | Profit Margin | 15 | 1530 | 19 | 360 | |||||||||||||||
OECD Resi | 286 | 27 | Sales Tax | 2505507 | 685912 | 5024 | 8654 | |||||||||||||||
144 | 65143189 | 17429501 | 137703 | 225000 | ||||||||||||||||||
57 | ||||||||||||||||||||||
43 | Selling price to Customer | 62637682 | 16743589 | 132679 | 216346 | |||||||||||||||||
14 | ||||||||||||||||||||||
14 | 1191 | 1533 | 1871 | 1480 | ||||||||||||||||||
Total cost | 11863 | 22545 | 3104 | 05896907216 | ||||||||||||||||||
Sales Tax | 526 | 951 | 161 | 1971 | ||||||||||||||||||
Profit Margin | 1480 | 1020 | 1575 | 729 | ||||||||||||||||||
Selling price to Customer | 14500 | 26026 | 3860 | |||||||||||||||||||
New SP | 13974 | 25075 | 3699 | |||||||||||||||||||
Margin | 15 | 10 | 16 | |||||||||||||||||||
Margin | 1 ton of oil equivalent | 418 Giga Joule | ||||||||||||||||||||
10^6 | 181 | 201 | 218 | 234 | 249 | |||||||||||||||||
27 | 30 | 32 | 35 | 38 | ||||||||||||||||||
50 | 55 | 58 | 61 | 64 | ||||||||||||||||||
95 | 104 | 113 | 119 | 128 | ||||||||||||||||||
14 | 195 | 217 | 238 | 258 | 278 | |||||||||||||||||
14 | 450 | 548 | 607 | 659 | 707 | 757 | ||||||||||||||||
43 | ||||||||||||||||||||||
57 | ||||||||||||||||||||||
144 |
Years | 2008 | 2009 | 2010 | 2011 | 2012 | 2013 | 2014 | 2015 | 2016 | 2017 | 2018 | 2019 | 2020 | |||||||||||||||
RsKWh from grid (Commercial)) | 110 | 113 | 117 | 120 | 124 | 128 | 131 | 135 | 139 | 144 | 148 | 152 | 157 | |||||||||||||||
RsKWh from grid (Residential)) | 40 | 41 | 42 | 44 | 45 | 46 | 48 | 49 | 51 | 52 | 54 | 55 | 57 | |||||||||||||||
RsKWh from grid (Industrial) | 60 | 62 | 64 | 66 | 68 | 70 | 72 | 74 | 76 | 78 | 81 | 83 | 86 | |||||||||||||||
RsKWh from solar | 140 | 133 | 127 | 121 | 115 | 110 | 104 | 99 | 95 | 90 | 86 | 82 | 78 |
Australia | 300000 | 1200000 | 2500 | ||||||||
India | 290000 | 1200000 | 2417 | ||||||||
Norway | 170000 | 1200000 | 1417 | ||||||||
United States | 160000 | 1200000 | 1333 | ||||||||
Canada | 100000 | 1200000 | 833 | ||||||||
South Africa | 35000 | 1200000 | 292 | ||||||||
Brazil | 16000 | 1200000 | 133 | ||||||||
Malaysia | 4500 | 1200000 | 038 | ||||||||
Other Countries | 95000 | 1200000 | 792 | ||||||||
World Total |
23 | 8 | 6 | 34 | 2 | |||||||||||||||||||
43 | |||||||||||||||||||||||
Orders | |||||||||||||||||||||||
Arushi | |||||||||||||||||||||||
No | KWp | Rs | |||||||||||||||||||||
FAG | 2875 | 949 | 69 | ||||||||||||||||||||
rest | 1000 | 33 | 24 | ||||||||||||||||||||
116 | 8200 | 27 | 75 | 132 | 500 | 165 | 12 | ||||||||||||||||
100 | 033 | 24 | |||||||||||||||||||||
100 | 033 | 24 | |||||||||||||||||||||
53 | 5800 | 61 | 64 | 68 | 100 | 033 | 24 | ||||||||||||||||
Resi | 50 | 55 | 58 | 61 | 64 | 400 | 132 | 96 | |||||||||||||||
150 | 05 | 36 | |||||||||||||||||||||
Ind | 19100 | 21200 | 230 | 247 | 263 | 100 | 033 | 24 | |||||||||||||||
181 | 201 | 218 | 234 | 249 | 50 | 017 | 12 | ||||||||||||||||
Comm | 28 | 32 | 34 | 37 | 40 | ||||||||||||||||||
27 | 30 | 32 | 35 | 38 | R Lite | 200 | 2 | 1412 | |||||||||||||||
15 | 015 | 106 | |||||||||||||||||||||
Trans | 100 | 110 | 119 | 126 | 135 | 100 | 1 | 706 | |||||||||||||||
95 | 104 | 113 | 119 | 128 | 25 | 025 | 176 | ||||||||||||||||
100 | 1 | 706 | |||||||||||||||||||||
Elec | 206 | 229 | 251 | 272 | 293 | 30 | 03 | 21 | |||||||||||||||
195 | 217 | 238 | 258 | 278 | 25 | 025 | 176 |
Sheet1
World energy by fuel type
Grid Parity in India
Grid Parity in India
Sheet3
IIT - Kanpur- CVBU LUCKNOW
Wind Power
IIT - Kanpur- CVBU LUCKNOW
bull A report on the Solar power says that the utilization of just 5of existing solar energy would suffice the Global energyrequirement
bull Technology is readily available for generation of Power heating cooking etc applications For industries an immediate thoughtof putting up solar power plant of rated capacity and solarconcentrator for Canteen Guest houses offices remotelylocated load centers would reduce the energy bill besidesprotecting the environment
Solar Power
IIT - Kanpur- CVBU LUCKNOW
Bio-Gas
Wastersquos of animals trees rice husk etc can be utilizedfor the generation of gases which inturn utilized forheating cooking applications
Bio-Diesel
As the cost of petroleum products touching the sky an immediate thought on alternate fuels is the top most order of demand today Proven technology for Bio-diesel from Jetropa amp Pengenia etc is readily available With these in line the demand on Petroleum product would come down by 25-35 In APCW premises all unused area can be utilized for Jetropa amp Pengenia cultivation inturn to sell in the market or for mines-vehicle like Dozer Dumper shovel etc application
Bio Fuels
IIT - Kanpur- CVBU LUCKNOW
Simple schematic
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustriesIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
We have Energy Management Cell in our Plant Which initiates amp Manages all sorts of Energy Conservation measuresacross the Plant
Energy Management System
Mr Pramod ChoudharyPlant Head Lucknow
DH ndash Mr S B MattaPlant services
MR -Lko Works Dr SB Matta
DH ndash Mr V AgrawalPaint shop
DH ndash Mr S N VermaTCF
DH ndash Mr U TauheedBIW
DH ndash Mr R K SinghIBF
DH ndash Mr R K SinghAxle Shop
DH ndashMr G V JoshiPlanning
DH ndash Mr A ChhariaMaterials amp ADD
DH ndash Mr Ankush GourHR
DH ndash Mr R K SinghCV- CX
Team Structure ndash ISO 50001
DH ndash Divisional Head
ISO 50001 CertificateEnergy Policy
2013 2016 2019
IIT - Kanpur- CVBU LUCKNOW
ENERGY MANAGEMENT SYSTEM ndash An Overview
TOP MANAGEMENT COMMITMENT
STAFF COMMITMENT
ENERGY AUDIT
ACTION PLAN
MONITORING amp TARGET SETTING
REVIEW amp DEVELOP PROFILE
LONG PAY BACK PROJECTS
IIT - Kanpur- CVBU LUCKNOW
Preliminary Energy audit
Detailed Energy audit
Plant Coordinator
GO AHEAD
Energy savings discussion and presentation
GO AHEAD for Implementation
Energy savings monitoring and interim report to Energy Mgmt Cell
Acceptance of Proposal
Submission of Techno commercial proposal
Team formation
Energy Management CellEnCon Implementation Methodology
copy Copyright Confidential Tata Motors Limited
Innovation Digital Transformation Project Planning amp Operation
3D layout of Manufacturing Line Process flow for Digital transformation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
44
Collaboration
Training
Layout
Maintenance
2D drawings using Auto Cad 3D digital Factory
No single platform for discussions and decision making among various stake-holder
Virtual Factory encouraged different agencies to work in more collaborate manner
Traditional training methods such as classroom teaching using PPTs and OJT
3D Digital Work-Instruction videos along with Quality and Safety awareness
Maintenance based on Real time data
Preventive Maintenance Breakdown Maintenance based on schedule
Collection of information from individual machines and preparing reports
Connected Machines IPMS Mobile App online quality parameter monitoring
Traditional Method Digital Method
Technology Landscape ndash before and after implementation
Factory Set-up time reduced
Issue identified and resolved before physical installationconstruction
Better Visualization of the process enables operator to learn fast
Down-time of machines reduced thusimproving OEE
Better tracking and control quality and Mc parameters Faster information exchange
Transformation Impact
No Virtual Simulation Expensive Physicals only for very critical processes
Virtual Simulation of Critical Processes helped to identified Potential issues
Short Project Lead time Saving on rework cost and time
Simulation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
Sales~10 Increase throughbull Levelled Productionbull Improvement in Customer Experience
Cost
Customer Complaint
Project Time
Quality
Employee Engagement
~15 Reduction through bull Inventory Optimizationbull Warranty Cost reductionbull COPQ Reduction
~15 Reduction through bull Robust Process Designbull Resulting Reliability of Product
~25 Reduction throughbull Better Project
ManagementWith Use of Simulations Avoided Rework
~25 Improvement throughbull Connected Equipment
bull Avoiding Defect Passing
~10 Improvement throughbull Layout Improvementbull Process Automation
bull Ergonomics amp Safety improvement
Quantitative Benefits and Awarded in CII Digital Transformation Meet
Innovation Digital Transformation Project Planning amp Operation
IIT - Kanpur- CVBU LUCKNOW
Teamwork Employee involvement amp MonitoringDaily Consumption Report
Daily Energy Audit Report
Daily Shopwise Report
Daily Solar Generation Report
Hourly Consumption Report-Plant
Hourly Consumption Report-Shop
Monthly Energy Consumption Report
Awar
enes
sle
vel
2017-18
Reporting of energy consumption of the plant and
individual shops on fortnightly and monthly
basis
2018-19
H1 Reporting of entire plantrsquos energy consumption on daily basis
Daily Energy Audit Report (DEAR) circulated across the plant to minimize
energy wastageH2 Reporting of entire plantrsquos and shop-wise energy consumption on
daily basis
2019-20
H1 Reporting of shop-wise energy consumption started on hourly
basisH1 Reporting of working dayrsquos
and non-working dayrsquos consumption separately for
identification of areasprocesses 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
ENERGY CONSUMPTION 2019-20Figures in KWH
FACTORY Dec-19 Jan-20 Feb-20 Mar-20EASTERN COMPLEXBIWBIW Cab 30103 29885 42825 7097BIW Cowl 17657 16650 20104 7438FDV 0 0 0 0COMP 13691 12555 15960 4155BIW Office others 3459 2845 3824 599Distribution Losses 5737 5686 8235 3398Total 70648 67620 90949 22688PAINT SHOPPTED 276243 270240 58056 125761Paint 199896 182651 252332 55852COMP 69201 71042 191305 32740Paint others 33456 34243 71892 16336Distribution Losses 52586 55324 32462 45001Total 631382 613501 606048 275690TCFAssly 84210 101803 92831 23993Trim Assly 12468 17988 15117 4219FDV 0 0 0 0Compressor 38154 41387 42232 13080TCF officeothers 19581 18255 15958 13560Distribution Losses 14262 16490 17609 10428Total 168676 195923 183747 65281
Rear Axle and Line-45 17252 16260 4125 1830Logistics Centre 14904 25247 20629 9615RSO 5597 9370 8390 8445
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
GSM Based Smart Control of Shop Floor Ventilation System
Concerns in present method bull One operator has to travel around 1 Km for manually switching off all FDVs in western complex due to control panel given at that particular
location and hence there is electrical energy wastage of 5137 KWHmonth due to travel time of around 20 mins
Present process Moving to
switching off SB1 FDV
(0 mins)
Moving to switching off SB2 FDV
(5 mins)
Moving to switching off F Block FDV
(15 mins)
Moving to switching off
SB4 FDV(20 mins)
Moving to switching off SB3 FDV
(10 mins)
Blower amp Control panel
FDV Locations in Line 1
EnCon Projects
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
LCA Solution
bull Remote switching off FDVs by integrating off operation of FDV with GSMmodem from one location Also message will be delivered to user thatwhich FDV has been switched off (wireless switching off operation is donethrough GSM modem to avoid cable cost and laying of cable line)
Benefits amp Horizontal Scope 1Energy saving - Energy saving of 41096 KWHannum by providing remote switching off FDVs
2 Cost Saving - Recurring cost saving of Rs 328 lakhsannum3 Environment- Reduction in carbon footprint (reduction of 337 tonne of CO2annum by energy saving)
4 SMS escalation to user for information of FDV switch off5No laying out of wire is required as it is wireless communication with help of GSM modem6 Horizontal deployment of GSM based control for other process machines of assembly line 12 and 3
Solution Cost-Rs 328 Lacs for all 5 FDVs
Remote switching off SB3 FDV (Instantly)
Control panel- Remote Switching off SB1 FDV
Remote switching off SB2 FDV (Instantly)
Remote switching off F Block FDV (Instantly)
Remote switching off SB4 FDV (Instantly)
GSM Based Smart Control of Shop Floor Ventilation System
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Innovative Projects LED Migration Project
Evolution of Lighting
LEDification Project
No expenses in LED- migration
OPEX model Lights Installation Testing amp
Commissioning of LED lights 5 yrs extended warranty
Scope amp Savings
Phase wise LEDification project
Entire plant in phases Better control schemes Reduction in consumption by
50 (Minimum)
Optimal design amp execution
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
Why LED for lighting
LED the best lighting option today
Energy efficient higher Lumens per Watts
No Mercury-Environmental friendly
No IR amp UV emissions Reduced heat generation
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Conventional Lighting system After LED Migration
Power Consumption 14 KW Lux level 125~200
Energy Cons-Monthly 6300 KWH 50400 INR-Annually 75600 KWH 604800 INR
65 KW (Red 464) 250~450 (Inc 250 )
2925 KWH 23400 INR (Red 464 )
35100 KWH 280800 INR
65 KW (Red 464) 250~450 (Inc 250 )
1312 KWH 10400 INR (Red 782 ) 15744 KWH 125952 INR
Occupancy Sensor
After Sensor installation
Occupancy sensor
Sensor Controlled
lightingGroup
Manual Controlled
Lighting group
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
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- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
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- Slide Number 34
- Slide Number 35
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- Slide Number 38
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- Slide Number 46
- Slide Number 47
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- Slide Number 49
- Slide Number 50
- Slide Number 51
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- Slide Number 57
- Slide Number 58
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- Slide Number 60
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- Slide Number 62
- Slide Number 63
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- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
Total cost | 55177211 | 14176846 | 107850 | 184319 | ||||||||||||||||||
World Resi | 485 | 46 | Profit Margin | 15 | 1530 | 19 | 360 | |||||||||||||||
OECD Resi | 286 | 27 | Sales Tax | 2505507 | 685912 | 5024 | 8654 | |||||||||||||||
144 | 65143189 | 17429501 | 137703 | 225000 | ||||||||||||||||||
57 | ||||||||||||||||||||||
43 | Selling price to Customer | 62637682 | 16743589 | 132679 | 216346 | |||||||||||||||||
14 | ||||||||||||||||||||||
14 | 1191 | 1533 | 1871 | 1480 | ||||||||||||||||||
Total cost | 11863 | 22545 | 3104 | 05896907216 | ||||||||||||||||||
Sales Tax | 526 | 951 | 161 | 1971 | ||||||||||||||||||
Profit Margin | 1480 | 1020 | 1575 | 729 | ||||||||||||||||||
Selling price to Customer | 14500 | 26026 | 3860 | |||||||||||||||||||
New SP | 13974 | 25075 | 3699 | |||||||||||||||||||
Margin | 15 | 10 | 16 | |||||||||||||||||||
Margin | 1 ton of oil equivalent | 418 Giga Joule | ||||||||||||||||||||
10^6 | 181 | 201 | 218 | 234 | 249 | |||||||||||||||||
27 | 30 | 32 | 35 | 38 | ||||||||||||||||||
50 | 55 | 58 | 61 | 64 | ||||||||||||||||||
95 | 104 | 113 | 119 | 128 | ||||||||||||||||||
14 | 195 | 217 | 238 | 258 | 278 | |||||||||||||||||
14 | 450 | 548 | 607 | 659 | 707 | 757 | ||||||||||||||||
43 | ||||||||||||||||||||||
57 | ||||||||||||||||||||||
144 |
Years | 2008 | 2009 | 2010 | 2011 | 2012 | 2013 | 2014 | 2015 | 2016 | 2017 | 2018 | 2019 | 2020 | |||||||||||||||
RsKWh from grid (Commercial)) | 110 | 113 | 117 | 120 | 124 | 128 | 131 | 135 | 139 | 144 | 148 | 152 | 157 | |||||||||||||||
RsKWh from grid (Residential)) | 40 | 41 | 42 | 44 | 45 | 46 | 48 | 49 | 51 | 52 | 54 | 55 | 57 | |||||||||||||||
RsKWh from grid (Industrial) | 60 | 62 | 64 | 66 | 68 | 70 | 72 | 74 | 76 | 78 | 81 | 83 | 86 | |||||||||||||||
RsKWh from solar | 140 | 133 | 127 | 121 | 115 | 110 | 104 | 99 | 95 | 90 | 86 | 82 | 78 |
Australia | 300000 | 1200000 | 2500 | ||||||||
India | 290000 | 1200000 | 2417 | ||||||||
Norway | 170000 | 1200000 | 1417 | ||||||||
United States | 160000 | 1200000 | 1333 | ||||||||
Canada | 100000 | 1200000 | 833 | ||||||||
South Africa | 35000 | 1200000 | 292 | ||||||||
Brazil | 16000 | 1200000 | 133 | ||||||||
Malaysia | 4500 | 1200000 | 038 | ||||||||
Other Countries | 95000 | 1200000 | 792 | ||||||||
World Total |
23 | 8 | 6 | 34 | 2 | |||||||||||||||||||
43 | |||||||||||||||||||||||
Orders | |||||||||||||||||||||||
Arushi | |||||||||||||||||||||||
No | KWp | Rs | |||||||||||||||||||||
FAG | 2875 | 949 | 69 | ||||||||||||||||||||
rest | 1000 | 33 | 24 | ||||||||||||||||||||
116 | 8200 | 27 | 75 | 132 | 500 | 165 | 12 | ||||||||||||||||
100 | 033 | 24 | |||||||||||||||||||||
100 | 033 | 24 | |||||||||||||||||||||
53 | 5800 | 61 | 64 | 68 | 100 | 033 | 24 | ||||||||||||||||
Resi | 50 | 55 | 58 | 61 | 64 | 400 | 132 | 96 | |||||||||||||||
150 | 05 | 36 | |||||||||||||||||||||
Ind | 19100 | 21200 | 230 | 247 | 263 | 100 | 033 | 24 | |||||||||||||||
181 | 201 | 218 | 234 | 249 | 50 | 017 | 12 | ||||||||||||||||
Comm | 28 | 32 | 34 | 37 | 40 | ||||||||||||||||||
27 | 30 | 32 | 35 | 38 | R Lite | 200 | 2 | 1412 | |||||||||||||||
15 | 015 | 106 | |||||||||||||||||||||
Trans | 100 | 110 | 119 | 126 | 135 | 100 | 1 | 706 | |||||||||||||||
95 | 104 | 113 | 119 | 128 | 25 | 025 | 176 | ||||||||||||||||
100 | 1 | 706 | |||||||||||||||||||||
Elec | 206 | 229 | 251 | 272 | 293 | 30 | 03 | 21 | |||||||||||||||
195 | 217 | 238 | 258 | 278 | 25 | 025 | 176 |
World energy by fuel type
Grid Parity in India
Grid Parity in India
Sheet3
IIT - Kanpur- CVBU LUCKNOW
Wind Power
IIT - Kanpur- CVBU LUCKNOW
bull A report on the Solar power says that the utilization of just 5of existing solar energy would suffice the Global energyrequirement
bull Technology is readily available for generation of Power heating cooking etc applications For industries an immediate thoughtof putting up solar power plant of rated capacity and solarconcentrator for Canteen Guest houses offices remotelylocated load centers would reduce the energy bill besidesprotecting the environment
Solar Power
IIT - Kanpur- CVBU LUCKNOW
Bio-Gas
Wastersquos of animals trees rice husk etc can be utilizedfor the generation of gases which inturn utilized forheating cooking applications
Bio-Diesel
As the cost of petroleum products touching the sky an immediate thought on alternate fuels is the top most order of demand today Proven technology for Bio-diesel from Jetropa amp Pengenia etc is readily available With these in line the demand on Petroleum product would come down by 25-35 In APCW premises all unused area can be utilized for Jetropa amp Pengenia cultivation inturn to sell in the market or for mines-vehicle like Dozer Dumper shovel etc application
Bio Fuels
IIT - Kanpur- CVBU LUCKNOW
Simple schematic
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustriesIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
We have Energy Management Cell in our Plant Which initiates amp Manages all sorts of Energy Conservation measuresacross the Plant
Energy Management System
Mr Pramod ChoudharyPlant Head Lucknow
DH ndash Mr S B MattaPlant services
MR -Lko Works Dr SB Matta
DH ndash Mr V AgrawalPaint shop
DH ndash Mr S N VermaTCF
DH ndash Mr U TauheedBIW
DH ndash Mr R K SinghIBF
DH ndash Mr R K SinghAxle Shop
DH ndashMr G V JoshiPlanning
DH ndash Mr A ChhariaMaterials amp ADD
DH ndash Mr Ankush GourHR
DH ndash Mr R K SinghCV- CX
Team Structure ndash ISO 50001
DH ndash Divisional Head
ISO 50001 CertificateEnergy Policy
2013 2016 2019
IIT - Kanpur- CVBU LUCKNOW
ENERGY MANAGEMENT SYSTEM ndash An Overview
TOP MANAGEMENT COMMITMENT
STAFF COMMITMENT
ENERGY AUDIT
ACTION PLAN
MONITORING amp TARGET SETTING
REVIEW amp DEVELOP PROFILE
LONG PAY BACK PROJECTS
IIT - Kanpur- CVBU LUCKNOW
Preliminary Energy audit
Detailed Energy audit
Plant Coordinator
GO AHEAD
Energy savings discussion and presentation
GO AHEAD for Implementation
Energy savings monitoring and interim report to Energy Mgmt Cell
Acceptance of Proposal
Submission of Techno commercial proposal
Team formation
Energy Management CellEnCon Implementation Methodology
copy Copyright Confidential Tata Motors Limited
Innovation Digital Transformation Project Planning amp Operation
3D layout of Manufacturing Line Process flow for Digital transformation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
44
Collaboration
Training
Layout
Maintenance
2D drawings using Auto Cad 3D digital Factory
No single platform for discussions and decision making among various stake-holder
Virtual Factory encouraged different agencies to work in more collaborate manner
Traditional training methods such as classroom teaching using PPTs and OJT
3D Digital Work-Instruction videos along with Quality and Safety awareness
Maintenance based on Real time data
Preventive Maintenance Breakdown Maintenance based on schedule
Collection of information from individual machines and preparing reports
Connected Machines IPMS Mobile App online quality parameter monitoring
Traditional Method Digital Method
Technology Landscape ndash before and after implementation
Factory Set-up time reduced
Issue identified and resolved before physical installationconstruction
Better Visualization of the process enables operator to learn fast
Down-time of machines reduced thusimproving OEE
Better tracking and control quality and Mc parameters Faster information exchange
Transformation Impact
No Virtual Simulation Expensive Physicals only for very critical processes
Virtual Simulation of Critical Processes helped to identified Potential issues
Short Project Lead time Saving on rework cost and time
Simulation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
Sales~10 Increase throughbull Levelled Productionbull Improvement in Customer Experience
Cost
Customer Complaint
Project Time
Quality
Employee Engagement
~15 Reduction through bull Inventory Optimizationbull Warranty Cost reductionbull COPQ Reduction
~15 Reduction through bull Robust Process Designbull Resulting Reliability of Product
~25 Reduction throughbull Better Project
ManagementWith Use of Simulations Avoided Rework
~25 Improvement throughbull Connected Equipment
bull Avoiding Defect Passing
~10 Improvement throughbull Layout Improvementbull Process Automation
bull Ergonomics amp Safety improvement
Quantitative Benefits and Awarded in CII Digital Transformation Meet
Innovation Digital Transformation Project Planning amp Operation
IIT - Kanpur- CVBU LUCKNOW
Teamwork Employee involvement amp MonitoringDaily Consumption Report
Daily Energy Audit Report
Daily Shopwise Report
Daily Solar Generation Report
Hourly Consumption Report-Plant
Hourly Consumption Report-Shop
Monthly Energy Consumption Report
Awar
enes
sle
vel
2017-18
Reporting of energy consumption of the plant and
individual shops on fortnightly and monthly
basis
2018-19
H1 Reporting of entire plantrsquos energy consumption on daily basis
Daily Energy Audit Report (DEAR) circulated across the plant to minimize
energy wastageH2 Reporting of entire plantrsquos and shop-wise energy consumption on
daily basis
2019-20
H1 Reporting of shop-wise energy consumption started on hourly
basisH1 Reporting of working dayrsquos
and non-working dayrsquos consumption separately for
identification of areasprocesses 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
ENERGY CONSUMPTION 2019-20Figures in KWH
FACTORY Dec-19 Jan-20 Feb-20 Mar-20EASTERN COMPLEXBIWBIW Cab 30103 29885 42825 7097BIW Cowl 17657 16650 20104 7438FDV 0 0 0 0COMP 13691 12555 15960 4155BIW Office others 3459 2845 3824 599Distribution Losses 5737 5686 8235 3398Total 70648 67620 90949 22688PAINT SHOPPTED 276243 270240 58056 125761Paint 199896 182651 252332 55852COMP 69201 71042 191305 32740Paint others 33456 34243 71892 16336Distribution Losses 52586 55324 32462 45001Total 631382 613501 606048 275690TCFAssly 84210 101803 92831 23993Trim Assly 12468 17988 15117 4219FDV 0 0 0 0Compressor 38154 41387 42232 13080TCF officeothers 19581 18255 15958 13560Distribution Losses 14262 16490 17609 10428Total 168676 195923 183747 65281
Rear Axle and Line-45 17252 16260 4125 1830Logistics Centre 14904 25247 20629 9615RSO 5597 9370 8390 8445
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
GSM Based Smart Control of Shop Floor Ventilation System
Concerns in present method bull One operator has to travel around 1 Km for manually switching off all FDVs in western complex due to control panel given at that particular
location and hence there is electrical energy wastage of 5137 KWHmonth due to travel time of around 20 mins
Present process Moving to
switching off SB1 FDV
(0 mins)
Moving to switching off SB2 FDV
(5 mins)
Moving to switching off F Block FDV
(15 mins)
Moving to switching off
SB4 FDV(20 mins)
Moving to switching off SB3 FDV
(10 mins)
Blower amp Control panel
FDV Locations in Line 1
EnCon Projects
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
LCA Solution
bull Remote switching off FDVs by integrating off operation of FDV with GSMmodem from one location Also message will be delivered to user thatwhich FDV has been switched off (wireless switching off operation is donethrough GSM modem to avoid cable cost and laying of cable line)
Benefits amp Horizontal Scope 1Energy saving - Energy saving of 41096 KWHannum by providing remote switching off FDVs
2 Cost Saving - Recurring cost saving of Rs 328 lakhsannum3 Environment- Reduction in carbon footprint (reduction of 337 tonne of CO2annum by energy saving)
4 SMS escalation to user for information of FDV switch off5No laying out of wire is required as it is wireless communication with help of GSM modem6 Horizontal deployment of GSM based control for other process machines of assembly line 12 and 3
Solution Cost-Rs 328 Lacs for all 5 FDVs
Remote switching off SB3 FDV (Instantly)
Control panel- Remote Switching off SB1 FDV
Remote switching off SB2 FDV (Instantly)
Remote switching off F Block FDV (Instantly)
Remote switching off SB4 FDV (Instantly)
GSM Based Smart Control of Shop Floor Ventilation System
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Innovative Projects LED Migration Project
Evolution of Lighting
LEDification Project
No expenses in LED- migration
OPEX model Lights Installation Testing amp
Commissioning of LED lights 5 yrs extended warranty
Scope amp Savings
Phase wise LEDification project
Entire plant in phases Better control schemes Reduction in consumption by
50 (Minimum)
Optimal design amp execution
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
Why LED for lighting
LED the best lighting option today
Energy efficient higher Lumens per Watts
No Mercury-Environmental friendly
No IR amp UV emissions Reduced heat generation
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Conventional Lighting system After LED Migration
Power Consumption 14 KW Lux level 125~200
Energy Cons-Monthly 6300 KWH 50400 INR-Annually 75600 KWH 604800 INR
65 KW (Red 464) 250~450 (Inc 250 )
2925 KWH 23400 INR (Red 464 )
35100 KWH 280800 INR
65 KW (Red 464) 250~450 (Inc 250 )
1312 KWH 10400 INR (Red 782 ) 15744 KWH 125952 INR
Occupancy Sensor
After Sensor installation
Occupancy sensor
Sensor Controlled
lightingGroup
Manual Controlled
Lighting group
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
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- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
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- Slide Number 46
- Slide Number 47
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- Slide Number 57
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- Slide Number 60
- Slide Number 61
- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
Total cost | 55177211 | 14176846 | 107850 | 184319 | ||||||||||||||||||
World Resi | 485 | 46 | Profit Margin | 15 | 1530 | 19 | 360 | |||||||||||||||
OECD Resi | 286 | 27 | Sales Tax | 2505507 | 685912 | 5024 | 8654 | |||||||||||||||
144 | 65143189 | 17429501 | 137703 | 225000 | ||||||||||||||||||
57 | ||||||||||||||||||||||
43 | Selling price to Customer | 62637682 | 16743589 | 132679 | 216346 | |||||||||||||||||
14 | ||||||||||||||||||||||
14 | 1191 | 1533 | 1871 | 1480 | ||||||||||||||||||
Total cost | 11863 | 22545 | 3104 | 05896907216 | ||||||||||||||||||
Sales Tax | 526 | 951 | 161 | 1971 | ||||||||||||||||||
Profit Margin | 1480 | 1020 | 1575 | 729 | ||||||||||||||||||
Selling price to Customer | 14500 | 26026 | 3860 | |||||||||||||||||||
New SP | 13974 | 25075 | 3699 | |||||||||||||||||||
Margin | 15 | 10 | 16 | |||||||||||||||||||
Margin | 1 ton of oil equivalent | 418 Giga Joule | ||||||||||||||||||||
10^6 | 181 | 201 | 218 | 234 | 249 | |||||||||||||||||
27 | 30 | 32 | 35 | 38 | ||||||||||||||||||
50 | 55 | 58 | 61 | 64 | ||||||||||||||||||
95 | 104 | 113 | 119 | 128 | ||||||||||||||||||
14 | 195 | 217 | 238 | 258 | 278 | |||||||||||||||||
14 | 450 | 548 | 607 | 659 | 707 | 757 | ||||||||||||||||
43 | ||||||||||||||||||||||
57 | ||||||||||||||||||||||
144 |
Years | 2008 | 2009 | 2010 | 2011 | 2012 | 2013 | 2014 | 2015 | 2016 | 2017 | 2018 | 2019 | 2020 | |||||||||||||||
RsKWh from grid (Commercial)) | 110 | 113 | 117 | 120 | 124 | 128 | 131 | 135 | 139 | 144 | 148 | 152 | 157 | |||||||||||||||
RsKWh from grid (Residential)) | 40 | 41 | 42 | 44 | 45 | 46 | 48 | 49 | 51 | 52 | 54 | 55 | 57 | |||||||||||||||
RsKWh from grid (Industrial) | 60 | 62 | 64 | 66 | 68 | 70 | 72 | 74 | 76 | 78 | 81 | 83 | 86 | |||||||||||||||
RsKWh from solar | 140 | 133 | 127 | 121 | 115 | 110 | 104 | 99 | 95 | 90 | 86 | 82 | 78 |
Australia | 300000 | 1200000 | 2500 | ||||||||
India | 290000 | 1200000 | 2417 | ||||||||
Norway | 170000 | 1200000 | 1417 | ||||||||
United States | 160000 | 1200000 | 1333 | ||||||||
Canada | 100000 | 1200000 | 833 | ||||||||
South Africa | 35000 | 1200000 | 292 | ||||||||
Brazil | 16000 | 1200000 | 133 | ||||||||
Malaysia | 4500 | 1200000 | 038 | ||||||||
Other Countries | 95000 | 1200000 | 792 | ||||||||
World Total |
Grid Parity in India
Grid Parity in India
Sheet3
IIT - Kanpur- CVBU LUCKNOW
Wind Power
IIT - Kanpur- CVBU LUCKNOW
bull A report on the Solar power says that the utilization of just 5of existing solar energy would suffice the Global energyrequirement
bull Technology is readily available for generation of Power heating cooking etc applications For industries an immediate thoughtof putting up solar power plant of rated capacity and solarconcentrator for Canteen Guest houses offices remotelylocated load centers would reduce the energy bill besidesprotecting the environment
Solar Power
IIT - Kanpur- CVBU LUCKNOW
Bio-Gas
Wastersquos of animals trees rice husk etc can be utilizedfor the generation of gases which inturn utilized forheating cooking applications
Bio-Diesel
As the cost of petroleum products touching the sky an immediate thought on alternate fuels is the top most order of demand today Proven technology for Bio-diesel from Jetropa amp Pengenia etc is readily available With these in line the demand on Petroleum product would come down by 25-35 In APCW premises all unused area can be utilized for Jetropa amp Pengenia cultivation inturn to sell in the market or for mines-vehicle like Dozer Dumper shovel etc application
Bio Fuels
IIT - Kanpur- CVBU LUCKNOW
Simple schematic
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustriesIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
We have Energy Management Cell in our Plant Which initiates amp Manages all sorts of Energy Conservation measuresacross the Plant
Energy Management System
Mr Pramod ChoudharyPlant Head Lucknow
DH ndash Mr S B MattaPlant services
MR -Lko Works Dr SB Matta
DH ndash Mr V AgrawalPaint shop
DH ndash Mr S N VermaTCF
DH ndash Mr U TauheedBIW
DH ndash Mr R K SinghIBF
DH ndash Mr R K SinghAxle Shop
DH ndashMr G V JoshiPlanning
DH ndash Mr A ChhariaMaterials amp ADD
DH ndash Mr Ankush GourHR
DH ndash Mr R K SinghCV- CX
Team Structure ndash ISO 50001
DH ndash Divisional Head
ISO 50001 CertificateEnergy Policy
2013 2016 2019
IIT - Kanpur- CVBU LUCKNOW
ENERGY MANAGEMENT SYSTEM ndash An Overview
TOP MANAGEMENT COMMITMENT
STAFF COMMITMENT
ENERGY AUDIT
ACTION PLAN
MONITORING amp TARGET SETTING
REVIEW amp DEVELOP PROFILE
LONG PAY BACK PROJECTS
IIT - Kanpur- CVBU LUCKNOW
Preliminary Energy audit
Detailed Energy audit
Plant Coordinator
GO AHEAD
Energy savings discussion and presentation
GO AHEAD for Implementation
Energy savings monitoring and interim report to Energy Mgmt Cell
Acceptance of Proposal
Submission of Techno commercial proposal
Team formation
Energy Management CellEnCon Implementation Methodology
copy Copyright Confidential Tata Motors Limited
Innovation Digital Transformation Project Planning amp Operation
3D layout of Manufacturing Line Process flow for Digital transformation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
44
Collaboration
Training
Layout
Maintenance
2D drawings using Auto Cad 3D digital Factory
No single platform for discussions and decision making among various stake-holder
Virtual Factory encouraged different agencies to work in more collaborate manner
Traditional training methods such as classroom teaching using PPTs and OJT
3D Digital Work-Instruction videos along with Quality and Safety awareness
Maintenance based on Real time data
Preventive Maintenance Breakdown Maintenance based on schedule
Collection of information from individual machines and preparing reports
Connected Machines IPMS Mobile App online quality parameter monitoring
Traditional Method Digital Method
Technology Landscape ndash before and after implementation
Factory Set-up time reduced
Issue identified and resolved before physical installationconstruction
Better Visualization of the process enables operator to learn fast
Down-time of machines reduced thusimproving OEE
Better tracking and control quality and Mc parameters Faster information exchange
Transformation Impact
No Virtual Simulation Expensive Physicals only for very critical processes
Virtual Simulation of Critical Processes helped to identified Potential issues
Short Project Lead time Saving on rework cost and time
Simulation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
Sales~10 Increase throughbull Levelled Productionbull Improvement in Customer Experience
Cost
Customer Complaint
Project Time
Quality
Employee Engagement
~15 Reduction through bull Inventory Optimizationbull Warranty Cost reductionbull COPQ Reduction
~15 Reduction through bull Robust Process Designbull Resulting Reliability of Product
~25 Reduction throughbull Better Project
ManagementWith Use of Simulations Avoided Rework
~25 Improvement throughbull Connected Equipment
bull Avoiding Defect Passing
~10 Improvement throughbull Layout Improvementbull Process Automation
bull Ergonomics amp Safety improvement
Quantitative Benefits and Awarded in CII Digital Transformation Meet
Innovation Digital Transformation Project Planning amp Operation
IIT - Kanpur- CVBU LUCKNOW
Teamwork Employee involvement amp MonitoringDaily Consumption Report
Daily Energy Audit Report
Daily Shopwise Report
Daily Solar Generation Report
Hourly Consumption Report-Plant
Hourly Consumption Report-Shop
Monthly Energy Consumption Report
Awar
enes
sle
vel
2017-18
Reporting of energy consumption of the plant and
individual shops on fortnightly and monthly
basis
2018-19
H1 Reporting of entire plantrsquos energy consumption on daily basis
Daily Energy Audit Report (DEAR) circulated across the plant to minimize
energy wastageH2 Reporting of entire plantrsquos and shop-wise energy consumption on
daily basis
2019-20
H1 Reporting of shop-wise energy consumption started on hourly
basisH1 Reporting of working dayrsquos
and non-working dayrsquos consumption separately for
identification of areasprocesses 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
ENERGY CONSUMPTION 2019-20Figures in KWH
FACTORY Dec-19 Jan-20 Feb-20 Mar-20EASTERN COMPLEXBIWBIW Cab 30103 29885 42825 7097BIW Cowl 17657 16650 20104 7438FDV 0 0 0 0COMP 13691 12555 15960 4155BIW Office others 3459 2845 3824 599Distribution Losses 5737 5686 8235 3398Total 70648 67620 90949 22688PAINT SHOPPTED 276243 270240 58056 125761Paint 199896 182651 252332 55852COMP 69201 71042 191305 32740Paint others 33456 34243 71892 16336Distribution Losses 52586 55324 32462 45001Total 631382 613501 606048 275690TCFAssly 84210 101803 92831 23993Trim Assly 12468 17988 15117 4219FDV 0 0 0 0Compressor 38154 41387 42232 13080TCF officeothers 19581 18255 15958 13560Distribution Losses 14262 16490 17609 10428Total 168676 195923 183747 65281
Rear Axle and Line-45 17252 16260 4125 1830Logistics Centre 14904 25247 20629 9615RSO 5597 9370 8390 8445
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
GSM Based Smart Control of Shop Floor Ventilation System
Concerns in present method bull One operator has to travel around 1 Km for manually switching off all FDVs in western complex due to control panel given at that particular
location and hence there is electrical energy wastage of 5137 KWHmonth due to travel time of around 20 mins
Present process Moving to
switching off SB1 FDV
(0 mins)
Moving to switching off SB2 FDV
(5 mins)
Moving to switching off F Block FDV
(15 mins)
Moving to switching off
SB4 FDV(20 mins)
Moving to switching off SB3 FDV
(10 mins)
Blower amp Control panel
FDV Locations in Line 1
EnCon Projects
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
LCA Solution
bull Remote switching off FDVs by integrating off operation of FDV with GSMmodem from one location Also message will be delivered to user thatwhich FDV has been switched off (wireless switching off operation is donethrough GSM modem to avoid cable cost and laying of cable line)
Benefits amp Horizontal Scope 1Energy saving - Energy saving of 41096 KWHannum by providing remote switching off FDVs
2 Cost Saving - Recurring cost saving of Rs 328 lakhsannum3 Environment- Reduction in carbon footprint (reduction of 337 tonne of CO2annum by energy saving)
4 SMS escalation to user for information of FDV switch off5No laying out of wire is required as it is wireless communication with help of GSM modem6 Horizontal deployment of GSM based control for other process machines of assembly line 12 and 3
Solution Cost-Rs 328 Lacs for all 5 FDVs
Remote switching off SB3 FDV (Instantly)
Control panel- Remote Switching off SB1 FDV
Remote switching off SB2 FDV (Instantly)
Remote switching off F Block FDV (Instantly)
Remote switching off SB4 FDV (Instantly)
GSM Based Smart Control of Shop Floor Ventilation System
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Innovative Projects LED Migration Project
Evolution of Lighting
LEDification Project
No expenses in LED- migration
OPEX model Lights Installation Testing amp
Commissioning of LED lights 5 yrs extended warranty
Scope amp Savings
Phase wise LEDification project
Entire plant in phases Better control schemes Reduction in consumption by
50 (Minimum)
Optimal design amp execution
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
Why LED for lighting
LED the best lighting option today
Energy efficient higher Lumens per Watts
No Mercury-Environmental friendly
No IR amp UV emissions Reduced heat generation
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Conventional Lighting system After LED Migration
Power Consumption 14 KW Lux level 125~200
Energy Cons-Monthly 6300 KWH 50400 INR-Annually 75600 KWH 604800 INR
65 KW (Red 464) 250~450 (Inc 250 )
2925 KWH 23400 INR (Red 464 )
35100 KWH 280800 INR
65 KW (Red 464) 250~450 (Inc 250 )
1312 KWH 10400 INR (Red 782 ) 15744 KWH 125952 INR
Occupancy Sensor
After Sensor installation
Occupancy sensor
Sensor Controlled
lightingGroup
Manual Controlled
Lighting group
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
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- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
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- Slide Number 46
- Slide Number 47
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- Slide Number 49
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- Slide Number 57
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- Slide Number 60
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- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
Total cost | 55177211 | 14176846 | 107850 | 184319 | ||||||||||||||||||
World Resi | 485 | 46 | Profit Margin | 15 | 1530 | 19 | 360 | |||||||||||||||
OECD Resi | 286 | 27 | Sales Tax | 2505507 | 685912 | 5024 | 8654 | |||||||||||||||
144 | 65143189 | 17429501 | 137703 | 225000 | ||||||||||||||||||
57 | ||||||||||||||||||||||
43 | Selling price to Customer | 62637682 | 16743589 | 132679 | 216346 | |||||||||||||||||
14 | ||||||||||||||||||||||
14 | 1191 | 1533 | 1871 | 1480 | ||||||||||||||||||
Total cost | 11863 | 22545 | 3104 | 05896907216 | ||||||||||||||||||
Sales Tax | 526 | 951 | 161 | 1971 | ||||||||||||||||||
Profit Margin | 1480 | 1020 | 1575 | 729 | ||||||||||||||||||
Selling price to Customer | 14500 | 26026 | 3860 | |||||||||||||||||||
New SP | 13974 | 25075 | 3699 | |||||||||||||||||||
Margin | 15 | 10 | 16 | |||||||||||||||||||
Margin | 1 ton of oil equivalent | 418 Giga Joule | ||||||||||||||||||||
10^6 | 181 | 201 | 218 | 234 | 249 | |||||||||||||||||
27 | 30 | 32 | 35 | 38 | ||||||||||||||||||
50 | 55 | 58 | 61 | 64 | ||||||||||||||||||
95 | 104 | 113 | 119 | 128 | ||||||||||||||||||
14 | 195 | 217 | 238 | 258 | 278 | |||||||||||||||||
14 | 450 | 548 | 607 | 659 | 707 | 757 | ||||||||||||||||
43 | ||||||||||||||||||||||
57 | ||||||||||||||||||||||
144 |
Years | 2008 | 2009 | 2010 | 2011 | 2012 | 2013 | 2014 | 2015 | 2016 | 2017 | 2018 | 2019 | 2020 | |||||||||||||||
RsKWh from grid (Commercial)) | 110 | 113 | 117 | 120 | 124 | 128 | 131 | 135 | 139 | 144 | 148 | 152 | 157 | |||||||||||||||
RsKWh from grid (Residential)) | 40 | 41 | 42 | 44 | 45 | 46 | 48 | 49 | 51 | 52 | 54 | 55 | 57 | |||||||||||||||
RsKWh from grid (Industrial) | 60 | 62 | 64 | 66 | 68 | 70 | 72 | 74 | 76 | 78 | 81 | 83 | 86 | |||||||||||||||
RsKWh from solar | 140 | 133 | 127 | 121 | 115 | 110 | 104 | 99 | 95 | 90 | 86 | 82 | 78 |
Grid Parity in India
Sheet3
IIT - Kanpur- CVBU LUCKNOW
Wind Power
IIT - Kanpur- CVBU LUCKNOW
