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

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

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

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.

Approach for Improvement Key Management Index Company Vision TPM Key Performance Index Company Mission Key Activity Index ISO 9001 ISO 14001 OHSAS 18001 ISO 50001- Initiated

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 - 1840 nos.

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

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

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

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

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 2010 -2015 Technology Up gradations Energy Optimization System Auto controls Waste Minimization 2002-2009 Energy Conservation Techniques- Localized control Human Dependent systems 1998-2001 Working on Legacy system 1985-1997 Year

Specific Energy Consumption Energy Consumption per unit of production Energy Unit Base Year Achieved Target 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 2013-14 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%

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

Stratification of Energy consumption Electrical Energy consumption LPG Energy consumption

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

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

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

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

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

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

Innovative projects

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

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

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.

Reduction of Inductive load losses Innovative Project -2

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 75 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

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

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

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

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

Electrical- Lighting Sr. Phase 1 Phase 2 Before After Street Light 300 Watt SV lamps 650 No.s Lamps Connected Load – 195 Kw Consumption 7.11 L Kwh/Yr 150 Watt CFL lamps Connected Load – 97.5 Kw Consumption 3.55 L Kwh/Yr 72 Watts LED lamps 80 Nos. Lamps Connected Load – 5.76 Kw Consumption -0.21 L kwh/Yr Energy saving : 3.56 L Kwh /Yr : Rs.24.95L/Yr Investment : Rs.12.6 Lacs Energy saving : 0.23 L Kwh /Yr : Rs.1.61 L/Yr Investment : Rs.8.0 Lacs

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- 4.24 L Kwh/Yr 156 watts Induction lamps 302 Nos. Lamps Connected Load – 47.0 Kw Consumption- 1.13 L Kwh/Yr 120 W LED High bay lamps – Under trials Energy saving : 3.12 L Kwh /Yr : Rs.21.87 L/Yr Investment : Rs. 31.71 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. 9.18 Lacs Saving : 0.43 L Kwh /Yr Rs. 3 Lacs Investment : 8 Lacs

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. 2.5 lacs

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 : 1.28 Lac kwh/Yr. Investment : Rs.16 lacs

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. 13.28 Lacs/Yr Investment : Rs.26 Lacs Energy Saving : Rs. 2.27 Lacs/Yr Investment : Rs. 2.68 Lacs Horizontal deployment – 3 Locations

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. 0.56 Lacs / Yr Investment : Rs. 0.78 Lacs Horizontal deployment : 5 Saving : 0.35 Lacs Kwh/Year Rs. 2.45 Lacs Investment :Rs. 4.3 Lacs Horizontal deployment : 2

Electrical- Compressed air Sr. Phase 1 Phase 2 Before After Compressed air Reciprocating compressors are running in central compressor houses. @ 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

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 : 0.1 Lacs kwh/Yr. Investment : Zero

Electrical- Cooling Energy Efficient equipment installation Before After Air Dryers -5000 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

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

Total Identified Points – 24 Heat Loss- 63456 K Cal /Hr Thermal Total Identified Points – 24 Heat Loss- 63456 K Cal /Hr Rectified Insulation of High heat Zone Saving - 27 Ton LPG /Year We have conducted Thermal Imaging for identifying heat losses in paint ovens

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.- 3.7 Kg/Hanger 2012-13 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 0.45 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

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. 3.12 Lacs

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

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 2010-11 65 949 573.48 239.28 41 19142 2011-12 1076 589.86 268.68 45 21494 2012-13 888 540.7 260.68 48 20854

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) / 32850 Kwh/Year Supplied By M/s Lanco Solar Energy Pvt Ltd. Commissioning by

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

Summary of ENCON projects Year of Implementation No. of Projects Savings Rs. Million Investment* 2009-2010 36 5.5 3.6 2010-2011 35 10.5 7.9 2011-2012 21 13.21 12.58 2012-2013 44 17.35 22.2 Grand Total 136 46.56 46.28

Electrical Energy Consumption / Vehicle Result Electrical Energy Consumption / Vehicle Kwh/Veh 69 % Energy Unit Base Year Achieved Target 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 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

Thermal Energy Consumption / Vehicle Result Thermal Energy Consumption / Vehicle Kg/Veh 48 % Energy Unit Base Year Achieved Target 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 LPG Kg / veh 2.53 2.75 2.4 2.8 2.2 2.1 1.77 1.45 1.3 1.17

Water Consumption / vehicle Result Water Consumption / vehicle 69 % Energy Unit Base Year Achieved Target 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 2013-14 Water m3 / veh 0.89 0.65 0.62 0.58 0.54 0.52 0.41 0.35 0.27 0.20

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

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

Energy consumption monitoring & Measurement

Energy consumption monitoring & Measurement

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

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

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

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

Environment Improvement Environment & carbon Reduction

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

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

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 .

Media Publications Unicef Report

Media Publications

Media Publications Sakal

Media Publications

Environment Improvement List of major environmental improvements 2012-13 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 10000 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.

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.

Recycling -Sustainable Development Water Conservation Rain Water Harvesting Recycling -Sustainable Development Rain water Pond of Capacity enhanced to 10000 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.

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

Water Conservation 6 8

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

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

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

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

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

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

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

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

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

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

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

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

Implementation of ENCON initiatives at Vendor’s end Sr 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 0.0.2 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 %

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 - 490 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

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

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

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

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

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