Can we foresee Tomorrow?

Transcription

1 Can we foresee Tomorrow?

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3 Our Plants 1. JAIRAJ ANCILLARIES PVT LTD Plant-1 Established: JAIRAJ ANCILLARIES PVT LTD Plant-2 Established: JAIRAJ ANCILLARIES PVT LTD Aurangabad Plant Established: JAIRAAJ GLOBAL RUDRAPUR Plant-4 Established: JAIRAJ PLASTOCHEM PVT LTD. Established 1987 (Plastics Division): 3-B-23, BP, NIT Faridabad , Haryana (India) (Metal cutting, Machining & Turning Division): Plot No.66, Sector-27-A, Faridabad , Haryana (India) (Plastics Division): Plot No. 105/1/1, MIDC Waluj, Aurangabad (Maharashtra) B-22 Rudrapur Industrial Estate, Rudrapur, Dist. U.S.Nagar, Uttarakhand(India) 20A/4 Industrial Area NIT Faridabad , Haryana (India)

4 ISO/TS 16949:2009 Certified Plastic Injection & Blow Moulded components manufacturing Alongwith Sheet Metal, Machining & Turned Automotive & Engineering Components and Assemblies Presentation : Energy Efficiency Measures

5 Machinery Facility Injection Moulding Blow Moulding Power Presses

6 In House Facility - Mould designing - Tool Room - Injection Moulding - Blow Moulding - Machining - Plastic hot plate welding - Spin welding - Ultrasonic welding - Vibration welding

7 Our Products Valve Seals Piston Rings Oil Reservoir Assembly for General Motors-4W (Car) Dust Covers for Shocker Assembly Oil Reservoir Assembly for Disc Brakes- Bajaj 3-W Guides Springs Automobile Parts YAD Dust Cover YP8 front YRA front YJC front Dust Cover Maruti - 4 W Shocker Assembly

8 Team for Energy Conservation

9 Energy Sources Electricity Fuel Lighting Water Compressed Air

10 Process Flow Diagram

11 Third Party Audit Report Energy Consumption details Share of Energy in KgOE HSD 28% HSD Cost 20% Share of Electrical Power by Cost Grid Power 72% Grid Energy Type HSD Total Power Energy consumption Lt * Kwh Energy in KgOE % Share in 27.53% 72.47% % KgOE Pur Power 80% Energy Cost Distribution ( ) Particular Rs.(Lakh) % of Total Grid - Electricity Diesel -DG Total Dalkia Energy Services Ltd

12 Third Party Audit Report Production and Specific energy consumption Cost of raw material consumed during January to March is Rs Lakh Cost of Energy during January to March is Rs Lakh The total power consumed during January to March is Mwh The contribution of energy cost wrt cost of raw material is 12.69% The Specific Energy Consumption is 1.98 Mwh for every Rs one lakh cost of raw material

13 Third Party Audit Report Evaluation of DG Set Details of DG Set Sr. No. Parameters UOM D.G. No.1 D.G. No.2 1 Make 2 Rating KVA Phase No Frequency Hz Rated Voltage Volt Rated Current Amp Power Factor No Measured PF No Maximum Load KW Average Load Kw Loading factor % 71.08% 78.26% 12 Flue Gas Temp o C HSD Consumption Lt/Hr SEC Kwh/Lt

14 Third Party Audit Report Cooling Tower Evaluation CoolingTower Cooling Tower Range o C 2.6 Cooling Tower Approach o C 3.5 Cooling Tower Effectiveness % 43.0

15 Third Party Audit Report Heat loss in IM Machine

16 Observation Third Party Audit Report Heat loss in IM Machine About two third of IM machine is having very low PF Surface temperature of IM machine number 9 & 10 is in the range of 48 to 58 Deg C which is satisfactory. Surface temperature of rest of IM machine are required to be brought in the same range. Sum of measured running load of twelve IM machine is Kw Heat loss in the same set of machine is about 4.32 KWh/Hr ( Except IM Machine number 9&10)

17 Third Party Audit Report Lighting Evaluation Lux Level Maximum lux measured is 199 luman in Director Room. Minimum lux Measured is 17 luman in gallery area. Av lux level is 67 luman LPD Maximum LPD is 45.9 W/sq M in MD store Minimum LPD is 1.7 W/sq M in conference room Av LPD is 9.1 W/sq M ILER value is less than 0.50 in almost all area of plant. Average ILER for complete plant is 0.27 which is not satisfactory and it require immediate attention. Lux level also need to be improved.