bull A report on the Solar power says that the utilization of just 5of existing solar energy would suffice the Global energyrequirement
bull Technology is readily available for generation of Power heating cooking etc applications For industries an immediate thoughtof putting up solar power plant of rated capacity and solarconcentrator for Canteen Guest houses offices remotelylocated load centers would reduce the energy bill besidesprotecting the environment
Solar Power
IIT - Kanpur- CVBU LUCKNOW
Bio-Gas
Wastersquos of animals trees rice husk etc can be utilizedfor the generation of gases which inturn utilized forheating cooking applications
Bio-Diesel
As the cost of petroleum products touching the sky an immediate thought on alternate fuels is the top most order of demand today Proven technology for Bio-diesel from Jetropa amp Pengenia etc is readily available With these in line the demand on Petroleum product would come down by 25-35 In APCW premises all unused area can be utilized for Jetropa amp Pengenia cultivation inturn to sell in the market or for mines-vehicle like Dozer Dumper shovel etc application
Bio Fuels
IIT - Kanpur- CVBU LUCKNOW
Simple schematic
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustriesIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
We have Energy Management Cell in our Plant Which initiates amp Manages all sorts of Energy Conservation measuresacross the Plant
Energy Management System
Mr Pramod ChoudharyPlant Head Lucknow
DH ndash Mr S B MattaPlant services
MR -Lko Works Dr SB Matta
DH ndash Mr V AgrawalPaint shop
DH ndash Mr S N VermaTCF
DH ndash Mr U TauheedBIW
DH ndash Mr R K SinghIBF
DH ndash Mr R K SinghAxle Shop
DH ndashMr G V JoshiPlanning
DH ndash Mr A ChhariaMaterials amp ADD
DH ndash Mr Ankush GourHR
DH ndash Mr R K SinghCV- CX
Team Structure ndash ISO 50001
DH ndash Divisional Head
ISO 50001 CertificateEnergy Policy
2013 2016 2019
IIT - Kanpur- CVBU LUCKNOW
ENERGY MANAGEMENT SYSTEM ndash An Overview
TOP MANAGEMENT COMMITMENT
STAFF COMMITMENT
ENERGY AUDIT
ACTION PLAN
MONITORING amp TARGET SETTING
REVIEW amp DEVELOP PROFILE
LONG PAY BACK PROJECTS
IIT - Kanpur- CVBU LUCKNOW
Preliminary Energy audit
Detailed Energy audit
Plant Coordinator
GO AHEAD
Energy savings discussion and presentation
GO AHEAD for Implementation
Energy savings monitoring and interim report to Energy Mgmt Cell
Acceptance of Proposal
Submission of Techno commercial proposal
Team formation
Energy Management CellEnCon Implementation Methodology
copy Copyright Confidential Tata Motors Limited
Innovation Digital Transformation Project Planning amp Operation
3D layout of Manufacturing Line Process flow for Digital transformation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
44
Collaboration
Training
Layout
Maintenance
2D drawings using Auto Cad 3D digital Factory
No single platform for discussions and decision making among various stake-holder
Virtual Factory encouraged different agencies to work in more collaborate manner
Traditional training methods such as classroom teaching using PPTs and OJT
3D Digital Work-Instruction videos along with Quality and Safety awareness
Maintenance based on Real time data
Preventive Maintenance Breakdown Maintenance based on schedule
Collection of information from individual machines and preparing reports
Connected Machines IPMS Mobile App online quality parameter monitoring
Traditional Method Digital Method
Technology Landscape ndash before and after implementation
Factory Set-up time reduced
Issue identified and resolved before physical installationconstruction
Better Visualization of the process enables operator to learn fast
Down-time of machines reduced thusimproving OEE
Better tracking and control quality and Mc parameters Faster information exchange
Transformation Impact
No Virtual Simulation Expensive Physicals only for very critical processes
Virtual Simulation of Critical Processes helped to identified Potential issues
Short Project Lead time Saving on rework cost and time
Simulation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
Sales~10 Increase throughbull Levelled Productionbull Improvement in Customer Experience
Cost
Customer Complaint
Project Time
Quality
Employee Engagement
~15 Reduction through bull Inventory Optimizationbull Warranty Cost reductionbull COPQ Reduction
~15 Reduction through bull Robust Process Designbull Resulting Reliability of Product
~25 Reduction throughbull Better Project
ManagementWith Use of Simulations Avoided Rework
~25 Improvement throughbull Connected Equipment
bull Avoiding Defect Passing
~10 Improvement throughbull Layout Improvementbull Process Automation
bull Ergonomics amp Safety improvement
Quantitative Benefits and Awarded in CII Digital Transformation Meet
Innovation Digital Transformation Project Planning amp Operation
IIT - Kanpur- CVBU LUCKNOW
Teamwork Employee involvement amp MonitoringDaily Consumption Report
Daily Energy Audit Report
Daily Shopwise Report
Daily Solar Generation Report
Hourly Consumption Report-Plant
Hourly Consumption Report-Shop
Monthly Energy Consumption Report
Awar
enes
sle
vel
2017-18
Reporting of energy consumption of the plant and
individual shops on fortnightly and monthly
basis
2018-19
H1 Reporting of entire plantrsquos energy consumption on daily basis
Daily Energy Audit Report (DEAR) circulated across the plant to minimize
energy wastageH2 Reporting of entire plantrsquos and shop-wise energy consumption on
daily basis
2019-20
H1 Reporting of shop-wise energy consumption started on hourly
basisH1 Reporting of working dayrsquos
and non-working dayrsquos consumption separately for
identification of areasprocesses 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
ENERGY CONSUMPTION 2019-20Figures in KWH
FACTORY Dec-19 Jan-20 Feb-20 Mar-20EASTERN COMPLEXBIWBIW Cab 30103 29885 42825 7097BIW Cowl 17657 16650 20104 7438FDV 0 0 0 0COMP 13691 12555 15960 4155BIW Office others 3459 2845 3824 599Distribution Losses 5737 5686 8235 3398Total 70648 67620 90949 22688PAINT SHOPPTED 276243 270240 58056 125761Paint 199896 182651 252332 55852COMP 69201 71042 191305 32740Paint others 33456 34243 71892 16336Distribution Losses 52586 55324 32462 45001Total 631382 613501 606048 275690TCFAssly 84210 101803 92831 23993Trim Assly 12468 17988 15117 4219FDV 0 0 0 0Compressor 38154 41387 42232 13080TCF officeothers 19581 18255 15958 13560Distribution Losses 14262 16490 17609 10428Total 168676 195923 183747 65281
Rear Axle and Line-45 17252 16260 4125 1830Logistics Centre 14904 25247 20629 9615RSO 5597 9370 8390 8445
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
GSM Based Smart Control of Shop Floor Ventilation System
Concerns in present method bull One operator has to travel around 1 Km for manually switching off all FDVs in western complex due to control panel given at that particular
location and hence there is electrical energy wastage of 5137 KWHmonth due to travel time of around 20 mins
Present process Moving to
switching off SB1 FDV
(0 mins)
Moving to switching off SB2 FDV
(5 mins)
Moving to switching off F Block FDV
(15 mins)
Moving to switching off
SB4 FDV(20 mins)
Moving to switching off SB3 FDV
(10 mins)
Blower amp Control panel
FDV Locations in Line 1
EnCon Projects
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
LCA Solution
bull Remote switching off FDVs by integrating off operation of FDV with GSMmodem from one location Also message will be delivered to user thatwhich FDV has been switched off (wireless switching off operation is donethrough GSM modem to avoid cable cost and laying of cable line)
Benefits amp Horizontal Scope 1Energy saving - Energy saving of 41096 KWHannum by providing remote switching off FDVs
2 Cost Saving - Recurring cost saving of Rs 328 lakhsannum3 Environment- Reduction in carbon footprint (reduction of 337 tonne of CO2annum by energy saving)
4 SMS escalation to user for information of FDV switch off5No laying out of wire is required as it is wireless communication with help of GSM modem6 Horizontal deployment of GSM based control for other process machines of assembly line 12 and 3
Solution Cost-Rs 328 Lacs for all 5 FDVs
Remote switching off SB3 FDV (Instantly)
Control panel- Remote Switching off SB1 FDV
Remote switching off SB2 FDV (Instantly)
Remote switching off F Block FDV (Instantly)
Remote switching off SB4 FDV (Instantly)
GSM Based Smart Control of Shop Floor Ventilation System
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Innovative Projects LED Migration Project
Evolution of Lighting
LEDification Project
No expenses in LED- migration
OPEX model Lights Installation Testing amp
Commissioning of LED lights 5 yrs extended warranty
Scope amp Savings
Phase wise LEDification project
Entire plant in phases Better control schemes Reduction in consumption by
50 (Minimum)
Optimal design amp execution
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
Why LED for lighting
LED the best lighting option today
Energy efficient higher Lumens per Watts
No Mercury-Environmental friendly
No IR amp UV emissions Reduced heat generation
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Conventional Lighting system After LED Migration
Power Consumption 14 KW Lux level 125~200
Energy Cons-Monthly 6300 KWH 50400 INR-Annually 75600 KWH 604800 INR
65 KW (Red 464) 250~450 (Inc 250 )
2925 KWH 23400 INR (Red 464 )
35100 KWH 280800 INR
65 KW (Red 464) 250~450 (Inc 250 )
1312 KWH 10400 INR (Red 782 ) 15744 KWH 125952 INR
Occupancy Sensor
After Sensor installation
Occupancy sensor
Sensor Controlled
lightingGroup
Manual Controlled
Lighting group
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
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- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
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- Slide Number 60
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- Slide Number 62
- Slide Number 63
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- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
Total cost | 55177211 | 14176846 | 107850 | 184319 | ||||||||||||||||||
World Resi | 485 | 46 | Profit Margin | 15 | 1530 | 19 | 360 | |||||||||||||||
OECD Resi | 286 | 27 | Sales Tax | 2505507 | 685912 | 5024 | 8654 | |||||||||||||||
144 | 65143189 | 17429501 | 137703 | 225000 | ||||||||||||||||||
57 | ||||||||||||||||||||||
43 | Selling price to Customer | 62637682 | 16743589 | 132679 | 216346 | |||||||||||||||||
14 | ||||||||||||||||||||||
14 | 1191 | 1533 | 1871 | 1480 | ||||||||||||||||||
Total cost | 11863 | 22545 | 3104 | 05896907216 | ||||||||||||||||||
Sales Tax | 526 | 951 | 161 | 1971 | ||||||||||||||||||
Profit Margin | 1480 | 1020 | 1575 | 729 | ||||||||||||||||||
Selling price to Customer | 14500 | 26026 | 3860 | |||||||||||||||||||
New SP | 13974 | 25075 | 3699 | |||||||||||||||||||
Margin | 15 | 10 | 16 | |||||||||||||||||||
Margin | 1 ton of oil equivalent | 418 Giga Joule | ||||||||||||||||||||
10^6 | 181 | 201 | 218 | 234 | 249 | |||||||||||||||||
27 | 30 | 32 | 35 | 38 | ||||||||||||||||||
50 | 55 | 58 | 61 | 64 | ||||||||||||||||||
95 | 104 | 113 | 119 | 128 | ||||||||||||||||||
14 | 195 | 217 | 238 | 258 | 278 | |||||||||||||||||
14 | 450 | 548 | 607 | 659 | 707 | 757 | ||||||||||||||||
43 | ||||||||||||||||||||||
57 | ||||||||||||||||||||||
144 |
Sheet3
IIT - Kanpur- CVBU LUCKNOW
Wind Power
IIT - Kanpur- CVBU LUCKNOW
bull A report on the Solar power says that the utilization of just 5of existing solar energy would suffice the Global energyrequirement
bull Technology is readily available for generation of Power heating cooking etc applications For industries an immediate thoughtof putting up solar power plant of rated capacity and solarconcentrator for Canteen Guest houses offices remotelylocated load centers would reduce the energy bill besidesprotecting the environment
Solar Power
IIT - Kanpur- CVBU LUCKNOW
Bio-Gas
Wastersquos of animals trees rice husk etc can be utilizedfor the generation of gases which inturn utilized forheating cooking applications
Bio-Diesel
As the cost of petroleum products touching the sky an immediate thought on alternate fuels is the top most order of demand today Proven technology for Bio-diesel from Jetropa amp Pengenia etc is readily available With these in line the demand on Petroleum product would come down by 25-35 In APCW premises all unused area can be utilized for Jetropa amp Pengenia cultivation inturn to sell in the market or for mines-vehicle like Dozer Dumper shovel etc application
Bio Fuels
IIT - Kanpur- CVBU LUCKNOW
Simple schematic
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustriesIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
We have Energy Management Cell in our Plant Which initiates amp Manages all sorts of Energy Conservation measuresacross the Plant
Energy Management System
Mr Pramod ChoudharyPlant Head Lucknow
DH ndash Mr S B MattaPlant services
MR -Lko Works Dr SB Matta
DH ndash Mr V AgrawalPaint shop
DH ndash Mr S N VermaTCF
DH ndash Mr U TauheedBIW
DH ndash Mr R K SinghIBF
DH ndash Mr R K SinghAxle Shop
DH ndashMr G V JoshiPlanning
DH ndash Mr A ChhariaMaterials amp ADD
DH ndash Mr Ankush GourHR
DH ndash Mr R K SinghCV- CX
Team Structure ndash ISO 50001
DH ndash Divisional Head
ISO 50001 CertificateEnergy Policy
2013 2016 2019
IIT - Kanpur- CVBU LUCKNOW
ENERGY MANAGEMENT SYSTEM ndash An Overview
TOP MANAGEMENT COMMITMENT
STAFF COMMITMENT
ENERGY AUDIT
ACTION PLAN
MONITORING amp TARGET SETTING
REVIEW amp DEVELOP PROFILE
LONG PAY BACK PROJECTS
IIT - Kanpur- CVBU LUCKNOW
Preliminary Energy audit
Detailed Energy audit
Plant Coordinator
GO AHEAD
Energy savings discussion and presentation
GO AHEAD for Implementation
Energy savings monitoring and interim report to Energy Mgmt Cell
Acceptance of Proposal
Submission of Techno commercial proposal
Team formation
Energy Management CellEnCon Implementation Methodology
copy Copyright Confidential Tata Motors Limited
Innovation Digital Transformation Project Planning amp Operation
3D layout of Manufacturing Line Process flow for Digital transformation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
44
Collaboration
Training
Layout
Maintenance
2D drawings using Auto Cad 3D digital Factory
No single platform for discussions and decision making among various stake-holder
Virtual Factory encouraged different agencies to work in more collaborate manner
Traditional training methods such as classroom teaching using PPTs and OJT
3D Digital Work-Instruction videos along with Quality and Safety awareness
Maintenance based on Real time data
Preventive Maintenance Breakdown Maintenance based on schedule
Collection of information from individual machines and preparing reports
Connected Machines IPMS Mobile App online quality parameter monitoring
Traditional Method Digital Method
Technology Landscape ndash before and after implementation
Factory Set-up time reduced
Issue identified and resolved before physical installationconstruction
Better Visualization of the process enables operator to learn fast
Down-time of machines reduced thusimproving OEE
Better tracking and control quality and Mc parameters Faster information exchange
Transformation Impact
No Virtual Simulation Expensive Physicals only for very critical processes
Virtual Simulation of Critical Processes helped to identified Potential issues
Short Project Lead time Saving on rework cost and time
Simulation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
Sales~10 Increase throughbull Levelled Productionbull Improvement in Customer Experience
Cost
Customer Complaint
Project Time
Quality
Employee Engagement
~15 Reduction through bull Inventory Optimizationbull Warranty Cost reductionbull COPQ Reduction
~15 Reduction through bull Robust Process Designbull Resulting Reliability of Product
~25 Reduction throughbull Better Project
ManagementWith Use of Simulations Avoided Rework
~25 Improvement throughbull Connected Equipment
bull Avoiding Defect Passing
~10 Improvement throughbull Layout Improvementbull Process Automation
bull Ergonomics amp Safety improvement
Quantitative Benefits and Awarded in CII Digital Transformation Meet
Innovation Digital Transformation Project Planning amp Operation
IIT - Kanpur- CVBU LUCKNOW
Teamwork Employee involvement amp MonitoringDaily Consumption Report
Daily Energy Audit Report
Daily Shopwise Report
Daily Solar Generation Report
Hourly Consumption Report-Plant
Hourly Consumption Report-Shop
Monthly Energy Consumption Report
Awar
enes
sle
vel
2017-18
Reporting of energy consumption of the plant and
individual shops on fortnightly and monthly
basis
2018-19
H1 Reporting of entire plantrsquos energy consumption on daily basis
Daily Energy Audit Report (DEAR) circulated across the plant to minimize
energy wastageH2 Reporting of entire plantrsquos and shop-wise energy consumption on
daily basis
2019-20
H1 Reporting of shop-wise energy consumption started on hourly
basisH1 Reporting of working dayrsquos
and non-working dayrsquos consumption separately for
identification of areasprocesses 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
ENERGY CONSUMPTION 2019-20Figures in KWH
FACTORY Dec-19 Jan-20 Feb-20 Mar-20EASTERN COMPLEXBIWBIW Cab 30103 29885 42825 7097BIW Cowl 17657 16650 20104 7438FDV 0 0 0 0COMP 13691 12555 15960 4155BIW Office others 3459 2845 3824 599Distribution Losses 5737 5686 8235 3398Total 70648 67620 90949 22688PAINT SHOPPTED 276243 270240 58056 125761Paint 199896 182651 252332 55852COMP 69201 71042 191305 32740Paint others 33456 34243 71892 16336Distribution Losses 52586 55324 32462 45001Total 631382 613501 606048 275690TCFAssly 84210 101803 92831 23993Trim Assly 12468 17988 15117 4219FDV 0 0 0 0Compressor 38154 41387 42232 13080TCF officeothers 19581 18255 15958 13560Distribution Losses 14262 16490 17609 10428Total 168676 195923 183747 65281
Rear Axle and Line-45 17252 16260 4125 1830Logistics Centre 14904 25247 20629 9615RSO 5597 9370 8390 8445
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
GSM Based Smart Control of Shop Floor Ventilation System
Concerns in present method bull One operator has to travel around 1 Km for manually switching off all FDVs in western complex due to control panel given at that particular
location and hence there is electrical energy wastage of 5137 KWHmonth due to travel time of around 20 mins
Present process Moving to
switching off SB1 FDV
(0 mins)
Moving to switching off SB2 FDV
(5 mins)
Moving to switching off F Block FDV
(15 mins)
Moving to switching off
SB4 FDV(20 mins)
Moving to switching off SB3 FDV
(10 mins)
Blower amp Control panel
FDV Locations in Line 1
EnCon Projects
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
LCA Solution
bull Remote switching off FDVs by integrating off operation of FDV with GSMmodem from one location Also message will be delivered to user thatwhich FDV has been switched off (wireless switching off operation is donethrough GSM modem to avoid cable cost and laying of cable line)
Benefits amp Horizontal Scope 1Energy saving - Energy saving of 41096 KWHannum by providing remote switching off FDVs
2 Cost Saving - Recurring cost saving of Rs 328 lakhsannum3 Environment- Reduction in carbon footprint (reduction of 337 tonne of CO2annum by energy saving)
4 SMS escalation to user for information of FDV switch off5No laying out of wire is required as it is wireless communication with help of GSM modem6 Horizontal deployment of GSM based control for other process machines of assembly line 12 and 3
Solution Cost-Rs 328 Lacs for all 5 FDVs
Remote switching off SB3 FDV (Instantly)
Control panel- Remote Switching off SB1 FDV
Remote switching off SB2 FDV (Instantly)
Remote switching off F Block FDV (Instantly)
Remote switching off SB4 FDV (Instantly)
GSM Based Smart Control of Shop Floor Ventilation System
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Innovative Projects LED Migration Project
Evolution of Lighting
LEDification Project
No expenses in LED- migration
OPEX model Lights Installation Testing amp
Commissioning of LED lights 5 yrs extended warranty
Scope amp Savings
Phase wise LEDification project
Entire plant in phases Better control schemes Reduction in consumption by
50 (Minimum)
Optimal design amp execution
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
Why LED for lighting
LED the best lighting option today
Energy efficient higher Lumens per Watts
No Mercury-Environmental friendly
No IR amp UV emissions Reduced heat generation
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Conventional Lighting system After LED Migration
Power Consumption 14 KW Lux level 125~200
Energy Cons-Monthly 6300 KWH 50400 INR-Annually 75600 KWH 604800 INR
65 KW (Red 464) 250~450 (Inc 250 )
2925 KWH 23400 INR (Red 464 )
35100 KWH 280800 INR
65 KW (Red 464) 250~450 (Inc 250 )
1312 KWH 10400 INR (Red 782 ) 15744 KWH 125952 INR
Occupancy Sensor
After Sensor installation
Occupancy sensor
Sensor Controlled
lightingGroup
Manual Controlled
Lighting group
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
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- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
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- Slide Number 35
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- Slide Number 47
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- Slide Number 50
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- Slide Number 57
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- Slide Number 60
- Slide Number 61
- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
Total cost | 55177211 | 14176846 | 107850 | 184319 | ||||||||||||||||||
World Resi | 485 | 46 | Profit Margin | 15 | 1530 | 19 | 360 | |||||||||||||||
OECD Resi | 286 | 27 | Sales Tax | 2505507 | 685912 | 5024 | 8654 | |||||||||||||||
144 | 65143189 | 17429501 | 137703 | 225000 | ||||||||||||||||||
57 | ||||||||||||||||||||||
43 | Selling price to Customer | 62637682 | 16743589 | 132679 | 216346 | |||||||||||||||||
14 | ||||||||||||||||||||||
14 | 1191 | 1533 | 1871 | 1480 | ||||||||||||||||||
Total cost | 11863 | 22545 | 3104 | 05896907216 | ||||||||||||||||||
Sales Tax | 526 | 951 | 161 | 1971 | ||||||||||||||||||
Profit Margin | 1480 | 1020 | 1575 | 729 | ||||||||||||||||||
Selling price to Customer | 14500 | 26026 | 3860 | |||||||||||||||||||
New SP | 13974 | 25075 | 3699 | |||||||||||||||||||
Margin | 15 | 10 | 16 | |||||||||||||||||||
Margin | 1 ton of oil equivalent | 418 Giga Joule | ||||||||||||||||||||
10^6 | 181 | 201 | 218 | 234 | 249 | |||||||||||||||||
27 | 30 | 32 | 35 | 38 | ||||||||||||||||||
50 | 55 | 58 | 61 | 64 | ||||||||||||||||||
95 | 104 | 113 | 119 | 128 | ||||||||||||||||||
14 | 195 | 217 | 238 | 258 | 278 | |||||||||||||||||
14 | 450 | 548 | 607 | 659 | 707 | 757 | ||||||||||||||||
43 | ||||||||||||||||||||||
57 | ||||||||||||||||||||||
144 |
IIT - Kanpur- CVBU LUCKNOW
Wind Power
IIT - Kanpur- CVBU LUCKNOW
bull A report on the Solar power says that the utilization of just 5of existing solar energy would suffice the Global energyrequirement
bull Technology is readily available for generation of Power heating cooking etc applications For industries an immediate thoughtof putting up solar power plant of rated capacity and solarconcentrator for Canteen Guest houses offices remotelylocated load centers would reduce the energy bill besidesprotecting the environment
Solar Power
IIT - Kanpur- CVBU LUCKNOW
Bio-Gas
Wastersquos of animals trees rice husk etc can be utilizedfor the generation of gases which inturn utilized forheating cooking applications
Bio-Diesel
As the cost of petroleum products touching the sky an immediate thought on alternate fuels is the top most order of demand today Proven technology for Bio-diesel from Jetropa amp Pengenia etc is readily available With these in line the demand on Petroleum product would come down by 25-35 In APCW premises all unused area can be utilized for Jetropa amp Pengenia cultivation inturn to sell in the market or for mines-vehicle like Dozer Dumper shovel etc application
Bio Fuels
IIT - Kanpur- CVBU LUCKNOW
Simple schematic
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustriesIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
We have Energy Management Cell in our Plant Which initiates amp Manages all sorts of Energy Conservation measuresacross the Plant
Energy Management System
Mr Pramod ChoudharyPlant Head Lucknow
DH ndash Mr S B MattaPlant services
MR -Lko Works Dr SB Matta
DH ndash Mr V AgrawalPaint shop
DH ndash Mr S N VermaTCF
DH ndash Mr U TauheedBIW
DH ndash Mr R K SinghIBF
DH ndash Mr R K SinghAxle Shop
DH ndashMr G V JoshiPlanning
DH ndash Mr A ChhariaMaterials amp ADD
DH ndash Mr Ankush GourHR
DH ndash Mr R K SinghCV- CX
Team Structure ndash ISO 50001
DH ndash Divisional Head
ISO 50001 CertificateEnergy Policy
2013 2016 2019
IIT - Kanpur- CVBU LUCKNOW
ENERGY MANAGEMENT SYSTEM ndash An Overview
TOP MANAGEMENT COMMITMENT
STAFF COMMITMENT
ENERGY AUDIT
ACTION PLAN
MONITORING amp TARGET SETTING
REVIEW amp DEVELOP PROFILE
LONG PAY BACK PROJECTS
IIT - Kanpur- CVBU LUCKNOW
Preliminary Energy audit
Detailed Energy audit
Plant Coordinator
GO AHEAD
Energy savings discussion and presentation
GO AHEAD for Implementation
Energy savings monitoring and interim report to Energy Mgmt Cell
Acceptance of Proposal
Submission of Techno commercial proposal
Team formation
Energy Management CellEnCon Implementation Methodology
copy Copyright Confidential Tata Motors Limited
Innovation Digital Transformation Project Planning amp Operation
3D layout of Manufacturing Line Process flow for Digital transformation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
44
Collaboration
Training
Layout
Maintenance
2D drawings using Auto Cad 3D digital Factory
No single platform for discussions and decision making among various stake-holder
Virtual Factory encouraged different agencies to work in more collaborate manner
Traditional training methods such as classroom teaching using PPTs and OJT
3D Digital Work-Instruction videos along with Quality and Safety awareness
Maintenance based on Real time data
Preventive Maintenance Breakdown Maintenance based on schedule
Collection of information from individual machines and preparing reports
Connected Machines IPMS Mobile App online quality parameter monitoring
Traditional Method Digital Method
Technology Landscape ndash before and after implementation
Factory Set-up time reduced
Issue identified and resolved before physical installationconstruction
Better Visualization of the process enables operator to learn fast
Down-time of machines reduced thusimproving OEE
Better tracking and control quality and Mc parameters Faster information exchange
Transformation Impact
No Virtual Simulation Expensive Physicals only for very critical processes
Virtual Simulation of Critical Processes helped to identified Potential issues
Short Project Lead time Saving on rework cost and time
Simulation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
Sales~10 Increase throughbull Levelled Productionbull Improvement in Customer Experience
Cost
Customer Complaint
Project Time
Quality
Employee Engagement
~15 Reduction through bull Inventory Optimizationbull Warranty Cost reductionbull COPQ Reduction
~15 Reduction through bull Robust Process Designbull Resulting Reliability of Product
~25 Reduction throughbull Better Project
ManagementWith Use of Simulations Avoided Rework
~25 Improvement throughbull Connected Equipment
bull Avoiding Defect Passing
~10 Improvement throughbull Layout Improvementbull Process Automation
bull Ergonomics amp Safety improvement
Quantitative Benefits and Awarded in CII Digital Transformation Meet
Innovation Digital Transformation Project Planning amp Operation
IIT - Kanpur- CVBU LUCKNOW
Teamwork Employee involvement amp MonitoringDaily Consumption Report
Daily Energy Audit Report
Daily Shopwise Report
Daily Solar Generation Report
Hourly Consumption Report-Plant
Hourly Consumption Report-Shop
Monthly Energy Consumption Report
Awar
enes
sle
vel
2017-18
Reporting of energy consumption of the plant and
individual shops on fortnightly and monthly
basis
2018-19
H1 Reporting of entire plantrsquos energy consumption on daily basis
Daily Energy Audit Report (DEAR) circulated across the plant to minimize
energy wastageH2 Reporting of entire plantrsquos and shop-wise energy consumption on
daily basis
2019-20
H1 Reporting of shop-wise energy consumption started on hourly
basisH1 Reporting of working dayrsquos
and non-working dayrsquos consumption separately for
identification of areasprocesses 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
ENERGY CONSUMPTION 2019-20Figures in KWH
FACTORY Dec-19 Jan-20 Feb-20 Mar-20EASTERN COMPLEXBIWBIW Cab 30103 29885 42825 7097BIW Cowl 17657 16650 20104 7438FDV 0 0 0 0COMP 13691 12555 15960 4155BIW Office others 3459 2845 3824 599Distribution Losses 5737 5686 8235 3398Total 70648 67620 90949 22688PAINT SHOPPTED 276243 270240 58056 125761Paint 199896 182651 252332 55852COMP 69201 71042 191305 32740Paint others 33456 34243 71892 16336Distribution Losses 52586 55324 32462 45001Total 631382 613501 606048 275690TCFAssly 84210 101803 92831 23993Trim Assly 12468 17988 15117 4219FDV 0 0 0 0Compressor 38154 41387 42232 13080TCF officeothers 19581 18255 15958 13560Distribution Losses 14262 16490 17609 10428Total 168676 195923 183747 65281
Rear Axle and Line-45 17252 16260 4125 1830Logistics Centre 14904 25247 20629 9615RSO 5597 9370 8390 8445
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
GSM Based Smart Control of Shop Floor Ventilation System
Concerns in present method bull One operator has to travel around 1 Km for manually switching off all FDVs in western complex due to control panel given at that particular
location and hence there is electrical energy wastage of 5137 KWHmonth due to travel time of around 20 mins
Present process Moving to
switching off SB1 FDV
(0 mins)
Moving to switching off SB2 FDV
(5 mins)
Moving to switching off F Block FDV
(15 mins)
Moving to switching off
SB4 FDV(20 mins)
Moving to switching off SB3 FDV
(10 mins)
Blower amp Control panel
FDV Locations in Line 1
EnCon Projects
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
LCA Solution
bull Remote switching off FDVs by integrating off operation of FDV with GSMmodem from one location Also message will be delivered to user thatwhich FDV has been switched off (wireless switching off operation is donethrough GSM modem to avoid cable cost and laying of cable line)
Benefits amp Horizontal Scope 1Energy saving - Energy saving of 41096 KWHannum by providing remote switching off FDVs
2 Cost Saving - Recurring cost saving of Rs 328 lakhsannum3 Environment- Reduction in carbon footprint (reduction of 337 tonne of CO2annum by energy saving)
4 SMS escalation to user for information of FDV switch off5No laying out of wire is required as it is wireless communication with help of GSM modem6 Horizontal deployment of GSM based control for other process machines of assembly line 12 and 3
Solution Cost-Rs 328 Lacs for all 5 FDVs
Remote switching off SB3 FDV (Instantly)
Control panel- Remote Switching off SB1 FDV
Remote switching off SB2 FDV (Instantly)
Remote switching off F Block FDV (Instantly)
Remote switching off SB4 FDV (Instantly)
GSM Based Smart Control of Shop Floor Ventilation System
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Innovative Projects LED Migration Project
Evolution of Lighting
LEDification Project
No expenses in LED- migration
OPEX model Lights Installation Testing amp
Commissioning of LED lights 5 yrs extended warranty
Scope amp Savings
Phase wise LEDification project
Entire plant in phases Better control schemes Reduction in consumption by
50 (Minimum)
Optimal design amp execution
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
Why LED for lighting
LED the best lighting option today
Energy efficient higher Lumens per Watts
No Mercury-Environmental friendly
No IR amp UV emissions Reduced heat generation
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Conventional Lighting system After LED Migration
Power Consumption 14 KW Lux level 125~200
Energy Cons-Monthly 6300 KWH 50400 INR-Annually 75600 KWH 604800 INR
65 KW (Red 464) 250~450 (Inc 250 )
2925 KWH 23400 INR (Red 464 )
35100 KWH 280800 INR
65 KW (Red 464) 250~450 (Inc 250 )
1312 KWH 10400 INR (Red 782 ) 15744 KWH 125952 INR
Occupancy Sensor
After Sensor installation
Occupancy sensor
Sensor Controlled
lightingGroup
Manual Controlled
Lighting group
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
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- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
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- Slide Number 60
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- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOW
bull A report on the Solar power says that the utilization of just 5of existing solar energy would suffice the Global energyrequirement
bull Technology is readily available for generation of Power heating cooking etc applications For industries an immediate thoughtof putting up solar power plant of rated capacity and solarconcentrator for Canteen Guest houses offices remotelylocated load centers would reduce the energy bill besidesprotecting the environment
Solar Power
IIT - Kanpur- CVBU LUCKNOW
Bio-Gas
Wastersquos of animals trees rice husk etc can be utilizedfor the generation of gases which inturn utilized forheating cooking applications
Bio-Diesel
As the cost of petroleum products touching the sky an immediate thought on alternate fuels is the top most order of demand today Proven technology for Bio-diesel from Jetropa amp Pengenia etc is readily available With these in line the demand on Petroleum product would come down by 25-35 In APCW premises all unused area can be utilized for Jetropa amp Pengenia cultivation inturn to sell in the market or for mines-vehicle like Dozer Dumper shovel etc application
Bio Fuels
IIT - Kanpur- CVBU LUCKNOW
Simple schematic
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustriesIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
We have Energy Management Cell in our Plant Which initiates amp Manages all sorts of Energy Conservation measuresacross the Plant
Energy Management System
Mr Pramod ChoudharyPlant Head Lucknow
DH ndash Mr S B MattaPlant services
MR -Lko Works Dr SB Matta
DH ndash Mr V AgrawalPaint shop
DH ndash Mr S N VermaTCF
DH ndash Mr U TauheedBIW
DH ndash Mr R K SinghIBF
DH ndash Mr R K SinghAxle Shop
DH ndashMr G V JoshiPlanning
DH ndash Mr A ChhariaMaterials amp ADD
DH ndash Mr Ankush GourHR
DH ndash Mr R K SinghCV- CX
Team Structure ndash ISO 50001
DH ndash Divisional Head
ISO 50001 CertificateEnergy Policy
2013 2016 2019
IIT - Kanpur- CVBU LUCKNOW
ENERGY MANAGEMENT SYSTEM ndash An Overview
TOP MANAGEMENT COMMITMENT
STAFF COMMITMENT
ENERGY AUDIT
ACTION PLAN
MONITORING amp TARGET SETTING
REVIEW amp DEVELOP PROFILE
LONG PAY BACK PROJECTS
IIT - Kanpur- CVBU LUCKNOW
Preliminary Energy audit
Detailed Energy audit
Plant Coordinator
GO AHEAD
Energy savings discussion and presentation
GO AHEAD for Implementation
Energy savings monitoring and interim report to Energy Mgmt Cell
Acceptance of Proposal
Submission of Techno commercial proposal
Team formation
Energy Management CellEnCon Implementation Methodology
copy Copyright Confidential Tata Motors Limited
Innovation Digital Transformation Project Planning amp Operation
3D layout of Manufacturing Line Process flow for Digital transformation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
44
Collaboration
Training
Layout
Maintenance
2D drawings using Auto Cad 3D digital Factory
No single platform for discussions and decision making among various stake-holder
Virtual Factory encouraged different agencies to work in more collaborate manner
Traditional training methods such as classroom teaching using PPTs and OJT
3D Digital Work-Instruction videos along with Quality and Safety awareness
Maintenance based on Real time data
Preventive Maintenance Breakdown Maintenance based on schedule
Collection of information from individual machines and preparing reports
Connected Machines IPMS Mobile App online quality parameter monitoring
Traditional Method Digital Method
Technology Landscape ndash before and after implementation
Factory Set-up time reduced
Issue identified and resolved before physical installationconstruction
Better Visualization of the process enables operator to learn fast
Down-time of machines reduced thusimproving OEE
Better tracking and control quality and Mc parameters Faster information exchange
Transformation Impact
No Virtual Simulation Expensive Physicals only for very critical processes
Virtual Simulation of Critical Processes helped to identified Potential issues
Short Project Lead time Saving on rework cost and time
Simulation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
Sales~10 Increase throughbull Levelled Productionbull Improvement in Customer Experience
Cost
Customer Complaint
Project Time
Quality
Employee Engagement
~15 Reduction through bull Inventory Optimizationbull Warranty Cost reductionbull COPQ Reduction
~15 Reduction through bull Robust Process Designbull Resulting Reliability of Product
~25 Reduction throughbull Better Project
ManagementWith Use of Simulations Avoided Rework
~25 Improvement throughbull Connected Equipment
bull Avoiding Defect Passing
~10 Improvement throughbull Layout Improvementbull Process Automation
bull Ergonomics amp Safety improvement
Quantitative Benefits and Awarded in CII Digital Transformation Meet
Innovation Digital Transformation Project Planning amp Operation
IIT - Kanpur- CVBU LUCKNOW
Teamwork Employee involvement amp MonitoringDaily Consumption Report
Daily Energy Audit Report
Daily Shopwise Report
Daily Solar Generation Report
Hourly Consumption Report-Plant
Hourly Consumption Report-Shop
Monthly Energy Consumption Report
Awar
enes
sle
vel
2017-18
Reporting of energy consumption of the plant and
individual shops on fortnightly and monthly
basis
2018-19
H1 Reporting of entire plantrsquos energy consumption on daily basis
Daily Energy Audit Report (DEAR) circulated across the plant to minimize
energy wastageH2 Reporting of entire plantrsquos and shop-wise energy consumption on
daily basis
2019-20
H1 Reporting of shop-wise energy consumption started on hourly
basisH1 Reporting of working dayrsquos
and non-working dayrsquos consumption separately for
identification of areasprocesses 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
ENERGY CONSUMPTION 2019-20Figures in KWH
FACTORY Dec-19 Jan-20 Feb-20 Mar-20EASTERN COMPLEXBIWBIW Cab 30103 29885 42825 7097BIW Cowl 17657 16650 20104 7438FDV 0 0 0 0COMP 13691 12555 15960 4155BIW Office others 3459 2845 3824 599Distribution Losses 5737 5686 8235 3398Total 70648 67620 90949 22688PAINT SHOPPTED 276243 270240 58056 125761Paint 199896 182651 252332 55852COMP 69201 71042 191305 32740Paint others 33456 34243 71892 16336Distribution Losses 52586 55324 32462 45001Total 631382 613501 606048 275690TCFAssly 84210 101803 92831 23993Trim Assly 12468 17988 15117 4219FDV 0 0 0 0Compressor 38154 41387 42232 13080TCF officeothers 19581 18255 15958 13560Distribution Losses 14262 16490 17609 10428Total 168676 195923 183747 65281
Rear Axle and Line-45 17252 16260 4125 1830Logistics Centre 14904 25247 20629 9615RSO 5597 9370 8390 8445
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
GSM Based Smart Control of Shop Floor Ventilation System
Concerns in present method bull One operator has to travel around 1 Km for manually switching off all FDVs in western complex due to control panel given at that particular
location and hence there is electrical energy wastage of 5137 KWHmonth due to travel time of around 20 mins
Present process Moving to
switching off SB1 FDV
(0 mins)
Moving to switching off SB2 FDV
(5 mins)
Moving to switching off F Block FDV
(15 mins)
Moving to switching off
SB4 FDV(20 mins)
Moving to switching off SB3 FDV
(10 mins)
Blower amp Control panel
FDV Locations in Line 1
EnCon Projects
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
LCA Solution
bull Remote switching off FDVs by integrating off operation of FDV with GSMmodem from one location Also message will be delivered to user thatwhich FDV has been switched off (wireless switching off operation is donethrough GSM modem to avoid cable cost and laying of cable line)
Benefits amp Horizontal Scope 1Energy saving - Energy saving of 41096 KWHannum by providing remote switching off FDVs
2 Cost Saving - Recurring cost saving of Rs 328 lakhsannum3 Environment- Reduction in carbon footprint (reduction of 337 tonne of CO2annum by energy saving)
4 SMS escalation to user for information of FDV switch off5No laying out of wire is required as it is wireless communication with help of GSM modem6 Horizontal deployment of GSM based control for other process machines of assembly line 12 and 3
Solution Cost-Rs 328 Lacs for all 5 FDVs
Remote switching off SB3 FDV (Instantly)
Control panel- Remote Switching off SB1 FDV
Remote switching off SB2 FDV (Instantly)
Remote switching off F Block FDV (Instantly)
Remote switching off SB4 FDV (Instantly)
GSM Based Smart Control of Shop Floor Ventilation System
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Innovative Projects LED Migration Project
Evolution of Lighting
LEDification Project
No expenses in LED- migration
OPEX model Lights Installation Testing amp
Commissioning of LED lights 5 yrs extended warranty
Scope amp Savings
Phase wise LEDification project
Entire plant in phases Better control schemes Reduction in consumption by
50 (Minimum)
Optimal design amp execution
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
Why LED for lighting
LED the best lighting option today
Energy efficient higher Lumens per Watts
No Mercury-Environmental friendly
No IR amp UV emissions Reduced heat generation
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Conventional Lighting system After LED Migration
Power Consumption 14 KW Lux level 125~200
