pp industrial 2nd cut revised
TRANSCRIPT
May’12 /SBU-INDUSTRIAL
P PRAMANIK19-05-2012
SBU - INDUSTRIAL
MANUFACTURING
May’12 /SBU-INDUSTRIAL
P PRAMANIK19-05-2012
SBU - INDUSTRIAL
MANUFACTURING
May’12 /SBU-INDUSTRIAL
High Value Manufacturing
SHAMNAGAR •Location - WEST BENGAL•Opens – 1946•Subject – INDUSTRIAL, FMIB, STANDBY
ROORKEE• Location - HIMACHAL PRADESH• Opens – PART OF EXIDE FROM 2012• Subject - INVERTER
THE INDUSTRIAL FACILITIES
HALDIA• Location – WEST BENGAL• Opened - 1980• Subject – FMIB, TRACTION, INDUSTRIAL
HOSUR• Location – TAMIL NADU• Opened - 1996• Subject – VRLA – UPS, INVERTER, TELECOM, RAILWAY
May’12 /SBU-INDUSTRIAL 4
TO LAUNCH PRODUCT AHEAD OF COMPETETION
TO HAVE COMPLETE PORTFOLIO OF PRODUCT
TO SHIFT FROM GRUDGE PURCHASE TO ASPIRATIONAL PURCHASE
TO HAVE FLEXIBILITY IN PRODUCTION PROCESS
VALUE ADDITION IS THE NXT GEN REQUIREMENT
TO FOCUS ON MAINTENANCE FREE PRODUCT
INDUSTRIAL -
MANUFACTURING STRATEGY
FOCUS ON CAPACITY ENHANCEMENT WITH MARKET DEMAND
VALUE ADDITION THROUGH INVESTMENT IN TECHNOLOGY
INVERTER AS PACKAGE WITH BATTERY
May’12 /SBU-INDUSTRIAL 5
INDUSTRIAL - TURN OVER
2007 - '08 2008 - '09 2009 - '10 2010 - '11 2011 - '12 BUDGET 2012 - '13
0
500
1000
1500
2000
2500
1103.17
1364.491556
1790.511959.93
2104
INDUSTRIAL - TURN OVER
` C
r.
May’12 /SBU-INDUSTRIAL 6
PRODUCTION TREND ( BATTERY & CELL )
2007-'08 2008-'09 2009 - '10 2010 - '11 2011 - '12 BUDGET 2012 - '13
0
500
1000
1500
2000
2500
1169.561334.24
1564.521760.42 1760.17
2024.19
INDUSTRIAL - PRODUCTION
MAh
May’12 /SBU-INDUSTRIAL 7
PRODUCTION TREND ( INVERTER )
NO
s
0
25000
50000
75000
100000
125000
150000
175000
200000
DEC '11 JAN '12 FEB '12 MAR '12 TARGET 2012 - '13
6818 11119 10132 16908
188000
INVERTER - PRODUCTION
NO
s
May’12 /SBU-INDUSTRIAL
NO
s`
CR.
DEC '11 JAN '12 FEB '12 MAR '120
5000
10000
15000
20000
6818
115509810
17348
DEC '11 JAN '12 FEB '12 MAR '120.00
2.00
4.00
6.00
8.00
2.08
4.39 3.83
7.07
DESPATCH TREND ( INVERTER )
DESPATCH ( INVERTER )
May’12 /SBU-INDUSTRIAL 9
LEARNINGS FROM SHINKOBE
CURED PLATE CHECKING PARAMTERS (METALIC SOUND, CRACK, COLOUR, ETC.,)
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
May’12 /SBU-INDUSTRIAL 10
LEARNINGS FROM SHINKOBE
IMPORTANCE & METHODOLOGY OF FTA ANALYSIS
KANBAN CONCEPT
IMPROVED METHODOLOGY OF FIELD RETURN BATTERY ANALYSIS
ADVANTAGES OF ABS CONTAINER FOR MEDIUM VRLA
ADVANTAGE OF COS FOR VRLA
ONLINE ACID WASH ROLLER PRESSURE MONITORING
May’12 /SBU-INDUSTRIAL 11
LEARNINGS FROM EAST PENN
SHOP FLOOR DATA MONITORING, STORAGE AND CONTROL VERY STRONG
PROPER TAINING THROUGH TRAINING MANUAL FOR EACH PROCESS
ORIFICE PASTER WITH DUMP PASTE RECLAIMED THROUGH BELT
CON CAST, PUNCHED GRID, CURING FOR FLAT PLATE
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 – BangaloreGOLD Award from ICQCC – HyderabadPAR EXCELLENCE Award NQCC – BangaloreSILVER Award - CCQCC – Bangalore
PAR EXCELLELLENCE Award – NCQC – VizagEXCELLENT Award – NCQC – VizagGOLD Award – QCFI – Kolkata1st in 23rd CONVENTION of QC – KolkataGOLD Award INTERNATIONA; QC – Hyderabad
QC AND SGA
May’12 /SBU-INDUSTRIAL 14
TRAINING
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
