PCBU
1
TEAM MEMBERSS G Nandanwadkar Deputy Manager (Heat Treatment) A P
Gosavi Senior Engineer (Paint Shop) K M Kulkarni Senior Engineer
(Engine Shop)
J K Tawade Assistant General Manager (Manufacturing)
FACILITATOR T.C.Patni Deputy General Manager (Manufacturing)
PCBU
2
COMPANY PROFILETATA MOTORS
One of India s largest private sector companies The leading
commercial vehicle manufacturer Annual turnover of over Rs 108
billion. The company has manufacturing plants at Jamshedpur,Pune
and Lucknow in UP.PASSENGER CAR BUSINESS UNIT AT PUNE
Born out of a vision to offer the Indian customer all the
comfort of a big car, at the price of a small car. The country s
first indigenously designed, developed and manufactured passenger
car. Launched the Tata Indigo, a sedan last year. Has a strong
client following not only in India but also in Europe.PCBU3
Plant Layout T.Axle Offices ETP Press Engine MaterialsComp
House
CVBUBIW
LPG Yard
Paint Shop
Assy. Shop
N
Sub Stn.
Pump HousePCBU4
Plant Profile: PCBU Pune Spread of Plant Production Level Total
shop Sub-stations Total connected load Maximum demand
- 178 acres. - 82000 Units (2002-03) - 27 Nos. - 65 Mw. - 15
MVA
PCBU
5
MANUFACTURING PROCESS
Committed Human Resource
Stamping
Transaxle & Heat Treatment
Material Resources
BIW
Pretreatment, coat & Painting Vehicle Assembly
Engine
Efficient Machinery & Equipment
Dispatch
Enabled Processes
PCBU
6
BREAK UP OF VARIABLE COST2002-2003
12% I 47%(2001-02 58%)T P ,F &W
26%
Sp
15%
ENCON DRIVERS TATA BUSINESS EXCELLENCE MODEL ISO 9000 ISO 14000
TPM KAIZENPCBU7
l C H 9 .H P i 9
2001-02 00 Kw /C
gi P l
S
wi
cH 9
iC . l
Kw /C
2002-03gi P i P l
PCBU
8
ENCON ACHIEVEMENTS
TOTAL ENCON PROJECTS IMPLEMENTED DURING - 003 TOTAL PROJECTS
TOTAL SAVINGS (Rs Lakh/Year)
0 3. 3
Savin s 3(Over the base fi ure of - 000)
PCBU
9
JOURNEY TO ARDS ENERGY EXCELLENCE T E MET ODOLOGY Benchmarking
Enhanced Capacity Utilization through Technology up gradation
Energy Audits Energy Conservation through low cost automation
Thermography :An Innovative way of Energy Conservation Energy
Conservation through Process Optimisation Energy Conservation
through rework elimination. TEP : Energy Conservation, An Attitude
of mind & not the effort. Sustainability through Continual
Improvement PCBU10
Benchmarkin Inputs from M/s arbor Associates(USA) on various
Automobile Manufacturing aspects such as: - Level of Automation -
AMH per Car - Quality norms and standards followed internationally
- Throughput Study of processes and practices followed in similar
industries Information sharing with domestic and international
players
PCBU
11
Benchmarkin Processing of Mercedes Benz Cars In Indica Paint
Shop has helped us to Benchmark our processes and practices with
that of Mercedes Benz Added benefit of Paint shop capacity
utilisation.
