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SBU - INDUSTRIAL
               MANUFACTURING



PARTICIPANTS
1) Pulak Pramanik – Industrial Overview
2) Subroto Sinha – Shamnagar Overview
3) Aloke Kr Sarkar – Haldia Overview
4) Kalyan Saha – Haldia Indl. Overview
                                               P PRAMANIK
5) M. Ramachandran – Hosur Overview                19-05-2012


                                          SBU-INDUSTRIAL   May’12 /
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)



                                                                                   SBU-INDUSTRIAL                    May’12 /
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



                                                       SBU-INDUSTRIAL   May’12 /   3
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



                                                    SBU-INDUSTRIAL   May’12 /   4
INDUSTRIAL - TURN OVER

                                INDUSTRIAL - TURN OVER
                                                                                  7%
        2500                                                       10 %                       %
                                                      15 %
                                                                                      2104
                                         14 %                        1960
        2000                24 %                       1791
                                          1556
` Cr.




        1500                 1364
                1103
        1000

         500

           0
               2007 - '08   2008 - '09   2009 - '10   2010 - '11    2011 - '12   BUDGET 2012 - '13



                                                                   SBU-INDUSTRIAL      May’12 /   5
PRODUCTION TREND ( BATTERY & CELL )

                         INDUSTRIAL - PRODUCTION
                                                                                 15 %
                                                                  0%
  2500
                                                   13 %                                      %
                                      17 %
                        14 %                                                      2024
  2000
                                                    1760           1760
                                       1565
MAh




  1500                  1334
             1170
  1000

      500

        0
            2007-'08   2008-'09       2009 - '10   2010 - '11    2011 - '12   BUDGET 2012 -
                                                                                  '13


                                                                SBU-INDUSTRIAL    May’12 /   6
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




                                                      SBU-INDUSTRIAL   May’12 /   7
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

                                                       SBU-INDUSTRIAL    May’12 /
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




                                              SBU-INDUSTRIAL   May’12 /   9
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




                                           SBU-INDUSTRIAL   May’12 / 10
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.

                                              SBU-INDUSTRIAL   May’12 / 11
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.




                                               SBU-INDUSTRIAL   May’12 / 12
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
                                                                          SBU-INDUSTRIAL       May’12 /
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



                                                                    SBU-INDUSTRIAL          May’12 / 14
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



                                                                                   SBU-INDUSTRIAL             May’12 / 15
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



                                                                   SBU-INDUSTRIAL              May’12 / 16
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


                                                                                                                  SBU-INDUSTRIAL   May’12 / 17
LEAD IN BLOOD
                         HOSUR & SHAMNAGAR DATA
                         REQUIRED
                    10            10        10
      µgm/DL




                Haldia      Shamnagar   Hosur




                                            SBU-INDUSTRIAL   May’12 / 18
INCIDENT TREND

                   SHAMNAGAR & HALDIA DATA REQUIRED
       148



                  64        64        58
                                                   42



     2007-08   2008-09   2009-10   2010-11      2011-12




                                             SBU-INDUSTRIAL   May’12 / 19
ACCIDENT TREND


                    10
                              SHAMNAGAR DATA REQUIRED




      3         3             3   3 3 3          3 3                  3
                         2                                  2 2
          1                                  1

      2007-08       2008-09       2009-10     2010-11       2011-12




                         HALDIA   HOSUR     SHAMNAGAR

                                                        SBU-INDUSTRIAL    May’12 / 20
ENVIRONMENTAL PARAMETERS

                      EFFLUENT GENERATION (KL/MT OF Pb)                                                                                                                     SLUDGE GENERATION (KG/MT OF Pb)
                               HALDIA                HOSUR                SHAMNAGAR                                                                                                    HALDIA            HOSUR           SHAMNAGAR
                                     3.33




                                                                                                                                                        82.1
               3.19




                                                                                                                                                                                                 78.9
                                                                                                         3.07
                                                                              2.94
                                                          3.1




                                                                                                                             2.84




                                                                                                                                                                               75




                                                                                                                                                                                                                               65.6




                                                                                                                                                                                                                                               63.4
 2.26




                                            2.15




                                                                                                                                                                                                                 53.6
                        2.1




                                                                1.72




                                                                                           1.26




                                                                                                                    1.22
        0.74




                                                                       0.47




                                                                                                  0.46
                              0.45




                                                   0.42




                                                                                                                                                                                       4.66




                                                                                                                                                                                                         3.58
                                                                                                                                                                  8.3




                                                                                                                                                                                                                        2.34




                                                                                                                                                                                                                                      1.78
                                                                                                                                                                                                                                      0.11
                                                                                                                                                                                      0.06
                                                                                                                                                                0.06




