Professional Documents
Culture Documents
Unit
Results
Best in class
Sp. Energy consumption
- Sp. Water consumption &
- Sp. Fuel consumption
Plant Greenery
- CVBU LUCKNOW
National Award In
Excellence in Energy Management 2010
Div Manager
Energy Auditor
Nitansh . Kamboj
Manager
Energy Manager
Md. Amir
Manager
- CVBU LUCKNOW
TML - Lucknow
- CVBU LUCKNOW
Plant Greenery
Sohrabji Godrej Green Business Centre
Facilities @ Lucknow
Who are we
Lucknow Works
Bus
Focused
ERC setup
Recon
Vehicle
Factory
Transmission
Factory
Integral Bus
Factory
Frame
Heat
Treatment
Module
Fabrication
Cowl
Machining
Module
Assembly
FBV
Head
Quarter
Weld Shop
Paint Shop
TCF
Cowl &
Cabin
Vehicle
Assembly
TMML
Vehicle
Assembly
Service
Training
center
- CVBU LUCKNOW
Plant Process
Transmission
Assembly
Engine
Assembly
Material
from
Vendor base -
Local,
Pune &
Jamshedpur
Chassis
Assembly
Cowl
Assembly
Paint
Shop
DISPATCH
SUPPLY
CHAIN
Axle
Assembly
DTC*
STU**
Private
Operator
BIW
Shop
- CVBU LUCKNOW
- CVBU LUCKNOW
ENCON Summary
- CVBU LUCKNOW
ENCON Projects
2006-2007
- CVBU LUCKNOW
ENCON Projects
2006-2007
- CVBU LUCKNOW
10
ENCON Projects
2006-2007
- CVBU LUCKNOW
11
ENCON Projects
2006-2007
- CVBU LUCKNOW
12
ENCON Projects
2006-2007
- CVBU LUCKNOW
13
ENCON Projects
2006-2007
- CVBU LUCKNOW
14
ENCON Projects
2006-2007
- CVBU LUCKNOW
15
ENCON Projects
2007-2008
- CVBU LUCKNOW
16
ENCON Projects
2007-2008
- CVBU LUCKNOW
17
ENCON Projects
2007-2008
- CVBU LUCKNOW
18
ENCON Projects
2007-2008
- CVBU LUCKNOW
19
ENCON Projects
2007-2008
- CVBU LUCKNOW
20
ENCON Projects
2007-2008
- CVBU LUCKNOW
21
ENCON Projects
2007-2008
- CVBU LUCKNOW
22
ENCON Projects
2007-2008
- CVBU LUCKNOW
23
ENCON Projects
2008-2009
- CVBU LUCKNOW
24
ENCON Projects
2008-2009
- CVBU LUCKNOW
25
ENCON Projects
2008-2009
- CVBU LUCKNOW
26
ENCON Projects
2008-2009
- CVBU LUCKNOW
27
ENCON Projects
2008-2009
- CVBU LUCKNOW
28
ENCON Projects
2008-2009
- CVBU LUCKNOW
29
ENCON Projects
2008-2009
- CVBU LUCKNOW
30
ENCON Projects
2008-2009
- CVBU LUCKNOW
31
ENCON Projects
2008-2009
- CVBU LUCKNOW
32
ENCON Projects
2008-2009
- CVBU LUCKNOW
33
ENCON Projects
2008-2009
- CVBU LUCKNOW
34
ENCON Projects
2008-2009
- CVBU LUCKNOW
35
ENCON Projects
2008-2009
- CVBU LUCKNOW
36
ENCON Projects
2008-2009
- CVBU LUCKNOW
37
ENCON Projects
2008-2009
- CVBU LUCKNOW
38
ENCON Projects
2008-2009
- CVBU LUCKNOW
39
2008-2009
ENCON Projects
- CVBU LUCKNOW
40
ENCON Projects
2009-2010
- CVBU LUCKNOW
41
ENCON Projects
2009-2010
- CVBU LUCKNOW
42
ENCON Projects
2009-2010
- CVBU LUCKNOW
43
ENCON Projects
2009-2010
- CVBU LUCKNOW
44
ENCON Projects
2009-2010
- CVBU LUCKNOW
45
ENCON Projects
2009-2010
- CVBU LUCKNOW
46
ENCON Projects
2009-2010
- CVBU LUCKNOW
47
ENCON Projects
2009-2010
- CVBU LUCKNOW
48
ENCON Projects
Zero Investment
Air
Blower
Burner
Air
Blower
Burner
Blower
Burner
Make:Maxon-Oven Pak400
Burner
Thermal O/p-426 KW
Temp 150 0 C
Vol-60,000 M3/Hr
After:
SEALER OVEN
After Consultation with OEM and Internal Quality controller, we found baking of Cowl after sealant paint at 110 0
C at its pregel stage, which fulfills the requirement. Accordingly one Burner out of three Burners has been
stopped.
