cii - k suryaprakash · 2018. 8. 31. · co operation respect & concern for people creative...
TRANSCRIPT
GREEN FOUNDRY
– CASCADING THE VISION
K Suryaprakash DIRECTOR(OPERATIONS)
Brakes India Limited
1Foundry Division
Sholinghur
Year of establishment 1981
Brakes India Foundry - Profile
Year of establishment 1981
Location Sholinghur, 120 Kilometer from Chennai
N b f l 727Number of employees 727
Total area 76 Acres
Built up area 28,000 Sq. Mts.
Sales turnover (2010-2011) Rs 601 Crores (US $ 131 Millions)
Production volume (2010-2011)
Exports share of turnover
74284 MT
42%
Industries catered to
- Automotive
R f i ti & Ai diti i
87%
13%
2
- Refrigeration & Air conditioning 13%
Vendors as partners
VISIONReturn to stock holders
Customer satisfaction
PUSH PULLstock holders satisfaction
Employees’ quality of life
3
q y
Excellence
Cultural values
Excellence
Commitment
Cultural values
Orderliness
Vibrancy
Cleanliness
H &
TransparencyOpennessCore Values
Harmony & Co operation
Respect & concern for people
Creative values
Humility Trust & Integrity
Basic Values
4Innovativeness Social
Responsibility
Human side of BI
B i i t
Atmosphere of care
D l t l i ti
Institute:• Free –Medical centre• Vocational training centre
Provide:• Housing for
employees
Basic requirements Developmental aspirations
Dedicated employeesocat o a t a g ce t e• Own vehicle scheme• Recreational club• Free –Education for wards• Computer literacy classes
• Subsidised food • Fair-price shops• Uniform • Health check ups
Empowerment of
Employees
p y
p
Vision Improve the quality of lifePUSH PULL BI one large
Employees
Vision Improve the quality of lifePUSH PULL family
Social meets Employee participation
• Periodical Family visits to foundry
• Sports day
• Awards of recognition
• Suggestion schemes
Ownership and accountability
Social meets p y p p
5Atmosphere of trust / Organisational climate
BIF – A responsible corporate citizenSocietal needs
Infrastructure EnvironmentProvided:• Drinking water• Communication facilities• Banking facilities
• Rain water harvesting• Zero discharge of
pollutants• Transport facilities• Housing scheme• Direct and Indirect
employment of local people
• Utilisation of waste• Utilisation of green power• Green belt development
p y p p
PUSH
Brakes India’s total identification with
Harmony with SholinghurUpliftment of Sholinghur PULLPUSH
SholinghurSholinghurp g PULL
Health Education
Setting up: Blood bankprimary health centre
Established:Higher secondary schoolTechnical training centre
6
centreAccident relief centre
Computer literacy classesComputer centres at V.I.T.
Individual needs
Improving Manufacturing Sustainability:An Overview
Th l f t i bilitThe goal of sustainability.
Every company when it comes to green manufacturing should be conserving natural resources for future generationsconserving natural resources for future generations.
Problem Statement Emphasisp
7
GREEN FOUNDRY – CASCADING THE VISIONGREEN FOUNDRY CASCADING THE VISION
Environmental issues Environmental issues have become part of every foundry’s core y y
activities.
To be successful & to survive, foundries have to be wise to how environmental issues affect our business.
8
GREEN FOUNDRY – CASCADING THE VISIONGREEN FOUNDRY CASCADING THE VISION
Foundries with their skill, knowledge andFoundries with their skill, knowledge andpractical information, need to unlockthese resources to reduce impact on theenvironment.
Recyclability is the Good environmentalpractice is not an
t di i li b tbiggest advantage of the foundry industry.
extra discipline but anintegral part of overallbusiness acumen.
9
GREEN FOUNDRY – CASCADING THE VISIONGREEN FOUNDRY CASCADING THE VISION
Foundries need to recognize how much waste iscosting them & identify benefits of reducing wastegeneration which is approximately 4% of the turnover
t d R M t d tiliti & k– wasted R.M, wasted utilities & rework.
Foundries need to L k f tFoundries need to measure environmental
Inappropriate use of water could be
Lack of top management commitment is
performance to assess the scope
could be costing foundries 1%
commitment is a big barrier to action
10
for improvements / savings.
%of turnover.
action.
GREEN FOUNDRY – CASCADING THE VISIONGREEN FOUNDRY CASCADING THE VISION
Foundries need to recognize how much waste iscosting them & identify benefits of reducing wastegeneration which is approximately 4% of the turnover
t d R M t d tiliti & k– wasted R.M, wasted utilities & rework.
