This document discusses sustainability practices in the engine manufacturing industry. It outlines how just-in-time production and reducing inventory impacts suppliers. It also describes the types of engines produced and their environmental and social impacts, including pollution effects. The document then discusses primary business activities and examples of value chain improvements from companies like reducing waste and increasing efficiency. Finally, it outlines best practices adopted by various engine companies focused on sustainability.

1. Management,
Bhubaneswar
Sustainability practices across Industries

2. PRESENTED BY :-
GROUP 7
PANKAJ GANDOTRA UM15094
PIYUSH UM15095
PRATISTHA SENAPATY UM15096
PREETI PATNAIK UM15097
PRITISH PRADHAN UM15098

3. Overview
 Industry driven by Just-In-Time production.
 Industry requires its suppliers to also provide materials and components
on a just-in-time basis to reduce inventory
 Clients of engines industry are especially original equipment
manufacturers
 Highly Competitive market because greater demand for higher quality
and more environmentally friendly engines

4. Types of Engines
 Light vehicle diesel engines
 Heavy duty diesel engines
 Hybrid and alternative fuel engines
 Engines are also classified according to:
 stroke
 fuel used
 method of ignition
 number of cylinder
 arrangement of cylinder

5. Environment & Social Impact
• Many engine industries exist now a days
• Engines are the most important prime movers available today
• They are the largest contributor of environmental pollution problems world wide.
Causes
• Automotive
• Emissions
• Filtrations
• Fuel Pumps
• Generators
• Industries
• Power generation
• Turbo technologies
Effects
• Cancer
• Cardiovascular &
Respiratory issues
• Pollution of air ,
Water &Soil
• Reduction in
visibility
• Global climate
change
Preventive Measures
• Fuel Changes : Reduction in sulphur and Aromatics content
• Technology changes : Engine modifications, Exhaust gas
recirculation, catalytic after treatment, Hybrid engines and fuel
cells. It takes some time to implement.
• Programs by pollution control agencies : They can mandate
the use of exhaust trap retrofits, smoke inspection of trucks and
off-road equipment.
Vision for Next 10 years
Decade of Clean DieselWhich will help to reduce the Environment & Social impact of this industry

6. Primary Activities-
Inbound Logistics- Using Just In Time,
kaizen to reduce costs, material,
storage
Operations- Using Lean Six sigma to
reduce wastage and costs
Sales and marketing- SaaS and CRM
such as sales force to minimise travel
Service- Online support reduce
engineer transit fuel costs. Preplanned
training schedules & maintenance
keep engine emissions low
Outbound Logistics- QC before
shipment, optimum loading, shipping
during lax traffic times
Source: http://slideplayer.com/slide/6118040/

7. Impact of value chain improvements
Sand used in casting of engine
block was ejected as engine
waste.
Addition of sand regeneration
equipment recycled 50 % of sand
Engine block face drying carried
out by gas dryer earlier. A lot of
gas energy was consumed
Replacing it with Microwave
furnace reduced energy required
Source:http://nett21.gec.jp/CP_DATA/en_inditech.php?tid=834
Organization Kubota Corporation Okajima Plant

8. Benefits Analysis
Energy savings City gas reduction 359 thousand metres cube/year
Raw materials reduction Reduction of new sand purchase
for core manufacture 5,000 t/year
Waste Reduction Waste soil Amount reduced: 4,000 t/year
Net savings by implementing Sand Regeneration
Equipment and Microwave Drying-
Cost for Introducing Technologies
(Yen)
130 million yen
Running Cost Before Introduction 170 million
yen/year
Running Cost After Introduction
91 million yen/year
Cost Advantage
79 million yen/year

9. BEST PRACTICES ADOPTED BY THE
COMPANIES IN
TERMS OF SUSTAINABILITY IN ENGINE
MANUFACTURING SECTOR

10. Kirloskar Oil Engines Limited
 KOEL is a leader in the manufacturing of
diesel engines, agricultural pumpsets and
generating sets
 Optimizing test cycle of engines thereby
reducing diesel consumption
 Installation of VFD (Variable Frequency
Drive) for Engine Painting blowers to save
power
 Installation of auto timer panel for Engine
testing Lighting system to avoid energy
wastage
 Use of Timer circuit for paint booth heaters
 Reduction in specific raw material
consumption.

11. Continued…
 Weight reduction of Crank Case, Crank Shaft, Structural Steel

12. Continued…
 Recycling of Engine Coolant, Engine Lubricating Oil

13. Cummins
 Cummins has been a pioneer in clean diesel technology
 Cummins introduced more than seventy new productsupdates all over
the world in 2013, many addressing emissions, fuel efficiency or both.
 Cummins strives to reach new ‘Zero Disposal’ challenge . Company in 2013
recycled about 89 percent of its waste
 A Cummins ReCon engine Or part requires about 85 percent less energy
than manufacturing a new engine or part
 Cummins has reduced company-wide water usage intensity by more than
30 percent, adjusted to total work hours

14. Ford’s Dagenham Diesel Center , UK
 The new Ford EcoBlue diesel engine production line at Dagenham Engine
Plant (Dagenham, United Kingdom ) will use less water and energy by
more than 50%.
 The reduction in the volume of coolant pumped reduce energy usage. 3
smaller coolant systems require 70% less energy
 Minimum quantity lubrication (MQL) machining tools—these replace
high coolant volumes with fine mists of oil to cool, lubricate and clean
during the metal working process—use 99.8% less water
 Cold testing technology that allows completed engines to be tested
without being started—saving 50,000 liters of diesel per year.
 Zero waste sent to landfill

15. Continental’s engine mounts with rubber
made from dandelion roots
 Continental has developed and tested engine mounts with rubber made
from dandelion roots
 The plant is potentially an alternative, environmentally friendly resource
and could further reduce dependency on traditionally produced natural
rubber
 It can also generate savings in CO2 emissions and transport costs.

16. Toyota to pioneer use of biosynthetic rubber
in engine
 Toyota is the first automaker to use biohydrin, a newly-developed
biosynthetic rubber product, in engine
 Biohydrin rubber is manufactured using plant-derived bio-materials
instead of epichlorohydrin
 These bio-materials achieve an estimated 20% reduction in material
lifecycle carbon emissions in comparison to conventional petroleum-
based hydrin rubber

17. Facts Say….
 In India, the policies and regulatory laws have not been very successful in
bringing down the pollution level of these companies
 R&D is lesser in compared to Global Players
 More of a Profit Oriented Market
 However, in US, since engines started being regulated by the U.S.
Environmental Protection Agency in the 1970s, there have been a drastic
reduction in emissions
 For example, on-highway diesel engines, emit 90 % less particulate matter
(PM) and oxides of nitrogen (NOx) today compared to just a little over a
decade ago, reaching near-zero levels