Air
Burner
Air
Blower
Temp 110 0 C
Burner
No Flame
Blower
SEALER OVEN
Blower
49
ENCON Projects
: 43.84 T CO2/annum
Sohrabji Godrej Green Business Centre
Zero Investment
6.2 bar
5.9 bar
5.7 bar
50
: 0.92 Lakh/annum
Sohrabji Godrej Green Business Centre
ENCON Projects
Low Investment
3 Motors
Cooling Zone
L2
L1
After :
Process improvement-Removed one motor after evaluate the
prime mover capacity to operate the roller bed conveyor
M3
Sensor
Long belt
M1
Cooling Zone
L1
51
: 1,085 KWH/annum
Sohrabji Godrej Green Business Centre
21
48
222
Total ENCONs
Zero Investments ENCONs
Low Investment ENCONs
Total ENCONS
Zero Investments ENCONs
Low Investment ENCONs
52
Electrical
Prodn. in
tons or any
other unit of
prodn.
Thermal
Rs Million
Eq. Veh.
Specific Energy
Consumption
Electrical
KWH / Ton
or unit of
prodn
Thermal
tons or kL
per ton or
unit of
prodn
KWH/Eq.Veh KL/Eq.Veh.
.
KWH *
Million
Rs Million
Type of
fuel
Tons/KL
(KL)
% redn.
% redn.
200506
13.81
55.45
HSD
600
--
31,049
445
0.0193
--
--
200607
15.52
62.49
HSD
720
24.85
43,073
360
0.0167
18.962
13.498
200708
15.77
64.30
HSD
768
25.52
46,725
337
0.0164
6.343
1.670
200809
12.02
50.64
HSD
612
20.31
33,366
359
0.0183
-6.379
-11.593
200910
14.27
60.93
HSD
715
27.30
65,495
218
0.0109
39.276
40.451
Best in Class
- G Cal / Ton
TML-LKO
- CVBU LUCKNOW
53
20
09
1
0
200
20
08
0
9
60 %
G Cal / Ton
kWh/MT & KL or MT/MT of Product
kWh/Tone of Cane & % of Steam on
% Aux iliary power consumption & Heat Rate (kCals/kWh)
Exa mple
** Specific energy cons umption during 2008 - 09 = (A)
Specific energy consumpt ion during 2007 - 08 = (B)
Reduct ion in Sp. Energy Consumption = B A x 100 = %
20
07
0
8
300
20
03
0
4
400
20
06
0
7
500
- kWh / kg
- kJ / kg
Fertilizer
Foundry
Sugar
Power Plant
20
05
0
6
600
Text ile
Ceramic
20
04
0
5
KWH/Eq. Vehicle
54
- CVBU LUCKNOW
54
Ultimate Object :
Based on above comparative SEC data of various companies, TATA Motors CVBU Lucknow plant is the
Most Energy Efficient Automobile company. As part of continual improvement we would further
reinvestigate all our processes to achieve further cost reduction by reducing Energy consumptions at
all levels.
To sustain the best achieved level :We are following robust process of assessment of performance vis-a-vis comparative information / benchmark
from different organisation & standards.
Our emphasis is on:
To optimise the use of Resources while using appropriate and innovative method to reduce the energy
consumption in all the areas of operation on the continuous basis through evaluation and improvement.
55
- CVBU LUCKNOW
Feb11
y
rg ell
e
C
En mt
g
M
Jan11
Nov10
Aug10
Jul10
Jun10
May10
Apr10
Dec10
Oct10
Planned
In progress
Completed
- CVBU LUCKNOW
56
Better
98
100
80
60
20
40
62
26
2007-08
2008-09
2009-10
35% of the
volumes are
from New
Models
- CVBU LUCKNOW
57
Implementation campaign
6 Task forces constituted for execution of ideas
generated in campaign (low hanging fruits)
Around 80 Lacs has been realized rest are in
pipeline for execution
I.P.R
Trial
Execution
Campaigns Launched
Opportunity Identification Campaign
Posting to "Innovation Council"
Novel Ideas in
Suggestion
Scheme
- CVBU LUCKNOW
58
Novel Ideas in
Kaizen & CFT
Special
Campaigns on
"Innovation"
Innovation Project :
Conservation of electricity through utilization of temperature from heated waste gases to
heat water in post wash chamber
MACHINE : 200 Kg/Hr CCHF
Before :
Post Wash operation:After the quenching process the metaquench42 oil layers needs to be cleaned from
the components. To remove this oil layer we perform the post wash operation in
which the components are dipped and wash with the spray of warm water which is
maintained at the temperature of 60C.
