CII Green Co Best practices Award 2016 · CII Green Co Best practices Award 2016. ... this policy...

KIRLOSKAR OIL ENGINES LIMITEDKIRLOSKAR OIL ENGINES LIMITED 1

Kirloskar Oil Engines Ltd, Kagal (Kolhapur)Kirloskar Oil Engines Ltd, Kagal (Kolhapur)

CII Green Co Best practices Award 2016

KIRLOSKAR OIL ENGINES LIMITED

Presentation Team.

2

• Sr. Manager

• Utilities.

Mr. Santosh Parab

• Dy. Manager

• Manufacturing.

Mr. Akshay Goud


About Kirloskar Oil Engines Ltd

Manufacturing Plants : Kagal (Kolhapur), Khadki (Pune), Nasik & Rajkot

� Total Employees as on date

- 1181

� Managers ( TL, GL & UL)

- 191

� Operators (Team Associates)

- 990

Initiatives

5S

QMS, EMS & OHSAS

ENCON

Kaizen & POKA YOKE

Autonomous Maintenance

Six Sigma, QC Activities

Standardized Work

TPS

Kagal ( Kolhapur ) Plant �

3

KIRLOSKAR OIL ENGINES LIMITEDKIRLOSKAR OIL ENGINES LIMITED 4

VALUES and VISION

KIRLOSKAR OIL ENGINES LTD., KAGALKIRLOSKAR OIL ENGINES LTD., KAGAL

Machining Lines

Cam Shaft

Connecting Rod

Crank Case

Cylinder Head

Crank Shaft

Engine Assembly

Engine

Dispatch

Manufacturing Process

Receive Bought out

finished components

Storage

Storage

Engine

Test

Engine

Paint

Engine

Up fitment

520-Jun-16

KIRLOSKAR OIL ENGINES LTD., KAGALKIRLOSKAR OIL ENGINES LTD., KAGAL 6

GreenCo – “Gold” Certified Plant


GreenCo – “Gold” Certified Plant

7

KIRLOSKAR OIL ENGINES LIMITED 8

IGBC – “Gold” Certified Building


IGBC – “Gold” Certified Building.


Greenco Journey.

• On Line Registration for Green co 14 June-14

• Formation of 28 people Cross-functional TeamJun-14

• Training from CII Team (Handholding) Jul-14

• Presentations sent to CII for Review . (Handholding)

Dec-14

• Working on Feedbacks & Resubmission (Handholding)

Jan -15

• Finalization of Presentation & Sharing to CIIFeb-15 & Mar-15

• Final On-Site AssessmentApril-15

• Greenco Gold AwardJune -15

KIRLOSKAR OIL ENGINES LIMITED20-Jun-16 11

Environmental Management System at KOEL Kagal



Quality, Environmental, Occupational Health and Safety ( QEHS ) PolicyWe, at Kirloskar Oil Engines Limited (KOEL), are engaged in Manufacturing of I.C. Engines , Generating

Sets and Pumpsets. We strongly believe that , it is the duty of everyone working in KOEL to implement

this policy this area of activities.

We are committed to :• Cost effective research, engineering development, manufacture, sales, services of products and

technologies and meetings the fullest satisfaction of our customers at the lowest possible cost to them by

complying with requirements.

• Continually improve the effectiveness of the Integrated management system.

• Comply with all applicable EHS legislation and other requirements.

• Prevent environmental pollution due to our activities, products and services.

• Prevent injuries and ill health in our activities at workplace.

We will strive to :• Conserve resources such as power, water, fuel, oil, compressed air and wood.

• Minimise use and adverse impact of hazardous chemicals handled.

• Minimise generation and adverse impact of hazardous waste.

We will communicate this policy to our employees & contractors & make it available to public interested

parties on request.

R. R. Deshpande

Date : 01 April 2014 Executive Director & Occupier

Green Policy


Specific Energy And Water Consumption

• Reduce by 3-5% every year over next ten years.

