Company TPM Policy Plant and its vendors in the same premises. Plant produces Discover, Boxer & Patina range of motorcycles.

Transcription

1 8th National Award for Excellence in Management- 7 Contents No. Bajaj Auto Ltd. Waluj Plant Company profile Manufacturing process Conservation cell Conservation Approach Indices Benchmarks 7 Conservation Methodology & Tree 8 Target Setting August, 7 Innovative Projects Other Encon Projects a) Electrical b) Thermal c) Use of renewable energy Environment & Carbon Reduction Utilization of waste Results Sustenance Future Project Achievements Corporate Office & Manufacturing Plants Topics 9 Company Vision & Mission through KMI, KPI & KAI Company Vision Pantnagar Plant (7) Company Mission Company TPM Policy Plant and its vendors in the same premises. Plant produces Discover, Boxer & Patina range of motorcycles. Waluj Plant (98) MC Plant Manufacturing of -wheelers Caters to the major export needs Waluj CV Plant Manufacturing of Wh & Wh models Approach for Improvement Chakan Plant (998) Manufacturing of High Performance bikes. Bajaj Auto has a global footprint with presence in countries with No. or No. position in 7 of them. Current Future ISO 9 Started in 9 Bajaj Auto Ltd - Corporate Office Akurdi, Pune ISO OHSAS 8 ISO - Initiated

2 Manufacturing Process Flow Chart Flow Chart - Conservation Program Press & Fabrication Vendor parts Aluminium Shop Domestic Dispatch Paint Company Vision/Mission Plant Vision/Mission Divisional Target Shop Level Target Vehicle Assembly Export Assembly & Packing Steel Shop Heat Treatment Engine Assembly Cost ReductionKK Pillar Export Dispatch Technical Improvement PM Pillar Central Gear Shop Manager Total Number of Equipments - 8 nos. Management Review Execution & Monitoring Budget Allocation Environment Improvement - SHE Pillar Encon Projects Conservation Cell Structure & Review Mechanism Details of year-wise efforts made in Technology Absorption relating to. Measurement system (LAN based) Micro mapping through power analyzer Average Time spent by Senior Executives in various functions Eliminate need Technology Up Gradations Administrative Issues, LCC (Life cycle cost ) analysis Green Manufacturing Initiatives, Measurement at feeder (Manual) Manufacturing excellence, TPMReview/Imple mentation, Technological & Developmental activities, Eliminate resource wastage Eliminate resource wastage Eliminate resource wastage Localized control Localized control Human Dependent systems YR Onward Human Dependent systems Working on Legacy system Level Level Level Level Captain ( Daily ) Manager ( Weekly ) Divisional head ( Fortnightly ) Plant head ( Monthly ) 7 Eliminate waste Eliminate waste Human Dependent systems Localized control Supply Chain Management, Review Mechanism System Auto controls System Auto controls New Products, Sharing best practices with stake holders Optimization Optimization Quality Management systems, Deep mining of Solar & Wind YR - YR 988- YR

3 Specific Consumption Saving & Budget Allocation Electricity LPG Water Capacity Utilization Consumption per unit of production & Capacity Utilization Unit Kwh/ veh Kg / veh m / veh Base Year 9 Achieved Target % SEC Reduction % In Year s In Last Years In last year Electrical ( Kwh/Veh) 7.8%.%.9% Fuel ( LPG) ( Kg/Veh) %.8% 9.7% Water ( Cu.m /Veh) 8.%.%.% Absolute Saving Year Elect. Saving (Lacs Kwh) Thermal (Fuel) saving M Kcal Elect. Consumption Lacs Kwh Thermal (Fuel) Consumption M Kcal Elect. Saving % Thermal Saving % Projects implemented through separate conservation budget allocated every year Year of Implementation No. of Projects Savings Rs. Million Investment* Rs. Million Budget allocated (Rs. Million) Specific Consumption-Benchmark consumption stratification & methodology BAL, Waluj Nearest competitor Global Electrical ( Kwh/Veh) 7.. NA Fuel ( LPG) ( Kg/Veh).8.9 NA Water ( Cub.Mtr/Veh.). ( Water Positive ). NA SN Electrical % Thermal % Lighting Compressed air Cooling Process Heat treatment Paint shop Others Canteen Activity Methodology Tools/ Techniques used No Standard Benchmarks are available for Automobile sector, These are collected as per our information's. Process wise energy consumption benchmarking started among our associates However, we are setting our own internal targets as: Min % Reduction in specific energy consumption wrt last year Audit Analysis To identify areas of energy conservation potential ( Internal & External) To identify equipments & Processes where energy conservation is possible Weekly / Monthly data through Pie charts & brainstorming Daily/weekly KWh, pressure, flow,volume etc.recording through bar charts,graphs Action Plan Activities for individual equipments with time frame Resource planning & activity charts Implementation Action for procurement & implementation WH Way Activity Charts Evaluation To analyze plan V/S Actual Gap Analysis & countermeasures Sustenance To Monitor the results Internal Audits