Post Wash Tank
LPG
Burners
Method used to raise the water temperature:LPG burner were used to raise the temperature of water to 60C.
59
- CVBU LUCKNOW
Innovation Project :
After :
Copper coil
Post Wash
Tank
Furnace
LPG Burners
(Partial Load)
Method used to raise the water temperature:Now a modification is made in the system in which the heat of the flue gases are extracted
and used to raise the temperature of water used for post wash.
The temperature of flue gases when burnt is 275C and with the help of heat exchanger we
recovered the heat. And this extracted heat is used to raise the water temperature of post
wash to the required level.
Benefits :
Total Carbon emission reductions per annum : 45
- CVBU LUCKNOW
T CO2
60
Innovation Project :
Optimisation of Cooling Zone Fans operation at Paint Shop
Paint shop gets the Cowl from BIW Shop (Weld shop) for painting. In Paint shop, it passes first from
Pretreatment stage, where oil, grease, dust & dirt is removed by hot water spray. Next, the Cowl body
passes from Phosphate Station to make it ready for primer coat in ED (Electro- Deposition).
A layer of primer is applies over the surface of cowl by CED process and reaches to the oven for baking
& drying at defined temperature i.e. 150C. This oven is horizontally connected with cooling zone, where
cowls gets cooled by two axial flow fans i.e.. 22KW & 30 KW.
Before:
The Cooling Zone - Axial flow fans are interlocked with the Pretreatment Stage conveyor as shown below.
The Cooling fans automatically comes into operation as soon as the conveyor starts. It is found always in
running mode once the line gets started. Cowl takes almost 2 hrs time to reach the oven from
Pretreatment stage.
Pretreatment(PT)
Hot water
Spray
+
Phosphating
22KW
CED
30KW
Oven Zone
Hot Air
Cooling Zone
Burner
Air Blower
61
- CVBU LUCKNOW
Innovation Project :
After :
A Position sensor has been provided at the starting end of cooling zone, which senses the entry of
cowl into oven subsequently it gives the start signal to the axial flow fan to run.
Pretreatment(PT)
Hot water
Spray
+
Phosphating
CED
Sensor
Oven Zone
Hot Air
Cooling Zone
Air Blower
Burner
Benefits :
Total Carbon emission reductions per annum : 112
- CVBU LUCKNOW
T CO2
62
Innovation Project :
Innovation Project:
Energy & Cost Optimisation
for transportation of modules
from Lucknow to Dharwad
63
Innovation Project :
Despatch of
Modules from
TML Lucknow to
TMML Dharwad
Options
By Road - DAC
Scenario-III
By Road On 40 Ft Trailer
Scenario-II
By Train
64
Innovation Project :
Transportation of 1 Chassis ( 1 Front & 1 Rear module) in 28 ft Trailer ( Existing Practice)
Existing Practice
Front module
Rear module
Trailer Bed
- CVBU LUCKNOW
65
Innovation Project :
Transportation of 1.5 Chassis ( 1 Front & 2 Rear module ) in 40 ft Trailer (Existing Practice)
Scenario -I
2
Front module
3
Rear module
Trailer Bed
- CVBU LUCKNOW
66
Innovation Project :
Transportation of 1.5 Chassis ( 2 Front & 1 Rear module ) in 40 ft Trailer (Existing Practice)
Scenario -I
2
Front module
Rear module
Trailer Bed
- CVBU LUCKNOW
67
Innovation Project :
Improved method of
module transportation
Scenario-II
Improvement in stacking of modules and maximizing
trailer utilisation
Transportation trials of 2 Chassis (2 Front & 2 Rear)
in a 40 ft Flat Bed Trailer
- CVBU LUCKNOW
68
Innovation Project :
2 Front & 2 Rear
modules loaded on
40 ft flat bed trailer
Front module
1
3
Rear module
Scenario -II
- CVBU LUCKNOW
69
Innovation Project :
Engine side
Suspension side
70
Scenario -II
Sohrabji Godrej Green Business Centre
Innovation Project :
Rear end
Supported on stand
Front Module
Scenario -II
- CVBU LUCKNOW
71
Innovation Project :
c
Engine side
U BOLT
- CVBU LUCKNOW
72
Resting at front
side
Innovation Project :
Scenario -II
- CVBU LUCKNOW
73
Innovation Project :
Transportation Trial
Rear module
Scenario -II
74
Innovation Project :
Improved method of
chassis transportation
Drive Away Chassis- Transportation of LPO-1618 RE LE
Chassis through road
Scenario-III
- CVBU LUCKNOW
75
Innovation Project :
Objective
To integrate the front and rear module so that complete chassis can be
driven down to Dharwad as a Drive away chassis for Bus body building.
