What if De-Energization?? Kaizens

Transcription

1 What if De-Energization?? Kaizens Green chemicals Renewable energy Employee involvement Briquette Fired Thermic fluid Heater Variable frequency Drives Blower efficiency improvement Conserving Energy Everywhere.. LED Lighting Solar energy Better capacity utilisation High volume low speed fans(hvls) Overall Equipment Effectiveness(OEE) Compressed air management Smart sense Monitoring Motor De-Rating Vendor Development Timers Technology up-gradation CII National Award for Excellence in Energy Management 2017 Conserving Energy Everywhere.. Presented By:- Mahesh V Kulkarni Anand Dande Vinay Sarode Godrej Interio Product portfolio Journey Of Energy Conservation Godrej Interio - Enriching life by transforming home and work spaces 176 product solutions for home and institution spaces Green Portfolio - 43 %. National Benchmark In furniture Manufacturing Kal bhi Aaj Bhi 6 Indoor Advantage certified products 3 BIFMA Level certified products 52 GREENGUARD certified products 16 GRIHA certified products 1

2 Process layout for Interio Shirwal Energy sources used in the plant Interio Shirwal Maintenance & Utilities Common Resources Quality 3.05 In house Solar Administration Supply Chain Lamination Resin preparation Lamination Plant II Wood Working Cutting Edge- Banding Drilling Membrane Pressing Lacquering Packing and Dispatch Powder coating Pre treatment Powder coating Metal Working Cutting Bending Notching Punching Welding Briquettes Diesel Solar(kWh) Electricity(kWh) Diesel(Lit) Briquette(kg) MSEDCL Energy Performance for the plant 66% reduction over baseline Energy Performance Specific energy Consumption trend (MJ/Sqm) Increase Over Last Year due to additional Plant commissioning Specific energy Consumption trend (MJ/Sqm) without Plant II Specific Energy reduction Benchmarking with national and international manufacturers Action plan to become Best in class % reduction % reduction 66% reduction

3 Comparing ourself with other industries Benchmarking our processes with International Manufacturer Wood working Benchmarking (kwh/sqm) better Powder coating benchmarking(mj/sqm) Analysis and action plan better Improvement in Energy Efficiency Compared to FY10 FY14 FY15 FY16 FY20 GOAL RETAIL DISTRIBUTION CENTER IKEA industry Division Flatline and Solid Wood IKEA Industry Division Board IKEA components Home furnishing Supplier Data(IKEA) FY12 FY14 FY15 FY16 Energy GWh Specific energy kwh/m * Source IKEA sustainability Report 2016 Interio Shirwal % reduction Vendor 1 Vendor 2 Godrej Interio Shirwal 0 Godrej appliances Godrej Company Company Company Interio Vikhroli Godrej Interio Shirwal SEC (MJ/sqm) for Wood Our focus = Energy conservation Approach Followed for Projects planning -Opportunity matrix List of energy intensive equipments No Name of equipment Units Rated Load % contribution to Total Electrical Energy % contribution to Total Thermal Energy Equipment Can this be eliminated? Alternate Process? Increase efficiency? Reduce consumption? Compressors New technology Use of Renewable Energy 1 Air Compressor 2 180kW 13% NA 2 Thermic fluid heater 1 NA 4.9% 19% 3 Pre Treatment line pumps 14 motors 4 Powder Coating blowers 6 blowers 7.5 kw x kw x 4 15kW x 6 8.8% 20 kw x 2 14 kw x 4 5 Dust extractor 4 133kW 16% NA 6 WDO and PCO burner 2 NA NA 80% total diesel consumption 7 Powder Coating oven 1 NA NA NA NA PT line motors Dust collectors Thermic fluid heater Cooling tower Hydraulic power packs ETP /STP / Water circulation system Press Shop Blowers for ovens Plant Lighting Air Conditioning 3