Specific Generation Of Waste & Waste Going To

Land Fills

• Reduce by 3-5% every year over next ten years

Use Of Renewables Energy

• Increase by 5% every year over next ten years.

GHG Emissions And Other Process Emissions

• Reduce by 3-5% every year over next ten years

Recyclable And Enhance Recyclability Of Resources

• Increase use of resources embedded in the

product.

Share Of Harvested Rainwater In The Overall

Annual Use Of Water

• Increase by 5% every year over next ten years

Life Cycle Assessment Criteria For New Products.

• Incorporate Life Cycle Assessment in alternative

technologies and products.

Adopt Green Purchase Policy

• Adopt Green Purchase policy & incorporate clean

technologies at design stage

Product Stewardship Program

• Promoting and managing Product Stewardship

Program, By forging partnership with business and

communities.

Depletion Of Natural Capital

• Reduce by 5% every year over next ten years

KOEL adopted CII program Mission for Sustainable Growth - 2007


Leadership & Strategy

Balance Score Card

Strategic Deployment Matrix

Plant Level Goals

Departmental Goals

Key Projects

Individual Goals


Sustenance

Critical to Quality

Cost of Poor Quality

Small Improvements

Six Sigma Projects/ VA VE

Quality cle projects

7 QC Projects

Kaizen and 5s

improvements projects

High Cost Areas




Reduce & Recycle

Raw Material VAVEPlant Conversion

Cost

Plant Conversion

CostCOPQ

• Foot Elimination.

• Drain Cock

Elimination.

• Rain Cap Elimination.

• Wooden Box

Elimination.

• Acc. Box size

Reduction

• Flywheel Weight Reduction.

• Integral Crankshaft.

• Crankcase Weight Reduction.

• Implementation Of

Aluminium Header, Rocker

Cover & Inlet Manifold.

• Reduction In Loctite

Consumption .

• Reduction In Diesel

Consumption.

• Reduction In Oil

Consumption.

• Use Of Water Base Chemical

instead Of Coolant.

• Reduction In Consumption

of Napkin.

• Reduction In Consumption

of Hand Gloves.

• Air Cleaner.

• Starter & Alternator.

• Air Guide Ring.

• Breather Pipe.

• Lube Oil Cooler.

• Turbocharger.

• Gear Casing.

• Lifting Hook.

• Fan body, Stator,

Impeller.

• Lube oil pressure

Sendor.

Key Projects


Presenting TodayW

eig

ht

Re

du

ctio

n • Crankcase

• Crankshaft

• Structural Steel

Wa

ste

Re

du

ctio

n • Joint sealant

Re

cycl

ing • Coolant

• Oil

• Packing

17


Weight Reduction

20-Jun-16 18

Greenco Best Practice


Weight reduction of Crank Case (VAVE) . Microsoft Excel

97-2003 Worksheet

Average weight of flat face

crank case was approx. 107

Kg.

VAVE crank case introduced

& Weight reduced up to 88

Kg.

Reduction in specific raw material consumption.


4990.5

4104.3

5239.8

4309.44180.1

3437.8

0.0

1000.0

2000.0

3000.0

4000.0

5000.0

6000.0

Before After Before After Before After

11-12 12-13 13-14

In T

on

sReduction in specific raw material consumption.


Crank shaft with balance

weight used for Power

Generation Engine series.

Integral Crank shaft

introduced for all PG

Engine series.



306.0

271.6

608.8

540.3

581.7

516.2

0.0

100.0

200.0

300.0

400.0

500.0

600.0

700.0

Plan Actual Plan Actual Plan Actual

12-13 13-14 14-15

In T

on

sReduction in specific raw material consumption.


EPI Building 165 m x 210 m : Structural

steel excluding gantry girder for crane

consumed was 2740 MT. it’s a 49% of

construction cost. Structural steel

consumption 7.35 kg/sq. ft.