Front Module
Rear Module
Integrated Chassis
- CVBU LUCKNOW
76
Innovation Project :
Requirements for Drive Away Chassis
6300 mm
at engine side
Wheel
base
Innovation Project :
77
Rear Module
Temporary Support
Structure
78
Innovation Project :
320mm
220mm
- CVBU LUCKNOW
390mm
79
Innovation Project :
- CVBU LUCKNOW
80
Innovation Project :
Transportation trial-DAC
Status of chassis
at Jhansi
Status of chassis
at Dewas
- CVBU LUCKNOW
81
Innovation Project :
Improved method of
chassis transportation
2-Tier Drive Away Chassis- Transportation of
LPO-1624 RE LE Chassis through road.
Scenario -IV
- CVBU LUCKNOW
82
Innovation Project :
Objectives:
To monitor the performance of 2-Tier Drive Away Chassis and collect transit
observations for further improvement in design of temporary support
structure and other accessories
To establish the process of dismantling LPO 1624 RE LE front & rear
modules which is loaded on the DAC along with temporary support structure
at TMML, Dharwad
To establish the process of recycling of temporary support structure and
other accessories.
- CVBU LUCKNOW
83
Innovation Project :
LPOLPO-16181618-RELE CHASSIS AT LUCKNOW BEFORE
DISPATCH.
- CVBU LUCKNOW
84
Innovation Project :
85
86
Innovation Project :
- CVBU LUCKNOW
Innovation Project :
Transit Observations
checklist:
- CVBU LUCKNOW
87
Innovation Project :
88
Front End
side
Sohrabji Godrej Green Business Centre
Innovation Project :
Process of Dismantling
- CVBU LUCKNOW
89
Innovation Project :
Process of Dismantling
Rear Module
resting on stand
Front Module
resting on stand
Rear module
dismantling. From
outside
Spare wheel
removal
Rear module
dismantling from
inside
Front module
dismantling.
Middle pillar
dismantling
Unfastening from
inside of Front
module.
Unfastening of U
bolts front mod. side.
Front module
unfastened from
middle structure.
- CVBU LUCKNOW
U-bolt dismantling
on rear module
Additional structure
Unfastening
90
Wiring harness
removal
Air pipe
unfastening
Innovation Project :
v TML Quality Check points:
Check for module sagging by measuring heights from ground level at predefined positions on front and rear module
Check for tyre wear
Functional testing of chassis to be done prior to dismantling of modules
Hole elongations to be checked after dismantling of modules
- CVBU LUCKNOW
91
Innovation Project :
- CVBU LUCKNOW
92
Innovation Project :
Summary
Jun09 July09
Aug09
Sep09 Nov09
Dec09 Feb10
Results :
Freight - Rs/Chassis or module set
48000
3.75
36000
Reduction by 75%
1.91
IV
Scenario
III
II
0.94
IV
III
II
12000
Learning
from
successful
implementation of this Project :
Raise the bar when the solution is
too obvious.
2.81
24000
Scenario
Learnings
93
- CVBU LUCKNOW
Source of EnCON
idea*
Idea
Extent of man-power involved
originated in
***
FY **
Middle Management &
2007-08
Top Managem ent, corporate
Maintenance Engineer
office, Middle Managem ent,
Energy Cell, Project Execution
Group, Maintenance Team .
Workmen & Supervis or
2007-08
Workm en, Supervis or, Sectional
Head, Energy Cell & Divis ional
Head
Middle Management &
2008-09
Top Managem ent, corporate
Maintenance Engineer
office, Middle Managem ent,
Energy Cell, Project Execution
Group, Maintenance Team .
Middle Management &
2008-09
Top Managem ent, corporate
Maintenance Engineer
office, Middle Managem ent,
Energy Cell, Project Execution
Group, Maintenance Team .
Workmen & Supervis or
2009-10
Workm en, Supervis or, Sectional
Head, Energy Cell & Divis ional
Head
2009-10
Progress of
implementation
Idea Implem ented
Towards Excellence
94
- CVBU LUCKNOW
94
Implementation Methodology
Plant Coordinator
Submission of Techno
commercial proposal
Acceptance of Proposal
GO AHEAD
Team formation
GO AHEAD for
Implementation
- CVBU LUCKNOW
95
Review by : Energy Auditor ,Asst GM, GM, Plant Head, Sr. VP &MD
This report gives the consumption, Monthly and cumulative, performance trends, and efforts taken. This report is sent
to Plant Head (CVBU - Pune) & respective Divisional Heads.
Review by : Energy Auditor ,Asst GM, GM, Plant Head, Sr. VP &MD
The performance of the Divisions with reference to the target both monthly and cumulative along with the performance
expected to achieve w r t the Target.
Review by : Energy Auditor ,Asst GM, GM, Plant Head, Sr. VP &MD
This report giving consumption performance of various areas along with the efforts taken by various Divisions. This
report is released to - Finance Division as Input for disclosures for Director's Report.