18 16/11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/ /11/2012 AS Per IEEE V THD & I THD should be less than 5% Third Party Audit Report Load and Harmonic Profile KW Profile Ave. I THD AVE.V THD

19 Third Party Audit Report Baseline Parameters The contribution of energy cost wrt cost of raw material is 12.69% The Specific Energy Consumption is 1.98 Mwh for every Rs one lakh cost of raw material SFC of DG1 is 2.26 Kwh/Lt SFC of DG 2 is 3.43 Kwh/lt Present Av PF 0.94 Present av Voltage V Grid Power cost (variable) is Rs. 5.1 per unit. HSD cost is Rs per litre.

20 16/11/ :36 16/11/ :35 16/11/ :25 16/11/ :15 16/11/ :05 16/11/ :56 16/11/ :46 16/11/ :28 16/11/ :18 16/11/ :56 17/11/ :46 17/11/ :48 17/11/ :10 17/11/ :00 17/11/ :17 17/11/ :36 17/11/ :26 17/11/ :16 17/11/ :06 17/11/ :56 17/11/ :46 Axis Title Third Party Audit Report EPIA1: Improvement in Power factor Present Condition Present av. Power factor as shown in utility bill is 0.94 Av Power during Measurement is Proposed Scheme It is recommended to improve it to 0.99 by installing PF controller along with additional 25 KVAR capacitor Bank Saving Minimum reduction in KVAh demand: kvah per annum Monetary benefit: Rs per annum Assumptions It is based on last year KWh consumption Rate:Rs. 5.1 per KVah Avg. PF Measured PF as in Utility Bill PF

21 16/11/ :36 16/11/ :09 16/11/ :34 16/11/ :59 16/11/ :24 16/11/ :49 16/11/ :14 16/11/ :39 16/11/ :04 16/11/ :29 16/11/ :54 16/11/ :19 16/11/ :44 16/11/ :58 16/11/ :23 16/11/ :48 16/11/ :13 16/11/ :38 16/11/ :03 16/11/ :28 16/11/ :53 17/11/ :18 17/11/ :43 17/11/ :08 17/11/ :33 17/11/ :58 17/11/ :23 17/11/ :48 17/11/ :13 17/11/ :38 17/11/ :03 17/11/ :28 17/11/ :53 17/11/ :18 17/11/ :43 17/11/ :08 17/11/ :33 17/11/ :58 17/11/ :23 17/11/ :48 17/11/ :13 17/11/ :38 17/11/ :03 17/11/ :28 17/11/ :53 17/11/ :18 17/11/ :43 17/11/ :08 Third Party Audit Report EPIA-2: Voltage optimization for single phase load 280 VLN Ave Present Condition Single phase connected load: kw Single phase av. voltage: V Single phase Min voltage: V Single phase Max voltage: V

22 Third Party Audit Report EPIA-2: Voltage optimization for single phase load Proposed Scheme Recommended single phase voltage: 210 volts Recommended to install servo stabilizer for single phase load to maintain 210 volts. Reduction in single phase voltage level: % Saving Reduction in KWH consumption: Kwh per annum Saving in Rs. : Rs per annum Assumption Average working hour is 20 per day and 300 day in year and Rate: Rs. 5.1 per KVah.

23 Third Party Audit Report EPIA-3: High Efficiency lighting system Present Condition Presently low efficacy lighting like Incandescent lamps and FTL 40 are in use Proposed Scheme It is recommended to change bulb to CFL and FTL 40 to T5 Saving Present Wattage Proposed Wattage No of appliance Saving in KW Bulb 100 W 100 CFL FTL 40 W 54 T FTL 36 W 50 T FTL 20 W 32 T Total Annual saving in Kwh Av Rate of Power 5.1 Saving in Rs per annum

24 Third Party Audit Report EPIA 4: Insulation of IM Machine Present Condition Presently most of machine are having surface temperature in the range of 88 Deg C to 180 Deg C Total skin loss of measured IM machines is 3869 Kcal/Hr Proposed Scheme It is recommended to insulate machine and bring the surface temperature in the range of 50 deg C Saving A saving of 3.5 Kwh/hr can be achieved resulting a saving of Kwh / annum Saving in Rs. is 1,06,774/annum Assumption One kwh is equal to 860 Kcal Unit rate Rs. 5.1/Kwh Average working hour is 20 per day and 300 day in year

25 S.No Roadmap for Energy conservation projects EE Measure Implemented Improvement of Power Factor Installation of high efficacy lighting Insulation of heater at all Injection Moulding Machines Installation of chiller better cooling in Moulds and reduce cycle time 10 to 20% Year Done Done Year Done Year Done Status Completed Completed Completed Completed 5 Mould Modification Done on going 6 Add Air Compressor with Energy Efficient Done Completed 7 Add Solar Power 15 KWA Done Completed