                                                                                                                                                                                                        0.05




                                                                                                                                                                                                                        0.06




                                                                                                                                                                                                                                                      0.05
 2007-08                2008-09             2009-10             2010-11                     2011-12                  2012-13                             2007-08                2008-09           2009-10        2010-11       2011-12         2012-13




                                                                                                         LIME CONSUMPTION (KG/MT OF Pb)
                                                                                                                   HALDIA                 HOSUR                  SHAMNAGAR
                                                                                 36.48




                                                                                                                                33.13
                                                                                                            35




                                                                                                                                                      19.44




                                                                                                                                                                             16.08




                                                                                                                                                                                               15.75
                                                                                                                                               9.33




                                                                                                                                                                     8.13




                                                                                                                                                                                        4.97




                                                                                                                                                                                                          4.85
                                                                                         4.61




                                                                                                                  2.59




                                                                                                                                        1.99




                                                                                                                                                                                     0.99
                                                                                                                                                               1.3
                                                                                                0




                                                                                                                         0




                                                                                     2007-08                    2008-09             2009-10            2010-11                2011-12           2012-13




                                                                                                                                                                                                         SBU-INDUSTRIAL                      May’12 / 21
xxxxxxxxxx
ENVIRONMENTAL PARAMETERS : -

                         LPG CONSUMPTION (KG/MT OF Pb)                                                                                                RAW WATER CONSUMPTION (KL/MT OF Pb)
                                                                                                                                                                                HALDIA                HOSUR              SHAMNAGAR
                                 HALDIA            HOSUR                  SHAMNAGAR




                                                                                                                                                                                    38.02
                                                                                                                                                      36.86
         36.21




                                                                                                                                                                                                          32.86
                 31.96




                                  31.04
                                 29.07




                                                                     28.05
                                                  27.42




                                                                                        26.69




                                                                                                                                                                                                                               26.34
                                                  26.23




                                                                    25.29




                                                                                       24.55




                                                                                                                                                                                                                                                     23.01
                                                                                                                 22.11
                                                                                                  21.67




                                                                                                                                                                                                                                                                     19.99
 17.89




                                                                               15.61
                                                           15.49
                                          15.14
                          16.5




                                                                                                                                      12.54




                                                                                                                                                                    10.44




                                                                                                                                                                                              10




                                                                                                                                                                                                                                       6.11




                                                                                                                                                                                                                                                              5.98
                                                                                                                                                                            3.107




                                                                                                                                                                                                                  6.9
                                                                                                                                              3.47




                                                                                                                                                                                                                                              2.83
                                                                                                                                                                                                   2.81




                                                                                                                                                                                                                        2.77
 2007-08                  2008-09         2009-10           2010-11            2011-12             2012-13                             2007-08                       2008-09                    2009-10           2010-11               2011-12                2012-13




                                                                          DM WATER CONSUMPTION (KL/MT OF Pb)
                                                                                         HALDIA              HOSUR                SHAMNAGAR
                                                          3.21




                                                                              2.78




                                                                                                  2.09




                                                                                                                         1.7




                                                                                                                                                     1.48




                                                                                                                                                                                1.41
                                                                   0.85




                                                                                                                               0.71
                                                                                       0.67




                                                                                                          0.67




                                                                                                                                                              0.7
                                                                          0




                                                                                              0




                                                                                                                 0




                                                                                                                                      0




                                                                                                                                                                    0




                                                                                                                                                                                            0
                                                          2007-08             2008-09             2009-10                2010-11                     2011-12                        2012-13




                                                                                                                                                                                                           SBU-INDUSTRIAL                                    May’12 / 22
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
                                                                           SBU-INDUSTRIAL      May’12 / 23
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
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

                                                                                                                 SBU-INDUSTRIAL                 May’12 / 25
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

                                                                                                                      SBU-INDUSTRIAL                  May’12 / 26
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




                                                                                                                    SBU-INDUSTRIAL                May’12 / 27
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
                                                                                                                SBU-INDUSTRIAL              May’12 / 28
METAL PASS BOOK SYSTEM
PRODUCTION AS PER SALES – THROUGH METAL PASS BOOK.




