18Th National Award for “Excellence in Energy Management – 2017” Confederation of Indian Industry Content of the Presentat
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8/30/2017 Content of the Presentation Company profile th 18 National Award for “Excellence in Energy Saving Projects Energy Management – 2017” Innovation in projects implemented Confederation of Indian Industry How close to Global best In SEC % Reduction in SEC w.r.t. previous years Involvement of employees, monitoring and reporting Presentation by , GHG Inventorisation Utilization of Renewable energy Kirloskar Oil Engines Limited (KOEL) Utilization of waste as a fuel Kagal, Kolhapur Plant Amount of replication arising out of Best Practices implemented on energy front in Green Supply Chain Implementation of corrective / preventive actions from ISO 50001, ISO 14000 & ISO 9000 certification KIRLOSKAR OIL ENGINES LIMITED 1 KIRLOSKAR OIL ENGINES LIMITED 2 GreenCo – “Gold” Certified Plant IGBC – “Gold” Certified Building KIRLOSKAR OIL ENGINES LIMITED 3 KIRLOSKAR OIL ENGINES LIMITED 4 1 8/30/2017 Accolades Energy & Environment Accolades Energy & Environment CII - National Award for “Excellence in Energy Efficient Unit 10-11, 11-12 , 13-14,14-15 & “ Energy Efficient Units” 12-13 & 15-16 Kirloskar Group Inter-competition Awards by auspicious hands of Eminent Personalities in Energy Sector KOEL won for “Parivartan Corporate Sustainability Stewardship Award” for their efforts in Resource Conservation 2 times 10-11 & 13-14 Kagal Plant also bagged 2nd Excellence Award for year 11-12 and “Certificate of Excellence” award for 15-16 in State Level Energy competition by MEDA in Engineering Sector KIRLOSKAR OIL ENGINES LIMITED 5 KIRLOSKAR OIL ENGINES LIMITED 6 About Kirloskar Oil Engines Ltd About Kirloskar Oil Engines Ltd Incorporated in 1946 as a part of the Kirloskar Group of Companies, KOEL is an engineering conglomerate, founded by the late Mr. Laxmanrao Kirloskar. KOEL is involved in the manufacture of internal combustion engines, generating sets and parts, which are used for various applications, such as agriculture, industrial, stationery power plants and construction equipment, among others. KIRLOSKAR OIL ENGINES LIMITED 7 KIRLOSKAR OIL ENGINES LIMITED 8 2 8/30/2017 Kirloskar Oil Engines Ltd-Kagal plant Our Values, Vision and Promise 2021 Kagal ( Kolhapur ) Plant Total Employees as on date - 1181 Managers ( TL, GL & UL) - 191 Operators (Team Associates) - 990 Initiatives TPS 5S QMS, EMS & OHSAS ENCON Kaizen & POKA YOKE Autonomous Maintenance Six Sigma, QC Activities Standardized Work KIRLOSKAR OIL ENGINES LIMITED 9 KIRLOSKAR OIL ENGINES LIMITED 10 KOEL adopted CII program Production Process at Kagal Mission for Sustainable Growth - 2007 Machining Lines Receive Bought out Specific Energy And Water Consumption Specific Generation Of Waste & Waste finished components •Reduce by 3-5% every year over next ten Going To Land Fills years. • Reduce by 3-5% every year over next ten Crank Case years Use Of Renewables Energy GHG Emissions And Other Process Storage • Increase by 5% every year over next ten Emissions Cylinder years. • Reduce by 3-5% every year over next ten Head years Engine Assembly Recyclable And Enhance Recyclability Of Share Of Harvested Rainwater In The Crankshaft Resources Overall Annual Use Of Water • Increase use of resources embedded in the • Increase by 5% every