26 Energy Saving Check Points Displayed WI for Energy saving

27 Improvement in Power Factor up to 0.99 / 1.0 APFC Panel 180 KVAR added for Improving Power Factor for annual saving of RS Without APFC Panel BEFORE Power Factor 0.88 AFTER Power Factor up to 0.99 / 1.0 BENEFITS :- Maintained the Power Factor up to 0.99 / 1.0 & resulting in Annual Saving of electricity bill Rs

28 Maintained the Power Factor up to 0.99 / 1.0 in DG Set Power Factor not use in DG set BEFORE AFTER Power Factor maintained in DG set up to 0.99 / 1.0 BENEFITS :- Maintained the Power Factor up to 0.99 / 1.0 for efficiency

29 Daily Monitoring of Power Factor POWER FACTOR AS ON DATE (MONTH OF August-2017) 0.99 Data of power factor is monitored on daily basis & circulated by Mail

30 VALUE Maintained the Power Factor up to 0.99 / 1.0 April 2015 to as on till date POWER FACTOR APR MAY JUN JUL AUG SEP OCT NOV DEC JAN FEB MAR POWER FACTOR PERIOD YEAR POWER FACTOR Maintained the Power Factor up to 0.99 / 1.0

31 LED / T-5 Tube Light Installed General Tube Light 40 Watt 40 Watt BEFORE Lux Light (250 Lux) 5 & 18 Watt AFTER LED / T5 Tube Light, Increase Lux Light (350 Lux) & Power saving Switch off appliances when not in use BENEFITS :- Annual saving and Improve Lux Light

32 Lighting arrangement as per Lux Light STD. BEFORE AFTER BENEFITS :- Improve / Maintained the Lux Light on Machines for Inspection

33 Replace refrigerator with Energy star ratings Old Refrigerator BEFORE Without star rating & Electricity consumption 800 Units / Year AFTER Electricity consumption 299 Units / Year BENEFITS :- Annual saving units 500

34 Replace all Air Conditioner with Energy star ratings BEFORE Without star rating AFTER Replace all Air Conditioner with Energy Higher star ratings BENEFITS :- Annual saving

35 Small DG set for Lighting use Use 125 KVA DG set BEFORE AFTER 40 KVA DG set use for lighting load BENEFITS :- Diesel / Fuel saving

36 Purchase Higher star rating / Energy Efficient Motors Energy Efficient Motors mandatory

37 VFD Standard VFD is Mandatory Standard or Retrofitted

38 VFD Standard Spare Barrels added to save Mould/ Material Chabge settings

39 Use of Natural Daylight Use of Natural Sunlight

40 Insulation of Heaters at all Injection Moulding Machines Insulation of heaters at all Injection Moulding Machines BENEFITS :- The Insulation provides personnel safety, reduces barrel energy losses by from 35% to 65% and reduces the load on the plant air conditioning system

41 Replace Air Compressor with Energy Efficient Old Local Air Compressor BEFORE AFTER Gravitas / FSCURTIS Air Compressor BENEFITS :- Air saving

42 Utilisation of renewable energy sources (Solar Power Project) Solar Power System 2 KWA BEFORE AFTER Solar Power System 15 KWA BENEFITS :- Increase Load & Solar power systems have reduce office electric bill.

43 VALUE IN INR (LAKH) Annual Sale v/s Energy Cost ANNUAL BASIC SALES V/S ENERGY COST ANNUAL SALES ENERGY COST PERIOD ANNUAL SALES ENERGY COST

44 Energy Saving through Mould Modification Summary of Energy Savings through Mould Modification S. NO. Mould Name Project Description Machine Capacity Before After Remarks 1 Piston Ring Convert 8 Cavity to 16 Cavity 60 Ton 60 Ton Improvement in productivity 2 Piston Ring Dia 38.5 Convert 1 Cavity to 4 Cavity 15 Ton 15 Ton Improvement in productivity 3 Inspection Plug seal Convert 2 Cavity to 4 Cavity 15 Ton 15 Ton Improvement in productivity 4 Raching Step Convert 2 Cavity to 4 Cavity 15 Ton 15 Ton Improvement in productivity 5 ORA Black Cap Convert 1 Cavity to 8 Cavity 60 Ton 60 Ton Improvement in productivity Part Name Machine Capacity No. of Cavity Cycle Time (Sec) Hourly production (Nos) BEFORE Piston Ring 60 Ton Piston Ring Dia Ton Inspection Plug seal 15 Ton Raching Step 15 Ton ORA Black Cap 60 Ton Production per % Improvement in Shift (Nos) Productivity /Shift AFTER Piston Ring 60 Ton Piston Ring Dia Ton Inspection Plug seal 15 Ton Raching Step 15 Ton ORA Black Cap 60 Ton

