CII 18th National Award for Excellence in Energy Management 2017 1 September 2017, HICC , Hyderabad CII - Sohrabji Godrej Green Business Centre Reduction in Energy Consumption & Usage of Renewable Energy. Khutale Engineering Pvt. Ltd. WELCOMES You Location : Satara ( 115 Kms away from Pune ) CII Godrej Interio Cluster IV – Closure Meet Manpower- 75+ (29 Females + 46 Males) Floor area 10700 sq ft. (+2800 Sq. Ft Expansion)
Introduction G arden G reen O utside & H ospital C lean I nside…! ▪ Manufacturer of Sheet Metal press components , ▪ Tubular fabrication, Assemblies with Conveyorized Powder Coating, ROHS Zinc Plating, Inspection – Testing, ETP and allied facilities ▪ An ISO 9001:2015 QMS & ISO 14001:2015 EMS certified company. ▪ Business Excellence Manufacturing Organization ▪ CRISIL rated SE1B company ▪ CII GreenCo Platinum Rated Company. 5
OUR CUSTOMERS
Journey of our Organization -Suppliers Excellence KEPL Certified as ISO Award & CSR from GID 1400:2004 EMS -GHG Study - Pune White Goods Lean Manufacturing Cluster 2017 - Associated with GAD 2016 - -KE becomes KEPL 2015 CII GreenCo KEPL Certified as 2014 Platinum ISO 9001:2000 Rating 2013 QMS -District Special 2010 Industries Achievement Award Award for 2009 GID Annual Established By Gov. Green Supplier Meet KHUTALE Maharashtra Initiatives Best Delivery 2017 2003 ENGINEERING from GID Performance 1. Gender -Platinum Associated with Award From Equality 2002 Award GAD GAD award CII Star Icon Associated with GPD from GID 2. Green Sustained 1996 Crusader Performance award award 2016 District Industries 3. Outstanding First Championship Awards Award by Gov. for Green manufacturing & contribution 1995 Maharashtra Energy & Cost at CII 9 th to Society National Cluster Summit to SEPC award 1989 2016 @ New Delhiat the Established hands of Mr Wolfgang SYNERGY ENGINEERS & POWDER COATERS Leidig GIZ
Green Vision Environment Friendly Energy Water Material Waste Products, Conservation Conservation Conservation Reduction Processes & Operations RoHS Compliant Reduction in products & Reduction in Energy Improvement processes, GHG Water Zero Waste to consumption YoY in RM yield emission consumption Land Fill reduction, Green YoY 100% Green YoY Supply Chain & Power by 2020. CSR Commitment • Concerned about Environment • Inspiration from Gandhiji’s thoughts on Environment • Motivation of Customer Godrej Appliance & Godrej Interio • Compliance of ISO 14001:2004 EMS Certification • Learning of CII Lean Clusters Journey
Green Policy is committed to Environment and conserve Natural Resources. The guiding principle of our Green Policy is , 5 R - Reduce, Reuse, Recycle, Renew and Respect . W e are committed to continually improve the Green performance in our Activities , Products and Services. We will strive to : • Conserve Natural resources such as Energy, Water, RM by optimization of their usage. • Ensure the use of energy efficient Processes , Products & Technologies to benefit all our stakeholders. • Adopt measures to prevent pollution by monitoring & controlling Process Water discharge, Air emission , Waste generation & Zero Landfill. • Recognize and reward the efforts of our employees in conservation of natural resources. Share and enrich our experiences in resource conservation within the company. • Promote use of Renewable Energy resources and 100% Green Power by 2020. • Abide by the legal requirements. We will continue to ensure that our operations comply with all local ,state and central statutory Rules Regulations and standards, relating to environment & conservation of natural resources. This policy is made available to all employees & our stakeholders. Place: Satara Shirish P. Khutale Date : 5 th June 2015 (World Environment Day) CMD
Drivers - • High Energy Cost • High GHG Emission in scope 2 • Green Manufacturing • Compliance of ISO 14001:2015 Reduction in Energy Consumption & Usage of Renewable Energy. Journey towards Excellence in Energy management…. Journey towards Excellence in Energy Management….