Energy Management Cell Prepares the Energy report Daily, Monthly( M), Quarterly (Q), Half-yearly (H) & Annual reports.
Plant Head & MD reviews M, QY, HY, Annual reports
- CVBU LUCKNOW
96
Ist Jan 10
Prev Yr
Consp
08-09
Units
Prev Yr
Eq. Veh
08-09
Nos.
Specific
Energy
08-09
KWH/Eq. Veh
Consp till
Dec
08-09
Units
Specific
Energy
till Dec 08
KWH/Eq. veh
Specific
Energy
till Dec 09
KW H/Eq. veh
CV + IB Fact
5707472
29,101
196
4,479,432
22,069
203
5,408,501
36,580
148
Trans Fact
3834062
4,265
899
3,026,580
3,251
931
2,905,410
2,833
1,026
Others
2453210
33,366
74
2,202,250
25,320
87
2,157,571
39,412
55
11994744
33,366
359
9,708,262
25,320
383
10,471,482
39,412
266
Total
From
Energy Auditor
Energy Auditor Cell
YTD
Status
3920
747
890
701
885
662
863
840
639
790
610
584
CV FACT
11%
MARCOPLO
16%
916
772
774
3794
Feb-10
3919
Dec-09
Oct-09
Nov-09
Sept-09
Aug-09
Jun-09
July-09
Apr-09
May-09
3733
856
March-10
3677
Actual 08-09
933
937
925
Jan-10
3611
Jan-10
3689
Actu al 09-10
935
885
3840
Feb-10
3605
4001
3820
Dec-09
4098
951
863
869
4145
Oct-09
4409
Aug-09
4600
Jun-09
4621
3705
Nov-09
Transmission Factory
963
4811
July-09
5011
May-09
4717
3890
4671
Apr-09
5083
4740
Actu al 08-09
Sept-09
Actual 09-10
March-10
CV Factory
1794
1757
1724
1472
1424
1434
1427
TGT 09-10
1618
TRAN FACT
12%
1426
1409
1343
1346
1305
1274
1249
1231
1219
1395
1259
1074
942
8 63
March-10
Jan-10
Dec-09
Nov-09
Oct-09
Sept-09
Aug-09
July-09
Jun-09
Apr-09
OT HERS
7%
RECON
2%
May-09
1011
Feb-10
1167
EAST COM P
46%
97
- CVBU LUCKNOW
Afforestation
Environmental Projects
Tata Motors CVBU Lucknow is plant is having plot area of 600 Acres. We have Green cover of 52%. We
celebrate World Environment Day, Earth Hour etc every year in the plant, at Vendor end and also at Villages
through CSR teams ( Corporate Social Responsibility ). Utilise every opportunity for tree plantation & spreading the
awareness on its importance across all the stake holders i.e. Community, Employees, Vendors & Business
associates
57436
60000
45436
50000
37836
40000
29236
30000
20686
20000
10686
10000
0
2004-05
2005-06
2006-07
2007-08
2008-09
2009-10
: 12,000 nos
98
2006-07
Environmental Projects
- CVBU LUCKNOW
99
2007-08
Environmental Projects
100
- CVBU LUCKNOW
100
2008-09
Environmental Projects
S.No
Year
200809
200809
Area
Whole Plant
CTP site
200809
STP Site in
Eastern
Complex
200809
W.complex &
Eastern
complex
200809
STP Site in
Western
Complex
Trigger for
improvement
Process
improvement
Facility required at
the bore well site to
monitor the frequency
variation in ground
water level
Installation of
Peizometer well at
different location
both in E.complex &
W. complex to
monitor th level of
ground water aquifer
& thereby complying
consent conditions
Tracking/ mainting
records for the
depletion or incres
in ground water
table
Waste coolant is
having very different
coplex chemical
property & needs
separte treatment
otherwise it
contaminates th
wholw homogenous
mixture & hinders in
treatment process
Facilitates the
provisions for heavy
load of domestic
effluent
Instllation of Coolant
treatment plant for
the effective
treatment of waste
coolant as
discharged from
grinding machine at
HT & Gear shop
Coolant is being
treated to crack the
heavy emulsion &
attain a level of
parameters which
doesn't disrupt after
mixing with the
quality of industrial
effluent
Installation of one
1200 KLD FAB
based STP for
treating the effluent
load generated from
different process &
activity & meeting
statutory
environmental
norms
Dedicated
Environmental
Laboratory for
undertaking testing
of essential
parameters & also
regulating the
dosing of chemicals
Enhancement of two
no. of 400 KLD
Fludized bed
reactor (FAB)
based STP to cater
the enhanced
domestic sewage
load & meeting
statutory
environmental
norms
Complete treatment
of sewage for
achieving the
parameters well
below the statutory
specified limiting
value
Inadequate provision
for chemical &
bilogical treatment of
the increased
sewage load
- CVBU LUCKNOW
Result achieved
Photographs
- -
Determination of
chemical dosing
quantity as per
influent quality for
effective treatment
- -
Complete treatment
of sewage for
achieving the
parameters well
below the statutory
specified limiting
value
101
101
2009-10
Environmental Projects
S.No
Year
200910
Area
Primary ETP
Site in Eastern
Complex
200910
Western
Complex
200910
Eastern
Complex
200910
Weatern
Complex
Trigger for
improvement
Waste water
generated from P ai nt
shop contains very
complex orgnic paint
resins which
essentially requires
prior physi cal &
chemical treatment
before sending i t to
secondary treatment
Uncontrolled use of
fresh water resource
at the major point
sources
200910
2009200809
10
Reducti on &
prci pitation of heavy
organi c particulates,
heavy metals etc.
