2. THE INDUSTRIAL FACILITIES
HALDIA HOSUR
• Location – WEST BENGAL • Location – TAMIL NADU
• Opened - 1980 • Opened - 1996
• Product Range – Solar, Traction, Standby, Flooded., GEL. • Product Range – VRLA, Standby, Telecom, Railway
High Value Manufacturing
ROORKEE
SHAMNAGAR
• Location - HIMACHAL PRADESH
• Location - WEST BENGAL
• Opens – PART OF EXIDE FROM 2012
• Opens – 1946
• Product Range – Inverter, Sign Wave, High Frequency
• Product Range – Plante, Standby(Flooded)
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3. MANUFACTURING STRATEGY
INDUSTRIAL -
FLEXIBILITY IN MANUFACTURING PROCESS TO MEET RAPID CHANGE IN MARKET
REQUIREMENT
NEXT GENERATION PRODUCT TO BE AHEAD OF COMPETITION -GEL , TI WITH
REMOTE SENSOR, NXT VRLA , INTEGRATED INVERTOR
CONSISTENCY THROUGH TECHNOLOGY & AUTOMATION – INDUSTRIAL COS, PASTE
FILLING, VRLA COS, etc.
TO SHIFT FROM GRUDGE PURCHASE TO ASPIRATIONAL PURCHASE
VALUE ADDITION THROUGH INVESTMENT IS THE NXT GEN REQUIREMENT
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4. MANUFACTURING STRATEGY
INDUSTRIAL -
TO FOCUS ON MAINTENANCE FREE PRODUCT
FOCUS ON CAPACITY ENHANCEMENT WITH MARKET DEMAND
IMPROVEMENT OF HUMAN RESOURCE BY CONTINOUS TRAINH AND SKILL
ENHANCEMENT.
INVERTER AS PACKAGE WITH BATTERY
REDUCTION IN MANUFACTURING COST BY IMPROVING MANUFACTURING EFFICIENCY
AND WASTE REDUCTION
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7. PRODUCTION TREND ( INVERTER )
INVERTER - PRODUCTION 188000
200000
175000
150000
NOs
125000
100000
75000
50000
11119 10132 16908
25000
0
JAN '12 FEB '12 MAR '12 TARGET 2012 - '13
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8. DESPATCH TREND ( INVERTER )
20000 17348
15000
NOs
11550
9810
10000
6818
5000
0
DEC '11 JAN '12 FEB '12 MAR '12
DESPATCH ( INVERTER )
8.00 7.07
6.00
4.39 3.83
` CR.
4.00
2.08
2.00
0.00
DEC '11 JAN '12 FEB '12 MAR '12
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9. LEARNINGS FROM SHINKOBE
EIL RECEIVED THE COMPLE DESIGN FOR 12V STANDBY –UPS, 2V
TELECOM, 2V RAILWAY BATTERIES FROM SHIN-KOBE.
CURED PLATE CHECKING PARAMTERS (METALIC
SOUND, CRACK, COLOUR, ETC.,)
IMPORTANCE OF NAM / PAM RATIO
IMPORTANCE OF ONLINE COMPRESSION CHECKING SYSTEM
FEATURES & ADVANTAGES OF BARCODE SYSTEM
PET SHEET WRAPPING FOR GROUP WITH EXPANDED NEGATIVES TO REDUCE
PROCESS REJECTION
STANDARDISATION OF CURING OVEN
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10. LEARNINGS FROM SHINKOBE
IMPORTANCE & METHODOLOGY OF FTA ANALYSIS
KANBAN CONCEPT
IMPROVED METHODOLOGY OF FIELD RETURN BATTERY ANALYSIS
ADVANTAGE OF COS FOR VRLA
ONLINE ACID WASH ROLLER PRESSURE MONITORING
ADVANTAGES OF ABS CONTAINER FOR MEDIUM VRLA
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11. LEARNINGS FROM EAST PENN
DIFFERENCE IN PROCESS, EIL Vs EPM.
OXIDE MAKING.
CONCAST, PASTE MAKING SEQUENCE, PASTING, TANK FORMATION, FLAT
TRACTION POSITIVE PLATE, COS ASSEMBLY.
DIFFERENCE IN PROCESS, EIL Vs EPM.
DESIGN AND OPENING /CLOSING PRESSURE OF SAFETY VALVE.
INCREASED PAM/NAM RATIO IN PRODUCT DESIGN.
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12. PROJECTS – EAST PENN
TANK FORMATION OF MET FOR RAILWAY.
TO REVISE THE ACTIVE MATERIAL RATIO OF VRAL PRODUCT.
TO IMPLEMENT PASTE MIXING SEQUENCE.
LEAK TESTING – DUNK TEST.
