Pp industrial - 11.05.2012

May’12 /SBU-INDUSTRIAL

P PRAMANIK19-05-2012

SBU - INDUSTRIAL

MANUFACTURING

PARTICIPANTS1) Pulak Pramanik – Industrial Overview2) Subroto Sinha – Shamnagar Overview3) Aloke Kr Sarkar – Haldia Overview4) Kalyan Saha – Haldia Indl. Overview5) M. Ramachandran – Hosur Overview


High Value Manufacturing

SHAMNAGAR • Location - WEST BENGAL• Opens – 1946• Product Range – Plante, Standby(Flooded)

ROORKEE• Location - HIMACHAL PRADESH• Opens – PART OF EXIDE FROM 2012• Product Range – Inverter, Sign Wave, High Frequency

THE INDUSTRIAL FACILITIES

HALDIA• Location – WEST BENGAL• Opened - 1980• Product Range – Solar, Traction, Standby, Flooded., GEL.

HOSUR• Location – TAMIL NADU• Opened - 1996• Product Range – VRLA, Standby, Telecom, Railway

May’12 /SBU-INDUSTRIAL 3

CONSISTENCY THROUGH TECHNOLOGY & AUTOMATION – INDUSTRIAL COS, PASTE FILLING, VRLA COS, etc.

TO SHIFT FROM GRUDGE PURCHASE TO ASPIRATIONAL PURCHASE

FLEXIBILITY IN MANUFACTURING PROCESS TO MEET RAPID CHANGE IN MARKET REQUIREMENT

VALUE ADDITION THROUGH INVESTMENT IS THE NXT GEN REQUIREMENT

INDUSTRIAL -

MANUFACTURING STRATEGY

NEXT GENERATION PRODUCT TO BE AHEAD OF COMPETITION -GEL , TI WITH REMOTE SENSOR, NXT VRLA , INTEGRATED INVERTOR

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





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





TO FOCUS ON MAINTENANCE FREE PRODUCT

FOCUS ON CAPACITY ENHANCEMENT WITH MARKET DEMAND

INVERTER AS PACKAGE WITH BATTERY

REDUCTION IN MANUFACTURING COST BY IMPROVING MANUFACTURING EFFICIENCY AND WASTE REDUCTION

IMPROVEMENT OF HUMAN RESOURCE BY CONTINOUS TRAINH AND SKILL ENHANCEMENT.

MANUFACTURING STRATEGY

INDUSTRIAL -










INDUSTRIAL - TURN OVER

1103

13641556

17911960

2104

0

500

1000

1500

2000

2500

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

INDUSTRIAL - TURN OVER

`C

r.

%

24 %

14 %

15 %10 %

7 %


PRODUCTION TREND ( BATTERY & CELL )

11701334

15651760 1760

2024

0

500

1000

1500

2000

2500

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

INDUSTRIAL - PRODUCTION

MA

h

14 %17 %

13 %0 %

15 %

%


PRODUCTION TREND ( INVERTER )

11119 10132 16908

188000

0

25000

50000

75000

100000

125000

150000

175000

200000

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

INVERTER - PRODUCTION

NO

s


NO

s`

CR

.

6818

115509810

17348

0

5000

10000

15000

20000

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

2.08

4.39 3.83

7.07

0.00

2.00

4.00

6.00

8.00

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

DESPATCH TREND ( INVERTER )

DESPATCH ( INVERTER )


LEARNINGS FROM SHINKOBE

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

EIL RECEIVED THE COMPLE DESIGN FOR 12V STANDBY –UPS, 2V TELECOM, 2V RAILWAY BATTERIES FROM SHIN-KOBE.

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
















LEARNINGS FROM SHINKOBE

IMPORTANCE & METHODOLOGY OF FTA ANALYSIS

KANBAN CONCEPT

IMPROVED METHODOLOGY OF FIELD RETURN BATTERY ANALYSIS

ADVANTAGE OF COS FOR VRLA

ONLINE ACID WASH ROLLER PRESSURE MONITORING

ADVANTAGES OF ABS CONTAINER FOR MEDIUM VRLA














LEARNINGS FROM EAST PENN

DIFFERENCE IN PROCESS, EIL Vs EPM.

OXIDE MAKING.

CONCAST, PASTE MAKING SEQUENCE, PASTING, TANK FORMATION, FLAT TRACTION POSITIVE PLATE, COS ASSEMBLY.

DIFFERENCE IN PROCESS, EIL Vs EPM.

DESIGN AND OPENING /CLOSING PRESSURE OF SAFETY VALVE.

INCREASED PAM/NAM RATIO IN PRODUCT DESIGN.














PROJECTS – EAST PENN

TANK FORMATION OF MET FOR RAILWAY.

TO REVISE THE ACTIVE MATERIAL RATIO OF VRAL PRODUCT.

TO IMPLEMENT PASTE MIXING SEQUENCE.

LEAK TESTING – DUNK TEST.