4 Action Plan to achieve Targets Plan Plan S M L Contribution to total energy Reduction 1 Minimising air leakages throughcontinuous arresting 3% kWh 2 VFD s for air compressors 1.5% kwh 3 Led lightingto replace all lamps in shop 2% kwh 4 Completed Ongoing Not started Constant torque VFDs to be installed in all press brakes and Hydraulic machines S = Short term (16-17) M = Medium term (17-18) L = Long term(18-19) 1% kwh 5 Replacement of fans with larger capacity HVLS fans on shop floor 1% 24902kWh 6 VFD for cyclone Motor 1% 23656kWh 7 Thermic fluid Heater Efficiency improvement 4% kgs 8 Motor De-Rating and loading efficiency improvements 2% kwh 9 Improving hook efficiency of Powder coating line 1% 6000 lit diesel /yr 10 Harmonic Reduction of the plant - Indirect Benefits. 11 Reduction in fixed energy consumption 4% 2,70,000 kwh 12 Purchase of energy efficient machines 1% kwh Zero investment projects done in last 3 years Title of Project Usage of low bake chemicals for powder coating line and elimination of Hot water generator Increase in speed of Pre Treatment line and Powder coating conveyer Year Annual Electrical Saving, (Million kwh) Annual Thermal Saving, (Million kcal) Total Annual Savings, (Million Rs) Investment Made (Rs million) Changing in Briquettes with Higher Calorific value briquettes Reduction of dust collector frequency to 45 Hz Resin formulation changed for lamination Elimination of Fume extractor pumps due to change in PT line chemicals Capability training of employees 1% Through kaizens 14 Automation of thermic fluid fuel intake 1% 26 ton briquettes 15 OEE and productivity improvement 1% MJ 13 Total Saving INR 1.1 Cr/annum Investment - INR 0 Projects implemented in last 3 years Title of Project Year Annual Electrical Saving, Million kwh Annual Thermal Saving, Million kcal Total Annual Investment Made (Rs Savings, Million Rs million) Lighting automation panels Changing of air guns to ventury type Air monitoring system automation Automated energy monitoring system VFD for cooling tower Changing of transparent sheets Timer circuits for all dust collectors Installation of diesel dispenser for monitoring consumption Replacement of Lamps in press shop to LED Capacitor panels to compressor and dust collector Replacement of 3 hydraulic press with one Press brake Replacement of Inefficient turret punch with advanced and efficient LVD turret PTO.. Projects implemented in last 3 years Title of Project Total Year Annual Electrical Saving, Million kwh Annual Thermal Saving, Million kcal Total Annual Savings, Million Rs Saving - INR 1.49 Cr/annum Investment Made (Rs million) VFD for RO HP pump Savings due to air leakage arresting Sensor based drain valves to Compressed air Led lighting for shop floor Thermic fluid heater briquette drying PT line auto cut off panel thermal paint coating of scl plates Installation of VFD for cyclone vacuum pump elimination Replacement of thermic fluid motor Lighting generator %Investment on Turnover Investment - INR 1.14 Cr 0.7 4

5 BasIc learning.. Energy conservation projects & Innovations The more you measure, the more you save Air Compressor Saving of 25 Lacs p.a Instrument :- Compressed air flow meter Instrument Cost 50,000/- INR to 2,00,000 INR Make VP, Vortex,SMC Flow meter Installed for Air measurement Cloud based Air monitoring system Machine wise Flow measurements Establishment of pressure flow diagram VFD installed for compressors Air leakage tags implemented Annual saving 25.2 lac INR Investment 4.5 lac 22.5% Electrical Consumption Before 2016 Replacement of guns with Ventury effect air guns Saving Potential - 25 Lac 13% Electrical Consumption as on date Daily Energy Saving of 1400 Kwh Specific energy consumption of compressor is 0.16kwh/cfm Installation of auto drain valves

