Resource Intensity Reduction - · PDF fileEnergy Pledge & Target Setting ... Resource Intensity Reduction Initiatives – Review During MRM ... 1st Prize for Kaizen on Energy

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Resource Intensity Reductionthrough ZED module in Vendor Cluster

Market leader in

Furniture Industry with Home, Office & Specialty Furniture

Heading for 2200 Cr +

Business in 16-17

Unmatched reach.

16 Branches & over 700 Dealers

Supported by 5

manufacturing locations and 95 major suppliers

One of the largest divisions of

Godrej & Boyce

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Godrej & Boyce – an organization with 119 years of Legacy

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Achieve 35% reduction in specific energy consumption ,50% reduction in specific water consumption ,15% use of renewable energy

Creating a Greener India

Carbon Neutrality, Positive Water Balance, Energy Efficiency & Renewable Energy Use Achieve Zero Waste to landfill

Beyond Sourcing

Good Green Vision

GETTING TOGETHER

LEARNING TOGETHER

ACHIEVING TOGETHER

Cluster Philosophy

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Bringing Non competing

Suppliers together

Commitment from Top

Management of Godrej Interio

Training & Guidance by

Expert CII Counsellors.

Periodic shop floor visits

for hand holding

Monthly

Progress review meetings

Rewards &

Recognition

Towards World Class Organisation

Vendor Cluster Journey

Low

Influence

High

Impact

High

Influence

High

Impact

Low

Influence

Low

Impact

High

Influence

Low

ImpactNature of Business

No. of Vendors

Steel Fabrication 24 No.

Wood Working 7 No.

Steel & Wood Working 3 No.

Packaging 3 No.

Sofa Manufacturing 1 No.

Gas springs Mfg 1 No.

Plastic components 1 No.

Bringing non competing suppliers together for cluster

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A goal without a plan is just a wish …

Training and Guidance by Experts

Advanced Training on Energy Efficient Systems by CII Expert

Faculties

Awareness on Management of Energy, Water and GHG emissions by

Godrej Interio Team

Basic Training on Resource management by CII Experts

6 Training Programs…17 Suppliers…1500+ Man hours…

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Energy Pledge & Target Setting

Parameter FY14-15 FY15-16 FY 16-17 FY 17-19

Energy, Water,

WasteBase line

15 % over

previous year

5 % over

previous year

3 % over

previous year

A Pledge to reduce resource Intensity by 25% in 3 years …

Handholding by Godrej Interio

Addressing entire team by Godrej top management

On site training programs covering all associates of Supplier

Guidance by Godrej top Management during Gemba walk in

MRM

17 Suppliers… 102 handholding visits so far ….

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Improvement scope Identified in Hand holding Visit(some Examples)

ResourceAreas Identified For Energy

Saving

Current

StatusTarget Action required to take

Target

Date

Electricity

To Optimize Utilization of

Compressors

112.5

kWh/hr83 kWh/hr

To install Centralized screw

type compressors unit along

with reservoir tank

16.12.15

To utilize waste steam from

Boiler to heat Furnace oil, Thus

eliminating the requirement of

electrical heater

7200 kWh /

Year

1800 kWh /

Year

To provide a steam

recirculating line around the

furnace oil tank to heat the

furnace oil.

07.11.15

To Reduce power consumption

on the skipper machine during

break hours

24000 kWh

/ Year

20400

kWh / Year

(15%

Reduction)

by making operation of dust

collector automatic and

independent of requirement

for manual

15.11.15

ResourceAreas Identified For Energy

Saving

Current

StatusTarget Action required to take

Target

Date

Water

To Reduce water consumption

by utilizing non potable water

generated after purification

from R.O plant

52000 Lit /

Month

Zero

wastage of

non potable

RO water

To provide a tank & pipeline &

connect the waste water

collected to toilet, gum making

and garden

23.10.15

To save water in rinsing process

of pre-treatment.

