Unit Profile :

Bajaj auto limited, Waluj ,Aurangabad, is a division of Bajaj Auto Limited, Pune, a
flagship company of Bajaj Group.Bajaj Group was formed by Mr.Jamanalal Bajaj in
1929. Bajaj Auto Limited, Pune started scooter production in 1960. As an expansion
plan, Bajaj Auto Limited, Waluj Plant is started in 1985. In 1999, a State of Art Plant
was started at Chakan.

Objectives of Bajaj Auto Limited are to cater the market needs of transportation by
providing 2 wheeler and 3 wheeler vehicles. BALW has been producing the
catalogue products to cater to the changing market requirements. Based on the
customer feedback, improvements are being made continuously in the existing
products. In the process of introducing new products, emission requirements are
being taken into consideration and products manufactured are meeting the regulatory
requirements.
The site of BAL-W is located in MIDC Waluj area.

Bajaj Auto Limited, is an ISO-9001 company, having ISO-9001 (2000) Quality

Management certification.

A constant watch is kept on the technological developments taking place in the areas
of energy reduction, waste reduction and pollution prevention. Environment
Management System is integral part of overall management systems at BALW. ISO
14001 certification was awarded to BAL-W in 1997 .
In 2003-04, Bajaj Auto Limited has posted its highest ever gross turnover of Rs.59.34
billion. Bajaj Auto has resolutely engaged in a process of fundamental change. This
has involved changes in the organisational structure; in product and models; in the
approach to markets and consumer preferences, in R&D engineering, product design
and speed to market; in rationalising of cost; and in a complete overhaul of the way in
which Bajaj Auto do business. This change process is now epitomised by Bajaj
Auto's new corporate identity.

Quality Policy, Environmental Policy and TPM Policy are guidelines for our
working. Photographs of the same are attached. (For readabilty, the said policies are
reproduced as it is).

Manufacturing Process

The industrial complex of Bajaj Auto Limited-Waluj is spread over an area of 906
acres. The manufacturing activity consists of manufacturing motorized 2-wheelers ,3-
wheelers & parts thereof and also machine tools required for captive consumption.
The scooter plant was started in 1985 and other plants were started subsequently.

The manufacturing process for 2-wheelers and 3-wheelers as well as machine

building is basically metal cutting and metal forming. The basic raw materials are
steel and aluminium. Surface treatment processes like heat treatment, painting and
electroplating are carried out in the factory.

Flow Chart of Manufacturing Process is depicted on next page:

Energy Conservation : Method and working at BALW

Top Management Committee fixes Corporate Objective for Energy every yearby
comparing performance with National / International Benchmark and targeting for
higher achievement.

The main objective is to operate most Cost Effective, Energy Efficient and Environment
friendly Plant.

Continuous Improvement in Working and close monitoring through Energy

Management System is carried out.

Energy audit and efficiency assessment is built-in Quality, Environment and TPM
Policies.

Awareness of Energy Conservation of all levels is reflected in continuous reduction of

conversion cost of the vehicles produced year to year.

Some of the activities are

¾ Technological upgradation - Usage of Flexible Machining Centers instead of Special

Purpose Machines.

¾ Implementation of Streamline Manufacturing Systems. Re-organization of

Machines/ Process as per Product Layout.

¾ Single Digit time in Minutes for Change of Dies/ Tool. Compactness in Working
area

¾ Reduction in rejection less than 1000 PPM (Parts Per Million) and aiming for
‘ZERO’ PPM.

¾ Nurturing of ‘Right First time Ok’ culture.

¾ Increase in Productivity of the workmen.

¾ Improvement in Processes and working methods.

¾ Utilization of Idle time.

¾ Minimization of Losses by TPM.

¾ Introduction of Direct on Line of material and elimination of stores.

The Energy conservation team/cell holds posters competition on Energy & Water
Conservation for all employees.This percolates the Energy saving aspects to workmen
level. Awareness level of conservation of energy amongst employee is very high.
System Followed is :
¾ Through the systems of Kaizens,TPM Circle/Quality Circles & suggestions, Energy
saving proposals are received.

¾ Economics & Technical Feasibility is studied by experts for above received

proposals for implementation.

¾ Every department set objectives against environment management plan yearly to

conserve Natural resources.

¾ Targets are set for Conservation of Natural resources.

¾ Posters are displayed at work places on awareness of conservation of Energy.

¾ Sharing of information through Intra-net among our other plants & horizontal
deployment.
 ENVIRONMENTAL POLICY

Bajaj Auto Ltd., manufacturer of two and three wheeler vehicles is committed to
prevention of pollution, continual improvement of our environmental performance and
compliance with all applicable environment legislation and regulation.

Towards this, we shall strive to :

Create a proactive environment management system that addresses all

environmentally significant aspect related to our products and processes,

Minimise the generation of waste and conserve resources through better

technology and practices, and

Promote environmental awareness amongst our employees and motivate them to

fulfill our commitments.

