1. Bajaj Auto Ltd. Welcomes you all Aurangabad Division
Energy Management 2013
Bajaj Auto Ltd.
Aurangabad Division
Welcomes you all

2. Contents Company profile Manufacturing process
Energy Conservation cell
Scope
Energy Indices /Benchmarks
Energy Conservation Methodology
Energy Conservation Approach
Energy cost loss Tree
Innovative Projects
Other Encon Projects
Electrical
Use of renewable energy
Thermal
Environment & Carbon Reduction
Utilization of waste
Results
Sustenance
Future Project
Achievements

3. Company Profile
The Bajaj group was established in 1945 by Shri. Jamanalal Bajaj, a close associate and disciple of Mahatma Gandhi.
He believed in sound and fair business practices based on respect for customers and integrity
Bajaj remains committed to these VALUES
Bajaj Group
Automotive
Electrical & Home Appliances
Steel & Engineering
Finance & Insurance
Power & Infrastructure
Bajaj Auto Limited - The flagship Company of the Bajaj Group.
Current world market standing
Ranked as the World’s fourth largest two & three wheeler manufacturer

4. Manufacturing locations Bajaj Auto Ltd- Corporate Office
Company Profile
Manufacturing locations
Pantnagar Plant –
Plant and its vendors in the same premises.
Plant produces Discover, Boxer & Platina range of motorcycles.
Bajaj Auto Ltd- Corporate Office
Akurdi, Pune
Waluj MC Plant -
Manufacturing of
2-wheelers
Caters to the major export needs.
Waluj CV Plant -
3-wheelers & parts thereof.
Chakan Plant -
Tries and tests various new concepts.
Manufacturing of High Performance bikes.

5. Approach for Improvement
Key
Management
Index
Company
Vision
TPM
Key
Performance
Index
Company
Mission
Key
Activity
Index
ISO 9001
ISO 14001
OHSAS 18001
ISO Initiated

6. Total Number of Equipments - 1840 nos.
Process Flow Chart
Press & Fab.
Aluminium Shop
Vendor parts
Domestic Dispatch
Paint
Steel Shop
Vehicle Assly
Engine Assly
Export Dispatch
Heat Treatment
Central Gear Shop
Total Number of Equipments nos.

7. Flow Chart - Energy Conservation Program
Company Vision/Mission
Plant Vision/Mission
Management Review
Shop Level Target
Execution & Monitoring
Energy Manager
Encon Projects
Budget Allocation

8. Energy Conservation Cell
Corporate
Bi-Monthly Review
Plant Head
Monthly Review
Fortnightly
Div Head
Div Head
Div Head
Div Head
Div Head
Div Head
Machine
Shops
CGS/HT
Paint Shop
Press & Fab
Assembly
Utility
Energy Mgr.
Weekly
Dept. Head
Dept. Head
Dept. Head
Dept. Head
Dept. Head
Dept. Head
Daily
Energy Captains
Energy Captains
Energy Captains
Energy Captains
Energy Captains
Energy Captains

9. Time spent by Senior Executives in various functions
Sr No.
Functions
Average time spent % 1
Manufacturing excellence
TPM- Review/Implementation 25 2
Green Manufacturing Initiatives 20 3
Technological & Developmental activities 15 4
New Products 5
Quality Management systems 10 6
Supply Chain Management 7
Administrative Issues
Sr No.
Review Mechanism
Level 1
Plant Head
Monthly
Level 2
DIV Head
Fortnightly
Level 3
Energy Manager
Weekly
Level 4
Energy Captain
Daily

10. Share the best practices among employees, vendors,suppliers
Encon Strategy
Eliminate wastage of Resources by maximizing Productivity of all
operations & Processes
Adopt in the faster pace for Deployment of all ideas in all areas
of Business Thru “Maximizing Involvement of People
Focus on accomplishing investment projects , with Payback
less than two year at faster pace & its horizontal deployment
Procurement of Energy Efficient Equipment for new installation
Earlier Conserve + Preserve + Reserve
Now- in addition to above: Reduce Reuse Recycle
Share the best practices among employees, vendors,suppliers
& other partners Implement More & More ENERGY KAIZEN

11. Approach towards Encon Working on Legacy system
Micro Level Monitoring
Judicial Energy Utilization
Harnessing Solar & Wind Energy
Carbon Emission Reduction
Sustainable Business Growth
Green Factory
Improvements
Technology Up gradations
Energy Optimization
System Auto controls
Waste Minimization
Energy Conservation Techniques-
Localized control
Human Dependent systems
Working on Legacy system
Year

12. Specific Energy Consumption
Energy Consumption per unit of production
Energy
Unit
Base Year
Achieved
Target
Electricity
Kwh/
veh
67.54
49.31
45.81
42.99
36.72
34.9
31.45
25.41
22.61
21.15
20.1
LPG
Kg / veh
2.53
2.75
2.4
2.8
2.2
2.1
1.77
1.45
1.33
1.26
Water
m3 / veh
0.89
0.65
0.62
0.58
0.54
0.52
0.41
0.35
0.27
0.25
SEC Reduction %
Sr.
Energy
In 10 Year s
In Last 3 Years
In last year 1
Electrical ( Kwh/Veh)
69%
32%
6.41% 2
Fuel ( LPG) ( Kg/Veh)
48%
38%
7.14% 3
Water ( Cu.m /Veh)
34%