PCBU
12
Ca acity UtilizationIntroduction of Various new Models on Indica
Platform1E+5 0
Indica : Base Model
900 00
Kwh / Car800 00
81892
700 00
6 5 1
City Rover
600 00
500 00
672000
Indica Estate
Tata Indigo 2000-01
00 00
300 00
200 00
Indica Sports100 00 0
8
2001-02
2002-03
Volumes
PCBU
13
Ener y Audits : IF You Measure You can Control Conducted various
Internal and Third party energy auditsSr No 1 Area Distribution
system Auditin A ency M/s BSES and M/s Nelco Measures Im lemented
as er audit findin s Harmonic Analysis with corrective measures
Redistribution of LT supply system and installation of HT
Capacitors in view of :Voltage drop optimization Optimum
Transformer loading Overall Power Factor Improvement Installation
of VFDs at 25 locations Savin s achieved 7 Kwh/Car
2
Pumps, Fans and Blowers Compressed Air System
M/s Nelco
12 Kwh/Car (Rs. 62.4 Lakhs/Annum) 8 Kwh/Car
3
M/s ARS Engineeri ng & CPED
Systematic approach to determine and arrest compressed air
leakages
PCBU
14
Ener y Audits : IF You Measure You can Control Conducted various
Internal and Third party energy auditsSr No 4 Area Heating and
cooling systems Water distribution and usage Lighting Auditin A
ency M/s IIPM Measures Im lemented as er audit findin s
Re-insulation, Replacement of worn out glass wool and cladding
Leakage arrestance for underground water piping, & Increased
frequency of booth water replenishment with the use of biocides Use
of latest lamps luminaries and gears, Optimization of lux level by
selective controls for day and night time requirements Savin s
achieved 2 Kg/Car (LPG/Propane) 3 M3 / Car (Water)
5
M/s Gaytri Erectors
6
Internal
2 Kwh/Car
PCBU
15
Case Study Ener y Conservation throu h low cost automation
Underbody spray application at Paint ShopSituation Before Manual
Operation High amount of air supply and Exhaust was required to
minimize the overspray and to provide comfort to the operator
Painters were required to go underneath of the cab to perform the
operation, making it highly unsafePower Consum tion : 0K PCBU16
Case Study Ener y Conservation throu h low cost automation
Underbody spray application (Automatic) at Paint ShopEncon
Measure Im lemented Desi ned and installed a low cost under body s
ray machine from salva ed machine com onents Reduced Air Su ly
Blowers motor ulley diameter from 300 mm and switched off mm to #
30 Kw Exhaust blowers
Benefits achieved Elimination of manual work and thereby overs
ray and comfort requirements Im roved er onomics Power Consum tion
: 0 Kwh
Net Savin Achieved
0000 Kwh/annumPCBU17
CASE STUDY : OVEN EAT BALANCE
Radiation Loss Heat Input Air Seal and and doors
Heat Zone
Exhaust Loss Air Seal and eat exchan er to re heat fresh air
Paint
Paint Baking OvenPCBU18
CASE STUDY : OVEN EAT BALANCE Thermo ra hy : An Innovative
wayLocation Descriptions:- Paint Shop Surfacer Paint Oven/ Heat
zone-1 (north side) AR01 Temperature (max.) 137.3C Observations:-
AR01 & AR02 are showing the hot zones on right side middle
portion. SP01 shows the normal temperature observed on the shell
which is 60 C Corrective Measures:- Attended the welding leakage
and replaced the lining. C 120
AR02 LI01 AR01
100
80
SP01
60
4 36. C
Total locations identified and attended:
3PCBU19
CASE STUDY : OVEN EAT BALANCE Thermo ra hy : An Innovative
wayLocation Descriptions:- CED Oven HZ-1 / East side AR01
Temperature (max.) 113.6C Observations:- AR01 shows a localized hot
spot, where as the normal temperature observed on the same surface
is around 60C only. Corrective Measures:- Attended the welding
leakage and replaced the lining3.9
A
I
6
39.3
Total locations identified and attended:
3PCBU20
Thermo ra hy : An Innovative wayThermal Images of Ovens, Furnace
and Gas Generator200 22 .1172.9
01
1 1.9
160
01
LI01
A 01
150A 01
120
A 02
LI01 72.6
0
5 LI01 6.7
2.0
169.0
A 01
1 0
1 070 A 01
01 120
120 100
A 02 LI01
100
60
0 50
2.
3.7
LI01 A 01
1
.
66.2
11 .5
1 0 120 100
1
01
60
I 1
01
60
0
6032.3
1.0
29.6
PCBU
21
LI01
50
A
1
A 1
2
A 01
3.1
60
01
60
160
A 020
LI01 01
A 01 LI01
16 .1
.
