Amara Raja Batteries Limited, Chittoor
Transcript of Amara Raja Batteries Limited, Chittoor
Apr 2017, Tirupati
2 5 t h , 2 6 t h 2 7 t h & 2 8 t h A u g u s t 2 0 2 0
C I I , H Y D E R A B A D ( v i r t u a l )
Team members:
M. Subhash, Head – Centre Of Excellence
K. B. Vinaya Sagar, Head – Energy management
Amara Raja Batteries Limited, Chittoor
Apr 2017, Tirupati
8/20/2020
2
Dr. Ramachandra N Galla
Founder & ChairmanJaydev Galla
MD & Vice Chairman
Amara Raja GroupAmara Raja Batteries Limited
Manufacturing Locations:
• 6 Plants in 200 Acres at Tirupathi, Rural place in INDIA
• Amara Raja Growth Corridor with 5 plants in 500Acres at Chittoor (Bangarupalyam), INDIA
• Providing Employment to nearly 15000 people directly
• The largest single manufacturing facility in Indian ocean rim
Our Innovative dynamism:
• Brought VRLA technology in two wheeler to India
• Exclusive Vendor to OE premium segment Vehicles
Ownership:
• Incorporated in 1985 & Public Limited Company Est. in 1991
Dec 1985Foundation stone laid for
Amara Raja Power System Ltd.
1986Amara Raja a
small beginning
• Established in 1985
• Cumulative investment of $ 521 Million
• Total built up area 6 Million Sq. ft
1584 1958 20622552
31773732
4225
52855867
67367755
8702
0100020003000400050006000700080009000
10000
Gross Turnover in Cr.
Amara Raja- A Clear differentiator
Apr 2017, Tirupati
The Amara Raja Way
To transform our increasing spheres of influence and to improve the quality of life by
building institutions that provide better access to better opportunities to more people. .
all the time.
Through the Amara Raja Way,
we will continually redefine business to
Deliver High Social Impact,
by
Anticipating Future Trends,
Building Preferred Brands and Leveraging
Talent & Technology.
Core Purpose:
Core Values: Group Vision 2025:
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Apr 2017, Tirupati
8/20/2020
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About our group…
Apr 2017, Tirupati
• Power Generation
• Transmission &
distribution
• Telecom
• Railways
• Offshore units
• 4 wheeler
• 3 wheeler
• 2 wheeler
• Tractors
• Trucks
• Inverters
Amara Raja Batteries Ltd. Our Brands & Products
Amaron Sleek
Power Stack Amaron Volt
5
Apr 2017, Tirupati
8/20/2020
6
Battery Manufacturing Process Flow - SBD
Apr 2017, Tirupati
Energy Consumption overview
7
122,464, 99.2%
1089, 0.8%
Plant Energy Consumption in TOE ( Ton of Oil Equivalent )
Electrical Thermal
Battery charging46%
Process equipment29%
Pollution control equipment
13%
Utilities12%
Energy Consumption in Battery Manufacturing
Electrical 142.4Mn Units
122,464TOE
Thermal 189TOE
Apr 2017, Tirupati
Specific Energy Consumption
SEC definition:
Kwh (units) required to produce
specific unit of batteries.
i.e., kWh / Specific unit
EnCon PROJECTS CAPACITY UTILIZATION ADDITIONAL MACHINERY
1,426
477
1,400
1%
47,287 46,784
42,472 40,267 39,971
38,972
FY16 (A) FY17 (A) FY18 (A) FY19 (A) FY20 (A) FY21 (P)
kWh
Per
Sp
ecif
ic u
nit
Financial year
SP. ENERGY CONSUMPTION PER SPECIFIC UNIT
2901
1563
1042
1,823
3,689
1,200
9%
904
1600
2901 5%
SP. Energy FY 16-20
2.5%
8
1%
0.7%
Apr 2017, Tirupati 9
Outsourcing \ Internal development
of material and/or processes
Specific Energy Consumption
Process Outsourcing No Change in Material
Procurement status
Hence, reduction of SEC is not influenced
by out sourcing of process \ internal
development of material.
35
80
44
32 56
55
76%74%
63%
0%
90%
0
6000
FY'18 FY'19 FY'20
In M
n A
h
Plant Capacity Vs Utilization
Plant Capacity Capacity Utilization
This drop in Capacity utilization resulted in
4% increase in SEC.