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13. QC AND SGA
HOSUR HALDIA
QC TEAM – 6
QC TEAM – 17
SGA TEAM – 44
SGA TEAM – 43
PROBLEMS SOLVED - 63 PEOPLE PROBLEMS SOLVED - 60
INVOLVEMENT
THROUGH
TOTAL EMPLOYEES SGA
QC & INVOLVED – 569
TOTAL NOS. OF AWARDS WON – 22
SHAMNAGAR
PAR EXCELLELLENCE Award – NCQC – Vizag
QC TEAM – 7
EXCELLENT Award – NCQC – Vizag
GOLD Award CCQCC – Bangalore SGA TEAM – 10 GOLD Award – QCFI – Kolkata
GOLD Award from ICQCC – Hyderabad 1st in 23rd CONVENTION of QC – Kolkata
PROBLEMS SOLVED - 25
PAR EXCELLENCE Award NQCC – Bangalore GOLD Award INTERNATIONA; QC – Hyderabad
SILVER Award - CCQCC – Bangalore
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14. TRAINING
TRAINING - HALDIA
Training Nos. Of Hours - Haldia
24720 TPM
18704
16400 SHE
13840
8120 PM
JH
Cost Control
2007-08 2008-09 2009-10 2010-11 2011-12
Training on Pallet Truck Operation
Training Nos. Of Heads - Haldia
Safety
6441
Quality
3157 Efficiency Management
2541 2410
2016
Fire Training
2007-08 2008-09 2009-10 2010-11 2011-12
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15. TRAINING
TRAINING - HOSUR
14702 Training Nos. Of Hours -Hosur
13751
Internal auditors training on TS/IMS
10465
8683 8483
Battery Technology
Statistical Process Control
7 QC Tools
2007-08 2008-09 2009-10 2010-11 2011-12 Legal requirement on environment, OHS management system
Small Group Activity
Training Nos. Of Heads - Hosur
3172 TPM / ITS pillar awareness
2055 1868 Quality circle concept & ITS Implementation
1090 606
Personal Effectiveness
Training on SHE Awareness
2007-08 2008-09 2009-10 2010-11 2011-12
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16. TRAINING
TRAINING - SHAMNAGAR
Training Nos. Of Hours - Shamnagar
3440
Cost / Expenses Control
2648
2056 Asset utilation / Maintenance
1832
1392
Inventory control
New QC Tools
Productivity / IE / Incentive Scheme
2007-08 2008-09 2009-10 2010-11 2011-12
Energy Conservation
Training Nos. Of Heads - Shamnagar
Communication and Presentation Skill
430
Battery design / Quality Systems
331
229 257
174 Pay Roll concept
HR & Porvic – Manufacturing Process
2007-08 2008-09 2009-10 2010-11 2011-12
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17. ILLUMINATION LEAD IN AIR
100 100 2
93
LUX (65 min.)
56
µgm/M3
0.85
0.072
Haldia(Industrial) Haldia(Traction) Shamnagar Hosur Haldia Shamnagar Hosur
LEAD IN WATER HOSUR DATA REQUIRED
5 5 5
µgm/KL
Haldia Shamnagar Hosur
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18. LEAD IN BLOOD
HOSUR & SHAMNAGAR DATA
REQUIRED
10 10 10
µgm/DL
Haldia Shamnagar Hosur
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23. CORPORATE SOCIAL RESPONSIBILITY ( CSR )
Exide Industries Limited is making sure that rural India stays healthy, wealthy and wise . In
this respect the company has taken new strategy for corporate governance and social
responsibilities in the works.
POLICY :
CSR is considered as one of the key business processes, which has been identified by the management
and considered critical to be a successful organization. Exide shall also establish the sub-processes to
internalize this key process with a mechanism to measure and control the effectiveness.
OBJECTIVES :
• To be a good corporate citizen is inextricably linked with the improved brand reputation. CSR
initiatives shall be considered as one of the most important drivers of the brand.
• With non financial parameters becoming more and more relevant, Exide’s focus on CSR is to enhance
the shareholders value through an all round approach towards all stakeholders.
SCRUCTURED CSR ACTIVITIES :
• HEALTHCARE
• EDUCATION
• ENVIRONMENT
• WOMEN EMPOWERMENT
• ASSISTANCE & PHILANTHROPY
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24. HEALTH CARE
Medical Camp ( Hosur ) - Supported Bagalur Health centre in organizing a medical camp
HEALTH CARE PROGRAM ( HALDIA ) - Polio Immunization Program, health check up , dental check up, eye
examination, medicine distribution, general check up, tube well installation, SBU-INDUSTRIAL May’12 / 24
25. BASIC EDUCATION
HARIJAN PRATHAMIK VIDYALAYA , ISWARDAHA JALPAI - Repair & refurbishing of school one day Science program at Kothapalli High school,
building, Beautification of school ground -Mini Park, Installation of Tube well, Beautification of Sevaganapalli Panchayath,
school -School Gate
ASSEMBLY OF GOD CHURCH, HALDIA - Electrification work was done at Electrification of Banskhana Bhuniarchak Primary School
Computer Room , New Staff Room , Class Rooms , Passage & Toilets.
