pp industrial 2nd cut revised

May’12 /SBU-INDUSTRIAL

P PRAMANIK19-05-2012

SBU - INDUSTRIAL

MANUFACTURING


High Value Manufacturing

SHAMNAGAR •Location - WEST BENGAL•Opens – 1946•Subject – INDUSTRIAL, FMIB, STANDBY

ROORKEE• Location - HIMACHAL PRADESH• Opens – PART OF EXIDE FROM 2012• Subject - INVERTER

THE INDUSTRIAL FACILITIES

HALDIA• Location – WEST BENGAL• Opened - 1980• Subject – FMIB, TRACTION, INDUSTRIAL

HOSUR• Location – TAMIL NADU• Opened - 1996• Subject – VRLA – UPS, INVERTER, TELECOM, RAILWAY

May’12 /SBU-INDUSTRIAL 4

TO LAUNCH PRODUCT AHEAD OF COMPETETION

TO HAVE COMPLETE PORTFOLIO OF PRODUCT

TO SHIFT FROM GRUDGE PURCHASE TO ASPIRATIONAL PURCHASE

TO HAVE FLEXIBILITY IN PRODUCTION PROCESS

VALUE ADDITION IS THE NXT GEN REQUIREMENT

TO FOCUS ON MAINTENANCE FREE PRODUCT

INDUSTRIAL -

MANUFACTURING STRATEGY

FOCUS ON CAPACITY ENHANCEMENT WITH MARKET DEMAND

VALUE ADDITION THROUGH INVESTMENT IN TECHNOLOGY

INVERTER AS PACKAGE WITH BATTERY

http://www.presentationpro.com/in/PDATCFT






http://www.presentationpro.com/power_designs.aspx













INDUSTRIAL - TURN OVER

2007 - '08 2008 - '09 2009 - '10 2010 - '11 2011 - '12 BUDGET 2012 - '13

0

500

1000

1500

2000

2500

1103.17

1364.491556

1790.511959.93

2104

INDUSTRIAL - TURN OVER

` C

r.


PRODUCTION TREND ( BATTERY & CELL )

2007-'08 2008-'09 2009 - '10 2010 - '11 2011 - '12 BUDGET 2012 - '13

0

500

1000

1500

2000

2500

1169.561334.24

1564.521760.42 1760.17

2024.19

INDUSTRIAL - PRODUCTION

MAh


PRODUCTION TREND ( INVERTER )

NO

s

0

25000

50000

75000

100000

125000

150000

175000

200000

DEC '11 JAN '12 FEB '12 MAR '12 TARGET 2012 - '13

6818 11119 10132 16908

188000

INVERTER - PRODUCTION

NO

s


NO

s`

CR.

DEC '11 JAN '12 FEB '12 MAR '120

5000

10000

15000

20000

6818

115509810

17348

DEC '11 JAN '12 FEB '12 MAR '120.00

2.00

4.00

6.00

8.00

2.08

4.39 3.83

7.07

DESPATCH TREND ( INVERTER )

DESPATCH ( INVERTER )


LEARNINGS FROM SHINKOBE

CURED PLATE CHECKING PARAMTERS (METALIC SOUND, CRACK, COLOUR, ETC.,)