13. Specific Energy Consumption-Benchmark
Sr.
Energy
BAL , Waluj
Nearest competitor
Global 1
Electrical ( Kwh/Veh)
21.15
24.55 NA 2
Fuel ( LPG) ( Kg/Veh)
1.33
2.6 3
Water ( Cub.Mtr/Veh.)
0.27
0.41 4
Diesel (Ltr/Veh)
0.09
2.3
No Standard Benchmarks are available for Automobile sector ,
However, we are setting our own internal targets as:
Min 5 % Reduction in specific energy consumption wrt last year

14. Stratification of Energy consumption
Electrical Energy consumption
LPG Energy consumption

15. Energy Conservation Methodology
Sr.
No.
Activity
Methodology
Tools used 1
Audit
To identify areas of energy conservation potential
Weekly / Monthly data through Pie charts & brainstorming 2
Analysis
To identify equipments & Processes where energy conservation is possible
Daily/weekly KWh, pressure, flow,volume etc.recording through bar charts,graphs 3
Action Plan
Identify activities for individual equipments with time frame
Resource planning & activity charts 4
Implementation
Action for procurement & implementation
6W2H Way Activity Charts 5
Evaluation
To analyze plan V/S Actual
Gap Analysis & countermeasures 6
Sustenance
To Monitor the results
Internal Audits

16. Energy Conservation Methodology & Idea
Electrical Energy
Loss Reduction / Elimination
Technological Improvement
Operational Control
Loss Elimination
Alternate Source
Efficient Equipment
Sr.
Idea 1
Transmission Loss 2
Distribution Loss 3
Power Factor & Harmonic loss 4
Light Power Loss 5
Unwanted illumination 6
Compressed air energy 7
Inefficient Equipment 8
Over Rated equipments
Sr.
Idea 1
Biogas for Heating 2
Solar Lighting 3
Wind Power Generation 4
Solar Water Heating 5
LPG Heating 6
Magnetic Energy
Sr.
Idea 1
LED/CFL/Induction Lamps 2
Efficient Motor/Pumps 3
Screw Compressor 4
Ceramic to Metal tube heater 5
Aluminium Pipes for compressed air .air 6
5 Star rating equipments 7
VFD for high HP Motors 8
Use of Soft Starter
Sr.
Idea 1
Metering & Monitoring 2
Auditing 3
Energy Captain 4
No Production on Off days

17. Reduction of Electrical Energy Consumption Per Vehicle
ENCON Idea Table
Reduction of Electrical Energy Consumption Per Vehicle
Sr No.
Approach
Idea 1
Eliminate wastage
Switched off sodium vapor lamps of 250 watts in non moving areas
Provided occupancy switches for lights in warehouse
Switched off Hydraulics during machine idle time. 2
Optimization
Use of VFD for compressors at set pressure (70 psi ±2)
Optimization of motor size
Task lighting 3
Energy Efficient Equipments
Installation of Energy efficient motors for compressors(96.3 %)
Installation of Energy efficient screw compressors (95 %)
Process equipments 4
Alternate Methods
Use of LPG heaters instead of electrical heaters .
Use of 150W CFL/Induction Lamps in place of 250 W HPSV lamps
Process change 5
Usage of renewable energy
Installation of natural air draft in place of electrical exhaust fans
Installation of transparent roofs/ Light Pipes for shops .
Utilization of solar energy for heating /Lighting /Power generation

18. Reduction of Compressed Air Consumption Per Vehicle
ENCON Idea Table
Reduction of Compressed Air Consumption Per Vehicle
Sr No.
Approach
Idea 1
Waste elimination -Arresting Leakages
Air Leakage data collection through audits from shops
Air leakage data through FAD tests.
Efficient usage of compressed air
Shut off valve during non working hours 2
Optimization of compressed air supply
providing localized compressors
Separation of air headers for Low pressure & High pressure requirement
Rerouting & Resizing of compressed air headers
Use of Air Boosters for High pressure application
Use of Aluminium pipes for air distribution in assembly shops 3
Elimination of compressed air usage
Use of Electrical operated tools

19. Energy Conservation Methodology & Idea Technological Improvement
Fuel (LPG) Energy
Loss
Technological Improvement
Operational Control
Loss Elimination
Alternate Source
Efficient Equipment
Sr.
Idea 1
Heat Loss through oven skin 2
Heat Loss Through Flue Gases 3
Heat Loss to Jigs & Fixtures
Sr.
Idea 1
Solar water heating 2
Use LNG
Sr.
Idea 1
Direct heating 2
Combustion Efficient Burner 3
Low Temperature process 4
Cycle Time Optimization
Sr.
Idea 1
Metering & Monitoring 2
Auditing 3
Energy Captain 4
No Production on Off days

20. Reduction of LPG consumption per Vehicle
ENCON Idea Table
Reduction of LPG consumption per Vehicle
Sr.no
Approach
Idea 1
Eliminate wastages
Eliminate of heat loss through Furnace /oven skins-Improve insulation 2
Optimization
Tuning of burners
Process change 3
Reuse of waste process heat
Use of low temperature flue gases heat energy

