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About Godrej 1 About Godrej Established in 1897, the Godrej Group today enjoys the patronage of 1.1 billion consumers globally across consumer goods, real estate, appliances, agriculture and many other businesses- with its geographical footprint extending beyond Earth, as Godrej engines power many of India's space missions. With a revenue of over USD 4.1 billion, Godrej looks to bring together their passion and purpose to make a difference through a ‘Good & Green strategy’ of shared value, in order to create a more inclusive and greener India. Segments: Aerospace | Agriculture | Consumer Goods | Home Appliances | Chemicals | Construction | Electronics | Furniture | Real Estate | Security Solutions | Infotech Operations: The Godrej group can be broadly divided into two major holding companies, working independently: Godrej Industries Ltd Godrej & Boyce Godrej and Boyce: A Godrej Group Company 14 SBU's catering to diverse markets- India, Europe, U.S., Middle East, Africa and South East Asia. Segments: Consumer durables, products for institutions, Industrial products Products: • High quality locks • Durables (refrigerators, washing machines, air conditioners, home security systems and safes, furniture) • Products for institutions (office furniture, audio-visual solutions, access control systems, perimeter security solutions, bank security solutions, beverage vending machines, interior solutions, hospital and laboratory furniture) • Industrial products (process equipment, materials handling equipment, industrial storage solutions, tooling, precision equipment) Godrej embarks on its Industry 4.0 Journey with SmartSense - Implements IoT powered Asset and Energy Insights for optimizing operations in its Indian Plants. About Godrej Interio One of the largest divisions of Godrej & Boyce and the Market leader in its segment. India’s largest furniture brand with 50 exclusive showrooms in 18 cities and through 800 dealer outlets. Offerings: Customers home and office furniture, solutions for laboratories, hospitals and healthcare establishments, education and training institutes, shipyards and navy, auditoriums and stadiums. 176 product solutions for home and institution spaces. Manufacturing Facilities: Supported by 5 Manufacturing Facilities in Bhagwanpur, Haridwar, Bhiwandi, Vikhroli & Shirwal Plant Fostering a culture of Sustainability National and International Green certifications Green Buildings Green Company Rating Plant Plant Continual improvement Shirwal Vikhroli beyond Platinum IGBC GOLD certified IGBC GOLD pre - certified Platinum factory – Shirwal Phase 2 Gold showroom Plant rating rating Shirwal May 2016 Gold March 2016 Plant rating Vikhroli May Silver 2015 rating June 2014 3 BIFMA Level Green Products 6 GRIHA certified 35 GREENGUARD certified products certified products products For FY 15-16 revenue contribution of green certified products = 16% 12 Challenges • Lack of a common infrastructure to capture and collate data from different models and makes of equipment • Machinery level data not available because they were connected to PLC • Lack of means to collect data from machines/equipment from different makes and models • Lack of visibility of all organisational KPI’s Energy Efficiency • Resources deployed in manual data collection • Errors from manual data collection • Inaccurate data/non-availability of critical data • Lack of a common infrastructure to capture and collate data from different models and makes of equipment Productivity • Inability to troubleshoot and find reasons for decreased production • Non-visibility of production parameters such as OEE, SEC • Inability to capture and collate data from different systems and sources Unscheduled downtime • Unnecessary maintenance activity/costs • Sub-optimal/inefficiently functioning of industrial assets (also resulting in a proportionate increase in energy consumption/costs) • Production losses from unscheduled breakdown Step 1: Digitization SmartSense Implementation (Acquire) SmartSense link+ gateways were implemented for data to be sent to the SmartSense cloud using GPRS Step 2: Converting Data into Insights Converting data into Insights #EnergyEfficiency Customised widgets using SmartSense Widget Maker Automated MIS Reports Real time Dashboard for all Energy and Process Parameters Real time Energy Audit to track any Anomalies User Defined and automated alerts for key situations SmartSense helped reduce energy losses from 13% to 2.5% within 6 months- by detecting unusual consumption and line losses through reports. 06:00 to 10:00 10:00 to 18:00 18:00 to 22:00 22:00 to 06:00 14,000.00 (offpeak) (Peak) (Normal) (Night) 12,000.00 10,000.00 8,000.00 6,000.00 4,000.00 2,000.00 - Department-wise monthly energy consumption trends where breaches are highlighted Heat Map- aiding instant tracking of abnormal Deviation alerts sent for voltage imbalance through energy consumption patterns SMS & email Converting data into Insights #Productivity SmartSense helped convert Production machine data into live KPIs that define the health of the machine Live Tracking of Machine Performance Vaccum Pump Oil Temperature Vaccum Pump Run Hours Cooling Tower Water Temperature Production Counter Visualisation and tracking of live machine KPIs Vaccum Pump Oil Temperature Vaccum Pump Run Hours Cooling Tower Water Temperature Production Counter SmartSense helped improve productivity by tracking machine performance and notifying any deviation for immediate action Converting data into Insights #Unscheduled Downtime SmartSense Motor Insights were implemented in critical motors of various makes in Godrej Interio. Using the PowerGenome Approach, Real Time health and issues were identified. Identification of Motor Mechanical Fault SmartSense Motor Insights helped prevent unscheduled breakdown by predicting impending failure. This also enabled Godrej Interio to optimize maintenance and energy costs and prevent production losses Identification of Motor Electrical Fault Converting data into Insights; Insights into Value Godrej has acted upon all of the actionable recommendations provided by SmartSense By solving the 3 fold challenges Godrej has been able to stride closer to its sustainability and profitability goals Energy Efficiency 22% PREVENTION OF 13% UNSCHEDULED BREAKDOWN Productivity MAINTENANCE COSTS ENERGY COSTS Unscheduled downtime Godrej Interio recognised by Confederation of Indian Industries Having addressed and shown significant improvements (savings) in terms of energy efficiency, productivity and unscheduled downtime, Godrej Interio was awarded the prestigious Greenco award by CII SmartSense expands implementation Having heard about Godrej Interio’s partnership with Ecolibrium and the resulting CII recognition, a few other Godrej Interio and Godrej & Boyce plants also began their journey with Ecolibrium to address similar concerns and challenges Ecolibrium’s approach to all of its Godrej implementations Condition Predictive Monitoring Insights Productivity Reduce Asset Downtime and inefficiencies Insights Identifies degradation of assets with root cause analysis and recommendations # PredictiveMaintenance OEE Optimization and Specific Energy consumption Enterprise Tracks utilization of machines and cost of unit produced Insights # OverallEquipmentEffectiveness Reduce cost of power Analyzyses energy consumption patterns and identifies leakages Enterprise with the root cause analysis and actionable Insights Dashboards # EnergyEfficiency SmartSense across Godrej plants Productivity Predictive Maintenance Energy Efficiency Shirwal Vikhroli With operational and business benefits being witnessed and recognized at Godrej Interio, Ecolibrium's solutions have now been extended to all Godrej & Boyce plants in India Ecolibrium has recently partnered with Godrej & Boyce for a combined effort in creating Smarter factories in line with Industry 4.0. Godrej & Boyce has 14 SBU's (including Godrej Interio) catering to diverse markets including India, Europe, U.S., Middle East, Africa and South East Asia. SmartSense serves as the single interface that Godrej Group uses to achieve their Sustainability Goals Corporate Office: 504, Venus Atlantis, Prahladnagar, Ahmedabad – 380015 India Mumbai | Delhi | Bangalore | Chennai | Pune| Singapore | Dubai | New York [email protected] www.ecolibriumenergy.com +91 79 4016 5151.
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