6 8/30/2017 Lighting Saving of lacs 76kw Lighting Load 10/06/2016 Instrument :- Lux meter Instrument Cost 5,000/- INR to 20,000 INR Purchase of Lux meter for monitoring lighting levels Make Fluke, testo 11kw Lighting Load 06/04/2017 Saving Potential - 10 Lac Establishment of Lux plan for entire shop floor Annual Savings lac INR New layout plan developed with help of Bajaj Lighting Solutions Replacement of Lights to LED lamps Number of Lights replaced 304 x 250W lights Investment made 11 lac INR 22 VFD for Cyclone Motor Instrument :- Power Analyzer and Logger Instrument Cost 50,000/- INR to 10,00,000 INR Title VFD for Cyclone Initiative Installed VFD to cyclone motor(45kw) of PT line used for powder recovery Reduced RPM of Motor to 45 hz thereby achieving saving Replacement of motor Title Improving Loading efficiency of motors Initiative Make Fluke, Krykard 22 De-Rating of 37 kw motor(oversized) at around 40% loading to a 22 kw Motor of higher loading near-about 78% Improvement in Motor performance and loading percentage of the motor Saving Potential - 50 lac INR Savings per annum 16,200 kwh Cost savings - 1,13 lac INR Benefits :-Savings 17,891 kwh annum Cost savings L INR 6

7 8/30/2017 Harmonic analysis Conducted Harmonic analysis for Plant at main incomer Solutions De-tuned capacitor bank and active harmonic filter Voltage Harmonics 2.03 % Current harmonics 16.1% Date 24/01/2017 Cost 10 lac INR Instrument :- Thermal Imager Instrument Cost 1,00,000/- INR to 10,00,000 INR Make Fluke, Testo Active harmonic filter 100 Amps Cost 12 lac INR Fixed passive filter / Line Filters Cost 6 Lac INR Saving Potential - 50 lac INR Thermal Imaging Insulation Repaired Instrument :- Moisture Meter Instrument Cost 5,000/- INR to 20,000 INR New Insulations installed Thermic Fluid Heater Make Fluke, Testo Thermal resistant Paint applied Air Curtains to be installed Saving Potential - 10 Lac Powder Coating Oven 7

8 Waste Heat Recovery project where in Compressor exhaust air is used to remove moisture of briquettes 84,200 kg briquettes saved annually Cost saving of 6.74 lac INR per annum Before Innovation 1 - Thermic fluid Heater After Hot Exhaust Air Innovation 2 - Vacuum pump elimination of SCL Initiative: - To reduce energy consumption of vacuum pumps in SCL machine used for lifting Description : - There are 2 x 1.5 kw motors which are being used as a vacuum pump for lifting and transferring of Finished boards through the machine in SCL operating for 18 hrs per day We have eliminated these vacuum pumps by putting ventury effect air valves which are producing the same suction with help of pneumatic air at 6bar. Saving 16,200 kwh per annum Cost Saving 1.16L INR Innovation 3 Pressure Locking System Pneumatic Pressure Required For Cleaning Application Volume of air is required and not Pressure Pressure Set at 3 bar from 6 bar and locked Innovation 04 Cycle time reduction for lamination with help of benchmarking Initiative :- 1. Initiative to increase productivity by Resin formulation change. 2. Initiative to reduce number of chemicals used in Resin preparation. Description :- -Hardener chemical :- P.T.S. Acid, Marpholine, DM Water replaced by KS ( single chemical). -Alton is replaced by FA. -DM Water is replaced by RO Water Energy Benefits Benefits : - -Reduction in formaldehyde consumption by 7% -Productivity increased by 33 % by reducing cycle time by 20 seconds. -Hardener Preparation process eliminated. - Variety of Chemicals inventory reduced. -DM water inventory eliminated. 32 Process running time reduced Energy saving - 88,746 kwh/ annum (INR 6,21,226) Briquette saving 109 ton /annum (INR 5,19,168) Total cost saving lac INR /annum worth energy Resin Kettle Impregnation line Short cycle lamination m/c 8