Installation of water
flow meter at
canteen, Recon
shop, frame paint
booth & cowl shop
for tracking &
regulating fresh
water consumpti on
Tracking &
regulating the water
consumption rate
Installtion of 6 nos.
of new borewells in
E. Complex to cater
the hi gh water
demand for
domestic, industrial,
process, fire service
etc.
Fullfillment of water
demand for
manufacturing
process
Earli er we had no
recirculation system
for the wash water
generated due to
washing of cowls
Fresh Water
resource
Conservati on
Inadequate provision
for chemical &
bilogical treatment of
the increased effluent
load
Enhancement of
one 400 KLD hitech E TP for treating
the enhanced
effluent load
generated from
different process &
activity & meeting
statutory
environmental
norms
Complete treatment
of effluent for
achieving the
parameters well
below the statutory
specifi ed li miting
value
Installation of one
1800 KLD hi-tech
secondary ETP for
treati ng the effluent
load generated from
different process &
activity & meeting
statutory
environmental
norms
Complete treatment
of effluent for
achieving the
parameters well
below the statutory
specifi ed li miting
value
ETP Si te in
Western
complex
ETP Si te in
Eastern
complex
Result achieved
Installation of one
450 KLD primary
ETP at paint booth
meeting for
undertaki ng batch
process treatment
Expansion project
Process
improvement
- CVBU LUCKNOW
102
Photographs
- -
Paint
Shop
TCF
- -
102
Sohrabji Godrej Green Business Centre
Winners
Senior Leaders
Union Leaders
Service providers
Vendor end
Winners
CSR
plantation at Jainabad
village
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- CVBU LUCKNOW
104
- CVBU LUCKNOW
105
- CVBU LUCKNOW
106
107
- CVBU LUCKNOW
Wind
Solar photovoltaic
Turbo ventillators
Installed Capacity
2007-08
Energy
Annual
Generated
Savings
(Lac kWh)
(Rs. In
Millions)
24.5 MW
2009-10
Energy
Annual Savings
Generated (Rs. In Millions)
(Lac kW h)
559
167
576
227
529
175
1,318
0.005
1,318
0.005
1,318
0.005
619,488
2.48
495,590
2.12
650,462
2.78
110 W
1,403,663 CFM
2008-09
Energy
Annual
Generated
Savings
(Lac kW h)
(Rs. In
Millions)
Installed
Capacity
700 LPD
2007-08
Equ Fuel
Annual
Savings
Savings
(kL)
(Rs.)
0.53
2008-09
Equ Fuel
Annual
Savings
Savings (Rs.)
(kL)
16,960
0.53
19,080
2009-10
Equ Fuel
Annual
Savings
Savings (Rs.)
(kL)
0.73
26,280
Lake lighting
- CVBU LUCKNOW
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Technology Absorption
Technology Absorption Details of year wise efforts made in technology absorption relating to energy
SN
Details of Technology
absorption
Saving
Capital
Potential investment
Absorbed/Learnt
from
KWH
Rs in Lakhs
388800 Less than jet ISHRAE - Indian
Society of Heating
nozzles
Refregirating &
Airconditioning
Engineers
300000 45Lakhs/eac Atals copco,
h
Sweden
109500
Implemented in
Plant / Sub
location
year of
Photograph
implementati
on
MARCOPOLO, E.C
2007-08
Eastern Complex
2007-08
Eastern Complex
2007-08
20000
Western Complex
2007-08
10000
Eastern Complex
2007-08
2008-09
14256
8.5
- CVBU LUCKNOW
ISHRE SEMINAR
109
Technology Absorption
Technology Absorption Details of year wise efforts made in technology absorption relating to energy
SN
Details of Technology
absorption
Saving
Potential
KWH
1069200
Capital
Absorbed/Learnt
investment
from
Rs in Lakhs
Almost same KRUGER ,
as backward Germany
curve
200000
75
Lkhs/each
Microprocessor based ES
system for centralised
controlling of compressors as
per air CFM demand.