Foundries need to L k f tFoundries need to measure environmental
Inappropriate use of water could be
Lack of top management commitment is
performance to assess the scope
could be costing foundries 1%
commitment is a big barrier to action
11
for improvements / savings.
%of turnover.
action.
Making Money is the Goal of the Organisation
The Goal……
Making Money is the Goal of the Organisation
Prof. Shiba san always says, “PROFIT should not be the only motive for a company.
A company should have noble goals, far beyond the immediate financial results.”
GovernmentInvestorsSociety
Stake-holder f th Fi ManagementLenders of the Firm g
EmployeesSuppliers
12H
EmployeesCustomers
Suppliers
GOING GREEN
Waste Management Solid
Waste ManagementWater
Resource Conservation
Internal environment
controlEco friendly
packingcontrol p g
13
GOING GREEN
Waste Management Solid
Waste ManagementWater
Resource Conservation
Internal environment
controlEco friendly
packingcontrol p g
14
New Market Value in foundry –Utilisation of solid waste
• Support from IISc• Concepts from
Stricter statutory and regulatory
Concepts from French Architect
PUSH
g ycompliance
Maximize Revenue f t PULL
Improvement in bottom line3-4% of the
PUSHBench Mark
Status in EMS performance
from waste PULLtop line
Solid Waste Disposal
Allocation of
Problem
Core Team
15
resourcesFormation
Sludge
Packing wood Buildings External
Office materialsLeaves
Paper Manures
g
Roads environment
Generation cycle
Sand
Incoming materials
Application cycleGreen belt
Utilization of solid waste
Dust Slag
Sand
Recycling Manufacturing
Lining
Stillages
16
Solid Waste Management
Utilization of solid waste
Towards ZERO solid waste discharge
Utilization of solid waste Sand
Land FillsBrick Manufacturing
Development of green belt
Concrete manufacturing
17
Solid Waste ManagementBrick Manufacturing
Compressive Strength : 20 to 25 Kg / cm2
8 3 1.5 1
Slag Return Sand River Sand Cement
0% 20% 40% 60% 80% 100%
Being used for non bearing loads
Compressive Strength of regular brick
18
20 to 25 Kg / cm2
Solid Waste ManagementBrick Manufacturing
Buildings constructed with stabilized mud blocks using foundry return sand
Administrative building
Executive Director’s Office
X – Ray laboratory
Buildings constructed with stabilized mud blocks using foundry return sand
19Roads constructed with return sand
For Compound wall construction
For Cupola lining & as base sand for floor moulding
Solid Waste Management
Utili ti f lid t
Towards ZERO solid waste discharge
Utilization of solid waste Sand
Land FillsBrick Manufacturing
Development of green belt
Concrete manufacturing
20
Solid Waste ManagementConcrete Manufacturing
Compressive Strength : 200 to 250 Kg / cm2
Slag Return Sand cement Graded Gravel
1.5 1 1 4
0% 20% 40% 60% 80% 100%
75 mmFinish Layer - ConcreteConcrete
road – Cross section
150 mm
200 mm
Second Layer – Lean Mix
Sub base - Concrete
21For construction of reinforced concrete works
300 / 600 mm
Sub grade - Concrete
Construction of reinforced concrete works
Concrete ManufacturingConstruction of reinforced concrete works
75 mm
150 mm
Finish Layer - Concrete
Second Layer – Lean Mix
Concrete road – Cross
section
22
200 mm
300 / 600 mm
Sub base - Concrete
Sub grade - Concrete
Solid Waste Management
Utilization of solid waste
Towards ZERO solid waste discharge
Utilization of solid waste Sand
Land FillsBrick Manufacturing
Development of green belt
Concrete manufacturing
23
Green belt development
Non-Cultivable Land to Cultivable Land
The foundry’s waste sand contains bentonite, which has
moisture retaining propertiesmoisture-retaining properties.
Arid land is made cultivable by filling up waste sand to aArid land is made cultivable by filling up waste sand to a
depth of 500 mm to develop green belt.