EPII Building 125m x 180 m : Structural steel

consumed is 1167 MT. Structural steel

consumption 4.82 kg/Sq. ft. It’s a 35.7% of

construction cost.

Before After


KIRLOSKAR OIL ENGINES LIMITEDKIRLOSKAR OIL ENGINES LIMITED20-Jun-16 24

Sr. no Description Crankcase Crankshaft Structural Steel

1 Methodology adopted VE VE Pre-Engineering

a What is result of senario creation

To reduce the weight of

Crankcase by reducing

Machined surface on Crankcase

To reduce the weight of

crankshaft by eliminating the

balance weight and making it

integral with the crankshaft

Reduction in structural Steel.

b How was it concieved

CFT meetings, DOE s,

Performance testing ,

Endurance testing and quality

parameter testing

CFT meetings, DOE s,

Performance testing ,

Endurance testing and quality

parameter testing

Analysis of different options,

Stability analysis, CFT, Virtual

Modelling

cOrganisation level at which the

seeding was done

Project mentioned under KRA in

the Balace score card at

Department level

Project mentioned under KRA

in the Balace score card at

Department level

Utilities Engineering

Managers

d

Was there any experimentation

prior to giving the shape to the

project etc

•Experimentation was done on

peripheral components except

5C critical components (

Crankcase, Crankshaft , Conrod ,

Cylinder Head and Camshaft)

•Experimentation was done

on peripheral components

except 5C critical

components ( Crankcase,

Crankshaft , Conrod , Cylinder

Head and Camshaft)

Site visits and virtual

modelling.

Weight reduction


Weight reduction


2What triggered the organization in

taking up the projectRM cost reduction RM cost reduction Project cost

3Why is the project unique

/innovative?

Challenging the quality

parameters and performance

parameters

Challenging the quality

parameters and performance

parameters

Structural & Reinforced steel

reduction maintaining the

required strength

4People Involvement in project

implementation

Sourcing , CRE , Supplier ,

Material s Production ,

Application Engineering QA , M E

& Maintainence CFT

Sourcing , CRE , Supplier ,


Application Engineering QA ,

M E & Maintainence CFT

Architects, Structural

Engineers/consultants, Civil

Engineers, Finance managers,

Manufacturing engineering

managers

a

·levels of participation, frequency of review/ evaluation, record of learning’s/

•Sourcing , CRE , Supplier ,


Application Engineering QA , M E

& Maintenance CFT

•Sourcing , CRE , Supplier ,


Application Engineering QA ,

M E & Maintenance CFT

Daily meetings, weekly

reviews, Minutes of metings.


Weight reduction


5

Challenges faced during

implementation of the project and

how they have been resolved

a ·Technical Challenges

Challenge to reduce weight

without detiorating the quality

parameters at same time

improving the performance ot

he engine

Challenge to reduce weight

without detiorating the

quality parameters at same

time improving the

performance ot he engine

Ensure required strength is

maintained

b ·Administrative Challenges To manage Smooth changeover

model wise proto

productionisation

To manage Smooth

changeover model wise

proto productionisation

Legal agreements, Work

permits.

c ·Maintenance Challenges Program modification for all

models on Crankcase line

Machine modification at The

machine shop for

accumulating the integral

model in SPM from Japan

Roof Access for maintenance

6Replication potential within the

sector or in different sectors

Horizontally deployment

started in High HP ( 6R, HA6)

engines and Low HP engines (

Varsha and E Series)

Horizontally deployment

started in High HP ( 6R, HA6)

engines and Low HP engines (

Varsha and E Series)

Replication for upcoming

sheds is in process.