21. Innovative projects

22. Distribution Loss reduction
Innovative Project -1
132 KV supply
from MSEDCL
GTL Limited
Energy meter
MRS
Shop Wise
Energy meters +
MSEB
Metered
consumption =
Plant Metering
Distribution Loss
Sr.
Key Initiative
Benefit 1
Electronic Energy meters
Idea generation, Prioritization of Energy work 2
Data logging system ( Cockpit) 3
Feedback Transformer(CT/PT) Calibration
Eliminate Metering error
Sr.
Key Initiative
Saving Achieved 1
Optimization of transformer loading
4.6 L Kwh 2
Switch off standby distribution transformer through isolation switches 3
Overhauling of distribution transformers 4
Power Factor Improvement by APFC 5
Harmonic suppression by active filters

23. Actions for loss reduction
Reduce Losses of distribution network
Innovative Project -1
Distribution Transformer-2 MVA( 11 KV/433 Volts) – 29 Nos. in Waluj Plant
Sr.
Actions for loss reduction
Activity
Saving
Total saving
Investment 1
Over hauling of distribution transformer
MS plate at secondary terminals replaced with SS plate
0.5 Kwh/Hr/
Transformer
1.27 L kwh/Yr
Rs.6.23 L 2
Switching off standby transformers
Standby transformer switched off with Isolator switch on transformer keeping 11 Kv cable charged-8 Nos.
2 Kwh/Hr/
2.1 L Kwh /Yr
RS.4.8 L 3
Load balancing ( between 50 to 70%) of transformers & switched off 4 Nos. transformers

24. Power Factor /Reactive power compensation at Press & Fabrication shop
Reduction of Inductive load losses
Innovative Project -2
Power Factor /Reactive power compensation at Press & Fabrication shop
Unity Power Factor Ensures reduction in distribution loss & get Incentives .
Balanced & stable Load can be catered using switched capacitors & can be contactor or Thyrister based.
Capacitors contributes in amplifying harmonics in system due to resonance.
Unbalanced load are large single phase loads distributed on 3 phase system with lot of diversity
Two Phase MIG welding machines are in use in large no. This is typical form of unbalanced load . As a result KVAR requirement differs in each phase & also changes very quickly .
It is not possible to compensate such requirement with simple switching capacitors.

25. Reduction of Inductive load losses
Innovative Project -2

26. Power Factor /Reactive power compensation at Press & Fabrication shop
Reduction of Inductive load losses
Innovative Project -2
Power Factor /Reactive power compensation at Press & Fabrication shop
Before
We can see
KVAR requirement varies from KVAR to 200 KVAr
Current varies from 500 A to 1200 A
Different in different phase – Typical unbalanced load
Power factor also varies from 0.6 to 0.95 & correction required is also unequal

27. Power Factor /Reactive power compensation at Press & Fabrication shop
Reduction of Inductive load losses
Innovative Project -2
Power Factor /Reactive power compensation at Press & Fabrication shop
After

28. Reduction of Inductive load losses
Innovative Project -2
Saving : 1.26 LKwh/ Yr
Investment : Rs. 15 lacs

29. Reduction of compressed air loss
Innovative Project -3
Sr.
Phase 1
Phase 2
Before
After 1
Consumption 17 % of Plant Consumption
Shop wise Metering for Compressed air
Conducted Compressed air audit
for leakages for plant through external agency
Conducted compressed air Audit for Pressure pattern
Total Air leakages – 1231 CFM
Mostly air leakages found through Air Gauges
Air leakages through pneumatic fittings
Result : Saving of one compressor of 1000 CFM .
Use of ultra sound Leakage identification unit
Regular leakage Audit internally .
Cell wise Compressed air Pipe lines for better control
Provided auto shutoff valves on lines
Electrically operated auto drain valves with level sensing on all air receivers
Identify all improper fittings & Replace with suitable model & Size

30. Reduction of compressed air loss
Sr.
Phase 1
Phase 2
Before
After
Air for Job Check
No air on off valve, Air Gauge continuous ON
Foot valve( ON -OFF)
in pneumatic circuit
Job Sensor & Valve control
Air for machine
Direct air connection to machines - Manual on/off valves
Soft Start valves to stop air when machine idle
Air shutoff valves for air feeders to production cell – Time controlled
No Job No Air
Dial
Gauge
Solenoid valve
Sensor Switch

31. Electrical- Lighting Sr. Phase 1 Phase 2 Before After Street Light
300 Watt SV lamps
650 No.s Lamps
Connected Load – 195 Kw
Consumption L Kwh/Yr
150 Watt CFL lamps
Connected Load – Kw
Consumption L Kwh/Yr
72 Watts LED lamps
80 Nos. Lamps
Connected Load – 5.76 Kw
Consumption L kwh/Yr
Energy saving : 3.56 L Kwh /Yr
: Rs.24.95L/Yr
Investment : Rs.12.6 Lacs
Energy saving : L Kwh /Yr
: Rs.1.61 L/Yr
Investment : Rs.8.0 Lacs