Energy Cons-Monthly 6300 KWH 50400 INR-Annually 75600 KWH 604800 INR
65 KW (Red 464) 250~450 (Inc 250 )
2925 KWH 23400 INR (Red 464 )
35100 KWH 280800 INR
65 KW (Red 464) 250~450 (Inc 250 )
1312 KWH 10400 INR (Red 782 ) 15744 KWH 125952 INR
Occupancy Sensor
After Sensor installation
Occupancy sensor
Sensor Controlled
lightingGroup
Manual Controlled
Lighting group
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
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- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
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- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
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- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
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- Slide Number 54
- Slide Number 55
- Slide Number 56
- Slide Number 57
- Slide Number 58
- Slide Number 59
- Slide Number 60
- Slide Number 61
- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOW
Bio-Gas
Wastersquos of animals trees rice husk etc can be utilizedfor the generation of gases which inturn utilized forheating cooking applications
Bio-Diesel
As the cost of petroleum products touching the sky an immediate thought on alternate fuels is the top most order of demand today Proven technology for Bio-diesel from Jetropa amp Pengenia etc is readily available With these in line the demand on Petroleum product would come down by 25-35 In APCW premises all unused area can be utilized for Jetropa amp Pengenia cultivation inturn to sell in the market or for mines-vehicle like Dozer Dumper shovel etc application
Bio Fuels
IIT - Kanpur- CVBU LUCKNOW
Simple schematic
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustriesIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
We have Energy Management Cell in our Plant Which initiates amp Manages all sorts of Energy Conservation measuresacross the Plant
Energy Management System
Mr Pramod ChoudharyPlant Head Lucknow
DH ndash Mr S B MattaPlant services
MR -Lko Works Dr SB Matta
DH ndash Mr V AgrawalPaint shop
DH ndash Mr S N VermaTCF
DH ndash Mr U TauheedBIW
DH ndash Mr R K SinghIBF
DH ndash Mr R K SinghAxle Shop
DH ndashMr G V JoshiPlanning
DH ndash Mr A ChhariaMaterials amp ADD
DH ndash Mr Ankush GourHR
DH ndash Mr R K SinghCV- CX
Team Structure ndash ISO 50001
DH ndash Divisional Head
ISO 50001 CertificateEnergy Policy
2013 2016 2019
IIT - Kanpur- CVBU LUCKNOW
ENERGY MANAGEMENT SYSTEM ndash An Overview
TOP MANAGEMENT COMMITMENT
STAFF COMMITMENT
ENERGY AUDIT
ACTION PLAN
MONITORING amp TARGET SETTING
REVIEW amp DEVELOP PROFILE
LONG PAY BACK PROJECTS
IIT - Kanpur- CVBU LUCKNOW
Preliminary Energy audit
Detailed Energy audit
Plant Coordinator
GO AHEAD
Energy savings discussion and presentation
GO AHEAD for Implementation
Energy savings monitoring and interim report to Energy Mgmt Cell
Acceptance of Proposal
Submission of Techno commercial proposal
Team formation
Energy Management CellEnCon Implementation Methodology
copy Copyright Confidential Tata Motors Limited
Innovation Digital Transformation Project Planning amp Operation
3D layout of Manufacturing Line Process flow for Digital transformation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
44
Collaboration
Training
Layout
Maintenance
2D drawings using Auto Cad 3D digital Factory
No single platform for discussions and decision making among various stake-holder
Virtual Factory encouraged different agencies to work in more collaborate manner
Traditional training methods such as classroom teaching using PPTs and OJT
3D Digital Work-Instruction videos along with Quality and Safety awareness
Maintenance based on Real time data
Preventive Maintenance Breakdown Maintenance based on schedule
Collection of information from individual machines and preparing reports
Connected Machines IPMS Mobile App online quality parameter monitoring
Traditional Method Digital Method
Technology Landscape ndash before and after implementation
Factory Set-up time reduced
Issue identified and resolved before physical installationconstruction
Better Visualization of the process enables operator to learn fast
Down-time of machines reduced thusimproving OEE
Better tracking and control quality and Mc parameters Faster information exchange
Transformation Impact
No Virtual Simulation Expensive Physicals only for very critical processes
Virtual Simulation of Critical Processes helped to identified Potential issues
Short Project Lead time Saving on rework cost and time
Simulation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
Sales~10 Increase throughbull Levelled Productionbull Improvement in Customer Experience
Cost
Customer Complaint
Project Time
Quality
Employee Engagement
~15 Reduction through bull Inventory Optimizationbull Warranty Cost reductionbull COPQ Reduction
~15 Reduction through bull Robust Process Designbull Resulting Reliability of Product
~25 Reduction throughbull Better Project
ManagementWith Use of Simulations Avoided Rework
~25 Improvement throughbull Connected Equipment
bull Avoiding Defect Passing
~10 Improvement throughbull Layout Improvementbull Process Automation
bull Ergonomics amp Safety improvement
Quantitative Benefits and Awarded in CII Digital Transformation Meet
Innovation Digital Transformation Project Planning amp Operation
IIT - Kanpur- CVBU LUCKNOW
Teamwork Employee involvement amp MonitoringDaily Consumption Report
Daily Energy Audit Report
Daily Shopwise Report
Daily Solar Generation Report
Hourly Consumption Report-Plant
Hourly Consumption Report-Shop
Monthly Energy Consumption Report
Awar
enes
sle
vel
2017-18
Reporting of energy consumption of the plant and
individual shops on fortnightly and monthly
basis
2018-19
H1 Reporting of entire plantrsquos energy consumption on daily basis
Daily Energy Audit Report (DEAR) circulated across the plant to minimize
energy wastageH2 Reporting of entire plantrsquos and shop-wise energy consumption on
daily basis
2019-20
H1 Reporting of shop-wise energy consumption started on hourly
basisH1 Reporting of working dayrsquos
and non-working dayrsquos consumption separately for
identification of areasprocesses 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
ENERGY CONSUMPTION 2019-20Figures in KWH
FACTORY Dec-19 Jan-20 Feb-20 Mar-20EASTERN COMPLEXBIWBIW Cab 30103 29885 42825 7097BIW Cowl 17657 16650 20104 7438FDV 0 0 0 0COMP 13691 12555 15960 4155BIW Office others 3459 2845 3824 599Distribution Losses 5737 5686 8235 3398Total 70648 67620 90949 22688PAINT SHOPPTED 276243 270240 58056 125761Paint 199896 182651 252332 55852COMP 69201 71042 191305 32740Paint others 33456 34243 71892 16336Distribution Losses 52586 55324 32462 45001Total 631382 613501 606048 275690TCFAssly 84210 101803 92831 23993Trim Assly 12468 17988 15117 4219FDV 0 0 0 0Compressor 38154 41387 42232 13080TCF officeothers 19581 18255 15958 13560Distribution Losses 14262 16490 17609 10428Total 168676 195923 183747 65281
Rear Axle and Line-45 17252 16260 4125 1830Logistics Centre 14904 25247 20629 9615RSO 5597 9370 8390 8445
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
GSM Based Smart Control of Shop Floor Ventilation System
Concerns in present method bull One operator has to travel around 1 Km for manually switching off all FDVs in western complex due to control panel given at that particular
location and hence there is electrical energy wastage of 5137 KWHmonth due to travel time of around 20 mins
Present process Moving to
switching off SB1 FDV
(0 mins)
Moving to switching off SB2 FDV
(5 mins)
Moving to switching off F Block FDV
(15 mins)
Moving to switching off
SB4 FDV(20 mins)
Moving to switching off SB3 FDV
(10 mins)
Blower amp Control panel
FDV Locations in Line 1
EnCon Projects
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
LCA Solution
bull Remote switching off FDVs by integrating off operation of FDV with GSMmodem from one location Also message will be delivered to user thatwhich FDV has been switched off (wireless switching off operation is donethrough GSM modem to avoid cable cost and laying of cable line)
Benefits amp Horizontal Scope 1Energy saving - Energy saving of 41096 KWHannum by providing remote switching off FDVs
2 Cost Saving - Recurring cost saving of Rs 328 lakhsannum3 Environment- Reduction in carbon footprint (reduction of 337 tonne of CO2annum by energy saving)
4 SMS escalation to user for information of FDV switch off5No laying out of wire is required as it is wireless communication with help of GSM modem6 Horizontal deployment of GSM based control for other process machines of assembly line 12 and 3
Solution Cost-Rs 328 Lacs for all 5 FDVs
Remote switching off SB3 FDV (Instantly)
Control panel- Remote Switching off SB1 FDV
Remote switching off SB2 FDV (Instantly)
Remote switching off F Block FDV (Instantly)
Remote switching off SB4 FDV (Instantly)
GSM Based Smart Control of Shop Floor Ventilation System
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Innovative Projects LED Migration Project
Evolution of Lighting
LEDification Project
No expenses in LED- migration
OPEX model Lights Installation Testing amp
Commissioning of LED lights 5 yrs extended warranty
Scope amp Savings
Phase wise LEDification project
Entire plant in phases Better control schemes Reduction in consumption by
50 (Minimum)
Optimal design amp execution
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
Why LED for lighting
LED the best lighting option today
Energy efficient higher Lumens per Watts
No Mercury-Environmental friendly
No IR amp UV emissions Reduced heat generation
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Conventional Lighting system After LED Migration
Power Consumption 14 KW Lux level 125~200
Energy Cons-Monthly 6300 KWH 50400 INR-Annually 75600 KWH 604800 INR
65 KW (Red 464) 250~450 (Inc 250 )
2925 KWH 23400 INR (Red 464 )
35100 KWH 280800 INR
65 KW (Red 464) 250~450 (Inc 250 )
1312 KWH 10400 INR (Red 782 ) 15744 KWH 125952 INR
Occupancy Sensor
After Sensor installation
Occupancy sensor
Sensor Controlled
lightingGroup
Manual Controlled
Lighting group
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
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- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
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- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOW
Simple schematic
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustriesIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
We have Energy Management Cell in our Plant Which initiates amp Manages all sorts of Energy Conservation measuresacross the Plant
Energy Management System
Mr Pramod ChoudharyPlant Head Lucknow
DH ndash Mr S B MattaPlant services
MR -Lko Works Dr SB Matta
DH ndash Mr V AgrawalPaint shop
DH ndash Mr S N VermaTCF
DH ndash Mr U TauheedBIW
DH ndash Mr R K SinghIBF
DH ndash Mr R K SinghAxle Shop
DH ndashMr G V JoshiPlanning
DH ndash Mr A ChhariaMaterials amp ADD
DH ndash Mr Ankush GourHR
DH ndash Mr R K SinghCV- CX
Team Structure ndash ISO 50001
DH ndash Divisional Head
ISO 50001 CertificateEnergy Policy
2013 2016 2019
IIT - Kanpur- CVBU LUCKNOW
ENERGY MANAGEMENT SYSTEM ndash An Overview
TOP MANAGEMENT COMMITMENT
STAFF COMMITMENT
ENERGY AUDIT
ACTION PLAN
MONITORING amp TARGET SETTING
REVIEW amp DEVELOP PROFILE
LONG PAY BACK PROJECTS
IIT - Kanpur- CVBU LUCKNOW
Preliminary Energy audit
Detailed Energy audit
Plant Coordinator
GO AHEAD
Energy savings discussion and presentation
GO AHEAD for Implementation
Energy savings monitoring and interim report to Energy Mgmt Cell
Acceptance of Proposal
Submission of Techno commercial proposal
Team formation
Energy Management CellEnCon Implementation Methodology
copy Copyright Confidential Tata Motors Limited
Innovation Digital Transformation Project Planning amp Operation
3D layout of Manufacturing Line Process flow for Digital transformation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
44
Collaboration
Training
Layout
Maintenance
2D drawings using Auto Cad 3D digital Factory
No single platform for discussions and decision making among various stake-holder
Virtual Factory encouraged different agencies to work in more collaborate manner
Traditional training methods such as classroom teaching using PPTs and OJT
3D Digital Work-Instruction videos along with Quality and Safety awareness
Maintenance based on Real time data
Preventive Maintenance Breakdown Maintenance based on schedule
Collection of information from individual machines and preparing reports
Connected Machines IPMS Mobile App online quality parameter monitoring
Traditional Method Digital Method
Technology Landscape ndash before and after implementation
Factory Set-up time reduced
Issue identified and resolved before physical installationconstruction
Better Visualization of the process enables operator to learn fast
Down-time of machines reduced thusimproving OEE
Better tracking and control quality and Mc parameters Faster information exchange
Transformation Impact
No Virtual Simulation Expensive Physicals only for very critical processes
Virtual Simulation of Critical Processes helped to identified Potential issues
Short Project Lead time Saving on rework cost and time
Simulation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
Sales~10 Increase throughbull Levelled Productionbull Improvement in Customer Experience
Cost
Customer Complaint
Project Time
Quality
Employee Engagement
~15 Reduction through bull Inventory Optimizationbull Warranty Cost reductionbull COPQ Reduction
~15 Reduction through bull Robust Process Designbull Resulting Reliability of Product
~25 Reduction throughbull Better Project
ManagementWith Use of Simulations Avoided Rework
~25 Improvement throughbull Connected Equipment
bull Avoiding Defect Passing
~10 Improvement throughbull Layout Improvementbull Process Automation
bull Ergonomics amp Safety improvement
Quantitative Benefits and Awarded in CII Digital Transformation Meet
Innovation Digital Transformation Project Planning amp Operation
IIT - Kanpur- CVBU LUCKNOW
Teamwork Employee involvement amp MonitoringDaily Consumption Report
Daily Energy Audit Report
Daily Shopwise Report
Daily Solar Generation Report
Hourly Consumption Report-Plant
Hourly Consumption Report-Shop
Monthly Energy Consumption Report
Awar
enes
sle
vel
2017-18
Reporting of energy consumption of the plant and
individual shops on fortnightly and monthly
basis
2018-19
H1 Reporting of entire plantrsquos energy consumption on daily basis
Daily Energy Audit Report (DEAR) circulated across the plant to minimize
energy wastageH2 Reporting of entire plantrsquos and shop-wise energy consumption on
daily basis
2019-20
H1 Reporting of shop-wise energy consumption started on hourly
basisH1 Reporting of working dayrsquos
and non-working dayrsquos consumption separately for
identification of areasprocesses 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
ENERGY CONSUMPTION 2019-20Figures in KWH
FACTORY Dec-19 Jan-20 Feb-20 Mar-20EASTERN COMPLEXBIWBIW Cab 30103 29885 42825 7097BIW Cowl 17657 16650 20104 7438FDV 0 0 0 0COMP 13691 12555 15960 4155BIW Office others 3459 2845 3824 599Distribution Losses 5737 5686 8235 3398Total 70648 67620 90949 22688PAINT SHOPPTED 276243 270240 58056 125761Paint 199896 182651 252332 55852COMP 69201 71042 191305 32740Paint others 33456 34243 71892 16336Distribution Losses 52586 55324 32462 45001Total 631382 613501 606048 275690TCFAssly 84210 101803 92831 23993Trim Assly 12468 17988 15117 4219FDV 0 0 0 0Compressor 38154 41387 42232 13080TCF officeothers 19581 18255 15958 13560Distribution Losses 14262 16490 17609 10428Total 168676 195923 183747 65281
Rear Axle and Line-45 17252 16260 4125 1830Logistics Centre 14904 25247 20629 9615RSO 5597 9370 8390 8445
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
GSM Based Smart Control of Shop Floor Ventilation System
Concerns in present method bull One operator has to travel around 1 Km for manually switching off all FDVs in western complex due to control panel given at that particular
location and hence there is electrical energy wastage of 5137 KWHmonth due to travel time of around 20 mins
Present process Moving to
switching off SB1 FDV
(0 mins)
Moving to switching off SB2 FDV
(5 mins)
Moving to switching off F Block FDV
(15 mins)
Moving to switching off
SB4 FDV(20 mins)
Moving to switching off SB3 FDV
(10 mins)
Blower amp Control panel
FDV Locations in Line 1
EnCon Projects
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
LCA Solution
bull Remote switching off FDVs by integrating off operation of FDV with GSMmodem from one location Also message will be delivered to user thatwhich FDV has been switched off (wireless switching off operation is donethrough GSM modem to avoid cable cost and laying of cable line)
Benefits amp Horizontal Scope 1Energy saving - Energy saving of 41096 KWHannum by providing remote switching off FDVs
2 Cost Saving - Recurring cost saving of Rs 328 lakhsannum3 Environment- Reduction in carbon footprint (reduction of 337 tonne of CO2annum by energy saving)
4 SMS escalation to user for information of FDV switch off5No laying out of wire is required as it is wireless communication with help of GSM modem6 Horizontal deployment of GSM based control for other process machines of assembly line 12 and 3
Solution Cost-Rs 328 Lacs for all 5 FDVs
Remote switching off SB3 FDV (Instantly)
Control panel- Remote Switching off SB1 FDV
Remote switching off SB2 FDV (Instantly)
Remote switching off F Block FDV (Instantly)
Remote switching off SB4 FDV (Instantly)
GSM Based Smart Control of Shop Floor Ventilation System
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Innovative Projects LED Migration Project
Evolution of Lighting
LEDification Project
No expenses in LED- migration
OPEX model Lights Installation Testing amp
Commissioning of LED lights 5 yrs extended warranty
Scope amp Savings
Phase wise LEDification project
Entire plant in phases Better control schemes Reduction in consumption by
50 (Minimum)
Optimal design amp execution
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
Why LED for lighting
LED the best lighting option today
Energy efficient higher Lumens per Watts
No Mercury-Environmental friendly
No IR amp UV emissions Reduced heat generation
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Conventional Lighting system After LED Migration
Power Consumption 14 KW Lux level 125~200
Energy Cons-Monthly 6300 KWH 50400 INR-Annually 75600 KWH 604800 INR
65 KW (Red 464) 250~450 (Inc 250 )
2925 KWH 23400 INR (Red 464 )
35100 KWH 280800 INR
65 KW (Red 464) 250~450 (Inc 250 )
1312 KWH 10400 INR (Red 782 ) 15744 KWH 125952 INR
Occupancy Sensor
After Sensor installation
Occupancy sensor
Sensor Controlled
lightingGroup
Manual Controlled
Lighting group
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
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- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
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- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustriesIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
We have Energy Management Cell in our Plant Which initiates amp Manages all sorts of Energy Conservation measuresacross the Plant
Energy Management System
Mr Pramod ChoudharyPlant Head Lucknow
DH ndash Mr S B MattaPlant services
MR -Lko Works Dr SB Matta
DH ndash Mr V AgrawalPaint shop
DH ndash Mr S N VermaTCF
DH ndash Mr U TauheedBIW
DH ndash Mr R K SinghIBF
DH ndash Mr R K SinghAxle Shop
DH ndashMr G V JoshiPlanning
DH ndash Mr A ChhariaMaterials amp ADD
DH ndash Mr Ankush GourHR
DH ndash Mr R K SinghCV- CX
Team Structure ndash ISO 50001
DH ndash Divisional Head
ISO 50001 CertificateEnergy Policy
2013 2016 2019
IIT - Kanpur- CVBU LUCKNOW
ENERGY MANAGEMENT SYSTEM ndash An Overview
TOP MANAGEMENT COMMITMENT
STAFF COMMITMENT
ENERGY AUDIT
ACTION PLAN
MONITORING amp TARGET SETTING
REVIEW amp DEVELOP PROFILE
LONG PAY BACK PROJECTS
IIT - Kanpur- CVBU LUCKNOW
Preliminary Energy audit
Detailed Energy audit
Plant Coordinator
GO AHEAD
Energy savings discussion and presentation
GO AHEAD for Implementation
Energy savings monitoring and interim report to Energy Mgmt Cell
Acceptance of Proposal
Submission of Techno commercial proposal
Team formation
Energy Management CellEnCon Implementation Methodology
copy Copyright Confidential Tata Motors Limited
Innovation Digital Transformation Project Planning amp Operation
3D layout of Manufacturing Line Process flow for Digital transformation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
44
Collaboration
Training
Layout
Maintenance
2D drawings using Auto Cad 3D digital Factory
No single platform for discussions and decision making among various stake-holder
Virtual Factory encouraged different agencies to work in more collaborate manner
Traditional training methods such as classroom teaching using PPTs and OJT
3D Digital Work-Instruction videos along with Quality and Safety awareness
Maintenance based on Real time data
Preventive Maintenance Breakdown Maintenance based on schedule
Collection of information from individual machines and preparing reports
Connected Machines IPMS Mobile App online quality parameter monitoring
Traditional Method Digital Method
Technology Landscape ndash before and after implementation
Factory Set-up time reduced
Issue identified and resolved before physical installationconstruction
Better Visualization of the process enables operator to learn fast
Down-time of machines reduced thusimproving OEE
Better tracking and control quality and Mc parameters Faster information exchange
Transformation Impact
No Virtual Simulation Expensive Physicals only for very critical processes
Virtual Simulation of Critical Processes helped to identified Potential issues
Short Project Lead time Saving on rework cost and time
Simulation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
Sales~10 Increase throughbull Levelled Productionbull Improvement in Customer Experience
Cost
Customer Complaint
Project Time
Quality
Employee Engagement
~15 Reduction through bull Inventory Optimizationbull Warranty Cost reductionbull COPQ Reduction
~15 Reduction through bull Robust Process Designbull Resulting Reliability of Product
~25 Reduction throughbull Better Project
ManagementWith Use of Simulations Avoided Rework
~25 Improvement throughbull Connected Equipment
bull Avoiding Defect Passing
~10 Improvement throughbull Layout Improvementbull Process Automation
bull Ergonomics amp Safety improvement
Quantitative Benefits and Awarded in CII Digital Transformation Meet
Innovation Digital Transformation Project Planning amp Operation
IIT - Kanpur- CVBU LUCKNOW
Teamwork Employee involvement amp MonitoringDaily Consumption Report
Daily Energy Audit Report
Daily Shopwise Report
Daily Solar Generation Report
Hourly Consumption Report-Plant
Hourly Consumption Report-Shop
Monthly Energy Consumption Report
Awar
enes
sle
vel
2017-18
Reporting of energy consumption of the plant and
individual shops on fortnightly and monthly
basis
2018-19
H1 Reporting of entire plantrsquos energy consumption on daily basis
Daily Energy Audit Report (DEAR) circulated across the plant to minimize
energy wastageH2 Reporting of entire plantrsquos and shop-wise energy consumption on
daily basis
2019-20
H1 Reporting of shop-wise energy consumption started on hourly
basisH1 Reporting of working dayrsquos
and non-working dayrsquos consumption separately for
identification of areasprocesses 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
ENERGY CONSUMPTION 2019-20Figures in KWH
FACTORY Dec-19 Jan-20 Feb-20 Mar-20EASTERN COMPLEXBIWBIW Cab 30103 29885 42825 7097BIW Cowl 17657 16650 20104 7438FDV 0 0 0 0COMP 13691 12555 15960 4155BIW Office others 3459 2845 3824 599Distribution Losses 5737 5686 8235 3398Total 70648 67620 90949 22688PAINT SHOPPTED 276243 270240 58056 125761Paint 199896 182651 252332 55852COMP 69201 71042 191305 32740Paint others 33456 34243 71892 16336Distribution Losses 52586 55324 32462 45001Total 631382 613501 606048 275690TCFAssly 84210 101803 92831 23993Trim Assly 12468 17988 15117 4219FDV 0 0 0 0Compressor 38154 41387 42232 13080TCF officeothers 19581 18255 15958 13560Distribution Losses 14262 16490 17609 10428Total 168676 195923 183747 65281
Rear Axle and Line-45 17252 16260 4125 1830Logistics Centre 14904 25247 20629 9615RSO 5597 9370 8390 8445
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
GSM Based Smart Control of Shop Floor Ventilation System
Concerns in present method bull One operator has to travel around 1 Km for manually switching off all FDVs in western complex due to control panel given at that particular
location and hence there is electrical energy wastage of 5137 KWHmonth due to travel time of around 20 mins
Present process Moving to
switching off SB1 FDV
(0 mins)
Moving to switching off SB2 FDV
(5 mins)
Moving to switching off F Block FDV
(15 mins)
Moving to switching off
SB4 FDV(20 mins)
Moving to switching off SB3 FDV
(10 mins)
Blower amp Control panel
FDV Locations in Line 1
EnCon Projects
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
LCA Solution
bull Remote switching off FDVs by integrating off operation of FDV with GSMmodem from one location Also message will be delivered to user thatwhich FDV has been switched off (wireless switching off operation is donethrough GSM modem to avoid cable cost and laying of cable line)
Benefits amp Horizontal Scope 1Energy saving - Energy saving of 41096 KWHannum by providing remote switching off FDVs
2 Cost Saving - Recurring cost saving of Rs 328 lakhsannum3 Environment- Reduction in carbon footprint (reduction of 337 tonne of CO2annum by energy saving)
4 SMS escalation to user for information of FDV switch off5No laying out of wire is required as it is wireless communication with help of GSM modem6 Horizontal deployment of GSM based control for other process machines of assembly line 12 and 3
Solution Cost-Rs 328 Lacs for all 5 FDVs
Remote switching off SB3 FDV (Instantly)
Control panel- Remote Switching off SB1 FDV
Remote switching off SB2 FDV (Instantly)
Remote switching off F Block FDV (Instantly)
Remote switching off SB4 FDV (Instantly)
GSM Based Smart Control of Shop Floor Ventilation System
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Innovative Projects LED Migration Project
Evolution of Lighting
LEDification Project
No expenses in LED- migration
OPEX model Lights Installation Testing amp
Commissioning of LED lights 5 yrs extended warranty
Scope amp Savings
Phase wise LEDification project
Entire plant in phases Better control schemes Reduction in consumption by
50 (Minimum)
Optimal design amp execution
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
Why LED for lighting
LED the best lighting option today
Energy efficient higher Lumens per Watts
No Mercury-Environmental friendly
No IR amp UV emissions Reduced heat generation
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Conventional Lighting system After LED Migration
Power Consumption 14 KW Lux level 125~200
Energy Cons-Monthly 6300 KWH 50400 INR-Annually 75600 KWH 604800 INR
65 KW (Red 464) 250~450 (Inc 250 )
2925 KWH 23400 INR (Red 464 )
35100 KWH 280800 INR
65 KW (Red 464) 250~450 (Inc 250 )
1312 KWH 10400 INR (Red 782 ) 15744 KWH 125952 INR
Occupancy Sensor
After Sensor installation
Occupancy sensor
Sensor Controlled
lightingGroup
Manual Controlled
Lighting group
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
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- Slide Number 55
- Slide Number 56
- Slide Number 57
- Slide Number 58
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- Slide Number 60
- Slide Number 61
- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustriesIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
We have Energy Management Cell in our Plant Which initiates amp Manages all sorts of Energy Conservation measuresacross the Plant
Energy Management System
Mr Pramod ChoudharyPlant Head Lucknow
DH ndash Mr S B MattaPlant services
MR -Lko Works Dr SB Matta
DH ndash Mr V AgrawalPaint shop
DH ndash Mr S N VermaTCF
DH ndash Mr U TauheedBIW
DH ndash Mr R K SinghIBF
DH ndash Mr R K SinghAxle Shop
DH ndashMr G V JoshiPlanning
DH ndash Mr A ChhariaMaterials amp ADD
DH ndash Mr Ankush GourHR
DH ndash Mr R K SinghCV- CX
Team Structure ndash ISO 50001
DH ndash Divisional Head
ISO 50001 CertificateEnergy Policy
2013 2016 2019
IIT - Kanpur- CVBU LUCKNOW
ENERGY MANAGEMENT SYSTEM ndash An Overview
TOP MANAGEMENT COMMITMENT
STAFF COMMITMENT
ENERGY AUDIT
ACTION PLAN
MONITORING amp TARGET SETTING
REVIEW amp DEVELOP PROFILE
LONG PAY BACK PROJECTS
IIT - Kanpur- CVBU LUCKNOW
Preliminary Energy audit
Detailed Energy audit
Plant Coordinator
GO AHEAD
Energy savings discussion and presentation
GO AHEAD for Implementation
Energy savings monitoring and interim report to Energy Mgmt Cell
Acceptance of Proposal
Submission of Techno commercial proposal
Team formation
Energy Management CellEnCon Implementation Methodology
copy Copyright Confidential Tata Motors Limited
Innovation Digital Transformation Project Planning amp Operation
3D layout of Manufacturing Line Process flow for Digital transformation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
44
Collaboration
Training
Layout
Maintenance
2D drawings using Auto Cad 3D digital Factory
No single platform for discussions and decision making among various stake-holder
Virtual Factory encouraged different agencies to work in more collaborate manner
Traditional training methods such as classroom teaching using PPTs and OJT
3D Digital Work-Instruction videos along with Quality and Safety awareness
Maintenance based on Real time data
Preventive Maintenance Breakdown Maintenance based on schedule
Collection of information from individual machines and preparing reports
Connected Machines IPMS Mobile App online quality parameter monitoring
Traditional Method Digital Method
Technology Landscape ndash before and after implementation
Factory Set-up time reduced
Issue identified and resolved before physical installationconstruction
Better Visualization of the process enables operator to learn fast
Down-time of machines reduced thusimproving OEE
Better tracking and control quality and Mc parameters Faster information exchange
Transformation Impact
No Virtual Simulation Expensive Physicals only for very critical processes
Virtual Simulation of Critical Processes helped to identified Potential issues
Short Project Lead time Saving on rework cost and time
Simulation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
Sales~10 Increase throughbull Levelled Productionbull Improvement in Customer Experience
Cost
Customer Complaint
Project Time
Quality
Employee Engagement
~15 Reduction through bull Inventory Optimizationbull Warranty Cost reductionbull COPQ Reduction
~15 Reduction through bull Robust Process Designbull Resulting Reliability of Product
~25 Reduction throughbull Better Project
ManagementWith Use of Simulations Avoided Rework
~25 Improvement throughbull Connected Equipment
bull Avoiding Defect Passing
~10 Improvement throughbull Layout Improvementbull Process Automation
bull Ergonomics amp Safety improvement
Quantitative Benefits and Awarded in CII Digital Transformation Meet
Innovation Digital Transformation Project Planning amp Operation
IIT - Kanpur- CVBU LUCKNOW
Teamwork Employee involvement amp MonitoringDaily Consumption Report
Daily Energy Audit Report
Daily Shopwise Report
Daily Solar Generation Report
Hourly Consumption Report-Plant
Hourly Consumption Report-Shop
Monthly Energy Consumption Report
Awar
enes
sle
vel
2017-18
Reporting of energy consumption of the plant and
individual shops on fortnightly and monthly
basis
2018-19
H1 Reporting of entire plantrsquos energy consumption on daily basis
Daily Energy Audit Report (DEAR) circulated across the plant to minimize
energy wastageH2 Reporting of entire plantrsquos and shop-wise energy consumption on
daily basis
2019-20
H1 Reporting of shop-wise energy consumption started on hourly
basisH1 Reporting of working dayrsquos
and non-working dayrsquos consumption separately for
identification of areasprocesses 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
ENERGY CONSUMPTION 2019-20Figures in KWH
FACTORY Dec-19 Jan-20 Feb-20 Mar-20EASTERN COMPLEXBIWBIW Cab 30103 29885 42825 7097BIW Cowl 17657 16650 20104 7438FDV 0 0 0 0COMP 13691 12555 15960 4155BIW Office others 3459 2845 3824 599Distribution Losses 5737 5686 8235 3398Total 70648 67620 90949 22688PAINT SHOPPTED 276243 270240 58056 125761Paint 199896 182651 252332 55852COMP 69201 71042 191305 32740Paint others 33456 34243 71892 16336Distribution Losses 52586 55324 32462 45001Total 631382 613501 606048 275690TCFAssly 84210 101803 92831 23993Trim Assly 12468 17988 15117 4219FDV 0 0 0 0Compressor 38154 41387 42232 13080TCF officeothers 19581 18255 15958 13560Distribution Losses 14262 16490 17609 10428Total 168676 195923 183747 65281
Rear Axle and Line-45 17252 16260 4125 1830Logistics Centre 14904 25247 20629 9615RSO 5597 9370 8390 8445
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
GSM Based Smart Control of Shop Floor Ventilation System
Concerns in present method bull One operator has to travel around 1 Km for manually switching off all FDVs in western complex due to control panel given at that particular
location and hence there is electrical energy wastage of 5137 KWHmonth due to travel time of around 20 mins
Present process Moving to
switching off SB1 FDV
(0 mins)
Moving to switching off SB2 FDV
(5 mins)
Moving to switching off F Block FDV
(15 mins)
Moving to switching off
SB4 FDV(20 mins)
Moving to switching off SB3 FDV
(10 mins)
Blower amp Control panel
FDV Locations in Line 1
EnCon Projects
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
LCA Solution
bull Remote switching off FDVs by integrating off operation of FDV with GSMmodem from one location Also message will be delivered to user thatwhich FDV has been switched off (wireless switching off operation is donethrough GSM modem to avoid cable cost and laying of cable line)
Benefits amp Horizontal Scope 1Energy saving - Energy saving of 41096 KWHannum by providing remote switching off FDVs
2 Cost Saving - Recurring cost saving of Rs 328 lakhsannum3 Environment- Reduction in carbon footprint (reduction of 337 tonne of CO2annum by energy saving)
4 SMS escalation to user for information of FDV switch off5No laying out of wire is required as it is wireless communication with help of GSM modem6 Horizontal deployment of GSM based control for other process machines of assembly line 12 and 3
Solution Cost-Rs 328 Lacs for all 5 FDVs
Remote switching off SB3 FDV (Instantly)
Control panel- Remote Switching off SB1 FDV
Remote switching off SB2 FDV (Instantly)
Remote switching off F Block FDV (Instantly)
Remote switching off SB4 FDV (Instantly)
GSM Based Smart Control of Shop Floor Ventilation System
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Innovative Projects LED Migration Project
Evolution of Lighting
LEDification Project
No expenses in LED- migration
OPEX model Lights Installation Testing amp
Commissioning of LED lights 5 yrs extended warranty
Scope amp Savings
Phase wise LEDification project
Entire plant in phases Better control schemes Reduction in consumption by
50 (Minimum)
Optimal design amp execution
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
Why LED for lighting
LED the best lighting option today
Energy efficient higher Lumens per Watts
No Mercury-Environmental friendly
No IR amp UV emissions Reduced heat generation
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Conventional Lighting system After LED Migration
Power Consumption 14 KW Lux level 125~200
Energy Cons-Monthly 6300 KWH 50400 INR-Annually 75600 KWH 604800 INR
65 KW (Red 464) 250~450 (Inc 250 )
2925 KWH 23400 INR (Red 464 )
35100 KWH 280800 INR
65 KW (Red 464) 250~450 (Inc 250 )
1312 KWH 10400 INR (Red 782 ) 15744 KWH 125952 INR
Occupancy Sensor
After Sensor installation
Occupancy sensor
Sensor Controlled
lightingGroup
Manual Controlled
Lighting group
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
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- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
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- Slide Number 28
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- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustriesIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
We have Energy Management Cell in our Plant Which initiates amp Manages all sorts of Energy Conservation measuresacross the Plant
Energy Management System
Mr Pramod ChoudharyPlant Head Lucknow
DH ndash Mr S B MattaPlant services
MR -Lko Works Dr SB Matta
DH ndash Mr V AgrawalPaint shop
DH ndash Mr S N VermaTCF
DH ndash Mr U TauheedBIW
DH ndash Mr R K SinghIBF
DH ndash Mr R K SinghAxle Shop
DH ndashMr G V JoshiPlanning
DH ndash Mr A ChhariaMaterials amp ADD
DH ndash Mr Ankush GourHR
DH ndash Mr R K SinghCV- CX
Team Structure ndash ISO 50001
DH ndash Divisional Head
ISO 50001 CertificateEnergy Policy
2013 2016 2019
IIT - Kanpur- CVBU LUCKNOW
ENERGY MANAGEMENT SYSTEM ndash An Overview
TOP MANAGEMENT COMMITMENT
STAFF COMMITMENT
ENERGY AUDIT
ACTION PLAN
MONITORING amp TARGET SETTING
REVIEW amp DEVELOP PROFILE
LONG PAY BACK PROJECTS
IIT - Kanpur- CVBU LUCKNOW
Preliminary Energy audit
Detailed Energy audit
Plant Coordinator
GO AHEAD
Energy savings discussion and presentation
GO AHEAD for Implementation
Energy savings monitoring and interim report to Energy Mgmt Cell
Acceptance of Proposal
Submission of Techno commercial proposal
Team formation
Energy Management CellEnCon Implementation Methodology
copy Copyright Confidential Tata Motors Limited
Innovation Digital Transformation Project Planning amp Operation
3D layout of Manufacturing Line Process flow for Digital transformation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
44
Collaboration
Training
Layout
Maintenance
2D drawings using Auto Cad 3D digital Factory
No single platform for discussions and decision making among various stake-holder
Virtual Factory encouraged different agencies to work in more collaborate manner
Traditional training methods such as classroom teaching using PPTs and OJT
3D Digital Work-Instruction videos along with Quality and Safety awareness
Maintenance based on Real time data
Preventive Maintenance Breakdown Maintenance based on schedule
Collection of information from individual machines and preparing reports
Connected Machines IPMS Mobile App online quality parameter monitoring
Traditional Method Digital Method
Technology Landscape ndash before and after implementation
Factory Set-up time reduced
Issue identified and resolved before physical installationconstruction
Better Visualization of the process enables operator to learn fast
Down-time of machines reduced thusimproving OEE
Better tracking and control quality and Mc parameters Faster information exchange
Transformation Impact
No Virtual Simulation Expensive Physicals only for very critical processes
Virtual Simulation of Critical Processes helped to identified Potential issues
Short Project Lead time Saving on rework cost and time
Simulation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
Sales~10 Increase throughbull Levelled Productionbull Improvement in Customer Experience
Cost
Customer Complaint
Project Time
Quality
Employee Engagement
~15 Reduction through bull Inventory Optimizationbull Warranty Cost reductionbull COPQ Reduction
~15 Reduction through bull Robust Process Designbull Resulting Reliability of Product
~25 Reduction throughbull Better Project
ManagementWith Use of Simulations Avoided Rework
~25 Improvement throughbull Connected Equipment
bull Avoiding Defect Passing
~10 Improvement throughbull Layout Improvementbull Process Automation
bull Ergonomics amp Safety improvement
Quantitative Benefits and Awarded in CII Digital Transformation Meet
Innovation Digital Transformation Project Planning amp Operation
IIT - Kanpur- CVBU LUCKNOW
Teamwork Employee involvement amp MonitoringDaily Consumption Report
Daily Energy Audit Report
Daily Shopwise Report
Daily Solar Generation Report
Hourly Consumption Report-Plant
Hourly Consumption Report-Shop
Monthly Energy Consumption Report
Awar
enes
sle
vel
2017-18
Reporting of energy consumption of the plant and
individual shops on fortnightly and monthly
basis
2018-19
H1 Reporting of entire plantrsquos energy consumption on daily basis
Daily Energy Audit Report (DEAR) circulated across the plant to minimize
energy wastageH2 Reporting of entire plantrsquos and shop-wise energy consumption on
daily basis
2019-20
H1 Reporting of shop-wise energy consumption started on hourly
basisH1 Reporting of working dayrsquos
and non-working dayrsquos consumption separately for
identification of areasprocesses 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
ENERGY CONSUMPTION 2019-20Figures in KWH
FACTORY Dec-19 Jan-20 Feb-20 Mar-20EASTERN COMPLEXBIWBIW Cab 30103 29885 42825 7097BIW Cowl 17657 16650 20104 7438FDV 0 0 0 0COMP 13691 12555 15960 4155BIW Office others 3459 2845 3824 599Distribution Losses 5737 5686 8235 3398Total 70648 67620 90949 22688PAINT SHOPPTED 276243 270240 58056 125761Paint 199896 182651 252332 55852COMP 69201 71042 191305 32740Paint others 33456 34243 71892 16336Distribution Losses 52586 55324 32462 45001Total 631382 613501 606048 275690TCFAssly 84210 101803 92831 23993Trim Assly 12468 17988 15117 4219FDV 0 0 0 0Compressor 38154 41387 42232 13080TCF officeothers 19581 18255 15958 13560Distribution Losses 14262 16490 17609 10428Total 168676 195923 183747 65281
Rear Axle and Line-45 17252 16260 4125 1830Logistics Centre 14904 25247 20629 9615RSO 5597 9370 8390 8445
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
GSM Based Smart Control of Shop Floor Ventilation System
Concerns in present method bull One operator has to travel around 1 Km for manually switching off all FDVs in western complex due to control panel given at that particular
