pp industrial - 11.05.2012
TRANSCRIPT
May’12 /SBU-INDUSTRIAL
P PRAMANIK19-05-2012
SBU - INDUSTRIAL
MANUFACTURING
PARTICIPANTS1) Pulak Pramanik – Industrial Overview2) Subroto Sinha – Shamnagar Overview3) Aloke Kr Sarkar – Haldia Overview4) Kalyan Saha – Haldia Indl. Overview5) M. Ramachandran – Hosur Overview
May’12 /SBU-INDUSTRIAL
High Value Manufacturing
SHAMNAGAR • Location - WEST BENGAL• Opens – 1946• Product Range – Plante, Standby(Flooded)
ROORKEE• Location - HIMACHAL PRADESH• Opens – PART OF EXIDE FROM 2012• Product Range – Inverter, Sign Wave, High Frequency
THE INDUSTRIAL FACILITIES
HALDIA• Location – WEST BENGAL• Opened - 1980• Product Range – Solar, Traction, Standby, Flooded., GEL.
HOSUR• Location – TAMIL NADU• Opened - 1996• Product Range – VRLA, Standby, Telecom, Railway
May’12 /SBU-INDUSTRIAL 3
CONSISTENCY THROUGH TECHNOLOGY & AUTOMATION – INDUSTRIAL COS, PASTE FILLING, VRLA COS, etc.
TO SHIFT FROM GRUDGE PURCHASE TO ASPIRATIONAL PURCHASE
FLEXIBILITY IN MANUFACTURING PROCESS TO MEET RAPID CHANGE IN MARKET REQUIREMENT
VALUE ADDITION THROUGH INVESTMENT IS THE NXT GEN REQUIREMENT
INDUSTRIAL -
MANUFACTURING STRATEGY
NEXT GENERATION PRODUCT TO BE AHEAD OF COMPETITION -GEL , TI WITH REMOTE SENSOR, NXT VRLA , INTEGRATED INVERTOR
May’12 /SBU-INDUSTRIAL 4
TO FOCUS ON MAINTENANCE FREE PRODUCT
FOCUS ON CAPACITY ENHANCEMENT WITH MARKET DEMAND
INVERTER AS PACKAGE WITH BATTERY
REDUCTION IN MANUFACTURING COST BY IMPROVING MANUFACTURING EFFICIENCY AND WASTE REDUCTION
IMPROVEMENT OF HUMAN RESOURCE BY CONTINOUS TRAINH AND SKILL ENHANCEMENT.
MANUFACTURING STRATEGY
INDUSTRIAL -
May’12 /SBU-INDUSTRIAL 5
INDUSTRIAL - TURN OVER
1103
13641556
17911960
2104
0
500
1000
1500
2000
2500
2007 - '08 2008 - '09 2009 - '10 2010 - '11 2011 - '12 BUDGET 2012 - '13
INDUSTRIAL - TURN OVER
`C
r.
%
24 %
14 %
15 %10 %
7 %
May’12 /SBU-INDUSTRIAL 6
PRODUCTION TREND ( BATTERY & CELL )
11701334
15651760 1760
2024
0
500
1000
1500
2000
2500
2007-'08 2008-'09 2009 - '10 2010 - '11 2011 - '12 BUDGET 2012 -'13
INDUSTRIAL - PRODUCTION
MA
h
14 %17 %
13 %0 %
15 %
%
May’12 /SBU-INDUSTRIAL 7
PRODUCTION TREND ( INVERTER )
11119 10132 16908
188000
0
25000
50000
75000
100000
125000
150000
175000
200000
JAN '12 FEB '12 MAR '12 TARGET 2012 - '13
INVERTER - PRODUCTION
NO
s
May’12 /SBU-INDUSTRIAL
NO
s`
CR
.