32. Electrical- Lighting Sr. Phase 1 Phase 2 Before After Shop Lights
300 watts SV High bay lamps
590 Nos. Lamps
Connected Load -177 Kw
Consumption L Kwh/Yr
156 watts Induction lamps
302 Nos. Lamps
Connected Load – 47.0 Kw
Consumption L Kwh/Yr
120 W LED High bay lamps – Under trials
Energy saving : 3.12 L Kwh /Yr
: Rs L/Yr
Investment : Rs Lacs
Office & assly line
FTL T8 ( 40 Watts) for shop & storage area lighting
FTL T5 ( 30 Watts) for shop & storage area lighting
1200 No.s T5 fitted
CFL /LED Lights : 200 Fittings of 80 Watts
Saving : 0.48 LKwh/ Yr
Investment : Rs Lacs
Saving : 0.43 L Kwh /Yr
Rs. 3 Lacs
Investment : 8 Lacs

33. Electrical- Lighting Paint Booth Lighting( flame proof)
Task Lighting in machine shops
Before
After
Before
After
Use of Structure
Tube lights (2*40 Watt)
at 5 meter height
Use of 36 W Tube light at 1 Meter Height
Use of 8 X 40 W Tubes
Use of 6X 36 W CFL
300 Fittings
Saving : 1.26 LKwh/ Yr
Investment : Rs. 30 lacs
Saving : 0.35 LKwh / Yr
Investment : Rs lacs

34. Electrical- Fans & Blowers
Replacement of 30 inch size Air circulator by 24 inch ( 150 Nos)
Installation of Spot cooling System
to replace Old type ARP system
Before
After
Before
After
350 Watts air circulators
Centralized ARP cooling system With 100HP motor
200 Watts air circulators
Breeze air spot coolers used With 2 HP blowers (18 No.)
Saving : 1.21 Lacs Kwh /Year
Investment : Rs. 7.5 Lacs
Saving : Lac kwh/Yr.
Investment : Rs.16 lacs

35. Electrical- Pumps & Motors
Pump Elimination
Pump Optimization
Before
After
Before
After
Application :Therrmic fluid circulation Motor power-25HP
37 Kw Motor
Total Load -67 Kw
75 Kw Motor
Total Load -102 Kw
25 HP gland pump replaced with
mechanical seal pump .
Also eliminate gland cooling pump of 5 HP
Energy Saving : Rs Lacs/Yr
Investment : Rs.26 Lacs
Energy Saving : Rs Lacs/Yr
Investment : Rs Lacs
Horizontal deployment – 3 Locations

36. Electrical- Pumps & Motors
Installation of VFD for
Exhaust blower in paint shop
Use of Energy Efficient motors
Before
After
Before
After
No VFD,
Exhaust blowers-7 Nos. running at constant speed for 18 hours /day
Conventional Motor used for
Actual Load – 37 KW
Energy Efficient motor
IE3 motors in paint shop
VFD Installed
Blowers running at 50 % speed in recess time
Saving : Rs Lacs / Yr
Investment : Rs Lacs
Horizontal deployment : 5
Saving : 0.35 Lacs Kwh/Year Rs Lacs
Investment :Rs. 4.3 Lacs
Horizontal deployment : 2

37. Electrical- Compressed air
Sr.
Phase 1
Phase 2
Before
After
Compressed air
Reciprocating compressors are running in central compressor 4.5 to 6 Bar
Atlas Copco /Ingersoll Rand screw compressors . Capacity 1000 CFM each @ 4.5 Bar
High Pressure compressed air -6 Bar through local compressor
Demand side management : Variable speed IR make NIRVAN compressor 1000 CFM -2 Nos.
Supply side Management : Controller for compressor operation
Installed air boosters for high pressure at 4 Locations ( 4.5 Bar to 6 Bar)
Saving ( Kwh) :12.0 Lacs /Year
Investment : Rs. 90 Lacs
Saving ( Kwh) : 2.0 Lacs /Year
Investment : Rs. 8 Lacs

38. Optimum temperature for ACs / coolers Localised storage tank
Electrical- Cooling
Fanless Cooling Tower
Optimum temperature for ACs / coolers
Before
After
Temperature settings
S N
Description
Before
( Deg.C.)
After 1
Room AC 21 24 2
Panel AC 30 34 3
Water coolers 18
Localised storage tank
Air Movement in cooling Tower induced
with the help of Exhaust Fan of 4 HP
Provided cooling tower equipped with water jet technology. i.e. Air movement in cooling tower induced with the help of water Jet.
Energy Saving : Rs.1 Lacs/Yr
Investment : Rs.1.8 Lacs
Horizontal deployment : 3 locations
Saving : Lacs kwh/Yr.
Investment : Zero

39. Electrical- Cooling Energy Efficient equipment installation Before
After
Air Dryers CFM capacity
With Reciprocating compressors replaced with Scroll compressors air dryers – 4 Nos.
CED Reciprocating chiller 110 TR
(0.9 Kw/TR)
Screw chiller 80 TR
(0.71Kw/TR)
Energy saving : 0.4 Lacs Kwh /Annum
Investment: 13 Lacs
Energy saving : 0.8 Lacs Kwh /Annum
Investment: 8 Lacs

