Havells India Limited

Case Study
Havells Sahibabad Plant: Replacement
of Thermoset (DMC) material with
Thermosetting (Nylon) which helps in
recycling and reuse in moulding.

Challenge:
Previously we used DMC for MCCB G, for A & L frame.
DMC is a non-recyclable material. This initiative has direct linkage to
SDG 11, 12.
Challenges found during manufacturing were: • SDG 11: Sustainable cities and communities: to make our
1. Breakage and difficulty in rework cities and human settlements inclusive, safe, resilient and
2. Non-recyclable sustainable. For which it is very much required to manage
3. Low productivity the generated waste.
4. Rework due to heavy flashes • SDG 12: Responsible consumption and production:
ensuring sustainable consumption and production
Steps taken: patterns
As a responsible business organisation of India, we are
trying to make continuous improvement in the field of waste

From 2014-15, we have

management. We are following 3R technology for waste
reduction (Reduce, Reuse & Recycle) . So our dedicated
team came up with a new idea to recycle and reuse our achieved 27% reduction up
material. By replacing DMC with Nylon through design & to 2017-18 in non-recyclable
material consumption. At
technology upgradation. Nylon is a recyclable material. We
optimized our resources with the use of a recyclable material
instead of a non-recyclable one. the same time, we have
Challenged observed during upgradation were:
increased our recyclable
1. Marketing and CRI acceptance
2. Design change material consumption.
3. Product validation
4. Machine availability and load balancing
We have improved our
5. Colour combination productivity by reducing
6. Renewed process parameters
cycle time by 60-70% per
Benefits achieved by this replacement include:
1. Use of eco-friendly material. piece.
2. Reduction in waste with the use of recyclable material.
3. Use of recyclable material has rendered us more As a result we also saved
environmentally sustainable. cost.
4. Cost saving: In addition to cycle time reduction, we have
by shifting to Nylon from
also reduced our costs.
DMC. We have achieved an
annual savings of
Rs. 62.8 lacs.
Havells India Limited

Case Study
Havells Neemrana Plant: Installation of five
new automatic state-of-the-art German
Welding Fumes Extraction System and
filters Unit, Kemper at Welding Shop &
Water Heater Plant
Challenge: This initiative has direct linkage to SDG 03, 12
Previously we had only 2 nos. of fume extraction system and SDG 03: Ensure healthy lives and promote well-being for
there were visual fumes in plant all at all ages
Some of the challenges faced during procurement : Substantially reduce the number of deaths and illnesses from
1. Selection of highest efficiency fume extraction system hazardous chemicals and air, water and soil pollution and
2. Online Remote Monitoring contamination
3. Selection of the right product SDG 12: Ensure sustainable consumption and production
4. Automatic dust tray cleaning alarm patterns
5. Visual air quality status display
Significantly reduce their release to air, water and soil in
Steps taken: order to minimize their adverse impacts on human health and
As a responsible business organisation of India, we are trying the environment
to make continuous improvement in the field of Occupational
Health & Safety. Hence we selected a world-class welding
fume extraction system to mitigate chronic health hazards.

Some of the difficulties we faced while selecting this system:

1. Multiple manufacturers
2. Selecting a proven and reliable product
3. Previous 2 nos of fume extraction system were of
sub-standard quality

Advantages of installing a new fumes extraction system:

1. Mitigate Chronic Health Hazard to employees: We

extract all welding fumes from source of generation.

2. Zero Air Pollution: We filter hazardous fumes particulates

matters (PM 2.5) from welding fumes and cleaned air is
released in the plant.

3. High Filtration Efficiency of all the Kemper units is more

than 99.99% and it can filter up to 0.1 micron size metal
dust which is carcinogenic in nature.

4. Improve motivation of welders : Now operators feel safe

and confident while working at the Weld shop.

5. Inside view of the Plant is very clear : welding fumes are

not visible.
Havells India Limited

Case Study
Havells Faridabad Plant: Improvement of Energy
Performance
Challenge faced: 4. Conservation of non-renewable energy.
Non-renewable energy resources of the earth are fast getting 5. Reduction in downtime and increase in productivity.
depleted. Hence there is an urgent need to explore new These initiatives have direct linkages to SDGs 13 and 7.
sources of energy. • SDG 7: affordable and clean energy; by energy efficient
Steps taken: practices and renewable energy sources.
Keeping this in mind, the Faridabad plant of Havells is • SDG 13: climate action; by afforestation, adaptation and
switching over to renewable sources of energy such as solar reduction in emission.
energy.
We use energy from different renewable sources at Faridabad
plant.
Some of the initiatives leading to energy savings:
1. Installation of 100 kWp capacity solar plant.
2. Introduction of Energy Performance Indicators (EnPI] for
each department.
The main objective of EnPIs is to help in achieving individual
yearly target for reduction in respective specific energy
consumption.
For example, EnPIs for Paint shop for Electricity and PNG are
tracked by Energy consumed per square inch of area painted.
To reduce energy consumption, we have also optimized the
process and reduced downtime. Apart from this, we have
also introduced several energy saving measures.
Some of the improvements achieved through this
replacement include:
1. Reduction in overall energy consumption.
2. Introduction of the concept of Clean energy
3. Energy optimization is achieved through renewable
energy.