160
100
A 02
6
100
1 0
01
100 90 0 70 0
A 01
! ! ! !
!
!
Thermo ra hy : An Innovative waySome More Thermal Images58.0C
61.9C 60 55 AR01 LI01 50 SP01 AR02 45 45 40 AR02 40 35.7C 38.7C
LI01 41.7C 50 50 AR01 60 LI01 SP01 AR01 55 AR02 70 SP01 83.3C
80
TCO-2 / Incinerator top portion
TCO-2 / Hot air duct above heat zone-2)
TCO-1 / Incinerator, on burner matting plate
69.5C AR01 LI01
139.3C
AR01 LI01 AR02
168.1C 160 140 120 100 80 60
120 SP01 60 AR01 100 SP01 50 LI01 80
60 SP01
40 40.7C 27.4C
43.7C
TCO-1 / West side
TCO-1 / Incinerator left side joint portion
SO-2 / Heat zone-1
PCBU
22
Case Study 3: Paint Booth Energy Conservation through Process
OptimisationFilters 1 Filters 3
Filters 2
Air Supply Blower
Filters 4 Filters 5Exhaust Blower
PCBU
23
Case Study 3 Energy Conservation through Process OptimisationBy
ass dam er
M
#ly blower with by ass dam er to adjust the down draftPCBU24
Paint booth fresh air su
Removed by ass dam er and blower RPM controlled with the hel of
VFD
VFD
M
#Savin achieved 3 000 kwh/annum
PCBU
25
Case Study Ener y Conservation throu h Process O timisation
Heat Treatment
Continuous Case Hardening FurnacePCBU26
O.K. Rework
M
M
M
Fresh Components
M
Continuous Case Hardening FurnacePCBU27
Rework
0.
Rework er day
K
Required Ener y er year.
000 units
PCBU
28
PCBU
29
Continuous Case Hardening Furnace
M
M
M
Fresh Components
M
PCBU
30
Continuous Case Hardening Furnace
M
M
M
M
Furnace Test Piece O.K. Low Case DepthPCBU31
M
M
M
M
Extend the cycle if the Case Depth is lowPCBU32
TEPTOTAL EMPLOYEE PARTICIPATIONAwareness generation through:
Training, Suggestion box & Unique Suggestion schemes, Slogans
and Picture competition Shop floor publicity to ENCON measures In
2002-03 Total 3253 suggestions received from 1835 employees Details
of Unique Su reduction estion Scheme held in Jan 003 for
IMCestions
Total no of su received
Electrical Encon ater Conservation Fuel Encon Com ressed air
Encon Oils Thinners Sealants Tools etc PCBU33
3
TEP TOTAL EMPLOYEE PARTICIPATIONKnowled e sharin Platforms : -
Share Caf : A unique Intranet site with access to all employees
- Tata World : An internet site for all Tata group employees
PCBU
34
TATA MOTORS PCBU
Sustainability Through Continual Improvement
PCBU
35
nd fo SElectricity (KWH/Car)
cific En14
y Consum ionCompressed air (KWH/Car)
12
=1
=' '
-
- 1
' 1- 2
' 2- 3
6 5
LPG (Kg/Car)
16 12
Water (M3/Car)
4 3
=2- 1 ' 1- 2 ' 2- 3
=4- 1 ' 1- 2 ' 2- 3
PCBU
36
Ener y Monitorin FormatsE ECTRICITY CONSUMPTION E EC C Car3 9. 3
8. 9 3 .% '' ' & % $ #
8-Oct 9-Oct 1 -Oct 11-Oct 1 -Oct 13-Oct 1 -Oct 1 -Oct 1 -Oct
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PCBU
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PCBUny
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Law of Ener y Conservation
Energy Can Neither be generated nor be destroyed, But.
It can certainly be Conserved & Reused
PCBU
40
We must not be selfish or timid if we hope to have a decent
world for our children and grandchildren. We simply must balance
our demand for energy with our rapidly shrinking resources. By
acting now we can control our future instead of letting the future
control us.
-Jimmy CarterPCBU41
Thank YouPCBU42
