Performance Management System Hero Honda

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					Green Manufacturing
Hero Honda Way




                      1
Driven By Customer’s Trust




       25 million + s m i l e s ..   2
The Voyage
           Hero Honda Motors Limited
         was incorporated on 19th Jan’84,
            as a joint venture between
        Honda Motor Co. of Japan (26%) &
     Hero Group of Industries of India (26%).




                                                3
The Brand


            Value


  Indian             Quality            Hi-Tech




    Durability Reliability
                               Global             Quality



                                                      4
The Brand


            Value


  Indian             Quality            Hi-Tech




    Durability Reliability
                               Global             Quality



                                                       5
The Mandate

   Be a world class manufacturer.
   Be a market leader.
   Provide highest level of
   customer satisfaction.
   Achieve excellence through
   teamwork.
   Create enduring relations with
   stakeholders
                                    6
Plants
                               Dharuhera Plant - Haryana
                               Production Started 1985




    Gurgaon Plant - Haryana
     Production Started 1997




                         Haridwar Plant - Uttrakhand
                         (Shrine Of Technology)
                         Production Started in April 2008

                                                            7
Our Connects




               8
                    Environmental Policy
        We at Hero Honda Motors Limited to demonstrate excellence in our environmental
        performance on continual basis, as an intrinsic element of our corporate philosophy.
        To achieve this we commit ourselves to :
    •   Integrate Environmental Attributes and Cleaner production in all our business processes
        and practices with specific consideration to substitution of hazardous chemicals, as viable and
        strengthen the greening of supply chain;
    •   Continue product innovation to improve fuel economy and environmental compatibility;
    •   Comply with all applicable environmental legislation and also controlling our environmental
        discharges through the principles of “ALARA” ( As Low As Reasonably Achievable);
    •   Institutionalize resource conservation, in particular, in the areas of oils, water, electrical
        energy, paints and chemicals;
    •    Enhance environmental awareness of our employees and dealers / vendors, while promoting
        their involvement in ensuring sound environmental management;

        We shall communicate this policy to all our employees and would make it available to
        interested parties.
                                                                                  PAWAN MUNJAL
                                                                                (Managing Director)
    Place:      New Delhi
    Date:       13.04.2002

 Our effort in this regard is guided by the direction provided by our worthy chairman,
                               Shri Brij Mohan Lall Munjal,
“We must do something for the community from whose land we generate our wealth”                           9
               Certifications
OHSAS :18000       ISO :9000    ISO :14000




                                             10
We cannot command Nature except by obeying her –


                                   Francis Bacon




                                                   11
Our Major Business Process



    Suppl
          y
    Chain
                                 Marketing
                Manufacturing   (After Sales
                                    Service)
         t
  Produc t
           en
 D evelopm




                                               12
                                        Dash Board at a glance
                               Energy Consumption - Total                                                                                    Water Consumption
                                      (MJ/ Vehicle)
                                                                                                                                                (KL/ Vehicle)
   700
                                                                                    1.2
                                                                                                                   1.07
   600

   500                                                                  48%
                                                                                    0.8
   400                                                                                                                       0.63                                                            73%
   300        615                                                                                                                      0.5
                      518                                                                                                                       0.41
   200                        396     375                                           0.4                                                                    0.32      0.29             0.29      0.28
                                                                                                                                                                                                02
                                              321     325     327     339     319
                                                                                                                                                                             0.27
   100

       0                                                                            0.0
            2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 2007- 2008-09                                 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07             2007- 2008-09
                                                                     08                                                                                                                08



                              Waste Oil Generation
                                                                                                                                      Carbon reduction
                                  (Ltr/ Vehicle)
0.12
                                                                                                                           Annual Reductions           Reductions from Cummulitive
           0.097
0.10
                    0.082                                                                                         160000
                                                                                                                             128209
0.08                                                                                                                                   123417