6441Training 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
May’12 /SBU-INDUSTRIAL 15
xxxxxxxxxx
TRAINING
2007-08 2008-09 2009-10 2010-11 2011-12
1392
18322056
2648
3440Training Nos. Of Hours - Shamnagar
2007-08 2008-09 2009-10 2010-11 2011-12
174229
257
331
430Training 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
May’12 /SBU-INDUSTRIAL 18
ENVIRONMENTAL PARAMETERS
2007-08 2008-09 2009-10 2010-11 2011-12 2012-13
2.262.1 2.15
1.72
1.26 1.220.73600000
00000010.45 0.42 0.474 0.461
1 1 1 1 1
EFFLUENT GENERATION (KL/MT OF Pb)
HALDIA HOSUR SHAMNAGAR
2007-08 2008-09 2009-10 2010-11 2011-12 2012-13
36.48 35 33.13
19.4416.08 15.75
4.61 2.59 1.99 1.3 0.991 1 1 1 1
LIME CONSUMPTION (KG/MT OF Pb)
HALDIA HOSUR SHAMNAGAR
2007-08 2008-09 2009-10 2010-11 2011-12 2012-13
82.175 78.9
53.665.6 63.4
8.3 4.66 3.58 2.34 1.781 1 1 1 1
SLUDGE GENERATION (KG/MT OF Pb)
HALDIA HOSUR SHAMNAGAR
2007-08 2008-09 2009-10 2010-11 2011-12 2012-13
3.212.78
2.091.7 1.48 1.410.85000000
0000001 0.670000000000001
0.670000000000001
0.710000000000001
0.700000000000001
1 1 1 1 1
DM WATER CONSUMPTION (KL/MT OF Pb)
HALDIA HOSUR SHAMNAGAR
May’12 /SBU-INDUSTRIAL 19
xxxxxxxxxx
ENVIRONMENTAL PARAMETERS : -
2007-08 2008-09 2009-10 2010-11 2011-12 2012-13
17.89 16.5 15.14 15.49 15.6121.67
36.2129.07 27.42 28.05 26.69
1 1 1 1 1
LPG CONSUMPTION (KG/MT OF Pb)
HALDIA HOSUR SHAMNAGAR
2007-08 2008-09 2009-10 2010-11 2011-12 2012-13
12.5410.44 10
6.9 6.11 5.983.47 3.107 2.81 2.77 2.83
1 1 1 1 1
RAW WATER CONSUMPTION (KL/MT OF Pb)
HALDIA HOSUR SHAMNAGAR
May’12 /SBU-INDUSTRIAL 20
Illumination level monitoring at different work areas in Industrial factorySpecification : 65 lux (minimum) as Factories Act 1948
Work area Apr"12 Work area Apr"12FMIB FACTORY Lx TRACTION FACTORY Lx
Spine Casting(South) 82 Lih- Shan 71Spine Casting(North) 81 Gaunlet room 119Oxide filling (New Sungwoon) 77 Maintenance Room 114Oxide filling (Sungwoon) 71 Spine Casting 72Oxide filling(Rotary Shaker) 70 Grid Casting 115Oxide Filling (Exide) 104 Pasting(feeding) 81Pasting (Grid feeding)not running 71 Pasting (Collecting end) 74Pasting (Plate collection)not running 78 Initial Assembly 81Lih Shan Oxide Mill (Middle) 41 Final Assembly 137Grid Casting (Middle) 76 OMI Charging 78Fitter's room 87 PP Cell Box Cutting 80Forming (South) 31Forming (North) 69Assembly -1 (initial) 98Assembly -1 (final) 83Assembly line - 2 (initial) 121Assembly line - 2 (final) 124Assembly line - 3 (initial) 121Assembly line - 3 (final) 137Assembly Line - 4(initial) 159Assembly Line - 4(final) 87Assembly Line - 5(initial) 81Assembly Line - 5(final) 91VRLA Charging 74Lug brushing 114Despatch building old 73PE charging 37Container punching / screen printing 75
May’12 /SBU-INDUSTRIAL 21
Illumination Area Spec Haldia
Actual
Industrial 65 Lux (minimum) 93
Traction 65 Lux (minimum) 100
Ambient Air Quality Parameter Spec Actual
PM10 100 µg / M3 85.43
PM2.5 60 µg / M3 47.28SO2 80 µg / M3 22.98NO2 80 µg / M3 33.42
Lead 1 µg / M3 0.85
Work Zone Volatile Material (PE Charging) H2SO4 1.0 mg / M3 0.81
Illumination level and Air Quality monitoring at different work areas of Industrial factory