40. Electrical –Method change
Electrical Heating TO LPG Heating
Electrical Heating TO Heat Pump
Before
After
Before
After
Heat pump For washing machine water heating
Electric Heater
Electric Heater
LPG Burner For Heating
Electric Heater was used
for Water heating of pre washer on CGC Furnace -54 KW
Electric Heater was used
for Water heating of washing machine
LPG Heating is used
Saving : Rs.1.75L / Year
Investment : Rs. 3.1 Lacs
Horizontal deployment : 20 locations
Saving : Rs.3.26L / Year
Investment : Rs. 3.5 Lacs

41. Total Identified Points – 24 Heat Loss- 63456 K Cal /Hr
Thermal
Total Identified Points – 24
Heat Loss K Cal /Hr
Rectified Insulation of High heat Zone
Saving Ton LPG /Year
We have conducted Thermal Imaging for identifying
heat losses in paint ovens

42. Thermal Sr. no. Shop Name Discription Year Annual Thermal
Investment made
Units (Mn T)
Rs. (Mn)
Rs Lacs 1
Paint Shop
Reduced hanger weight to minimize heat loss Kg/Hanger
0.0041
0.2173
1.00 2
Scheduled running of ED process Line Running -18 Hrs /Day
0.057
3.021
0.00 3
Heat treatment
Salt heating by Quenching hot empty fixtures
0.001
0.053 4
Optimize fixture weight to reduce heat loss
0.50 5
Maintaining furnace temperature 700O C on Weekly Off days 6
Single pilot flame with flame sensor for burning exhaust gases of furnaces 7
Paint Shop MCD
Provided Low temperature degreasing chemicals.Paint shop 8
Reduced Meri oven cycle time. 3.0 Hrs/ Cycle
0.006
0.318 9
Heat Treatment
Less process time for mm Case depth of KTM Gear - Shaving route
0.002
0.106 10
Cleaning of PTCED Loading rods in shot blasting 11
Use burners Flue gases for heating dryer.
0.0771
4.0863
4.5

43. Use of Renewable Energy
Installation of transparent roofs
in dispatch yard
Solar water Heating System
Make up water is heated by Solar water heating system which reduces load on LPG water heater
Transparent roofs-
Qty: 78 No.s
LPG Saving : 3396 Kg / Year
Saving : Rs.1.4 Lacs / Year
Investment : Rs. 5 Lacs
Saving : Rs. 4 Lacs / Year
Investment : Rs Lacs

44. Use of Renewable Energy
Reflective system
Solar Lighting – Use of Light Pipes in assembly
Light Collector
& diffuser
Roof Installation
Light Pipe Size
Eqv. Wattage
Light out Put
Area Coverage
Energy Saving
Investment
Carbon reduction
530 Mm
300 Watts
4000 Lux
500 Sq Ft
1100 Kwh/Year
0.21 Lacs
0.88 Ton/Year
Horizontal Deployment : 25

45. Use of Renewable Energy
Generation of Electrical Energy with Windmill Power Project
At SATARA & SUPA area in Maharashtra Wind mills are installed
for Electrical Power Generation.
Target
Year
Installed Capacity
Wind power Generated
Waluj Plant consumption
Wind Power adjusted
Contribution
Equiv. CO2 emission reduction
(MW)
( L kwh) %
Tons 65
949
573.48
239.28 41
19142
1076
589.86
268.68 45
21494
888
540.7
260.68 48
20854

46. Use of Renewable Energy
Solar Photo Voltaic Power Plant -20 Kw Installed at Bal Waluj
Capacity
20 kWp Grid Connected Solar Power Plant
Location
Roof compressor House -8
Area Utilised
240 M2
No. of Solar Panel 72
Solar Module
280 watts each
Solar Chip
Polycrystelline
Solar Moduel Make
Lanco
DC voltage
720 Volt
Invertor Make
Refu
Invertor Model
Refusol
Invertor capacity
19.2 Kva
Invertor Output
3 Phase/415 V /50 Hz
Power generation
90 Kwh/day ( Avg) / Kwh/Year
Supplied By
M/s Lanco Solar Energy Pvt Ltd.
Commissioning by

47. Use of Renewable Energy Solar Photo voltaic Power Plant- 20 Kw
Future Projects :
Rooftop Solar Power Plant Up to 10 MW
Open access Power trading

48. Summary of ENCON projects
Year of Implementation
No. of Projects
Savings
Rs. Million
Investment* 36
5.5
3.6 35
10.5
7.9 21
13.21
12.58 44
17.35
22.2
Grand Total
136
46.56
46.28

49. Electrical Energy Consumption / Vehicle
Result
Electrical Energy Consumption / Vehicle
Kwh/Veh
69 %
Energy
Unit
Base Year
Achieved
Target
Electricity
Kwh/
veh
67.54
49.31
45.81
42.99
36.72
34.9
31.45
25.41
22.61
21.15
19.0

50. Thermal Energy Consumption / Vehicle
Result
Thermal Energy Consumption / Vehicle
Kg/Veh
48 %
Energy
Unit
Base Year
Achieved
Target
LPG
Kg / veh
2.53
2.75
2.4
2.8
2.2
2.1
1.77
1.45
1.3
1.17

51. Water Consumption / vehicle
Result
Water Consumption / vehicle
69 %
Energy
Unit
Base Year
Achieved
Target
Water
m3 / veh
0.89
0.65
0.62
0.58
0.54
0.52
0.41
0.35
0.27
0.20