6818
115509810
17348
0
5000
10000
15000
20000
DEC '11 JAN '12 FEB '12 MAR '12
2.08
4.39 3.83
7.07
0.00
2.00
4.00
6.00
8.00
DEC '11 JAN '12 FEB '12 MAR '12
DESPATCH TREND ( INVERTER )
DESPATCH ( INVERTER )
May’12 /SBU-INDUSTRIAL 9
LEARNINGS FROM SHINKOBE
IMPORTANCE OF NAM / PAM RATIO
IMPORTANCE OF ONLINE COMPRESSION CHECKING SYSTEM
STANDARDISATION OF CURING OVEN
FEATURES & ADVANTAGES OF BARCODE SYSTEM
PET SHEET WRAPPING FOR GROUP WITH EXPANDED NEGATIVES TO REDUCE PROCESS REJECTION
EIL RECEIVED THE COMPLE DESIGN FOR 12V STANDBY –UPS, 2V TELECOM, 2V RAILWAY BATTERIES FROM SHIN-KOBE.
CURED PLATE CHECKING PARAMTERS (METALIC SOUND, CRACK, COLOUR, ETC.,)
May’12 /SBU-INDUSTRIAL 10
LEARNINGS FROM SHINKOBE
IMPORTANCE & METHODOLOGY OF FTA ANALYSIS
KANBAN CONCEPT
IMPROVED METHODOLOGY OF FIELD RETURN BATTERY ANALYSIS
ADVANTAGE OF COS FOR VRLA
ONLINE ACID WASH ROLLER PRESSURE MONITORING
ADVANTAGES OF ABS CONTAINER FOR MEDIUM VRLA
May’12 /SBU-INDUSTRIAL 11
LEARNINGS FROM EAST PENN
DIFFERENCE IN PROCESS, EIL Vs EPM.
OXIDE MAKING.
CONCAST, PASTE MAKING SEQUENCE, PASTING, TANK FORMATION, FLAT TRACTION POSITIVE PLATE, COS ASSEMBLY.
DIFFERENCE IN PROCESS, EIL Vs EPM.
DESIGN AND OPENING /CLOSING PRESSURE OF SAFETY VALVE.
INCREASED PAM/NAM RATIO IN PRODUCT DESIGN.
May’12 /SBU-INDUSTRIAL 12
PROJECTS – EAST PENN
TANK FORMATION OF MET FOR RAILWAY.
TO REVISE THE ACTIVE MATERIAL RATIO OF VRAL PRODUCT.
TO IMPLEMENT PASTE MIXING SEQUENCE.
LEAK TESTING – DUNK TEST.
May’12 /SBU-INDUSTRIAL
PEOPLE INVOLVEMENT
THROUGH QC & SGA TOTAL EMPLOYEES INVOLVED – 569
TOTAL NOS. OF AWARDS WON – 22
SHAMNAGARQC TEAM – 7
SGA TEAM – 10
PROBLEMS SOLVED - 25
HALDIAQC TEAM – 17
SGA TEAM – 43
PROBLEMS SOLVED - 60
HOSURQC TEAM – 6
SGA TEAM – 44
PROBLEMS SOLVED - 63
GOLD Award CCQCC – Bangalore
GOLD Award from ICQCC – Hyderabad
PAR EXCELLENCE Award NQCC – Bangalore
SILVER Award - CCQCC – Bangalore
PAR EXCELLELLENCE Award – NCQC – Vizag
EXCELLENT Award – NCQC – Vizag
GOLD Award – QCFI – Kolkata
1st in 23rd CONVENTION of QC – Kolkata
GOLD Award INTERNATIONA; QC – Hyderabad
QC AND SGA
May’12 /SBU-INDUSTRIAL 14
TRAINING - HALDIA
2007-08 2008-09 2009-10 2010-11 2011-12
24720
1870416400
8120
13840
Training Nos. Of Hours - Haldia
2007-08 2008-09 2009-10 2010-11 2011-12
31572541
20162410
6441
Training Nos. Of Heads - Haldia
T P M
S H E
P M
J H
Cost Control
Training on Pallet Truck Operation
Safety
Quality
Efficiency Management
Fire Training
TRAINING
May’12 /SBU-INDUSTRIAL 15
TRAINING - HOSUR
2007-08 2008-09 2009-10 2010-11 2011-12
1470213751
104658683 8483
Training Nos. Of Hours -Hosur
2007-08 2008-09 2009-10 2010-11 2011-12
31722055 1868
1090 606
Training Nos. Of Heads - Hosur
Internal auditors training on TS/IMS
Battery Technology
Statistical Process Control
7 QC Tools
Legal requirement on environment, OHS management system
Small Group Activity
TPM / ITS pillar awareness
Quality circle concept & ITS Implementation
