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TATA Motors Limited, Dharwad (Karnataka)

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TATA Motors Limited, Dharwad (Karnataka) First Prize Automobile Manufacturing TATA MOTORS LIMITED Dharwad (Karnataka) Unit Profile Tata Motors Limited is India’s largest automobile company, with consolidated revenues of INR 2,63,695 crores (USD 42.19 billion) in 2014-15. Through subsidiaries and associate companies, Tata Motors has operations in the UK, South Korea, Thailand, South Africa and Indonesia. Among them is Jaguar Land Rover, the business comprising the two iconic British brands. TATA MOTORS is the leader in commercial vehicles in each segment, and among the top in passenger vehicles with winning products in the compact, midsize car and utility vehicle segments. It is also the world’s fifth largest truck manufacturer and fourth largest bus manufacturer. The Tata Motors Group’s over 66,593 employees are guided by the mission “to be passionate in anticipating and providing the best vehicles and experiences that excite its customers globally.” Established in 1945, Tata Motors’ presence cuts across the length and breadth of India. Over 9 million Tata vehicles ply on Indian roads, since the first rolled out in 1954. The company’s manufacturing base in India is spread across Jamshedpur (Jharkhand), Pune (Maharashtra), Lucknow (Uttar Pradesh), Pantnagar (Uttarakhand), Sanand (Gujarat) and Dharwad (Karnataka). The company’s dealership, sales, services and spare parts network comprises over 6,000 touch points. Tata Motors Ltd., Dharwad Plant is the youngest plant amongst other TATA MOTORS plant, started manufacturing Small Commercial Vehicles (Tata Ace Zip) in March, 2012 with an installed capacity of 150 Vehicles per shift. Manufacturing of Light Commercial Vehicles was started towards end of H2 financial year 2013-14 with the installed capacity of 40 Vehicles per shift. 36 Energy Consumption Details The Energy consumption has reduced by 12.10% compared to last FY 13-14 even though there is significant raise of production by 14.78%. However the absolute energy consumption has a steady decline from the last FY 13-14 due to various conservation measures taken. The Energy scenario of TML Dharwad for past two years is given below. Absolute Energy Consumption Specific Energy Consumption. 37 Description Unit 2012-13 2013-14 2014-15 Annualproduction Small Nos 15382 24992 29328 and Light Commercial Vehicle. Total Electrical Energy Lacs KWh 60.32 59.31 52.45 consumption/annum Specific Energy consumption kWh / Veh. 250 193 181.9 - Electrical Total Thermal Energy Million Kcal 3242.091 3517.696 3176.35 consumption/annum Specific Energy consumption Million Kcal/Veh. 0.211 0.141 0.12 - Thermal Energy Conservation in 2014 – 2015 Sl.No. Project description Electricity Fuels* Total savings Investment (Lakh kWh) HSD (kL) (Rs. Lacs) incurred on the project Rs. (Lacs) 1 Avoid idle running of Water circulation 0.00225 - 0.0185625 0 pump by interlocking with blowers in ASU1 2 Avoid idle running of Water circulation pump by interlocking with blowers in ASU 2 0.00225 0.0185625 0 3 Reduction by preventing idle Water recirculation system by providing control 0.099 0.81675 0 through PLC and display on HMI 4 Replacement of 250 Watt sodium lamp with existing High bay Lamp (160Watt) 0.00216 0.01782 0.08 in inlet Pump house & Blower shed 5 Cooling fans were remaining continuously on. Now body presence will trigger to 0.00432 0.03564 0 control fans status. 6 Use of portable compressor for Non 1.04124 8.59026 9.8101 Production Hour activities. 7 VFD to be installed for Blower No. 2 and 3. 0.359111111 2.962666667 2.2396 8 Automatic switching ON/OFF of fume extractor with MIG Welding. (1 No in 0.06545 0.5399625 0 Stn No.200 and 2 No in Stn No.500: Total 3 No’s) 9 Robot fan switching off as per temperature. 0.145008 1.196316 0 1 0 Cycle time reduction by 9 sec. 0.284433962 2.346580189 0 1 1 Motion sensed lighting in PCC end of line 0.00768 0.06336 0 1 2 VFD for blower of paint touch up booth. 0.01776 0.14652 0.491 1 3 Replacement of present air curtains by flappable curtains ( industrial grade ) 0.009 0.07425 0 1 4 Different Switches to be provided for fans at Engine dressing line 0.009 0.07425 0 1 5 Elimination of heaters in Glass Glazing machine 0.06912 0.57024 0 1 6 Elimination of motorized drive of tire transfer in Inflator machine 0.0006944 0.0057288 0 1 7 Hot Water circulation system controlled through Temperature sensor. 