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:

3

Apr 2017, Tirupati

8/20/2020

4

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.


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


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


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



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



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


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



Environmental Benefits:

CO2 Avoided per Annum = 2400 Tons

Heaters



Ø 300mm

Ø 300mm

Air Inlet

Air Exhaust

Heaters



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


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




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


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


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


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


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


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


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


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


Mn

kW

h

Power Generation

10 2452

80

124

133


Mn

. Rs.

Savings


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


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


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


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


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


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


3No device control for charger

AHU unit

Temerature control is installed for

AHU’s


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


Examples of specific Energy consumption Reduction kaizens

Fortnight review of Energy saving projects byPlant head with plant Encon team.

Kaizens Green Belt projects


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


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)


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.


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

Apr 2017, Tirupati

Amara Raja believes in …..

Thank you

59

Feedback: [email protected]

amara raja batteries limited, chittoor

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