Personal Effectiveness
Training on SHE Awareness
TRAINING
May’12 /SBU-INDUSTRIAL 16
TRAINING - SHAMNAGAR
2007-08 2008-09 2009-10 2010-11 2011-12
13921832 2056
2648
3440
Training Nos. Of Hours - Shamnagar
2007-08 2008-09 2009-10 2010-11 2011-12
174229 257
331
430
Training Nos. Of Heads - Shamnagar
Cost / Expenses Control
Asset utilation / Maintenance
Inventory control
New QC Tools
Productivity / IE / Incentive Scheme
Energy Conservation
Communication and Presentation Skill
Battery design / Quality Systems
Pay Roll concept
HR & Porvic – Manufacturing Process
TRAINING
May’12 /SBU-INDUSTRIAL 17
ILLUMINATION
Haldia(Industrial) Haldia(Traction) Shamnagar Hosur
93100 100
56
LUX
(6
5 m
in.)LEAD IN AIR
Haldia Shamnagar Hosur
0.85
0.072
2
µgm
/M3
LEAD IN WATER
Haldia Shamnagar Hosur
5 5 5
µgm
/KL
HOSUR DATA REQUIRED
May’12 /SBU-INDUSTRIAL 18
LEAD IN BLOOD
Haldia Shamnagar Hosur
10 10 10
µgm
/DL HOSUR & SHAMNAGAR DATA REQUIRED
May’12 /SBU-INDUSTRIAL 19
INCIDENT TREND
2007-08 2008-09 2009-10 2010-11 2011-12
148
64 64 5842
SHAMNAGAR & HALDIA DATA REQUIRED
May’12 /SBU-INDUSTRIAL 20
ACCIDENT TREND
2007-08 2008-09 2009-10 2010-11 2011-12
3
10
3
12
12
3 32
3 3 3 3 3
HALDIA HOSUR SHAMNAGAR
SHAMNAGAR DATA REQUIRED
May’12 /SBU-INDUSTRIAL 21
ENVIRONMENTAL PARAMETERS
2.2
6
2.1 2.1
5
1.7
2
1.2
6
1.2
2
0.7
4
0.4
5
0.4
2
0.4
7
0.4
6
3.1
9
3.3
3
3.1
2.9
4
3.0
7
2.8
4
2007-08 2008-09 2009-10 2010-11 2011-12 2012-13
EFFLUENT GENERATION (KL/MT OF Pb)
HALDIA HOSUR SHAMNAGAR
36
.48
35
33
.13
19
.44
16
.08
15
.75
4.6
1
2.5
9
1.9
9
1.3
0.9
9
0 0
9.3
3
8.1
3
4.9
7
4.8
5
2007-08 2008-09 2009-10 2010-11 2011-12 2012-13
LIME CONSUMPTION (KG/MT OF Pb)
HALDIA HOSUR SHAMNAGAR
82
.1
75 78
.9
53
.6 65
.6
63
.4
8.3
4.6
6
3.5
8
2.3
4
1.7
8
0.0
6
0.0
6
0.0
5
0.0
6
0.1
1
0.0
5
2007-08 2008-09 2009-10 2010-11 2011-12 2012-13
SLUDGE GENERATION (KG/MT OF Pb)
HALDIA HOSUR SHAMNAGAR
May’12 /SBU-INDUSTRIAL 22
xxxxxxxxxx
ENVIRONMENTAL PARAMETERS : -
17
.89
16
.5
15
.14
15
.49
15
.61
21
.67
36
.21
29
.07
27
.42
28
.05
26
.69
31
.96
31
.04
26
.23
25
.29
24
.55
22
.11
2007-08 2008-09 2009-10 2010-11 2011-12 2012-13
LPG CONSUMPTION (KG/MT OF Pb)
HALDIA HOSUR SHAMNAGAR
12
.54
10
.44
10
6.9
6.1
1
5.9
8
3.4
7
3.1
07
2.8
1
2.7
7
2.8
3
36
.86
38
.02
32
.86
26
.34
23
.01
19
.99
2007-08 2008-09 2009-10 2010-11 2011-12 2012-13
RAW WATER CONSUMPTION (KL/MT OF Pb) HALDIA HOSUR SHAMNAGAR
3.2
1
2.7
8
2.0
9
1.7
1.4
8
1.4
1
0.8
5
0.6
7
0.6
7
0.7
1
0.7
0 0 0 0 0 0
2007-08 2008-09 2009-10 2010-11 2011-12 2012-13
DM WATER CONSUMPTION (KL/MT OF Pb)
HALDIA HOSUR SHAMNAGAR
May’12 /SBU-INDUSTRIAL 23
CORPORATE SOCIAL RESPONSIBILITY ( CSR )
SCRUCTURED CSR ACTIVITIES :• HEALTHCARE
• EDUCATION
• ENVIRONMENT
• WOMEN EMPOWERMENT
• ASSISTANCE & PHILANTHROPY
Exide Industries Limited is making sure that rural India stays healthy, wealthy and wise . Inthis respect the company has taken new strategy for corporate governance and socialresponsibilities in the works.