4 Conservation Methodology & Conservation Methodology & : Compressed air Electrical Reduction of Compressed Air Consumption Per Vehicle Loss Compressed Air Loss Reduction / Elimination Technological Improvement Operational Control Renewable Loss Improvement Alternate Source/Recovery Optimization Efficient Equipment Approach Waste elimination - Arresting Leakages Optimization of compressed air supply Elimination of compressed air usage SN Light Power Loss Unwanted illumination Compressed air energy Inefficient Equipment Transmission Loss Power Factor Harmonics Transformer Loss 7 Micro Level Analysis Visible Loss Invisible Loss SN Biogas for Heating Solar Lighting Solar Power generation Wind Power Generation Solar Water Heating LPG Heating Process Change 7 IR Heating 8 Recovery-Heat Pump SN VFD for high HP Motors Optimization of Motor/Pumps Life cycle cost analysis Task Lighting SN LED/CFL/Induction Lamps Efficient Motor/Pumps Screw Compressor Ceramic to Metal tube heater Aluminium Pipes for compressed air.air Star rating equipments 7 Use of Soft Starter 8 Scroll Compressors SN Metering & Monitoring Auditing Captain No Production on Off days Sharing Best practices with stake holders SN Natural air draft in place of electrical exhaust fans Transparent roofs/ Light Pipes for shops Solar energy for heating /Lighting /Power generation Air Leakage data collection through audits from shops Air leakage data through FAD tests. Efficient usage of compressed air Shut off valve during non working hours providing localized compressors Separation of air headers for Low pressure & High pressure requirement Rerouting & Resizing of compressed air headers Use of Air Boosters for High pressure application Use of Aluminum pipes for air distribution in assembly shops Use of Electrical operated tools Use of electrical operated vacuum pumps Eliminate Deburring operations Conservation Methodology & : Fuel ( LPG ) Target Setting To achieve specific Electrical energy consumption per Vehicle to Kwh in year 7-8 We require : Fuel (LPG) Loss Technological Improvement Operational Control Loss Elimination Alternate Source Efficient Equipment Heat recovery Monitoring & Audits Consumption reduction How to achieve Per month by.7 Lacs Kwh Per Day by 8 Kwh Consumption reduction Per Hour by Kwh Target Heat Loss through oven skin Heat Loss Through Flue Gases Heat Loss to Jigs & Fixtures Tuning of burners Optimize air velocity of oven Air curtain to reduce heat loss Solar water heating Use LNG Infrared Heating Bio Gas Direct heating IR Combustion Efficient Burner Low Temperature process Cycle Time Optimization Heat recovery from Process Flue gases Metering & Monitoring Auditing Thermal mapping Captain No Production on Off days Efficient Equipment Fix Load reduction Load Reduction by 8 Kwh Alternate Wastage reduction Variable Load reduction Operational Control Load Reduction by Kwh

5 Innovative Project Reduce consumption for Seam welding process Seam Welding process : A resistance welding process which produces coalescence at the faying surfaces The two parts held together under the pressure of The electrodes, weld heat obtained from I X R X t ( I = Current passing through electrodes, R = Circuit resistance, t = Duration ). The resulting weld is a series of overlapping resistance spot welds made progressively along a joint by rotating the electrodes. A/C Seam Welding AC Welding Process Two Phase: Input supply Innovative Project Reduce consumption for Seam welding process Secondary out put Input phase AC supply Firing angle control with Thyrister Voltage Step down Machine : Process : Welding cycle : Low voltage AC for welding Ram & Cylinder Current Regulation Features : Upper Electrode Lower Electrode Current Regulation limited to once per cycle Milisec( Hz) High Peak Current Weld Time More Inductance losses at Secondary Needs power factor correction equipment 7 8 Innovative Project MFDC Welding Process Input phase AC supply Innovative Project Reduce consumption of Seam welding machine Comparaison AC Single Phase vs. MFDC Mains Peak current Demand Power Saving AC to MFDC Welding A/C to DC & DC to AC ( Medium Frequency ) MS. V = A AC Mains Current Input supply Inverter O/P Secondary out put Voltage Step down MS V AC Mains Voltage MS. V = A MFAC Mains Current Hz Low voltage DC for welding Current Regulation Features : Process Programming to millisecond time base Current Regulation within msec DC Weld Current -No inductance losses in Secondary Balanced Load, per phase low current Reduced conductor, Transformer size Unity Power Factor Reduced Peak demand current Weld Time weld time is % shorter AC: current with inherent off times MF: compact pulse 9