location and hence there is electrical energy wastage of 5137 KWHmonth due to travel time of around 20 mins
Present process Moving to
switching off SB1 FDV
(0 mins)
Moving to switching off SB2 FDV
(5 mins)
Moving to switching off F Block FDV
(15 mins)
Moving to switching off
SB4 FDV(20 mins)
Moving to switching off SB3 FDV
(10 mins)
Blower amp Control panel
FDV Locations in Line 1
EnCon Projects
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
LCA Solution
bull Remote switching off FDVs by integrating off operation of FDV with GSMmodem from one location Also message will be delivered to user thatwhich FDV has been switched off (wireless switching off operation is donethrough GSM modem to avoid cable cost and laying of cable line)
Benefits amp Horizontal Scope 1Energy saving - Energy saving of 41096 KWHannum by providing remote switching off FDVs
2 Cost Saving - Recurring cost saving of Rs 328 lakhsannum3 Environment- Reduction in carbon footprint (reduction of 337 tonne of CO2annum by energy saving)
4 SMS escalation to user for information of FDV switch off5No laying out of wire is required as it is wireless communication with help of GSM modem6 Horizontal deployment of GSM based control for other process machines of assembly line 12 and 3
Solution Cost-Rs 328 Lacs for all 5 FDVs
Remote switching off SB3 FDV (Instantly)
Control panel- Remote Switching off SB1 FDV
Remote switching off SB2 FDV (Instantly)
Remote switching off F Block FDV (Instantly)
Remote switching off SB4 FDV (Instantly)
GSM Based Smart Control of Shop Floor Ventilation System
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Innovative Projects LED Migration Project
Evolution of Lighting
LEDification Project
No expenses in LED- migration
OPEX model Lights Installation Testing amp
Commissioning of LED lights 5 yrs extended warranty
Scope amp Savings
Phase wise LEDification project
Entire plant in phases Better control schemes Reduction in consumption by
50 (Minimum)
Optimal design amp execution
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
Why LED for lighting
LED the best lighting option today
Energy efficient higher Lumens per Watts
No Mercury-Environmental friendly
No IR amp UV emissions Reduced heat generation
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Conventional Lighting system After LED Migration
Power Consumption 14 KW Lux level 125~200
Energy Cons-Monthly 6300 KWH 50400 INR-Annually 75600 KWH 604800 INR
65 KW (Red 464) 250~450 (Inc 250 )
2925 KWH 23400 INR (Red 464 )
35100 KWH 280800 INR
65 KW (Red 464) 250~450 (Inc 250 )
1312 KWH 10400 INR (Red 782 ) 15744 KWH 125952 INR
Occupancy Sensor
After Sensor installation
Occupancy sensor
Sensor Controlled
lightingGroup
Manual Controlled
Lighting group
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
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- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
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- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
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- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
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- Slide Number 53
- Slide Number 54
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- Slide Number 58
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- Slide Number 60
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- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustriesIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
We have Energy Management Cell in our Plant Which initiates amp Manages all sorts of Energy Conservation measuresacross the Plant
Energy Management System
Mr Pramod ChoudharyPlant Head Lucknow
DH ndash Mr S B MattaPlant services
MR -Lko Works Dr SB Matta
DH ndash Mr V AgrawalPaint shop
DH ndash Mr S N VermaTCF
DH ndash Mr U TauheedBIW
DH ndash Mr R K SinghIBF
DH ndash Mr R K SinghAxle Shop
DH ndashMr G V JoshiPlanning
DH ndash Mr A ChhariaMaterials amp ADD
DH ndash Mr Ankush GourHR
DH ndash Mr R K SinghCV- CX
Team Structure ndash ISO 50001
DH ndash Divisional Head
ISO 50001 CertificateEnergy Policy
2013 2016 2019
IIT - Kanpur- CVBU LUCKNOW
ENERGY MANAGEMENT SYSTEM ndash An Overview
TOP MANAGEMENT COMMITMENT
STAFF COMMITMENT
ENERGY AUDIT
ACTION PLAN
MONITORING amp TARGET SETTING
REVIEW amp DEVELOP PROFILE
LONG PAY BACK PROJECTS
IIT - Kanpur- CVBU LUCKNOW
Preliminary Energy audit
Detailed Energy audit
Plant Coordinator
GO AHEAD
Energy savings discussion and presentation
GO AHEAD for Implementation
Energy savings monitoring and interim report to Energy Mgmt Cell
Acceptance of Proposal
Submission of Techno commercial proposal
Team formation
Energy Management CellEnCon Implementation Methodology
copy Copyright Confidential Tata Motors Limited
Innovation Digital Transformation Project Planning amp Operation
3D layout of Manufacturing Line Process flow for Digital transformation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
44
Collaboration
Training
Layout
Maintenance
2D drawings using Auto Cad 3D digital Factory
No single platform for discussions and decision making among various stake-holder
Virtual Factory encouraged different agencies to work in more collaborate manner
Traditional training methods such as classroom teaching using PPTs and OJT
3D Digital Work-Instruction videos along with Quality and Safety awareness
Maintenance based on Real time data
Preventive Maintenance Breakdown Maintenance based on schedule
Collection of information from individual machines and preparing reports
Connected Machines IPMS Mobile App online quality parameter monitoring
Traditional Method Digital Method
Technology Landscape ndash before and after implementation
Factory Set-up time reduced
Issue identified and resolved before physical installationconstruction
Better Visualization of the process enables operator to learn fast
Down-time of machines reduced thusimproving OEE
Better tracking and control quality and Mc parameters Faster information exchange
Transformation Impact
No Virtual Simulation Expensive Physicals only for very critical processes
Virtual Simulation of Critical Processes helped to identified Potential issues
Short Project Lead time Saving on rework cost and time
Simulation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
Sales~10 Increase throughbull Levelled Productionbull Improvement in Customer Experience
Cost
Customer Complaint
Project Time
Quality
Employee Engagement
~15 Reduction through bull Inventory Optimizationbull Warranty Cost reductionbull COPQ Reduction
~15 Reduction through bull Robust Process Designbull Resulting Reliability of Product
~25 Reduction throughbull Better Project
ManagementWith Use of Simulations Avoided Rework
~25 Improvement throughbull Connected Equipment
bull Avoiding Defect Passing
~10 Improvement throughbull Layout Improvementbull Process Automation
bull Ergonomics amp Safety improvement
Quantitative Benefits and Awarded in CII Digital Transformation Meet
Innovation Digital Transformation Project Planning amp Operation
IIT - Kanpur- CVBU LUCKNOW
Teamwork Employee involvement amp MonitoringDaily Consumption Report
Daily Energy Audit Report
Daily Shopwise Report
Daily Solar Generation Report
Hourly Consumption Report-Plant
Hourly Consumption Report-Shop
Monthly Energy Consumption Report
Awar
enes
sle
vel
2017-18
Reporting of energy consumption of the plant and
individual shops on fortnightly and monthly
basis
2018-19
H1 Reporting of entire plantrsquos energy consumption on daily basis
Daily Energy Audit Report (DEAR) circulated across the plant to minimize
energy wastageH2 Reporting of entire plantrsquos and shop-wise energy consumption on
daily basis
2019-20
H1 Reporting of shop-wise energy consumption started on hourly
basisH1 Reporting of working dayrsquos
and non-working dayrsquos consumption separately for
identification of areasprocesses 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
ENERGY CONSUMPTION 2019-20Figures in KWH
FACTORY Dec-19 Jan-20 Feb-20 Mar-20EASTERN COMPLEXBIWBIW Cab 30103 29885 42825 7097BIW Cowl 17657 16650 20104 7438FDV 0 0 0 0COMP 13691 12555 15960 4155BIW Office others 3459 2845 3824 599Distribution Losses 5737 5686 8235 3398Total 70648 67620 90949 22688PAINT SHOPPTED 276243 270240 58056 125761Paint 199896 182651 252332 55852COMP 69201 71042 191305 32740Paint others 33456 34243 71892 16336Distribution Losses 52586 55324 32462 45001Total 631382 613501 606048 275690TCFAssly 84210 101803 92831 23993Trim Assly 12468 17988 15117 4219FDV 0 0 0 0Compressor 38154 41387 42232 13080TCF officeothers 19581 18255 15958 13560Distribution Losses 14262 16490 17609 10428Total 168676 195923 183747 65281
Rear Axle and Line-45 17252 16260 4125 1830Logistics Centre 14904 25247 20629 9615RSO 5597 9370 8390 8445
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
GSM Based Smart Control of Shop Floor Ventilation System
Concerns in present method bull One operator has to travel around 1 Km for manually switching off all FDVs in western complex due to control panel given at that particular
location and hence there is electrical energy wastage of 5137 KWHmonth due to travel time of around 20 mins
Present process Moving to
switching off SB1 FDV
(0 mins)
Moving to switching off SB2 FDV
(5 mins)
Moving to switching off F Block FDV
(15 mins)
Moving to switching off
SB4 FDV(20 mins)
Moving to switching off SB3 FDV
(10 mins)
Blower amp Control panel
FDV Locations in Line 1
EnCon Projects
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
LCA Solution
bull Remote switching off FDVs by integrating off operation of FDV with GSMmodem from one location Also message will be delivered to user thatwhich FDV has been switched off (wireless switching off operation is donethrough GSM modem to avoid cable cost and laying of cable line)
Benefits amp Horizontal Scope 1Energy saving - Energy saving of 41096 KWHannum by providing remote switching off FDVs
2 Cost Saving - Recurring cost saving of Rs 328 lakhsannum3 Environment- Reduction in carbon footprint (reduction of 337 tonne of CO2annum by energy saving)
4 SMS escalation to user for information of FDV switch off5No laying out of wire is required as it is wireless communication with help of GSM modem6 Horizontal deployment of GSM based control for other process machines of assembly line 12 and 3
Solution Cost-Rs 328 Lacs for all 5 FDVs
Remote switching off SB3 FDV (Instantly)
Control panel- Remote Switching off SB1 FDV
Remote switching off SB2 FDV (Instantly)
Remote switching off F Block FDV (Instantly)
Remote switching off SB4 FDV (Instantly)
GSM Based Smart Control of Shop Floor Ventilation System
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Innovative Projects LED Migration Project
Evolution of Lighting
LEDification Project
No expenses in LED- migration
OPEX model Lights Installation Testing amp
Commissioning of LED lights 5 yrs extended warranty
Scope amp Savings
Phase wise LEDification project
Entire plant in phases Better control schemes Reduction in consumption by
50 (Minimum)
Optimal design amp execution
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
Why LED for lighting
LED the best lighting option today
Energy efficient higher Lumens per Watts
No Mercury-Environmental friendly
No IR amp UV emissions Reduced heat generation
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Conventional Lighting system After LED Migration
Power Consumption 14 KW Lux level 125~200
Energy Cons-Monthly 6300 KWH 50400 INR-Annually 75600 KWH 604800 INR
65 KW (Red 464) 250~450 (Inc 250 )
2925 KWH 23400 INR (Red 464 )
35100 KWH 280800 INR
65 KW (Red 464) 250~450 (Inc 250 )
1312 KWH 10400 INR (Red 782 ) 15744 KWH 125952 INR
Occupancy Sensor
After Sensor installation
Occupancy sensor
Sensor Controlled
lightingGroup
Manual Controlled
Lighting group
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
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- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
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- Slide Number 35
- Slide Number 36
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- Slide Number 43
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- Slide Number 46
- Slide Number 47
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- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustriesIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
We have Energy Management Cell in our Plant Which initiates amp Manages all sorts of Energy Conservation measuresacross the Plant
Energy Management System
Mr Pramod ChoudharyPlant Head Lucknow
DH ndash Mr S B MattaPlant services
MR -Lko Works Dr SB Matta
DH ndash Mr V AgrawalPaint shop
DH ndash Mr S N VermaTCF
DH ndash Mr U TauheedBIW
DH ndash Mr R K SinghIBF
DH ndash Mr R K SinghAxle Shop
DH ndashMr G V JoshiPlanning
DH ndash Mr A ChhariaMaterials amp ADD
DH ndash Mr Ankush GourHR
DH ndash Mr R K SinghCV- CX
Team Structure ndash ISO 50001
DH ndash Divisional Head
ISO 50001 CertificateEnergy Policy
2013 2016 2019
IIT - Kanpur- CVBU LUCKNOW
ENERGY MANAGEMENT SYSTEM ndash An Overview
TOP MANAGEMENT COMMITMENT
STAFF COMMITMENT
ENERGY AUDIT
ACTION PLAN
MONITORING amp TARGET SETTING
REVIEW amp DEVELOP PROFILE
LONG PAY BACK PROJECTS
IIT - Kanpur- CVBU LUCKNOW
Preliminary Energy audit
Detailed Energy audit
Plant Coordinator
GO AHEAD
Energy savings discussion and presentation
GO AHEAD for Implementation
Energy savings monitoring and interim report to Energy Mgmt Cell
Acceptance of Proposal
Submission of Techno commercial proposal
Team formation
Energy Management CellEnCon Implementation Methodology
copy Copyright Confidential Tata Motors Limited
Innovation Digital Transformation Project Planning amp Operation
3D layout of Manufacturing Line Process flow for Digital transformation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
44
Collaboration
Training
Layout
Maintenance
2D drawings using Auto Cad 3D digital Factory
No single platform for discussions and decision making among various stake-holder
Virtual Factory encouraged different agencies to work in more collaborate manner
Traditional training methods such as classroom teaching using PPTs and OJT
3D Digital Work-Instruction videos along with Quality and Safety awareness
Maintenance based on Real time data
Preventive Maintenance Breakdown Maintenance based on schedule
Collection of information from individual machines and preparing reports
Connected Machines IPMS Mobile App online quality parameter monitoring
Traditional Method Digital Method
Technology Landscape ndash before and after implementation
Factory Set-up time reduced
Issue identified and resolved before physical installationconstruction
Better Visualization of the process enables operator to learn fast
Down-time of machines reduced thusimproving OEE
Better tracking and control quality and Mc parameters Faster information exchange
Transformation Impact
No Virtual Simulation Expensive Physicals only for very critical processes
Virtual Simulation of Critical Processes helped to identified Potential issues
Short Project Lead time Saving on rework cost and time
Simulation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
Sales~10 Increase throughbull Levelled Productionbull Improvement in Customer Experience
Cost
Customer Complaint
Project Time
Quality
Employee Engagement
~15 Reduction through bull Inventory Optimizationbull Warranty Cost reductionbull COPQ Reduction
~15 Reduction through bull Robust Process Designbull Resulting Reliability of Product
~25 Reduction throughbull Better Project
ManagementWith Use of Simulations Avoided Rework
~25 Improvement throughbull Connected Equipment
bull Avoiding Defect Passing
~10 Improvement throughbull Layout Improvementbull Process Automation
bull Ergonomics amp Safety improvement
Quantitative Benefits and Awarded in CII Digital Transformation Meet
Innovation Digital Transformation Project Planning amp Operation
IIT - Kanpur- CVBU LUCKNOW
Teamwork Employee involvement amp MonitoringDaily Consumption Report
Daily Energy Audit Report
Daily Shopwise Report
Daily Solar Generation Report
Hourly Consumption Report-Plant
Hourly Consumption Report-Shop
Monthly Energy Consumption Report
Awar
enes
sle
vel
2017-18
Reporting of energy consumption of the plant and
individual shops on fortnightly and monthly
basis
2018-19
H1 Reporting of entire plantrsquos energy consumption on daily basis
Daily Energy Audit Report (DEAR) circulated across the plant to minimize
energy wastageH2 Reporting of entire plantrsquos and shop-wise energy consumption on
daily basis
2019-20
H1 Reporting of shop-wise energy consumption started on hourly
basisH1 Reporting of working dayrsquos
and non-working dayrsquos consumption separately for
identification of areasprocesses 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
ENERGY CONSUMPTION 2019-20Figures in KWH
FACTORY Dec-19 Jan-20 Feb-20 Mar-20EASTERN COMPLEXBIWBIW Cab 30103 29885 42825 7097BIW Cowl 17657 16650 20104 7438FDV 0 0 0 0COMP 13691 12555 15960 4155BIW Office others 3459 2845 3824 599Distribution Losses 5737 5686 8235 3398Total 70648 67620 90949 22688PAINT SHOPPTED 276243 270240 58056 125761Paint 199896 182651 252332 55852COMP 69201 71042 191305 32740Paint others 33456 34243 71892 16336Distribution Losses 52586 55324 32462 45001Total 631382 613501 606048 275690TCFAssly 84210 101803 92831 23993Trim Assly 12468 17988 15117 4219FDV 0 0 0 0Compressor 38154 41387 42232 13080TCF officeothers 19581 18255 15958 13560Distribution Losses 14262 16490 17609 10428Total 168676 195923 183747 65281
Rear Axle and Line-45 17252 16260 4125 1830Logistics Centre 14904 25247 20629 9615RSO 5597 9370 8390 8445
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
GSM Based Smart Control of Shop Floor Ventilation System
Concerns in present method bull One operator has to travel around 1 Km for manually switching off all FDVs in western complex due to control panel given at that particular
location and hence there is electrical energy wastage of 5137 KWHmonth due to travel time of around 20 mins
Present process Moving to
switching off SB1 FDV
(0 mins)
Moving to switching off SB2 FDV
(5 mins)
Moving to switching off F Block FDV
(15 mins)
Moving to switching off
SB4 FDV(20 mins)
Moving to switching off SB3 FDV
(10 mins)
Blower amp Control panel
FDV Locations in Line 1
EnCon Projects
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
LCA Solution
bull Remote switching off FDVs by integrating off operation of FDV with GSMmodem from one location Also message will be delivered to user thatwhich FDV has been switched off (wireless switching off operation is donethrough GSM modem to avoid cable cost and laying of cable line)
Benefits amp Horizontal Scope 1Energy saving - Energy saving of 41096 KWHannum by providing remote switching off FDVs
2 Cost Saving - Recurring cost saving of Rs 328 lakhsannum3 Environment- Reduction in carbon footprint (reduction of 337 tonne of CO2annum by energy saving)
4 SMS escalation to user for information of FDV switch off5No laying out of wire is required as it is wireless communication with help of GSM modem6 Horizontal deployment of GSM based control for other process machines of assembly line 12 and 3
Solution Cost-Rs 328 Lacs for all 5 FDVs
Remote switching off SB3 FDV (Instantly)
Control panel- Remote Switching off SB1 FDV
Remote switching off SB2 FDV (Instantly)
Remote switching off F Block FDV (Instantly)
Remote switching off SB4 FDV (Instantly)
GSM Based Smart Control of Shop Floor Ventilation System
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Innovative Projects LED Migration Project
Evolution of Lighting
LEDification Project
No expenses in LED- migration
OPEX model Lights Installation Testing amp
Commissioning of LED lights 5 yrs extended warranty
Scope amp Savings
Phase wise LEDification project
Entire plant in phases Better control schemes Reduction in consumption by
50 (Minimum)
Optimal design amp execution
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
Why LED for lighting
LED the best lighting option today
Energy efficient higher Lumens per Watts
No Mercury-Environmental friendly
No IR amp UV emissions Reduced heat generation
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Conventional Lighting system After LED Migration
Power Consumption 14 KW Lux level 125~200
Energy Cons-Monthly 6300 KWH 50400 INR-Annually 75600 KWH 604800 INR
65 KW (Red 464) 250~450 (Inc 250 )
2925 KWH 23400 INR (Red 464 )
35100 KWH 280800 INR
65 KW (Red 464) 250~450 (Inc 250 )
1312 KWH 10400 INR (Red 782 ) 15744 KWH 125952 INR
Occupancy Sensor
After Sensor installation
Occupancy sensor
Sensor Controlled
lightingGroup
Manual Controlled
Lighting group
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
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- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
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- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
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- Slide Number 49
- Slide Number 50
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- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation Residentialrsquos Buildings amp Offices
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustriesIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
We have Energy Management Cell in our Plant Which initiates amp Manages all sorts of Energy Conservation measuresacross the Plant
Energy Management System
Mr Pramod ChoudharyPlant Head Lucknow
DH ndash Mr S B MattaPlant services
MR -Lko Works Dr SB Matta
DH ndash Mr V AgrawalPaint shop
DH ndash Mr S N VermaTCF
DH ndash Mr U TauheedBIW
DH ndash Mr R K SinghIBF
DH ndash Mr R K SinghAxle Shop
DH ndashMr G V JoshiPlanning
DH ndash Mr A ChhariaMaterials amp ADD
DH ndash Mr Ankush GourHR
DH ndash Mr R K SinghCV- CX
Team Structure ndash ISO 50001
DH ndash Divisional Head
ISO 50001 CertificateEnergy Policy
2013 2016 2019
IIT - Kanpur- CVBU LUCKNOW
ENERGY MANAGEMENT SYSTEM ndash An Overview
TOP MANAGEMENT COMMITMENT
STAFF COMMITMENT
ENERGY AUDIT
ACTION PLAN
MONITORING amp TARGET SETTING
REVIEW amp DEVELOP PROFILE
LONG PAY BACK PROJECTS
IIT - Kanpur- CVBU LUCKNOW
Preliminary Energy audit
Detailed Energy audit
Plant Coordinator
GO AHEAD
Energy savings discussion and presentation
GO AHEAD for Implementation
Energy savings monitoring and interim report to Energy Mgmt Cell
Acceptance of Proposal
Submission of Techno commercial proposal
Team formation
Energy Management CellEnCon Implementation Methodology
copy Copyright Confidential Tata Motors Limited
Innovation Digital Transformation Project Planning amp Operation
3D layout of Manufacturing Line Process flow for Digital transformation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
44
Collaboration
Training
Layout
Maintenance
2D drawings using Auto Cad 3D digital Factory
No single platform for discussions and decision making among various stake-holder
Virtual Factory encouraged different agencies to work in more collaborate manner
Traditional training methods such as classroom teaching using PPTs and OJT
3D Digital Work-Instruction videos along with Quality and Safety awareness
Maintenance based on Real time data
Preventive Maintenance Breakdown Maintenance based on schedule
Collection of information from individual machines and preparing reports
Connected Machines IPMS Mobile App online quality parameter monitoring
Traditional Method Digital Method
Technology Landscape ndash before and after implementation
Factory Set-up time reduced
Issue identified and resolved before physical installationconstruction
Better Visualization of the process enables operator to learn fast
Down-time of machines reduced thusimproving OEE
Better tracking and control quality and Mc parameters Faster information exchange
Transformation Impact
No Virtual Simulation Expensive Physicals only for very critical processes
Virtual Simulation of Critical Processes helped to identified Potential issues
Short Project Lead time Saving on rework cost and time
Simulation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
Sales~10 Increase throughbull Levelled Productionbull Improvement in Customer Experience
Cost
Customer Complaint
Project Time
Quality
Employee Engagement
~15 Reduction through bull Inventory Optimizationbull Warranty Cost reductionbull COPQ Reduction
~15 Reduction through bull Robust Process Designbull Resulting Reliability of Product
~25 Reduction throughbull Better Project
ManagementWith Use of Simulations Avoided Rework
~25 Improvement throughbull Connected Equipment
bull Avoiding Defect Passing
~10 Improvement throughbull Layout Improvementbull Process Automation
bull Ergonomics amp Safety improvement
Quantitative Benefits and Awarded in CII Digital Transformation Meet
Innovation Digital Transformation Project Planning amp Operation
IIT - Kanpur- CVBU LUCKNOW
Teamwork Employee involvement amp MonitoringDaily Consumption Report
Daily Energy Audit Report
Daily Shopwise Report
Daily Solar Generation Report
Hourly Consumption Report-Plant
Hourly Consumption Report-Shop
Monthly Energy Consumption Report
Awar
enes
sle
vel
2017-18
Reporting of energy consumption of the plant and
individual shops on fortnightly and monthly
basis
2018-19
H1 Reporting of entire plantrsquos energy consumption on daily basis
Daily Energy Audit Report (DEAR) circulated across the plant to minimize
energy wastageH2 Reporting of entire plantrsquos and shop-wise energy consumption on
daily basis
2019-20
H1 Reporting of shop-wise energy consumption started on hourly
basisH1 Reporting of working dayrsquos
and non-working dayrsquos consumption separately for
identification of areasprocesses 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
ENERGY CONSUMPTION 2019-20Figures in KWH
FACTORY Dec-19 Jan-20 Feb-20 Mar-20EASTERN COMPLEXBIWBIW Cab 30103 29885 42825 7097BIW Cowl 17657 16650 20104 7438FDV 0 0 0 0COMP 13691 12555 15960 4155BIW Office others 3459 2845 3824 599Distribution Losses 5737 5686 8235 3398Total 70648 67620 90949 22688PAINT SHOPPTED 276243 270240 58056 125761Paint 199896 182651 252332 55852COMP 69201 71042 191305 32740Paint others 33456 34243 71892 16336Distribution Losses 52586 55324 32462 45001Total 631382 613501 606048 275690TCFAssly 84210 101803 92831 23993Trim Assly 12468 17988 15117 4219FDV 0 0 0 0Compressor 38154 41387 42232 13080TCF officeothers 19581 18255 15958 13560Distribution Losses 14262 16490 17609 10428Total 168676 195923 183747 65281
Rear Axle and Line-45 17252 16260 4125 1830Logistics Centre 14904 25247 20629 9615RSO 5597 9370 8390 8445
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
GSM Based Smart Control of Shop Floor Ventilation System
Concerns in present method bull One operator has to travel around 1 Km for manually switching off all FDVs in western complex due to control panel given at that particular
location and hence there is electrical energy wastage of 5137 KWHmonth due to travel time of around 20 mins
Present process Moving to
switching off SB1 FDV
(0 mins)
Moving to switching off SB2 FDV
(5 mins)
Moving to switching off F Block FDV
(15 mins)
Moving to switching off
SB4 FDV(20 mins)
Moving to switching off SB3 FDV
(10 mins)
Blower amp Control panel
FDV Locations in Line 1
EnCon Projects
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
LCA Solution
bull Remote switching off FDVs by integrating off operation of FDV with GSMmodem from one location Also message will be delivered to user thatwhich FDV has been switched off (wireless switching off operation is donethrough GSM modem to avoid cable cost and laying of cable line)
Benefits amp Horizontal Scope 1Energy saving - Energy saving of 41096 KWHannum by providing remote switching off FDVs
2 Cost Saving - Recurring cost saving of Rs 328 lakhsannum3 Environment- Reduction in carbon footprint (reduction of 337 tonne of CO2annum by energy saving)
4 SMS escalation to user for information of FDV switch off5No laying out of wire is required as it is wireless communication with help of GSM modem6 Horizontal deployment of GSM based control for other process machines of assembly line 12 and 3
Solution Cost-Rs 328 Lacs for all 5 FDVs
Remote switching off SB3 FDV (Instantly)
Control panel- Remote Switching off SB1 FDV
Remote switching off SB2 FDV (Instantly)
Remote switching off F Block FDV (Instantly)
Remote switching off SB4 FDV (Instantly)
GSM Based Smart Control of Shop Floor Ventilation System
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Innovative Projects LED Migration Project
Evolution of Lighting
LEDification Project
No expenses in LED- migration
OPEX model Lights Installation Testing amp
Commissioning of LED lights 5 yrs extended warranty
Scope amp Savings
Phase wise LEDification project
Entire plant in phases Better control schemes Reduction in consumption by
50 (Minimum)
Optimal design amp execution
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
Why LED for lighting
LED the best lighting option today
Energy efficient higher Lumens per Watts
No Mercury-Environmental friendly
No IR amp UV emissions Reduced heat generation
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Conventional Lighting system After LED Migration
Power Consumption 14 KW Lux level 125~200
Energy Cons-Monthly 6300 KWH 50400 INR-Annually 75600 KWH 604800 INR
65 KW (Red 464) 250~450 (Inc 250 )
2925 KWH 23400 INR (Red 464 )
35100 KWH 280800 INR
65 KW (Red 464) 250~450 (Inc 250 )
1312 KWH 10400 INR (Red 782 ) 15744 KWH 125952 INR
Occupancy Sensor
After Sensor installation
Occupancy sensor
Sensor Controlled
lightingGroup
Manual Controlled
Lighting group
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Slide Number 55
- Slide Number 56
- Slide Number 57
- Slide Number 58
- Slide Number 59
- Slide Number 60
- Slide Number 61
- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustriesIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
We have Energy Management Cell in our Plant Which initiates amp Manages all sorts of Energy Conservation measuresacross the Plant
Energy Management System
Mr Pramod ChoudharyPlant Head Lucknow
DH ndash Mr S B MattaPlant services
MR -Lko Works Dr SB Matta
DH ndash Mr V AgrawalPaint shop
DH ndash Mr S N VermaTCF
DH ndash Mr U TauheedBIW
DH ndash Mr R K SinghIBF
DH ndash Mr R K SinghAxle Shop
DH ndashMr G V JoshiPlanning
DH ndash Mr A ChhariaMaterials amp ADD
DH ndash Mr Ankush GourHR
DH ndash Mr R K SinghCV- CX
Team Structure ndash ISO 50001
DH ndash Divisional Head
ISO 50001 CertificateEnergy Policy
2013 2016 2019
IIT - Kanpur- CVBU LUCKNOW
ENERGY MANAGEMENT SYSTEM ndash An Overview
TOP MANAGEMENT COMMITMENT
STAFF COMMITMENT
ENERGY AUDIT
ACTION PLAN
MONITORING amp TARGET SETTING
REVIEW amp DEVELOP PROFILE
LONG PAY BACK PROJECTS
IIT - Kanpur- CVBU LUCKNOW
Preliminary Energy audit
Detailed Energy audit
Plant Coordinator
GO AHEAD
Energy savings discussion and presentation
GO AHEAD for Implementation
Energy savings monitoring and interim report to Energy Mgmt Cell
Acceptance of Proposal
Submission of Techno commercial proposal
Team formation
Energy Management CellEnCon Implementation Methodology
copy Copyright Confidential Tata Motors Limited
Innovation Digital Transformation Project Planning amp Operation
3D layout of Manufacturing Line Process flow for Digital transformation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
44
Collaboration
Training
Layout
Maintenance
2D drawings using Auto Cad 3D digital Factory
No single platform for discussions and decision making among various stake-holder
Virtual Factory encouraged different agencies to work in more collaborate manner
Traditional training methods such as classroom teaching using PPTs and OJT
3D Digital Work-Instruction videos along with Quality and Safety awareness
Maintenance based on Real time data
Preventive Maintenance Breakdown Maintenance based on schedule
Collection of information from individual machines and preparing reports
Connected Machines IPMS Mobile App online quality parameter monitoring
Traditional Method Digital Method
Technology Landscape ndash before and after implementation
Factory Set-up time reduced
Issue identified and resolved before physical installationconstruction
Better Visualization of the process enables operator to learn fast
Down-time of machines reduced thusimproving OEE
Better tracking and control quality and Mc parameters Faster information exchange
Transformation Impact
No Virtual Simulation Expensive Physicals only for very critical processes
Virtual Simulation of Critical Processes helped to identified Potential issues
Short Project Lead time Saving on rework cost and time
Simulation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
Sales~10 Increase throughbull Levelled Productionbull Improvement in Customer Experience
Cost
Customer Complaint
Project Time
Quality
Employee Engagement
~15 Reduction through bull Inventory Optimizationbull Warranty Cost reductionbull COPQ Reduction
~15 Reduction through bull Robust Process Designbull Resulting Reliability of Product
~25 Reduction throughbull Better Project
ManagementWith Use of Simulations Avoided Rework
~25 Improvement throughbull Connected Equipment
bull Avoiding Defect Passing
~10 Improvement throughbull Layout Improvementbull Process Automation
bull Ergonomics amp Safety improvement
Quantitative Benefits and Awarded in CII Digital Transformation Meet
Innovation Digital Transformation Project Planning amp Operation
IIT - Kanpur- CVBU LUCKNOW
Teamwork Employee involvement amp MonitoringDaily Consumption Report
Daily Energy Audit Report
Daily Shopwise Report
Daily Solar Generation Report
Hourly Consumption Report-Plant
Hourly Consumption Report-Shop
Monthly Energy Consumption Report
Awar
enes
sle
vel
2017-18
Reporting of energy consumption of the plant and
individual shops on fortnightly and monthly
basis
2018-19
H1 Reporting of entire plantrsquos energy consumption on daily basis
Daily Energy Audit Report (DEAR) circulated across the plant to minimize
energy wastageH2 Reporting of entire plantrsquos and shop-wise energy consumption on
daily basis
2019-20
H1 Reporting of shop-wise energy consumption started on hourly
basisH1 Reporting of working dayrsquos
and non-working dayrsquos consumption separately for
identification of areasprocesses 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
ENERGY CONSUMPTION 2019-20Figures in KWH
FACTORY Dec-19 Jan-20 Feb-20 Mar-20EASTERN COMPLEXBIWBIW Cab 30103 29885 42825 7097BIW Cowl 17657 16650 20104 7438FDV 0 0 0 0COMP 13691 12555 15960 4155BIW Office others 3459 2845 3824 599Distribution Losses 5737 5686 8235 3398Total 70648 67620 90949 22688PAINT SHOPPTED 276243 270240 58056 125761Paint 199896 182651 252332 55852COMP 69201 71042 191305 32740Paint others 33456 34243 71892 16336Distribution Losses 52586 55324 32462 45001Total 631382 613501 606048 275690TCFAssly 84210 101803 92831 23993Trim Assly 12468 17988 15117 4219FDV 0 0 0 0Compressor 38154 41387 42232 13080TCF officeothers 19581 18255 15958 13560Distribution Losses 14262 16490 17609 10428Total 168676 195923 183747 65281
Rear Axle and Line-45 17252 16260 4125 1830Logistics Centre 14904 25247 20629 9615RSO 5597 9370 8390 8445
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
GSM Based Smart Control of Shop Floor Ventilation System
Concerns in present method bull One operator has to travel around 1 Km for manually switching off all FDVs in western complex due to control panel given at that particular
location and hence there is electrical energy wastage of 5137 KWHmonth due to travel time of around 20 mins
Present process Moving to
switching off SB1 FDV
(0 mins)
Moving to switching off SB2 FDV
(5 mins)
Moving to switching off F Block FDV
(15 mins)
Moving to switching off
SB4 FDV(20 mins)
Moving to switching off SB3 FDV
(10 mins)
Blower amp Control panel
FDV Locations in Line 1
EnCon Projects
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
LCA Solution
bull Remote switching off FDVs by integrating off operation of FDV with GSMmodem from one location Also message will be delivered to user thatwhich FDV has been switched off (wireless switching off operation is donethrough GSM modem to avoid cable cost and laying of cable line)
Benefits amp Horizontal Scope 1Energy saving - Energy saving of 41096 KWHannum by providing remote switching off FDVs
2 Cost Saving - Recurring cost saving of Rs 328 lakhsannum3 Environment- Reduction in carbon footprint (reduction of 337 tonne of CO2annum by energy saving)
4 SMS escalation to user for information of FDV switch off5No laying out of wire is required as it is wireless communication with help of GSM modem6 Horizontal deployment of GSM based control for other process machines of assembly line 12 and 3
Solution Cost-Rs 328 Lacs for all 5 FDVs
Remote switching off SB3 FDV (Instantly)
Control panel- Remote Switching off SB1 FDV
Remote switching off SB2 FDV (Instantly)
Remote switching off F Block FDV (Instantly)
Remote switching off SB4 FDV (Instantly)
GSM Based Smart Control of Shop Floor Ventilation System
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Innovative Projects LED Migration Project
Evolution of Lighting
LEDification Project
No expenses in LED- migration
OPEX model Lights Installation Testing amp
Commissioning of LED lights 5 yrs extended warranty
Scope amp Savings
Phase wise LEDification project
Entire plant in phases Better control schemes Reduction in consumption by
50 (Minimum)
Optimal design amp execution
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
Why LED for lighting
LED the best lighting option today
Energy efficient higher Lumens per Watts
No Mercury-Environmental friendly
No IR amp UV emissions Reduced heat generation
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Conventional Lighting system After LED Migration
Power Consumption 14 KW Lux level 125~200
Energy Cons-Monthly 6300 KWH 50400 INR-Annually 75600 KWH 604800 INR
65 KW (Red 464) 250~450 (Inc 250 )
2925 KWH 23400 INR (Red 464 )
35100 KWH 280800 INR
65 KW (Red 464) 250~450 (Inc 250 )
1312 KWH 10400 INR (Red 782 ) 15744 KWH 125952 INR
Occupancy Sensor
After Sensor installation
Occupancy sensor
Sensor Controlled
lightingGroup
Manual Controlled
Lighting group
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Slide Number 55
- Slide Number 56
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- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustriesIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
We have Energy Management Cell in our Plant Which initiates amp Manages all sorts of Energy Conservation measuresacross the Plant
Energy Management System
Mr Pramod ChoudharyPlant Head Lucknow
DH ndash Mr S B MattaPlant services
MR -Lko Works Dr SB Matta
DH ndash Mr V AgrawalPaint shop
DH ndash Mr S N VermaTCF
DH ndash Mr U TauheedBIW
DH ndash Mr R K SinghIBF
DH ndash Mr R K SinghAxle Shop
DH ndashMr G V JoshiPlanning
DH ndash Mr A ChhariaMaterials amp ADD
DH ndash Mr Ankush GourHR
DH ndash Mr R K SinghCV- CX
Team Structure ndash ISO 50001
DH ndash Divisional Head
ISO 50001 CertificateEnergy Policy
2013 2016 2019
IIT - Kanpur- CVBU LUCKNOW
ENERGY MANAGEMENT SYSTEM ndash An Overview
TOP MANAGEMENT COMMITMENT
STAFF COMMITMENT
ENERGY AUDIT
ACTION PLAN
MONITORING amp TARGET SETTING
REVIEW amp DEVELOP PROFILE
LONG PAY BACK PROJECTS
IIT - Kanpur- CVBU LUCKNOW
Preliminary Energy audit
Detailed Energy audit
Plant Coordinator
GO AHEAD
Energy savings discussion and presentation
GO AHEAD for Implementation
Energy savings monitoring and interim report to Energy Mgmt Cell
Acceptance of Proposal
Submission of Techno commercial proposal
Team formation
Energy Management CellEnCon Implementation Methodology
copy Copyright Confidential Tata Motors Limited
Innovation Digital Transformation Project Planning amp Operation
3D layout of Manufacturing Line Process flow for Digital transformation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
44
Collaboration
Training
Layout
Maintenance
2D drawings using Auto Cad 3D digital Factory
No single platform for discussions and decision making among various stake-holder
Virtual Factory encouraged different agencies to work in more collaborate manner
Traditional training methods such as classroom teaching using PPTs and OJT
3D Digital Work-Instruction videos along with Quality and Safety awareness
Maintenance based on Real time data
Preventive Maintenance Breakdown Maintenance based on schedule
Collection of information from individual machines and preparing reports
Connected Machines IPMS Mobile App online quality parameter monitoring
Traditional Method Digital Method
Technology Landscape ndash before and after implementation
Factory Set-up time reduced
Issue identified and resolved before physical installationconstruction
Better Visualization of the process enables operator to learn fast
Down-time of machines reduced thusimproving OEE
Better tracking and control quality and Mc parameters Faster information exchange
Transformation Impact
No Virtual Simulation Expensive Physicals only for very critical processes
Virtual Simulation of Critical Processes helped to identified Potential issues
Short Project Lead time Saving on rework cost and time
Simulation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
Sales~10 Increase throughbull Levelled Productionbull Improvement in Customer Experience
Cost
Customer Complaint
Project Time
Quality
Employee Engagement
~15 Reduction through bull Inventory Optimizationbull Warranty Cost reductionbull COPQ Reduction
~15 Reduction through bull Robust Process Designbull Resulting Reliability of Product
~25 Reduction throughbull Better Project
ManagementWith Use of Simulations Avoided Rework
~25 Improvement throughbull Connected Equipment
bull Avoiding Defect Passing
~10 Improvement throughbull Layout Improvementbull Process Automation
bull Ergonomics amp Safety improvement
Quantitative Benefits and Awarded in CII Digital Transformation Meet
Innovation Digital Transformation Project Planning amp Operation
IIT - Kanpur- CVBU LUCKNOW
Teamwork Employee involvement amp MonitoringDaily Consumption Report
Daily Energy Audit Report
Daily Shopwise Report