BIF converted 6 acres of arid land to green belt (Kitchen
24garden, lawn & flowering trees)
Green belt development
25Pilot project for a lawn and kitchen garden (2.5 acres)
Zero discharge and reuse of solid waste
Green belt development
Zero discharge and reuse of solid waste
26Return sand / slag are used as base sand for developing green belt
Green belt development
Flowering Plants
27
Green belt development
Green belt development – Housing colony
28
Green belt development
Sand Foundry 1 & 2 Sand Foundry 3 Permanent Mould
Foundry – Bird’s eye view
Sand Foundry 1 & 2 Sand Foundry 3 Permanent Mould Foundry
Pattern & Die Shop Administrative office building
29
Green belt development
Biodegradable Materials
Withered LeavesMaterials
MANURE
30Sludge From Sewage
Treatment Plant
R lt
Utilization of solid waste
16.8
16
18Results
Bette
r
10.91
12.3
14.1
12
14
n
B
7.88
10
Rs. i
n M
illlio
n
ActualTarget
4.14
6
R
0
2
2004 2005 2006 2007 2008 2009
31
2004-05
2005-06
2006-07
2007-08
2008-09
2009-10
GOING GREEN
Waste Management Solid
Waste ManagementWater
Resource Conservation
Internal environment
controlEco friendly
packingcontrol p g
32
Waste Management - Water
S ft Pl tSoftener Plant
Treated Sewage Water
For cooling towers
33Gardening Purpose Cupola Shell Cooling
GOING GREEN
Waste Management Solid
Waste ManagementWater
Resource Conservation
Internal environment
control
Eco friendly packingcontrol p g
34
Dust mapping
O A
DR
Dust prone area
35Not to scale
Kaizen improvement activities – Dust reduction
Before AfterBefore After Before After Before After
Flat rollers to trough rollers to contain spillagesInclined to horizontal conveyors to contain spillages
B f Aft After Before After
36Improved negative suction through an additional dust collector
Providing U type skirting to avoid belt damage and sand spillages
Noise mapping
R O
A D
37Not to scaleSources of noise
Kaizen improvement activities –Noise reduction
Before After Before After
Rubber sheath over the wear plate of the vibro charger to contain noise
Replacement of didion drum with disa cool drum to contain noise and improve castings quality
R lt
94
100
110
120
Result Result Better
Better
97.9
86.382
88
dB
103.880
90
100dB
38
86.3
70
76
Before After
84.2
60
70
Before After
Heat mapping
R O
A
R
Sources of heat
39Not to scale
Kaizen improvement activities – Heat reduction
Casting conveyor for quicker removal of castings and thereby minimising the heat radiation
50 Result ResultB
ette
Bette
Turbo vents at the melting platform
4541 1
38
42
46
50
eg C
elsi
us
42.536
39
42
45
g C
elsi
us
Result Result er
er
40
41.1
30
34
De
Before After
38.5
30
33
36
Deg
Before After
Prevention of pollution Emission level reduction
Annealing furnace:Annealing furnace:
An alternate cleaner fuel (superior kerosene oil – SKO) which has higher combustion
efficiency and lower emission levels is being used instead of light diesel oil there by minimizing
the emission levels at the furnace outlet.
Sulphur di oxide
63
60
80
30.540
60
g/cu
.m
Before
0
20
µg Before
After
4141
0Usage of LDO Usage of SKO
Scrubber for cupola
4242
Installation of dust collector for cupola charging
4343
Establishment of environmental laboratory and air quality parameters
Environment Monitoring & Review
monitored fortnightly
Spectro photo meter Air ovenAir sampler p p Air oven p
4444
Incubator Distilled water plantAir sampler
Prevention of pollution
Activity: To improve the environmental performance to become uniqueActivity: To improve the environmental performance to become unique
Ambient air quality
Year SPM NOx SO2
Govt Norms
360µg/cu.m
80µg/cu.m
80µg/cu.m
244 29 21
232 27 11
238 21 9Air quality sampler
238 21 9
194 23 5
173 18 5
187 9 0.40
170 10 0.20
4545Dust extractors to improve
workplace environment
2003 199 9.7 0.12
2010 149 13 0.15
Kaizen improvement activities – Heat reduction
I l t ti f f i dl ffi i t ti liImplementation of eco-friendly energy efficient evaporative cooling system in the Die cast area
50
Result
Better
433834
38
42
46
Deg
Cel
sius
4646
38
30
34
Before After
Reduction in “leapfrogging from lily pad to lily pad.”
GREEN FIELD FOUNDRY AT JHAGADIA
With th i i t t f GettingWith the main intent of Getting closer to the customer and
thereby reducing the Carbon
4747
Foot-print
Global foot prints
Reduction in “leapfrogging from lily pad to lily pad.”