IMPORTANCE OF NAM / PAM RATIO

IMPORTANCE OF ONLINE COMPRESSION CHECKING SYSTEM

STANDARDISATION OF CURING OVEN

FEATURES & ADVANTAGES OF BARCODE SYSTEM

PET SHEET WRAPPING FOR GROUP WITH EXPANDED NEGATIVES TO REDUCE PROCESS REJECTION














LEARNINGS FROM SHINKOBE

IMPORTANCE & METHODOLOGY OF FTA ANALYSIS

KANBAN CONCEPT

IMPROVED METHODOLOGY OF FIELD RETURN BATTERY ANALYSIS

ADVANTAGES OF ABS CONTAINER FOR MEDIUM VRLA

ADVANTAGE OF COS FOR VRLA

ONLINE ACID WASH ROLLER PRESSURE MONITORING














LEARNINGS FROM EAST PENN

SHOP FLOOR DATA MONITORING, STORAGE AND CONTROL VERY STRONG

PROPER TAINING THROUGH TRAINING MANUAL FOR EACH PROCESS

ORIFICE PASTER WITH DUMP PASTE RECLAIMED THROUGH BELT

CON CAST, PUNCHED GRID, CURING FOR FLAT PLATE










PEOPLE INVOLVEMENT THROUGH QC & SGA TOTAL EMPLOYEES INVOLVED – 569

TOTAL NOS. OF AWARDS WON – 22

SHAMNAGARQC TEAM – 7

SGA TEAM – 10

PROBLEMS SOLVED - 25

HALDIAQC TEAM – 17

SGA TEAM – 43


HOSURQC TEAM – 6

SGA TEAM – 44


GOLD Award CCQCC – BangaloreGOLD Award from ICQCC – HyderabadPAR EXCELLENCE Award NQCC – BangaloreSILVER Award - CCQCC – Bangalore

PAR EXCELLELLENCE Award – NCQC – VizagEXCELLENT Award – NCQC – VizagGOLD Award – QCFI – Kolkata1st in 23rd CONVENTION of QC – KolkataGOLD Award INTERNATIONA; QC – Hyderabad

QC AND SGA


TRAINING

2007-08 2008-09 2009-10 2010-11 2011-12

24720

1870416400

8120

13840

Training Nos. Of Hours - Haldia

2007-08 2008-09 2009-10 2010-11 2011-12

31572541

20162410

6441Training Nos. Of Heads - Haldia

T P M

S H E

P M

J H

Cost Control

Training on Pallet Truck Operation

Safety

Quality

Efficiency Management

Fire Training


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TRAINING

2007-08 2008-09 2009-10 2010-11 2011-12

1392

18322056

2648

3440Training Nos. Of Hours - Shamnagar

2007-08 2008-09 2009-10 2010-11 2011-12

174229

257

331

430Training Nos. Of Heads - Shamnagar

Cost / Expenses Control

Asset utilation / Maintenance

Inventory control

New QC Tools

Productivity / IE / Incentive Scheme

Energy Conservation

Communication and Presentation Skill

Battery design / Quality Systems

Pay Roll concept

HR & Porvic – Manufacturing Process


ENVIRONMENTAL PARAMETERS

2007-08 2008-09 2009-10 2010-11 2011-12 2012-13

2.262.1 2.15

1.72

1.26 1.220.73600000

00000010.45 0.42 0.474 0.461

1 1 1 1 1

EFFLUENT GENERATION (KL/MT OF Pb)

HALDIA HOSUR SHAMNAGAR

2007-08 2008-09 2009-10 2010-11 2011-12 2012-13

36.48 35 33.13

19.4416.08 15.75

4.61 2.59 1.99 1.3 0.991 1 1 1 1

LIME CONSUMPTION (KG/MT OF Pb)


2007-08 2008-09 2009-10 2010-11 2011-12 2012-13

82.175 78.9

53.665.6 63.4

8.3 4.66 3.58 2.34 1.781 1 1 1 1

SLUDGE GENERATION (KG/MT OF Pb)


2007-08 2008-09 2009-10 2010-11 2011-12 2012-13

3.212.78

2.091.7 1.48 1.410.85000000

0000001 0.670000000000001

0.670000000000001

0.710000000000001

0.700000000000001

1 1 1 1 1

DM WATER CONSUMPTION (KL/MT OF Pb)



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ENVIRONMENTAL PARAMETERS : -

2007-08 2008-09 2009-10 2010-11 2011-12 2012-13

17.89 16.5 15.14 15.49 15.6121.67

36.2129.07 27.42 28.05 26.69

1 1 1 1 1

LPG CONSUMPTION (KG/MT OF Pb)


2007-08 2008-09 2009-10 2010-11 2011-12 2012-13

12.5410.44 10

6.9 6.11 5.983.47 3.107 2.81 2.77 2.83

1 1 1 1 1

RAW WATER CONSUMPTION (KL/MT OF Pb)



Illumination level monitoring at different work areas in Industrial factorySpecification : 65 lux (minimum) as Factories Act 1948