May’12 /SBU-INDUSTRIAL 22
Sound level monitoring at different work areas in Industrial factoryPermitted exposure : 90 dBA for 8 hours as per WB Factories Rules 1958 MONTH : APRIL,2012
LOCATION:
INDUSTRIAL LOCATION : TRACTION
Sl. No.DATE OF
SAMPLING AREA OF SAMPLING RESULT REMARKS AREA OF SAMPLING RESULT REMARKS dB (A) dB (A)
1 18.04.2012 Lih shan control room 80.7 Grid Casting area 82.4 2 18.04.2012 In front of Lih - shan m/c 91.1 Ear plug Assembly area 76.1
3 18.04.2012 Casting area (middle) 68.0 Lih - shan oxide mill area 87.1 4 18.04.2012 Near Sungwoon filling m/c 94.3 Ear plug Pasting area 81.4 5 18.04.2012 Rotary shaker(Inside) 95.0 Ear plug Slurry filling area 67.2 6 18.04.2012 Rotary shaker(outside) 86.7 Cell charging area 65.7 7 18.04.2012 Exide filling 87.9 Cell Box cutting area 96.7 Ear plug8 18.04.2012 Pasting 83.2 Hadi area 79.6 9 18.04.2012 Autospine area (middle) 82.7 Compressor room 79.8
10 18.04.2012 Forming area (Middle) 76.5 RO/DM plant 70.8 11 18.04.2012 Near Plate drying oven 80.5 12 18.04.2012 Packing area 65.8 13 18.04.2012 Despatch building (Middle) 65.1 14 18.04.2012 Assembly line - 1 (IT) & 2(EL) 81.2 15 18.04.2012 Assembly line 2(EL) & 3(HR) 81.5 16 18.04.2012 Assembly line 3(HR) & 4(IT) 78.9 17 18.04.2012 Assembly Line 4(IT) & 5(IQ) 73.6 18 18.04.2012 Assembly line 6(YKP) 74.2 19 18.04.2012 Lug brushing 84.7
May’12 /SBU-INDUSTRIAL 23
Area Spec Haldia
IndustrialGrid casting 90 d(B)A 82.4Ball mill 90 d(B)A 76.5Pasting 90 d(B)A 84.8Rotary Shaker 90 d(B)A 95.1Sungwoon 90 d(B)A 94.7Exide Filling 90 d(B)A 85.5Despatch 90 d(B)A 63DG Room 105 d(B)A 102.8Screw Compressor 90 d(B)A 81.8
OthersRO / DM Plant 90 d(B)A 73.6
Sound level monitoring at different work areas in Industrial factory
May’12 /SBU-INDUSTRIAL 24
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
NOS
May’12 /SBU-INDUSTRIAL 25
INCIDENT TREND
2007-08 2008-09 2009-10 2010-11 2011-12
148
64 64 5842NOS
May’12 /SBU-INDUSTRIAL 26
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 . In this respect the company has taken new strategy for corporate governance and social responsibilities 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 27
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 28
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 29
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 30
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 31
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 Deceased Karthik’s Education up to High School
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 32
xxxxxxxxxx
SOUND : -Any Comments about Sound -
2007-08 2008-09 2009-10 2010-11 2011-12
1
2
3 3
2Haldia
2007-08 2008-09 2009-10 2010-11 2011-12
1
2
3 3
2Shamnagar
2007-08 2008-09 2009-10 2010-11 2011-12
1
2
3 3
2Hosur
May’12 /SBU-INDUSTRIAL 33
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ILLUMINATION LAVEL : -
Any Comments -
2007-08 2008-09 2009-10 2010-11 2011-12
1
2
3 3
2Haldia
2007-08 2008-09 2009-10 2010-11 2011-12
1
2
3 3
2Shamnagar
2007-08 2008-09 2009-10 2010-11 2011-12
1
2
3 3
2Hosur
May’12 /SBU-INDUSTRIAL 34