6 kw ::8. PM 9// :9 Innovative Project Reduce consumption of Seam welding machine Parameters Comparison : SR Parameter Phase AC Machine Phase MFDC Machine Transformer KVA 7 KVA Frequency Hz Hz Primary Voltage Volt Volts Secondary Voltage 8 V AC 8V DC Secondary Current KA AC KA DC Primary Current Amp Amp 7 Weld ( Heat ) Time Cycle m sec 8 Cool Time Cycles m sec 9 Total welding cycle Time / Fuel Tank 7 Sec 7 Sec load KW.8 KW Required / Fuel Tank. Kwh. Kwh Saving /Tank. Kwh Saving /Day ( Tanks / Day ) Kwh Saving /Annum Kwh Result : Conventional Machine Annual Electrical energy consumption % 9 MFDC Machine Annual Saving : 7 Kwh Annual saving :.8 Rs / Yr Investment cost :. 8 Lacs Innovative Project Reduce hidden energy loss in CNC machines & SPMs OBJECTIVE Optimize Consumption in machining process by eliminating hidden losses Methodology Monitor energy consumption trends for one equipment Assembly wise electrical load mapping Mapping of equipment cycle time & mode wise energy consumption stratification Identify loss elements during each mode generation - Set targets and execute action plan Monitor results Sustenance action Pneumatic Hydraulics Equipment level Mapping Assembly level Mapping Tools Electronics Cycle Time level Mapping Emg. Off Non Cutting time Cutting time Innovative Project Reduce hidden energy loss in CNC machines & SPMs Assembly level Mapping Equipment Operation Mode Innovative Project Reduce hidden energy loss in CNC machines & SPMs % of Power consumption Parts consuming energy even operation do not need it, due to logic/wiring errors Reductio n gain A. Emergency OFF to % Pumps, Power supplies, Drives, Sensors, Displays, Panel AC, Chillers Change Logic to disable % B. Idle, non cutting Parts remains On like through coolant pumps, Hyd Pumps, Air Gauges, Spindle functions not required to % (Ready to start) oriented during each mode. % C. Cutting / Machining % Slide Feeds very high, Spindle RPM high Optimize Parameter % consumption during (A + B) A: Emergency Off Loss reduction B: M/C Idle loss reduction Only CNC/PLC CPU is given power Disable functions not required in Idle mode by adding 8 minutes timers in logic Cycle Time level 8 % Power % Power Saving in Emergency % Power Saving in Idle mode