Apr 2017, Tirupati 10
SEC ( Section wise )
3420
3534 49
68
4413 52
09
2457
9
311
875
OX
P
GR
P
PS
T
OV
N
AS
M
FR
M
FIN
LG
T
Kw
h/ M
n A
h
Medium VRLA
3936
4519
1070 34
10 4803
2590
1392
5864
1562
3
788
600
120
OX
P
GR
C
ST
C
XS…
OP…
XP…
OV
N
AS
M
FR
M
FIN
LG
T
CO
M
Kw
h/M
nA
h
Automotive36
22
1094 48
19
3790
5287
4385
1925
8
359
1268
137
OX
P
GR
P
ST
C
PS
T
OV
N
AS
M
FR
M
FIN
LG
T
CO
M
kwh
/Mn
Ah
Tublar
6938 15
153
7752
1128
7
3406
3
2699
5
6491
889
685
OX
P
WS
C
PS
T
OV
N
AS
M
FR
M
FIN
LG
T
CO
M
Kw
h/M
n A
h
Two wheeler
Apr 2017, Tirupati
3.033.45
4.97
ARBL Compt 1 Compt 2
Po
wer
& F
uel
Co
stas
% o
f Tu
rn o
ver
National Benchmarking
40,267 41,370
54,500 62,100 60,370
ARBL, CTR ARBL, TPT JCI, China JCI, US JCI, Germany
kW-h
/ S
p. u
nit
International Benchmarking
Data Source: Annual reports of 2018-19
Benchmarking
11
Addition of
renewable energy
IGBT technology
rectifiers
Punch grid
technology
Heat recovery
systems
Lead pot design
modification
Further Focusing on..
IIOTProcess
optimization
Apr 2017, Tirupati
1.7 1.8 1.7
4.0 4.88.6
FY18 FY19 FY20
Mn
. kW
h
Mn. kWh Savings
No investment Investement
10.5 10.9 10.2
23.6 28.951.8
0.0
50.0
100.0
FY18 FY19 FY20M
n. R
s.
Cost Savings
No investment Investement
151.7 173.5256.6
FY18 FY19 FY20
0
200
400
Mn
. Rs.
Investments Towards EnCon
Statistics on EnCon Projects
12
ROI:
With Solar -90 Months.
W/o Solar - 4 Months.
715 15
9
13
32
FY18 FY19 FY20
No
of
pro
ject
s
Encon projects trend
No investment Investment
Apr 2017, Tirupati
Statistics on EnCon Projects
13
YearNo of
Projects
Investment
( in Mn )
Savings
( in Mn )
Payback
( in Years )
FY18 16 151.7 34.1 4.4
FY19 28 173.5 39.8 4.4
FY20 47 256.65 62.01 4.1
YearNo of
Projects
Investment
( in Mn )
Savings
( in Mn )
Payback
( in Years )
FY18 13 0.96 10.3 0.1
FY19 27 3.51 17.9 0.2
FY20 44 9.65 29.23 0.3
With out
Solar PV
Projects
With Solar
PV
Projects
Apr 2017, Tirupati 14
Before After
1.Replacement of Contactors with SCRs.Heater controls were through contactors. These were
replaced with SCRs for energy saving and precise temperature control.Energy savings/Annum: Rs 1.57 Mn. HD : 3.12 Mn
14
2.Replacement of Pneumatic vibrator with electrical in Silo.Pneumatic vibrators are replaced with electrical vibrators that leads to less energy and air consumption.
Energy savings/Annum: Rs 1.24 Mn. HD : 2.6 Mn
.
3. Optimization of condenser pumps with Compressor
Interlocking of Condenser pumps with compressor in water chillers for 5 nos.Energy savings/Annum: Rs 1 Mn. HD : 2.2 Mn
Energy Saving Projects
Apr 2017, Tirupati 15
Before After
4.Lead level optimization in lead melt pots.Molten Lead level reduced in lead melting pots by 150
mm with out affecting productivityEnergy savings/Annum: Rs 0.9 Mn. HD : 2 Mn
5. Reduction of Skin temperature of the lead potsSkin temperature is reduced from 100°c to 68°c by
applying ES-70HT engrave paint.
Energy savings/ Annum: Rs 0.85 Mn. HD : 1.9 Mn
6.Adopting latest technology: IE3 electrical pumps in place of AODD pump.In ETP, for slurry transfer, we were using AODD pumps .