                                                                                     Carbon Reduction in Tonnes
                            0.071
                                                                                                                  120000

0.06
                                    0.048
                                            0.043
                                                                        87%                                       80000
                                                                                                                                                       84163

                                                                                                                                                                  55320
0.04                                                0.035
                                                                                                                                                                            31003      33278
                                                            0.025                                                 40000
                                                                                                                                        4792           39254
0.02                                                                0.013   0.012                                              0                                  28843     24317        -2275
                                                                                                                      0
                                                                                                                             2008~9    2009~10     2010~11        2011~12   2012~13   2013~14
0.00
                                                                                                                  -40000
           2000-    2001-   2002-   2003-   2004-   2005-   2006-   2007-   2008-                                                                                                                      13
            01       02      03      04      05      06      07      08      09
               Green Manufacturing

                       Green
                   Infrastructure


   Water                                Paint
Conservation                         Conservation



                  Manufacturing



      Oil                             Energy
  Conservation                      Conservation

                                                    14
                       Green Roof
• Conserve Energy by moderating temperature on roof and
  surrounding areas.
• Dramatically reduce storm water runoff volume and peak flow
  rate .
• Restore the ecological and aesthetic value of urban open space .
• Protect conventional roofing system, typically doubling the
  service life of the underlying waterproofing membrane .


                   Sedum

                                               Coverage 45000m
                                              ( TTL covered area
                                              ~0.125 Million m ) ie
                                                     36%

                                                                      15
                      Secured LandFill Facility
                                                                                WASTE CATEGORIES

                                                                       Cat.         Waste Type
                                                                       12.5         Phosphate Sludge
                                                                       34.3         Chemical Sludge (ETP)
                                                                       34.4         Oil Sludge (ITP)
                                                                       36.2         Incineration Ash



 Leach Collection                                                     (Designed & Constructed by NPC & GEPIL)


                                                         Waste



                  Leach pipe                                                                          Soil
                    Liners          Blue line (Bottom)              Blue line (Sides)            Orange line
                  Top layer       Mastic Asphalt (2.5 cm)        Mastic Asphalt (2.5 cm)    Geo Textile (200 gsm)
Liner System




                                   3% Voids, 0-11 mm
                                                                  Modified Plaster Base
                 Seal Layers             Particle                                              HDPE (1.5 mm)
                                                                 Bituminous Felt (3 mm)
                                    (4 cm ) X 3 layers
                                   5% Voids, 0-16 mm
                 Base Layer             Particles                  PCC (75-100 mm)                    -
                                    (5 cm ) X 2 layers
                                  10-45 mm Particle (10
               Foundation Layer                                             -                         -         16
                                         cm)
           Usage of Natural gas
              (With effect from April ’10)
• Natural Gas based power Generation
  (Gradual replacement of existing
  system )
• Alongwith Heat recovery system for
  Hot water generation & Air
  conditioning .

    Advantage :-
     • Co2 reduction ie cleaner power
       ~ 15,000 ton
     • Cheaper power

•    Usage of Natural Gas inplace of
    Propane /HSD in Paint Shop, Heat
    Treatment , Canteen Area, Fludised
    bed , Incinerator
•
    Advantage:
     • Clean & cheap Fuel                    17
     • Co2 reduction ~ 3000 ton
                     Fludised bed for Paint
                        Hanger Cleaning




Sr. No.          Parameters                                     Result
                                 The controlled combustion process ensure complete combustion of the
  1.      Carbon Emission             waste and flue gases hence generation of smoke and other un-
                                      burnt gases are eliminated
                                 Average process time for a one Basket load ( about 45 KG Paint Load
  2.      Process Time               ) is 60 minutes, against the average time of 120 minutes for the
                                     same load with conventional Process
          Quality of processed   Zero Deformation is achieved with Fluidized bed against the average
  3.
              Parts                  100 % deformation of parts proceed with conventional method.
  4.      Work environment       The working environment is 100 % safe and clean for the operator