xxxxxxxxxx
LEAD IN BLOOD -Any Comments -
2007-08 2008-09 2009-10 2010-11 2011-12
1
2
3 3
2Haldia
2007-08 2008-09 2009-10 2010-11 2011-12
1
2
3 3
2Shamnagar
2007-08 2008-09 2009-10 2010-11 2011-12
1
2
3 3
2Hosur
May’12 /SBU-INDUSTRIAL 35
xxxxxxxxxx
LEAD IN AIR - Any Comments -
2007-08 2008-09 2009-10 2010-11 2011-12
1
2
3 3
2Haldia
2007-08 2008-09 2009-10 2010-11 2011-12
1
2
3 3
2Shamnagar
2007-08 2008-09 2009-10 2010-11 2011-12
1
2
3 3
2Hosur
May’12 /SBU-INDUSTRIAL 36
2007-08 2008-09 2009-10 2010-11 2011-12 2012-13
1191 1304 13421225 1234 12001126 1050 955 946 994
1 1 1 1 1
POWER CONSUMPTION (KWH/MT OF Pb)
HALDIA HOSUR SHAMNAGAR
2007-08 2008-09 2009-10 2010-11 2011-12 2012-13
0.916
0.956000000000001
0.951000000000001
0.979000000000001 0.982 0.9840.98 0.988 0.991 0.992 0.9931 1 1 1 1
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
TREND OF KWH PER MT LEAD AT INDUSTRIAL FACTORY
Maintained Power factor of the plant at around 0.99. Maintained Load factor of the plant at around 75%. Introduction of Compressed Air Management system for optimum use of Air Compressors at plant. Installation of SCR controlled heating systems at Lead Pots of Wirtz Casting & Auto spine machines. Use of one no. Cooling Tower in place of two nos. Cooling towers for Hadi & Wirtz Casting machines. Installation of LDRs at different locations for automatic switching ON/OFF of shopfloor lights during daytime. Installation of 28W T5 Energy saver fluorescent lamps in place of conventional 40W lamps at different locations in the plant. Electrical interlocking of fresh air & exhaust blower motors in the plant with Production machines to stop idle running of blowers during non-productive hours.
May’12 /SBU-INDUSTRIAL 38
POWER COST (Rs per Ah)
2007-08 2008-09 2009-10 2010-11 2011-12
0.226 0.2440.29 0.293 0.286
RS/AH
May’12 /SBU-INDUSTRIAL 39
FUEL COST (Rs per Ah)
2007-08 2008-09 2009-10 2010-11 2011-12
0.05900000000000
01 0.061
0.044
0.058 0.058
RS/AH
May’12 /SBU-INDUSTRIAL 40
MIGRATED BEST PRACTICES FROM HOSUR
May’12 /SBU-INDUSTRIAL 41
BLUE FLAME LADLE BURNERBLUE FLAME LADLE BURNER
Burner with yellow flame New burner with VENTURI has been developed
OBJECTIVE: To reduce LPG consumption
May’12 /SBU-INDUSTRIAL 42
DESCRIPTION:Guards provided and so the spillage has been eliminated
BEFORE AFTER
DESCRIPTION:Rejected lead materials spilled out
from the c/v
OBJECTIVE: To eliminate the spillage while conveying rejected grids.
‘Z’ CONVEYOR GAURD‘Z’ CONVEYOR GAURD
May’12 /SBU-INDUSTRIAL 43
BEFORE AFTERWooden Pallets Are Used for grid stacking.
Replaced with Metal Pallets To Avoid The Pallet Damage
WOODEN PALLET ELIMINATIONWOODEN PALLET ELIMINATION
May’12 /SBU-INDUSTRIAL 44
LPG LEAD POT FOR BALLMILLLPG LEAD POT FOR BALLMILL
Electrical Lead Melting Pot LP Gas fired Lead Melting Pot
OBJECTIVE: To reduce energy consumption
BENEFITSBENEFITS Heaters are eliminated Energy savings = 86.125MW per month Cost Savings (Excluding LPG cost) = Rs2.78 Lacs per month
May’12 /SBU-INDUSTRIAL 45
BALL MILL ACOUSTIC ENCLOSUREBALL MILL ACOUSTIC ENCLOSUREOBJECTIVE: To reduce noise level in reaction blower & exhaust blower.