Donation of Books to School Children & Library through Sri Sri Donation of Books to School Children & Library through Sri Sri
Ramkrishna Sarada Sathi Sangha – Chak Dariberia Ramkrishna Sarada Sathi Sangha – Chak Dariberia
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26. ENVIRONMENT
World Environment day celebration ( Hosur ) - School Children on Procession, Distribution of free Saplings, Clean Hosur program
World Environment Day celebration ( Haldia ) - Rally by Exide Employees, Environmental Drama, Flag hoisting, plantation, sapling distribution, visit, training
Community awareness program on HIV/AIDS - Tableau , Rally
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27. WOMEN EMPOWERMENT
Activities for Women empowerment ( Village - Iswardaha Jalpai ) - Vocational Training, Distribution of sewing machine, Employees’ Uniform made by Self help Women
Group
Activities for women Empowerment ( Hosur ) - Purchasing of hand gloves manufactured by units employing women
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28. ASSISTANCE & PHILONTHROPY
Adopted Children of Deceased
combat malnutrition- save 600
To Karthik’s Education up to High
children below 5yrs across the country School
Administer Vit-A to 45000 children K.Sowmiya - 2nd std
across the country K.Ragul -1st std
Donation to Ramkrishna Mission Sevashrama , Tamluk for Supply of
drinking water by construction of an underground reservoir with Donation of Battery for Power Supply in Homeopathy Dispensary
RCC wall & Main Temple to Natshal Sri Sri Ramakrishna Ashram
Donation food & cloths for flood victim, cart for handicraft, blood donation camp
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29. METAL PASS BOOK SYSTEM
PRODUCTION AS PER SALES – THROUGH METAL PASS BOOK.
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32. ENERGY CONSUMPTION AND CONSERVATION
JUN’12
Maintained Power factor of the plant at
around 0.99.
MAY’12 Maintained Load factor of the plant at
around 75%.
Introduction of Compressed Air
APR’12
Management system for optimum use of
Air Compressors at plant.
Installation of SCR controlled heating
systems at Lead Pots of Wirtz Casting &
COST SAVED UP TO MAR’12 MAR’12 Auto spine machines.
Rs.26,499/- PER DAY Use of one no. Cooling Tower in place of
ENERGY SAVED /DAY : 4527.51 KWH two nos. Cooling towers for Hadi & Wirtz
FEB’12 COST SAVED: Rs.26,499 PER DAY Casting machines.
Installation of LDRs at different locations
ENERGY SAVED /DAY : 4455.69 KWH for automatic switching ON/OFF of
shopfloor lights during daytime.
JAN’12 COST SAVED: Rs.26,032 PER DAY Installation of 28W T5 Energy saver
fluorescent lamps in place of conventional
ENERGY SAVED /DAY : 4381.69 KWH
40W lamps at different locations in the
DEC’11 COST SAVED: Rs.25,555 PER DAY plant.
Electrical interlocking of fresh air &
ENERGY SAVED /DAY : 4351.69 KWH exhaust blower motors in the plant with
Production machines to stop idle running of
NOV’11 COST SAVED: Rs.25,405 PER DAY
blowers during non-productive hours.
SBU-INDUSTRIAL May’12 /
33. POWER COST (Rs per Ah)
SHAMNAGAR & HALDIA DATA REQUIRED
0.29 0.293 0.286
0.244
0.226
2007-08 2008-09 2009-10 2010-11 2011-12
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37. BEST PRACTICE - HOSUR
BEST PRACTICE - HALDIA
BEST PRACTICE - SHAMNAGAR
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38. PATH AHEAD
Reverse the
manufacturing
employment trends Manufacturing
Could investment
in manufacturing 25% of
high intensity
Step-change in the UK has seized the
engineering &
Should competitiveness of manufacturing
technology
the opportunity
nation
Afford rapid
Establish the Skills & education
growth in
mechanism for rebalanced
Will applied science
economic towards science &
& innovation
development engineering
investment
0-5 years 5-10 years 10+ years
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39. PATH AHEAD
Adaptability is vital
"It is not the strongest of the species that survives,
nor the most intelligent; it is the one that is most
adaptable to change."
-- Charles Robert Darwin (1809-82)
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