180000
Implemented in
Plant / Sub
location
All over E.C
year of
Photograph
implementati
on
2008-09
Atals copco,
Sweden
Eastern Complex
2008-09
12 Lakh
Chicago
Pneumatic, US
Eastern Complex
2008-09
7884
4500000
CII Seminar,
Chandigarh
2008-09
52560
1500000
2009-10
2000
160000
Seminar
orgainised by
TATA BP solar
Western Complex
2009-10
225000
7500000
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2010-11
(Work in
progress)
Summary
60%
16579
15114
16000
T CO 2
14000
11247
12000
10000
8500
8000
6632
6000
4000
2000
2007-08
2008-09
2009-10
2010-11
2011-12
Upto July10
Total Carbon reduction : T CO2 : 913
- CVBU LUCKNOW
111
Summary
Impact of ENCON, Innovation & Carbon emission reduction measures on reduction of cost
of production goods.
- CVBU LUCKNOW
112
Waste Management
Input Waste
Recycle
Process Waste
Reuse
Output Waste
Incinerate
Plant Internal
&
External Authorized Agency
113
- CVBU LUCKNOW
Waste Management
Waste generated = Waste utilised
SN
Type of
the
Waste
used
Name of the
Waste generated
Details of the
Waste
generated
UO
M
Qty of waste
generated
2009-10
Qty of waste
generated and
utilised
2009-10
Snap shots
Packing
Wood
From Packing
Kg
3,079,418
3,079,418
Packing
Carton
From Packing
Kg
800,240
800,240
Packing
Polythene
From Packing
Kg
79,210
71,289
Packing
Jute Cartons
From Packing
Kg
167,310
158,945
11
Process
From Machining
& Grinding
Lt
8,610
6,027
Process
From Engine
Reconditioning
Kg
2,730
1,911
Process
Paint Sludge
From Paint
Booths
Kg
30,000
30,000
9 incinerable waste
Used Coolant
From Machining
& Grinding
Kg
100,000
100,000
2 incinerable waste
storing material
8
9
Process
Process
ETP Sludge
10 Process
Paint Drums - MS
11 Process
From ETP
Drying Bed
From Painting
Process
From Oil
Process
12 Process
Chips
From Gear
Cutting
13 Process
MS Offcuts
From
Construction &
Fabrication
Kg
30,000
30,000
Nos.
35,000
35,000
Nos.
3,000
2,100
Disposed as
Disposed as
Disposed as
Kg
60,000
39,000
--
Kg
100,000
77,000
--
Sold to recycler
forsecondary use of
steel, for fabrication
of stands and fixtures
for internal use
114
NABL certification
OHSAS 18001:2007
ISO/TS certification
ISO 14001 certification
2003-04
2007-08
2009-10
115
- CVBU LUCKNOW
2011-12
Sohrabji Godrej Green Business Centre
2009-10
- CVBU LUCKNOW
116
2011-12
Clause
4.5.2
4.3.2
4.3.1
NCR Description
Correction
Corrective Action
Environmental board
displayed outside the main
entrance does not have
updated information on Air &
water consent with validity &
analysis of treated effluent
There is no evidence of
analysis of used oil before
disposal to authorised recyler
Di splay of updated
information on Air and Water
consent, analysis report of
treated effluent & analysis of
used oil as per requirement
will be reviewed in MR
meeting in order to maintain
continuity.
Henceforth, used oil will be
analysed before di sposa
Following changes in
applicable legal requirements
not i dentified in Legal
Register
Hazardous Waste
Management & Handling
Rules amendments -2008
Petroleum rules 2002
Indian Electricity rules
amendments-2002
Status
Closed
Closed
Cla use
4.5.2
NCR De scription
Correction
Corrective Action
- CVBU LUCKNOW
117
Status
Closed
Cla use
8.2.3.1
NCR De scription
Understanding on basic
statistical concepts and
utilization of control charts is
inadequate.
8.1.2
7.3.3
Correction
A systematic approach of
performing process studies
on new assembly processes
to establish the objectives for
process capability, reliability,
maintainability and availability
is not in place.
Corrective Action
Status
Closed
Closed
Closed
118
All TATA Group companies can access the TKC internet based portal.
Every one can learn & share the knowledge
Vibes- Tata Motors Intranet
All TATA Motors employees can access the VIBES-the Intra net portal through which knowledge can be
enhanced through learning & sharing.
Knowledge through Learning (KTL) of CVBU
Lucknow Plant, in 2009-10 year contributed 3680 numbers of knowledge pieces in the KTL Book of CVBU.