These were replaced with Electrically operated centrifugal pumps with UHMW-PE semi opened impeller.Energy savings/Annum: Rs 0.49 Mn. HD : 1.6 Mn
Energy Saving Projects
Apr 2017, Tirupati 16
Before After
7. Adopting latest technology: LED in place of T5 FTL125 nos of 2X 28W T5 lamps with 36 Watts LED fittings in
TBD formation75 nos of 250w MH lamp fittings with 120W LED fittings in Stores mezzanine floor. Energy savings/Annum: Rs 0.54 Mn. HD : 0.8 Mn
8. Optimization of Hydraulic power packsSix Hydraulic power packs of 20hp each are running to
cater six grid caster machines. Removed all six machines and fixed one 10HP pack.Energy savings/Annum: Rs 0.24 Mn. HD : 0.58 Mn
16
9. Optimization of Compressor air for washing.Trans vector nozzle in place of air gun, which reduced compressor air consumption by 50%.Energy savings/Annum: Rs 0.16 Mn. HD : 0.38 Mn
Energy Saving Projects
Apr 2017, Tirupati 17
List of Ongoing Energy saving projects - FY' 20 - 21
Amara Raja Batteries Ltd - Chittoor
S No Title of project
Annual
savings in
Kwh
Annual
savings in
Mn Rs
Investment in
Mn Rs
Pay back in
monthsYear
1 Replacement SCR with IGBT / SCR wit zerocross over in lead pot165,900 1.00 0.37 4
FY'20-21
2 Roof top solar installation in TBD north side & south exansion 8.24 MW8,680,685 52.08 395.00 91
FY'20-21
3 Install Fan less cooling tower in ABD2 Grid casting cooling tower47,250 0.28 0.50 21
FY'20-21
4 Skin temperature reduction in leadPot 136,500 0.82 0.44 6
FY'20-21
5 IR Heaters for pasting flash dryers 378,000 2.27 1.80 10
FY'20-21
6 Replace pneumatically operated vibrators with electrical vibrators 97,978 0.59 0.63 13
FY'20-21
7 Replace existing conventional lamps with LED in Formation charging Area128,700 0.77 1.40 22
FY'20-21
8 Replacement of Centrifugal blower with BLDC fans in Fresh Air systems220,200 1.32 2.55 23
FY'20-21
9 Install Auto descaling system for water chillers 182,700 1.10 1.95 21
FY'20-21
10 Replace with direct coupling in place of blower belts for ovens129,660 0.78 0.32 5
FY'20-21
11 Replace AODD pumps with energy efficient centrifugal pumps 251,640 1.51 1.05 8
FY'20-21
12 Provide Occupancy sensors for TBD Chargers rooms9,240 0.06 0.05 10
FY'20-21
Total for 2020-21 10,428,453 62.6 406.06 77.9
FY'20-21
Ongoing Energy saving projects for FY’21
Apr 2017, Tirupati 18
Innovative Project – 1Energy Optimization in Curing and Drying ovens
Ø 450mm
Ø 450mm
Air Exhaust Air Inlet
Heaters144KW
Recirculation Blower
Anode & Cathode Plates Stands
Loading Cycle
• 8hrs
• 46℃
• 100%RH
Cure Cycle
• 16Hrs.
• 50℃
• 100%RH
Inter Dry
• 8Hrs
• 53℃
• 60%RH
Dry Cycle
• 21Hrs
• 65℃
• <20%RH
Oven process
Inlet damper size: 450mm
Outlet damper size: 450mm
Energy consumption: 2200units per Cycle
BeforeInlet damper size:
300mm
Outlet damper size: 300mm
Energy consumption: 1500units per Cycle
After
Apr 2017, Tirupati 19
Innovative Project – 1Energy Optimization in Curing and Drying ovens
Environmental Benefits:
CO2 Avoided per Annum = 2400 Tons
Heaters
Recirculation Blower
Anode & Cathode Plates Stands
Ø 300mm
Ø 300mm
Air Inlet
Air Exhaust
Heaters
Recirculation Blower
Anode & Cathode Plates Stands
Ø 300mm
Ø 300mm
Air Inlet
Air Exhaust
One Cycle
700 Units saving
Rs 4200 Saving
One Oven
1,17,600 Units
Rs
7.06Mn
Completed
25 ovens
2.9Mn Units
Rs
17.64 Mn
Scope for HD
78 ovens and 9Mn
Units
Apr 2017, Tirupati 20
Oven-02
Outlet duct Dia@ 450mm
Inlet Duct Dia@ 450mm
Blower
DamperDamper
450 mm450 mm
Oven-02
300mm Dia SS Plate
Outlet duct @ 450mm
Inlet Duct @ 450mm
Blower
Damper
Damper
BEFORE AFTER
Innovative Project – 1Energy Optimization in Curing and Drying ovens
Apr 2017, Tirupati 21
Innovative Project – 1Energy Optimization in Curing and Drying ovens
BEFORE
Power consumption did not reach to Minimum value
Power consumption >100KW
AFTER
Power consumption <100KW
Power consumption reach to Minimum value and optimized the
usage
Apr 2017, Tirupati 22
Proposed set up:Instead of phase angle control, these SCRs aretriggered by zero cross over firing techniques,there by achieving same energy saving with outaffecting power quality in the grid.
