Maruti Suzuki India Ltd
Title of case study:
Energy Consumption Reduction in KB-Machine Shop
Project implementation start and end date:
April 2013 to March 2014
Is it in continued operation now?: Yes
Problem identification: Why was this problem selected? What methodology was adopted to identify the problem?
Our management gave us a target of 5% reduction in electricity cost.
Electricity is the major contributor of total cost in machine shop. It amounts to almost 40% of total cost.
The Energy cost has been increasing steadily over last few years due to increasing rates of power and fuel oil. The unit energy cost has raised by 31% in the last financial year.
Hence the project on Energy consumption reduction was taken up.
Data collection: What data was collected? What methodology was adopted to collect the data?
Histograms and Bar graphs were used to do analyse the monthly and daily Electricity consumption of shop and individual lines.
Analysis and development of solution: What analysis was done? What alternate solutions were identified? Why was this particular solution chosen?
Based on the data collected, Energy consumption monitoring was divided into two parts:
- Off-time Energy Consumption reduction: Holiday and Break-time Consumption monitoring.
- Line Running time Energy consumption: Day-wise Consumption monitoring
Line Running time Energy consumption: Combined tool Development
- Redistribution of operation.
- Machine wise process study for understanding the power supply requirement
- Machine auxiliary capacity checking for rationalization of pumps
- VA/VE drive for idea generation for component weight reduction
- One equipment – one second drive for cycle-time reductio
Off-time Energy Consumption reduction:
- Layout checking and mapping with objective of auxiliary running as per production plan.
- Air-washer
- Exhaust fans
- Air-supply
- Centralized coolant system
- Electrical Supply to individual lines
- Study of machines which cannot be switched off during holidays.
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Implementation: How was the chosen solution tested/validated and implemented?
Line Running Consumption Reduction:
- Combination tool development
- Tool development for Crank bore roughing and Seat area machining simultaneously on one machine. (machine-100 + machine-90) sparing of one machine.
- Increase in number of cutting edges of Tappet machining tool for reduced cycle time from 113 sec to 103 sec in machine-150 of cylinder head line.
Operation optimization/Redistribution of operations.
The head mounting hole spot facing operation of machine-40 were distributed to machine-70A and machine-70B in cylinder head line. This resulted in sparing of machine-40.
- Optimization of Auxiliaries:
- Actual load and efficiency calculation
- Checking of spare capacity, using formulae and NPSH graphs resulting in optimization of pump
Sparing Chiller Units by clubbing units of Stand-alone Coolant Systems and connecting to Centralized Coolant system.
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- Interlocking of Hydraulic Power Packs and Mist-collectors with machine idling.
- Optimization of Panel A/C temperature based on capacity:
Energy saving for one degree change in set temperature was studied. Makers of the machines were contacted to know the respective optimum temperature setting.
- VA/VE Ideas:
- EGR hole extra boss was eliminated from component casting,
- Raw material reduction in Holes of component raw material.
- These activities helped in reducing machining time, thus the cycle time.
- Off-time Energy Consumption reduction:
- Utility mapping and running as per requirement
- Air-washer supply path was changed selective operation of during situations when only one of the two lines run.
- Machining Lines were provided with individual Compressed air controllers so that during selective operation of lines, compressed air is not consumed by inactive lines.
- Implementation of Switch-off plan for machines during off-time:
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- Timer control was done on utilities (Airwashers, Exhaust, Compressed Air) as per production plan.
- The Quality Team of the shop and support functions of the lines were educated about these activities through display of Kaizen Sheets. All the changes which were directly affecting machining were updated in the Quality standard sheets. The Quality aspects were reviewed by:
- Daily monitoring of trends and its review by top management
- Display of changes on Change Point Control Board of the lines., Quality parameters were validated based on daily checking of components.
- Process change approvals were taken from respective engineering departments.
Has the solution been institutionalized? If yes, describe how briefly
The systems mentioned above have been institutionalized after implementation. The Process sheets related to the modifications were also Updated. These changes have been updated in the operational standards which were approved by the authorities.
Benefits to organization: What benefits accrued to the organization as a result of the implementation of the project?
- Operational benefits: Describe the physical benefits from the project here:
- The Productivity has increased by reduction of cycle time in the machines where the new tools were introduced.
- The activities undertaken have resulted in Energy consumption reduction of 9% of total Energy over the period of one year.
- The project aided the standardization of working parameters in auxiliary units of machines.
- Financial benefits: Describe the financial benefits directly attributable to this project here:
Energy saving : Rs. 2.0 Crore
Scope for horizontal deployment: Can the solution implemented in this project be deployed horizontally in other areas in the organization? Is there a scope to deploy this in other industries? Has any such deployment been made? If so describe.
- The improvements done in the shops have been updated in the Central portal of Maruti where users from other shops/plants of Maruti can understand them.
- Energy saving activities have been done in other shops/plants, sharing of ideas and successful improvements is an on-going activity.
Entrants may give any other relevant information here that can prove helpful to make it a winning entry: - The Energy resources are depleting at a fast rate. We must devise innovative ways to address this issue. The activities mentioned above are a part of our continuous effort towards this cause.