9 Innovation 05 - Zirconium based pre treatment and Bioremediation with help of Auto-Tech Fruits of Energy Conservation Initiative:- To initialize Zirconium (Phosphate free) coating for pre-treatment line Description: - Existing iron phosphate pre-treatment process replaced with Zirconium coating (GREEN tech) for environment concern - Operates at ambient temperature -Passivation Tank removed, power & water savings accrued. Benefits: - Long life- Improved cleaner life due to bioremediation - Lowered energy costs - Eliminated scale and sludge build-up in nozzles and risers - Reduced time required for line cleaning and tank dumps - Lower burden on waste water treatment with phosphorusfree pretreatment Saving Cost saving 3.3 lacs per annum by elimination of Pumps Degreasing Pre cleaning Water rinse 1 Water Rinse 2 Zirconium Degreasing Coating 2 Water Rinse 3 Water Rinse 4 Passivation Powder coating Application submitted to MSEDCL to reduce Contract demand Awareness creation Activities Employee involvement & Energy conservation awareness Kaizens, suggestion boxes Trainings given to employees Competitions organized Poster, slogans, quiz etc Celebration of days Encon week, Earth Day, Energy Hour etc Energy Score cards and stickers Mailers and Handouts to employees for EnCon Poster and Slogan Competition themed Save Energy Save Future Energy Conservation stickers 9

10 8/30/2017 Kaizens sheet Shirwal Plant Plant Dept Kaizen No. IN Activity in : KK JH QM PM HSE Type of Loss : Energy Loss KAIZEN SHEET Kaizen Idea : To install VFD panel OTPM DM Kaizen Theme : To reduce energy consumption in Compressor System Problem Description: Compressor Consumes about 22 % of total electricity Before E&T Countermeasure : VFD panel fitted Bench Mark 50% reduction Target Mar Start date Finish date Mar16 Team Members : Mr. Mahesh Kulkarni Mr. Anand Dande, Mr Nishant Ganorkar, Mr A. Chaudhari P Q C D S M E Benefits in After Sustenance Plan : S.N. Activity Resp. 1 Monitoring power consumption Anand Dande Frequency Remarks Monthly Done Analysis : Result : Energy consumption has Why 1 Electrical energy wastage in Compressed air reduced by 10% systems Why 2- Compressor runs at high speed when not Annual Savings 3,69,061 kwh required Annual Cost saving 25,89,143 Rs Monitoring mechanisms Energy monitoring Project monitoring Reporting formats ISO methodologies Key word : high speed when not required Energy Monitoring system Smart Sense software Monitoring and measurement:gantt Chart for monitoring of Projects planned and implementation Features of EMS Cloud based system with storage space upto 3 years of data Data provided by EMS kwh Department wise consumption Machine wise consumption Daily reports to all Members

11 STRENGTHENING ENERGY MANAGEMENT SYSTEM ISO TOOLS Energy Management Cell Energy Use Register and significant energy use Performance Indicators at Plant and Dept level Setting Baseline and target Register of Opportunities and Energy Management Programs Internal ISO audits and External Energy Audits Environmental projects & Projects related to reduction in Carbon emissions Energy Review Carbon Neutral Plan Inventorization of Emission in absolute MT of C02e MT.Co2 Scope 1 Scope 2 Scope Consumpti on Briquettes(kg) 5,70,146 Solar Roof Top Electricity (kwh) Equivalent in Fossil fuel 187 KL of HSD Emission saved in MTCO2e 506 2,71, Total MTCO2e saved Scope 1+2 MTCO2e GHG Offset in FY % Absolute Reduction in MT CO2e % reduction kgco2e/sqm 12% reduction Non-Hazardous Waste Material Reuse Wall shelf Painting Small Table & chair Waste Particle Board Drawer Units Decorative articles Made from wood scrap Particle board ceiling and walls Wall clocks

12 8/30/2017 Waste Water Management at Village Palashi Problem Identified/Impact Tree Plantation drive Funds (in Lakhs) NGO Partner 80 WOTR The natural water stream polluted by inputs from 4 sewage streams Environment Protection Improved hygiene Water will be conserved and used for other purposes Community Meeting Work in Progress Water Treatment of 4lac Litre/day Roadmap for Renewable energy in the Plant Renewable energy Share Renewable Energy In the Plant Renewable Energy Non renewable energy Mid term Targets 50% RE (201819) Short Term Target 40% RE (201718) Pellet based burners for WDO and/or PCO Long term Targets 60% RE (2020) Solar concentrators to be used in plant Heating application Additional Solar Panels on roofs 48 12