Daily Solar Generation Report
Hourly Consumption Report-Plant
Hourly Consumption Report-Shop
Monthly Energy Consumption Report
Awar
enes
sle
vel
2017-18
Reporting of energy consumption of the plant and
individual shops on fortnightly and monthly
basis
2018-19
H1 Reporting of entire plantrsquos energy consumption on daily basis
Daily Energy Audit Report (DEAR) circulated across the plant to minimize
energy wastageH2 Reporting of entire plantrsquos and shop-wise energy consumption on
daily basis
2019-20
H1 Reporting of shop-wise energy consumption started on hourly
basisH1 Reporting of working dayrsquos
and non-working dayrsquos consumption separately for
identification of areasprocesses 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
ENERGY CONSUMPTION 2019-20Figures in KWH
FACTORY Dec-19 Jan-20 Feb-20 Mar-20EASTERN COMPLEXBIWBIW Cab 30103 29885 42825 7097BIW Cowl 17657 16650 20104 7438FDV 0 0 0 0COMP 13691 12555 15960 4155BIW Office others 3459 2845 3824 599Distribution Losses 5737 5686 8235 3398Total 70648 67620 90949 22688PAINT SHOPPTED 276243 270240 58056 125761Paint 199896 182651 252332 55852COMP 69201 71042 191305 32740Paint others 33456 34243 71892 16336Distribution Losses 52586 55324 32462 45001Total 631382 613501 606048 275690TCFAssly 84210 101803 92831 23993Trim Assly 12468 17988 15117 4219FDV 0 0 0 0Compressor 38154 41387 42232 13080TCF officeothers 19581 18255 15958 13560Distribution Losses 14262 16490 17609 10428Total 168676 195923 183747 65281
Rear Axle and Line-45 17252 16260 4125 1830Logistics Centre 14904 25247 20629 9615RSO 5597 9370 8390 8445
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
GSM Based Smart Control of Shop Floor Ventilation System
Concerns in present method bull One operator has to travel around 1 Km for manually switching off all FDVs in western complex due to control panel given at that particular
location and hence there is electrical energy wastage of 5137 KWHmonth due to travel time of around 20 mins
Present process Moving to
switching off SB1 FDV
(0 mins)
Moving to switching off SB2 FDV
(5 mins)
Moving to switching off F Block FDV
(15 mins)
Moving to switching off
SB4 FDV(20 mins)
Moving to switching off SB3 FDV
(10 mins)
Blower amp Control panel
FDV Locations in Line 1
EnCon Projects
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
LCA Solution
bull Remote switching off FDVs by integrating off operation of FDV with GSMmodem from one location Also message will be delivered to user thatwhich FDV has been switched off (wireless switching off operation is donethrough GSM modem to avoid cable cost and laying of cable line)
Benefits amp Horizontal Scope 1Energy saving - Energy saving of 41096 KWHannum by providing remote switching off FDVs
2 Cost Saving - Recurring cost saving of Rs 328 lakhsannum3 Environment- Reduction in carbon footprint (reduction of 337 tonne of CO2annum by energy saving)
4 SMS escalation to user for information of FDV switch off5No laying out of wire is required as it is wireless communication with help of GSM modem6 Horizontal deployment of GSM based control for other process machines of assembly line 12 and 3
Solution Cost-Rs 328 Lacs for all 5 FDVs
Remote switching off SB3 FDV (Instantly)
Control panel- Remote Switching off SB1 FDV
Remote switching off SB2 FDV (Instantly)
Remote switching off F Block FDV (Instantly)
Remote switching off SB4 FDV (Instantly)
GSM Based Smart Control of Shop Floor Ventilation System
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Innovative Projects LED Migration Project
Evolution of Lighting
LEDification Project
No expenses in LED- migration
OPEX model Lights Installation Testing amp
Commissioning of LED lights 5 yrs extended warranty
Scope amp Savings
Phase wise LEDification project
Entire plant in phases Better control schemes Reduction in consumption by
50 (Minimum)
Optimal design amp execution
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
Why LED for lighting
LED the best lighting option today
Energy efficient higher Lumens per Watts
No Mercury-Environmental friendly
No IR amp UV emissions Reduced heat generation
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Conventional Lighting system After LED Migration
Power Consumption 14 KW Lux level 125~200
Energy Cons-Monthly 6300 KWH 50400 INR-Annually 75600 KWH 604800 INR
65 KW (Red 464) 250~450 (Inc 250 )
2925 KWH 23400 INR (Red 464 )
35100 KWH 280800 INR
65 KW (Red 464) 250~450 (Inc 250 )
1312 KWH 10400 INR (Red 782 ) 15744 KWH 125952 INR
Occupancy Sensor
After Sensor installation
Occupancy sensor
Sensor Controlled
lightingGroup
Manual Controlled
Lighting group
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
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- Slide Number 18
- Bio-Gas
- Slide Number 21
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- Slide Number 45
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- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
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- Slide Number 53
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- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy Conservation IndustriesIndustries
Source of data httpsbeeindiagovin Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustriesIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
We have Energy Management Cell in our Plant Which initiates amp Manages all sorts of Energy Conservation measuresacross the Plant
Energy Management System
Mr Pramod ChoudharyPlant Head Lucknow
DH ndash Mr S B MattaPlant services
MR -Lko Works Dr SB Matta
DH ndash Mr V AgrawalPaint shop
DH ndash Mr S N VermaTCF
DH ndash Mr U TauheedBIW
DH ndash Mr R K SinghIBF
DH ndash Mr R K SinghAxle Shop
DH ndashMr G V JoshiPlanning
DH ndash Mr A ChhariaMaterials amp ADD
DH ndash Mr Ankush GourHR
DH ndash Mr R K SinghCV- CX
Team Structure ndash ISO 50001
DH ndash Divisional Head
ISO 50001 CertificateEnergy Policy
2013 2016 2019
IIT - Kanpur- CVBU LUCKNOW
ENERGY MANAGEMENT SYSTEM ndash An Overview
TOP MANAGEMENT COMMITMENT
STAFF COMMITMENT
ENERGY AUDIT
ACTION PLAN
MONITORING amp TARGET SETTING
REVIEW amp DEVELOP PROFILE
LONG PAY BACK PROJECTS
IIT - Kanpur- CVBU LUCKNOW
Preliminary Energy audit
Detailed Energy audit
Plant Coordinator
GO AHEAD
Energy savings discussion and presentation
GO AHEAD for Implementation
Energy savings monitoring and interim report to Energy Mgmt Cell
Acceptance of Proposal
Submission of Techno commercial proposal
Team formation
Energy Management CellEnCon Implementation Methodology
copy Copyright Confidential Tata Motors Limited
Innovation Digital Transformation Project Planning amp Operation
3D layout of Manufacturing Line Process flow for Digital transformation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
44
Collaboration
Training
Layout
Maintenance
2D drawings using Auto Cad 3D digital Factory
No single platform for discussions and decision making among various stake-holder
Virtual Factory encouraged different agencies to work in more collaborate manner
Traditional training methods such as classroom teaching using PPTs and OJT
3D Digital Work-Instruction videos along with Quality and Safety awareness
Maintenance based on Real time data
Preventive Maintenance Breakdown Maintenance based on schedule
Collection of information from individual machines and preparing reports
Connected Machines IPMS Mobile App online quality parameter monitoring
Traditional Method Digital Method
Technology Landscape ndash before and after implementation
Factory Set-up time reduced
Issue identified and resolved before physical installationconstruction
Better Visualization of the process enables operator to learn fast
Down-time of machines reduced thusimproving OEE
Better tracking and control quality and Mc parameters Faster information exchange
Transformation Impact
No Virtual Simulation Expensive Physicals only for very critical processes
Virtual Simulation of Critical Processes helped to identified Potential issues
Short Project Lead time Saving on rework cost and time
Simulation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
Sales~10 Increase throughbull Levelled Productionbull Improvement in Customer Experience
Cost
Customer Complaint
Project Time
Quality
Employee Engagement
~15 Reduction through bull Inventory Optimizationbull Warranty Cost reductionbull COPQ Reduction
~15 Reduction through bull Robust Process Designbull Resulting Reliability of Product
~25 Reduction throughbull Better Project
ManagementWith Use of Simulations Avoided Rework
~25 Improvement throughbull Connected Equipment
bull Avoiding Defect Passing
~10 Improvement throughbull Layout Improvementbull Process Automation
bull Ergonomics amp Safety improvement
Quantitative Benefits and Awarded in CII Digital Transformation Meet
Innovation Digital Transformation Project Planning amp Operation
IIT - Kanpur- CVBU LUCKNOW
Teamwork Employee involvement amp MonitoringDaily Consumption Report
Daily Energy Audit Report
Daily Shopwise Report
Daily Solar Generation Report
Hourly Consumption Report-Plant
Hourly Consumption Report-Shop
Monthly Energy Consumption Report
Awar
enes
sle
vel
2017-18
Reporting of energy consumption of the plant and
individual shops on fortnightly and monthly
basis
2018-19
H1 Reporting of entire plantrsquos energy consumption on daily basis
Daily Energy Audit Report (DEAR) circulated across the plant to minimize
energy wastageH2 Reporting of entire plantrsquos and shop-wise energy consumption on
daily basis
2019-20
H1 Reporting of shop-wise energy consumption started on hourly
basisH1 Reporting of working dayrsquos
and non-working dayrsquos consumption separately for
identification of areasprocesses 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
ENERGY CONSUMPTION 2019-20Figures in KWH
FACTORY Dec-19 Jan-20 Feb-20 Mar-20EASTERN COMPLEXBIWBIW Cab 30103 29885 42825 7097BIW Cowl 17657 16650 20104 7438FDV 0 0 0 0COMP 13691 12555 15960 4155BIW Office others 3459 2845 3824 599Distribution Losses 5737 5686 8235 3398Total 70648 67620 90949 22688PAINT SHOPPTED 276243 270240 58056 125761Paint 199896 182651 252332 55852COMP 69201 71042 191305 32740Paint others 33456 34243 71892 16336Distribution Losses 52586 55324 32462 45001Total 631382 613501 606048 275690TCFAssly 84210 101803 92831 23993Trim Assly 12468 17988 15117 4219FDV 0 0 0 0Compressor 38154 41387 42232 13080TCF officeothers 19581 18255 15958 13560Distribution Losses 14262 16490 17609 10428Total 168676 195923 183747 65281
Rear Axle and Line-45 17252 16260 4125 1830Logistics Centre 14904 25247 20629 9615RSO 5597 9370 8390 8445
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
GSM Based Smart Control of Shop Floor Ventilation System
Concerns in present method bull One operator has to travel around 1 Km for manually switching off all FDVs in western complex due to control panel given at that particular
location and hence there is electrical energy wastage of 5137 KWHmonth due to travel time of around 20 mins
Present process Moving to
switching off SB1 FDV
(0 mins)
Moving to switching off SB2 FDV
(5 mins)
Moving to switching off F Block FDV
(15 mins)
Moving to switching off
SB4 FDV(20 mins)
Moving to switching off SB3 FDV
(10 mins)
Blower amp Control panel
FDV Locations in Line 1
EnCon Projects
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
LCA Solution
bull Remote switching off FDVs by integrating off operation of FDV with GSMmodem from one location Also message will be delivered to user thatwhich FDV has been switched off (wireless switching off operation is donethrough GSM modem to avoid cable cost and laying of cable line)
Benefits amp Horizontal Scope 1Energy saving - Energy saving of 41096 KWHannum by providing remote switching off FDVs
2 Cost Saving - Recurring cost saving of Rs 328 lakhsannum3 Environment- Reduction in carbon footprint (reduction of 337 tonne of CO2annum by energy saving)
4 SMS escalation to user for information of FDV switch off5No laying out of wire is required as it is wireless communication with help of GSM modem6 Horizontal deployment of GSM based control for other process machines of assembly line 12 and 3
Solution Cost-Rs 328 Lacs for all 5 FDVs
Remote switching off SB3 FDV (Instantly)
Control panel- Remote Switching off SB1 FDV
Remote switching off SB2 FDV (Instantly)
Remote switching off F Block FDV (Instantly)
Remote switching off SB4 FDV (Instantly)
GSM Based Smart Control of Shop Floor Ventilation System
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Innovative Projects LED Migration Project
Evolution of Lighting
LEDification Project
No expenses in LED- migration
OPEX model Lights Installation Testing amp
Commissioning of LED lights 5 yrs extended warranty
Scope amp Savings
Phase wise LEDification project
Entire plant in phases Better control schemes Reduction in consumption by
50 (Minimum)
Optimal design amp execution
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
Why LED for lighting
LED the best lighting option today
Energy efficient higher Lumens per Watts
No Mercury-Environmental friendly
No IR amp UV emissions Reduced heat generation
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Conventional Lighting system After LED Migration
Power Consumption 14 KW Lux level 125~200
Energy Cons-Monthly 6300 KWH 50400 INR-Annually 75600 KWH 604800 INR
65 KW (Red 464) 250~450 (Inc 250 )
2925 KWH 23400 INR (Red 464 )
35100 KWH 280800 INR
65 KW (Red 464) 250~450 (Inc 250 )
1312 KWH 10400 INR (Red 782 ) 15744 KWH 125952 INR
Occupancy Sensor
After Sensor installation
Occupancy sensor
Sensor Controlled
lightingGroup
Manual Controlled
Lighting group
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
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- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
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- Slide Number 34
- Slide Number 35
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- Slide Number 38
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- Slide Number 43
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- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustriesIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
We have Energy Management Cell in our Plant Which initiates amp Manages all sorts of Energy Conservation measuresacross the Plant
Energy Management System
Mr Pramod ChoudharyPlant Head Lucknow
DH ndash Mr S B MattaPlant services
MR -Lko Works Dr SB Matta
DH ndash Mr V AgrawalPaint shop
DH ndash Mr S N VermaTCF
DH ndash Mr U TauheedBIW
DH ndash Mr R K SinghIBF
DH ndash Mr R K SinghAxle Shop
DH ndashMr G V JoshiPlanning
DH ndash Mr A ChhariaMaterials amp ADD
DH ndash Mr Ankush GourHR
DH ndash Mr R K SinghCV- CX
Team Structure ndash ISO 50001
DH ndash Divisional Head
ISO 50001 CertificateEnergy Policy
2013 2016 2019
IIT - Kanpur- CVBU LUCKNOW
ENERGY MANAGEMENT SYSTEM ndash An Overview
TOP MANAGEMENT COMMITMENT
STAFF COMMITMENT
ENERGY AUDIT
ACTION PLAN
MONITORING amp TARGET SETTING
REVIEW amp DEVELOP PROFILE
LONG PAY BACK PROJECTS
IIT - Kanpur- CVBU LUCKNOW
Preliminary Energy audit
Detailed Energy audit
Plant Coordinator
GO AHEAD
Energy savings discussion and presentation
GO AHEAD for Implementation
Energy savings monitoring and interim report to Energy Mgmt Cell
Acceptance of Proposal
Submission of Techno commercial proposal
Team formation
Energy Management CellEnCon Implementation Methodology
copy Copyright Confidential Tata Motors Limited
Innovation Digital Transformation Project Planning amp Operation
3D layout of Manufacturing Line Process flow for Digital transformation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
44
Collaboration
Training
Layout
Maintenance
2D drawings using Auto Cad 3D digital Factory
No single platform for discussions and decision making among various stake-holder
Virtual Factory encouraged different agencies to work in more collaborate manner
Traditional training methods such as classroom teaching using PPTs and OJT
3D Digital Work-Instruction videos along with Quality and Safety awareness
Maintenance based on Real time data
Preventive Maintenance Breakdown Maintenance based on schedule
Collection of information from individual machines and preparing reports
Connected Machines IPMS Mobile App online quality parameter monitoring
Traditional Method Digital Method
Technology Landscape ndash before and after implementation
Factory Set-up time reduced
Issue identified and resolved before physical installationconstruction
Better Visualization of the process enables operator to learn fast
Down-time of machines reduced thusimproving OEE
Better tracking and control quality and Mc parameters Faster information exchange
Transformation Impact
No Virtual Simulation Expensive Physicals only for very critical processes
Virtual Simulation of Critical Processes helped to identified Potential issues
Short Project Lead time Saving on rework cost and time
Simulation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
Sales~10 Increase throughbull Levelled Productionbull Improvement in Customer Experience
Cost
Customer Complaint
Project Time
Quality
Employee Engagement
~15 Reduction through bull Inventory Optimizationbull Warranty Cost reductionbull COPQ Reduction
~15 Reduction through bull Robust Process Designbull Resulting Reliability of Product
~25 Reduction throughbull Better Project
ManagementWith Use of Simulations Avoided Rework
~25 Improvement throughbull Connected Equipment
bull Avoiding Defect Passing
~10 Improvement throughbull Layout Improvementbull Process Automation
bull Ergonomics amp Safety improvement
Quantitative Benefits and Awarded in CII Digital Transformation Meet
Innovation Digital Transformation Project Planning amp Operation
IIT - Kanpur- CVBU LUCKNOW
Teamwork Employee involvement amp MonitoringDaily Consumption Report
Daily Energy Audit Report
Daily Shopwise Report
Daily Solar Generation Report
Hourly Consumption Report-Plant
Hourly Consumption Report-Shop
Monthly Energy Consumption Report
Awar
enes
sle
vel
2017-18
Reporting of energy consumption of the plant and
individual shops on fortnightly and monthly
basis
2018-19
H1 Reporting of entire plantrsquos energy consumption on daily basis
Daily Energy Audit Report (DEAR) circulated across the plant to minimize
energy wastageH2 Reporting of entire plantrsquos and shop-wise energy consumption on
daily basis
2019-20
H1 Reporting of shop-wise energy consumption started on hourly
basisH1 Reporting of working dayrsquos
and non-working dayrsquos consumption separately for
identification of areasprocesses 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
ENERGY CONSUMPTION 2019-20Figures in KWH
FACTORY Dec-19 Jan-20 Feb-20 Mar-20EASTERN COMPLEXBIWBIW Cab 30103 29885 42825 7097BIW Cowl 17657 16650 20104 7438FDV 0 0 0 0COMP 13691 12555 15960 4155BIW Office others 3459 2845 3824 599Distribution Losses 5737 5686 8235 3398Total 70648 67620 90949 22688PAINT SHOPPTED 276243 270240 58056 125761Paint 199896 182651 252332 55852COMP 69201 71042 191305 32740Paint others 33456 34243 71892 16336Distribution Losses 52586 55324 32462 45001Total 631382 613501 606048 275690TCFAssly 84210 101803 92831 23993Trim Assly 12468 17988 15117 4219FDV 0 0 0 0Compressor 38154 41387 42232 13080TCF officeothers 19581 18255 15958 13560Distribution Losses 14262 16490 17609 10428Total 168676 195923 183747 65281
Rear Axle and Line-45 17252 16260 4125 1830Logistics Centre 14904 25247 20629 9615RSO 5597 9370 8390 8445
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
GSM Based Smart Control of Shop Floor Ventilation System
Concerns in present method bull One operator has to travel around 1 Km for manually switching off all FDVs in western complex due to control panel given at that particular
location and hence there is electrical energy wastage of 5137 KWHmonth due to travel time of around 20 mins
Present process Moving to
switching off SB1 FDV
(0 mins)
Moving to switching off SB2 FDV
(5 mins)
Moving to switching off F Block FDV
(15 mins)
Moving to switching off
SB4 FDV(20 mins)
Moving to switching off SB3 FDV
(10 mins)
Blower amp Control panel
FDV Locations in Line 1
EnCon Projects
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
LCA Solution
bull Remote switching off FDVs by integrating off operation of FDV with GSMmodem from one location Also message will be delivered to user thatwhich FDV has been switched off (wireless switching off operation is donethrough GSM modem to avoid cable cost and laying of cable line)
Benefits amp Horizontal Scope 1Energy saving - Energy saving of 41096 KWHannum by providing remote switching off FDVs
2 Cost Saving - Recurring cost saving of Rs 328 lakhsannum3 Environment- Reduction in carbon footprint (reduction of 337 tonne of CO2annum by energy saving)
4 SMS escalation to user for information of FDV switch off5No laying out of wire is required as it is wireless communication with help of GSM modem6 Horizontal deployment of GSM based control for other process machines of assembly line 12 and 3
Solution Cost-Rs 328 Lacs for all 5 FDVs
Remote switching off SB3 FDV (Instantly)
Control panel- Remote Switching off SB1 FDV
Remote switching off SB2 FDV (Instantly)
Remote switching off F Block FDV (Instantly)
Remote switching off SB4 FDV (Instantly)
GSM Based Smart Control of Shop Floor Ventilation System
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Innovative Projects LED Migration Project
Evolution of Lighting
LEDification Project
No expenses in LED- migration
OPEX model Lights Installation Testing amp
Commissioning of LED lights 5 yrs extended warranty
Scope amp Savings
Phase wise LEDification project
Entire plant in phases Better control schemes Reduction in consumption by
50 (Minimum)
Optimal design amp execution
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
Why LED for lighting
LED the best lighting option today
Energy efficient higher Lumens per Watts
No Mercury-Environmental friendly
No IR amp UV emissions Reduced heat generation
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Conventional Lighting system After LED Migration
Power Consumption 14 KW Lux level 125~200
Energy Cons-Monthly 6300 KWH 50400 INR-Annually 75600 KWH 604800 INR
65 KW (Red 464) 250~450 (Inc 250 )
2925 KWH 23400 INR (Red 464 )
35100 KWH 280800 INR
65 KW (Red 464) 250~450 (Inc 250 )
1312 KWH 10400 INR (Red 782 ) 15744 KWH 125952 INR
Occupancy Sensor
After Sensor installation
Occupancy sensor
Sensor Controlled
lightingGroup
Manual Controlled
Lighting group
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
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- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
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- Slide Number 47
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- Slide Number 50
- Slide Number 51
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- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
We have Energy Management Cell in our Plant Which initiates amp Manages all sorts of Energy Conservation measuresacross the Plant
Energy Management System
Mr Pramod ChoudharyPlant Head Lucknow
DH ndash Mr S B MattaPlant services
MR -Lko Works Dr SB Matta
DH ndash Mr V AgrawalPaint shop
DH ndash Mr S N VermaTCF
DH ndash Mr U TauheedBIW
DH ndash Mr R K SinghIBF
DH ndash Mr R K SinghAxle Shop
DH ndashMr G V JoshiPlanning
DH ndash Mr A ChhariaMaterials amp ADD
DH ndash Mr Ankush GourHR
DH ndash Mr R K SinghCV- CX
Team Structure ndash ISO 50001
DH ndash Divisional Head
ISO 50001 CertificateEnergy Policy
2013 2016 2019
IIT - Kanpur- CVBU LUCKNOW
ENERGY MANAGEMENT SYSTEM ndash An Overview
TOP MANAGEMENT COMMITMENT
STAFF COMMITMENT
ENERGY AUDIT
ACTION PLAN
MONITORING amp TARGET SETTING
REVIEW amp DEVELOP PROFILE
LONG PAY BACK PROJECTS
IIT - Kanpur- CVBU LUCKNOW
Preliminary Energy audit
Detailed Energy audit
Plant Coordinator
GO AHEAD
Energy savings discussion and presentation
GO AHEAD for Implementation
Energy savings monitoring and interim report to Energy Mgmt Cell
Acceptance of Proposal
Submission of Techno commercial proposal
Team formation
Energy Management CellEnCon Implementation Methodology
copy Copyright Confidential Tata Motors Limited
Innovation Digital Transformation Project Planning amp Operation
3D layout of Manufacturing Line Process flow for Digital transformation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
44
Collaboration
Training
Layout
Maintenance
2D drawings using Auto Cad 3D digital Factory
No single platform for discussions and decision making among various stake-holder
Virtual Factory encouraged different agencies to work in more collaborate manner
Traditional training methods such as classroom teaching using PPTs and OJT
3D Digital Work-Instruction videos along with Quality and Safety awareness
Maintenance based on Real time data
Preventive Maintenance Breakdown Maintenance based on schedule
Collection of information from individual machines and preparing reports
Connected Machines IPMS Mobile App online quality parameter monitoring
Traditional Method Digital Method
Technology Landscape ndash before and after implementation
Factory Set-up time reduced
Issue identified and resolved before physical installationconstruction
Better Visualization of the process enables operator to learn fast
Down-time of machines reduced thusimproving OEE
Better tracking and control quality and Mc parameters Faster information exchange
Transformation Impact
No Virtual Simulation Expensive Physicals only for very critical processes
Virtual Simulation of Critical Processes helped to identified Potential issues
Short Project Lead time Saving on rework cost and time
Simulation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
Sales~10 Increase throughbull Levelled Productionbull Improvement in Customer Experience
Cost
Customer Complaint
Project Time
Quality
Employee Engagement
~15 Reduction through bull Inventory Optimizationbull Warranty Cost reductionbull COPQ Reduction
~15 Reduction through bull Robust Process Designbull Resulting Reliability of Product
~25 Reduction throughbull Better Project
ManagementWith Use of Simulations Avoided Rework
~25 Improvement throughbull Connected Equipment
bull Avoiding Defect Passing
~10 Improvement throughbull Layout Improvementbull Process Automation
bull Ergonomics amp Safety improvement
Quantitative Benefits and Awarded in CII Digital Transformation Meet
Innovation Digital Transformation Project Planning amp Operation
IIT - Kanpur- CVBU LUCKNOW
Teamwork Employee involvement amp MonitoringDaily Consumption Report
Daily Energy Audit Report
Daily Shopwise Report
Daily Solar Generation Report
Hourly Consumption Report-Plant
Hourly Consumption Report-Shop
Monthly Energy Consumption Report
Awar
enes
sle
vel
2017-18
Reporting of energy consumption of the plant and
individual shops on fortnightly and monthly
basis
2018-19
H1 Reporting of entire plantrsquos energy consumption on daily basis
Daily Energy Audit Report (DEAR) circulated across the plant to minimize
energy wastageH2 Reporting of entire plantrsquos and shop-wise energy consumption on
daily basis
2019-20
H1 Reporting of shop-wise energy consumption started on hourly
basisH1 Reporting of working dayrsquos
and non-working dayrsquos consumption separately for
identification of areasprocesses 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
ENERGY CONSUMPTION 2019-20Figures in KWH
FACTORY Dec-19 Jan-20 Feb-20 Mar-20EASTERN COMPLEXBIWBIW Cab 30103 29885 42825 7097BIW Cowl 17657 16650 20104 7438FDV 0 0 0 0COMP 13691 12555 15960 4155BIW Office others 3459 2845 3824 599Distribution Losses 5737 5686 8235 3398Total 70648 67620 90949 22688PAINT SHOPPTED 276243 270240 58056 125761Paint 199896 182651 252332 55852COMP 69201 71042 191305 32740Paint others 33456 34243 71892 16336Distribution Losses 52586 55324 32462 45001Total 631382 613501 606048 275690TCFAssly 84210 101803 92831 23993Trim Assly 12468 17988 15117 4219FDV 0 0 0 0Compressor 38154 41387 42232 13080TCF officeothers 19581 18255 15958 13560Distribution Losses 14262 16490 17609 10428Total 168676 195923 183747 65281
Rear Axle and Line-45 17252 16260 4125 1830Logistics Centre 14904 25247 20629 9615RSO 5597 9370 8390 8445
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
GSM Based Smart Control of Shop Floor Ventilation System
Concerns in present method bull One operator has to travel around 1 Km for manually switching off all FDVs in western complex due to control panel given at that particular
location and hence there is electrical energy wastage of 5137 KWHmonth due to travel time of around 20 mins
Present process Moving to
switching off SB1 FDV
(0 mins)
Moving to switching off SB2 FDV
(5 mins)
Moving to switching off F Block FDV
(15 mins)
Moving to switching off
SB4 FDV(20 mins)
Moving to switching off SB3 FDV
(10 mins)
Blower amp Control panel
FDV Locations in Line 1
EnCon Projects
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
LCA Solution
bull Remote switching off FDVs by integrating off operation of FDV with GSMmodem from one location Also message will be delivered to user thatwhich FDV has been switched off (wireless switching off operation is donethrough GSM modem to avoid cable cost and laying of cable line)
Benefits amp Horizontal Scope 1Energy saving - Energy saving of 41096 KWHannum by providing remote switching off FDVs
2 Cost Saving - Recurring cost saving of Rs 328 lakhsannum3 Environment- Reduction in carbon footprint (reduction of 337 tonne of CO2annum by energy saving)
4 SMS escalation to user for information of FDV switch off5No laying out of wire is required as it is wireless communication with help of GSM modem6 Horizontal deployment of GSM based control for other process machines of assembly line 12 and 3
Solution Cost-Rs 328 Lacs for all 5 FDVs
Remote switching off SB3 FDV (Instantly)
Control panel- Remote Switching off SB1 FDV
Remote switching off SB2 FDV (Instantly)
Remote switching off F Block FDV (Instantly)
Remote switching off SB4 FDV (Instantly)
GSM Based Smart Control of Shop Floor Ventilation System
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Innovative Projects LED Migration Project
Evolution of Lighting
LEDification Project
No expenses in LED- migration
OPEX model Lights Installation Testing amp
Commissioning of LED lights 5 yrs extended warranty
Scope amp Savings
Phase wise LEDification project
Entire plant in phases Better control schemes Reduction in consumption by
50 (Minimum)
Optimal design amp execution
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
Why LED for lighting
LED the best lighting option today
Energy efficient higher Lumens per Watts
No Mercury-Environmental friendly
No IR amp UV emissions Reduced heat generation
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Conventional Lighting system After LED Migration
Power Consumption 14 KW Lux level 125~200
Energy Cons-Monthly 6300 KWH 50400 INR-Annually 75600 KWH 604800 INR
65 KW (Red 464) 250~450 (Inc 250 )
2925 KWH 23400 INR (Red 464 )
35100 KWH 280800 INR
65 KW (Red 464) 250~450 (Inc 250 )
1312 KWH 10400 INR (Red 782 ) 15744 KWH 125952 INR
Occupancy Sensor
After Sensor installation
Occupancy sensor
Sensor Controlled
lightingGroup
Manual Controlled
Lighting group
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Slide Number 55
- Slide Number 56
- Slide Number 57
- Slide Number 58
- Slide Number 59
- Slide Number 60
- Slide Number 61
- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
We have Energy Management Cell in our Plant Which initiates amp Manages all sorts of Energy Conservation measuresacross the Plant
Energy Management System
Mr Pramod ChoudharyPlant Head Lucknow
DH ndash Mr S B MattaPlant services
MR -Lko Works Dr SB Matta
DH ndash Mr V AgrawalPaint shop
DH ndash Mr S N VermaTCF
DH ndash Mr U TauheedBIW
DH ndash Mr R K SinghIBF
DH ndash Mr R K SinghAxle Shop
DH ndashMr G V JoshiPlanning
DH ndash Mr A ChhariaMaterials amp ADD
DH ndash Mr Ankush GourHR
DH ndash Mr R K SinghCV- CX
Team Structure ndash ISO 50001
DH ndash Divisional Head
ISO 50001 CertificateEnergy Policy
2013 2016 2019
IIT - Kanpur- CVBU LUCKNOW
ENERGY MANAGEMENT SYSTEM ndash An Overview
TOP MANAGEMENT COMMITMENT
STAFF COMMITMENT
ENERGY AUDIT
ACTION PLAN
MONITORING amp TARGET SETTING
REVIEW amp DEVELOP PROFILE
LONG PAY BACK PROJECTS
IIT - Kanpur- CVBU LUCKNOW
Preliminary Energy audit
Detailed Energy audit
Plant Coordinator
GO AHEAD
Energy savings discussion and presentation
GO AHEAD for Implementation
Energy savings monitoring and interim report to Energy Mgmt Cell
Acceptance of Proposal
Submission of Techno commercial proposal
Team formation
Energy Management CellEnCon Implementation Methodology
copy Copyright Confidential Tata Motors Limited
Innovation Digital Transformation Project Planning amp Operation
3D layout of Manufacturing Line Process flow for Digital transformation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
44
Collaboration
Training
Layout
Maintenance
2D drawings using Auto Cad 3D digital Factory
No single platform for discussions and decision making among various stake-holder
Virtual Factory encouraged different agencies to work in more collaborate manner
Traditional training methods such as classroom teaching using PPTs and OJT
3D Digital Work-Instruction videos along with Quality and Safety awareness
Maintenance based on Real time data
Preventive Maintenance Breakdown Maintenance based on schedule
Collection of information from individual machines and preparing reports
Connected Machines IPMS Mobile App online quality parameter monitoring
Traditional Method Digital Method
Technology Landscape ndash before and after implementation
Factory Set-up time reduced
Issue identified and resolved before physical installationconstruction
Better Visualization of the process enables operator to learn fast
Down-time of machines reduced thusimproving OEE
Better tracking and control quality and Mc parameters Faster information exchange
Transformation Impact
No Virtual Simulation Expensive Physicals only for very critical processes
Virtual Simulation of Critical Processes helped to identified Potential issues
Short Project Lead time Saving on rework cost and time
Simulation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
Sales~10 Increase throughbull Levelled Productionbull Improvement in Customer Experience
Cost
Customer Complaint
Project Time
Quality
Employee Engagement
~15 Reduction through bull Inventory Optimizationbull Warranty Cost reductionbull COPQ Reduction
~15 Reduction through bull Robust Process Designbull Resulting Reliability of Product
~25 Reduction throughbull Better Project
ManagementWith Use of Simulations Avoided Rework
~25 Improvement throughbull Connected Equipment
bull Avoiding Defect Passing
~10 Improvement throughbull Layout Improvementbull Process Automation
bull Ergonomics amp Safety improvement
Quantitative Benefits and Awarded in CII Digital Transformation Meet
Innovation Digital Transformation Project Planning amp Operation
IIT - Kanpur- CVBU LUCKNOW
Teamwork Employee involvement amp MonitoringDaily Consumption Report
Daily Energy Audit Report
Daily Shopwise Report
Daily Solar Generation Report
Hourly Consumption Report-Plant
Hourly Consumption Report-Shop
Monthly Energy Consumption Report
Awar
enes
sle
vel
2017-18
Reporting of energy consumption of the plant and
individual shops on fortnightly and monthly
basis
2018-19
H1 Reporting of entire plantrsquos energy consumption on daily basis
Daily Energy Audit Report (DEAR) circulated across the plant to minimize
energy wastageH2 Reporting of entire plantrsquos and shop-wise energy consumption on
daily basis
2019-20
H1 Reporting of shop-wise energy consumption started on hourly
basisH1 Reporting of working dayrsquos
and non-working dayrsquos consumption separately for
identification of areasprocesses 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
ENERGY CONSUMPTION 2019-20Figures in KWH
FACTORY Dec-19 Jan-20 Feb-20 Mar-20EASTERN COMPLEXBIWBIW Cab 30103 29885 42825 7097BIW Cowl 17657 16650 20104 7438FDV 0 0 0 0COMP 13691 12555 15960 4155BIW Office others 3459 2845 3824 599Distribution Losses 5737 5686 8235 3398Total 70648 67620 90949 22688PAINT SHOPPTED 276243 270240 58056 125761Paint 199896 182651 252332 55852COMP 69201 71042 191305 32740Paint others 33456 34243 71892 16336Distribution Losses 52586 55324 32462 45001Total 631382 613501 606048 275690TCFAssly 84210 101803 92831 23993Trim Assly 12468 17988 15117 4219FDV 0 0 0 0Compressor 38154 41387 42232 13080TCF officeothers 19581 18255 15958 13560Distribution Losses 14262 16490 17609 10428Total 168676 195923 183747 65281
Rear Axle and Line-45 17252 16260 4125 1830Logistics Centre 14904 25247 20629 9615RSO 5597 9370 8390 8445
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
GSM Based Smart Control of Shop Floor Ventilation System
Concerns in present method bull One operator has to travel around 1 Km for manually switching off all FDVs in western complex due to control panel given at that particular
location and hence there is electrical energy wastage of 5137 KWHmonth due to travel time of around 20 mins
Present process Moving to
switching off SB1 FDV
(0 mins)
Moving to switching off SB2 FDV
(5 mins)
Moving to switching off F Block FDV
(15 mins)
Moving to switching off
SB4 FDV(20 mins)
Moving to switching off SB3 FDV
(10 mins)
Blower amp Control panel
FDV Locations in Line 1
EnCon Projects
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
LCA Solution
bull Remote switching off FDVs by integrating off operation of FDV with GSMmodem from one location Also message will be delivered to user thatwhich FDV has been switched off (wireless switching off operation is donethrough GSM modem to avoid cable cost and laying of cable line)
Benefits amp Horizontal Scope 1Energy saving - Energy saving of 41096 KWHannum by providing remote switching off FDVs
2 Cost Saving - Recurring cost saving of Rs 328 lakhsannum3 Environment- Reduction in carbon footprint (reduction of 337 tonne of CO2annum by energy saving)
4 SMS escalation to user for information of FDV switch off5No laying out of wire is required as it is wireless communication with help of GSM modem6 Horizontal deployment of GSM based control for other process machines of assembly line 12 and 3
Solution Cost-Rs 328 Lacs for all 5 FDVs
Remote switching off SB3 FDV (Instantly)
Control panel- Remote Switching off SB1 FDV
Remote switching off SB2 FDV (Instantly)
Remote switching off F Block FDV (Instantly)
Remote switching off SB4 FDV (Instantly)
GSM Based Smart Control of Shop Floor Ventilation System
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Innovative Projects LED Migration Project
Evolution of Lighting
LEDification Project
No expenses in LED- migration
OPEX model Lights Installation Testing amp
Commissioning of LED lights 5 yrs extended warranty
Scope amp Savings
Phase wise LEDification project
Entire plant in phases Better control schemes Reduction in consumption by
50 (Minimum)
Optimal design amp execution
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
Why LED for lighting
LED the best lighting option today
Energy efficient higher Lumens per Watts
No Mercury-Environmental friendly
No IR amp UV emissions Reduced heat generation
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Conventional Lighting system After LED Migration
Power Consumption 14 KW Lux level 125~200
Energy Cons-Monthly 6300 KWH 50400 INR-Annually 75600 KWH 604800 INR
65 KW (Red 464) 250~450 (Inc 250 )
2925 KWH 23400 INR (Red 464 )
35100 KWH 280800 INR
65 KW (Red 464) 250~450 (Inc 250 )
1312 KWH 10400 INR (Red 782 ) 15744 KWH 125952 INR
Occupancy Sensor
After Sensor installation
Occupancy sensor
Sensor Controlled
lightingGroup
Manual Controlled
Lighting group
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
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- Slide Number 26
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- Slide Number 28
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- Slide Number 39
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- Slide Number 56
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- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
We have Energy Management Cell in our Plant Which initiates amp Manages all sorts of Energy Conservation measuresacross the Plant
Energy Management System
Mr Pramod ChoudharyPlant Head Lucknow
DH ndash Mr S B MattaPlant services
MR -Lko Works Dr SB Matta
DH ndash Mr V AgrawalPaint shop
DH ndash Mr S N VermaTCF
DH ndash Mr U TauheedBIW
DH ndash Mr R K SinghIBF
DH ndash Mr R K SinghAxle Shop
DH ndashMr G V JoshiPlanning
DH ndash Mr A ChhariaMaterials amp ADD
DH ndash Mr Ankush GourHR
DH ndash Mr R K SinghCV- CX
Team Structure ndash ISO 50001
DH ndash Divisional Head
ISO 50001 CertificateEnergy Policy
2013 2016 2019
IIT - Kanpur- CVBU LUCKNOW
ENERGY MANAGEMENT SYSTEM ndash An Overview
TOP MANAGEMENT COMMITMENT
STAFF COMMITMENT
ENERGY AUDIT
ACTION PLAN
MONITORING amp TARGET SETTING
REVIEW amp DEVELOP PROFILE
LONG PAY BACK PROJECTS
IIT - Kanpur- CVBU LUCKNOW
Preliminary Energy audit
Detailed Energy audit
Plant Coordinator
GO AHEAD
Energy savings discussion and presentation
GO AHEAD for Implementation
Energy savings monitoring and interim report to Energy Mgmt Cell
Acceptance of Proposal
Submission of Techno commercial proposal
Team formation
Energy Management CellEnCon Implementation Methodology
copy Copyright Confidential Tata Motors Limited
Innovation Digital Transformation Project Planning amp Operation
3D layout of Manufacturing Line Process flow for Digital transformation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
44
Collaboration
Training
Layout
Maintenance
2D drawings using Auto Cad 3D digital Factory
No single platform for discussions and decision making among various stake-holder
Virtual Factory encouraged different agencies to work in more collaborate manner
Traditional training methods such as classroom teaching using PPTs and OJT
3D Digital Work-Instruction videos along with Quality and Safety awareness
Maintenance based on Real time data