7 kw Wh ::8. PM 9// 9// ::8. PM s /Div :9. (min:s) :9. (min:s) s /Div ::7. PM 9// 9// ::7. PM Innovative Project Reduce hidden energy loss in CNC machines & SPMs Innovative Project Reduce hidden energy loss in CNC machines & SPMs Mode Observation Consuming Parts Category to Save A B Servo System Drive Fan Electronic Nil Spindle Motor Fan Electrical Spindle Fan disconnect with EMG Stop Panel AC Electrical Panel AC disconnect with EMG Stop Machine Lamp Electrical Machine Lamp disconnect with EMG Stop Power Consumption LCD Display Unit Electronic Screen Saver mode active for LCD during Emergency Stop Hyd Chiller unit Electrical Chiller disconnect with EMG Stop Cutting oil Chiller Unit Electrical Cutting Oil Chiller with EMG Stop Power Saving Mode Electronic Active power saving mode Coolant tank/ Pipe insulation Thermal Insulate cutting oil chiller unit Through Coolant Motor Continues running Electrical Run Through coolant motor with M-Code Power Consumption Servo System Electronic Tune servo parameter during Non Cutting/ Idle Hydraulic Motor condition Electronic Hyd motor VFD control Spindle is at Orientation during idle Electronic Remove orientation from Auto retune and tool change program Status of Hidden Power Saving During Non Cutting time (A & B)- Machines Mode Observation Consuming Parts Category to Save C Consumption during cutting time Consumption( Wh / component) Table. Magazine. Spindle Motor & Amplifier Electronic Optimization of Cutting parameter Like RPM, Acceleration & Slides, Table and Pallets Electronic Deceleration time of non bottle neck machine FRD : Stratification of Consumption & related Parameters X Axis. Y Axis. Z Axis. Consumption/Cycle X Y & Z axis =. Wh Saving Potential identified through : Parameter Optimization. Rapid Feed (Override). Acceleration Time. Deceleration Time. Velocity Gain Energizing Mode Saving Potential Identified(Kwh/M) No of Activities Identified & Completed Saving Achieved / Month A -Emergency Stop 9 8 B-Non Cutting / Idle Spindle. Spindle =. Wh. RPM (Override). Acceleration Time. Deceleration Time Total Innovative Project Reduce hidden energy loss in CNC machines & SPMs Innovative Project Reduce hidden energy loss in CNC machines & SPMs X,Y, Z Axis Power & Consumption With Rapid to m/min Result - Total Saving of Machine Shop Power Cycle time = 9 = 8 Wh High Power Peaks at X,Y & Z axis Parameter Optimization Effect Parameter SAVING Rapid (m/min) (Para ) Power Consumption Wh/Cycle 8 8 Wh/ cycle Component Quality OK OK Cycle Time (sec) 9 (in Limit) Bottleneck Time (sec) Yearly Power Consumption (KWh) KWh Power Cycle time = = Wh Slide & Spindle yearly Saving = Kwh/machine Horizontal deployment Machines completed : Nos 7 Lower Power Peaks at OK Spindle RPM Reduction Effect Parameter SAVING Spindle RPM Override % 9% Power Consumption Wh/Cycle 8 9 Wh/Cycl Component Quality OK OK Cycle Time (sec) 9 (In limit) Bottleneck Time (sec) Yearly Power Consumption (KWh) 8 9KWH Kwh 7,9, Machine Shop Consumption/ Month,8,8 8,7,89 Shop Total Current Consumption Actions on A & B mode No of actions competed ( A+B+C ) : Nos. % Achieved- Conventional saving method saving Cost Saving 8.% 9.8%,, Actions on A, B & C mode :, KWh / Month : Rs.. Lacs / Month Annual Cost Saving : Rs..8 Lacs 7

8 Reduction of compressed air loss Other Encon Projects : Air Compressors Monitoring & Controlling Utility Equipment :Compressor House Kaizen Theme : Reduce compressor house energy consumption. : Common grid Line. Result : One compressor completely eliminated saving 7 KWH/Day Real time Compressed Air consumption monitoring; Which helps in identifying abnormal air consumption & Countermeasures Dedicated compressor provided for WH, CVD & MCD. It leads to under utilization of compressor Air Supply CH- WH Air Supply CH- CVD Air Supply CH- MCD Compressed air net work modified & Provided Inter plant grid line. CH- Air Supply WH Grid CH- CVD Grid CH- Air Supply MCD KWH/Day % Compressor Compressor Compressor Compressor Compressor Compressor Compressor 7 Compressor 8 Compressed air energy consumption Parameter CH- CH- CH- Total No. of Compressor Generation (CFM) Demand 8 9 (KWH) Surplus Compressed air energy consumption Parameter CH- CH- CH- Total No. of Compressor 9 Generation (CFM) Demand 8 9 (KWH) 8 Surplus Power Saving : 7 KWH/Day Cost Saving.9 Lac /Year CGS HT Al Steel Engine CKD FA Paint P&F Root Cause : Old design Surplus CFM cannot be utilized due to non availability of common Grid Sustenance : Air leakage audit compliance Horizontal deployment : CV engine Assembly & MCD stores 9 Electrical- Cooling Other Encon Projects : Electrical- cooling Kaizen : Reduce energy cost by using energy efficient panel AC Deeply Interface - OEM New Technology Status : Nishida machine idle mode energy consumption is more as : Use Rittal make energy efficient panel AC panel AC consumption is more Present Status : ) Panel AC consumption is more because of low - ) Compressor : No electronic control over compressor. Efficiency of compressor is less. ) Thermostat : thermostat is used for temp. sensing Countermeasure : )Compressor: Electronically controlled & energy efficient. )Thermostat: Temperature is measured & processed through microprocessor & sensors )Cooling fans: efficient fans are used ) Cooling fans : Local make fans are used )Filters : Due to nano coated surface no need of filter ) Filters : In case of filter choke up AC efficiency get reduced )Insulation: Rear& front side cooling units are insulated with foam ) Insulation :Rear side & front side of cooling unit are not insulated Theme : Air circulators load reduction Multiple Air Circulators HVLS feet air circulators Theme : Reduce comfort cooling system load M&G make Matted fleece filter after week Filter condition after week it reduces efficiency Root Cause : Panel AC consumption is more because of using less efficient parts (old technology) Rittal make Result: consumption reduced by 7% Idle mode consumption - Nishidha.7. Benefit : Filter cleaning activity eliminated from PM Horizontal deployment : machines With electronic PCB inside Multiple inch air circulators used for comfort cooling Watts air circulators Nos - 9 KW Annual saving Rs : 8. lac Investment cost Rs : Lac Single HVLS feet air circulators used for comfort cooling. K Watts air circulators Qty : nos - KW Air supply unit used for comfort cooling Centralized ARP cooling system With HP motor- 9 Nos Spot coolers used for comfort cooling Breeze air spot coolers used With HP blowers (8No.) Horizontal deployment : locations Annual saving Rs : : L Kwh/ Yr Investment cost Rs : Rs. lacs 8