Work area Apr"12 Work area Apr"12FMIB FACTORY Lx TRACTION FACTORY Lx

Spine Casting(South) 82 Lih- Shan 71Spine Casting(North) 81 Gaunlet room 119Oxide filling (New Sungwoon) 77 Maintenance Room 114Oxide filling (Sungwoon) 71 Spine Casting 72Oxide filling(Rotary Shaker) 70 Grid Casting 115Oxide Filling (Exide) 104 Pasting(feeding) 81Pasting (Grid feeding)not running 71 Pasting (Collecting end) 74Pasting (Plate collection)not running 78 Initial Assembly 81Lih Shan Oxide Mill (Middle) 41 Final Assembly 137Grid Casting (Middle) 76 OMI Charging 78Fitter's room 87 PP Cell Box Cutting 80Forming (South) 31Forming (North) 69Assembly -1 (initial) 98Assembly -1 (final) 83Assembly line - 2 (initial) 121Assembly line - 2 (final) 124Assembly line - 3 (initial) 121Assembly line - 3 (final) 137Assembly Line - 4(initial) 159Assembly Line - 4(final) 87Assembly Line - 5(initial) 81Assembly Line - 5(final) 91VRLA Charging 74Lug brushing 114Despatch building old 73PE charging 37Container punching / screen printing 75


Illumination Area Spec Haldia

Actual

Industrial 65 Lux (minimum) 93

Traction 65 Lux (minimum) 100

Ambient Air Quality Parameter Spec Actual

PM10 100 µg / M3 85.43

PM2.5 60 µg / M3 47.28SO2 80 µg / M3 22.98NO2 80 µg / M3 33.42

Lead 1 µg / M3 0.85

Work Zone Volatile Material (PE Charging) H2SO4 1.0 mg / M3 0.81

Illumination level and Air Quality monitoring at different work areas of Industrial factory


Sound level monitoring at different work areas in Industrial factoryPermitted exposure : 90 dBA for 8 hours as per WB Factories Rules 1958 MONTH : APRIL,2012

LOCATION:

INDUSTRIAL LOCATION : TRACTION

Sl. No.DATE OF

SAMPLING AREA OF SAMPLING RESULT REMARKS AREA OF SAMPLING RESULT REMARKS dB (A) dB (A)

1 18.04.2012 Lih shan control room 80.7 Grid Casting area 82.4 2 18.04.2012 In front of Lih - shan m/c 91.1 Ear plug Assembly area 76.1

3 18.04.2012 Casting area (middle) 68.0 Lih - shan oxide mill area 87.1 4 18.04.2012 Near Sungwoon filling m/c 94.3 Ear plug Pasting area 81.4 5 18.04.2012 Rotary shaker(Inside) 95.0 Ear plug Slurry filling area 67.2 6 18.04.2012 Rotary shaker(outside) 86.7 Cell charging area 65.7 7 18.04.2012 Exide filling 87.9 Cell Box cutting area 96.7 Ear plug8 18.04.2012 Pasting 83.2 Hadi area 79.6 9 18.04.2012 Autospine area (middle) 82.7 Compressor room 79.8

10 18.04.2012 Forming area (Middle) 76.5 RO/DM plant 70.8 11 18.04.2012 Near Plate drying oven 80.5 12 18.04.2012 Packing area 65.8 13 18.04.2012 Despatch building (Middle) 65.1 14 18.04.2012 Assembly line - 1 (IT) & 2(EL) 81.2 15 18.04.2012 Assembly line 2(EL) & 3(HR) 81.5 16 18.04.2012 Assembly line 3(HR) & 4(IT) 78.9 17 18.04.2012 Assembly Line 4(IT) & 5(IQ) 73.6 18 18.04.2012 Assembly line 6(YKP) 74.2 19 18.04.2012 Lug brushing 84.7


Area Spec Haldia

IndustrialGrid casting 90 d(B)A 82.4Ball mill 90 d(B)A 76.5Pasting 90 d(B)A 84.8Rotary Shaker 90 d(B)A 95.1Sungwoon 90 d(B)A 94.7Exide Filling 90 d(B)A 85.5Despatch 90 d(B)A 63DG Room 105 d(B)A 102.8Screw Compressor 90 d(B)A 81.8