                                             SBU-INDUSTRIAL   May’12 /
REPLENISHMENT SYSTEM
WEEKLY SALES TO PRODUCTION REPLENISHMENT SCHEME




                                            SBU-INDUSTRIAL   May’12 / 30
ENERGY COST AND CONSERVATION

                                                      POWER CONSUMPTION (KWH/MT OF Pb)
                                                                HALDIA             HOSUR            SHAMNAGAR




                                                               1342
                             1304




                                                                                 1260




                                                                                                                                1234
                                                                                                 1225
                                               1221




                                                                                                                                                          1200
    1191




                                                                                                                   1171




                                                                                                                                                  1135
                      1134
              1126




                                       1050




                                                                                                                                          994




                                                                                                                                                                            987
                                                                         955




                                                                                                           946
            2007-08                  2008-09                           2009-10                           2010-11                        2011-12                   2012-13


                                                                           POWER FACTOR
                                                      HALDIA                             HOSUR                             SHAMNAGAR




                                                                                                                                          0.993
                                                                                                           0.992
                                                                         0.991
                                       0.988




                                                                                 0.988




                                                                                                                   0.987




                                                                                                                                                          0.984
                                                                                                                                0.982
                                                                                                 0.979




                                                                                                                                                  0.975
              0.98




                                               0.98
                      0.97




                                                                                                                                                                            0.97
                             0.956




                                                               0.951
    0.916




            2007-08                  2008-09                           2009-10                           2010-11                        2011-12                   2012-13



                                                                                                                                          SBU-INDUSTRIAL                May’12 / 31
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 /
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




                                             SBU-INDUSTRIAL   May’12 / 33
FUEL COST (Rs per Ah)

                   SHAMNAGAR & HALDIA DATA REQUIRED
      0.059     0.061               0.058        0.058
                          0.044




     2007-08   2008-09   2009-10   2010-11      2011-12




                                             SBU-INDUSTRIAL   May’12 / 34
KAIZENS
KAIZENS - HALDIA




KAIZENS - HOSUR




KAIZENS - SHAMNAGAR




                      SBU-INDUSTRIAL   May’12 /
MIGRATED BEST PRACTICES




       SBU-INDUSTRIAL   May’12 / 36
BEST PRACTICE - HOSUR




BEST PRACTICE - HALDIA




BEST PRACTICE - SHAMNAGAR




                            SBU-INDUSTRIAL   May’12 /
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

                                                    SBU-INDUSTRIAL   May’12 / 38
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)
                                             SBU-INDUSTRIAL   May’12 / 39