Investment: Rs 0.7 Mn Savings: Rs 0.36 Mn ROI : 1.9 Years
Innovative Project – 2SCR with Zero cross over firing for heater controls
Existing Set up:Lead melting pots are having electrical heaters, controlled bySCR with Phase angle control to achieve process parameters within set limits. These SCRs do save energy, but generates moreharmonics in the grid and affecting power quality.
Benefits: Harmonics are not generated. Power factor improved. Optimum control on process parameters
like temperature and Humidity.
Zero Cross over firing technique
Apr 2017, Tirupati 23
Before Condition:
• Low power factor• High harmonics in the circuit.
After Condition: • Near Unity Power factor• No Harmonics generated in the circuit• Additional Energy savings: 60000 units
Innovative Project – 2SCR with Zero cross over firing for heater controls
THD (I) more than 28%
THD (I) less than 9%
Norms: • I THD : less than 10%• V THD : less than 5%
HD: 35 lead melting
pots
Apr 2017, Tirupati 24
BR
AN
CH
DU
CT-1
Asse
mb
ly Line
-1
BR
AN
CH
DU
CT-2
Asse
mb
ly Line
-2
Drop
Drop
Drop
Drop
Bag House Blower
Ch
imn
ey
Existing System Drop
Drop
Drop
Drop
Common header duct is installed for all the lines in Dust extraction system.
Innovative Project – 3Redesigning of Dust extraction system ducts
Apr 2017, Tirupati 25
BR
AN
CH
DU
CT-1
Asse
mb
ly line
-1
Drop
Drop
Drop
BR
AN
CH
DU
CT-2
Asse
mb
ly line
-2
Drop
Drop
Drop
Bag House Blower
Ch
imn
ey
Every Line Individually
Connecting to Bag House
Regulating type Electrically Actuated
Blower Inlet Damper
Pneumatic Dampers in the Branch Ducts
DropDrop
Modified System
Energy savings per annum 2.4 Mn Rs
Individual header ducts are installed instead of having common header duct
Innovative Project – 3Redesigning of Dust extraction system ducts
Apr 2017, Tirupati 26
Previous Setup Revised Setup
Other project -1; Positive ovens cycle time reduction
Previous Set up: Excess cycle time oration in positive ovens Total Oven process duration : 53 Hrs.
Revised set up: Elimination of 16 hrs. curing cycle in positive ovens Revised Oven process duration : 37 Hrs.
Benefits: Productivity improved by 30% Capital cost saving in expansion project: Rs 40 Mn. Energy saving : 16000 KWH
Apr 2017, Tirupati 27
Other project-2; Skin Temperature Reduction
Thermal imager showing 85 °C
Before After
Lead oxide Reactor pot skin temperature is reduced after providing insulation of ceramic wool. And proving Thermal insulators between fixing clamps to avoid conduction of heat through fixing mechanism.
Energy savings per annum: Rs 0.6 Mn.
Lead Oxide Reactor pot skin temperature reduction:
Thermal imager showing 56 °C
HD: 12 Reactor Pots
Apr 2017, Tirupati 28
Other project-3; Direct Driven System
BEFORE AFTER
Motor speed : 1440 RPMBlower speed : 996 RPMFrequency : 50 Hz
Motor speed : 996 RPMBlower speed : 996 RPMFrequency : 33.4 Hz
Energy savings per annum: Rs 3.1 Mn. HD: 78 Ovens
Apr 2017, Tirupati
Renewable Energy Roof Top Solar Panels
29
1.26 3.
57
6.20 9.
75 14.4
5
15.5
5
FY17 FY18 FY19 FY20 FY21 FY22
MW
p
Capacity
1.8
3.7 5.
6 8.2 9.