OthersRO / DM Plant 90 d(B)A 73.6

Sound level monitoring at different work areas in Industrial factory


ACCIDENT TREND

2007-08 2008-09 2009-10 2010-11 2011-12

3

10

3

12

12

3 32

3 3 3 3 3


NOS


INCIDENT TREND

2007-08 2008-09 2009-10 2010-11 2011-12

148

64 64 5842NOS


CORPORATE SOCIAL RESPONSIBILITY ( CSR )

SCRUCTURED CSR ACTIVITIES :• HEALTHCARE• EDUCATION• ENVIRONMENT• WOMEN EMPOWERMENT• ASSISTANCE & PHILANTHROPY

Exide Industries Limited is making sure that rural India stays healthy, wealthy and wise . In this respect the company has taken new strategy for corporate governance and social responsibilities in the works.

POLICY :

CSR is considered as one of the key business processes, which has been identified by the management and considered critical to be a successful organization. Exide shall also establish the sub-processes to internalize this key process with a mechanism to measure and control the effectiveness.

OBJECTIVES :

• To be a good corporate citizen is inextricably linked with the improved brand reputation. CSR initiatives shall be considered as one of the most important drivers of the brand.

• With non financial parameters becoming more and more relevant, Exide’s focus on CSR is to enhance the shareholders value through an all round approach towards all stakeholders.


HEALTH CARE

Medical Camp ( Hosur ) - Supported Bagalur Health centre in organizing a medical camp

HEALTH CARE PROGRAM ( HALDIA ) - Polio Immunization Program, health check up , dental check up, eye examination, medicine distribution, general check up, tube well installation,


BASIC EDUCATION

HARIJAN PRATHAMIK VIDYALAYA , ISWARDAHA JALPAI - Repair & refurbishing of school building, Beautification of school ground -Mini Park, Installation of Tube well, Beautification of school -

School Gate

one day Science program at Kothapalli High school,Sevaganapalli Panchayath,

ASSEMBLY OF GOD CHURCH, HALDIA - Electrification work was done at Computer Room , New Staff Room , Class Rooms , Passage & Toilets.

Electrification of Banskhana Bhuniarchak Primary School

Donation of Books to School Children & Library through Sri Sri Ramkrishna Sarada Sathi Sangha – Chak Dariberia

Donation of Books to School Children & Library through Sri Sri Ramkrishna Sarada Sathi Sangha – Chak Dariberia


ENVIRONMENT

World Environment day celebration ( Hosur ) - School Children on Procession, Distribution of free Saplings, Clean Hosur program

World Environment Day celebration ( Haldia ) - Rally by Exide Employees, Environmental Drama, Flag hoisting, plantation, sapling distribution, visit, training Community awareness program on HIV/AIDS - Tableau , Rally


WOMEN EMPOWERMENT

Activities for Women empowerment ( Village - Iswardaha Jalpai ) - Vocational Training, Distribution of sewing machine, Employees’ Uniform made by Self help Women Group

Activities for women Empowerment ( Hosur ) - Purchasing of hand gloves manufactured by units employing women


ASSISTANCE & PHILONTHROPY

To combat malnutrition- save 600 children below 5yrs across the country

Administer Vit-A to 45000 children across the country

Adopted Children of Deceased Karthik’s Education up to High School

K.Sowmiya - 2nd std K.Ragul -1st std

Donation to Ramkrishna Mission Sevashrama , Tamluk for Supply of drinking water by construction of an underground reservoir with

RCC wallDonation of Battery for Power Supply in Homeopathy Dispensary

& Main Temple to Natshal Sri Sri Ramakrishna Ashram

Donation food & cloths for flood victim, cart for handicraft, blood donation camp


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SOUND : -Any Comments about Sound -

2007-08 2008-09 2009-10 2010-11 2011-12

1

2

3 3

2Haldia

2007-08 2008-09 2009-10 2010-11 2011-12

1

2

3 3

2Shamnagar

2007-08 2008-09 2009-10 2010-11 2011-12

1

2

3 3

2Hosur


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ILLUMINATION LAVEL : -

Any Comments -

2007-08 2008-09 2009-10 2010-11 2011-12

1

2

3 3

2Haldia

2007-08 2008-09 2009-10 2010-11 2011-12

1

2

3 3

2Shamnagar

2007-08 2008-09 2009-10 2010-11 2011-12

1

2

3 3

2Hosur


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LEAD IN BLOOD -Any Comments -

