This document provides recommendations for saving electricity and air consumption in machine shops. It lists 12 ways to reduce energy usage, such as switching off lights when not needed, turning off equipment when not in use, reducing closing delays on automatic doors, cleaning and maintaining equipment regularly, installing insulation, replacing lights with LED bulbs, using natural airflow, checking air conditioning lines, optimizing appliance settings, making conservation a collaborative effort, using renewable energy sources, and properly maintaining airlocks, windows, and air exhaust systems. The overall goal is to cut costs and reduce the burden on utility companies by improving energy efficiency in machine shop operations.

1. HOW TO SAVE ELECTRICITY
CONSUMPTION IN
MACHINE SHOP

2. SUMMER TRAINING PROJECT REPORT
MARUTI SUZUKI INDIA LTD.
GURGAON PLANT
PROJECT GUIDANCE:KHEM CHAND
MGR, MACHINE SHOP
GURGAON PLANT
SUBMITTED BY: ASHU
ROLL NO.:8220702
BRANCH: ELECTRICAL &
INSTRUMENTATION,DEPTT. OF
INSTRUMENTATION, KURUKSHETRA
UNIVERSITY

3. PREFACE
 This report documents the work done during the summer internship at casting
shop, Maruti Suzuki India Ltd., Gurgaon under the supervision of my mentor Mr.
khem Chand. I spent most of my time in studying the process flow and
applications. Each section of the machine shop and the processes involved are
explained in brief. Proir to that a brief introduction of the company and plant have
been incorporated which I came across as my first step into the automobile
industry. The report includes the project study and analysis. During my summer
training tenure, I have gained a lot of knowledge about the various applications
and process at machine shop, safety standards and quality standards under the
supervision and guidance of my mentor. I also gained experience of working at an
esteemed organization like this one. I would very much admire criticism,
suggestions.

4. ACKNOWLEDGEMENT
 Industrial training is an indispensable part of any curriculum. It provides the students
with an opportunity to gain experience on the practical application of our knowledge.
 I express my gratitude to all the people at Maruti Suzuki India Limited who helped me
during the past four weeks. The exposure and experience gained at Maruti has been
unique.
 I would sincerely like to thank MR. KHEM CHAND(MGR, MACHINE SHOP, GURGAON)
for giving me this opportunity to work in their department and guiding me through
the projects for their department and guiding me through the projects for their
constant guidance and support.
 I would also like to express my sincere gratitude to the Maruti Suzuki Training Academy
their able guidance and keen interest in my training period.

5. DO’s and DONT’s to save electricity and
air consumption in Machining lines
 1. Lighting
 Switching off lights remains one of the easiest ways to save on energy but it’s
surprising how often lights are kept on, even when no one is in the lit area. This
problem is compounded in when employees go in and out of various buildings
and work areas as they go about their duties.
 Incorporate automated lighting systems that make adjustments based on the
room’s occupancy or daylight availability. You can also install day/night switches
to automatically control outdoor lighting. Additionally, install motion detector
sensors that only switch lights on when the area is in use.

6.  2.Turn off and run equipment only when required
 Ensure you shut off machinery and equipment when not in use. Walking through
your plant after-hours and ensuring equipment is powered down when not in use
can result in significant savings over time.
 Specifically, reduce the operating pressure of your air compressor, check for
leakages, and turn it off completely when not in use.

7.  3.Reduce closing door delay
 Automatic doors are a great way for manufacturing businesses, which require a
cold room or refrigerated storage, to save on energy as they use sensors or a
time delay to close the door.
 Energy savings can be made by reducing the close delay timeframe on automatic
doors, and limiting the frequency of cool room access as far as its practical.

8.  4. Clean and maintain equipment
 Regular cleaning and planned maintenance of your electrical and mechanical
equipment will go a long way towards optimising its performance and lifespan, which
can translate to energy efficiency savings.
 5. Insulation
 Insulation acts as a barrier against temperature shifts, making it much easier to keep
the workplace warmer in winter and cooler in summer. By installing insulation in the
roof, and walls of your workspace, you can reduce the amount of energy needed to
maintain room temperature during heat loss and heat gain. This is one of the most
practical and cost effective ways to make your facility more energy efficient.

9.  6. Air conditioning and heating
 Newer heating and cooling systems will be far more efficient than old ones, so it may
be worth getting systems more than 10 years old replaced. Both blow heaters and
portable radiators use significant amounts of electricity and will chew through the
power bills so discourage their use. Lastly ensure your air conditioning and heating are
set to the optimum points during the seasons.
 ‘Setting the temperature to 25 degrees Celsius could cut your office's daily air-
conditioning energy consumption by 18 per cent,’ ABC reports.

10.  7. Shade windows and walls
 Often, the primary source of heat entering a building is via unprotected windows.
The sun’s radiant energy can generate the same local heat as a single bar
radiator but Save energy by using fixed or adjustable shading, planting trees and
vegetation or installing sun filters on the windows and walls of the workplace—
especially industrial sheds— to protect it from radiant energy.
 This will reduce the impact of those extreme Australian summer temperatures,
improve comfort and save energy.

11.  8. Replace existing lights with LED
 In 2009, Australia commenced the phase out of incandescent bulbs and it is
estimated that this has saved nearly as much as 400,000 homes’ worth of
electricity consumption every year. LED bulbs use about a quarter of the
energy to produce the same light as halogens and can last five to ten times
longer. This makes them the logical lighting choice for energy savings, particularly
when manufacturing workspaces need adequate and plentiful lighting.

13.  9.Use natural airflow:
 Opening a window, or building door is a simple energy saving technique that can
help reduce air conditioning and heating costs by relying on natural ventilation
for climate control. Especially as many places in Australia experience up to one
hundred days per year with nice enough weather that you can open windows or a
roller door.
 10.Check air conditioning lines:
 Make sure that pipe lagging on all refrigerant lines are intact as insulation is
absolutely crucial, especially if the air conditioner is an outdoor unit. If the air
conditioner lines are not insulated, it's just absorbing heat from the environment
and cooling the outside air instead of the building and vice versa in winter.

14.  11. Optimise appliances:
 Depending on the appliances used in the workplace, you can optimise their settings to increase
energy savings. For example, you can increase the drinks fridge temperature in the kitchen by one
or two degrees to save energy without impacting employees or business.
 12. Make it collaborative, not top down
 Any energy savings initiative should be collaborative and involve all employees. If you want your
employees to change their behaviour they need to do it when you’re not in the room. So,
communicate the real business costs. Let them know how it affects the bottom line, and regularly
raise energy at toolbox meetings or monthly company meetups, to keep it top of mind. People will
want to do their part if you let them.

15.  Renewable Energy: The use of renewable energy in industrial facilities can also be a
source of cost-saving and reducing demand on the utility company. For ex- On
industrial scale, installing solar panel and shifting lighting load to it can help in
reducing the burden of power generation greatly.
 Some Other Points:
 Install only well-functioned airlocks, windows and entry and exit doors which cause
heat losses in the plant facility.
 Monitor the air exhaust from the ovens so as not to be excessive in the plant facility.
Ovens help to heat up the automobiles so to ensure that the hot air transmission from
the ovens is not too high.
 Install the direct air conditioning towers rather than overhead tubes in the facility and
maintained the air conditioner regularly.

16. THANKS