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 – Bangalore

GOLD Award from ICQCC – Hyderabad

PAR EXCELLENCE Award NQCC – Bangalore

SILVER Award - CCQCC – Bangalore

PAR EXCELLELLENCE Award – NCQC – Vizag

EXCELLENT Award – NCQC – Vizag

GOLD Award – QCFI – Kolkata

1st in 23rd CONVENTION of QC – Kolkata

GOLD Award INTERNATIONA; QC – Hyderabad

QC AND SGA


TRAINING - HALDIA

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

6441

Training 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

TRAINING


TRAINING - HOSUR

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

1470213751

104658683 8483

Training Nos. Of Hours -Hosur

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

31722055 1868

1090 606

Training Nos. Of Heads - Hosur

Internal auditors training on TS/IMS

Battery Technology

Statistical Process Control

7 QC Tools

Legal requirement on environment, OHS management system

Small Group Activity

TPM / ITS pillar awareness

Quality circle concept & ITS Implementation

Personal Effectiveness

Training on SHE Awareness

TRAINING


TRAINING - SHAMNAGAR

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

13921832 2056

2648

3440

Training Nos. Of Hours - Shamnagar

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

174229 257

331

430

Training 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

TRAINING


ILLUMINATION

Haldia(Industrial) Haldia(Traction) Shamnagar Hosur

93100 100

56

LUX

(6

5 m

in.)LEAD IN AIR

Haldia Shamnagar Hosur

0.85

0.072

2

µgm

/M3

LEAD IN WATER


5 5 5

µgm

/KL

HOSUR DATA REQUIRED


LEAD IN BLOOD


10 10 10

µgm

/DL HOSUR & SHAMNAGAR DATA REQUIRED


INCIDENT TREND

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

148

64 64 5842

SHAMNAGAR & HALDIA DATA REQUIRED


ACCIDENT TREND

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

3

10

3

12

12

3 32

3 3 3 3 3

HALDIA HOSUR SHAMNAGAR

SHAMNAGAR DATA REQUIRED


ENVIRONMENTAL PARAMETERS

2.2

6

2.1 2.1

5

1.7

2

1.2

6

1.2

2

0.7

4

0.4

5

0.4

2

0.4

7

0.4

6

3.1

9

3.3

3

3.1

2.9

4

3.0

7

2.8

4

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

EFFLUENT GENERATION (KL/MT OF Pb)


36

.48

35

33

.13

19

.44

16

.08

15

.75

4.6

1

2.5

9

1.9

9

1.3

0.9

9

0 0

9.3

3

8.1

3

4.9

7

4.8

5

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

LIME CONSUMPTION (KG/MT OF Pb)


82

.1

75 78

.9

53

.6 65

.6

63

.4

8.3

4.6

6

3.5

8

2.3

4

1.7

8

0.0

6

0.0

6

0.0

5

0.0

6

0.1

1

0.0

5

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

SLUDGE GENERATION (KG/MT OF Pb)



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ENVIRONMENTAL PARAMETERS : -

17

.89

16

.5

15

.14

15

.49

15

.61

21

.67

36

.21

29

.07

27

.42

28

.05

26

.69

31

.96

31

.04

26

.23

25

.29

24

.55

22

.11

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

LPG CONSUMPTION (KG/MT OF Pb)


12

.54

10

.44

10

6.9

6.1

1

5.9

8

3.4

7

3.1

07

2.8

1

2.7

7

2.8

3

36

.86

38

.02

32

.86

26

.34

23

.01

19

.99

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

RAW WATER CONSUMPTION (KL/MT OF Pb) HALDIA HOSUR SHAMNAGAR

3.2

1

2.7

8

2.0

9

1.7

1.4

8

1.4

1

0.8

5

0.6

7

0.6

7

0.7

1

0.7

0 0 0 0 0 0

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

DM WATER CONSUMPTION (KL/MT OF Pb)



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 . Inthis respect the company has taken new strategy for corporate governance and socialresponsibilities 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 DeceasedKarthik’s Education up to HighSchool

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


METAL PASS BOOK SYSTEM

PRODUCTION AS PER SALES – THROUGH METAL PASS BOOK.


REPLENISHMENT SYSTEM

WEEKLY SALES TO PRODUCTION REPLENISHMENT SCHEME


11

91

13

04

13

42

12

25

12

34

12

00

11

26

10

50

95

5

94

6

99

4

11

34

12

21

12

60

11

71

11

35

98

7

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

POWER CONSUMPTION (KWH/MT OF Pb) HALDIA HOSUR SHAMNAGAR

0.9

16

0.9

56

0.9

51 0

.97

9

0.9

82

0.9

84

0.9

8

0.9

88

0.9

91

0.9

92

0.9

93

0.9

7

0.9

8

0.9

88

0.9

87

0.9

75

0.9

7

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

POWER FACTOR HALDIA HOSUR SHAMNAGAR

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





Maintained Power factor of the plant ataround 0.99.Maintained Load factor of the plant ataround 75%. Introduction of Compressed AirManagement system for optimum use ofAir Compressors at plant. Installation of SCR controlled heatingsystems at Lead Pots of Wirtz Casting &Auto spine machines. Use of one no. Cooling Tower in place oftwo nos. Cooling towers for Hadi & WirtzCasting machines. Installation of LDRs at different locationsfor automatic switching ON/OFF ofshopfloor lights during daytime. Installation of 28W T5 Energy saverfluorescent lamps in place of conventional40W lamps at different locations in theplant. Electrical interlocking of fresh air &exhaust blower motors in the plant withProduction machines to stop idle running ofblowers during non-productive hours.


POWER COST (Rs per Ah)

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

0.2260.244

0.29 0.293 0.286SHAMNAGAR & HALDIA DATA REQUIRED


FUEL COST (Rs per Ah)

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

0.059 0.061

0.044

0.058 0.058

SHAMNAGAR & HALDIA DATA REQUIRED


KAIZENS

KAIZENS - HALDIA

KAIZENS - HOSUR

KAIZENS - SHAMNAGAR


MIGRATED BEST PRACTICES


BEST PRACTICE - HOSUR

BEST PRACTICE - HALDIA

BEST PRACTICE - SHAMNAGAR


PATH AHEAD

Could

Reverse the employment trends

in manufacturing

manufacturing investment

Manufacturing25% of

ShouldStep-change in the competitiveness of

the

UK has seized the manufacturing

opportunity

high intensity engineering &

technology nation

Will

Establish the 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)

Business

Pp industrial - 11.05.2012