52. SUSTENANCE Sustenance Activities
Loss Identification& Corrective actions
Monitoring & Measurement
Audits
Review
Technology
Up gradation
Education & Training
HD of Kaizen
Regular Shop Audit
by Energy Captains
Daily/Monthly
Electrical Energy
Internal
Audits
Daily
Review by
Div Head
Adoption of
Energy efficient
Technology for
Manufacturing,
Monitoring
Energy
Managers
Training
Implement
ENCON project
Daily/Monthly
LPG
External
Audits
Leakage
Identification
Daily/
Weekly
Review by
Plant Head
Energy
Captains
Training
HD of
ENCON project
in other shops.
Plant, Vendors
Daily/Monthly
Water
Consumption
Data Analysis
Group
Leaders
Training
Daily/Monthly
Fuel
Energy Index
Review by
Corporate
Vendor
Training
EMS

53. Energy consumption monitoring & Measurement
SCADA
300 Electrical Energy Meters
Monitoring up to shop Feeder
10 LPG Flow Meters
Monitoring up to Oven
10 Air Flow meters
Monitoring up to shop
55 Water meters
Monitoring up to shop

54. Energy consumption monitoring & Measurement

55. Energy consumption monitoring & Measurement

56. Monitoring and Reporting system
External Audit
Sr.
Year
Audit for
Projects ( Nos. )
Saving Potential
Status 1
2008
Electrical, Thermal 21
20 L kwh
17 L kwh 2
2011
Compressed Air 3
6.5 L Kwh
5.5 L KWh
Water system
1500 Cub m/day
1500 Cub.M. /d 4
2012
Power System- PF & Harmonics 8
1.2 L Kwh
0.8 L Kwh 5
Process Pumps & Motors 10
2.7 L Kwh
WIP 6
Thermal - Thermography for Ovens 7
63456K Cal
Compressed Air System
7 L Kwh
Compressed Air Leakages
6 L KWh
3 L KWh 9
2013
Chillers
2.62 L Kwh

57. Awareness creation Awareness through communication Energy Captains
5 Axis Training
Latest Technology
Training
Kaizen
Appreciation
Event
Competition
Monthly Kaizen
Karakuri
State & National level
Small Group Activity
Karakuri
Engineering Kaizen
Managerial Kaizen
Energy Boards at shop
ENCON week
Poster display
Energy Seminar
New Product display
Best Kaizen Award
Best Energy Captain
Energy Efficient Shop

58. Awareness creation Energy Conservation Week - 14th-20th Dec
Celebration of Energy conservation day-14th Dec -12
Energy Conservation Week - 14th-20th Dec
Energy Efficient product display for vendors
Participant on Energy Day

59. Awareness creation Kaizen matrix
Sr.
Loss
Elimination
Alternate
source
Efficient
Equipment
Operational Control
Total 1
Machining 15 2 14 5 36
Paint 23 4 3 45
Press & Fab. 16 12 7
Assembly 19
Utility 18 46 89 9 62 22
182
Kaizen Ideas generated & implementation through our 105 Energy Captains

60. Environment Improvement
Environment & carbon Reduction

61. Water Conservation Scenario - Water Consumption at Waluj:
Production Up
by 55 %
Water consumption Down
by 44 %
Recharging of Ground Water
Constructed Recharging of Ground Water : 2190 Cu. Mtr  / Day

62. Stratification of Water consumption
Sr.
Water
Industrial cooling
Process
Domestic 1
Water consumption - % 7 59 34

63. Reduction of Water Consumption Per Vehicle
ENCON Idea Table
Reduction of Water Consumption Per Vehicle
Sr.no
Approach
Idea 1
Eliminate wastages
Optimization of network & eliminate water
leakages from supply lines
Use of one Touch Tap orifice ( 4mm ) for
domestic water taps .
Localized water tanks for shops 2
Reuse of waste water
Use of treated water for horticulture .
Use of Treated water with UF & RO for process. 3
Use of Rain Water
Storage in water harvesting ponds.
Ground recharging with rain water .

64. Media Publications
Unicef Report

65. Media Publications

66. Media Publications
Sakal

67. Media Publications

68. Environment Improvement
List of major environmental improvements
Sr No.
Environment Improvement 1
No water is discharged outside the company. 2
Tree Plantation by all employees in plant – 4500 Plants 3
Rain water harvesting pond capacity increased to Cub Mtr 4
Implementing E-waste norms prescribed by MPCB. 5
Ground water recharging with rain water (Patented with KEDIA FARM PATTERN) by deep percolation technique. Capacity -8 L kL 6
100 % recycling of Industrial effluent by Installation of RO + UF Plant of capacity 1000 M3 / day. This being used for process. 7
Reduce consumption of packaging material by 35 % (Polythene bags, corrugated boxes) in last 7 years. No packaging materials for transporting material from vendors 8
Effluent treatment plant (ETP) has been upgraded to separate industrial & domestic effluent resulting in better quality of treated water.