9 List of ENCON projects List of ENCON projects LIST OF ENCON PROJECTS IMPLEMENTED IN -7 Sr Title of Project Year Annual Annual Annual Annual Thermal Investment Electrical Electrical Cost Thermal Payback Saving, Made Saving, Saving Saving, months Million (Rs million) Million kwh Rs Million Rs Million kcal Micro mapping of equipment & countermeasures Resizing of Hydrallic Power Pack Pump -7 Installation of High mast flood light system W Induction Lamps In place of W SV lamps - no.s LED Task Lights for machines nos LED Fittings [V AC and V DC] For KV Switchyard LED lights in toilet blocks efficient LED lighting on assembly conveyours Installation of LED lights for Offices & shops Use of Roof insulators to reduce cooling loads inside shops HVLS fans -8 no ETP equipment mapping & actions Air Leakage Audits & Countermeasures Audits through Captains & Countermeasures Micro mapping of air leakages & standardization of fittings Use of heat Pump for washing machine - no Installation of induction high bay lamp LED Task Lights for machines LED lights in toilet blocks efficient LED lighting on assembly conveyors LIST OF ENCON PROJECTS IMPLEMENTED IN -7 Annual Annual Annual Thermal Electrical Electrical Cost Sr Title of Project Year Saving, Saving, Saving Million Million kwh Rs Million kcal Heat Loss reduction through insulation on hot water lines of washing machines Annual Thermal Saving, Rs Million Investment Payback Made months (Rs million) Use of heat Pump for washing machine - no Optimization of coolant system load through Coolant shutoff valve for machines Replacement of manual drain valves of Compressor Air receivers Efficient blowers & Motors no Magnetic separator with earth magnet Thyrister controllers for heaters of washing machines - 7 no Magnetic Resonators for LPG fired burners -HD Restoration of roof top Solar water heater Heat Loss reduction through insulation on Oven Total Natural Resource Conservation : Fuel ( LPG ) Natural Resource Conservation : Fuel ( LPG ) Kaizen theme : To reduce the energy consumption by design change : Protect Dolly exposed area Result : LPG consumption reduced from to kg. Theme : To reduce fuel consumption at Baking oven LPG Consumption (Kg/Month) Kg/Month Paint shop - oven Magnetic Resonator Dolleys are used to move sets for painting in robotic painting booth During painting process, paint gets deposited on dolly which needs to be cleaned by burning in jig stripping plant Total no. of dolleys = Cleaning frequency = Monthly Time required for activity = Hrs Fuel : Kg / Month Dolly Cover Dolly. Dolly design changed for cover adoption. Provision of dolly cover in robotic painting booth.. Cleaning frequency revision : Half yearly. Fuel consumption- Kg/M Fuel Saving : Kg / Annum Maxon make gas burner is used for paint burnerfuel consumption is more because of low combustion efficiency LPG required for one burner / Hour. Kg Use of magnetic resonance Polarized fuel easily attracts the air, improving specific area of contact between air and fuel. It enhances combustion efficiency. LPG required for one burner / Hour. Kg saving : % Root Cause : Dolly Exposed to paint process Sustenance : Weekly cleaning & grease mopping of the covers Horizontal Deployment : Nil Horizontal deployment : nos. Fuel saving : kg / year 9