45 Manufacturing cost reduction : Development of Multi Cavities Moulds Piston Ring Piston Ring Dia 38.5 ORA Black Cap Inspection Plug seal Raching Step

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47 Best Suggestion & Performance Award- Energy saving Energy saving awards

48 Chiller for better cooling in Moulds INSTALLATION OF TWO CHILLER S FOR BETTER COOLING IN MOULDS AND CYCLE TIME REDUCE Chiller for Better Cooling BENEFITS :- Installation of chiller better cooling in Moulds and reduce cycle time 10% to 20%

49 Rain Water Harvesting RAIN WATER HARVESTING PROVIDED Collected of water from the roofs of buildings & surfaces on which rain falls and stored in rainwater tanks.

50 Energy Efficiency Measures : Actual Investment v/s Saving S.No. EE Measure Implemented Status Improvement of Power Factor Installation of high efficacy lighting Insulation of heater at all Injection Moulding Machines Installation of chiller better cooling in Moulds and reduce cycle time 10% to 20% Investment (in Lakh Rs) Total annual Saving Rs Lakhs Energy Annual Savings (In Lakh Rs.) Completed Completed Completed Completed Mould Modification Completed Total

51 ZERO PPM Award: 8 June 2017 JaiRaj Plant-1 / JPPL : Awarded excellent performance in achieving Quality & Delivery targets from Gabriel India Ltd. (Gurgaon).

52 100% Delivery Performance Award: 8 June 2017 JaiRaj Plant-1 / JPPL : Awarded excellent performance in achieving Quality & Delivery targets from Gabriel India Ltd. (Gurgaon).

53 Exceptional Response to New Developments Award: 21 July 2017 JaiRaj Plant-1 / JPPL : Awarded for Response to New Developments from Gabriel India Ltd.

54 State Award for JaiRaj JaiRaj Plant-1 Awarded State-level Second Prize, Trophy and Rs.50,000 from Govt. of Haryana for Energy Conservation in Small Industry Category

55 Awards & Accolades Best Supplier Award Best Vendor Award Star Performer Trophy and Award High Performance

56 Member of the CII Cluster Development Progamme conducted by L.M. Thapar Center for Competitiveness. Member of the Factory Improvement Programme conducted by ILO Member of lean Manufacturing Cluster

57 FOUNDING PRINCIPLES Striving for best manufacturing practices Enlightened by knowledge Supported by technology Strengthened by our team Encouraged by our bankers Governed by business ethics Passionate towards environment Committed to social responsibility Trusted by our customers.

58 LED THE WORLD BANK FUNDED GEF PROJECT IN FARIDABAD AS CLUSTER COORDINATOR 50+ Awareness Sessions on Energy Efficiency Walkthrough Audits 400 DPRs and Audits 400 MSMEs made Energy Efficient

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60 Awakening Solution Finding Resource Mobilization Campaign Challenges Implementation

61 Awakening Losses identified through Efficiency drop upon repair/ rewinding of Motors Rs.1.5 lakh per month Rs.18.0 lakh per annuum

62 Awakening Losses identified through Efficiency drop upon repair/ rewinding of Motors Rs.1.5 lakh per month Rs.18.0 lakh per annuum

63 Solution Finding Setting up of World Class Motor Knowledge Centre One Stop Centre for Repair, Rewinding & Testing + Skill Development for Electricians & Motor Rewinders

64 Resource Mobilization Cost of Testing Centre: Rs.1.0 Cr Cost of Repair & Rewinding Centre: Rs.1.5 Cr

65 UNLEASHING THE POWER OF COLLECTIVE GROWTH Creation of a Cluster

66 Campaign Road Shows Series of Meetings SIDBI The World Bank BEE

67 RESULTS The World Bank Rs.30 lakh Grant for Testing Centre BEE Supporting Partner

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69 Challenge Repair/ Rewinding Facility..? Bridge the Huge Gap in Resources Create Mobile Facility

70 New SME Law If anything goes wrong, Fix it! (To hell with Murphy)

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73 New Support Govt. of Haryana steps in Grants Rs.1.80 crore Entrepreneurs contributing Rs.50 lakh

74 Centre of Excellence for Electric Motors Faridabad

75 Active wear, Sports wear, Yoga wear 1. Responsible Cotton 2. Recycled PET

76 IAmNewIndia

77 I am New India Entrepreneur I decide NOT just to raise Problems But Find or Create Solutions.

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79 ENERGY EFFICIENCY is our commitment!