13 Solar Power Plant (365 kw) Briquette Fired Thermic fluid heater Installed Solar Power Plant (365 kw) on Apr 16 Daily Co2 reduction- 720 Kg per day In Future, we will be adding additional 100 kw Solar power Plant inhouse 8.8 Solar Energy Contribution 91.2 In-house briquette fired thermic fluid heater used for lamination process Fueled Used - Briquettes made from peanut shells and agro waste Energy generated by this heater accounts to about 42 % of total thermal load of the plant briquettes MSEDCL Solar 49 Solar Power Plant (365 kw) 50 Approach for Energy conservation at vendors Highlights Encon By Vendors Incentives and rewards Sharing of feedback and knowledge Cluster Formation for Facilitation Training programs for Vendors 10 key suppliers are Greenco Rated 100% supply chain involvement Audits and Reviews Hand Holding Completed 4 Clusters 13

14 Green Initiatives by our vendor - Khutale Engg Green Initiative by our Vendor - P M Electro-auto Pvt Ltd Before After Before After LPG Rs.1.80/SF t. 15 Min BT. Wt114 Kgs. LPG Rs.1.50/S Ft. 10 Min BT Wt.40 Kgs Use of CFL Use of LED High LPG consumption due to MS trolleys Low LPG consumption due to Aluminium trolleys Optimized compressed air thru centralized unit Polycarbonate Transparent Sheets & Turbo Ventilators Organizing PUC camp for employees vehicles 30 Frames loaded for baking 40 Frames loaded for baking No provision for Waste powder Tray for waste powder collection Improper utilization of space in baking oven Optimum space utilization after trolley modification 15 Tanks Pretreatment Process Optimized Gas Fired Burner For Hot Water Generator To Run Pretreatment Line. Green Initiative : - More than 300 Nos. plantation done in 3 Acres land. Certifications and recognitions Name of the Award Year of Receipt Given by Management system as per ISO 14001: TUV NORD Management system as per ISO 9001: TUV NORD Management system as per BS OHSAS 18001: TUV NORD GreenCo Best Practices Award for Design For Environment 2015 CII GBC Green Company Rating System- Gold Rating 2015 CII GBC Green Company Rating System- Platinum Rating 2016 CII GBC B.G. Deshmukh Award for Excellence in CSR 2015 Maratha chamber of commerce and agriculture Home Retailer of the Year Award 2016 Indian retail congress 2016 by Franchise India Marketer of the year Award 2015 DMAi (DirectMarketingAssociation, India) Special Award for energy saving 2016 PDPC pune Winners in excellence in Associate group 2016 PDPC pune Winner in Associate General Engineering 2016 PDPC pune Runner- up in Management General Engineering 2016 PDPC pune Excellent energy efficient Unit CII Energy Summit CII GBC Most Useful Presentation CII energy Summit CII GBC First Prize 11 th State Level award for energy Conservation 2017 MEDA Pune Management System as per ISO 50001: TUV nord First Runner Up CII Energy Circle 2017 CII GBC From us.. 14

15 to our suppliers Powder coating Analysis Powder coating Analysis Points to be noted:- Plant 13 has component of cupboards hence area is more in terms of Square meters painted. On the other hand Shirwal has a mix of tile sheets and hollow metal frames hence reduced square meter coating Average rated loss is 15-16% due to type of product Mar 16 data AREA % Frames Tubes Shirwal Plant 13 Considering 15 % loss from frames modified Graph SEC for powder coating Action Plan to improve SEC- Improving Hook efficiency of Powder coating line Replacement of diesel burner with pellet fired burner Batch loading reduction in running time of PT line by optimizing load Panels Total Sqm 0 Plant Shirwal

16 Back up slide As per GHG protocol Chapter 9, GHG emissions from Briquettes are reported separately as GHG emissions from biologically sequestered carbon 16