Energy intensity reduced

by 19.07% in 2017-18
over 2016-17.
Havells India Limited

Case Study
Havells Alwar Plant: Alternative eco-friendly
techniques of combustion
Challenge faced: 3. Higher CO emissions are observed during briquette
One of the problems we were facing in our Alwar plant was combustion. However the emissions due to incomplete
that when the furnace oil is atomized with air in the burner combustion can be effectively controlled by an optimized
and fired, it produces hot flue gases which then pass into combustion process, i.e., enhanced mixing.
the boiler tubes to generate steam. Furnace oil fired boilers 4. Reduction of secondary pollutants i.e., SOx and NOx
contribute to greenhouse gas emissions and secondary is achieved
pollutants as well.
Problems faced: This initiative helps
us to achieve a total
1. Excess emission of SOx, CO2, NOx.
2. We had to use fossil fuel for the operation.
3. Breathing problems were observed hence it it became an
emergency for us to solve the issue.
savings of INR 16,53,423.
4. Supreme Court banned the usage of furnace oil in
National Capital Region for any power generation
operation.

Steps taken:
Our dedicated team discovered that briquette is a better
alternative to address this issue.
The efficiency of the new combined fire tube and water tube
boiler is determined by using indirect method approach, also
called as heat-loss method. The efficiency of boiler when
fired with briquettes is found to be lower than when fired with
furnace oil.
Valuable benefits from this change include:
1. A significant reduction in the operating cost of boiler is
achieved by fuel conversion technology.
2. Emissions of furnace oil boiler as compared to briquette
boiler. The Sulphur oxides (SOx), Nitrogen oxides (NOx),
Carbon dioxide (CO2) emission levels are low while firing
briquettes. Carbon monoxide (CO) emission level due
to incomplete combustion of fuel is more when firing
briquettes. But it can be controlled by an optimized
combustion process.
3. This conversion of fuel utilizing briquettes in boiler offers
many economic, social and environmental benefits.
This alternative method also helps us in achieving SDG 13.
(Afforestation, Emissions Reduction, Adaptation)

1. Conserving fossil fuel reserves i.e., reducing petroleum oil

requirement by use of renewable source of energy can be
achieved.
2. Reduction in the amount of greenhouse gas emissions i.e.
CO2 emission reduction is obtained.
Havells India Limited

Case Study
Havells Haridwar Plant:
Reduction in power
consumption through VFD

Challenge:
Power consumption at our paint shop at Haridwar plant was
very high. The overall unit consumption at this unit was 190
Unit/hr. resulting in high power consumption for the entire
process.

Steps taken:
To solve this problem, our dedicated team has installed a
Variable Frequency Drive in the liquid paint shop that has
reduced the power consumption at this facility. A variable
frequency drive is a type of motor controller that drives
an electric motor and has the advantage of changing the
frequency and voltage supplied to the electric motor. A VFD
facilitates running of a motor. at the required load instead of
running it at peak load all the time.

Impacts of the transformation:

The installation of VFD results in reduced power consumption
as compared to the previous system.

Related SDG’s
This action aligns with SDG 12: Responsible Consumption
and Production: Ensuring Sustainable Consumption &
Production Patterns.

Remarkable reduction in
electricity consumption at
liquid paint shop from 19O
unit/hr to 16O unit/hr.
•A
 nnual electricity saving @
Rs. 6.22/unit.
•T
 otal savings achieved
Rs. 113,97,26O
Havells India Limited

Case Study
Havells Baddi Plant: Towards
Zero Accidents:

Challenge: Related SDGs:

There are total 40 power presses in our Baddi plant. 1. SDG 3: Good health and wellbeing: Ensure health and
Rendering the operations of these presses 1OO% safe is a safety and promote wellbeing for all irrespective of age.
major H&S concern area. 2. SDG 8: Decent work and economic growth: promoting
Difficulties identified: sustained, inclusive and sustainable economic growth, full
1. Though these are power presses, setting the tool is and productive employment and decent work for all.
a manual process to be done by employees before
operation commences.
2. As the tool setting process is manual the operator is
vulnerable to dangers of cutting or injury.
Steps taken:
Havells India Limited is committed to providing provide an
100% workplace safety for
ultimate safe work environment for all its employees with zero press operators.
accidents.
Our dedicated team explored solutions and finally came up
with integrated power presses with engineering control which
could stop power operation if the hands of the operator
inadvertently touched the machine.
This was achieved through:
1. Light Curtain Type IV installed at power presses. Designed
to automatically stop the press cycle (stroke) if the
sensing field is interrupted.
2. Mechanical Guards with Electrical interlocks installed to
stop press when guards are opened:
a. Guard shall prevent entry of hands or other body parts
into the point-of-operation by reaching through, over,
under or around the machine.
b. Guard shall offer visibility of the point-of-operation,
consistent with requirements of the operation being
performed.
c. Guard shall be fixed with fasteners which cannot
be easily removed by the operator to minimize the
possibility of misuse or removal of essential parts.

Benefits accruing through this initiative include:

1. 100% safety while working at power presses.
2. Safety interlocks are designed and programmed not to be
bypassed.
3. Full automation of pressing operation.