10 Use of Renewable Use of Renewable Generation of Electrical with Windmill Power Project 8 At SATARA & SUPA area in Maharashtra Wind mills are installed for Electrical Power Generation. Particulars Photo Saving Investment Solar energy for power generation Solar Photo Voltaic Power Plant - Kw L Kwh/ Yr Rs. 7.lacs Wind energy generated is transferred to other Bajaj auto associates for Use of Solar water Heating System Solar heater to preheat make up water of washing machine / canteen 9 Kg/ Yr Rs. lacs Year Installed Capacity Wind power Generated Waluj Plant consumption Wind Power adjusted Contribution Equiv. CO emission reduction Use of natural light Light pipes Shop day light. Qty : No's. L Kwh/ Yr Rs..8 lacs (MW) ( L kwh) ( L kwh) ( L kwh) % Tons Nil *** Use of natural light Transparent sheets installed in dispatch area. Qtn : No's Future Project - MW Solar Power Plant 8.8 L Kwh/ Yr Rs..7 lacs We are moving towards ENERGY POSITIVE company Our water conservation activities has grown from within fence to Outside Fence Water Conservation activities in Plant Approach Target BAL Waluj Plant Measurement & monitoring Operational control Using Innovative ideas Reduce Water consumption to 8 M /Day in FY -7 (8% ) Water harvesting Ponds - M BAL Waluj Plant Vendors Activities Through BAVA Sharing learnings /Techniques /initiative of water conservation in Plant Reduce Water consumption to 8 M/Day in FY -7 (% ) Water Positive through harvesting BAL Waluj Plant Society-CSR Activities through JBGVS Vendors Activities Through BAVA Creating awareness Sharing Knowledge Finance support Water harvesting Contribution in Draught free Maharashtra Methodology & Loss Reduction / Elimination Loss Elimination Distribution leakages Loss Optimization of water pipe line network Re-routing of water lines Above ground Use Of water saving taps Use of Breeze air coolers to reduce the evaporation loss Use of natural draft cooling towers Evaporation loss reduction of 7 rainwater pond Alternate Method Water Use of Tek-Talis Process in place of Phosphating Use of air cooled compressors instead of water cooled Use of Drip Irrigation / Sprinkler system for horticulture Rain water harvesting ponds. Ground recharging with rain water. Eco - Chips for wastewater 7 Biofilteration for wastewater Technological Improvement Use of treated water for horticulture Use of Treated water with RO for process. Recycle/Reuse Use of Treated water with UF for Domestic uses. Use cooler cleaning water for floor cleaning Reduce wastewater by providing diffused aeriation Multiple Effective Evaporator Operational Control Metering & Monitoring Auditing Captain No Production on Off days Controlled Pumping Hours Water level controller & synchronized pumping 9

11 Water Conservation Rain Water Harvesting Approach for Carbon Reduction Sustainable Development Carbon foot print CO Emission Better CO Absorption Better Rain water Pond No. Rain water Pond No Rain water Pond No. Rain water Pond No. Rain Water Harvesting Ponds Capacity Pond No. Pond no Pond no Pond no Pond no Length meters 7 Under Width meters. Construction Depth meters.... Volume Cu meters Annual Consumption. Lakh Kl Annual ground Recharge Capacity 8. Lakh KL Direct Emissions Indirect Emissions Direct Absorption CO emission (owned / CO emission sources (not owned / CO emissions (generation of CO absorption by tree plantation controlled by company) directly controlled by company) purchased Electricity) Ground Water Recharge This water available for Farmers /Society Fuel consumption.electricity losses in trans.& distribution.external vendor part movement.vehicle Distribution &Employee Commuting Purchased electricity Consumed in manufacturing of product We, at Waluj Plant,giving more to ground through recharging rain water than we consume Paint shop Internal Movement Testing Manufacturing shops Production Up by 7 % This makes us WATER POSITIVE Oven Heating Material / Engine Handling Vehicle Shifting Vehicle testing Engine testing M/c & Equipment Running Lights, AC, Air circulators Running Compressors Running Carbon Reduction- O releasing tree plantation Tree for Carbon Mapping : Logistic ) O releasing shrubs : "Tulsi gives out oxygen for hours and ozone for four hours a day along with the formation of nascent oxygen which absorbs harmful gases like carbon monoxide, carbon dioxide and sulphur dioxide from the environment," Tulsi Plantation of Tulsi Clusters Completed on Locations ( -7 ) ) O releasing plants : Peepal Banyan Plantation of Peepal & Banyan plant Nos each completed -7 Movement Internal Testing Carbon Emission from External Movement Carbon Reduction- Inventorisation Mitigation Material Handling Vehicle Shifting Engine Vehicle Employee Transportation Vendor Part movement Vehicle Distribution Year* Scope Emissions CO e (MT) Scope Emissions CO e (MT) Scope Emissions CO e (MT)** Total reduction in emissions intensity since baseline year study CO e (MT) 78. NA Base Year NA NA NA NA NA NA Optimize Route Reduce No. of Trips Eliminate Movements Fuel Consumption Reduction Eliminate Multi-handling Use of Alternate equipment ( e g. Use of BOPT ) Use of Belt for material movement Distance Reduction Optimize Route Increase Loadability Increase occupancy Milk Run Route Reduce distance ( bring vendor near to BAL) Increase vehicle cube capacity