9
10.5
FY17 FY18 FY19 FY20 FY21 FY22%
Renewable Energy share in Overall Energy
1.62
3.68 8.
67 13.3
8 20.6
5
22.1
2
FY17 FY18 FY19 FY20 FY21 FY22
Mn
kW
h
Power Generation
10 2452
80
124
133
FY17 FY18 FY19 FY20 FY21 FY22
Mn
. Rs.
Savings
Apr 2017, Tirupati 30
Smart Solar Avg.4% of Improvement in Solar energy
generation by real time monitoring
Weather Monitoring –Irradiance in watts/m2
Arial View
Inverter Wise details
Life time export.
String Wise monitoring.
Plant wise Capacity Vs Generation
Plant wise comparison
Plant Wise Efficiency
Renewable Energy Roof Top Solar
Apr 2017, Tirupati
Composting Machine Ready for Plantation use
Canteen Food Waste Processing
Utilization of Waste Material
31
391469 486
FY18 FY19 FY20
Mn
Kca
l
Canteen Food Waste Utilization
Packing wood optimization
2633
42
FY18 FY19 FY20
% o
f
Re
use
/Re
cycle
Reuse\ Recycle of packing wood
686803
1266
FY18 FY19 FY20M
n K
cal
Packing Wood Waste Utilization
Apr 2017, Tirupati 32
Utilization waste - Reduction of wood utilization
Project -1:Reuse of Wooden pallets from warehouses
• 50% of Packing material of wooden pallets, are retrieved from ware houses and reused.
• Fresh Single use wooden pallets during Packing reduced from 75% to 50%.
Project -2:Usage of PP pallets
PP (Poly propylene) Pallet
• Wooden pallets are replaced with PP pallets.• Percentage of PP Pallets increased from 20%
to 50% in this year. Targeted 100% in FY 21
Epoxy painted Pallet
Benefits: Wood Savings: 1 lakh CFT Savings of 5000 Trees per year 20 hectares deforestation
Apr 2017, Tirupati
Waste water for gardening after treatment
33
ETP Slurry Agitator tank clarifier water storage tank
30,000 KL water saved per year
Utilization waste
RO reject water into gutter RO reject water to GardenPlanted 50000 trees and garden to built green belt in the premises
Before After
Apr 2017, Tirupati
Green House Gas (GHG) Inventorization
0.087 0.0860.075 0.071 0.063 0.059
FY16 (A) FY17 (A) FY18 (A) FY19 (A) FY20 (A) FY21 (T)CO
2 in
T/
Mn
. A
h
Scope 1: Direct GHG Emissions
48.22 38.78 37.66 33.72 31.34 28.83 26.24
FY15 (A)FY16 (A)FY17 (A)FY18 (A)FY19 (A)FY20 (A)FY21 (P)CO
2 in
T/
Mn
. A
h
Scope 2: Electricity Indirect GHG Emissions
4.42 4.253.57 3.32 3.05 2.98
FY16 (A) FY17 (A) FY18 (A) FY19 (A) FY20 (A) FY21 (T)CO
2 in
T/
Mn
. A
h
Scope 3: Other Indirect GHG Emissions
Scope-3 Reduction plan:
34
16MT- Without GPS
<20% to 50%
21 /28MT -GPS
2% 35%
20ft Containers-17.5 to 25MT
0% 20%
20ft/4a0ftContainers
Apr 2017, Tirupati
Environmental monitoring
35
Work place monitoring
Ambient air monitoring Monitoring of supplied air Dust extraction system monitoring Scrubber monitoring
Monitoring of acid mist Monitoring of DG sets
Apr 2017, Tirupati
36
Emissions - Air quality monitoring
53 4855 5549 47
Jan'20 Jun'20
Ambient Air Quality - PM10 (in µg/Nm3)
Loc1 Loc2 Loc3
Standard : 100 µg/Nm3
25 2426 2624 25
Jan'20 Jun'20
Ambient Air Quality - PM2.5 (in µg/Nm3)
Near TBD DG Set Near Substation Near Canteen
Standard : 60 µg/Nm3
0.55 0.58
0.18 0.220.38 0.31
jan'20 Jun'20
Ambient Air Quality - Lead (in µg/Nm3)
Near TBD DG Set Near Substation Near Canteen
Standard : 1 µg/Nm3
Installed Continuous Ambient Air Quality Monitoring Station (CAAQMS)
Working up to the expectations and values are within the standards
Apr 2017, Tirupati
Green belt development
37
Green belt development across all group companies
Approx.. 50,000 saplings were planted and count
continues..