Sr.

noDescription Crankcase Crankshaft Structural Steel

8Tangible benefits & Intangible

benefits achieved

aInvestment made & annual

monetary savings achieved

•Cost saving achieved of Rs

16.84 cr. for crankcase

•Cost saving achieved of

Rs2.5 Cr. for Crankshaft34 Cr. Invested. 1.6 Cr. Saved

bRaw material saving,

environmental benefits, 3241 tons 255 tons

1573 tons of Steel saved,

Aesthetically pleasing, less

obstruction for roof

lightings,

Weight reduction


Waste reduction

20-Jun-16 28



Waste reduction of hazardous Joint

Sealant.


A .Reduce Wastages.

1.By Eliminating purging cycle.

2.By eliminating Excess Wastage

in Locktite Bucket.

B .Optimization By Six sigma Method

1.Reducing Bid size .

2.Converting Manual Application

Method to Machine.

Reduction in Wastages.


A.REDUCING WASTAGE

1.Purging cycle

elimination

2.Bucket Waste

elimination

Purging cycle: 8.5

gms. Sealant

wastage per

engine

Eliminated

purging cycle

Use of thin sheet

< 1 mm Causes

3Kgs wastage of

Loctite 5060 per

bucket

Sealant wastage

reduced using

thick sheet 3 mm

thickness.

Reduction in Sealant Wastages.


B. By Six Sigma Optimization Method.B. By Six Sigma Optimization Method.

1.Optimization of

Loctite bid size by Six

sigma methodology

2.Optimization of

by modification of

application method

4 mm Loctite

bid size

2.5 mm

Loctite bid

size

Loctite

dispensed

Manually

Loctite

dispensing by

CNC machine



C. Converting Manual Application Method to Machine

Fixture for machine

dispensing Loctite bid after

dispensing on

machine

Loctite Dispensing

at machine

Hydraulic plate Loctite dispensing at Lube oil sump

machine for FIP cover



Hydraulic plate Loctite dispensing at Front cover

machine For Hydraulic plate

Fixture for machine

dispensing Loctite bid after

dispensing on

machine

Loctite Dispensing

at machine

C. Converting Manual Application Method to Machine



1620

665.4

1380

450.6

2060

231

2100

161

0

500

1000

1500

2000

2500

Loctite

bucket

Loctite

cartridge

Loctite

bucket

Loctite

cartridge

Loctite

bucket

Loctite

cartridge

Loctite

bucket

Loctite

cartridge

10-11 11-12 12-13 13-14

20-Jun-16 35

Loctite saving.

In above graph You can see the trend of Loctite cartridge Consumption has been

reduced( Rs 4/gram. ) and Loctite bucket is being increasing( Rs 2/gram. ) due to

Converting manual method of Loctite application by CNC Machine application



Waste reduction

20-Jun-16 36

Sr. no Description Sealant waste reduction1 Methodology adopted Six Sigma methodology

a What is result of senario creationAmazed with savings achieved after the senario creation and the

amount of hazardous material wastage saved

b How was it concieved DMAIC , USE of DOE

cOrganisation level at which the seeding

was done

Project mentioned under KRA in the Balace score card at

Department level

dWas there any experimentation prior to

giving the shape to the project etc

Experimentation was only done with the pump pressure and air

pressure but the results did not sustain so we went for design

change of the needle for getting consistency in the bid size

2What triggered the organization in taking

up the projectPlant conversion cost reduction

3 Why is the project unique /innovative?

This project is unique because we challenged the deign of

machine ,Why bid size cannot be reduced further and why the

wastages cannot be arrested and found solution for all


Waste reduction

Sr. no Description Sealant waste reduction

4 People Involvement in project implementation TA to Department head

a·levels of participation, frequency of review/ evaluation, record of learning’s/

Kaizens, 5s improvemnts,QC and Six sigma participation and KRA

for the department head for the improvement right from TA till

Unit HOD

Frequency of review was on weekly basis

5Challenges faced during implementation of the project and how

they have been resolved

a ·Technical Challenges Challenge faced with machine maker for reduction of inner dia

of the needle size

b ·Administrative Challenges To take trials and implement new settings without disturbing the

product quality

c ·Maintenance Challenges Maintenance for reduction of Bid size with optimal pressure

settings

6 Replication potential within the sector or in different sectorsPlant wide implementation for all machines used for dispensing

the Sealant


Waste reduction

20-Jun-16 38

Sr. no Description Sealant waste reduction

7How the project helped in achieving

National/International Benchmarks

The bid size used in other industries is also upto 2.5

mm we have challenged it upto 1.8 mm but didn’t

get satisfactory results at 1.8 mm for all

applications.