We, at Bajaj Auto, pledge ourselves towards creating and preserving a cleaner
environment.

Rahul Bajaj
Date :16-12-1998 Chairman & Managing Director
 TPM POLICY

We at Bajaj Auto adopt "TOTAL PRODUCTIVE MAINTENANCE" as a means of

creating a safe and participative work environment in which all employees target the
elimination of losses in order to continuously enhance the capacity, flexibility, reliability
and capability of its processes, leading to higher employee morale and greater
organisational profitability.

Rajiv Bajaj
Date : 11-03-2000 Joint Managing Director
 QUALITY POLICY

We at Bajaj Auto continue to firmly belive in providing the customer "VALUE FOR
MONEY, FOR YEARS" through our products and services. This we shall maintain and
improve.

In our decision making, quality, safety and service will be given as much consideration
as productivity, cost and delivery.

Quality shall be built into every aspect of our work life and business operation. Quality
improvement and customer satisfaction shall be the responsibility of every employee.

Rahul Bajaj
Date :19-01-1992 Chairman & Managing Director.
Bajaj Auto Limited : Environmental Policy , TPM Policy and Quality Policy
 ENERGY CONSERVATION CELL

• Sr. Officer of the company is identified as incharge/co-orinator for energy conservation objectives set by the
company for past many yrs.

• We have designated Energy Manager for carrying out activities for efficient use of Energy and its
conservation.

• To comply with energy consumption norms & standards set by bureau of energy efficiency & national
productivity council.

• To take measures necessary to create awareness & disseminate information for efficient use of energy &
its conservation.

• Organise training of personnel & specialists in the techniques for efficient use of energy & its
conservation.

• To take preferential steps to use energy efficient equipments.

RESPONSIBILITIES & DUTIES OF ENERGY MANAGER

1 Prepare an annual activity plan & present to management concerning financially attractive investments to
reduce energy costs .
2 Establish an energy conservation cell within the firm with management consent about the mandate & task
of cell.
3 Initiate activities to improve monitoring & process control to reduce energy costs.

4. Analyze equipment performance with respect to energy efficiency.

5 Ensure proper functioning & calibration of instrumentation required to assess level of energ consumption
directly or indirectly.
6. Prepare information material & conduct internal workshops about the topic for other staff.
7. Improve disaggregating of energy consumption data down to shop level or profit centre of a firm.
8. Establish a methodology how to accurately calculate the specific energy consumption of various products/
services or activity of firm.
9. Develop & manage training programme for energy efficiency at operating level.
10. Co-ordinate nomination of management personnel for External programms
11. Create knowledge bank on sectoral , national & intrnational development on energy efficiency
technology & management system & information denomination.
12. Develop integral system of energy efficiency & environmental upgradation .
13. Wide internal & external networking .
14. Co-ordinate implementation of energy audit / efficiencyImprovement projects through external agencies.
15. Establish and/or participate in information exchange with other energy managers of the same sector
through association.

DUTIES :
1 Report to bee & state level designated agency once a year. The information with regard to the energy
consumed & action taken in the recommendation of the accredited energy auditor as per BEE format.
2 Establish an improved data recording, collection & analysis system to keep track of energy consumption.
3 Provide support to accredited energy audit firm retained by the company for the conduct of energy audit.
4 Provide information to BEE as demanded in the act, &and with respect to the tasks given by a mandate,
and the job description.
5 Prepare a scheme for efficient use of energy & its conservation & implement such scheme keeping in
view of the economic stability of the investment in such firm &manner as may be provided in the
regulations of the energy conservation act.
MONITORING THE PROGRESS OF ACTIVITIES.

VP (O)

Plant
Head
Plant
Energy conservation
Comitee

Divn.
Heads
Divn.
Energy conservation
Committee
Dept.
Heads

Dept.
Energy conservation
Committee
Engineers

Members/cellmem
Circle bers
Members
Project Write-up:

Project :

Pumps are identified as a basic unit for improvement / verification for Energy
Conservation. All pumps are looked at for following aspects :

1.Impleller size reduction

2.Combining activities of pumps
3.Removal of not required pumps
4.Modification in coolant tanks & circuits
5.Modification in hydraulic circuits
6.Usuage of timers/ control circuits.
7. Reduced HP .

Background and Methodolgy :

Over-rated pumps/ Circuits are installed by manufactures of machines.

The various pumps installed on machines and process equipment study was carried out to
Take actual load versus connected load as well as machine layouts.
Data of actual loads and lay-outs was collected. After analysing, plan was formulated for

9 Impeller trimming for avoiding throttled valve circuits.

9 Start Delta Star circuit provision instead of Star delta for higher HP Motors.
9 Variable Frequency Drives (VFD) for centralised coolant system.
9 Combination of coolant pumps by modification of piping of machines in cells.
9 Low rated motors installed for pumps.
9 Modification of hydraulic circuits for combination of pumps.
9 Use of unloading valve in hydraulic circuits resulting in total/ partial removal of oil
chiller unit or low capacity oil chiller units.