Apr 2017, Tirupati
Green belt development
38
250Acres of barren hillock Adopted for greenery Development at Petamitta village in the year 2007 30acres purchased and donated to Government Planted 65,000trees as on date 20Tribal families employed Protected by all round fence Plant varieties(Jamun, Neem, Amla and, other medicinal
20acres of lakes developed for the purpose of rain water harvesting and to recharge the ground water levels.
Apr 2017, Tirupati
Benefits of Life Cycle cost in
New plant during design stage.
Green Supply Chain- Best Practices on Energy Front
39
Energy savings of More than 2Mn Units
Auto descaling
systems for chillers
IE3\4 Motors for all equipment
BLDC motors for Fresh air
systems
Aluminium pipe for
compressed air lines
VFDs for all water pumps
with feedback sensors.
LED Light fittings for total plant
Fan less cooling tower
IGBT Battery chargers
Hybrid Active filters
Apr 2017, Tirupati 40
Time line chart for creating awareness on EnCon to suppliers
ActivitiesQ
3 Q3 FY20 Q4 FY20 Q1 FY21 Q2 FY21 Q3 FY21 Q4 FY21 Remarks
P
A
P
A
P
A
P
A
P
A
P
A6
Projects identification and
execution by phase-2
suppliers
Prioritizing the suppliers
4
Projects identification and
execution by phase-1
suppliers Under progress
5Awareness to suppliers
(Phase-2)
2
3Awareness to suppliers
(Phase-1)
Time line chart
Subjuct: Creating awareness on ISO 50001 to suppliers
1 Identification of suppliers
Green Supply Chain- Best Practices on Energy Front
Awareness Session
Award Received by one of our supplier
Apr 2017, Tirupati 41
Road map for sustainability certificate
Jan'20 Feb'20 Mar'20 Apr'20 May'20
W-1 W-2 W-3 W-4 W-1 W-2 W-3 W-4 W-1 W-2 W-3 W-4 W-1 W-2 W-3 W-4
Plan
Actual
Plan
Actual
Plan
Actual
Plan
Actual
Plan
Actual
Plan
Actual
Plan
Actual
Plan
Actual
Plan
Actual
Plan
Actual Under progress10 Getting the BSR score card from Ecovadis
7
Selection of subscription/year as
Basic(1655$)/Premium(2420$)/Corporate(7740$)
and get approval.
Note: Premium for 3yrs is 5445$ (3.92lakhs)
8Uploading the supporting documents in Ecovadis
website.
9Process the payment for the subscription approved
in the s.no.7
4Discussion on questionnaire & its requirements with
all relevant funtional HOD`s
5Collecting supporting documents for the
questionnaire from HOD`s
6Review all supporting documents with
Sr.Management and get consensus.
1Provide awareness on Ecovadis & the importance of
BSR to all relevant Staff
2 Registration in Ecovadis portal
3 Getting customized questionnaire from Ecovadis
`
S. No Task Plan/ActualJun`20 Jul`20 Aug`20 Sep`20
Apr 2017, Tirupati
01
ROHS
IMDS
REACH
HCSMSELV
Conflict Minerals
GADSL
Customer Requirements
ROHS: Restriction of hazardous materials
IMDS: International material data system
REACH: Registration, Evaluation and authorization & Restriction of Chemicals
HCSMS: Honda chemical substance management system
ELV: End life of vehicle
CMRT: Conflict mineral reporting template
GADSL: Global Automotive Declarable substance list
ARBL receiving thesedeclaration requestsfrom different OEMs…
Statutory & Regulatory Training Material
… and ARBL is complying to all these requirements and bagged many awards from OEMs as preferred supplier.
Regulations:
Apr 2017, Tirupati
Online Energy MonitoringMeter’s Status
Solar Energy Generation Trend
Online plant power demand Monitoring
43
Benefits
• Reliable Data availability to all stake holders• View periodical reports of SEC and EnPIs.• Take corrective actions during abnormal
conditions• Identifying opportunities for improvements.• Inter plant comparison.
Apr 2017, Tirupati
TEI &Team Work /Operator level
44
Skit Competition
8,07
5
11,7
59
14,0
54
16,970 1,938
3,057 3,905
4,689
9.4
12.614.9
16.3
0
5
10
15
20
-
5,000
10,000
15,000
20,000
25,000
FY17 FY18 FY19 FY20 Sugg
est
ion
s/ E
mp
.