12 Carbon Reduction Waste utilization Summary - Reduction in Carbon Emission / veh (Kgs.) :. Heat recovery from waste flue gases at Low Temperature are installed in Paint shops % SN Waste Heat Recovery System installed at LPG Saving Kg/Year Investment ( Rs. Lacs) Paint shop ED oven exhaust 9.7 HWG Aquatherm Paint shop Exhaust. Paint shop Exhaust Oven- Locations FY - FY - FY - FY - FY - FY - FY -7 FY 7-8(Tgt) Reduction in Carbon Emission Total. Utilization of canteen waste Theme : Use of Bio Gas Plant in Canteen LPG Yard Bio gas Plant Next We have Planned Bio-mass reactor for GAS generation to be used for process T / Day Bio-mass From municipal waste Canteen burners operating with LPG Canteen burners operating with Bio gas Saving : Kg/ Day = : Rs..8 lacs / Year Eco friendly Packing Eco friendly Packing Summary of Kaizens for Reduction of Packing Material in Tons Kaizens for plastic reduction Sr No Kaizen Model Remark Kilo Ton reduced p.a Packing Redesign SKD Wooden pallet to Steel pallet SKD (All Models) Implemented. Deleted wood.7 Kaizen Model Remark Ton reduced p.a Packing Redesign SPD Wooden case to Steel Cage Egypt Export - SPD Implemented. Deleted wood.8 Packing Redesign Wooden pallet Thickness reduction Packing Redesign Corrugated Sleeve Deletion Bangladesh - CKD Implemented. Reduced wood. CKD Bangladesh : CT- Platina ES/KS Disover-G Discover- Pulsar- Implemented. Reduced Corrugation.9 Packing Redesign Steel Pallet / Frame & Stretch Wrapping Deletion SKD (All Models) Implemented Reduced Plastic. Packing Redesign Steel Pallet / Frame & Stretch Wrapping Deletion SKD (All Models) Implemented. Reduced Plastic. Packing Redesign Blue Polycover Deletion SKD (All Models) Implemented. Reduced Plastic.7 Packing Redesign Blue Polycover Deletion SKD (All Models) Implemented Reduced Plastic.9 7 Packing Standardization Reduce Bubble bag size for Side Cover, Seat Cowl & Front Fender Pulsar- CKD Implemented. Reduced Plastic.9 Total Ton Reduced p.a 8. No of Trees saved Packing Standardiz ation Reduce Bubble bag size for Side Cover, Seat Cowl & Front Fender Pulsar- Implemented. Reduced Plastic

13 BAL Green Purchasing Policy Corrective /Preventive actions from ISO audits Re-certification of ISO audit conducted by BVC -.9. to.9. No Non conformance was observed Corrective actions completed for points suggested for Improvement : SN Suggestions for Improvement Status ER Needs to be revised as ) water pollution is specified as nonsignificant ) consumption of electricity for battery charging is not considered Completed. Secondary containment needs to be provided for paint and thinner Completed storage. Our Management System is integrated with TPM SHE pillar activity 9 Result Sustenance Kwh/Veh BM 7... Electrical Consumption Target.89 M /Veh. - BM....7 Kg/Veh.. - BM.8.7. Water Consumption.77 Thermal Consumption Target Target Loss Identification& Corrective actions Regular Shop Audit by Captains Leakage Identification Consumption Data Analysis Monitoring & Measurement Daily/Monthly Electrical Daily/Monthly LPG Daily/Monthly Water Daily/Monthly Fuel EMS Audits Internal Audits External Audits Sustenance Activities Review Daily Review by Div Head Daily/ Weekly Review by Plant Head Index Review by Corporate Technology Up gradation Adoption of efficient Technology for Manufacturing, Monitoring Education & Training Managers Training Captains Training Group Leaders Training Vendor Training HD of Kaizen Implement ENCON project HD of ENCON project in other shops. Plant, Vendors