year over next ten Engine Engine Testing Painting product. years Up fitment Storage Dispatch Life Cycle Assessment Criteria For New Adopt Green Purchase Policy Camshaft Products. •Adopt Green Purchase policy & • Incorporate Life Cycle Assessment in incorporate clean technologies at design alternative technologies and products. stage Product Stewardship Program Depletion Of Natural Capital Connecting •Promoting and managing Product • Reduce by 5% every year over next ten rod Stewardship Program, By forging years partnership with business and communities. KIRLOSKAR OIL ENGINES LIMITED 11 KIRLOSKAR OIL ENGINES LIMITED 12 3 8/30/2017 KOEL- Energy Policy Doshas in Ayurveda and Pachmahabhutas Benchmarking of products with the Executive Chairmanregional and national Shri. best. Atul Solar energy Kirloskar signed Energy Policy - HVAC indicatesProcurement Strong of high Commitment energy efficient products and technologies Movement from Top Management towards Eliminating wastage of energy and ENCON promoting reuse and recycling of resources 3rd RevisionPromoting in and increasing repsect use of to renewable energy resources, within Wind energy Fossil fuels Changes in Globaland outside Energy Scenario Adopting New Building Norms Processes Key Highlights of Policy of Highlights Key Illumination Involving all stake holders in the energy conservation Sharing and enriching our experiences on energy conservation within & Outside group Electrical & Thermal resources Water KIRLOSKAR OIL ENGINES LIMITED 13 KIRLOSKAR OIL ENGINES LIMITED 14 Energy and Environment Environmental & Energy Policy. ISO 14001:2015 Certification for Environmental Management system. GreenCo Gold Certification Green Building. Energy Conservation. Employee Involvement Renewable energy. Water Conservation. Rain water Harvesting Waste Recovery. Hazardous Waste Management. Online Energy Monitoring. Carbon foot Print Reduction. Sustainability Reporting. KIRLOSKAR OIL ENGINES LIMITED 15 KIRLOSKAR OIL ENGINES LIMITED 16 4 8/30/2017 ENCON Team Energy planning-Idea Generation Chairman & Mentor -VMD Leader-NNK Champion-SPP Maintenance Utility Stores Planning Production Finance HR SCM KIRLOSKAR OIL ENGINES LIMITED 17 KIRLOSKAR OIL ENGINES LIMITED 18 Employee Involvement & Employee Involvement & ENCON Capacity Building Programs ENCON Capacity Building Programs No of Training No of Training Date of Duratio Date of Duratio SN Training Program Faculty particip Man- SN Training Program Faculty participan Man- Training n (Hr.) Training n (Hr.) ants hrs. ts hrs. CII- 14th National Energy 19th& 20th 9 EMS & OHSAS Awareness Mr.Nilesh Upankar 12-Sep’13 3 32 96 1 Conservation Award CII Hyderabad 16 5 80 August 14 Mr.Shailendra Hyderabad 10 Six Sigma Green Belt 19-20-Feb ’14 8 46 368 th Rahigude th 20 January 2 MEDA 9 State Level Award MEDA Pune 4 5 20 Mr.Shailendra 19-20-Mar’ 14 11 Six Sigma Green Belt 8 70 560 ISO 50001 Lead Auditor 7th April to Rahigude 14 3 BSI Pune 45 2 90 Course 11th April 14 Green Building Rating 12 CII 28-29-Nov’ 13 16 2 32 4 IEX Power Trading MCCIA 9th May 13 3 5 15 Systems Parivartan Sustainability Sustainability Outlook 17th October 13 EMS Legislation Mr.Sachin Rahalkar 09-Jul’ 13 4 22 88 5 9 2 18 Award New Delhi 13` 14 OHS Legislation Mr.Sachin Rahalkar 10-Jul’13 3 22 66 26th& 27th 6 GreenCo Summit, Chennai CII GreenCo team 16 3 48 Jun 14 GreenCo Meeting Pune – CII GreenCo Pune 