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Pp industrial - 11.05.2012

  • 1. SBU - INDUSTRIAL MANUFACTURING PARTICIPANTS 1) Pulak Pramanik – Industrial Overview 2) Subroto Sinha – Shamnagar Overview 3) Aloke Kr Sarkar – Haldia Overview 4) Kalyan Saha – Haldia Indl. Overview P PRAMANIK 5) M. Ramachandran – Hosur Overview 19-05-2012 SBU-INDUSTRIAL May’12 /
  • 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) SBU-INDUSTRIAL May’12 /
  • 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 SBU-INDUSTRIAL May’12 / 3
  • 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 SBU-INDUSTRIAL May’12 / 4
  • 5. INDUSTRIAL - TURN OVER INDUSTRIAL - TURN OVER 7% 2500 10 % % 15 % 2104 14 % 1960 2000 24 % 1791 1556 ` Cr. 1500 1364 1103 1000 500 0 2007 - '08 2008 - '09 2009 - '10 2010 - '11 2011 - '12 BUDGET 2012 - '13 SBU-INDUSTRIAL May’12 / 5
  • 6. PRODUCTION TREND ( BATTERY & CELL ) INDUSTRIAL - PRODUCTION 15 % 0% 2500 13 % % 17 % 14 % 2024 2000 1760 1760 1565 MAh 1500 1334 1170 1000 500 0 2007-'08 2008-'09 2009 - '10 2010 - '11 2011 - '12 BUDGET 2012 - '13 SBU-INDUSTRIAL May’12 / 6
  • 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 SBU-INDUSTRIAL May’12 / 7
  • 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 SBU-INDUSTRIAL May’12 /
  • 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 SBU-INDUSTRIAL May’12 / 9
  • 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 SBU-INDUSTRIAL May’12 / 10
  • 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. SBU-INDUSTRIAL May’12 / 11
  • 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. SBU-INDUSTRIAL May’12 / 12
  • 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 SBU-INDUSTRIAL May’12 /
  • 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 SBU-INDUSTRIAL May’12 / 14
  • 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 SBU-INDUSTRIAL May’12 / 15
  • 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 SBU-INDUSTRIAL May’12 / 16
  • 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 SBU-INDUSTRIAL May’12 / 17
  • 18. LEAD IN BLOOD HOSUR & SHAMNAGAR DATA REQUIRED 10 10 10 µgm/DL Haldia Shamnagar Hosur SBU-INDUSTRIAL May’12 / 18
  • 19. INCIDENT TREND SHAMNAGAR & HALDIA DATA REQUIRED 148 64 64 58 42 2007-08 2008-09 2009-10 2010-11 2011-12 SBU-INDUSTRIAL May’12 / 19
  • 20. ACCIDENT TREND 10 SHAMNAGAR DATA REQUIRED 3 3 3 3 3 3 3 3 3 2 2 2 1 1 2007-08 2008-09 2009-10 2010-11 2011-12 HALDIA HOSUR SHAMNAGAR SBU-INDUSTRIAL May’12 / 20
  • 21. ENVIRONMENTAL PARAMETERS EFFLUENT GENERATION (KL/MT OF Pb) SLUDGE GENERATION (KG/MT OF Pb) HALDIA HOSUR SHAMNAGAR HALDIA HOSUR SHAMNAGAR 3.33 82.1 3.19 78.9 3.07 2.94 3.1 2.84 75 65.6 63.4 2.26 2.15 53.6 2.1 1.72 1.26 1.22 0.74 0.47 0.46 0.45 0.42 4.66 3.58 8.3 2.34 1.78 0.11 0.06 0.06 0.05 0.06 0.05 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 LIME CONSUMPTION (KG/MT OF Pb) HALDIA HOSUR SHAMNAGAR 36.48 33.13 35 19.44 16.08 15.75 9.33 8.13 4.97 4.85 4.61 2.59 1.99 0.99 1.3 0 0 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 SBU-INDUSTRIAL May’12 / 21
  • 22. xxxxxxxxxx ENVIRONMENTAL PARAMETERS : - LPG CONSUMPTION (KG/MT OF Pb) RAW WATER CONSUMPTION (KL/MT OF Pb) HALDIA HOSUR SHAMNAGAR HALDIA HOSUR SHAMNAGAR 38.02 36.86 36.21 32.86 31.96 31.04 29.07 28.05 27.42 26.69 26.34 26.23 25.29 24.55 23.01 22.11 21.67 19.99 17.89 15.61 15.49 15.14 16.5 12.54 10.44 10 6.11 5.98 3.107 6.9 3.47 2.83 2.81 2.77 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 DM WATER CONSUMPTION (KL/MT OF Pb) HALDIA HOSUR SHAMNAGAR 3.21 2.78 2.09 1.7 1.48 1.41 0.85 0.71 0.67 0.67 0.7 0 0 0 0 0 0 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 SBU-INDUSTRIAL May’12 / 22
  • 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 SBU-INDUSTRIAL May’12 / 23
  • 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 SBU-INDUSTRIAL May’12 / 25
  • 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 SBU-INDUSTRIAL May’12 / 26
  • 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 SBU-INDUSTRIAL May’12 / 27
  • 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 SBU-INDUSTRIAL May’12 / 28
  • 29. METAL PASS BOOK SYSTEM PRODUCTION AS PER SALES – THROUGH METAL PASS BOOK. SBU-INDUSTRIAL May’12 /
  • 30. REPLENISHMENT SYSTEM WEEKLY SALES TO PRODUCTION REPLENISHMENT SCHEME SBU-INDUSTRIAL May’12 / 30
  • 31. ENERGY COST AND CONSERVATION POWER CONSUMPTION (KWH/MT OF Pb) HALDIA HOSUR SHAMNAGAR 1342 1304 1260 1234 1225 1221 1200 1191 1171 1135 1134 1126 1050 994 987 955 946 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 POWER FACTOR HALDIA HOSUR SHAMNAGAR 0.993 0.992 0.991 0.988 0.988 0.987 0.984 0.982 0.979 0.975 0.98 0.98 0.97 0.97 0.956 0.951 0.916 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 SBU-INDUSTRIAL May’12 / 31
  • 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 SBU-INDUSTRIAL May’12 / 33
  • 34. FUEL COST (Rs per Ah) SHAMNAGAR & HALDIA DATA REQUIRED 0.059 0.061 0.058 0.058 0.044 2007-08 2008-09 2009-10 2010-11 2011-12 SBU-INDUSTRIAL May’12 / 34
  • 35. KAIZENS KAIZENS - HALDIA KAIZENS - HOSUR KAIZENS - SHAMNAGAR SBU-INDUSTRIAL May’12 /
  • 36. MIGRATED BEST PRACTICES SBU-INDUSTRIAL May’12 / 36
  • 37. BEST PRACTICE - HOSUR BEST PRACTICE - HALDIA BEST PRACTICE - SHAMNAGAR SBU-INDUSTRIAL May’12 /
  • 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 SBU-INDUSTRIAL May’12 / 38
  • 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) SBU-INDUSTRIAL May’12 / 39