POLICY :
CSR is considered as one of the key business processes, which has been identified by the management and considered critical to be a successful organization. Exide shall also establish the sub-processes to internalize this key process with a mechanism to measure and control the effectiveness.
OBJECTIVES :
• To be a good corporate citizen is inextricably linked with the improved brand reputation. CSR initiatives shall be considered as one of the most important drivers of the brand.
• With non financial parameters becoming more and more relevant, Exide’s focus on CSR is to enhance the shareholders value through an all round approach towards all stakeholders.
May’12 /SBU-INDUSTRIAL 24
HEALTH CARE
Medical Camp ( Hosur ) - Supported Bagalur Health centre in organizing a medical camp
HEALTH CARE PROGRAM ( HALDIA ) - Polio Immunization Program, health check up , dental check up, eye examination, medicine distribution, general check up, tube well installation,
May’12 /SBU-INDUSTRIAL 25
BASIC EDUCATION
HARIJAN PRATHAMIK VIDYALAYA , ISWARDAHA JALPAI - Repair & refurbishing of school
building, Beautification of school ground -Mini Park, Installation of Tube well, Beautification of school -School Gate
one day Science program at Kothapalli High school,Sevaganapalli Panchayath,
ASSEMBLY OF GOD CHURCH, HALDIA - Electrification work was done at Computer Room , New Staff Room , Class Rooms , Passage & Toilets.
Electrification of Banskhana Bhuniarchak Primary School
Donation of Books to School Children & Library through Sri Sri Ramkrishna Sarada Sathi Sangha – Chak Dariberia
Donation of Books to School Children & Library through Sri Sri Ramkrishna Sarada Sathi Sangha – Chak Dariberia
May’12 /SBU-INDUSTRIAL 26
ENVIRONMENT
World Environment day celebration ( Hosur ) - School Children on Procession, Distribution of free Saplings, Clean Hosur program
World Environment Day celebration ( Haldia ) - Rally by Exide Employees, Environmental Drama, Flag hoisting, plantation, sapling distribution, visit, training Community awareness program on HIV/AIDS - Tableau , Rally
May’12 /SBU-INDUSTRIAL 27
WOMEN EMPOWERMENT
Activities for Women empowerment ( Village - Iswardaha Jalpai ) - Vocational Training, Distribution of sewing machine, Employees’ Uniform made by Self help Women Group
Activities for women Empowerment ( Hosur ) - Purchasing of hand gloves manufactured by units employing women
May’12 /SBU-INDUSTRIAL 28
ASSISTANCE & PHILONTHROPY
To combat malnutrition- save 600 children below 5yrs across the country
Administer Vit-A to 45000 children across the country
Adopted Children of DeceasedKarthik’s Education up to HighSchool
K.Sowmiya - 2nd std K.Ragul -1st std
Donation to Ramkrishna Mission Sevashrama , Tamluk for Supply of drinking water by construction of an underground reservoir with
RCC wallDonation of Battery for Power Supply in Homeopathy Dispensary
& Main Temple to Natshal Sri Sri Ramakrishna Ashram
Donation food & cloths for flood victim, cart for handicraft, blood donation camp
May’12 /SBU-INDUSTRIAL
METAL PASS BOOK SYSTEM
PRODUCTION AS PER SALES – THROUGH METAL PASS BOOK.