14 consumption monitoring & Measurement consumption monitoring & Measurement On Line real Time Monitoring SCADA More than Electrical Meters Monitoring up to shop Feeder LPG Flow Meters Monitoring up to Oven Water meters Monitoring up to shop Air Flow meters Monitoring up to shop Awareness creation ENCON Awareness creation Kaizen matrix Awareness through communication Captains Axis Training Latest Technology Training Monthly Kaizen Karakuri State & National level ENCON week Poster display Seminar New Product display Competition Kaizen Event Appreciation Small Group Activity Karakuri Engineering Kaizen Managerial Kaizen Boards at shop Best Kaizen Award Best Captain Efficient Shop Efficient Equipment Operational Control Total Assembly 8 Utility 7 Total Process Loss Elimination Alternate source Machining Paint Press & Fab. Kaizen implemented by all employees with support from Captains

15 Kaizen by captain Conservation through external Audits Kaizen : To reduce energy consumption by cooling method change : Stopping use of chiller plant at low ambient temperature. Result : Power consumption reduced by : 8 kwh / month Year Audit for Projects ( Nos. ) Saving Potential Status Compressed Air. L Kwh. L KWh At PTED line, during ED process heat is generated due to exothermic reaction. ED bath temperature 8-'C. ED Batch cooling through chiller plant -8 TR Chiller condenser cooling through cooling tower. Power Consumption : 77 kwh / year Chillar running at no load during Low ambient temp..chilling plant mode to cooling tower mode Changeover pipeline circuit modification.. At low ambient temperature, changeover of chiller plant with cooling tower mode done to maintain temperature of ED bath. Power Consumption (kwh/month) Water system Cu Mtr/day Cu Mtr/d Power System- PF & Harmonics 8. L Kwh.8 L Kwh Process Pumps & Motors.7 L Kwh. L Kwh Thermal - Thermography for Ovens 7 K Cal 8 K Cal Compressed Air System 7 L Kwh. L Kwh 7 Compressed Air Leakages(On going) L KWh L KWh Power Saving : kwh / Annum 8 Chillers. L Kwh. L Kwh 9 Lighting System. L Kwh.7 L Kwh Use Of Renewable energy Ton LPG. Ton LPG CII Water Audit Cu Mtr/Day 7 Cu Mtr Thermal Audit for HT & Paint Shop Ton LPG Ton LPG Root Cause : Idle running of chillar at Reduced Cooling requirement during Low ambient temp. Sustenance Action : Scheduled PM activity of chiller & cooling Tower Horizontal Deployment : Nil 7 8 Future Projects Awards & Accolades LIST OF ENCON PROJECTSPLANNED IN 7-8 S.No. Title of Project (KW) (KW) Annual Electrical Saving, Million kwh Annual Electrical Investment Payback Cost Saving (Rs million) months Rs Million Replacement of old Street Light Fittings by new LED Street Light Fittings with GI Octagonal Poles (Road from Main Gate to GM Office) Installation of LED Tube Lights Watt in place of Convetional 8 W In MRS Installation of LED Tube Lights Watt in place of Convetional 8 W In 8 no Sub Stations Installation of inductuion high bay lamp W In place of W SV lamps - no.s MCD FA Sales,MCD Paint,DG House Replacement of Existing Fixed and Contactor Switched Capacitors by Thyristor Switched RTPFC Panels and De-tuned Capacitors - Total 8..8 Panels at Substation Nos.8, and. Old inefficient chiller, conversion from Recip to scroll comp. of Paint shop.. Kw/Tr to.9 Kw/Tr Use of Efficient Cassette Type Split A/Cs in place of Conventional Air Conditioner Installation of LED lights for Offices & shops HVLS fans -8 no ETP equipment Efficient blowers & Motors Micro mapping of air leakages & standardization of fittings Rerouting & Replacement of underground Compressed Air Grid line from CVD Engine assly to MCD Steel shop corner Compressed Air Pressure optimisation by use of portable Small Compressors on holidays LED Fittings [V AC and V DC] For KV Switchyard Installation of High mast flood light system inplace of existing Street Lights Elimination of Compressors for Pneumatically Operated KV Circuit Breakers; by Modifying Circuit Breakers to Spring Mechanism Total CII- Efficient Unit Award CII- Excellence Unit Award CII- Excellence Unit Award MEDA- Excellence in Conservation & Management Award // CII- Excellence Unit Award