8 Tangible benefits & Intangible benefits achieved

aInvestment made & annual monetary savings

achieved•Cost saving 1.09 crore

b Raw material saving, environmental benefits, 6.2 tons Hazardous waste reduced


5000 lit./month of Glycol

based coolant need to be

disposed to CHWTSDF.

Geo-Guard chemical is added

3% Concentration with water.

Elimination of Glycol based Coolant using Recyclable Water based Chemical

After implementation disposal of coolant was

eliminated & is 100% recycled in ETP

Recycling of Engine Coolant.


Geo-Guard 4021

Form: Liquid

Geo-Guard 4021 is a water-based cleaner and rust inhibitor for

steel and aluminium, which is non-caustic and contains no

nitrites. Provides up to 30 days indoor protection.

Recycling of Coolant.

COD 66000

Very high


Use of Treated Oil

Recycling of Engine Lubricating Oil


220

146134

0

50

100

150

200

250

2011-2012 2012-2013 2013-2014

Qty

Re

cycl

ed

in

kil

oli

tre

s.

Lub Oil Quantity Recycled in kl.

Recycling of Coolant.


Use of Recycled Hydraulic Oil

Recycling of Machine Hydraulic Oil.


Engines supplied with

four transportation foots.

Out of that flywheel end side two

removed & scrapped at customer end.

To avoid the RM consumption, flywheel end

side foots welded on returnable skid.

RM Consumption Through Foot Elimination.

Recycling of packing mountings.


Recycling of Packaging.


Before After

Varsha Engines supplied with

Wooden Packing which was

disposed.

Varsha Engines supplied with

Corrugated box packing.

Recycling of Packaging.