Preventive Maintenance Breakdown Maintenance based on schedule
Collection of information from individual machines and preparing reports
Connected Machines IPMS Mobile App online quality parameter monitoring
Traditional Method Digital Method
Technology Landscape ndash before and after implementation
Factory Set-up time reduced
Issue identified and resolved before physical installationconstruction
Better Visualization of the process enables operator to learn fast
Down-time of machines reduced thusimproving OEE
Better tracking and control quality and Mc parameters Faster information exchange
Transformation Impact
No Virtual Simulation Expensive Physicals only for very critical processes
Virtual Simulation of Critical Processes helped to identified Potential issues
Short Project Lead time Saving on rework cost and time
Simulation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
Sales~10 Increase throughbull Levelled Productionbull Improvement in Customer Experience
Cost
Customer Complaint
Project Time
Quality
Employee Engagement
~15 Reduction through bull Inventory Optimizationbull Warranty Cost reductionbull COPQ Reduction
~15 Reduction through bull Robust Process Designbull Resulting Reliability of Product
~25 Reduction throughbull Better Project
ManagementWith Use of Simulations Avoided Rework
~25 Improvement throughbull Connected Equipment
bull Avoiding Defect Passing
~10 Improvement throughbull Layout Improvementbull Process Automation
bull Ergonomics amp Safety improvement
Quantitative Benefits and Awarded in CII Digital Transformation Meet
Innovation Digital Transformation Project Planning amp Operation
IIT - Kanpur- CVBU LUCKNOW
Teamwork Employee involvement amp MonitoringDaily Consumption Report
Daily Energy Audit Report
Daily Shopwise Report
Daily Solar Generation Report
Hourly Consumption Report-Plant
Hourly Consumption Report-Shop
Monthly Energy Consumption Report
Awar
enes
sle
vel
2017-18
Reporting of energy consumption of the plant and
individual shops on fortnightly and monthly
basis
2018-19
H1 Reporting of entire plantrsquos energy consumption on daily basis
Daily Energy Audit Report (DEAR) circulated across the plant to minimize
energy wastageH2 Reporting of entire plantrsquos and shop-wise energy consumption on
daily basis
2019-20
H1 Reporting of shop-wise energy consumption started on hourly
basisH1 Reporting of working dayrsquos
and non-working dayrsquos consumption separately for
identification of areasprocesses 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
ENERGY CONSUMPTION 2019-20Figures in KWH
FACTORY Dec-19 Jan-20 Feb-20 Mar-20EASTERN COMPLEXBIWBIW Cab 30103 29885 42825 7097BIW Cowl 17657 16650 20104 7438FDV 0 0 0 0COMP 13691 12555 15960 4155BIW Office others 3459 2845 3824 599Distribution Losses 5737 5686 8235 3398Total 70648 67620 90949 22688PAINT SHOPPTED 276243 270240 58056 125761Paint 199896 182651 252332 55852COMP 69201 71042 191305 32740Paint others 33456 34243 71892 16336Distribution Losses 52586 55324 32462 45001Total 631382 613501 606048 275690TCFAssly 84210 101803 92831 23993Trim Assly 12468 17988 15117 4219FDV 0 0 0 0Compressor 38154 41387 42232 13080TCF officeothers 19581 18255 15958 13560Distribution Losses 14262 16490 17609 10428Total 168676 195923 183747 65281
Rear Axle and Line-45 17252 16260 4125 1830Logistics Centre 14904 25247 20629 9615RSO 5597 9370 8390 8445
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
GSM Based Smart Control of Shop Floor Ventilation System
Concerns in present method bull One operator has to travel around 1 Km for manually switching off all FDVs in western complex due to control panel given at that particular
location and hence there is electrical energy wastage of 5137 KWHmonth due to travel time of around 20 mins
Present process Moving to
switching off SB1 FDV
(0 mins)
Moving to switching off SB2 FDV
(5 mins)
Moving to switching off F Block FDV
(15 mins)
Moving to switching off
SB4 FDV(20 mins)
Moving to switching off SB3 FDV
(10 mins)
Blower amp Control panel
FDV Locations in Line 1
EnCon Projects
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
LCA Solution
bull Remote switching off FDVs by integrating off operation of FDV with GSMmodem from one location Also message will be delivered to user thatwhich FDV has been switched off (wireless switching off operation is donethrough GSM modem to avoid cable cost and laying of cable line)
Benefits amp Horizontal Scope 1Energy saving - Energy saving of 41096 KWHannum by providing remote switching off FDVs
2 Cost Saving - Recurring cost saving of Rs 328 lakhsannum3 Environment- Reduction in carbon footprint (reduction of 337 tonne of CO2annum by energy saving)
4 SMS escalation to user for information of FDV switch off5No laying out of wire is required as it is wireless communication with help of GSM modem6 Horizontal deployment of GSM based control for other process machines of assembly line 12 and 3
Solution Cost-Rs 328 Lacs for all 5 FDVs
Remote switching off SB3 FDV (Instantly)
Control panel- Remote Switching off SB1 FDV
Remote switching off SB2 FDV (Instantly)
Remote switching off F Block FDV (Instantly)
Remote switching off SB4 FDV (Instantly)
GSM Based Smart Control of Shop Floor Ventilation System
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Innovative Projects LED Migration Project
Evolution of Lighting
LEDification Project
No expenses in LED- migration
OPEX model Lights Installation Testing amp
Commissioning of LED lights 5 yrs extended warranty
Scope amp Savings
Phase wise LEDification project
Entire plant in phases Better control schemes Reduction in consumption by
50 (Minimum)
Optimal design amp execution
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
Why LED for lighting
LED the best lighting option today
Energy efficient higher Lumens per Watts
No Mercury-Environmental friendly
No IR amp UV emissions Reduced heat generation
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Conventional Lighting system After LED Migration
Power Consumption 14 KW Lux level 125~200
Energy Cons-Monthly 6300 KWH 50400 INR-Annually 75600 KWH 604800 INR
65 KW (Red 464) 250~450 (Inc 250 )
2925 KWH 23400 INR (Red 464 )
35100 KWH 280800 INR
65 KW (Red 464) 250~450 (Inc 250 )
1312 KWH 10400 INR (Red 782 ) 15744 KWH 125952 INR
Occupancy Sensor
After Sensor installation
Occupancy sensor
Sensor Controlled
lightingGroup
Manual Controlled
Lighting group
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
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- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
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- Slide Number 28
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- Slide Number 39
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- Slide Number 42
- Slide Number 43
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- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
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- Slide Number 53
- Slide Number 54
- Slide Number 55
- Slide Number 56
- Slide Number 57
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- Slide Number 60
- Slide Number 61
- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
We have Energy Management Cell in our Plant Which initiates amp Manages all sorts of Energy Conservation measuresacross the Plant
Energy Management System
Mr Pramod ChoudharyPlant Head Lucknow
DH ndash Mr S B MattaPlant services
MR -Lko Works Dr SB Matta
DH ndash Mr V AgrawalPaint shop
DH ndash Mr S N VermaTCF
DH ndash Mr U TauheedBIW
DH ndash Mr R K SinghIBF
DH ndash Mr R K SinghAxle Shop
DH ndashMr G V JoshiPlanning
DH ndash Mr A ChhariaMaterials amp ADD
DH ndash Mr Ankush GourHR
DH ndash Mr R K SinghCV- CX
Team Structure ndash ISO 50001
DH ndash Divisional Head
ISO 50001 CertificateEnergy Policy
2013 2016 2019
IIT - Kanpur- CVBU LUCKNOW
ENERGY MANAGEMENT SYSTEM ndash An Overview
TOP MANAGEMENT COMMITMENT
STAFF COMMITMENT
ENERGY AUDIT
ACTION PLAN
MONITORING amp TARGET SETTING
REVIEW amp DEVELOP PROFILE
LONG PAY BACK PROJECTS
IIT - Kanpur- CVBU LUCKNOW
Preliminary Energy audit
Detailed Energy audit
Plant Coordinator
GO AHEAD
Energy savings discussion and presentation
GO AHEAD for Implementation
Energy savings monitoring and interim report to Energy Mgmt Cell
Acceptance of Proposal
Submission of Techno commercial proposal
Team formation
Energy Management CellEnCon Implementation Methodology
copy Copyright Confidential Tata Motors Limited
Innovation Digital Transformation Project Planning amp Operation
3D layout of Manufacturing Line Process flow for Digital transformation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
44
Collaboration
Training
Layout
Maintenance
2D drawings using Auto Cad 3D digital Factory
No single platform for discussions and decision making among various stake-holder
Virtual Factory encouraged different agencies to work in more collaborate manner
Traditional training methods such as classroom teaching using PPTs and OJT
3D Digital Work-Instruction videos along with Quality and Safety awareness
Maintenance based on Real time data
Preventive Maintenance Breakdown Maintenance based on schedule
Collection of information from individual machines and preparing reports
Connected Machines IPMS Mobile App online quality parameter monitoring
Traditional Method Digital Method
Technology Landscape ndash before and after implementation
Factory Set-up time reduced
Issue identified and resolved before physical installationconstruction
Better Visualization of the process enables operator to learn fast
Down-time of machines reduced thusimproving OEE
Better tracking and control quality and Mc parameters Faster information exchange
Transformation Impact
No Virtual Simulation Expensive Physicals only for very critical processes
Virtual Simulation of Critical Processes helped to identified Potential issues
Short Project Lead time Saving on rework cost and time
Simulation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
Sales~10 Increase throughbull Levelled Productionbull Improvement in Customer Experience
Cost
Customer Complaint
Project Time
Quality
Employee Engagement
~15 Reduction through bull Inventory Optimizationbull Warranty Cost reductionbull COPQ Reduction
~15 Reduction through bull Robust Process Designbull Resulting Reliability of Product
~25 Reduction throughbull Better Project
ManagementWith Use of Simulations Avoided Rework
~25 Improvement throughbull Connected Equipment
bull Avoiding Defect Passing
~10 Improvement throughbull Layout Improvementbull Process Automation
bull Ergonomics amp Safety improvement
Quantitative Benefits and Awarded in CII Digital Transformation Meet
Innovation Digital Transformation Project Planning amp Operation
IIT - Kanpur- CVBU LUCKNOW
Teamwork Employee involvement amp MonitoringDaily Consumption Report
Daily Energy Audit Report
Daily Shopwise Report
Daily Solar Generation Report
Hourly Consumption Report-Plant
Hourly Consumption Report-Shop
Monthly Energy Consumption Report
Awar
enes
sle
vel
2017-18
Reporting of energy consumption of the plant and
individual shops on fortnightly and monthly
basis
2018-19
H1 Reporting of entire plantrsquos energy consumption on daily basis
Daily Energy Audit Report (DEAR) circulated across the plant to minimize
energy wastageH2 Reporting of entire plantrsquos and shop-wise energy consumption on
daily basis
2019-20
H1 Reporting of shop-wise energy consumption started on hourly
basisH1 Reporting of working dayrsquos
and non-working dayrsquos consumption separately for
identification of areasprocesses 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
ENERGY CONSUMPTION 2019-20Figures in KWH
FACTORY Dec-19 Jan-20 Feb-20 Mar-20EASTERN COMPLEXBIWBIW Cab 30103 29885 42825 7097BIW Cowl 17657 16650 20104 7438FDV 0 0 0 0COMP 13691 12555 15960 4155BIW Office others 3459 2845 3824 599Distribution Losses 5737 5686 8235 3398Total 70648 67620 90949 22688PAINT SHOPPTED 276243 270240 58056 125761Paint 199896 182651 252332 55852COMP 69201 71042 191305 32740Paint others 33456 34243 71892 16336Distribution Losses 52586 55324 32462 45001Total 631382 613501 606048 275690TCFAssly 84210 101803 92831 23993Trim Assly 12468 17988 15117 4219FDV 0 0 0 0Compressor 38154 41387 42232 13080TCF officeothers 19581 18255 15958 13560Distribution Losses 14262 16490 17609 10428Total 168676 195923 183747 65281
Rear Axle and Line-45 17252 16260 4125 1830Logistics Centre 14904 25247 20629 9615RSO 5597 9370 8390 8445
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
GSM Based Smart Control of Shop Floor Ventilation System
Concerns in present method bull One operator has to travel around 1 Km for manually switching off all FDVs in western complex due to control panel given at that particular
location and hence there is electrical energy wastage of 5137 KWHmonth due to travel time of around 20 mins
Present process Moving to
switching off SB1 FDV
(0 mins)
Moving to switching off SB2 FDV
(5 mins)
Moving to switching off F Block FDV
(15 mins)
Moving to switching off
SB4 FDV(20 mins)
Moving to switching off SB3 FDV
(10 mins)
Blower amp Control panel
FDV Locations in Line 1
EnCon Projects
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
LCA Solution
bull Remote switching off FDVs by integrating off operation of FDV with GSMmodem from one location Also message will be delivered to user thatwhich FDV has been switched off (wireless switching off operation is donethrough GSM modem to avoid cable cost and laying of cable line)
Benefits amp Horizontal Scope 1Energy saving - Energy saving of 41096 KWHannum by providing remote switching off FDVs
2 Cost Saving - Recurring cost saving of Rs 328 lakhsannum3 Environment- Reduction in carbon footprint (reduction of 337 tonne of CO2annum by energy saving)
4 SMS escalation to user for information of FDV switch off5No laying out of wire is required as it is wireless communication with help of GSM modem6 Horizontal deployment of GSM based control for other process machines of assembly line 12 and 3
Solution Cost-Rs 328 Lacs for all 5 FDVs
Remote switching off SB3 FDV (Instantly)
Control panel- Remote Switching off SB1 FDV
Remote switching off SB2 FDV (Instantly)
Remote switching off F Block FDV (Instantly)
Remote switching off SB4 FDV (Instantly)
GSM Based Smart Control of Shop Floor Ventilation System
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Innovative Projects LED Migration Project
Evolution of Lighting
LEDification Project
No expenses in LED- migration
OPEX model Lights Installation Testing amp
Commissioning of LED lights 5 yrs extended warranty
Scope amp Savings
Phase wise LEDification project
Entire plant in phases Better control schemes Reduction in consumption by
50 (Minimum)
Optimal design amp execution
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
Why LED for lighting
LED the best lighting option today
Energy efficient higher Lumens per Watts
No Mercury-Environmental friendly
No IR amp UV emissions Reduced heat generation
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Conventional Lighting system After LED Migration
Power Consumption 14 KW Lux level 125~200
Energy Cons-Monthly 6300 KWH 50400 INR-Annually 75600 KWH 604800 INR
65 KW (Red 464) 250~450 (Inc 250 )
2925 KWH 23400 INR (Red 464 )
35100 KWH 280800 INR
65 KW (Red 464) 250~450 (Inc 250 )
1312 KWH 10400 INR (Red 782 ) 15744 KWH 125952 INR
Occupancy Sensor
After Sensor installation
Occupancy sensor
Sensor Controlled
lightingGroup
Manual Controlled
Lighting group
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
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- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
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- Slide Number 41
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- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
We have Energy Management Cell in our Plant Which initiates amp Manages all sorts of Energy Conservation measuresacross the Plant
Energy Management System
Mr Pramod ChoudharyPlant Head Lucknow
DH ndash Mr S B MattaPlant services
MR -Lko Works Dr SB Matta
DH ndash Mr V AgrawalPaint shop
DH ndash Mr S N VermaTCF
DH ndash Mr U TauheedBIW
DH ndash Mr R K SinghIBF
DH ndash Mr R K SinghAxle Shop
DH ndashMr G V JoshiPlanning
DH ndash Mr A ChhariaMaterials amp ADD
DH ndash Mr Ankush GourHR
DH ndash Mr R K SinghCV- CX
Team Structure ndash ISO 50001
DH ndash Divisional Head
ISO 50001 CertificateEnergy Policy
2013 2016 2019
IIT - Kanpur- CVBU LUCKNOW
ENERGY MANAGEMENT SYSTEM ndash An Overview
TOP MANAGEMENT COMMITMENT
STAFF COMMITMENT
ENERGY AUDIT
ACTION PLAN
MONITORING amp TARGET SETTING
REVIEW amp DEVELOP PROFILE
LONG PAY BACK PROJECTS
IIT - Kanpur- CVBU LUCKNOW
Preliminary Energy audit
Detailed Energy audit
Plant Coordinator
GO AHEAD
Energy savings discussion and presentation
GO AHEAD for Implementation
Energy savings monitoring and interim report to Energy Mgmt Cell
Acceptance of Proposal
Submission of Techno commercial proposal
Team formation
Energy Management CellEnCon Implementation Methodology
copy Copyright Confidential Tata Motors Limited
Innovation Digital Transformation Project Planning amp Operation
3D layout of Manufacturing Line Process flow for Digital transformation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
44
Collaboration
Training
Layout
Maintenance
2D drawings using Auto Cad 3D digital Factory
No single platform for discussions and decision making among various stake-holder
Virtual Factory encouraged different agencies to work in more collaborate manner
Traditional training methods such as classroom teaching using PPTs and OJT
3D Digital Work-Instruction videos along with Quality and Safety awareness
Maintenance based on Real time data
Preventive Maintenance Breakdown Maintenance based on schedule
Collection of information from individual machines and preparing reports
Connected Machines IPMS Mobile App online quality parameter monitoring
Traditional Method Digital Method
Technology Landscape ndash before and after implementation
Factory Set-up time reduced
Issue identified and resolved before physical installationconstruction
Better Visualization of the process enables operator to learn fast
Down-time of machines reduced thusimproving OEE
Better tracking and control quality and Mc parameters Faster information exchange
Transformation Impact
No Virtual Simulation Expensive Physicals only for very critical processes
Virtual Simulation of Critical Processes helped to identified Potential issues
Short Project Lead time Saving on rework cost and time
Simulation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
Sales~10 Increase throughbull Levelled Productionbull Improvement in Customer Experience
Cost
Customer Complaint
Project Time
Quality
Employee Engagement
~15 Reduction through bull Inventory Optimizationbull Warranty Cost reductionbull COPQ Reduction
~15 Reduction through bull Robust Process Designbull Resulting Reliability of Product
~25 Reduction throughbull Better Project
ManagementWith Use of Simulations Avoided Rework
~25 Improvement throughbull Connected Equipment
bull Avoiding Defect Passing
~10 Improvement throughbull Layout Improvementbull Process Automation
bull Ergonomics amp Safety improvement
Quantitative Benefits and Awarded in CII Digital Transformation Meet
Innovation Digital Transformation Project Planning amp Operation
IIT - Kanpur- CVBU LUCKNOW
Teamwork Employee involvement amp MonitoringDaily Consumption Report
Daily Energy Audit Report
Daily Shopwise Report
Daily Solar Generation Report
Hourly Consumption Report-Plant
Hourly Consumption Report-Shop
Monthly Energy Consumption Report
Awar
enes
sle
vel
2017-18
Reporting of energy consumption of the plant and
individual shops on fortnightly and monthly
basis
2018-19
H1 Reporting of entire plantrsquos energy consumption on daily basis
Daily Energy Audit Report (DEAR) circulated across the plant to minimize
energy wastageH2 Reporting of entire plantrsquos and shop-wise energy consumption on
daily basis
2019-20
H1 Reporting of shop-wise energy consumption started on hourly
basisH1 Reporting of working dayrsquos
and non-working dayrsquos consumption separately for
identification of areasprocesses 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
ENERGY CONSUMPTION 2019-20Figures in KWH
FACTORY Dec-19 Jan-20 Feb-20 Mar-20EASTERN COMPLEXBIWBIW Cab 30103 29885 42825 7097BIW Cowl 17657 16650 20104 7438FDV 0 0 0 0COMP 13691 12555 15960 4155BIW Office others 3459 2845 3824 599Distribution Losses 5737 5686 8235 3398Total 70648 67620 90949 22688PAINT SHOPPTED 276243 270240 58056 125761Paint 199896 182651 252332 55852COMP 69201 71042 191305 32740Paint others 33456 34243 71892 16336Distribution Losses 52586 55324 32462 45001Total 631382 613501 606048 275690TCFAssly 84210 101803 92831 23993Trim Assly 12468 17988 15117 4219FDV 0 0 0 0Compressor 38154 41387 42232 13080TCF officeothers 19581 18255 15958 13560Distribution Losses 14262 16490 17609 10428Total 168676 195923 183747 65281
Rear Axle and Line-45 17252 16260 4125 1830Logistics Centre 14904 25247 20629 9615RSO 5597 9370 8390 8445
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
GSM Based Smart Control of Shop Floor Ventilation System
Concerns in present method bull One operator has to travel around 1 Km for manually switching off all FDVs in western complex due to control panel given at that particular
location and hence there is electrical energy wastage of 5137 KWHmonth due to travel time of around 20 mins
Present process Moving to
switching off SB1 FDV
(0 mins)
Moving to switching off SB2 FDV
(5 mins)
Moving to switching off F Block FDV
(15 mins)
Moving to switching off
SB4 FDV(20 mins)
Moving to switching off SB3 FDV
(10 mins)
Blower amp Control panel
FDV Locations in Line 1
EnCon Projects
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
LCA Solution
bull Remote switching off FDVs by integrating off operation of FDV with GSMmodem from one location Also message will be delivered to user thatwhich FDV has been switched off (wireless switching off operation is donethrough GSM modem to avoid cable cost and laying of cable line)
Benefits amp Horizontal Scope 1Energy saving - Energy saving of 41096 KWHannum by providing remote switching off FDVs
2 Cost Saving - Recurring cost saving of Rs 328 lakhsannum3 Environment- Reduction in carbon footprint (reduction of 337 tonne of CO2annum by energy saving)
4 SMS escalation to user for information of FDV switch off5No laying out of wire is required as it is wireless communication with help of GSM modem6 Horizontal deployment of GSM based control for other process machines of assembly line 12 and 3
Solution Cost-Rs 328 Lacs for all 5 FDVs
Remote switching off SB3 FDV (Instantly)
Control panel- Remote Switching off SB1 FDV
Remote switching off SB2 FDV (Instantly)
Remote switching off F Block FDV (Instantly)
Remote switching off SB4 FDV (Instantly)
GSM Based Smart Control of Shop Floor Ventilation System
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Innovative Projects LED Migration Project
Evolution of Lighting
LEDification Project
No expenses in LED- migration
OPEX model Lights Installation Testing amp
Commissioning of LED lights 5 yrs extended warranty
Scope amp Savings
Phase wise LEDification project
Entire plant in phases Better control schemes Reduction in consumption by
50 (Minimum)
Optimal design amp execution
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
Why LED for lighting
LED the best lighting option today
Energy efficient higher Lumens per Watts
No Mercury-Environmental friendly
No IR amp UV emissions Reduced heat generation
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Conventional Lighting system After LED Migration
Power Consumption 14 KW Lux level 125~200
Energy Cons-Monthly 6300 KWH 50400 INR-Annually 75600 KWH 604800 INR
65 KW (Red 464) 250~450 (Inc 250 )
2925 KWH 23400 INR (Red 464 )
35100 KWH 280800 INR
65 KW (Red 464) 250~450 (Inc 250 )
1312 KWH 10400 INR (Red 782 ) 15744 KWH 125952 INR
Occupancy Sensor
After Sensor installation
Occupancy sensor
Sensor Controlled
lightingGroup
Manual Controlled
Lighting group
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
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- Slide Number 12
- Slide Number 13
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- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
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- Slide Number 34
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- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
We have Energy Management Cell in our Plant Which initiates amp Manages all sorts of Energy Conservation measuresacross the Plant
Energy Management System
Mr Pramod ChoudharyPlant Head Lucknow
DH ndash Mr S B MattaPlant services
MR -Lko Works Dr SB Matta
DH ndash Mr V AgrawalPaint shop
DH ndash Mr S N VermaTCF
DH ndash Mr U TauheedBIW
DH ndash Mr R K SinghIBF
DH ndash Mr R K SinghAxle Shop
DH ndashMr G V JoshiPlanning
DH ndash Mr A ChhariaMaterials amp ADD
DH ndash Mr Ankush GourHR
DH ndash Mr R K SinghCV- CX
Team Structure ndash ISO 50001
DH ndash Divisional Head
ISO 50001 CertificateEnergy Policy
2013 2016 2019
IIT - Kanpur- CVBU LUCKNOW
ENERGY MANAGEMENT SYSTEM ndash An Overview
TOP MANAGEMENT COMMITMENT
STAFF COMMITMENT
ENERGY AUDIT
ACTION PLAN
MONITORING amp TARGET SETTING
REVIEW amp DEVELOP PROFILE
LONG PAY BACK PROJECTS
IIT - Kanpur- CVBU LUCKNOW
Preliminary Energy audit
Detailed Energy audit
Plant Coordinator
GO AHEAD
Energy savings discussion and presentation
GO AHEAD for Implementation
Energy savings monitoring and interim report to Energy Mgmt Cell
Acceptance of Proposal
Submission of Techno commercial proposal
Team formation
Energy Management CellEnCon Implementation Methodology
copy Copyright Confidential Tata Motors Limited
Innovation Digital Transformation Project Planning amp Operation
3D layout of Manufacturing Line Process flow for Digital transformation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
44
Collaboration
Training
Layout
Maintenance
2D drawings using Auto Cad 3D digital Factory
No single platform for discussions and decision making among various stake-holder
Virtual Factory encouraged different agencies to work in more collaborate manner
Traditional training methods such as classroom teaching using PPTs and OJT
3D Digital Work-Instruction videos along with Quality and Safety awareness
Maintenance based on Real time data
Preventive Maintenance Breakdown Maintenance based on schedule
Collection of information from individual machines and preparing reports
Connected Machines IPMS Mobile App online quality parameter monitoring
Traditional Method Digital Method
Technology Landscape ndash before and after implementation
Factory Set-up time reduced
Issue identified and resolved before physical installationconstruction
Better Visualization of the process enables operator to learn fast
Down-time of machines reduced thusimproving OEE
Better tracking and control quality and Mc parameters Faster information exchange
Transformation Impact
No Virtual Simulation Expensive Physicals only for very critical processes
Virtual Simulation of Critical Processes helped to identified Potential issues
Short Project Lead time Saving on rework cost and time
Simulation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
Sales~10 Increase throughbull Levelled Productionbull Improvement in Customer Experience
Cost
Customer Complaint
Project Time
Quality
Employee Engagement
~15 Reduction through bull Inventory Optimizationbull Warranty Cost reductionbull COPQ Reduction
~15 Reduction through bull Robust Process Designbull Resulting Reliability of Product
~25 Reduction throughbull Better Project
ManagementWith Use of Simulations Avoided Rework
~25 Improvement throughbull Connected Equipment
bull Avoiding Defect Passing
~10 Improvement throughbull Layout Improvementbull Process Automation
bull Ergonomics amp Safety improvement
Quantitative Benefits and Awarded in CII Digital Transformation Meet
Innovation Digital Transformation Project Planning amp Operation
IIT - Kanpur- CVBU LUCKNOW
Teamwork Employee involvement amp MonitoringDaily Consumption Report
Daily Energy Audit Report
Daily Shopwise Report
Daily Solar Generation Report
Hourly Consumption Report-Plant
Hourly Consumption Report-Shop
Monthly Energy Consumption Report
Awar
enes
sle
vel
2017-18
Reporting of energy consumption of the plant and
individual shops on fortnightly and monthly
basis
2018-19
H1 Reporting of entire plantrsquos energy consumption on daily basis
Daily Energy Audit Report (DEAR) circulated across the plant to minimize
energy wastageH2 Reporting of entire plantrsquos and shop-wise energy consumption on
daily basis
2019-20
H1 Reporting of shop-wise energy consumption started on hourly
basisH1 Reporting of working dayrsquos
and non-working dayrsquos consumption separately for
identification of areasprocesses 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
ENERGY CONSUMPTION 2019-20Figures in KWH
FACTORY Dec-19 Jan-20 Feb-20 Mar-20EASTERN COMPLEXBIWBIW Cab 30103 29885 42825 7097BIW Cowl 17657 16650 20104 7438FDV 0 0 0 0COMP 13691 12555 15960 4155BIW Office others 3459 2845 3824 599Distribution Losses 5737 5686 8235 3398Total 70648 67620 90949 22688PAINT SHOPPTED 276243 270240 58056 125761Paint 199896 182651 252332 55852COMP 69201 71042 191305 32740Paint others 33456 34243 71892 16336Distribution Losses 52586 55324 32462 45001Total 631382 613501 606048 275690TCFAssly 84210 101803 92831 23993Trim Assly 12468 17988 15117 4219FDV 0 0 0 0Compressor 38154 41387 42232 13080TCF officeothers 19581 18255 15958 13560Distribution Losses 14262 16490 17609 10428Total 168676 195923 183747 65281
Rear Axle and Line-45 17252 16260 4125 1830Logistics Centre 14904 25247 20629 9615RSO 5597 9370 8390 8445
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
GSM Based Smart Control of Shop Floor Ventilation System
Concerns in present method bull One operator has to travel around 1 Km for manually switching off all FDVs in western complex due to control panel given at that particular
location and hence there is electrical energy wastage of 5137 KWHmonth due to travel time of around 20 mins
Present process Moving to
switching off SB1 FDV
(0 mins)
Moving to switching off SB2 FDV
(5 mins)
Moving to switching off F Block FDV
(15 mins)
Moving to switching off
SB4 FDV(20 mins)
Moving to switching off SB3 FDV
(10 mins)
Blower amp Control panel
FDV Locations in Line 1
EnCon Projects
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
LCA Solution
bull Remote switching off FDVs by integrating off operation of FDV with GSMmodem from one location Also message will be delivered to user thatwhich FDV has been switched off (wireless switching off operation is donethrough GSM modem to avoid cable cost and laying of cable line)
Benefits amp Horizontal Scope 1Energy saving - Energy saving of 41096 KWHannum by providing remote switching off FDVs
2 Cost Saving - Recurring cost saving of Rs 328 lakhsannum3 Environment- Reduction in carbon footprint (reduction of 337 tonne of CO2annum by energy saving)
4 SMS escalation to user for information of FDV switch off5No laying out of wire is required as it is wireless communication with help of GSM modem6 Horizontal deployment of GSM based control for other process machines of assembly line 12 and 3
Solution Cost-Rs 328 Lacs for all 5 FDVs
Remote switching off SB3 FDV (Instantly)
Control panel- Remote Switching off SB1 FDV
Remote switching off SB2 FDV (Instantly)
Remote switching off F Block FDV (Instantly)
Remote switching off SB4 FDV (Instantly)
GSM Based Smart Control of Shop Floor Ventilation System
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Innovative Projects LED Migration Project
Evolution of Lighting
LEDification Project
No expenses in LED- migration
OPEX model Lights Installation Testing amp
Commissioning of LED lights 5 yrs extended warranty
Scope amp Savings
Phase wise LEDification project
Entire plant in phases Better control schemes Reduction in consumption by
50 (Minimum)
Optimal design amp execution
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
Why LED for lighting
LED the best lighting option today
Energy efficient higher Lumens per Watts
No Mercury-Environmental friendly
No IR amp UV emissions Reduced heat generation
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Conventional Lighting system After LED Migration
Power Consumption 14 KW Lux level 125~200
Energy Cons-Monthly 6300 KWH 50400 INR-Annually 75600 KWH 604800 INR
65 KW (Red 464) 250~450 (Inc 250 )
2925 KWH 23400 INR (Red 464 )
35100 KWH 280800 INR
65 KW (Red 464) 250~450 (Inc 250 )
1312 KWH 10400 INR (Red 782 ) 15744 KWH 125952 INR
Occupancy Sensor
After Sensor installation
Occupancy sensor
Sensor Controlled
lightingGroup
Manual Controlled
Lighting group
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Slide Number 55
- Slide Number 56
- Slide Number 57
- Slide Number 58
- Slide Number 59
- Slide Number 60
- Slide Number 61
- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOW
Some tips for Energy ConservationIndustries
Source of data httpsbeeindiagovin
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
We have Energy Management Cell in our Plant Which initiates amp Manages all sorts of Energy Conservation measuresacross the Plant
Energy Management System
Mr Pramod ChoudharyPlant Head Lucknow
DH ndash Mr S B MattaPlant services
MR -Lko Works Dr SB Matta
DH ndash Mr V AgrawalPaint shop
DH ndash Mr S N VermaTCF
DH ndash Mr U TauheedBIW
DH ndash Mr R K SinghIBF
DH ndash Mr R K SinghAxle Shop
DH ndashMr G V JoshiPlanning
DH ndash Mr A ChhariaMaterials amp ADD
DH ndash Mr Ankush GourHR
DH ndash Mr R K SinghCV- CX
Team Structure ndash ISO 50001
DH ndash Divisional Head
ISO 50001 CertificateEnergy Policy
2013 2016 2019
IIT - Kanpur- CVBU LUCKNOW
ENERGY MANAGEMENT SYSTEM ndash An Overview
TOP MANAGEMENT COMMITMENT
STAFF COMMITMENT
ENERGY AUDIT
ACTION PLAN
MONITORING amp TARGET SETTING
REVIEW amp DEVELOP PROFILE
LONG PAY BACK PROJECTS
IIT - Kanpur- CVBU LUCKNOW
Preliminary Energy audit
Detailed Energy audit
Plant Coordinator
GO AHEAD
Energy savings discussion and presentation
GO AHEAD for Implementation
Energy savings monitoring and interim report to Energy Mgmt Cell
Acceptance of Proposal
Submission of Techno commercial proposal
Team formation
Energy Management CellEnCon Implementation Methodology
copy Copyright Confidential Tata Motors Limited
Innovation Digital Transformation Project Planning amp Operation
3D layout of Manufacturing Line Process flow for Digital transformation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
44
Collaboration
Training
Layout
Maintenance
2D drawings using Auto Cad 3D digital Factory
No single platform for discussions and decision making among various stake-holder
Virtual Factory encouraged different agencies to work in more collaborate manner
Traditional training methods such as classroom teaching using PPTs and OJT
3D Digital Work-Instruction videos along with Quality and Safety awareness
Maintenance based on Real time data
Preventive Maintenance Breakdown Maintenance based on schedule
Collection of information from individual machines and preparing reports
Connected Machines IPMS Mobile App online quality parameter monitoring
Traditional Method Digital Method
Technology Landscape ndash before and after implementation
Factory Set-up time reduced
Issue identified and resolved before physical installationconstruction
Better Visualization of the process enables operator to learn fast
Down-time of machines reduced thusimproving OEE
Better tracking and control quality and Mc parameters Faster information exchange
Transformation Impact
No Virtual Simulation Expensive Physicals only for very critical processes
Virtual Simulation of Critical Processes helped to identified Potential issues
Short Project Lead time Saving on rework cost and time
Simulation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
Sales~10 Increase throughbull Levelled Productionbull Improvement in Customer Experience
Cost
Customer Complaint
Project Time
Quality
Employee Engagement
~15 Reduction through bull Inventory Optimizationbull Warranty Cost reductionbull COPQ Reduction
~15 Reduction through bull Robust Process Designbull Resulting Reliability of Product
~25 Reduction throughbull Better Project
ManagementWith Use of Simulations Avoided Rework
~25 Improvement throughbull Connected Equipment
bull Avoiding Defect Passing
~10 Improvement throughbull Layout Improvementbull Process Automation
bull Ergonomics amp Safety improvement
Quantitative Benefits and Awarded in CII Digital Transformation Meet
Innovation Digital Transformation Project Planning amp Operation
IIT - Kanpur- CVBU LUCKNOW
Teamwork Employee involvement amp MonitoringDaily Consumption Report
Daily Energy Audit Report
Daily Shopwise Report
Daily Solar Generation Report
Hourly Consumption Report-Plant
Hourly Consumption Report-Shop
Monthly Energy Consumption Report
Awar
enes
sle
vel
2017-18
Reporting of energy consumption of the plant and
individual shops on fortnightly and monthly
basis
2018-19
H1 Reporting of entire plantrsquos energy consumption on daily basis
Daily Energy Audit Report (DEAR) circulated across the plant to minimize
energy wastageH2 Reporting of entire plantrsquos and shop-wise energy consumption on
daily basis
2019-20
H1 Reporting of shop-wise energy consumption started on hourly
basisH1 Reporting of working dayrsquos
and non-working dayrsquos consumption separately for
identification of areasprocesses 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
ENERGY CONSUMPTION 2019-20Figures in KWH
FACTORY Dec-19 Jan-20 Feb-20 Mar-20EASTERN COMPLEXBIWBIW Cab 30103 29885 42825 7097BIW Cowl 17657 16650 20104 7438FDV 0 0 0 0COMP 13691 12555 15960 4155BIW Office others 3459 2845 3824 599Distribution Losses 5737 5686 8235 3398Total 70648 67620 90949 22688PAINT SHOPPTED 276243 270240 58056 125761Paint 199896 182651 252332 55852COMP 69201 71042 191305 32740Paint others 33456 34243 71892 16336Distribution Losses 52586 55324 32462 45001Total 631382 613501 606048 275690TCFAssly 84210 101803 92831 23993Trim Assly 12468 17988 15117 4219FDV 0 0 0 0Compressor 38154 41387 42232 13080TCF officeothers 19581 18255 15958 13560Distribution Losses 14262 16490 17609 10428Total 168676 195923 183747 65281
Rear Axle and Line-45 17252 16260 4125 1830Logistics Centre 14904 25247 20629 9615RSO 5597 9370 8390 8445
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
GSM Based Smart Control of Shop Floor Ventilation System
Concerns in present method bull One operator has to travel around 1 Km for manually switching off all FDVs in western complex due to control panel given at that particular
location and hence there is electrical energy wastage of 5137 KWHmonth due to travel time of around 20 mins
Present process Moving to
switching off SB1 FDV
(0 mins)
Moving to switching off SB2 FDV
(5 mins)
Moving to switching off F Block FDV
(15 mins)
Moving to switching off
SB4 FDV(20 mins)
Moving to switching off SB3 FDV
(10 mins)
Blower amp Control panel
FDV Locations in Line 1
EnCon Projects
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
LCA Solution
bull Remote switching off FDVs by integrating off operation of FDV with GSMmodem from one location Also message will be delivered to user thatwhich FDV has been switched off (wireless switching off operation is donethrough GSM modem to avoid cable cost and laying of cable line)
Benefits amp Horizontal Scope 1Energy saving - Energy saving of 41096 KWHannum by providing remote switching off FDVs
2 Cost Saving - Recurring cost saving of Rs 328 lakhsannum3 Environment- Reduction in carbon footprint (reduction of 337 tonne of CO2annum by energy saving)
4 SMS escalation to user for information of FDV switch off5No laying out of wire is required as it is wireless communication with help of GSM modem6 Horizontal deployment of GSM based control for other process machines of assembly line 12 and 3
Solution Cost-Rs 328 Lacs for all 5 FDVs
Remote switching off SB3 FDV (Instantly)
Control panel- Remote Switching off SB1 FDV
Remote switching off SB2 FDV (Instantly)
Remote switching off F Block FDV (Instantly)
Remote switching off SB4 FDV (Instantly)
GSM Based Smart Control of Shop Floor Ventilation System
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Innovative Projects LED Migration Project
Evolution of Lighting
LEDification Project
No expenses in LED- migration
OPEX model Lights Installation Testing amp
Commissioning of LED lights 5 yrs extended warranty
Scope amp Savings
Phase wise LEDification project
Entire plant in phases Better control schemes Reduction in consumption by
50 (Minimum)
Optimal design amp execution
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
Why LED for lighting
LED the best lighting option today
Energy efficient higher Lumens per Watts
No Mercury-Environmental friendly
No IR amp UV emissions Reduced heat generation
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Conventional Lighting system After LED Migration
Power Consumption 14 KW Lux level 125~200
Energy Cons-Monthly 6300 KWH 50400 INR-Annually 75600 KWH 604800 INR
65 KW (Red 464) 250~450 (Inc 250 )
2925 KWH 23400 INR (Red 464 )
35100 KWH 280800 INR
65 KW (Red 464) 250~450 (Inc 250 )
1312 KWH 10400 INR (Red 782 ) 15744 KWH 125952 INR
Occupancy Sensor
After Sensor installation
Occupancy sensor
Sensor Controlled
lightingGroup
Manual Controlled
Lighting group
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Slide Number 55
- Slide Number 56
- Slide Number 57
- Slide Number 58
- Slide Number 59
- Slide Number 60
- Slide Number 61
- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOW
We are talking about hellip
An Overview of Tata Group amp Tata Motors
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
Way Forward
Energy Efficiency in TransportationEnergy Excellence Tata Motors
E R A S E Approach
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
We have Energy Management Cell in our Plant Which initiates amp Manages all sorts of Energy Conservation measuresacross the Plant