2007-08 2008-09 2009-10 2010-11 2011-12

1

2

3 3

2Haldia

2007-08 2008-09 2009-10 2010-11 2011-12

1

2

3 3

2Shamnagar

2007-08 2008-09 2009-10 2010-11 2011-12

1

2

3 3

2Hosur


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LEAD IN AIR - Any Comments -

2007-08 2008-09 2009-10 2010-11 2011-12

1

2

3 3

2Haldia

2007-08 2008-09 2009-10 2010-11 2011-12

1

2

3 3

2Shamnagar

2007-08 2008-09 2009-10 2010-11 2011-12

1

2

3 3

2Hosur


2007-08 2008-09 2009-10 2010-11 2011-12 2012-13

1191 1304 13421225 1234 12001126 1050 955 946 994

1 1 1 1 1

POWER CONSUMPTION (KWH/MT OF Pb)


2007-08 2008-09 2009-10 2010-11 2011-12 2012-13

0.916

0.956000000000001

0.951000000000001

0.979000000000001 0.982 0.9840.98 0.988 0.991 0.992 0.9931 1 1 1 1

POWER FACTOR


ENERGY COST AND CONSERVATION


NOV’11

DEC’11

JAN’12

FEB’12

MAR’12

ENERGY CONSUMPTION AND CONSERVATION

MAY’12

COST SAVED UP TO MAR’12 Rs.26,499/- PER DAY

ENERGY SAVED /DAY : 4351.69 KWH

COST SAVED: Rs.25,405 PER DAY

JUN’12



APR’12





TREND OF KWH PER MT LEAD AT INDUSTRIAL FACTORY

Maintained Power factor of the plant at around 0.99. Maintained Load factor of the plant at around 75%. Introduction of Compressed Air Management system for optimum use of Air Compressors at plant. Installation of SCR controlled heating systems at Lead Pots of Wirtz Casting & Auto spine machines. Use of one no. Cooling Tower in place of two nos. Cooling towers for Hadi & Wirtz Casting machines. Installation of LDRs at different locations for automatic switching ON/OFF of shopfloor lights during daytime. Installation of 28W T5 Energy saver fluorescent lamps in place of conventional 40W lamps at different locations in the plant. Electrical interlocking of fresh air & exhaust blower motors in the plant with Production machines to stop idle running of blowers during non-productive hours.


POWER COST (Rs per Ah)

2007-08 2008-09 2009-10 2010-11 2011-12

0.226 0.2440.29 0.293 0.286

RS/AH


FUEL COST (Rs per Ah)

2007-08 2008-09 2009-10 2010-11 2011-12

0.05900000000000

01 0.061

0.044

0.058 0.058

RS/AH


MIGRATED BEST PRACTICES FROM HOSUR


BLUE FLAME LADLE BURNERBLUE FLAME LADLE BURNER

Burner with yellow flame New burner with VENTURI has been developed

OBJECTIVE: To reduce LPG consumption


DESCRIPTION:Guards provided and so the spillage has been eliminated

BEFORE AFTER

DESCRIPTION:Rejected lead materials spilled out

from the c/v

OBJECTIVE: To eliminate the spillage while conveying rejected grids.

‘Z’ CONVEYOR GAURD‘Z’ CONVEYOR GAURD


BEFORE AFTERWooden Pallets Are Used for grid stacking.

Replaced with Metal Pallets To Avoid The Pallet Damage

WOODEN PALLET ELIMINATIONWOODEN PALLET ELIMINATION


LPG LEAD POT FOR BALLMILLLPG LEAD POT FOR BALLMILL

Electrical Lead Melting Pot LP Gas fired Lead Melting Pot

OBJECTIVE: To reduce energy consumption

BENEFITSBENEFITS Heaters are eliminated Energy savings = 86.125MW per month Cost Savings (Excluding LPG cost) = Rs2.78 Lacs per month


BALL MILL ACOUSTIC ENCLOSUREBALL MILL ACOUSTIC ENCLOSUREOBJECTIVE: To reduce noise level in reaction blower & exhaust blower.