                                                                                                    18
                      Rain Water Harvesting
           HHML Rain Water Harvesting System
Catchment's                                     Existing
Buildings Area (m2)                               57421
Roads Area (m2)                                    5725
Average Annual Rainfall (mm)                       726
Water Harvesting (m3)(Runoff coefficient
                                                  28128           726 mm Avg.
for Buildings = 0.85, Roads = 0.7)
                                                               Rainfall in the region
Total Water Harvesting (m3)                       38344


    Year         Water table below            Initiatives
               ground level (bgl) in m
 Feb, 2004     15.1m (bgl),                Building area
 June 2005     16.8 m (bgl)                Building area
 June 2006     17.6 m (bgl)                Building area
 June 2007     16.2 m (bgl)                Building area +
                                           Road run off +    Rain Water Harvesting Well
 Dec 2008      15.4 m (bgl)
                                           Water                  Site Photograph
                                           management
                                                                                        19
Continuous positive recharging of under ground water table since 2007
              Waste Reduction/Reuse/
                Recycle Initiatives
                                     Convert Organic waste (Canteen
                                     & Garden) into useful Compost.




•   Hygienic disposal of Municipal waste : ~ 500Kg/day/Plant
•   Manure generation                    : ~ 200 Kg/day/Plant
•   Manure available to Employees for greening their residential   20
    surrounding
           Substitution of Hazardous
             Construction Material
SUBSTITUTION OF ASBESTOS ROOF SHEET WITH COLOURED M.S. PRECOATED SHEETS




  Replaced 29500 M2 Asbestos Roof Sheet since
  last 3 year in different area .
                                                                 21
          Sewage Treatment Plant




                                                               DECANTER




                  ZERO DISCHARGE PLANT

   STP                        Water Treatment /                 Use in
Discharge                        Purification                   Process
                                                                                            22
eg Gurgaon plant 400 KL/Day                       DG set cooling tower requirement = 400KL/day
              Effluent Treatment Plant




Environmental Laboratory                     Intermediate Treatment Plant
                                             (For cutting oil emulsion)
                                                             De Emulsification

                  Photometer and COD                           Oil Separation
                        Reactor

 Oven & BOD
  incubator
                                                             Sludge Separation


                                                             Discharge to STP
              Oil Separator &                                              23
  pH Meter      water bath      Desiccator
                                               Reduced load on ETP
                       Incinerator
                         Air Pollution
Addl. Secondary          Control Device
Chamber to increase                       •    High temp. paint
the residing time of                          sludge burning
Flue Gases                                    facility with air
                                              pollution
                                              monitoring /
                                              control system

                                               Waste heat
                                              recovery system
                                              for usage in
                                              other processes.

                                               Maintain the
                                              stringent /
                                              advanced PCB
                                              norms




                                                          24
               Green Manufacturing

                       Green
                   Infrastructure


   Water                                Paint
Conservation                         Conservation



                  Manufacturing



      Oil                             Energy
  Conservation                      Conservation

                                                    25
         Recycling of Paint Sludge

     Conversion of paint sludge to primer paint


                                    Paint Primer
   Paint
                Additives            (732 Ltrs)
   Sludge
                (650 kg)                  +
(500 kg wet)
                                Residual Waste 2-3%




                                                  26
       Solvent Recovery in Paint Shop
     PREVENTION OF POLLUTION – REDUCE/REUSE/RECYCLE/RECOVERY

                                        PREVIOUS          PRESENT
                                         STATUS           STATUS
THEME-
  Recovery of                                             COLOUR
  thinner from                          COLOUR
                                        CHANGE
                                                          CHANGE

  waste
  Thinner
  (Cleaning
  Process)                             GENERATION
                                                       GENERATION
                                                           OF
                                           OF
                                                      WASTE THINNER
                                      WASTE THINNER