METHODOLOGY 11.Future 10.Horizontal Plans Deployment 8. Result 9 . Standardization 6.Root 5.Data Cause Analysis 3.Milestone 7. Action chart 4.Data Collection 2. Team 1.Problem Identification
PROBLEM IDENTIFICATION High energy cost per MT material processed Pledge For Energy Conservation Electricity per MT . 60 57.76 50 43.26 40 38.48 38.52 30 20 10 0 2013-14 2014-15 2015-16 2016-17 Energy Cost to Sale % graph 0.6 0.5 0.54 0.4 0.3 0.34 0.31 0.30 0.2 0.1 0 2013-14 2014-15 2015-16 2016-17
Energy Management Team Energy Management Team – Roles & Responsibilities Approval & Decisions, Mr. Shirish Khutale Fund Allocation, Identification & CEO Rewards & Approval of Recognition Small Project, Sustenance Mr. Rajendra Borate Plant Head Energy Audit, Ideas sharing in Monitoring, various departments, Follow Up, Training & Mr. Prakash Sawant Analysis Awareness Programs Energy Manager Data Mr. Mahendra Pawar Mr. Sagar Jadhav Collection, KEPL Energy Mgmt Cell SEPC Energy Mgmt Cell Suggestions, Kaizen Inputs Mr. Dilip Mr. Jayant Mr. Shankar Mr. Ajit Shinde Salunkhe Shinde More
Electricity Monitoring of KEPL Unit Electricity Consumption in kWh Sr. No. Section 15- 15- 15- 15- 15- Avg. % 15-Apr May 15-Jun 15-Jul 15-Oct 16-Jan16-Feb16-Mar Aug Sep Nov Dec Top Bottom 1 /Cab Back Line 1192 1133 877 234 542 637 828 410 624 714 727 747 722 19% 2 General Press 413 423 401 422 467 466 486 360 502 612 579 646 481 13% Fabrication 3 489 506 481 492 541 542 568 439 588 696 663 733 562 15% Shop Press Break 4 290 288 255 270 286 383 375 390 481 543 459 556 381 10% Machine Drilling & 5 Cutting 404 416 379 389 438 448 482 354 497 609 573 636 469 12% Section 6 Office 114 122 96 101 155 161 182 61 211 317 205 362 174 5% Shearing 7 375 388 368 376 338 420 447 276 338 338 529 534 394 10% Machine Air 8 662 660 656 657 661 659 655 651 665 668 751 672 668 17% Compressor 9 Total 3852 100% 3939 3936 3513 2941 3428 3716 4023 2940 3906 4497 4486 4886 Q1 Q2 Q3 Q4 11,388 10,085 10,869 13,869 15- 15- 15- 15- 15- 16-Jan16-Feb16-Mar Cumm Month 15-Apr May 15-Jun 15-Jul 15-Oct Aug Sep Nov Dec . Production 118.58 101.34 77.46 63.03 70.91 91.88 91.16 70.12 98.85 126.35 147.09 143.01 1199.8 (mt) Total electrical consumption 3939 3936 3513 2941 3428 3716 4023 2940 3906 4497 4486 4886 46,211 (kWh) Energy Consumed / mt 33.22 38.84 45.35 46.66 48.34 40.44 44.13 41.93 39.51 35.59 30.5 34.16 38.52
Electricity Monitoring Electricity Consumption – Contributors Top Bottom /Cab Back Line 17% 19% General Press Fabrication Shop 10% 13% Press Break Machine 5% Drilling & Cutting Section Office 12% 15% Shearing Machine 10% Air Compressor
Data Analysis A ir Compressor New Development New Developm Trial-Spin TP/BTM Line ent Trial Component 60 3231 33 31 293031 Small 56.31 31 29 26272829 2728272829 50 Component 28 272828 29 2727 on CNC 40 kWh/MT 27 2525 25 Bending M/c kWh/MT 26.83 25 26.48 31.46 2223 30 23.12 23.43 20.82 23 17.91 16 16.18 20 21 13.16 13.31 13.49 18.95 21.42 12.09 11.99 20.17 10.79 10.96 10.39 9.91 10.07 10.25 19 10 10.54 17 9.62 15 0 Days Days General Line “C” CLASS 160 143.65 Rework in Item walnut strip 140 Production 109.86 120 107.14 103.91 95.14 92.28 100 kWh/MT 85.05 87.08 95.14 93.52 69.48 69.27 80 82.06 56.55 60 47.17 47.81 46.76 42.19 59.75 48.91 46.96 28.35 40 45.40 36.62 28.98 20 23.02 0 Days
Sr. No. Improvement Projects Identification 01 Addition of Roof Transparent Sheets . 02 Addition of Roof Air Ventilators . 03 CFL 1718W (38 nos.) to LED Light 870W (32 nos.) 04 Conventional Air Gun to Trans vector Air Gun 05 Reciprocating Compressor to Screw compressor 06 Addition of VFDs . 07 Optimum usage of HP Elect. motors . 08 Transformer based Welding M/Cs to Inverter based Welding Machines . 09 Installation of Roof top solar System(30kW) 10 Procurement of Cut to size RM to eliminate shearing operation 11 M.S. Trolleys to Aluminum Trolleys(LPG) GI Airlines to Aluminum Airlines. 12
IMPROVEMENTS BEFORE AFTER RESULTS 2000 Watts /Day 1500 1000 1718 870 500 0 Before AFTER Use of CFL (1718 Watts) Replace CFL by LED(870Watts ) Benefits : Saved 848 watts per Day Horizontal Deployment : All CFL changed to LED AFTER RESULTS BEFORE 100 Kwh/Day 80 88.35 72.06 60 40 20 0 BEFORE AFTER Trans vector Nozzle gun Conventional Air gun Benefits : Saved 16.29 Kwh/Day Horizontal Deployment : Replace all 3 air guns by Trans vector AirGuns
IMPROVEMENTS BEFORE AFTER RESULTS 90 88.35 Kwh/Day 85 80 78.2 75 70 BEFORE AFTER Reciprocating Air Compressor . Energy efficient Screw Compressor Benefits : saving 10.15 Kwh/Day Horizontal Deployment : Use screw compressor in both KEPL & SEPC Unit. AFTER RESULTS BEFORE 2 1.95 Kwh/day 1.5 1 0.225 0.5 0 BEFORE AFTER Angle cutting on cut-off Machine. Die designed to cut in single stroke) Benefits : Saved 1.72 Kwh/Day Horizontal Deployment : Square & Rectangular pipe and Rod cutting
Recommend
More recommend