May’12 /SBU-INDUSTRIAL 30
REPLENISHMENT SYSTEM
WEEKLY SALES TO PRODUCTION REPLENISHMENT SCHEME
May’12 /SBU-INDUSTRIAL 31
11
91
13
04
13
42
12
25
12
34
12
00
11
26
10
50
95
5
94
6
99
4
11
34
12
21
12
60
11
71
11
35
98
7
2007-08 2008-09 2009-10 2010-11 2011-12 2012-13
POWER CONSUMPTION (KWH/MT OF Pb) HALDIA HOSUR SHAMNAGAR
0.9
16
0.9
56
0.9
51 0
.97
9
0.9
82
0.9
84
0.9
8
0.9
88
0.9
91
0.9
92
0.9
93
0.9
7
0.9
8
0.9
88
0.9
87
0.9
75
0.9
7
2007-08 2008-09 2009-10 2010-11 2011-12 2012-13
POWER FACTOR HALDIA HOSUR SHAMNAGAR
ENERGY COST AND CONSERVATION
May’12 /SBU-INDUSTRIAL
NOV’11
DEC’11
JAN’12
FEB’12
MAR’12
ENERGY CONSUMPTION AND CONSERVATION
MAY’12
COST SAVED UP TO MAR’12
Rs.26,499/- PER DAY
ENERGY SAVED /DAY : 4351.69 KWH
COST SAVED: Rs.25,405 PER DAY
JUN’12
ENERGY SAVED /DAY : 4381.69 KWH
COST SAVED: Rs.25,555 PER DAY
APR’12
ENERGY SAVED /DAY : 4455.69 KWH
COST SAVED: Rs.26,032 PER DAY
ENERGY SAVED /DAY : 4527.51 KWH
COST SAVED: Rs.26,499 PER DAY
Maintained Power factor of the plant ataround 0.99.Maintained Load factor of the plant ataround 75%. Introduction of Compressed AirManagement system for optimum use ofAir Compressors at plant. Installation of SCR controlled heatingsystems at Lead Pots of Wirtz Casting &Auto spine machines. Use of one no. Cooling Tower in place oftwo nos. Cooling towers for Hadi & WirtzCasting machines. Installation of LDRs at different locationsfor automatic switching ON/OFF ofshopfloor lights during daytime. Installation of 28W T5 Energy saverfluorescent lamps in place of conventional40W lamps at different locations in theplant. Electrical interlocking of fresh air &exhaust blower motors in the plant withProduction machines to stop idle running ofblowers during non-productive hours.
May’12 /SBU-INDUSTRIAL 33
POWER COST (Rs per Ah)
2007-08 2008-09 2009-10 2010-11 2011-12
0.2260.244
0.29 0.293 0.286SHAMNAGAR & HALDIA DATA REQUIRED
May’12 /SBU-INDUSTRIAL 34
FUEL COST (Rs per Ah)
2007-08 2008-09 2009-10 2010-11 2011-12
0.059 0.061
0.044
0.058 0.058
SHAMNAGAR & HALDIA DATA REQUIRED
May’12 /SBU-INDUSTRIAL
KAIZENS
KAIZENS - HALDIA
KAIZENS - HOSUR
KAIZENS - SHAMNAGAR
May’12 /SBU-INDUSTRIAL 36
MIGRATED BEST PRACTICES
May’12 /SBU-INDUSTRIAL
BEST PRACTICE - HOSUR
BEST PRACTICE - HALDIA
BEST PRACTICE - SHAMNAGAR
May’12 /SBU-INDUSTRIAL 38
PATH AHEAD
Could
Reverse the employment trends
in manufacturing
manufacturing investment
Manufacturing25% of
ShouldStep-change in the competitiveness of
the
UK has seized the manufacturing
opportunity
high intensity engineering &
technology nation
Will
Establish the mechanism for
economic development
Skills & education rebalanced
towards science & engineering
Afford rapid growth in
applied science & innovation investment
0-5 years 5-10 years 10+ years
May’12 /SBU-INDUSTRIAL 39
PATH AHEAD
Adaptability is vital
"It is not the strongest of the species that survives, nor the most intelligent; it is the one that is most
adaptable to change."
-- Charles Robert Darwin (1809-82)