SAVING -
  Approx.180
  liters of
  cleaning                                MOVED
                                                          REUSE
  thinner per                               TO
                                                      IN BELL & GUN
                                                        CLEANING
                                        SCRAP YARD
  day per plant

                                                                    27
   TECHNOLOGY CHANGE

Water based painting system – A.C.E.D




                                        28
Paint Conservation Initiative
 SOURCE REDUCTION–Technology Change

Bell Painting system introduced in Paint shop




                                                29
               Green Manufacturing

                       Green
                   Infrastructure


   Water                                Paint
Conservation                         Conservation



                  Manufacturing



      Oil                             Energy
  Conservation                      Conservation

                                                    30
       Energy Conservation Initiative

Waste Heat Recovery System
on existing Power Generators for
Hot water generation (Paint Shop)

Advantage :-
• Fuel saving ( ~ 0.6 Million liter/ Year )
• Co2 reduction



Replacement of Aluminum alloy
fans by FRP fans of cooling tower

Advantage :-
•Power saving
•Co 2 reduction
                                              31
         Energy Conservation Initiative


SOLENOID VALVES FITTED IN THE
CIRCUITS OF PNEUMATIC
GAUGES TO STOP SUPPLY OF AIR
AUTOMATICALLY



Replacement of copper Ballast
with Electronic ballast in all task
lighting

Advantage :-
•Power Saving ~ 1.4 Million KWH /
Year
• Co2 reduction
                                          32
         Energy Conservation Initiative

Power Saving Circuit in all
machine panel of engine plant

Advantage :-
• Power Saving . eg at Gurgaon
Plant Engine plant area is ~ 0.35 Million
KWH / Year


V.S.D in Air compressor.

Advantage :-
• Power saving eg at Gurgaon Plant
is ~ 80,000 KWH / Year

                                            33
        Energy Conservation Initiative


Real Time Clock on Panels of
Engine Assly, HT, Canteen boiler,
for operation optimisation .

Advantage :-
• Power Saving eg at Gurgaon Plant
saving is ~ 0.18 Million KWH / Year

Power Factor Correction Panels for
load running on state electricity
power

 Advantage :
• Cost saving through Improved
Power Factor eg at Dharuhera plant power
factor improvement upto0.99                34
        Energy Conservation Initiative


Installation of Transparent sheet
on roof top.

Advantage :-
• Higher usage of Natural light &
Optimum usage of task lighting

Replacing electrical exhaust fans
with Roof Wind Ventilator (non
conventional source of energy).

Advantage :-
• Power Saving     eg at Gurgaon Plant
105 electrical fan was replaced with 225
wind ventilator leading a power saving
                                           35
of 31,500KWH/Month
               Green Manufacturing

                       Green
                   Infrastructure


   Water                                Paint
Conservation                         Conservation



                  Manufacturing



      Oil                             Energy
  Conservation                      Conservation

                                                    36
            Oil Conservation Initiative


Installation of Chip
Wringer to Recover
neat cutting oil from
Chips generated from
m/c operation.

Oil recovery= 56 Ltr/
Day/ Plant


 On line Hydraulic oil
   filtration system
   on Presses.

 SAVINGS- ~ 1200
   liters / Yr                            37
         Oil Conservation Initiative
            COOLANT FILTRATION M/C

Trolley mounted filtration
  machine .

Advantage :-
  Check growth of
  anaerobic bacteria
  Reduced effluent load on
  ETP
  Increased life of coolant
  Reduced consumption of
  cutting oil
  Improved surface finish
  & quality
  Improved tool life

                                       38
               Green Manufacturing

                       Green
                   Infrastructure


   Water                                Paint
Conservation                         Conservation



                  Manufacturing



      Oil                             Energy
  Conservation                      Conservation