No
. of
Sugg
est
ion
s
Employee suggestion scheme
262366 452 512812
1824
118
186225
264
0
50
100
150
200
250
300
-150
50
250
450
650
FY17 FY18 FY19 FY20
No
. of
circ
les
form
ed
.
No
. of
pro
ject
s co
mp
lete
d
Quality control circles (QCC)
Awareness session
Poster Competition
Best suggestion
Quiz Competition Best QCC Team
Apr 2017, Tirupati
TEI & team work/Supervisor level
45
4968
82985
611
16
2.87 3.34
5.7
6.9
0
2
4
6
8
0
20
40
60
80
100
120
FY17 FY18 FY19 FY20
Savi
ngs
in M
n. R
s.
No
. of
pro
ject
s co
mp
lete
d
Six sigma Green BeltSl no Problem Idea Before After
1
Timer based solinoid valve
installed at Air compressor
receiver tank.
installing Auto Matic Moisture darin
valve instead of Timer based solinoid
valve at Air compressor receiver tank
Energy savings : 0.03 Mns/anum
2
More Energy Consumption due
to unnecessary exhaust suction
ducts in Assembly pollution
control equipment's 3 Nos
Closing the unnecessary exhaust suction
ducts in Assembly pollution control
equipment's 3Nos
Energy savings : 4.8 Mns/anum
3No device control for charger
AHU unit
Temerature control is installed for
AHU’s
Energy savings : 0.23 Mns/anum
4
Acid is filling from main tank
Header line to fresh acid
storage tank through pump.
And
Provided acid filling from main tank
Header line to battery through Gravity
flow so pump Eliminated. And Acid
suction will be done in Battery by AODD
pump and that acid will return to tank .
so that removed the acid storage tank
Energy savings : 0.14 Mns/anum
Examples of specific Energy consumption Reduction kaizens
Fortnight review of Energy saving projects byPlant head with plant Encon team.
Kaizens Green Belt projects
Apr 2017, Tirupati 46
Investment for EnCon as % of turnover
0.25
0.52
0.74
FY18 FY19 FY20
% o
f Tu
rn o
ver
37.6%
39.0%
36.7%
FY'18 FY'19 FY'20
3
9
16
26
FY17 FY18 FY19 FY20
Mn
Kw
h
Energy Cost as % of Conversion cost
10 1114
182 2
3
42.46 2.28
2.923.22
0
1
2
3
4
0
5
10
15
20
25
FY17 FY18 FY19 FY20
Savi
ngs
in M
nR
s.
No
. of
pro
ject
s C
om
ple
ted
Six sigma Black Belt
Cumulative Energy savings
Monthly review of Energy saving projects byCOO with plant Encon team.
TEI & team work/Middle Management Level
Apr 2017, Tirupati 47
ISO 50001 : 2018 certification
Certified ISO 50001 : 2018 without NCR and major observations
ISO 50001 : 2018 certificate Unveiling by CEO
Awareness on ISO 50001 : 2018
34
93
134
FY'18 FY'19 FY'20
No
of
En
PIs
Energy performance Indicators (EnPI's)
Apr 2017, Tirupati 48
Energy saving projects identified after energy summit
Sl no Problem Idea Before After Benefit
1More Energy Consumption due to
continueous running of split Ac's
Provide Energy saver unit for slit
AC's
2Power is transmitted to blowers
via belt drives
Belt driven transmission will be
replaced with direct coupling
transmission.
Induction motors will be replaced
with Brushless DC motors(BLDC).
3
Water will be cooled in the
existing cooling towers, where it
will be operated with the help of
a fan
Water will be cooled in the cooling
towers, where there will be no
requirement of fan.
4
Timer based solinoid valve
installed at Air compressor
receiver tank.
installing Auto Matic Moisture
darin valve instead of Timer based
solinoid valve at Air compressor
receiver tank
5Classical V-belts are used in power
transmission in DE & FE system.
