AMS Conference Speeding production through new technology usage

Transcription

1 AMS Conference 2013 Speeding production through new technology usage

2 Let us embrace Science and the new technologies unfettered, for it is these which will liberate mankind from the myth of god, and free us from our age old fears, from disease, death and the sweat of labor. Claude Vorilhon (French Auto Sports Journalist)

3 Mission: Hero MotoCorp s mission is to become a global enterprise fulfilling its customers needs and aspirations for mobility, setting benchmarks in technology, styling and quality so that it converts its customers into its brand advocates. The Company will provide an engaging environment for its people to perform to their true potential. It will continue its focus on value creation and enduring relationships with its partners.

4 Milestones 1984 Hero Honda Motors Ltd. Incorporated 1985 First motorcycle "CD 100" rolled out from Dharuhera Plant 1997 Gurgaon plant inaugurated Hero Honda No. 1 Two Wheeler Co. for 3rd consecutive year. Splendor - World s largest selling model for 3 rd year in a row 5,000,000th motorcycle produced Haridwar plant inaugurated New Technology Partners : EBR (USA), AVL (Austria) Engines Engineering (Italy) Hero Honda retains World no. 1 status for the 10 th year in a row 2012 New Licensing agreement between Hero Honda and Honda Motor Co. Ltd. Name of the Company changed to Hero MotoCorp Ltd. 2011

5 Our Manufacturing Units: Manufacturing Units Location Production Started Dharuhera 1985 Gurgaon 1997 Haridwar 2008

6 Indian 2 Wheeler Industry:: H1 Status (H1) 7.9 Million 0.4 Million, 1.5 5% Million, 19% 1.7 Million, 21% (H1) 8.0 Million 0.35 m, 5% 6 Million, 76% Motorcycle Scooter Mopeds 6 Million, 74% Motorcycle Scooter Mopeds

7 Business Challenges Global economic scenario - The global manufacturing and trade cycle has begun to reaccelerate, particularly in the emerging market economies. - Indicators of manufacturing activity suggest that in advanced economies is only beginning to stabilize. Consumption growth eased marginally during the latest slowdown. Auto industry scenario in India - Low demand in FY 14 coupled with a excess capacity and intensifying competition is likely to reduce industry operating margins. - Global economic scenario coupled with Govt reforms will be one of the key drivers for growth in Auto industry in India. - Focus on industrialization / Infrastructure policies will also play a major role in a long term. Role of Indian Industry as a key consumer market - Competitive standards of Indian industry needs to achieve new heights considering the aspirations of local / overseas consumers in terms of Cost / Quality.

8 Major Challenges: Indian Manufacturing Sector External Internal Fragile Economy across country and globe. Slow Infrastructure development (Roads / Ports / Power ) Govt. policies (Import / Bank rates / Tax regimes ) Competition from local and global players (Cost / Quality / Volumes ) Industrial Relations issues. Sustaining Consistency in growth.

9 New Technology A brief overview

10 Approach towards New Technology. Hero Way Make Business Sense Learn Apply Learn Cycle New Tech. Product Quality Up Time bound activity Enhance Process reliability

11 Challenges ahead Continued focus on design and development capability Explore and establish in New market Cost and delivery of product Manage the business variability Sustain leadership position

12 Philosophy of operations and supply chain Flexibility in manufacturing Focus on new technology and innovation Bench mark with the best manufacturing practices Continuous focus on -People and stake holder development -Resource conservation

13 New Technology Process Gear Rolling: Improve the gear geometry. Consistency profile geometry: same profile obtained on the 1 st rolled parts as on the th The Heat Treatment distortion are taken care during roll design Improve the Gear surface quality. Excellent Surface Finish Ra >0.02 Improve the mechanical properties of Gears. Better resistance to wearing compared to shaving. Better resistance to pitting compared to shaving. Steel is formed not cut Improve Productivity / Quality parameters

14 New Technology Process Assembly Lines Synchronisation Improve Productivity / Logistics / Flexibility

15 New Technology Process F/B Cy. Mill R/Mill L/T WASH R/Mill Gravity C/V Realize PQCDMS parameters Slat C/V Skilled M/P 1 Nos. Semi Skilled M/P 4 Nos. Flexible SPM 5 Nos. Flexible GPM 20 Nos. 1 time flex. SPM 1 No. Gantry Robo

16 New Technology Process Fuel Tank Blank Optimization Improve Productivity / Optimize Cost

17 New Technology Energy Saving Natural Gas based power Generation (Gradual replacement of existing system) Along with Usage of Natural Gas inplace of Propane /HSD in Paint Shop, Heat Treatment, Canteen Area, Fluidized bed, Incinerator Replacing approx. 150 LKg FO per annum with Natural Gas (Gurgaon + Dharuhera) Improve Power Cost and reduce environment hazard Replacing approx. 80 LKg Propane per annum with Natural Gas (Gurgaon + Dharuhera)

18 New Technology Energy Saving Conserve Energy by moderating temperature on roof and surrounding areas (approx mtr2 area with green roof & 3 C temp. reduction) Improve Saving of Productivity by 240 kw/day Providing Electrical Comfort energy Conditions for workers External Internal -- Confidential 18 Internal - Confidential Title: Green Initiative 18

19 New Technology Energy Saving Vapor Absorption Machine Waste heat of 3 nos Gas Generato rs Jacket water Jacket water 92=> 80 C Chilled water 7=> 12 C Improve Energy Conservation thru Green Initiatives Generation of 580 TR Chilled water for A/C system to replace existing Electrical Chillers of Engine assly, Prod. Offices, BOI, Pai nt shop etc (saving of 400 kwh) 19

20 New Technology Energy Saving Plant Roof The Plant is Commissioned & Generating Power. Saving benefits from the Plant : 1) Annual KWH Saving: 1.56 L KWh, Annual FO Saving: Ton 2) Annual CO 2 Emission Reduction : Ton Future Plans : 1)Installation of 80 KW PV Solar Power Plant at Dharuhera Plant 2) Installation of 100 KW PV Solar Power Plant at Haridwar Plant 3) Exploring Solar Water Heating Systems for Canteen & Process Heating (Paint Shop). 4) Exploring solar based Air conditioning using VAM. Cost Optimization / Contribute to Environment

21 Some Future Plans: 1. Energy efficient shops / plants. 2. Extensive use of alternate source of energy. 3. Green building Concepts. 4. Timely up-gradation in technology. 5. Focused Automation

22 To Conclude. In a world of rapid and continuous change, we must have the courage and vision to challenge our traditional assumptions, defy prevailing business currents, identify opportunities and go after them, changing the rules of the game, to bring unlooked for benefits to customers.

23 Thank you