7 13th June 14 4 3 12 Total man TATA Motor Visit Chapter Team Hrs. 1897 One day workshop MEDA Kolhapur & Department of 13th February 8 6 5 30 Renewable energy & Energy , Shivaji 14 energy efficiency University KIRLOSKAR OIL ENGINES LIMITED 19 KIRLOSKAR OIL ENGINES LIMITED 20 5 8/30/2017 Energy Efficiency Energy Efficiency Celebration ENCON WEEK Every Year (14 Dec. to 20 Dec.) Celebration ENCON WEEK Every Year (14 Dec. to 20Dec.) Tree Plantation Competition Response From Employees 16-17 Poem Competition -213 Encon Gallery competition - 8 Poster Competition – 120 Opportunities – 11 Encon Projects - 46 Slogan Competition - 1322 Encon Project - 100 Total 1878 Entries Suggestions - 58 Award Function KIRLOSKAR OIL ENGINES LIMITED KIRLOSKAR OIL ENGINES LIMITED 22 Creating Sustainable Future Energy Efficiency Mass Tree Plantation Celebration World Environment Day This year 1251 Trees are planted on the occasion of World Environment day . Till date @ 7000 Trees are well grown up in the Plant premises Celebration of World Environment Day KIRLOSKAR OIL ENGINES LIMITED 23 KIRLOSKAR OIL ENGINES LIMITED 6 8/30/2017 Energy Pyramid for Efficient use and adoption of renewable energy Grid Energy dependency further reduced by increased use of Renewable Energy sources & devices Energy Requirement reduced by adoption of Sustainability energy efficiency measures, process changes & new Energy …A Resource products Business As usual energy requirements & adopting operating changes KIRLOSKAR OIL ENGINES LIMITED 25 KIRLOSKAR OIL ENGINES LIMITED 26 Power & Fuel 2016-17 Power & Fuel 2016-17 Deaprtmentwise Energy consumption share FY16-17 Share of various energy sources Cost of energy, Rs.M LPG, LPG, 20% 8.05 7.9% 29% MSEDCL, 34.1% 8% HSD, MSEDCL, 0% HSD, 1% 66.09 88.20 8% 38.5% 6% 3% 4% 12% Wind+Solar, 9% 19.5% Wind+Solar, 31.17 EP-1 Machine shop EP-1 ME -ATPP EP-1 SE-ATPP EP-2 Machine shop EP-2 ATPP Genset and fabrication Common utilities Fire fighting ETP Lighting Compressor KIRLOSKAR OIL ENGINES LIMITED 27 KIRLOSKAR OIL ENGINES LIMITED 28 7 8/30/2017 Savings VS Investment FY 14-17 Savings Vs Investment 35 30 32.24 25 20 Energy Conservation Activities 15 Better Rs.Million 10.77 10 5 3.65 0 14-15 15-16 16-17 Total annual Savings (Rs. Million) Total Investment (Rs. Million) Cumulative savings (Rs. Million) KIRLOSKAR OIL ENGINES LIMITED 29 KIRLOSKAR OIL ENGINES LIMITED 30 Project Summary Project Summary Energy Saving from FY 2014-15 to 2016-17 Energy Saving from FY 2014-15 to 2016-17 Moderate Investment Low Investment projects Numbers of ENCON Projects Total Cost Saving projects (Rs. M 0-1) (Rs. M 1-5) 138 Rs.322.4 Lakh Total -72 Total -58 Savings, Rs. M- 7.83 Savings, Rs. M- 11.63 Annual Energy Annual Fuel High Investment projects Savings Saving Investment Rs. Simple Payback (million kWh) (million kcal) 76 Lakh 3 Months (Rs. M 5 and above) 2.2 13.68 Total -8 Savings, Rs. M- 12.78 KIRLOSKAR OIL ENGINES LIMITED 31 KIRLOSKAR OIL ENGINES LIMITED 32 8 8/30/2017 M/C Shop - ENCON Project Sr. Possible Cost Project Title Line Name No. Saving in Lac. To Provide electrical switch/autosenses near to the core plug pressing station on DV-Cylinder 1 DV Cyl. Head Line 0.08 Head Line on OP-80 station To save electrical power cost by providing separate hydraulic motor ON/OFF system on 2 OP40/50 Pressing machine & also provide only one hydraulic system for two m/c in single 6R 6K Cyl.