Recycling

20-Jun-16 48

Sr. no Description Coolant Engine oil recyclingHydraulic oil

recycling

Elimination of

footsKBL skids

Corrugated

boxes

1 Methodology adopted Kaizen Kaizen Kaizen Kaizen Kaizen Kaizen

aWhat is result of senario

creation

It was found that the

new type of coolant

used is biodegradable

as compared to the old

which was glycol based

Hence easy to be

recycled at ETP

We were wasting oil

since we were

scrapping oil only one

cyle of engine running

for 28 mins so thought

of recycling the same

Unnecessary

scrapping of

Hydraulic oil

instead started

recycling

Saving were huge

and the part sent

to the AGOEM and

OEM was being

scrapped this

triggered the idea

generation

To reduce use

of wood and

start reclable

kind of Skid

Toreduce the

wooden boxes

and start the

corrugated

boxes

b How was it concieved

Bidegradable product

to be used instead of

Glycol based product

By discussion and

conduction meetings

with CRE, QA , ME and

production teams

By discussion and

conduction

meetings with QA ,

ME and production

teams

By Discussing with

AGOM and OEM

and MarketingQA

to develop

recyclable foots

attached to the

skids

Horizontal

deployment

Horizontal

deployment

cOrganisation level at which

the seeding was done

Project mentioned

under KRA in the

Balace score card at

Department level

Project mentioned

under KRA in the


Department level

Project mentioned

under KRA in the


Department level

Project mentioned

under KRA in the

Balace score card

at Department

level

Project

mentioned

under KRA in

the Balace

score card at

Department

level

Project

mentioned

under KRA in

the Balance

score card at

Department

level

2

What triggered the

organization in taking up

the project

Plant conversion cost

reduction

Plant conversion cost

reduction

Plant conversion

cost reductionRM cost

Plant

conversion

cost

Plant

conversion cost


Sr. no Description Coolant Engine oil

recycling

Hydraulic oil

recycling

Elimination of

footsKBL skids

Corrugated

boxes

3 Why is the project unique /innovative?

Huge resistance

from QA and CRE

department but

were convienced as

it passed the

endurance test

Huge resistance

from QA and

CRE department

but were

convienced as it

passed the

endurance test

100% recycling oil

inhouse

Stopped

Unnecessary of the

part being

scrapped at

Customer End

Stopping of

Wood to save

Nature Go

Green

Stopping of

Wood to save

Nature Go

Green

a

·levels of participation, frequency of review/ evaluation, record of

learning’s/

Production ,

Application

Engineering ,

CRE,QA , M E &

Maintenance CFT

Production ,

Application

Engineering ,

CRE,QA , M E &

Maintenance

CFT

Production ,

Application

Engineering ,

CRE,QA , M E &

Maintenance CFT

Production ,

Application

Engineering ,

CRE,QA , M E &

Maintenance CFT

Production ,

Application,

MArketing

Engineering ,

CRE,QA , M E

CFT

Production ,

Application,

MArketing

Engineering ,

CRE,QA , M E

CFT

a ·Technical Challenges

TO go for Water

based against

Glycol based

coolant

Oil properties

Detioration

after 5 Re cycles

To ensure the

required properties

of oil are

maintained.

To make recyclable

foots by arresting

its degrees of

freedom

To get

corrugated box

which will

sustain weight

and will not

damage the

product

b ·Administrative Challenges To get approval

from CRE and Qa it

took 8 months

To make

smooth

changeover for

all production

models

To make smooth

changeover for all

Hydraulic oil using

machines

Modification of

3000 skids in 2

months time

To Mfg 200

new skid for

KBL

c ·Maintenance Challenges

To keep a check

on silica

percentage in

recycled oil

To keep a check on

filter replacement

on time

Maintaing the

skids after 20- 50

trips

Recycling


Sr.

noDescription Coolant

Engine oil

recycling

Hydraulic oil

recycling

Elimination of

footsKBL skids

Corrugated

boxes

4Replication potential within the

sector or in different sectors

Yet to be

deployed for

High HP engines

Deployed for

High HP

models

Yet to be

deployed in EP II

To be

Horizontally

deployed to

HIgh HP Skids

Deployment

to be done

for Export

models

Deployment

to be done

for Export

models

5Tangible benefits & Intangible

benefits achieved

aInvestment made & annual

monetary savings achieved0.485 4.87 0.65 2 0.27 1.42

bRaw material saving,

environmental benefits,

65000 lit cool+

65000 lit water88% recycling 100% recycling 2580 tons 74 tons 1095 tons

Recycling


CII - National Award for “Excellence in Energy Efficient Unit 10-11, 11-12 , 13-14, 15-16 &

“ Energy Efficient Units” 12-13

KOEL won for “Parivartan Corporate Sustainability Stewardship Award” for their efforts in

Resource Conservation 2 times 10-11 & 13-14

Accolades Energy & Environment

Kagal Plant also bagged 2nd Excellence Award in State Level Energy competition by MEDA in

Engineering Sector for year 11-12


Accolades Energy & Environment

Kirloskar Group Inter-competition Awards by auspicious

hands of Eminent Personalities in Energy Sector


Carbon Foot-print Assessment being undertaken by KOEL is

pioneering efforts in their sector

Corporate Sustainability Reporting & Carbon Foot Print Reports

�KOEL is the First Engine Manufacturing company in India, who

released Corporate Sustainability Reports consecutively for 5 years.

�Reports are available on KOEL’s & GRI website.

53


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CII Green Co Best practices Award 2016 · CII Green Co Best practices Award 2016. ... this policy...

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