312.5 KL

/Day

125 KL /

Day

To make arrangement for Water

transfer from tank 2 to tank 1 &

similarly from tank 4 to tank 3

for optimize utilization of water

30.10.15

To use recycled water from ETP

is used for gardening

15000 L /

Day

Zero

wastage of

recycled

water

To provide system to use water

for gardening11.11.15

Improvement scope Identified in Hand holding Visit(some Examples)

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ResourceAreas Identified For Energy

Saving

Current

StatusTarget Action required to take

Target

Date

Waste

To change the sheet size for

achieving better optimization

(yield improvement)

8.1 % 5.8 %

To check with supplier and

buy cut to size material to

Reduce scrap %

24.12.15

To check possibility of recycling

of EPS waste generated in the

plant

318 Cubic

feet

Zero waste

of EPS

To Landfill

To find out vendor for

recycling of EPS waste15.10.15

To reuse scrap generated in

process as RM for new product

120 kg /

Month

Zero waste

for some

products

Used 3 ply carton scrap by

sticking 3 strips made it 21

ply to use it as fitment.

15.10.15

Improvement scope Identified in Hand holding Visit(some Examples)

Monthly progress review meetings

Monthly reviews are conducted by rotation with cluster suppliers in

presence of CII Mentor & Godrej Top Management

Suppliers present their ideas and thoughts including those on green

manufacturing.

Supplier’s progress is monitored on Green as well as other initiatives

during these meetings.

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Resource Action Decided Target Date Status

Benefit

Achieved /

Year

Remark (unit

saving Annual)

Electricity

1Replaced 30 HP dust collector with Separate Dust Collectors of 10HP &

7.5HP and Only 7.5 HP dust collector used for Night sift.Decd’15 Completed 4,15,800/- 4950 kWh

2 Install VFD with pressure transducer for 30HP compressor. Jan'16Progress as per

plan- -

3Replaced fluorescent lamps of 360 watts (in total) with CFL bulbs. 164

watts ( in total )Dec'15 Completed 2,148/- 252 kWh

Water

1 Recycled water from ETP is used for gardening Nov'15 Completed 12600/- 180 KL

2 Changed the normal water taps with Push type water taps Jan'16 Completed 2100/- 30 KL

3

In pretreatment , Auto valve system for water rinse tanks (no-3, 6 & 7)

i.e. water flow will start automatically only when cage with material is

dipped in tank

Feb’16Progress as per

plan- -

Waste

1 To buy sheet in cut to length form to reduce process scrap Oct’15 Completed 8,73,600 2.72 % waste reduction

2 To purchase material in cut to length strips for all sizes above 150mm Nov'15 Completed 80,000/- 1.9 % waste reduction

3 Recycling of EPS ste generated in our plant Nov’15 Completed 5600/-Recycling of 318 Cubic ft

EPS. Zero Landfill

Red – Crossed Tgt. Date Green – Completed Yellow – Progress as per plan

Resource Intensity Reduction Initiatives – Review During MRM

Energy Conservation53 Projects …Average per project Saving of 23%

Name of the Associate /

VendorTitle of Project

Units Saved

(kWh/month)

Project Specific

Improvement (%)

Khutale Engg Pvt Ltd Installation of solar energy system 6000 100%

Wudhouse Designs Pvt

Ltd

To reduce the electricity consumption by

replacing CFL bulb with LED507 59%

To reduce the electricity consumption by

decentralizing the dust collection system1,523 22%

Corru cartons (I) Pvt ltd

Conversion of 20 tube lights of 36W in to

CFL of 18W94 50%

Replaced asbestos sheets with Transparent

polycarbonate & GICC sheets280 20%

M/s. P. M. ELECTRO-AUTO

PVT. LTD

Optimized Utilization of Compressors by

installing Centralized screw type

compressors unit along with reservoir tank

27 24%

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Name of the

Associate / VendorTitle of Project

Units Saved

(KL /month)

Project Specific

Improvement (%)

Corru Cartons (I)

Pvt Ltd

Utilization of non potable water generated after

purification from R.O plant for Gardening and Flushing

purpose.