BENEFITS: Noise reduced Improved working environment Operator morale has increased.
May’12 /SBU-INDUSTRIAL 46
TAKEOUT GEAR ROLLERTAKEOUT GEAR ROLLER
BEFORE AFTER
Chain sprocket drive provided in take out
c/v. Plate sticking problem due to poor
gape
Gear teeth roller provided to provide
the gape b/n the plates.
BENEFITS: Quality improved & Curing Process Improved.
AREA: SHINKOBE 1 PASTING M/C
May’12 /SBU-INDUSTRIAL 47
ADHESIVE & COHESIVE TESTER FOR PLATE CURING STRENGTHADHESIVE & COHESIVE TESTER FOR PLATE CURING STRENGTH
Load penetration instrument developed
BENEFITS:Improved quality assurance
PLATE CURING STRENGTH DATA
TYPE Min. Max. AVG.SPEC
ARRIVED
26AH POSITIVE
5.8 6.4 6.0 >5.0 PSI
38AH POSITIVE
7.0 7.7 7.4 >7.0 PSI
38AH POSITIVE (Gel / LL
Type)
5.5 6.3 5.9 >5.0 PSI
INVASAFE POSITIVE
5.6 6.1 5.9 >5.0 PSI
INVASAFE POSITIVE (Gel / LL
Type)
5.4 6.32 5.8 >5.0 PSI
100AH POSITIVE
5.4 7.1 6.0 >5.0 PSI
100AH POSITIVE (Gel / LL
Type)
5.2 7.02 6.08 >5.0 PSI
NMST POSITIVE
11.6 17.6 13.4>12.0
PSIMET
POSITIVE10.8 15.2 12.5
>12.0 PSI
May’12 /SBU-INDUSTRIAL 48
ONLINE PASTING DRAIN pH SENSORONLINE PASTING DRAIN pH SENSOR
To identify the acid discharge due to leakage
or overflow
APR MAY JUN JUL AUG SEP OCT NOV DEC JAN FEB MAR0
1
2
3
4
5
6
7
5.6 5.55.2
5.5 5.7 5.6 5.4 5.35.0 5.1 5.1 5.2
1.9 1.81.4 1.5 1.4 1.5 1.5
1.9 2.1 2.02.4 2.4
EFFLUENT pH TREND
2010-11 2009-10
pH
May’12 /SBU-INDUSTRIAL 49
NEGATIVE PLATE WASHING AUTOMATIONNEGATIVE PLATE WASHING AUTOMATION
May’12 /SBU-INDUSTRIAL 50
VERTICAL STORAGE SYSTEMVERTICAL STORAGE SYSTEM
Charged Batteries were stored in the floor
Vertical storage racks introduced
BENEFITS:
Floor Space saving &
100% FIFO system followed
May’12 /SBU-INDUSTRIAL 51
ELIMINATION OF THERMOCOL USAGEELIMINATION OF THERMOCOL USAGE
THERMOCOL was used for battery stacking after charging for storage. DISADV:
Environmental pollution Can’t be recycled.
It is replaced with HARD RUBBER SHEET.ADV:
Reusable
May’12 /SBU-INDUSTRIAL 52
ONLINE MATERIAL RESERVATION (MR) THRO SAPONLINE MATERIAL RESERVATION (MR) THRO SAP
May’12 /SBU-INDUSTRIAL 53
PNEUMATIC CYLINDER FOR ACID WASH ROLLERPNEUMATIC CYLINDER FOR ACID WASH ROLLER
Easy to adjust the roller pressureBetter thickness controlUniform acid washGood surface finishing
BEFORE AFTER
May’12 /SBU-INDUSTRIAL 54
PATH AHEAD
CouldReverse the
employment trends in manufacturing
UK a magnet location for
manufacturing investment
Manufacturing 25% of UK GDP
ShouldStep-change in the competitiveness of the UK supply chain
UK has seized the low-carbon
manufacturing opportunity
UK a high intensity
engineering & technology
nation
Will
Establish the HVM TIC as a new
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 55
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)