Energy Management System
Mr Pramod ChoudharyPlant Head Lucknow
DH ndash Mr S B MattaPlant services
MR -Lko Works Dr SB Matta
DH ndash Mr V AgrawalPaint shop
DH ndash Mr S N VermaTCF
DH ndash Mr U TauheedBIW
DH ndash Mr R K SinghIBF
DH ndash Mr R K SinghAxle Shop
DH ndashMr G V JoshiPlanning
DH ndash Mr A ChhariaMaterials amp ADD
DH ndash Mr Ankush GourHR
DH ndash Mr R K SinghCV- CX
Team Structure ndash ISO 50001
DH ndash Divisional Head
ISO 50001 CertificateEnergy Policy
2013 2016 2019
IIT - Kanpur- CVBU LUCKNOW
ENERGY MANAGEMENT SYSTEM ndash An Overview
TOP MANAGEMENT COMMITMENT
STAFF COMMITMENT
ENERGY AUDIT
ACTION PLAN
MONITORING amp TARGET SETTING
REVIEW amp DEVELOP PROFILE
LONG PAY BACK PROJECTS
IIT - Kanpur- CVBU LUCKNOW
Preliminary Energy audit
Detailed Energy audit
Plant Coordinator
GO AHEAD
Energy savings discussion and presentation
GO AHEAD for Implementation
Energy savings monitoring and interim report to Energy Mgmt Cell
Acceptance of Proposal
Submission of Techno commercial proposal
Team formation
Energy Management CellEnCon Implementation Methodology
copy Copyright Confidential Tata Motors Limited
Innovation Digital Transformation Project Planning amp Operation
3D layout of Manufacturing Line Process flow for Digital transformation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
44
Collaboration
Training
Layout
Maintenance
2D drawings using Auto Cad 3D digital Factory
No single platform for discussions and decision making among various stake-holder
Virtual Factory encouraged different agencies to work in more collaborate manner
Traditional training methods such as classroom teaching using PPTs and OJT
3D Digital Work-Instruction videos along with Quality and Safety awareness
Maintenance based on Real time data
Preventive Maintenance Breakdown Maintenance based on schedule
Collection of information from individual machines and preparing reports
Connected Machines IPMS Mobile App online quality parameter monitoring
Traditional Method Digital Method
Technology Landscape ndash before and after implementation
Factory Set-up time reduced
Issue identified and resolved before physical installationconstruction
Better Visualization of the process enables operator to learn fast
Down-time of machines reduced thusimproving OEE
Better tracking and control quality and Mc parameters Faster information exchange
Transformation Impact
No Virtual Simulation Expensive Physicals only for very critical processes
Virtual Simulation of Critical Processes helped to identified Potential issues
Short Project Lead time Saving on rework cost and time
Simulation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
Sales~10 Increase throughbull Levelled Productionbull Improvement in Customer Experience
Cost
Customer Complaint
Project Time
Quality
Employee Engagement
~15 Reduction through bull Inventory Optimizationbull Warranty Cost reductionbull COPQ Reduction
~15 Reduction through bull Robust Process Designbull Resulting Reliability of Product
~25 Reduction throughbull Better Project
ManagementWith Use of Simulations Avoided Rework
~25 Improvement throughbull Connected Equipment
bull Avoiding Defect Passing
~10 Improvement throughbull Layout Improvementbull Process Automation
bull Ergonomics amp Safety improvement
Quantitative Benefits and Awarded in CII Digital Transformation Meet
Innovation Digital Transformation Project Planning amp Operation
IIT - Kanpur- CVBU LUCKNOW
Teamwork Employee involvement amp MonitoringDaily Consumption Report
Daily Energy Audit Report
Daily Shopwise Report
Daily Solar Generation Report
Hourly Consumption Report-Plant
Hourly Consumption Report-Shop
Monthly Energy Consumption Report
Awar
enes
sle
vel
2017-18
Reporting of energy consumption of the plant and
individual shops on fortnightly and monthly
basis
2018-19
H1 Reporting of entire plantrsquos energy consumption on daily basis
Daily Energy Audit Report (DEAR) circulated across the plant to minimize
energy wastageH2 Reporting of entire plantrsquos and shop-wise energy consumption on
daily basis
2019-20
H1 Reporting of shop-wise energy consumption started on hourly
basisH1 Reporting of working dayrsquos
and non-working dayrsquos consumption separately for
identification of areasprocesses 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
ENERGY CONSUMPTION 2019-20Figures in KWH
FACTORY Dec-19 Jan-20 Feb-20 Mar-20EASTERN COMPLEXBIWBIW Cab 30103 29885 42825 7097BIW Cowl 17657 16650 20104 7438FDV 0 0 0 0COMP 13691 12555 15960 4155BIW Office others 3459 2845 3824 599Distribution Losses 5737 5686 8235 3398Total 70648 67620 90949 22688PAINT SHOPPTED 276243 270240 58056 125761Paint 199896 182651 252332 55852COMP 69201 71042 191305 32740Paint others 33456 34243 71892 16336Distribution Losses 52586 55324 32462 45001Total 631382 613501 606048 275690TCFAssly 84210 101803 92831 23993Trim Assly 12468 17988 15117 4219FDV 0 0 0 0Compressor 38154 41387 42232 13080TCF officeothers 19581 18255 15958 13560Distribution Losses 14262 16490 17609 10428Total 168676 195923 183747 65281
Rear Axle and Line-45 17252 16260 4125 1830Logistics Centre 14904 25247 20629 9615RSO 5597 9370 8390 8445
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
GSM Based Smart Control of Shop Floor Ventilation System
Concerns in present method bull One operator has to travel around 1 Km for manually switching off all FDVs in western complex due to control panel given at that particular
location and hence there is electrical energy wastage of 5137 KWHmonth due to travel time of around 20 mins
Present process Moving to
switching off SB1 FDV
(0 mins)
Moving to switching off SB2 FDV
(5 mins)
Moving to switching off F Block FDV
(15 mins)
Moving to switching off
SB4 FDV(20 mins)
Moving to switching off SB3 FDV
(10 mins)
Blower amp Control panel
FDV Locations in Line 1
EnCon Projects
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
LCA Solution
bull Remote switching off FDVs by integrating off operation of FDV with GSMmodem from one location Also message will be delivered to user thatwhich FDV has been switched off (wireless switching off operation is donethrough GSM modem to avoid cable cost and laying of cable line)
Benefits amp Horizontal Scope 1Energy saving - Energy saving of 41096 KWHannum by providing remote switching off FDVs
2 Cost Saving - Recurring cost saving of Rs 328 lakhsannum3 Environment- Reduction in carbon footprint (reduction of 337 tonne of CO2annum by energy saving)
4 SMS escalation to user for information of FDV switch off5No laying out of wire is required as it is wireless communication with help of GSM modem6 Horizontal deployment of GSM based control for other process machines of assembly line 12 and 3
Solution Cost-Rs 328 Lacs for all 5 FDVs
Remote switching off SB3 FDV (Instantly)
Control panel- Remote Switching off SB1 FDV
Remote switching off SB2 FDV (Instantly)
Remote switching off F Block FDV (Instantly)
Remote switching off SB4 FDV (Instantly)
GSM Based Smart Control of Shop Floor Ventilation System
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Innovative Projects LED Migration Project
Evolution of Lighting
LEDification Project
No expenses in LED- migration
OPEX model Lights Installation Testing amp
Commissioning of LED lights 5 yrs extended warranty
Scope amp Savings
Phase wise LEDification project
Entire plant in phases Better control schemes Reduction in consumption by
50 (Minimum)
Optimal design amp execution
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
Why LED for lighting
LED the best lighting option today
Energy efficient higher Lumens per Watts
No Mercury-Environmental friendly
No IR amp UV emissions Reduced heat generation
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Conventional Lighting system After LED Migration
Power Consumption 14 KW Lux level 125~200
Energy Cons-Monthly 6300 KWH 50400 INR-Annually 75600 KWH 604800 INR
65 KW (Red 464) 250~450 (Inc 250 )
2925 KWH 23400 INR (Red 464 )
35100 KWH 280800 INR
65 KW (Red 464) 250~450 (Inc 250 )
1312 KWH 10400 INR (Red 782 ) 15744 KWH 125952 INR
Occupancy Sensor
After Sensor installation
Occupancy sensor
Sensor Controlled
lightingGroup
Manual Controlled
Lighting group
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
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- Bio-Gas
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- Thank You
-
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
We have Energy Management Cell in our Plant Which initiates amp Manages all sorts of Energy Conservation measuresacross the Plant
Energy Management System
Mr Pramod ChoudharyPlant Head Lucknow
DH ndash Mr S B MattaPlant services
MR -Lko Works Dr SB Matta
DH ndash Mr V AgrawalPaint shop
DH ndash Mr S N VermaTCF
DH ndash Mr U TauheedBIW
DH ndash Mr R K SinghIBF
DH ndash Mr R K SinghAxle Shop
DH ndashMr G V JoshiPlanning
DH ndash Mr A ChhariaMaterials amp ADD
DH ndash Mr Ankush GourHR
DH ndash Mr R K SinghCV- CX
Team Structure ndash ISO 50001
DH ndash Divisional Head
ISO 50001 CertificateEnergy Policy
2013 2016 2019
IIT - Kanpur- CVBU LUCKNOW
ENERGY MANAGEMENT SYSTEM ndash An Overview
TOP MANAGEMENT COMMITMENT
STAFF COMMITMENT
ENERGY AUDIT
ACTION PLAN
MONITORING amp TARGET SETTING
REVIEW amp DEVELOP PROFILE
LONG PAY BACK PROJECTS
IIT - Kanpur- CVBU LUCKNOW
Preliminary Energy audit
Detailed Energy audit
Plant Coordinator
GO AHEAD
Energy savings discussion and presentation
GO AHEAD for Implementation
Energy savings monitoring and interim report to Energy Mgmt Cell
Acceptance of Proposal
Submission of Techno commercial proposal
Team formation
Energy Management CellEnCon Implementation Methodology
copy Copyright Confidential Tata Motors Limited
Innovation Digital Transformation Project Planning amp Operation
3D layout of Manufacturing Line Process flow for Digital transformation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
44
Collaboration
Training
Layout
Maintenance
2D drawings using Auto Cad 3D digital Factory
No single platform for discussions and decision making among various stake-holder
Virtual Factory encouraged different agencies to work in more collaborate manner
Traditional training methods such as classroom teaching using PPTs and OJT
3D Digital Work-Instruction videos along with Quality and Safety awareness
Maintenance based on Real time data
Preventive Maintenance Breakdown Maintenance based on schedule
Collection of information from individual machines and preparing reports
Connected Machines IPMS Mobile App online quality parameter monitoring
Traditional Method Digital Method
Technology Landscape ndash before and after implementation
Factory Set-up time reduced
Issue identified and resolved before physical installationconstruction
Better Visualization of the process enables operator to learn fast
Down-time of machines reduced thusimproving OEE
Better tracking and control quality and Mc parameters Faster information exchange
Transformation Impact
No Virtual Simulation Expensive Physicals only for very critical processes
Virtual Simulation of Critical Processes helped to identified Potential issues
Short Project Lead time Saving on rework cost and time
Simulation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
Sales~10 Increase throughbull Levelled Productionbull Improvement in Customer Experience
Cost
Customer Complaint
Project Time
Quality
Employee Engagement
~15 Reduction through bull Inventory Optimizationbull Warranty Cost reductionbull COPQ Reduction
~15 Reduction through bull Robust Process Designbull Resulting Reliability of Product
~25 Reduction throughbull Better Project
ManagementWith Use of Simulations Avoided Rework
~25 Improvement throughbull Connected Equipment
bull Avoiding Defect Passing
~10 Improvement throughbull Layout Improvementbull Process Automation
bull Ergonomics amp Safety improvement
Quantitative Benefits and Awarded in CII Digital Transformation Meet
Innovation Digital Transformation Project Planning amp Operation
IIT - Kanpur- CVBU LUCKNOW
Teamwork Employee involvement amp MonitoringDaily Consumption Report
Daily Energy Audit Report
Daily Shopwise Report
Daily Solar Generation Report
Hourly Consumption Report-Plant
Hourly Consumption Report-Shop
Monthly Energy Consumption Report
Awar
enes
sle
vel
2017-18
Reporting of energy consumption of the plant and
individual shops on fortnightly and monthly
basis
2018-19
H1 Reporting of entire plantrsquos energy consumption on daily basis
Daily Energy Audit Report (DEAR) circulated across the plant to minimize
energy wastageH2 Reporting of entire plantrsquos and shop-wise energy consumption on
daily basis
2019-20
H1 Reporting of shop-wise energy consumption started on hourly
basisH1 Reporting of working dayrsquos
and non-working dayrsquos consumption separately for
identification of areasprocesses 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
ENERGY CONSUMPTION 2019-20Figures in KWH
FACTORY Dec-19 Jan-20 Feb-20 Mar-20EASTERN COMPLEXBIWBIW Cab 30103 29885 42825 7097BIW Cowl 17657 16650 20104 7438FDV 0 0 0 0COMP 13691 12555 15960 4155BIW Office others 3459 2845 3824 599Distribution Losses 5737 5686 8235 3398Total 70648 67620 90949 22688PAINT SHOPPTED 276243 270240 58056 125761Paint 199896 182651 252332 55852COMP 69201 71042 191305 32740Paint others 33456 34243 71892 16336Distribution Losses 52586 55324 32462 45001Total 631382 613501 606048 275690TCFAssly 84210 101803 92831 23993Trim Assly 12468 17988 15117 4219FDV 0 0 0 0Compressor 38154 41387 42232 13080TCF officeothers 19581 18255 15958 13560Distribution Losses 14262 16490 17609 10428Total 168676 195923 183747 65281
Rear Axle and Line-45 17252 16260 4125 1830Logistics Centre 14904 25247 20629 9615RSO 5597 9370 8390 8445
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
GSM Based Smart Control of Shop Floor Ventilation System
Concerns in present method bull One operator has to travel around 1 Km for manually switching off all FDVs in western complex due to control panel given at that particular
location and hence there is electrical energy wastage of 5137 KWHmonth due to travel time of around 20 mins
Present process Moving to
switching off SB1 FDV
(0 mins)
Moving to switching off SB2 FDV
(5 mins)
Moving to switching off F Block FDV
(15 mins)
Moving to switching off
SB4 FDV(20 mins)
Moving to switching off SB3 FDV
(10 mins)
Blower amp Control panel
FDV Locations in Line 1
EnCon Projects
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
LCA Solution
bull Remote switching off FDVs by integrating off operation of FDV with GSMmodem from one location Also message will be delivered to user thatwhich FDV has been switched off (wireless switching off operation is donethrough GSM modem to avoid cable cost and laying of cable line)
Benefits amp Horizontal Scope 1Energy saving - Energy saving of 41096 KWHannum by providing remote switching off FDVs
2 Cost Saving - Recurring cost saving of Rs 328 lakhsannum3 Environment- Reduction in carbon footprint (reduction of 337 tonne of CO2annum by energy saving)
4 SMS escalation to user for information of FDV switch off5No laying out of wire is required as it is wireless communication with help of GSM modem6 Horizontal deployment of GSM based control for other process machines of assembly line 12 and 3
Solution Cost-Rs 328 Lacs for all 5 FDVs
Remote switching off SB3 FDV (Instantly)
Control panel- Remote Switching off SB1 FDV
Remote switching off SB2 FDV (Instantly)
Remote switching off F Block FDV (Instantly)
Remote switching off SB4 FDV (Instantly)
GSM Based Smart Control of Shop Floor Ventilation System
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Innovative Projects LED Migration Project
Evolution of Lighting
LEDification Project
No expenses in LED- migration
OPEX model Lights Installation Testing amp
Commissioning of LED lights 5 yrs extended warranty
Scope amp Savings
Phase wise LEDification project
Entire plant in phases Better control schemes Reduction in consumption by
50 (Minimum)
Optimal design amp execution
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
Why LED for lighting
LED the best lighting option today
Energy efficient higher Lumens per Watts
No Mercury-Environmental friendly
No IR amp UV emissions Reduced heat generation
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Conventional Lighting system After LED Migration
Power Consumption 14 KW Lux level 125~200
Energy Cons-Monthly 6300 KWH 50400 INR-Annually 75600 KWH 604800 INR
65 KW (Red 464) 250~450 (Inc 250 )
2925 KWH 23400 INR (Red 464 )
35100 KWH 280800 INR
65 KW (Red 464) 250~450 (Inc 250 )
1312 KWH 10400 INR (Red 782 ) 15744 KWH 125952 INR
Occupancy Sensor
After Sensor installation
Occupancy sensor
Sensor Controlled
lightingGroup
Manual Controlled
Lighting group
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
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- Slide Number 12
- Slide Number 13
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- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
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- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
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- Slide Number 54
- Slide Number 55
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- Slide Number 57
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- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOW
ENERGY MANAGEMENT SYSTEM ndash An Overview
TOP MANAGEMENT COMMITMENT
STAFF COMMITMENT
ENERGY AUDIT
ACTION PLAN
MONITORING amp TARGET SETTING
REVIEW amp DEVELOP PROFILE
LONG PAY BACK PROJECTS
IIT - Kanpur- CVBU LUCKNOW
Preliminary Energy audit
Detailed Energy audit
Plant Coordinator
GO AHEAD
Energy savings discussion and presentation
GO AHEAD for Implementation
Energy savings monitoring and interim report to Energy Mgmt Cell
Acceptance of Proposal
Submission of Techno commercial proposal
Team formation
Energy Management CellEnCon Implementation Methodology
copy Copyright Confidential Tata Motors Limited
Innovation Digital Transformation Project Planning amp Operation
3D layout of Manufacturing Line Process flow for Digital transformation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
44
Collaboration
Training
Layout
Maintenance
2D drawings using Auto Cad 3D digital Factory
No single platform for discussions and decision making among various stake-holder
Virtual Factory encouraged different agencies to work in more collaborate manner
Traditional training methods such as classroom teaching using PPTs and OJT
3D Digital Work-Instruction videos along with Quality and Safety awareness
Maintenance based on Real time data
Preventive Maintenance Breakdown Maintenance based on schedule
Collection of information from individual machines and preparing reports
Connected Machines IPMS Mobile App online quality parameter monitoring
Traditional Method Digital Method
Technology Landscape ndash before and after implementation
Factory Set-up time reduced
Issue identified and resolved before physical installationconstruction
Better Visualization of the process enables operator to learn fast
Down-time of machines reduced thusimproving OEE
Better tracking and control quality and Mc parameters Faster information exchange
Transformation Impact
No Virtual Simulation Expensive Physicals only for very critical processes
Virtual Simulation of Critical Processes helped to identified Potential issues
Short Project Lead time Saving on rework cost and time
Simulation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
Sales~10 Increase throughbull Levelled Productionbull Improvement in Customer Experience
Cost
Customer Complaint
Project Time
Quality
Employee Engagement
~15 Reduction through bull Inventory Optimizationbull Warranty Cost reductionbull COPQ Reduction
~15 Reduction through bull Robust Process Designbull Resulting Reliability of Product
~25 Reduction throughbull Better Project
ManagementWith Use of Simulations Avoided Rework
~25 Improvement throughbull Connected Equipment
bull Avoiding Defect Passing
~10 Improvement throughbull Layout Improvementbull Process Automation
bull Ergonomics amp Safety improvement
Quantitative Benefits and Awarded in CII Digital Transformation Meet
Innovation Digital Transformation Project Planning amp Operation
IIT - Kanpur- CVBU LUCKNOW
Teamwork Employee involvement amp MonitoringDaily Consumption Report
Daily Energy Audit Report
Daily Shopwise Report
Daily Solar Generation Report
Hourly Consumption Report-Plant
Hourly Consumption Report-Shop
Monthly Energy Consumption Report
Awar
enes
sle
vel
2017-18
Reporting of energy consumption of the plant and
individual shops on fortnightly and monthly
basis
2018-19
H1 Reporting of entire plantrsquos energy consumption on daily basis
Daily Energy Audit Report (DEAR) circulated across the plant to minimize
energy wastageH2 Reporting of entire plantrsquos and shop-wise energy consumption on
daily basis
2019-20
H1 Reporting of shop-wise energy consumption started on hourly
basisH1 Reporting of working dayrsquos
and non-working dayrsquos consumption separately for
identification of areasprocesses 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
ENERGY CONSUMPTION 2019-20Figures in KWH
FACTORY Dec-19 Jan-20 Feb-20 Mar-20EASTERN COMPLEXBIWBIW Cab 30103 29885 42825 7097BIW Cowl 17657 16650 20104 7438FDV 0 0 0 0COMP 13691 12555 15960 4155BIW Office others 3459 2845 3824 599Distribution Losses 5737 5686 8235 3398Total 70648 67620 90949 22688PAINT SHOPPTED 276243 270240 58056 125761Paint 199896 182651 252332 55852COMP 69201 71042 191305 32740Paint others 33456 34243 71892 16336Distribution Losses 52586 55324 32462 45001Total 631382 613501 606048 275690TCFAssly 84210 101803 92831 23993Trim Assly 12468 17988 15117 4219FDV 0 0 0 0Compressor 38154 41387 42232 13080TCF officeothers 19581 18255 15958 13560Distribution Losses 14262 16490 17609 10428Total 168676 195923 183747 65281
Rear Axle and Line-45 17252 16260 4125 1830Logistics Centre 14904 25247 20629 9615RSO 5597 9370 8390 8445
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
GSM Based Smart Control of Shop Floor Ventilation System
Concerns in present method bull One operator has to travel around 1 Km for manually switching off all FDVs in western complex due to control panel given at that particular
location and hence there is electrical energy wastage of 5137 KWHmonth due to travel time of around 20 mins
Present process Moving to
switching off SB1 FDV
(0 mins)
Moving to switching off SB2 FDV
(5 mins)
Moving to switching off F Block FDV
(15 mins)
Moving to switching off
SB4 FDV(20 mins)
Moving to switching off SB3 FDV
(10 mins)
Blower amp Control panel
FDV Locations in Line 1
EnCon Projects
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
LCA Solution
bull Remote switching off FDVs by integrating off operation of FDV with GSMmodem from one location Also message will be delivered to user thatwhich FDV has been switched off (wireless switching off operation is donethrough GSM modem to avoid cable cost and laying of cable line)
Benefits amp Horizontal Scope 1Energy saving - Energy saving of 41096 KWHannum by providing remote switching off FDVs
2 Cost Saving - Recurring cost saving of Rs 328 lakhsannum3 Environment- Reduction in carbon footprint (reduction of 337 tonne of CO2annum by energy saving)
4 SMS escalation to user for information of FDV switch off5No laying out of wire is required as it is wireless communication with help of GSM modem6 Horizontal deployment of GSM based control for other process machines of assembly line 12 and 3
Solution Cost-Rs 328 Lacs for all 5 FDVs
Remote switching off SB3 FDV (Instantly)
Control panel- Remote Switching off SB1 FDV
Remote switching off SB2 FDV (Instantly)
Remote switching off F Block FDV (Instantly)
Remote switching off SB4 FDV (Instantly)
GSM Based Smart Control of Shop Floor Ventilation System
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Innovative Projects LED Migration Project
Evolution of Lighting
LEDification Project
No expenses in LED- migration
OPEX model Lights Installation Testing amp
Commissioning of LED lights 5 yrs extended warranty
Scope amp Savings
Phase wise LEDification project
Entire plant in phases Better control schemes Reduction in consumption by
50 (Minimum)
Optimal design amp execution
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
Why LED for lighting
LED the best lighting option today
Energy efficient higher Lumens per Watts
No Mercury-Environmental friendly
No IR amp UV emissions Reduced heat generation
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Conventional Lighting system After LED Migration
Power Consumption 14 KW Lux level 125~200
Energy Cons-Monthly 6300 KWH 50400 INR-Annually 75600 KWH 604800 INR
65 KW (Red 464) 250~450 (Inc 250 )
2925 KWH 23400 INR (Red 464 )
35100 KWH 280800 INR
65 KW (Red 464) 250~450 (Inc 250 )
1312 KWH 10400 INR (Red 782 ) 15744 KWH 125952 INR
Occupancy Sensor
After Sensor installation
Occupancy sensor
Sensor Controlled
lightingGroup
Manual Controlled
Lighting group
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Slide Number 55
- Slide Number 56
- Slide Number 57
- Slide Number 58
- Slide Number 59
- Slide Number 60
- Slide Number 61
- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOW
Preliminary Energy audit
Detailed Energy audit
Plant Coordinator
GO AHEAD
Energy savings discussion and presentation
GO AHEAD for Implementation
Energy savings monitoring and interim report to Energy Mgmt Cell
Acceptance of Proposal
Submission of Techno commercial proposal
Team formation
Energy Management CellEnCon Implementation Methodology
copy Copyright Confidential Tata Motors Limited
Innovation Digital Transformation Project Planning amp Operation
3D layout of Manufacturing Line Process flow for Digital transformation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
44
Collaboration
Training
Layout
Maintenance
2D drawings using Auto Cad 3D digital Factory
No single platform for discussions and decision making among various stake-holder
Virtual Factory encouraged different agencies to work in more collaborate manner
Traditional training methods such as classroom teaching using PPTs and OJT
3D Digital Work-Instruction videos along with Quality and Safety awareness
Maintenance based on Real time data
Preventive Maintenance Breakdown Maintenance based on schedule
Collection of information from individual machines and preparing reports
Connected Machines IPMS Mobile App online quality parameter monitoring
Traditional Method Digital Method
Technology Landscape ndash before and after implementation
Factory Set-up time reduced
Issue identified and resolved before physical installationconstruction
Better Visualization of the process enables operator to learn fast
Down-time of machines reduced thusimproving OEE
Better tracking and control quality and Mc parameters Faster information exchange
Transformation Impact
No Virtual Simulation Expensive Physicals only for very critical processes
Virtual Simulation of Critical Processes helped to identified Potential issues
Short Project Lead time Saving on rework cost and time
Simulation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
Sales~10 Increase throughbull Levelled Productionbull Improvement in Customer Experience
Cost
Customer Complaint
Project Time
Quality
Employee Engagement
~15 Reduction through bull Inventory Optimizationbull Warranty Cost reductionbull COPQ Reduction
~15 Reduction through bull Robust Process Designbull Resulting Reliability of Product
~25 Reduction throughbull Better Project
ManagementWith Use of Simulations Avoided Rework
~25 Improvement throughbull Connected Equipment
bull Avoiding Defect Passing
~10 Improvement throughbull Layout Improvementbull Process Automation
bull Ergonomics amp Safety improvement
Quantitative Benefits and Awarded in CII Digital Transformation Meet
Innovation Digital Transformation Project Planning amp Operation
IIT - Kanpur- CVBU LUCKNOW
Teamwork Employee involvement amp MonitoringDaily Consumption Report
Daily Energy Audit Report
Daily Shopwise Report
Daily Solar Generation Report
Hourly Consumption Report-Plant
Hourly Consumption Report-Shop
Monthly Energy Consumption Report
Awar
enes
sle
vel
2017-18
Reporting of energy consumption of the plant and
individual shops on fortnightly and monthly
basis
2018-19
H1 Reporting of entire plantrsquos energy consumption on daily basis
Daily Energy Audit Report (DEAR) circulated across the plant to minimize
energy wastageH2 Reporting of entire plantrsquos and shop-wise energy consumption on
daily basis
2019-20
H1 Reporting of shop-wise energy consumption started on hourly
basisH1 Reporting of working dayrsquos
and non-working dayrsquos consumption separately for
identification of areasprocesses 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
ENERGY CONSUMPTION 2019-20Figures in KWH
FACTORY Dec-19 Jan-20 Feb-20 Mar-20EASTERN COMPLEXBIWBIW Cab 30103 29885 42825 7097BIW Cowl 17657 16650 20104 7438FDV 0 0 0 0COMP 13691 12555 15960 4155BIW Office others 3459 2845 3824 599Distribution Losses 5737 5686 8235 3398Total 70648 67620 90949 22688PAINT SHOPPTED 276243 270240 58056 125761Paint 199896 182651 252332 55852COMP 69201 71042 191305 32740Paint others 33456 34243 71892 16336Distribution Losses 52586 55324 32462 45001Total 631382 613501 606048 275690TCFAssly 84210 101803 92831 23993Trim Assly 12468 17988 15117 4219FDV 0 0 0 0Compressor 38154 41387 42232 13080TCF officeothers 19581 18255 15958 13560Distribution Losses 14262 16490 17609 10428Total 168676 195923 183747 65281
Rear Axle and Line-45 17252 16260 4125 1830Logistics Centre 14904 25247 20629 9615RSO 5597 9370 8390 8445
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
GSM Based Smart Control of Shop Floor Ventilation System
Concerns in present method bull One operator has to travel around 1 Km for manually switching off all FDVs in western complex due to control panel given at that particular
location and hence there is electrical energy wastage of 5137 KWHmonth due to travel time of around 20 mins
Present process Moving to
switching off SB1 FDV
(0 mins)
Moving to switching off SB2 FDV
(5 mins)
Moving to switching off F Block FDV
(15 mins)
Moving to switching off
SB4 FDV(20 mins)
Moving to switching off SB3 FDV
(10 mins)
Blower amp Control panel
FDV Locations in Line 1
EnCon Projects
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
LCA Solution
bull Remote switching off FDVs by integrating off operation of FDV with GSMmodem from one location Also message will be delivered to user thatwhich FDV has been switched off (wireless switching off operation is donethrough GSM modem to avoid cable cost and laying of cable line)
Benefits amp Horizontal Scope 1Energy saving - Energy saving of 41096 KWHannum by providing remote switching off FDVs
2 Cost Saving - Recurring cost saving of Rs 328 lakhsannum3 Environment- Reduction in carbon footprint (reduction of 337 tonne of CO2annum by energy saving)
4 SMS escalation to user for information of FDV switch off5No laying out of wire is required as it is wireless communication with help of GSM modem6 Horizontal deployment of GSM based control for other process machines of assembly line 12 and 3
Solution Cost-Rs 328 Lacs for all 5 FDVs
Remote switching off SB3 FDV (Instantly)
Control panel- Remote Switching off SB1 FDV
Remote switching off SB2 FDV (Instantly)
Remote switching off F Block FDV (Instantly)
Remote switching off SB4 FDV (Instantly)
GSM Based Smart Control of Shop Floor Ventilation System
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Innovative Projects LED Migration Project
Evolution of Lighting
LEDification Project
No expenses in LED- migration
OPEX model Lights Installation Testing amp
Commissioning of LED lights 5 yrs extended warranty
Scope amp Savings
Phase wise LEDification project
Entire plant in phases Better control schemes Reduction in consumption by
50 (Minimum)
Optimal design amp execution
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
Why LED for lighting
LED the best lighting option today
Energy efficient higher Lumens per Watts
No Mercury-Environmental friendly
No IR amp UV emissions Reduced heat generation
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Conventional Lighting system After LED Migration
Power Consumption 14 KW Lux level 125~200
Energy Cons-Monthly 6300 KWH 50400 INR-Annually 75600 KWH 604800 INR
65 KW (Red 464) 250~450 (Inc 250 )
2925 KWH 23400 INR (Red 464 )
35100 KWH 280800 INR
65 KW (Red 464) 250~450 (Inc 250 )
1312 KWH 10400 INR (Red 782 ) 15744 KWH 125952 INR
Occupancy Sensor
After Sensor installation
Occupancy sensor
Sensor Controlled
lightingGroup
Manual Controlled
Lighting group
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Slide Number 55
- Slide Number 56
- Slide Number 57
- Slide Number 58
- Slide Number 59
- Slide Number 60
- Slide Number 61
- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
copy Copyright Confidential Tata Motors Limited
Innovation Digital Transformation Project Planning amp Operation
3D layout of Manufacturing Line Process flow for Digital transformation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
44
Collaboration
Training
Layout
Maintenance
2D drawings using Auto Cad 3D digital Factory
No single platform for discussions and decision making among various stake-holder
Virtual Factory encouraged different agencies to work in more collaborate manner
Traditional training methods such as classroom teaching using PPTs and OJT
3D Digital Work-Instruction videos along with Quality and Safety awareness
Maintenance based on Real time data
Preventive Maintenance Breakdown Maintenance based on schedule
Collection of information from individual machines and preparing reports
Connected Machines IPMS Mobile App online quality parameter monitoring
Traditional Method Digital Method
Technology Landscape ndash before and after implementation
Factory Set-up time reduced
Issue identified and resolved before physical installationconstruction
Better Visualization of the process enables operator to learn fast
Down-time of machines reduced thusimproving OEE
Better tracking and control quality and Mc parameters Faster information exchange
Transformation Impact
No Virtual Simulation Expensive Physicals only for very critical processes
Virtual Simulation of Critical Processes helped to identified Potential issues
Short Project Lead time Saving on rework cost and time
Simulation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
Sales~10 Increase throughbull Levelled Productionbull Improvement in Customer Experience
Cost
Customer Complaint
Project Time
Quality
Employee Engagement
~15 Reduction through bull Inventory Optimizationbull Warranty Cost reductionbull COPQ Reduction
~15 Reduction through bull Robust Process Designbull Resulting Reliability of Product
~25 Reduction throughbull Better Project
ManagementWith Use of Simulations Avoided Rework
~25 Improvement throughbull Connected Equipment
bull Avoiding Defect Passing
~10 Improvement throughbull Layout Improvementbull Process Automation
bull Ergonomics amp Safety improvement
Quantitative Benefits and Awarded in CII Digital Transformation Meet
Innovation Digital Transformation Project Planning amp Operation
IIT - Kanpur- CVBU LUCKNOW
Teamwork Employee involvement amp MonitoringDaily Consumption Report
Daily Energy Audit Report
Daily Shopwise Report
Daily Solar Generation Report
Hourly Consumption Report-Plant
Hourly Consumption Report-Shop
Monthly Energy Consumption Report
Awar
enes
sle
vel
2017-18
Reporting of energy consumption of the plant and
individual shops on fortnightly and monthly
basis
2018-19
H1 Reporting of entire plantrsquos energy consumption on daily basis
Daily Energy Audit Report (DEAR) circulated across the plant to minimize
energy wastageH2 Reporting of entire plantrsquos and shop-wise energy consumption on
daily basis
2019-20
H1 Reporting of shop-wise energy consumption started on hourly
basisH1 Reporting of working dayrsquos
and non-working dayrsquos consumption separately for
identification of areasprocesses 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
ENERGY CONSUMPTION 2019-20Figures in KWH
FACTORY Dec-19 Jan-20 Feb-20 Mar-20EASTERN COMPLEXBIWBIW Cab 30103 29885 42825 7097BIW Cowl 17657 16650 20104 7438FDV 0 0 0 0COMP 13691 12555 15960 4155BIW Office others 3459 2845 3824 599Distribution Losses 5737 5686 8235 3398Total 70648 67620 90949 22688PAINT SHOPPTED 276243 270240 58056 125761Paint 199896 182651 252332 55852COMP 69201 71042 191305 32740Paint others 33456 34243 71892 16336Distribution Losses 52586 55324 32462 45001Total 631382 613501 606048 275690TCFAssly 84210 101803 92831 23993Trim Assly 12468 17988 15117 4219FDV 0 0 0 0Compressor 38154 41387 42232 13080TCF officeothers 19581 18255 15958 13560Distribution Losses 14262 16490 17609 10428Total 168676 195923 183747 65281
Rear Axle and Line-45 17252 16260 4125 1830Logistics Centre 14904 25247 20629 9615RSO 5597 9370 8390 8445
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
GSM Based Smart Control of Shop Floor Ventilation System
Concerns in present method bull One operator has to travel around 1 Km for manually switching off all FDVs in western complex due to control panel given at that particular
location and hence there is electrical energy wastage of 5137 KWHmonth due to travel time of around 20 mins
Present process Moving to
switching off SB1 FDV
(0 mins)
Moving to switching off SB2 FDV
(5 mins)
Moving to switching off F Block FDV
(15 mins)
Moving to switching off
SB4 FDV(20 mins)
Moving to switching off SB3 FDV
(10 mins)
Blower amp Control panel
FDV Locations in Line 1
EnCon Projects
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
LCA Solution
bull Remote switching off FDVs by integrating off operation of FDV with GSMmodem from one location Also message will be delivered to user thatwhich FDV has been switched off (wireless switching off operation is donethrough GSM modem to avoid cable cost and laying of cable line)
Benefits amp Horizontal Scope 1Energy saving - Energy saving of 41096 KWHannum by providing remote switching off FDVs
2 Cost Saving - Recurring cost saving of Rs 328 lakhsannum3 Environment- Reduction in carbon footprint (reduction of 337 tonne of CO2annum by energy saving)
4 SMS escalation to user for information of FDV switch off5No laying out of wire is required as it is wireless communication with help of GSM modem6 Horizontal deployment of GSM based control for other process machines of assembly line 12 and 3
Solution Cost-Rs 328 Lacs for all 5 FDVs
Remote switching off SB3 FDV (Instantly)
Control panel- Remote Switching off SB1 FDV
Remote switching off SB2 FDV (Instantly)
Remote switching off F Block FDV (Instantly)
Remote switching off SB4 FDV (Instantly)
GSM Based Smart Control of Shop Floor Ventilation System
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Innovative Projects LED Migration Project
Evolution of Lighting
LEDification Project
No expenses in LED- migration
OPEX model Lights Installation Testing amp
Commissioning of LED lights 5 yrs extended warranty
Scope amp Savings
Phase wise LEDification project
Entire plant in phases Better control schemes Reduction in consumption by
50 (Minimum)
Optimal design amp execution
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
Why LED for lighting
LED the best lighting option today
Energy efficient higher Lumens per Watts
No Mercury-Environmental friendly
No IR amp UV emissions Reduced heat generation
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Conventional Lighting system After LED Migration
Power Consumption 14 KW Lux level 125~200
Energy Cons-Monthly 6300 KWH 50400 INR-Annually 75600 KWH 604800 INR
65 KW (Red 464) 250~450 (Inc 250 )
2925 KWH 23400 INR (Red 464 )
35100 KWH 280800 INR
65 KW (Red 464) 250~450 (Inc 250 )
1312 KWH 10400 INR (Red 782 ) 15744 KWH 125952 INR
Occupancy Sensor
After Sensor installation
Occupancy sensor
Sensor Controlled
lightingGroup
Manual Controlled
Lighting group
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
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- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
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- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
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- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
copy Copyright Confidential Tata Motors Limited
44
Collaboration
Training
Layout
Maintenance
2D drawings using Auto Cad 3D digital Factory
No single platform for discussions and decision making among various stake-holder
Virtual Factory encouraged different agencies to work in more collaborate manner
Traditional training methods such as classroom teaching using PPTs and OJT
3D Digital Work-Instruction videos along with Quality and Safety awareness
Maintenance based on Real time data
Preventive Maintenance Breakdown Maintenance based on schedule
Collection of information from individual machines and preparing reports
Connected Machines IPMS Mobile App online quality parameter monitoring
Traditional Method Digital Method
Technology Landscape ndash before and after implementation
Factory Set-up time reduced
Issue identified and resolved before physical installationconstruction
Better Visualization of the process enables operator to learn fast
Down-time of machines reduced thusimproving OEE
Better tracking and control quality and Mc parameters Faster information exchange
Transformation Impact
No Virtual Simulation Expensive Physicals only for very critical processes
Virtual Simulation of Critical Processes helped to identified Potential issues
Short Project Lead time Saving on rework cost and time
Simulation
Innovation Digital Transformation Project Planning amp Operation
copy Copyright Confidential Tata Motors Limited
Sales~10 Increase throughbull Levelled Productionbull Improvement in Customer Experience
Cost
Customer Complaint
Project Time
Quality
Employee Engagement
~15 Reduction through bull Inventory Optimizationbull Warranty Cost reductionbull COPQ Reduction