Also a CD comprising of all the improvements were released. The divisions /departments who contributed
significantly were also felicitated subsequently.
Plant head inaugurating the KTL CD
Divisions / Departments
which contributed
significantly were
Planning,
Manufacturing, Central
Quality, Transmission
Factory, Assembly Line
planning, Sourcing,
Vehicle Factory, Lean
Manufacturing, PTPA,
PE, Integral Bus
Factory, Sustenance &
Training Centre
In-house/External training
program
Knowledge sharing through
Plant visits
Sharing of the best practices
implemented though
Video Conferencing
119
- CVBU LUCKNOW
Through Associates
TATA Motors Ltd. - CVBU Lucknow has conducted special drives at business associates /Vendor end to
optimise the over all vendor management process. We have conduced KAIZENs AT VENDORs END. The
results of this special drive are,
KAIZEN Exercises within Plant & at TMLs Vendors
108
82
88
60
84
84
48
70
40
09-10
60
IInd Qtr
Ist Qtr
08-09
09-10
IVth Qtr
IInd Qtr
Ist Qtr
08-09
IIIrd Qtr
21
20
0
84
81
78
80
80
IVth Qtr
108
103
100
Better
Target : 80
90
IIIrd Qtr
Target : 100
Sustenance (%)
KaizenKaizen
Sustenance
in %
Better
No of Kaiz en Events
Major Kaizen
TM & LS Participation ( % )
Employee
Participation in %
80
40
81
76
82
82
09-10
Better
Target : 80
100
60
40
IIIrd Qtr
IInd Qtr
Ist Qtr
21
20
08-09
IVth Qtr
- CVBU LUCKNOW
120
Aligning associates to Changing Market Scenario & Optimising overall productivity process
TATA Motors Ltd. - CVBU Lucknow has conducted special drives at business associates /Vendor to optimise
the over all vendor management process. We have conduced QUALITY AT SOURCE event in November09
& December09. The results of this special drive are,
- CVBU LUCKNOW
121
Through Associates
TATA Motors Ltd. - CVBU Lucknow has conducted various programs like Technology Up gradation awareness
program, Modern trend in vehicle assembly system, Green Initiatives, Energy Conservation measures etc to
business associates / vendor to enhance the productivity & quality of material they supply inturn reduce the cost
of poor quality.
The Quality Month communication has been conducted in December2009 at Tata Motors-Lucknow plant and all
the associates/vendors participated the event. Various rewards been given to vendors for their good quality of
product. Couple of snap shots are,
- CVBU LUCKNOW
122
- CVBU LUCKNOW
Tata Motors
Jamshedpur
123
CII
ISHRAE
BEE
Tata Motors
Lucknow
ISO 9001
Vendors
Associates
KNOME
Yugandhara
Tata Motors
Pune
Knowledge Pond
OSHAS
Enterprise
System Manual
TKC
Innovista
Climate
Change
Safety
TQMS
CSR
Tata Daewoo
Hispano
Vibes
Tata Motors
Pantnagar
Jagaur
&
LandRover
Tata Motors
Sanand
- CVBU LUCKNOW
124
Results of the replication arising out of Best Practices implemented on energy front through
associates are
Process has been institutionalized at Lucknow
Rs in Crores
Better
Better
0.31
0.3
0.27
0.25
0.19
0.2
0.15
0.1
2007-08
2008-09
2009-10
- CVBU LUCKNOW
2006-07
Energy Cost as a
% of
manufacturing
cost in 2009-10 is
0.192 %
Best in Class
125
2007-2009
2)
3)
List of Awards
1)
2)
1)
2)
4)
Tata Motors bags the NDTV Profit Business Leadership Award 2008
5)
Tata Motors has been ranked First in India in Investor Relations, in the Thomson Reuters
6)
Tata Motors has been awarded the 'Top Exporter Gold Trophy in the Large Enterprise category by the Engineering
3)
Tata Motors has received the Emerson Network Power and Express Computer Uptime Champion Award 2007
The Aggregates Business of Tata Motors' Commercial Vehicle Business Unit has won the 'Best Supplier Award 2007
from Escorts Construction Equipment Ltd (ECEL).
- CVBU LUCKNOW
126
Thank You ! ! !
127
- CVBU LUCKNOW
Mode of transportation
1 TRAILER-28 FT
Load
Carrying
Capacity
48000 15T
2 TRAILER-40 FT-3516
72000 20T
1.5
72000 20T
Rate
No of
chassis per
Trailer
1
17100
1500
750
4550
2
17100
1500
750
2799
Scenario
17100
1500
750
4550
23900
24000 Scenario - III
Cost per
Chassis
Scenario - IV
9500
750
375
1400
12025
12000 Scenario - IV
Assumptions :
Cost of temporary support recycling is not considered.
- CVBU LUCKNOW
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129