The above process was horizontally deployed in various area. This has lead to tap good
amount of energy saving in plant.
Energy Reduction :

Saving
Methodology Implemented at Kwh/
Month
Usuage of timers/ control circuits. ABB Robot cooling unit linked with m/c 195
Coolant circulation modified for sunday 1293
Coolant pump on linked with hyd pump 1126
w859 250 T Hyd press oil cooling pump control 101
Sub-Total 2715
Removal of not required pumps Phosphate gland cooling pump of 2050
Conversion of thermax pumps removed 2145
Sub-Total 4195
Impleller size reduction ED bath circulation pump impeller chgd 2500
Sub-Total 2500
Modification in coolant tanks & Combined spray water rinse stages with one pump 8237
circuits
For w7598 techno aid m/c coolant gun 80
Combination of coolant tank FIGE 1540
Piping Modified for W7684 212
w 7780,7781,7785, 7773,7774,5209,5o42,5044, 1330
FBD Cover Thakoor drill tap 2 m/cs Combination of 104
pumps.
w7077 drill tap spm piping modified 145
Removed 5 nos. coolant pumps by piping 910
Removed coolant pump from mazak m/c by 435
w6252 Washing m/c piping modified 2000
13m/cs Coolant pump removed 1820
W6241 coolant tank removed & combined with other 1540
m/c
Booster pump of solar water heating 2016
Sub-Total 20369
Modification in hydraulic circuits Modification in hyd ckt on xlo spm w-6306 325
Sub-Total 325
Reduced HP . Coolant pump motor of lower HP installed. 1350
W5739 2HP pump replaced by 0.25 hp 565
PTCED air washer pump & water circuit motors- Lower 1000
HP
Booster pump of elptg replaced 10 hp by 2hp pump 2808
Booster pump of w office replaced 10hp by 2hp 312
Sub-Total 6035
Grand-Total 36139

Total yearly lacs Kwh (36139 x 12 ) 4.34

Total yearly saving in Rs. 15.52 lacs

 Lower Rated Motors : In Paint Shop-Motor Cycle Division installed pumps were oversize
and delivery valve were in throttle condition. Now motor of low rated installed. Fig.1
shows both- previous and current condition. HP of motor before replacing was of 25 HP,
now it is 15 HP. This is horizontally deployed whereever high rating motors were installed
considering the process requirements.

Fig 1

High Rated Motor. Low Rated Motor.

Combination of Coolant pipes so as to utilise one pump for two machines by modifying
coolant circulation pipe lines and return chutes.
Fig. 2 and 3 shows the same.

Pipe Modification done.

From this additional pipe
coolant is supplied to
another machine.

Project in Implementation Examples

VFD Installed for Centralised Coolant System (Aluminium Shop- Motor Cycle Division)
Fig.4 shows VFD Panels Installed. Fig 5. Shows the actual KW, current drawn, frequency.
Earlier 55 KW motor was drawing 105 amp. After installation of VFD and setting of
Frequency for 45.5 Hz. Now the current drawn is 68.4 amp.

Fig. 4 Fig.5
Manufacturing Flow Chart

Manufacturing Process For Two Wheelers & Three Wheelers

MS Castings Crank Misc.Alu. Misc. Nuts Sheet

& Forgings Case Castings & Bolts Plates

Buffing & Cutting

Heat To Size
Treatment

Machining Machining Buffing Electro- Pressing

Plating

Heat Wheel Weld/Buff

Treatment Assembly Chassis
Grinding Forming

Bought
Out
Components

Minor Engine Engine Final Painting Chassis

Assemblies Assembly Testing Assembly Forming

Quality
Testing

Despatch
For
Sale
 Specific Consumption of Electrical Energy, Water, LPG and LDO per equivalent of vehicle.

Electrical Consumption Water Consumption

3
100 2.63
90 KWh Per Veh. Cu.Meter Per Veh.
90
2.5
80
67

Cu.Mt. / VEH.
70 2
57 55
KWH / VEH.

60
1.5 1.25
50
0.97
0.89
40
1
30
20 0.5
10
0 0
2000-01 2001-02 2002-03 2003-04 2000-01 2001-02 2002-03 2003-04

LPG Consumption
Kg./ Veh LDO Consumption
Lit/ Veh.
6 2

1.87
4.95
5

4 1.23
3.63
Liter.

1.03
3 1 0.9
Kg

2.64 2.6

2
1

0
0
2000-01 2001-02 2002-03 2003-04
2000-01 2001-02 2002-03 2003-04