52 100%

Khutale Engg Pvt Ltd Usage of recycled water from ETP for gardening . 15 100%

Silver Techno Mech

Pvt Ltd

Water saving in rinsing process of pre-treatment by

making arrangement for Water transfer from tank 2 to

tank 1 & similarly from tank 4 to tank 3 to optimize

utilization of water

196 63%

P M Electro-Auto

Pvt Ltd

Installation of Sludge separator unit & Drip drop

addition system in pre-treatment process to reduce

water changeover frequency.

23 28%

Shreeji Industries

Harvested

1,25,000Liters of

water in last 2

years

U.G. Tank

25K ltrs

Water Conservation17 Projects …Average per project Saving of 37%

Name of the

Associate / VendorTitle of Project

Units Saved

(Units /month)

Project Specific

Improvement (%)

Silver Techno Mech

Pvt Ltd

To maintain even temperature in oven at all points by

changing position of louvers (Saving of LPG) 876 kg / month 13%

P M Electro-Auto Pvt

Ltd, Nashik

Gas saving by blocking first two louvers in dry off

oven to reduce heat loss338 kg / month 3.21%

P M Electro-Auto Pvt

Ltd, Palghar

To use residual LPG in the cylinder by installing Liquid

Take Off System7.2 Kg / month 0.05%

Fuel Conservation23 Projects …Average per project saving of 7%

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Name of the

Associate / VendorTitle of Project

Units Saved

(Units /month)

Project Specific

Improvement (%)

Corru Cartons (I)

Pvt LtdRecycling of thermocole waste generated in the plant 318 Cu.ft/ month 100%

Corru Cartons (I)

Pvt LtdTo reuse in-process scrap as RM for new product 120 kg / month 100%

Khutale Engg

Pvt Ltd

Procurement of cut to length steel (RM) for better

optimization2240 Kg / month 26%

Carefine Woodworks

Pvt Ltd

Material Size optimization (wooden boards) from size

8X6 & 9X6 to size 7X6 & 9X5.

Product mix production planning for better material

utilization

2342 kg / month 25.3%

Waste Reduction50 Projects …Average per project Saving of 12%

Guidelines for Weighted Average

For Powder coating

Suppliers

For Other

Suppliers

Resource Weight age Weight age

Electricity 30 % 40 %

Water 30 % 20 %

Wastage 20 % 40 %

Fuel 20 % N/A

Overall Resource Intensity Reduction of 13.65 % …

Resource intensive Suppliers

Weighted Average

Reduction in

Resource Intensity

Khutale Engg Pvt Ltd 41.90%

Wudhouse Designs Pvt Ltd 24.90%

Jay Industries 15.30%

P M Electro auto Pvt Ltd, Palghar 14.85%

Carefine Woodworks Pvt Ltd 13.40%

P M Electro auto Pvt Ltd, nasik 12.11%

Overall Average Reduction 13.65%

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Recognitions for Green initiatives at Interio annual Supplier’s meet

M/s P M Electro Auto’s significant contribution towards Interio’s BIFMA

Gold certification

M/s Vishwadeep for innovative use of Bio-Fuel

M/s Zenith Metaplast for tree plantation program

Awards at National cluster for Green initiatives

1st Prize for Case Study on resource conservation

M/s MechTech

1st Prize for Kaizen on material conservation

M/s V K Fabricators

1st Prize for Kaizen on Energy conservation

M/s PM Electro Auto

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Lesson from the Corn Farmer …

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Sharing of Good Practices with the Industry

M/s Vishwadeepsharing innovative use of Bio-Fuel and

won Prize in CII Green Conclave

Kaizen in Green Category

Mr. Avinash Sonavane from Godrej Interio

sharing Project on Transport mile

reduction through Packaging

improvement

Mr Atul Sohani, Godrej Interio sharing on

Green Supply chain during Greenco

Conference, 2015

M/s Khutale Engg sharing Energy &

water saving initiatives & won Prize @ CII Green

Conclave Kaizen in Green

Category

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Happy to ShareOur Corn …

Thank You

Atul SohaniAssociate VP - Strategic [email protected]