69. Recycling -Sustainable Development
Water Conservation
Recycling -Sustainable Development
Theme
Reduce Water consumption by recycling the water for processes
Before
After
Treated water was used only for Horticulture activities.
Treated water is recycled through RO plant and used for processes.
RO Plant
Effluent
Effluent Treatment Plant
Use for Horticulture
Use for Process
Investment
Rs.3.0 Cr
Qty
2 Nos.
Water Saving / Day
700 Cu. Mtr.

70. Recycling -Sustainable Development
Water Conservation
Rain Water Harvesting
Recycling -Sustainable Development
Rain water Pond of Capacity enhanced to M3
FY 12-13
FY 13-14
Investment
Rs.12 Lacs
Qty 1
Water Storage Capacity
10000 Cu. Mtr.
Investment
Rs. 24 Lacs
Qty 1
Water Storage Capacity
10000 Cu. Mtr.

71. Recycling -Sustainable Development
Water Conservation
Ground Water Recharge
Recycling -Sustainable Development
FY 12-13
FY 13-14
Investment
Rs.15 Lacs
Qty (KFP)
50 Nos.
Water Recharging / year
1.5 Lac KL
Investment
Rs.36 Lacs
Qty (KFP)
160 Nos.
Water Recharging / year
8.0 Lac KL

72. Water Conservation 6 8

73. Waste Heat Recovery System installed at
Waste utilization
Heat recovery from waste flue gases at Low Temperature are installed in Paint shops SN
Waste Heat Recovery System installed at
LPG Saving Kg/Year
Investment
( Rs. Lacs) 1
Paint shop ED oven exhaust
26100
9.75 2
HWG Aquatherm PTCED Exhaust
10416
5.5 3
HWG Aquatherm Paint shop Exhaust 4
PTCED line Oven Exhaust
38626 9 5
Paint shop Exhaust Oven- 4 Locations
37135
12.5

74. LPG GAS USED FOR CANTEEN
Waste utilization
Use of Bio Gas Plant in Canteen
Before
After
LPG GAS USED FOR CANTEEN
Saving – 22 Kg /day LPG
Saving = Rs 2.6 Lacs/ Annum

75. Reuse of Quenching Salt Kulfi Pots for salt collection
Waste utilization
Reuse of Quenching Salt
Heat treatment
Before
After
Washer
Salt water inlet
from Shop
components
Hot water
Salt +water
Burner
To ETP.
Kulfi Pots for salt collection
Weekly Draining to ETP.
No provision of Salt recovery
Wastage of Quenching Salt
during Washing of components.
Salt recovery by evaporation of water.
Investment – Rs. 35 Lacs

76. Re-Use of Waste Packing Material
Waste utilization
Waste Paper recycle
Re-Use of Waste Packing Material

77. Carbon Reduction
Summary - Reduction in Carbon Emission / veh (Kgs.) :
19 %
Reduction in Carbon Emission –Total

78. Tree for Carbon Mapping : Logistic
Carbon Reduction
Tree for Carbon Mapping : Logistic
Carbon Mapping
Internal
External
Movement
Testing
Employee Transportation
Vehicle Distribution
Material Handling
Vehicle Shifting
Engine
Vehicle
Vendor Part movement
Under Company’s Control
Fuel Consumption Reduction
Distance Reduction

79. Idea Tree : Reduction of Carbon Emissions
Carbon Reduction
Idea Tree : Reduction of Carbon Emissions
Carbon Emission From
Internal Logistics
External Logistics
Sr.
Idea 1
Optimize Route 2
Reduce No. of Trips 3
Eliminate Movements 4
Eliminate Multi-handling 5
Use of Alternate equipment ( e g. Use of BOPT ) 6
Use of Belt for material movement
Sr.
Idea 1
Optimize Route 2
Increase Loadability 3
Increase occupancy 4
Milk Run Route 5
Reduce distance ( bring vendor near to BAL) 6
Increase vehicle cube capacity

80. Carbon Reduction through - Logistics Improvement
M/s. BAL & M/s. Skoda Joint Initiative

81. Import Export Carbon Reduction Before Condition Container flow for
SKODA
JNPT PORT
Skoda
JNPT PORT
Filled Container
Empty Container
Export
Container
flow for
Bajaj Auto
JNPT PORT
BAL
JNPT PORT
Empty Container
Filled Container

82. Trip Distance Reduction - Container Transport
Carbon Reduction
Trip Distance Reduction - Container Transport
After Condition
JNPT PORT
Skoda
BAL
JNPT PORT
Filled Container
Empty Container
Filled Container

83. Carbon Reduction through Logistics Improvement
Trip Distance Reduction - Container Transport
Carbon Reduction through Logistics Improvement
Saving in travelling Distance per Trip
Net reduction in Diesel per Trip
Total Carbon Reduction per Trip
No. of Trips per Year
960 Km
192 Lit.
509 Kg.
3600 Nos.
1832 Tons / Year
Net Carbon Reduction
Next objective – Explore use of import containers from local industries

84. Promoting Renewed Partnership
Methodology - Implementation of ENCON initiatives at
Vendor’s end
Formation of Vendor TPM Cell
Inputs to Vendor on TPM Philosophy
Handholding on
Loss Reduction
(16 type of Losses)
Practical Training at Learning Centre - BAL
Help to Identify Improvement Projects
Promoting Renewed Partnership
Appreciate the Improvements
Sharing of Improvements across the Bajaj Auto Vendor Association
Consultation from Company Experts for Implementation