0.0396 0.3267 0 38 1 8 Using of insulating curtains to prevent direct sunlight in Metrological lab and thus reduce AC consumption 0.0175 0.07425 0 1 9 Driving the wax and touch up booth blowers (2nos) through VFD. (VFD panel) 0.36 3.267 1.5 2 0 Fixing motion sensor to sense the human presence in office to switch On/Off fans 0.003 0.0249 0.015 2 1 Energy loss due to delay in switching ON/OFF of water circulation system, fixing of operating box of ground floor to operate the system. 0.07425 0.6125625 0.02 2 2 Avoiding Idle running of Entry and Exit Air Seal blowers on shut down of ovens 0.06912 0.57024 0 2 3 Replaced the T5 tube light by LED lamp (20 W x 2Nos / fitting). Savings of 68W /fitting. 25 fittings has been replaced. 0.0408 0.3366 0 2 4 PLC program changed and avoided conveyor 0.013728 0.113256 0 running in case when there is no pallet. 2 5 Interlock of Chiller with GEMA and booth conveyor 0.57404 0.47064 0.4 2 6 To switch off The motor cooling fan when it’s motor in OFF condition 0.00222 0.01831 0 2 7 Relocation of chiller unit outside paint shop. 0.2592 2.1384 0 2 8 Interlocking of fume extractor m/c with co2 m/c. 0.0036 0.0297 0 2 9 Modifying logic of hydraulic power pack motor in Nash piercing m/c 0.0495 0.40838 0 3 0 Low temp Degreasing chemical for ACC line. 0 28.8 14.66496 0 3 1 ACC & PCC oven nozzles modified to optimum required temperature. 0 17.59 8.799 0 3 2 ACC oven doors were open when there is interruption. Resulting into bypassing for 0 0.72 0.3600000 0 passage 8 bodies due to manual interpretation. There by resulting into energy loss. Now Door closes when there is no interruptions. 3 3 Hot water is circulated only to Reaction Rinse tank and temp of Reaction Rinse is increased to 58 p c (Range 54p c to 0 14.4 7.2 0 58p c). The drop in temp over 10-12 Hrs. of non-production time is 4 p c to 5p c. Hence effective temp to be increased is 1 p c during next day start up. 3 4 Switching Off High Mast Light fittings in TML_DWD plant on requirement basis 1.70264 13.961648 0 without compromising of safety and security demands. 3 5 Installed VSD equipment to 1500 CFM rated screw compressor in compressor house for compressed 1.62632 13.335824 0 air generation on daily basis to meet the production requirements 3 6 Reduction of Compressed air leakages at generation & distribution system 0.25753 2.111746 0 by conducting regular audits in all manufacturing & service areas. 3 7 Reduced compressed air (CA) pressure set points & distributing through IC 0.33358 2.735356 0 units as per the requirement of production shops. Shop wise IC units set points TOTAL 7.545105473 61.51 89.03694166 14.5557 39 Energy Conservation Achievements 1. Use of portable compressor for Non-Production Hour activities in Paint Shop. Before: Booth cleaning of Paint booth is carried out during color change in non- production hours. Centralized compressor was required to be switched on for booth cleaning activity for 3 to 4 hours which is of the rating 250 kW, hence portable compressor was installed of the rating 18 kW to reduce energy consumption After: Portable compressor provided for booth cleaning activity. Power Energy Saving kWh/year: 104124 kWh/year Saving Per year: 8.59 Lacs. Investment made: Rs.9.81 lacs. Payback Period: 0.8 yrs. 2. Use of Low Temp Degreasing chemical of ACC line in Paint Shop. Before: The values of temperature in the tanks were 56, 53 & 52 degree respectively. After: Degreasing chemical used to reduce the temperature inside the tanks for the process and hence reduce fuel consumption Fuel Saving KL/Year : 28800 KL/Year Saving Per Year : 14.40 Lacs Investment made : 0 3. Paint Shop Hot water generator water recirculation at Paint Shop. Before: Reaction Rinse tank temperature was at 45 degree during start up. After: Hot water is circulated only to Reaction Rinse tank and temp of Reaction Rinse is increased to 58 p c (Range 54p c to 58p c). The drop in temp over 10-12 Hrs. of non-production time is 4 p c to 5p c. Hence effective temp to be increased is 1 p c during next day startup. Fuel Saving KL/Year : 14400 KL/Year Saving Per Year : 7.20 Lacs Investment made : 0 40 Energy Policy 41.
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