~15 Reduction through bull Robust Process Designbull Resulting Reliability of Product
~25 Reduction throughbull Better Project
ManagementWith Use of Simulations Avoided Rework
~25 Improvement throughbull Connected Equipment
bull Avoiding Defect Passing
~10 Improvement throughbull Layout Improvementbull Process Automation
bull Ergonomics amp Safety improvement
Quantitative Benefits and Awarded in CII Digital Transformation Meet
Innovation Digital Transformation Project Planning amp Operation
IIT - Kanpur- CVBU LUCKNOW
Teamwork Employee involvement amp MonitoringDaily Consumption Report
Daily Energy Audit Report
Daily Shopwise Report
Daily Solar Generation Report
Hourly Consumption Report-Plant
Hourly Consumption Report-Shop
Monthly Energy Consumption Report
Awar
enes
sle
vel
2017-18
Reporting of energy consumption of the plant and
individual shops on fortnightly and monthly
basis
2018-19
H1 Reporting of entire plantrsquos energy consumption on daily basis
Daily Energy Audit Report (DEAR) circulated across the plant to minimize
energy wastageH2 Reporting of entire plantrsquos and shop-wise energy consumption on
daily basis
2019-20
H1 Reporting of shop-wise energy consumption started on hourly
basisH1 Reporting of working dayrsquos
and non-working dayrsquos consumption separately for
identification of areasprocesses 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
ENERGY CONSUMPTION 2019-20Figures in KWH
FACTORY Dec-19 Jan-20 Feb-20 Mar-20EASTERN COMPLEXBIWBIW Cab 30103 29885 42825 7097BIW Cowl 17657 16650 20104 7438FDV 0 0 0 0COMP 13691 12555 15960 4155BIW Office others 3459 2845 3824 599Distribution Losses 5737 5686 8235 3398Total 70648 67620 90949 22688PAINT SHOPPTED 276243 270240 58056 125761Paint 199896 182651 252332 55852COMP 69201 71042 191305 32740Paint others 33456 34243 71892 16336Distribution Losses 52586 55324 32462 45001Total 631382 613501 606048 275690TCFAssly 84210 101803 92831 23993Trim Assly 12468 17988 15117 4219FDV 0 0 0 0Compressor 38154 41387 42232 13080TCF officeothers 19581 18255 15958 13560Distribution Losses 14262 16490 17609 10428Total 168676 195923 183747 65281
Rear Axle and Line-45 17252 16260 4125 1830Logistics Centre 14904 25247 20629 9615RSO 5597 9370 8390 8445
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
GSM Based Smart Control of Shop Floor Ventilation System
Concerns in present method bull One operator has to travel around 1 Km for manually switching off all FDVs in western complex due to control panel given at that particular
location and hence there is electrical energy wastage of 5137 KWHmonth due to travel time of around 20 mins
Present process Moving to
switching off SB1 FDV
(0 mins)
Moving to switching off SB2 FDV
(5 mins)
Moving to switching off F Block FDV
(15 mins)
Moving to switching off
SB4 FDV(20 mins)
Moving to switching off SB3 FDV
(10 mins)
Blower amp Control panel
FDV Locations in Line 1
EnCon Projects
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
LCA Solution
bull Remote switching off FDVs by integrating off operation of FDV with GSMmodem from one location Also message will be delivered to user thatwhich FDV has been switched off (wireless switching off operation is donethrough GSM modem to avoid cable cost and laying of cable line)
Benefits amp Horizontal Scope 1Energy saving - Energy saving of 41096 KWHannum by providing remote switching off FDVs
2 Cost Saving - Recurring cost saving of Rs 328 lakhsannum3 Environment- Reduction in carbon footprint (reduction of 337 tonne of CO2annum by energy saving)
4 SMS escalation to user for information of FDV switch off5No laying out of wire is required as it is wireless communication with help of GSM modem6 Horizontal deployment of GSM based control for other process machines of assembly line 12 and 3
Solution Cost-Rs 328 Lacs for all 5 FDVs
Remote switching off SB3 FDV (Instantly)
Control panel- Remote Switching off SB1 FDV
Remote switching off SB2 FDV (Instantly)
Remote switching off F Block FDV (Instantly)
Remote switching off SB4 FDV (Instantly)
GSM Based Smart Control of Shop Floor Ventilation System
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Innovative Projects LED Migration Project
Evolution of Lighting
LEDification Project
No expenses in LED- migration
OPEX model Lights Installation Testing amp
Commissioning of LED lights 5 yrs extended warranty
Scope amp Savings
Phase wise LEDification project
Entire plant in phases Better control schemes Reduction in consumption by
50 (Minimum)
Optimal design amp execution
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
Why LED for lighting
LED the best lighting option today
Energy efficient higher Lumens per Watts
No Mercury-Environmental friendly
No IR amp UV emissions Reduced heat generation
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Conventional Lighting system After LED Migration
Power Consumption 14 KW Lux level 125~200
Energy Cons-Monthly 6300 KWH 50400 INR-Annually 75600 KWH 604800 INR
65 KW (Red 464) 250~450 (Inc 250 )
2925 KWH 23400 INR (Red 464 )
35100 KWH 280800 INR
65 KW (Red 464) 250~450 (Inc 250 )
1312 KWH 10400 INR (Red 782 ) 15744 KWH 125952 INR
Occupancy Sensor
After Sensor installation
Occupancy sensor
Sensor Controlled
lightingGroup
Manual Controlled
Lighting group
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Slide Number 55
- Slide Number 56
- Slide Number 57
- Slide Number 58
- Slide Number 59
- Slide Number 60
- Slide Number 61
- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
copy Copyright Confidential Tata Motors Limited
Sales~10 Increase throughbull Levelled Productionbull Improvement in Customer Experience
Cost
Customer Complaint
Project Time
Quality
Employee Engagement
~15 Reduction through bull Inventory Optimizationbull Warranty Cost reductionbull COPQ Reduction
~15 Reduction through bull Robust Process Designbull Resulting Reliability of Product
~25 Reduction throughbull Better Project
ManagementWith Use of Simulations Avoided Rework
~25 Improvement throughbull Connected Equipment
bull Avoiding Defect Passing
~10 Improvement throughbull Layout Improvementbull Process Automation
bull Ergonomics amp Safety improvement
Quantitative Benefits and Awarded in CII Digital Transformation Meet
Innovation Digital Transformation Project Planning amp Operation
IIT - Kanpur- CVBU LUCKNOW
Teamwork Employee involvement amp MonitoringDaily Consumption Report
Daily Energy Audit Report
Daily Shopwise Report
Daily Solar Generation Report
Hourly Consumption Report-Plant
Hourly Consumption Report-Shop
Monthly Energy Consumption Report
Awar
enes
sle
vel
2017-18
Reporting of energy consumption of the plant and
individual shops on fortnightly and monthly
basis
2018-19
H1 Reporting of entire plantrsquos energy consumption on daily basis
Daily Energy Audit Report (DEAR) circulated across the plant to minimize
energy wastageH2 Reporting of entire plantrsquos and shop-wise energy consumption on
daily basis
2019-20
H1 Reporting of shop-wise energy consumption started on hourly
basisH1 Reporting of working dayrsquos
and non-working dayrsquos consumption separately for
identification of areasprocesses 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
ENERGY CONSUMPTION 2019-20Figures in KWH
FACTORY Dec-19 Jan-20 Feb-20 Mar-20EASTERN COMPLEXBIWBIW Cab 30103 29885 42825 7097BIW Cowl 17657 16650 20104 7438FDV 0 0 0 0COMP 13691 12555 15960 4155BIW Office others 3459 2845 3824 599Distribution Losses 5737 5686 8235 3398Total 70648 67620 90949 22688PAINT SHOPPTED 276243 270240 58056 125761Paint 199896 182651 252332 55852COMP 69201 71042 191305 32740Paint others 33456 34243 71892 16336Distribution Losses 52586 55324 32462 45001Total 631382 613501 606048 275690TCFAssly 84210 101803 92831 23993Trim Assly 12468 17988 15117 4219FDV 0 0 0 0Compressor 38154 41387 42232 13080TCF officeothers 19581 18255 15958 13560Distribution Losses 14262 16490 17609 10428Total 168676 195923 183747 65281
Rear Axle and Line-45 17252 16260 4125 1830Logistics Centre 14904 25247 20629 9615RSO 5597 9370 8390 8445
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
GSM Based Smart Control of Shop Floor Ventilation System
Concerns in present method bull One operator has to travel around 1 Km for manually switching off all FDVs in western complex due to control panel given at that particular
location and hence there is electrical energy wastage of 5137 KWHmonth due to travel time of around 20 mins
Present process Moving to
switching off SB1 FDV
(0 mins)
Moving to switching off SB2 FDV
(5 mins)
Moving to switching off F Block FDV
(15 mins)
Moving to switching off
SB4 FDV(20 mins)
Moving to switching off SB3 FDV
(10 mins)
Blower amp Control panel
FDV Locations in Line 1
EnCon Projects
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
LCA Solution
bull Remote switching off FDVs by integrating off operation of FDV with GSMmodem from one location Also message will be delivered to user thatwhich FDV has been switched off (wireless switching off operation is donethrough GSM modem to avoid cable cost and laying of cable line)
Benefits amp Horizontal Scope 1Energy saving - Energy saving of 41096 KWHannum by providing remote switching off FDVs
2 Cost Saving - Recurring cost saving of Rs 328 lakhsannum3 Environment- Reduction in carbon footprint (reduction of 337 tonne of CO2annum by energy saving)
4 SMS escalation to user for information of FDV switch off5No laying out of wire is required as it is wireless communication with help of GSM modem6 Horizontal deployment of GSM based control for other process machines of assembly line 12 and 3
Solution Cost-Rs 328 Lacs for all 5 FDVs
Remote switching off SB3 FDV (Instantly)
Control panel- Remote Switching off SB1 FDV
Remote switching off SB2 FDV (Instantly)
Remote switching off F Block FDV (Instantly)
Remote switching off SB4 FDV (Instantly)
GSM Based Smart Control of Shop Floor Ventilation System
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Innovative Projects LED Migration Project
Evolution of Lighting
LEDification Project
No expenses in LED- migration
OPEX model Lights Installation Testing amp
Commissioning of LED lights 5 yrs extended warranty
Scope amp Savings
Phase wise LEDification project
Entire plant in phases Better control schemes Reduction in consumption by
50 (Minimum)
Optimal design amp execution
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
Why LED for lighting
LED the best lighting option today
Energy efficient higher Lumens per Watts
No Mercury-Environmental friendly
No IR amp UV emissions Reduced heat generation
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Conventional Lighting system After LED Migration
Power Consumption 14 KW Lux level 125~200
Energy Cons-Monthly 6300 KWH 50400 INR-Annually 75600 KWH 604800 INR
65 KW (Red 464) 250~450 (Inc 250 )
2925 KWH 23400 INR (Red 464 )
35100 KWH 280800 INR
65 KW (Red 464) 250~450 (Inc 250 )
1312 KWH 10400 INR (Red 782 ) 15744 KWH 125952 INR
Occupancy Sensor
After Sensor installation
Occupancy sensor
Sensor Controlled
lightingGroup
Manual Controlled
Lighting group
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Slide Number 55
- Slide Number 56
- Slide Number 57
- Slide Number 58
- Slide Number 59
- Slide Number 60
- Slide Number 61
- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOW
Teamwork Employee involvement amp MonitoringDaily Consumption Report
Daily Energy Audit Report
Daily Shopwise Report
Daily Solar Generation Report
Hourly Consumption Report-Plant
Hourly Consumption Report-Shop
Monthly Energy Consumption Report
Awar
enes
sle
vel
2017-18
Reporting of energy consumption of the plant and
individual shops on fortnightly and monthly
basis
2018-19
H1 Reporting of entire plantrsquos energy consumption on daily basis
Daily Energy Audit Report (DEAR) circulated across the plant to minimize
energy wastageH2 Reporting of entire plantrsquos and shop-wise energy consumption on
daily basis
2019-20
H1 Reporting of shop-wise energy consumption started on hourly
basisH1 Reporting of working dayrsquos
and non-working dayrsquos consumption separately for
identification of areasprocesses 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
ENERGY CONSUMPTION 2019-20Figures in KWH
FACTORY Dec-19 Jan-20 Feb-20 Mar-20EASTERN COMPLEXBIWBIW Cab 30103 29885 42825 7097BIW Cowl 17657 16650 20104 7438FDV 0 0 0 0COMP 13691 12555 15960 4155BIW Office others 3459 2845 3824 599Distribution Losses 5737 5686 8235 3398Total 70648 67620 90949 22688PAINT SHOPPTED 276243 270240 58056 125761Paint 199896 182651 252332 55852COMP 69201 71042 191305 32740Paint others 33456 34243 71892 16336Distribution Losses 52586 55324 32462 45001Total 631382 613501 606048 275690TCFAssly 84210 101803 92831 23993Trim Assly 12468 17988 15117 4219FDV 0 0 0 0Compressor 38154 41387 42232 13080TCF officeothers 19581 18255 15958 13560Distribution Losses 14262 16490 17609 10428Total 168676 195923 183747 65281
Rear Axle and Line-45 17252 16260 4125 1830Logistics Centre 14904 25247 20629 9615RSO 5597 9370 8390 8445
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
GSM Based Smart Control of Shop Floor Ventilation System
Concerns in present method bull One operator has to travel around 1 Km for manually switching off all FDVs in western complex due to control panel given at that particular
location and hence there is electrical energy wastage of 5137 KWHmonth due to travel time of around 20 mins
Present process Moving to
switching off SB1 FDV
(0 mins)
Moving to switching off SB2 FDV
(5 mins)
Moving to switching off F Block FDV
(15 mins)
Moving to switching off
SB4 FDV(20 mins)
Moving to switching off SB3 FDV
(10 mins)
Blower amp Control panel
FDV Locations in Line 1
EnCon Projects
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
LCA Solution
bull Remote switching off FDVs by integrating off operation of FDV with GSMmodem from one location Also message will be delivered to user thatwhich FDV has been switched off (wireless switching off operation is donethrough GSM modem to avoid cable cost and laying of cable line)
Benefits amp Horizontal Scope 1Energy saving - Energy saving of 41096 KWHannum by providing remote switching off FDVs
2 Cost Saving - Recurring cost saving of Rs 328 lakhsannum3 Environment- Reduction in carbon footprint (reduction of 337 tonne of CO2annum by energy saving)
4 SMS escalation to user for information of FDV switch off5No laying out of wire is required as it is wireless communication with help of GSM modem6 Horizontal deployment of GSM based control for other process machines of assembly line 12 and 3
Solution Cost-Rs 328 Lacs for all 5 FDVs
Remote switching off SB3 FDV (Instantly)
Control panel- Remote Switching off SB1 FDV
Remote switching off SB2 FDV (Instantly)
Remote switching off F Block FDV (Instantly)
Remote switching off SB4 FDV (Instantly)
GSM Based Smart Control of Shop Floor Ventilation System
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Innovative Projects LED Migration Project
Evolution of Lighting
LEDification Project
No expenses in LED- migration
OPEX model Lights Installation Testing amp
Commissioning of LED lights 5 yrs extended warranty
Scope amp Savings
Phase wise LEDification project
Entire plant in phases Better control schemes Reduction in consumption by
50 (Minimum)
Optimal design amp execution
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
Why LED for lighting
LED the best lighting option today
Energy efficient higher Lumens per Watts
No Mercury-Environmental friendly
No IR amp UV emissions Reduced heat generation
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Conventional Lighting system After LED Migration
Power Consumption 14 KW Lux level 125~200
Energy Cons-Monthly 6300 KWH 50400 INR-Annually 75600 KWH 604800 INR
65 KW (Red 464) 250~450 (Inc 250 )
2925 KWH 23400 INR (Red 464 )
35100 KWH 280800 INR
65 KW (Red 464) 250~450 (Inc 250 )
1312 KWH 10400 INR (Red 782 ) 15744 KWH 125952 INR
Occupancy Sensor
After Sensor installation
Occupancy sensor
Sensor Controlled
lightingGroup
Manual Controlled
Lighting group
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Slide Number 55
- Slide Number 56
- Slide Number 57
- Slide Number 58
- Slide Number 59
- Slide Number 60
- Slide Number 61
- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
GSM Based Smart Control of Shop Floor Ventilation System
Concerns in present method bull One operator has to travel around 1 Km for manually switching off all FDVs in western complex due to control panel given at that particular
location and hence there is electrical energy wastage of 5137 KWHmonth due to travel time of around 20 mins
Present process Moving to
switching off SB1 FDV
(0 mins)
Moving to switching off SB2 FDV
(5 mins)
Moving to switching off F Block FDV
(15 mins)
Moving to switching off
SB4 FDV(20 mins)
Moving to switching off SB3 FDV
(10 mins)
Blower amp Control panel
FDV Locations in Line 1
EnCon Projects
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
LCA Solution
bull Remote switching off FDVs by integrating off operation of FDV with GSMmodem from one location Also message will be delivered to user thatwhich FDV has been switched off (wireless switching off operation is donethrough GSM modem to avoid cable cost and laying of cable line)
Benefits amp Horizontal Scope 1Energy saving - Energy saving of 41096 KWHannum by providing remote switching off FDVs
2 Cost Saving - Recurring cost saving of Rs 328 lakhsannum3 Environment- Reduction in carbon footprint (reduction of 337 tonne of CO2annum by energy saving)
4 SMS escalation to user for information of FDV switch off5No laying out of wire is required as it is wireless communication with help of GSM modem6 Horizontal deployment of GSM based control for other process machines of assembly line 12 and 3
Solution Cost-Rs 328 Lacs for all 5 FDVs
Remote switching off SB3 FDV (Instantly)
Control panel- Remote Switching off SB1 FDV
Remote switching off SB2 FDV (Instantly)
Remote switching off F Block FDV (Instantly)
Remote switching off SB4 FDV (Instantly)
GSM Based Smart Control of Shop Floor Ventilation System
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Innovative Projects LED Migration Project
Evolution of Lighting
LEDification Project
No expenses in LED- migration
OPEX model Lights Installation Testing amp
Commissioning of LED lights 5 yrs extended warranty
Scope amp Savings
Phase wise LEDification project
Entire plant in phases Better control schemes Reduction in consumption by
50 (Minimum)
Optimal design amp execution
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
Why LED for lighting
LED the best lighting option today
Energy efficient higher Lumens per Watts
No Mercury-Environmental friendly
No IR amp UV emissions Reduced heat generation
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Conventional Lighting system After LED Migration
Power Consumption 14 KW Lux level 125~200
Energy Cons-Monthly 6300 KWH 50400 INR-Annually 75600 KWH 604800 INR
65 KW (Red 464) 250~450 (Inc 250 )
2925 KWH 23400 INR (Red 464 )
35100 KWH 280800 INR
65 KW (Red 464) 250~450 (Inc 250 )
1312 KWH 10400 INR (Red 782 ) 15744 KWH 125952 INR
Occupancy Sensor
After Sensor installation
Occupancy sensor
Sensor Controlled
lightingGroup
Manual Controlled
Lighting group
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Slide Number 55
- Slide Number 56
- Slide Number 57
- Slide Number 58
- Slide Number 59
- Slide Number 60
- Slide Number 61
- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
LCA Solution
bull Remote switching off FDVs by integrating off operation of FDV with GSMmodem from one location Also message will be delivered to user thatwhich FDV has been switched off (wireless switching off operation is donethrough GSM modem to avoid cable cost and laying of cable line)
Benefits amp Horizontal Scope 1Energy saving - Energy saving of 41096 KWHannum by providing remote switching off FDVs
2 Cost Saving - Recurring cost saving of Rs 328 lakhsannum3 Environment- Reduction in carbon footprint (reduction of 337 tonne of CO2annum by energy saving)
4 SMS escalation to user for information of FDV switch off5No laying out of wire is required as it is wireless communication with help of GSM modem6 Horizontal deployment of GSM based control for other process machines of assembly line 12 and 3
Solution Cost-Rs 328 Lacs for all 5 FDVs
Remote switching off SB3 FDV (Instantly)
Control panel- Remote Switching off SB1 FDV
Remote switching off SB2 FDV (Instantly)
Remote switching off F Block FDV (Instantly)
Remote switching off SB4 FDV (Instantly)
GSM Based Smart Control of Shop Floor Ventilation System
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Innovative Projects LED Migration Project
Evolution of Lighting
LEDification Project
No expenses in LED- migration
OPEX model Lights Installation Testing amp
Commissioning of LED lights 5 yrs extended warranty
Scope amp Savings
Phase wise LEDification project
Entire plant in phases Better control schemes Reduction in consumption by
50 (Minimum)
Optimal design amp execution
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
Why LED for lighting
LED the best lighting option today
Energy efficient higher Lumens per Watts
No Mercury-Environmental friendly
No IR amp UV emissions Reduced heat generation
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Conventional Lighting system After LED Migration
Power Consumption 14 KW Lux level 125~200
Energy Cons-Monthly 6300 KWH 50400 INR-Annually 75600 KWH 604800 INR
65 KW (Red 464) 250~450 (Inc 250 )
2925 KWH 23400 INR (Red 464 )
35100 KWH 280800 INR
65 KW (Red 464) 250~450 (Inc 250 )
1312 KWH 10400 INR (Red 782 ) 15744 KWH 125952 INR
Occupancy Sensor
After Sensor installation
Occupancy sensor
Sensor Controlled
lightingGroup
Manual Controlled
Lighting group
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Slide Number 55
- Slide Number 56
- Slide Number 57
- Slide Number 58
- Slide Number 59
- Slide Number 60
- Slide Number 61
- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOW
Innovative Projects LED Migration Project
Evolution of Lighting
LEDification Project
No expenses in LED- migration
OPEX model Lights Installation Testing amp
Commissioning of LED lights 5 yrs extended warranty
Scope amp Savings
Phase wise LEDification project
Entire plant in phases Better control schemes Reduction in consumption by
50 (Minimum)
Optimal design amp execution
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
Why LED for lighting
LED the best lighting option today
Energy efficient higher Lumens per Watts
No Mercury-Environmental friendly
No IR amp UV emissions Reduced heat generation
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Conventional Lighting system After LED Migration
Power Consumption 14 KW Lux level 125~200
Energy Cons-Monthly 6300 KWH 50400 INR-Annually 75600 KWH 604800 INR
65 KW (Red 464) 250~450 (Inc 250 )
2925 KWH 23400 INR (Red 464 )
35100 KWH 280800 INR
65 KW (Red 464) 250~450 (Inc 250 )
1312 KWH 10400 INR (Red 782 ) 15744 KWH 125952 INR
Occupancy Sensor
After Sensor installation
Occupancy sensor
Sensor Controlled
lightingGroup
Manual Controlled
Lighting group
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Slide Number 55
- Slide Number 56
- Slide Number 57
- Slide Number 58
- Slide Number 59
- Slide Number 60
- Slide Number 61
- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOW
Conventional Lighting system After LED Migration
Power Consumption 14 KW Lux level 125~200
Energy Cons-Monthly 6300 KWH 50400 INR-Annually 75600 KWH 604800 INR
65 KW (Red 464) 250~450 (Inc 250 )
2925 KWH 23400 INR (Red 464 )
35100 KWH 280800 INR
65 KW (Red 464) 250~450 (Inc 250 )
1312 KWH 10400 INR (Red 782 ) 15744 KWH 125952 INR
Occupancy Sensor
After Sensor installation
Occupancy sensor
Sensor Controlled
lightingGroup
Manual Controlled
Lighting group
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Slide Number 55
- Slide Number 56
- Slide Number 57
- Slide Number 58
- Slide Number 59
- Slide Number 60
- Slide Number 61
- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOW
Hot Water (85degc)
At TML Lucknow plant we have Paint shop for painting face cowl of the vehicles It contains 3 Nos of Propanefired Ovens ( ED TC 1 amp 2) Internal temperature is maintained at 160-180 degC and its hot flue gases wereexhausted through preheater to atmosphere But still Flue gas was having a substantial heat energy which can beutilized for useful work OVEN at paint shop
KOD Hot WaterRinse Degrease Activation Phosphating
PT Tanks
Return Water (75degc)
828100 Kcalhr
TC-2 Oven
TC-1 Oven
ED Oven
Flue gases (Temp 220degC)
Hot Water Generator
2
Hot Water Generator
1 Hot Water Generator(HWG) generates hot water of 85degCfor Pre treatment (PT) process on white of Cowl HWGuse Propane gas as a fuel for burner applicationSupply Hot water 85 degC goes to PT process and returns at75 degC
Waste Heat Recovery System
ENCON-ProjectEnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Slide Number 55
- Slide Number 56
- Slide Number 57
- Slide Number 58
- Slide Number 59
- Slide Number 60
- Slide Number 61
- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOW
Installation of Heat Exchanger With diverter valve Assy- ED Oven
Shell amp Tube Heat Exchanger
Motorized Actuated
Diverter valve
Stainless Steel Ducting
Flow Meter
Hot Water OP
Cold water IP
Pressure Indicator
Resistance temperature
detectors
DP Water Switch Flue Gas Back
Pressure Switch
Allen Bradley PLC panel
Control Logic L71
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Slide Number 55
- Slide Number 56
- Slide Number 57
- Slide Number 58
- Slide Number 59
- Slide Number 60
- Slide Number 61
- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOW
HMI screen to operate the WHRS safely
HOT WATER GENERATOR has been stopped
Log BookAnnual saving ndash 268 Tons of Propane Gas
Rs 1554 MillionsPay back- Less than 1 Year
Annual carbon abatement- 429 Tons of CO2
ENCON-Project Waste Heat Recovery System
WHRS Started
Tons
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Slide Number 55
- Slide Number 56
- Slide Number 57
- Slide Number 58
- Slide Number 59
- Slide Number 60
- Slide Number 61
- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOW
Benefits1 Reduction in energy consumption by 5-6 by enhancing thermal efficiency of equipments2 Zero Maintenance cost3 Leads to a cleaner environment4 Eliminates use of fuel additives
Energy Saving = 17 Tons of Propane Gas yearRs 98 Lakhs
306 Tons of CO2e
Important ENCON Projects Flux maxiox
Principle of workingConversion of para-hydrogen to higher energizedortho-hydrogen through magnetic stimulation iethe application of the proper magnetic field tochange the state of hydrogen molecules whichenhances the energy of atom amp general fuelactivity Hydrocarbon fuel molecules treated withthe magnetic energy of the Flux Maxiox tend tode-cluster creating smaller Particles more radiallypenetrated by oxygen thus leading to completecombustion They become more normalizeddistanced from each other having bigger surfaceavailable for bonding with oxygen In thecombustion chamber increased reactivity ofoxygen is achieved resulting in better oxidation ofthe primary hydrogen elements further oxidationof the carbon element the secondary fuelelement
Before At TML Paint shop we have propane based Ovens and hot water generator equipment There weconsume average of 1500 tons of propane gas every year During ISO 50001 implementation we startedcalculating Ovens efficiency which triggered us to work on increasing its efficiency
After We studied and explored the opportunity in this regard We have seenFlux maxiox from CII amp learned that by using this we can increase theefficiency of paint shop Ovens amp hot water generator equipments So Weimplemented this technology which increased the efficiency of equipmentsubstantially
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Slide Number 55
- Slide Number 56
- Slide Number 57
- Slide Number 58
- Slide Number 59
- Slide Number 60
- Slide Number 61
- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOW
Before In continuation drive of Lighting optimization in offices amp shops we encountered an opportunity in PEshop There lighting fittings were roof ceiling suspended which was covering entire height of the shop Howeverrequired effective height of the lighting was half of the shop height of 8 Mtr It was not only energy wastage alsoinaccessible for maintenance The wiring of the lights was such that the lights in unnecessary areas could not besegregated and switched OFF This led to energy wastage and difficulty in maintenance as well
ENCON Projects Optimisation of Shop Lighting System
After Energy Management cell co-ordinated with PE shop team and conducted a brainstorming session forimproving the shoprsquos lighting system As an outcome of the session it was decided to replace the existinglights with energy-efficient LED tubelights Also reduced effective height of the lights to 5 M which was easilyaccessible zone wise for maintenance and resulted in energy saving
BenefitsEnergy savingIncrease in illuminationEasy maintenance of lights due to lower heightEnhanced life of lightsLocalized need-based zone-wise lighting control
Energy Saving 27000 KWH yearCost saving Rs 213 Lakh year
Carbon Abatement 22 tCO2e
Height8 M
Overhead lightHPSV 250 W
Floor Level
Height5 M
Wall-mounted LED lights
Floor Level
DrawbacksHigh energy consumptionIllumination at border line of requirementDifficulty in maintenance due to greater mounting height of lightsLights could not be switched OFF when not required
Reduced effective Volume of illumination
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Slide Number 55
- Slide Number 56
- Slide Number 57
- Slide Number 58
- Slide Number 59
- Slide Number 60
- Slide Number 61
- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOW
Before Lucknow works was working on 6 days per week The assembly lines were running at under capacity dueto market recession It has resulted in increasing trend of SEC due to higher Fixed load contribution especially inassembly shops
Important ENCON Projects Optimisation of production timings
After Energy Management cell co-ordinated with Manufacturing Supply chain HR amp Admin Union and otherconcerned agencies to operate the plant in 5 days per week based instead of 6 days per week keeping thesame working hours per week This has resulted in reducing fixed load energy consumption substantiallyBesides this significant energy reduction in canteen conservancy transportation comfort loads in offices ampshops etc been achieved
Mon Tue Wed Thru Fri Sat Sun
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Shop floor loads Office loads Comfort Load Canteen services Transportation services Cregraveche services Training center
Data center loadOther utilities
Non working day fixedload
Mon Tue Wed Thru Fri Sat Sun
Energy Saving = 20 Lakhs KWH yearEnergy cost = Rs 140 lakhs year
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Slide Number 55
- Slide Number 56
- Slide Number 57
- Slide Number 58
- Slide Number 59
- Slide Number 60
- Slide Number 61
- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOW
Before-We had conventional lighting in our Line -1 we studied the lux level and found that when the lights were off during day time the lux level drop to 200 Lumen which was far below the required lux level of 400 Lumen so the operators used to keep the lights on in day time also
After-We have Installed light pipes in our main line and also provided transparent sheets in roof at logistics area so that we can increase the lux level to 500 Lumen without switching the lights on during day time since we used light pipes hence there was no increase in shop floor temperature also
Cost Saving Rs 6 Lakh annumElectrical Saving 85000 KWHCarbon Abatement 697 tCo2
Roll Out areaMain LineFrame Shop
Assembly Line
Lux Level ndash500 with Light Pipe
Important ENCON Projects Light Pipe
Lux Level ndash200 without electrical light
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Slide Number 55
- Slide Number 56
- Slide Number 57
- Slide Number 58
- Slide Number 59
- Slide Number 60
- Slide Number 61
- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOW
In Phase 1 The compressed air pr of 62 bar was under usage earlier The Linepressure of the Compressed air reduced to 59 bar with no effect on the pressuredelivered at the end user
In Phase 2 After detailed study and agreement from end user further reduced thepressure setting optimally at 57 bar
Before Condition Phase 1
Total Investment 0 Lakh Total Savings 092 LakhannumPayback Immediate
Optimizing the Compressor Pressure
ENCON Projects Zero Investment
Compressor House Phase 2
62 bar 59 bar 57 bar
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Slide Number 55
- Slide Number 56
- Slide Number 57
- Slide Number 58
- Slide Number 59
- Slide Number 60
- Slide Number 61
- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOW
After Process improvement-Removed one motor after evaluate the prime mover capacity to operate the roller bed conveyor
In Paint shop after Top Coat amp Sealer Oven cowl passes through the cooling Zone on roller bed conveyor for cooling the cowl body by forced draft blower
BeforeRoller bed conveyor operates with three motor which connected with roller operated conveyor belt
3 Motors
Long belt
Optimisation of Cooling Zone- Roller Belt operation in Paint Shop
Cooling Zone
M1M3 Sensor
Cooling Zone
M1M3 M2Sensor
L1L2
L1
ENCON Projects Low Investment
Total Investment 0 Lakh Total Savings 1085 KWHannumPayback 5 Months
EnCon Projects
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Slide Number 55
- Slide Number 56
- Slide Number 57
- Slide Number 58
- Slide Number 59
- Slide Number 60
- Slide Number 61
- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
Before
Method used to raise the water temperature-LPG burner were used to raise the temperature of water to 60degC
Post Wash operation-After the quenching process the metaquench42 oil layers needs to be cleaned from the components To remove this oil layer we perform the post wash operation in which the components are dipped and wash with the spray of warm water which is maintained at the temperature of 60degC
Post Wash Tank
Conservation of electricity through utilization of temperature from heated waste gases to heat water in post wash chamber
Innovation Project
MACHINE 200 KgHr CCHF
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Slide Number 55
- Slide Number 56
- Slide Number 57
- Slide Number 58
- Slide Number 59
- Slide Number 60
- Slide Number 61
- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOW
LPG Burners
(Partial Load)
Method used to raise the water temperature-Now a modification is made in the system in which the heat of the flue gases are extracted and used to raise the temperature of water used for post wash
The temperature of flue gases when burnt is 275degC and with the help of heat exchanger we recovered the heat And this extracted heat is used to raise the water temperature of post wash to the required level
Furnace
Copper coil
Post Wash Tank
Total Carbon emission reductions per annum 45 T CO2
Benefits
Innovation Project
After
X
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Slide Number 55
- Slide Number 56
- Slide Number 57
- Slide Number 58
- Slide Number 59
- Slide Number 60
- Slide Number 61
- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOW
Optimisation of Cooling Zone ndash Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting In Paint shop it passes first fromPretreatment stage where oil grease dust amp dirt is removed by hot water spray Next the Cowl bodypasses from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition)
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for bakingamp drying at defined temperature ie 150degC This oven is horizontally connected with cooling zone wherecowls gets cooled by two axial flow fans ie 22KW amp 30 KWBeforeThe Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown belowThe Cooling fans automatically comes into operation as soon as the conveyor starts It is found always inrunning mode once the line gets started Cowl takes almost 2 hrs time to reach the oven fromPretreatment stage
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
30KW22KW
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Traveling time till Cooling Zone is 2
Hrs
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Slide Number 55
- Slide Number 56
- Slide Number 57
- Slide Number 58
- Slide Number 59
- Slide Number 60
- Slide Number 61
- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOW
After A Position sensor has been provided at the starting end of cooling zone which senses the entry ofcowl into oven subsequently it gives the start signal to the axial flow fan to run
Total Carbon emission reductions per annum 112 T CO2
Benefits
+ + + +++ +CED
Pretreatment(PT)
Hot water Spray Phosphating
Air BlowerBurner
Hot Air
Oven Zone
Cooling Zone
Sensor
Innovation Project
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Slide Number 55
- Slide Number 56
- Slide Number 57
- Slide Number 58
- Slide Number 59
- Slide Number 60
- Slide Number 61
- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOW
An Overview of Tata Group amp Tata Motors
We are talking about hellip
Our Strategic Directionhellip
Renewable Energy ndash Ways amp Means
ENCON ndash Residential DC NW
Energy Scenarios ndash Indian perspective
ENCON ndash Industry Infrastructure amp Building
E R A S E Approach
Way Forward
Energy Excellence Tata Motors
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Slide Number 55
- Slide Number 56
- Slide Number 57
- Slide Number 58
- Slide Number 59
- Slide Number 60
- Slide Number 61
- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 65
E-R-A-S-E Principle
E- Eliminate lsquoNeedrsquoKey questions 1) Do we really need this process for desirable outcome 2) Do we need Energy input in this process for desired outcome
Solution Process Innovation
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
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- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
E-R-A-S-E Principle R- Reduce Energy consumption Sp Energy
consumptionKey questions 1) How much is productive and non-productive energy2) How can I reduce non-productive energy use3) How can I improve throughput Solution Measurement amp Analyses
Operational Control Operational efficiency
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
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- Slide Number 61
- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc
67
E-R-A-S-E Principle
A- Alternative energy sources amp Application innovation
Key questions 1) Is there an alternative cost effective and efficient energy source available2) What is my application advantage
Solution Energy efficient technologies Alternative fuels Heat recovery Renewable Energy
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
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- Slide Number 33
- Slide Number 34
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- Slide Number 56
- Slide Number 57
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- Slide Number 60
- Slide Number 61
- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 68
E-R-A-S-E Principle
S-Sizing of equipment
Key questions 1) What is the equipment capacity2) What is the actual demand throughout the process And why 3) How can I right-size the equipment capacity
Solution Right sizing of equipment process demand
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
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- Slide Number 56
- Slide Number 57
- Slide Number 58
- Slide Number 59
- Slide Number 60
- Slide Number 61
- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOWCopyright Confidential Tata Motors Limitedc 69
E-R-A-S-E Principle
E-Efficiency improvements Elimination of lossesKey questions 1) Is there excessive Noise Heat Vibration Radiation or leakage 2) What is my equipmentprocess energy efficiency3) How can I improve it further4) What is the best efficiency point
Solution Energy efficient technologies and optimum loading for best efficiency Loss elimination
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
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- Slide Number 49
- Slide Number 50
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- Slide Number 55
- Slide Number 56
- Slide Number 57
- Slide Number 58
- Slide Number 59
- Slide Number 60
- Slide Number 61
- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-
IIT - Kanpur- CVBU LUCKNOW
Our Message through this presentation is
ldquoSystematic Sustainable Continual improvements
Knowledge sharing Innovation and Team Workrdquo
are the core pillars to make a unit an
ldquoExcellent Energy Efficient unit ldquo
Thank You
- Slide Number 1
- Slide Number 2
- Slide Number 3
- Slide Number 4
- Slide Number 5
- Slide Number 7
- Slide Number 8
- Slide Number 9
- Slide Number 10
- Slide Number 11
- Slide Number 12
- Slide Number 13
- Slide Number 14
- Slide Number 15
- Slide Number 16
- Slide Number 17
- Slide Number 18
- Bio-Gas
- Slide Number 21
- Slide Number 22
- Slide Number 23
- Slide Number 24
- Slide Number 25
- Slide Number 26
- Slide Number 27
- Slide Number 28
- Slide Number 29
- Slide Number 30
- Slide Number 31
- Slide Number 32
- Slide Number 33
- Slide Number 34
- Slide Number 35
- Slide Number 36
- Slide Number 37
- Slide Number 38
- Slide Number 39
- Slide Number 40
- Slide Number 41
- Slide Number 42
- Slide Number 43
- Slide Number 44
- Slide Number 45
- Slide Number 46
- Slide Number 47
- Slide Number 48
- Slide Number 49
- Slide Number 50
- Slide Number 51
- Slide Number 52
- Slide Number 53
- Slide Number 54
- Slide Number 55
- Slide Number 56
- Slide Number 57
- Slide Number 58
- Slide Number 59
- Slide Number 60
- Slide Number 61
- Slide Number 62
- Slide Number 63
- Slide Number 64
- Slide Number 65
- Slide Number 66
- Slide Number 67
- Slide Number 68
- Slide Number 69
- Thank You
-