85. Implementation of ENCON initiatives at Vendor’s endSr
Name of vendor
Product
Per unit Energy consumed
% improvement
Inputs / projects provided to the vendor/ associate
Before
After 1
M/s Duro valve (I) Pvt Ltd, Aurangabad
Valves production
0.20Kwh/ Valve
0.17Kwh/Val ve
33 %
Training , Visit to our plant , Help in Energy Audit & Implementation of projects 2
M/s Badve Engineering Unit 2, Aurangabad
Silencer production
3.6Kwh/Sile ncer
3.3 Kwh/ Silencer
8.33 %
Training , Visit to our plant , Waste elimination, Timed control operation 3
M/s Varroc Polymers Pvt Ltd. Pl. 2
Mirror production
0.32 Kwh/Unit
Kwh/Unit
37.5 %
Training , Visit to our plant , Waste elimination, Renewable energy usages, Efficient equipments , Optimized heat utilization.
Similar ENCON projects (453) are implemented across 58 Vendors. In last one year .Average % improvement achieved is 17 %

86. Saving Potential (Rs./year)
Future Projects
Sr. no.
Shop Name
Description
Electrical
Thermal LPG
Saving Potential (Rs./year)
Investment to be made
Lkwh/ Year
Ton/ year
LRs. /Year
Rs Lacs
Loss reduction 1
Utility
Transmission loss reduction by switch off standby transformer
2.2
15.42
5.20 2
Loss reduction by Power Factor Improvement
2.1
14.72
15.00 3
Elimination of compressed air leakages through cell wise shutoff valves & replcement of fittings type . 6
42.06
25.00
Lighting/cooling 4
Utilities
Induction Lighting for shops nos
21.03
49.00 5
Installation of LED lights for Offices & shops
14.02
30.00
All Shops
Installation of transparrent roof sheets for Shops
0.21
1.47
12.00 7
Machine shops
Installation of Occupancy sensors for Shop work places
0.5
3.51
3.00 8
Office
Roof top garden for reduction of temperature inside offices by 10 deg c
1.2
8.41
7.50 9
All shops
Installation Of Breez air cooling system in place of ARP
0.72
5.05
13.50 10
Installation of Galvalume sheeting with insulation for temperature reduction by 3 Deg c
7.01
20.00 11
Paint shop
Installation of Water cooled scrol chiller for paint shop -60 TR
1.1
7.71
18.50
Method Change 12
Machine shop
Use of Heat pumps for Washing machine water heating
0.66
4.63
Pumps /AHU 13
Installation of energy efficient pumps for coolant system ( downsizining) -3 Nos.
1.89
13.25
18.00 14
Paint Shops
Installation of VFD s for air handeling system
0.12
0.84
4.50 15
Installation of energy efficient pumps- 15 no.
0.9
6.31 16
Installation of energy efficient motors- 7 no.
0.42
2.94
6.00
Renewable Energy
0.00 17
Installation of off grid solar power system-100 Kwp( Upto 10 MW)
1.5
10.52
80.00 18
Solar Air conditioners unit ( 30 TR)
1.57
11.01
63.00

87. Saving Potential (Rs./year)
Future Projects
Sr. no.
Shop Name
Description
Electrical
Thermal LPG
Saving Potential (Rs./year)
Investment to be made
Lkwh/ Year
Ton/ year
LRs. /Year
Rs Lacs
Thermal 19
Paint shop/Heat treatment
Magnetic Resonanse for LPG lines for improving combustion 1
0.65
2.00 20
Heat tretment
Installtion of heat recovery for system for washing stage water heating 4
2.6
3.00 21
PTCED
Direct heating for phosphate tank 2
1.3
12.00
Air & Chillers 22
Utilities
Variale speed compressor -NIRVAN- 2 Nos. 1000CFM in place of Reciprocating compressors
6.6
36.3
48.00 23
Installation of scroll compresor air dryers for compressed air -2 Nos.
0.5
2.75
6.00 24
MCD shop
Use of Air boosters for high pressure compressed air instead of localised compressors -2 No.
0.45
2.25
34.64 7
235.8
465.7
Total Projets : 24 No.s
Total Saving Expected : 235 Lakhs
Total Investment Expected : 465 Lakhs

88. CII- Efficient Unit Award 2012
Awards & Accolades
CII- Efficient Unit Award 2012
CII- Excellent Energy Efficient Unit Award 2013

89. MEDA- Excellence in Energy Conservation & Management Award 2012
Awards & Accolades
MEDA- Excellence in Energy Conservation & Management Award 2012

90. Awards & Accolades Sr Year Award Agency 1 2013
Excellent energy efficient unit award at National Level
CII- GBC 2
2012
State Level award for Excellence in Energy conservation & Management
MEDA 3
Energy Efficient unit award at National Level 4
Green Manufacturing Excellence Award –Challenger category
Frost & Sullivan 5
2009 6
2008 7
Excellent water efficient unit award at National level 8
2007 9
2006 10 11
CII-GBC 12
2005 13 14
2004 15
2003/2004

91. Thanks Conserve for Today… Preserve for Tomorrow….
Reserve for future Generation….Also
Reduce Reuse Recycle
Thanks