Plant LayoutGreen field foundry at oman being establishedGlobal foot prints
Planned Buildup Area 17725 Sqr Mts for 2 PhasesPlanned Buildup Area 17725 Sqr.Mts for 2 PhasesLocation Oman
Foundry 1 Foundry 2Capacity 18000 MT/Year 18000 MT/Year
4848
Capacity 18000 MT/Year 18000 MT/Year
Date of Commissioning Mar 2008 Mar 2011
GOING GREEN
Waste Management Solid
Waste ManagementWater
Resource Conservation
Internal environment
controlEco friendly
packingcontrol p g
49
Resource conservation - Energy
BIF is focusing on the resources conservation implementation by adopting the best practices emerging out of Environmental Management System to ISO : 14001 : 2004 and Energy Management System to BS-EN : 16001 : 2009 through PolicyManagement System to BS-EN : 16001 : 2009 through Policy Deployment
50
Resource conservation - Energy
Energy Distribution TreeInput Power-100%
Energy Distribution Tree
Available Power -96.7 %
Moulding-7.87%20 Kaizens
Melting-83.19%45 Kaizens
Utilities-3.86%11 Kaizens
Finishing-1.78%10 Kaizens
Sand Plant5.88%
Furnace79.71%
Auxiliary3.48%
Molding m/c1.95%
Melting69%
Holding10.71%
Cooling pumps2.99%
Crane & Hoist0.48%
Dust control3.44%
Mixer2.44%
51
Resource conservation - Energy
Energy monitoring & reporting systems
110 KV15000 KVA
33 KV9950 KVA
33KV9850 KVA
Energy monitoring & reporting systems
15000 KVA 9950 KVA 9850 KVA
SAPTotal demand - 34800 KVATotal demand - 34800 KVA
Energy Report
52
Resource conservation - Energy
Energy performance review
Frequency Review details Members
Energy performance review
ency
Daily•Review of energy performance(heat wise and shift wise)
All circle committee members &Daily (heat wise and shift wise)
•Corrective and preventive actionsmembers & Supervisors
•Gap analysis Department head & Weekly
•Gap analysis•Corrective and preventive actions
pDeputy Energy chairman
Monthly
• Review of Monthly and yearly targets• Review of Policy deployment
I t ti iti
Deputy Energy chairman, Energy Chairman & CEO
53
• Improvement activities
Resource conservation - Energy
Energy performance review
Frequency Review details Members
Energy performance review
ency
Daily•Review of energy performance(heat wise and shift wise)
All circle committee members &Daily (heat wise and shift wise)
•Corrective and preventive actionsmembers & Supervisors
•Gap analysis Department head & Weekly
•Gap analysis•Corrective and preventive actions
pDeputy Energy chairman
Monthly
• Review of Monthly and yearly targets• Review of Policy deployment
I t ti iti
Deputy Energy chairman, Energy Chairman & CEO
54
• Improvement activities
Implemented innovative energy management
Wind24%
2010-2011
BIF Energy consumption pattern 2001- 2011
Wind13%
2009-2010
24%
3rd Party18%
Gas48%
State grid10%
13%
3rd PartyGas50%
State grid29%
2008 2009Wind13%State Grid
45%
8%2008-2009
2006 2007Gas42%
Wind12%State grid
40%
2006-2007
Gas48%
2001-2002
5555
Resource conservation - Energy
56
Resource conservation - Energy
Energy cost as a % of Sales
24
21.7
21
18.7
16.218
14.013.1 13.4
13.915
122003-
042004-
052005-
062006-
072007-
082008-
092009-10
57Years
Actual Target
Resource conservation
- Water
58
Rain water harvesting
Resource conservation - Water
Rain water is being harvested in strategically located
59
Rain water is being harvested in strategically located harvesting plants
GOING GREEN
Waste Management Solid
Waste ManagementWater
Resource Conservation
Internal environment
controlEco friendly
packingcontrol p g
60
Eco friendly Packing
Waste utilisation – Conservation of wood
StillagesWooden scraps
61
The wooden scraps from the incoming materials are used for making stillages
Waste utilisation Conservation of wood
Eco friendly Packing
To conserve wood, the wooden pallets are slowly being phased out by using reusablepallets / steel pallets.
Waste utilisation – Conservation of wood
Before After
W h l d d d ti b i i th i ht f ti / b Ab t
62
We have also reduced wood consumption by increasing the weight of castings / box. About 85 % of Indian customers receive their deliveries through steel pallets / gunny bags
Wage War on WasteWage War on Waste
GREEN MAKES BUSINESS SENSE
63
W W W tWage War on Waste
ReduceRefuse
Waste
ReuseRecycle Reusey
64
GREEN MAKES BUSINESS SENSEGREEN MAKES BUSINESS SENSE
DO YOU WANTDO YOU WANT
TO FLUSH THE PROFITS
DOWN THE DRAIN ?
65
Thank youThank you
66