BENEFITS: Noise reduced Improved working environment Operator morale has increased.


TAKEOUT GEAR ROLLERTAKEOUT GEAR ROLLER

BEFORE AFTER

Chain sprocket drive provided in take out

c/v. Plate sticking problem due to poor

gape

Gear teeth roller provided to provide

the gape b/n the plates.

BENEFITS: Quality improved & Curing Process Improved.

AREA: SHINKOBE 1 PASTING M/C


ADHESIVE & COHESIVE TESTER FOR PLATE CURING STRENGTHADHESIVE & COHESIVE TESTER FOR PLATE CURING STRENGTH

Load penetration instrument developed

BENEFITS:Improved quality assurance

PLATE CURING STRENGTH DATA

TYPE Min. Max. AVG.SPEC

ARRIVED

26AH POSITIVE

5.8 6.4 6.0 >5.0 PSI

38AH POSITIVE

7.0 7.7 7.4 >7.0 PSI

38AH POSITIVE (Gel / LL

Type)

5.5 6.3 5.9 >5.0 PSI

INVASAFE POSITIVE

5.6 6.1 5.9 >5.0 PSI

INVASAFE POSITIVE (Gel / LL

Type)

5.4 6.32 5.8 >5.0 PSI

100AH POSITIVE

5.4 7.1 6.0 >5.0 PSI

100AH POSITIVE (Gel / LL

Type)

5.2 7.02 6.08 >5.0 PSI

NMST POSITIVE

11.6 17.6 13.4>12.0

PSIMET

POSITIVE10.8 15.2 12.5

>12.0 PSI


ONLINE PASTING DRAIN pH SENSORONLINE PASTING DRAIN pH SENSOR

To identify the acid discharge due to leakage

or overflow

APR MAY JUN JUL AUG SEP OCT NOV DEC JAN FEB MAR0

1

2

3

4

5

6

7

5.6 5.55.2

5.5 5.7 5.6 5.4 5.35.0 5.1 5.1 5.2

1.9 1.81.4 1.5 1.4 1.5 1.5

1.9 2.1 2.02.4 2.4

EFFLUENT pH TREND

2010-11 2009-10

pH


NEGATIVE PLATE WASHING AUTOMATIONNEGATIVE PLATE WASHING AUTOMATION


VERTICAL STORAGE SYSTEMVERTICAL STORAGE SYSTEM

Charged Batteries were stored in the floor

Vertical storage racks introduced

BENEFITS:

Floor Space saving &

100% FIFO system followed


ELIMINATION OF THERMOCOL USAGEELIMINATION OF THERMOCOL USAGE

THERMOCOL was used for battery stacking after charging for storage. DISADV:

Environmental pollution Can’t be recycled.

It is replaced with HARD RUBBER SHEET.ADV:

Reusable


ONLINE MATERIAL RESERVATION (MR) THRO SAPONLINE MATERIAL RESERVATION (MR) THRO SAP


PNEUMATIC CYLINDER FOR ACID WASH ROLLERPNEUMATIC CYLINDER FOR ACID WASH ROLLER

Easy to adjust the roller pressureBetter thickness controlUniform acid washGood surface finishing

BEFORE AFTER


PATH AHEAD

CouldReverse the

employment trends in manufacturing

UK a magnet location for

manufacturing investment

Manufacturing 25% of UK GDP

ShouldStep-change in the competitiveness of the UK supply chain

UK has seized the low-carbon

manufacturing opportunity

UK a high intensity

engineering & technology

nation

Will

Establish the HVM TIC as a new

mechanism for economic

development

Skills & education rebalanced

towards science & engineering

Afford rapid growth in

applied science & innovation investment

0-5 years 5-10 years 10+ years


PATH AHEAD

Adaptability is vital

"It is not the strongest of the species that survives, nor the most intelligent; it is the one that is most

adaptable to change."-- Charles Robert Darwin (1809-82)

pp industrial 2nd cut revised

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