                                                    39
                      Water Conservation Initiative
             Recycling of Treated Effluent of STP(400 KL/Day)


                                                        Process
Treated Effluent of




                                                          RO
       STP




                                           Water
                                          Softeners




                      Filtration System
                                                      Used in Genset
                                                      cooling towers
                                                                  40
Our Major Business Process



    Suppl
          y
    Chain
                                 Marketing
                Manufacturing   (After Sales
                                    Service)
         t
  Produc t
           en
 D evelopm




                                               41
                Green Vendor
         Development Program (GVDP)




OBJECTIVE
• De-Risking the Supply Chain, up-gradation by Knowledge Sharing
  and Expanding the Horizons of Environmental Practices among the
  Supply Chain Partners
• Collaborative Approach to Conserve and Protect Environment to
  Meet Our Societal Commitment
• Better Business Sustainability & Improved Vision for the      42
  Challenges ahead
       Green Vendor
Development Program (GVDP)




                             43
               GVDP Clusters

                 Cluster – 1
                    Petro
                  Chemical
                Consumption



 Cluster –4
                                 Cluster – 2
Die Casting/
                                    Metal
 Machining
                  GVDP           Forming &
                                    Metal
                                  Removal




                  Cluster – 3
                   Painting/
                 Plating/ Heat
                  Treatment
                                               44
        Green Vendor
 Development Program (GVDP)




ROAD MAP




                              45
                     Green Vendor
              Development Program (GVDP)




       Completed          Ongoing




SAVINGS / BENEFITS




                                                                                                  46
Other Earn pillars are Waste reduction , Pollution prevention , Haz. Waste substitution , Legal
Green Supply Chain



     Promoting
     Reusable
     Packaging



                     47
Our Major Business Process



    Suppl
          y
    Chain
                                 Marketing
                Manufacturing   (After Sales
                                    Service)
         t
  Produc t
           en
 D evelopm




                                               48
           Green Product / Process
           Development Initiative
  Modified the Passivation process Hexavalent Chrome
     Passivation to Trivalent chrome Passivation


       Spindle kick Starter         Various Nut & Bolts




Cr6 Passivation   Cr3 Passivation     Cr3 Passivation


                                                          49
                    Green Product / Process
                    Development Initiative
  Substitution of Haz. Materials – Asbestos to Non Asbestos
                                                     BRAKE SHOE
    • Asbestos Weight =
      100 ~ 150 gm/
      vehicle (ie approx
      asbestos consumption
      500 Tons per year)
                                                      GASKETS
    • Phase out period =
      March’ 2006 onwards




Non asbestos material is a multi layered material
comprising of NBR type rubber , valcanizated
material , inorganic powders & aramid type fibres)                50
Our Major Business Process



    Suppl
          y
    Chain
                                 Marketing
                Manufacturing   (After Sales
                                    Service)
         t
  Produc t
           en
 D evelopm




                                               51
                       Green Dealer

                               Effluent Discharge System
OBJECTIVES
•   To promote sound
    environmental
    practices at dealerships

•   To create awareness
    amongst customers on
    better functional &
    environmental
    performance of
    motorcycle



                                                           52
                Green Dealer

Motorcycle Exhaust System   Wastage Segregation




                             Different colored bins
                                provided for the
                            segregation of metallic /
                            rubber parts, hazardous
                              material and the bio-
                               degradable waste
                                                    53
               Green Dealer
  Eco friendly genset   Trainings & Awarness




Mobile genset with a
canopy for its silent
 operations in the
     workshop
                                               54
         Carbon Free Movement ……
      a continuous journey (Product & Facility)
Broad Road Map

                                                     Foot print
                                                      review
                                       Execution
                                      monitoring &
                                       updation
                        Road Map &
                          Project
                        declaration
               Bench
              marking
Carbon foot
 printing                                              Updations
                                                          &
                                                       Revisions

                                                                   55
There is a sufficiency in the world for man's need
            but not for man's greed –

                                 Mahatma Gandhi



                                                56
And the Journey Continues …………………
                                    57

				
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