Replace the Classical V-belts with
cogged teeth belts in power
transmission
Energy saving projects identified after energy summit
0.83Mns/anum
0.03 Mns/anum
0.61
0.47Mns/anum
1.82Mns/anum
Apr 2017, Tirupati
8/20/2020
49
Motion sensors in formation tub area
Total Area covered: 5000Sq.mts
Energy savings in all charger’s room: per annum 0.3 Mn Rs
Total Area covered: 18,000Sq.mts
Energy savings in all formation sections: per annum 0.21 Mn Rs
Apr 2017, Tirupati
High Volume Low Speed (HVLS) air flow system
50
High volume low sped air flow Breezels fans are installed in shop floor
Apr 2017, Tirupati
51
Speciality paste additives to enhance curing
and formation process performance
Innovative Plate making technologies to
conserve the Raw materials
Advanced friction resistant coating techniques
for the Battery assembly process
Ni-Zn chemistry for superior high rate
discharge performance
Sodium Based Batteries for higher safety &
sustainability
Li-ion batteries for EV/ESS applicationsPowering the Rural communities with system
solutions
Selling Energy instead of Selling Batteries
Smart batteries for the smart customer
Graphene based lead acid batteries for the
existing tough applications
Advanced Lead Acid Batteries for upcoming
new applications
EFB product Range for Idle Start Stop
Application
Special Thanks to CII for organizing “India Sweden Innovations’
Acceleration” Program
Way forward (Next 5 Years)
Apr 2017, Tirupati
IIOT Implementation
Key Drivers:
Consistant Quality
Strategy: Plan:
5 Phase Road Map
Training
ARMS Studios
Full Implementation
of 1 plantComplete
ARBL
Pilot
Approach:
Apr 2017, Tirupati
8/20/2020
53
Pilot projects of IIOT
S. No Projects Title Status
1 Street light monitoring Completed
4 Air quality monitoring drone Completed
5 Tub temperature monitoring Completed
6 Fork Lift Monitoring Completed
9 Assembly line in 3D Completed
10 Machine Predictive Maintenance (COS) Completed
11 FE Fire Detection and Suppression system Completed
12 Transformer Health Monitoring Completed
13 Smart DG System Completed
14 Smart Utilities Completed
18 Smart Solar Completed
19 Oven Process Control Completed
20 Liquid Level Monitoring Completed
21 Smart Car Parking Completed
22 Smart Sensors Demo Completed
23 Data Transmission over Sound & LI –FI Completed
Using IIOT platform we started collecting the data on real time from machine.
Apr 2017, Tirupati 54
o Water conservation
o Number of projects taken up:
Check dams 23, tanks distilled 3
o Benefit reached to :12panchayats,
covering 60 villages
o 30 bed primary health centre under PPP
Program (Public Private Partnership
Program)
o Social Forestry
o 250 Hectare of barren hillock Adopted
o Planted 2,00,000 trees as on date at
Karakambadi
o Amara Raja Skill Development Centre
Petamitta
o Fully integrated residential skill
development centre for rural youth
o 5 Acres of land
o Capacity for 800 students per year
o Amara Raja Junior College, Pettamitta
o 3 schools & 1 Junior College
o 3200 plus students
o Affordable Quality education
o State 3rd Rank in College Results for
Academic year 2016
o State 7,8,9 Ranks In College Results
for Academic year 2017 & one student
got seat in NIT Puducherry.
CSR Initiatives
o Amara Raja Vidyalayam at
Karakambadi
o Amara Raja Vidyalayam at
Diguvamagham
Apr 2017, Tirupati
379.88125.63
122.96
37.55
35.88
11.51
6.89
0 100 200 300 400
Contribution to Educational…
Utilities
Infrastructure
Agriculture & Minor Irrigation…
Health
Road Works
Environment (Eco Projects)
Value in million Rupees
CSR - Activity Wise Distribution
CSR Initiatives
57 83 96 120 160 143 147 144102 159 242 338 458618
761908
1052
1999 -2012
FY13 FY14 FY15 FY16 FY17 FY18 FY19 FY20
Amount Spent for CSR Activity
Amount spent in Mn. Rs. Cum. amount
55
2.27
3.343.03 3.04
2.17
FY'16 FY'17 FY'18 FY'19 FY'20
% o
f P
rofi
t
Amount Spent on CSR
Apr 2017, Tirupati
8/20/2020
56
Energy Conservation Week celebrations
Guests speech Guests for Energy conservation day celebrations
Awareness session on Energy conservation for Amara Raja school children
Painting competitions for Amara Raja school children
Apr 2017, Tirupati
8/20/2020
57
Amara Raja Awards & Accolades
Excellence in Energy Efficiency and most useful presentation award from CII
Energy Efficiency award from CII TPM Award from JIPM - JAPAN
Winner - Best Commercial Roof Top PV Company of the year
Organisations with Great Managers’ Six Sigma National Award
Apr 2017, Tirupati
8/20/2020
58
Amara Raja Awards & Accolades