Manu Yantralaya Pvt. Ltd.
Energy Management System Manual
Rev 0 01/09/14 Issue 1 01/09/14 Page 1 of 35
Energy Management System Manual
Manu Yantralaya Pvt. Ltd. F-701,702 Sitapura Industrial Area, Jaipur – 302022 (Raj) India Tel : +91 141 2771412, 3278283 Fax : +91 141 2771410 E-mail :
[email protected] Web Site : www.manujaipur.com
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Energy Management System Manual
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Foreword 1. This manual describes the adopted by this organisation
Energy
Management
System
as
2. This manual is prepared in accordance with the requirements of ISO 50001: 2011 standard. 3. The system in accordance to the above referred standard is prepared for the entire Energy Management System of the organisation. 4. The various sections of this manual define the way in which the company addresses each clause of the standard. 5. This manual is the property of our organization and is a controlled document. 6. It may not be reproduced, either in part or full, without prior written permission of the company. 7. For hard copies, stamp in red ink by controlling authority is treated as evidence of control.
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Table of Contents Section No. EnMS-I EnMS-II EnMS-III EnMS-IV EnMS-V EnMS-VI EnMS-VII EnMS-VIII EnMS-IX EnMS-4.1 EnMS-4.2 EnMS-4.2 EnMS-4.2 EnMS-4.3 EnMS-4.4 EnMS-4.4 EnMS-4.4 EnMS-4.4 EnMS-4.4 EnMS-4.4 EnMS-4.4 EnMS-4.5 EnMS-4.5 EnMS-4.5 EnMS-4.5 EnMS-4.5 EnMS-4.5 EnMS-4.5 EnMS-4.5 EnMS-4.5 EnMS-4.5 EnMS-4.6 EnMS-4.6 EnMS-4.6 Prepared By Reviewed By
Description Cover Page Foreword Table of Contents Introduction Process Chart Declaration & Scope Amendment Record Distribution & Abbreviation List List of Procedures General Requirements Management Responsibility Top Management Management Representative Energy Policy Energy Planning General Legal requirements and other requirements Energy Review Energy baseline Energy Performance Indicators Energy Objectives , Energy targets and energy action management plan Implementation and Operation General Competence , training and awareness Communication Documentation Documentation requirements Control of Documents Operational control Design Procurement of energy services , products, equipments and energy Checking Monitoring, measurement and analysis Evaluation of compliance with legal requirements and other requirements MR MR
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ISO 50001 Clause 4.1 4.2 4.2.1 4.2.2 4.3 4.4 4.4.1
Page No. 1 2 3-4 5 6 7 8 9 10 11 12 12 13 14 15 16
4.4.2
16
4.4.3 4.4.4 4.4.5
17 18 19
4.4.6
20
4.5 4.5.1 4.5.2 4.5.3 4.5.4 4.5.4.1 4.5.4.2 4.5.5 4.5.6
21 21 22 23 24 24 25 26 27
4.5.7
28
4.6 4.6.1
29 29 30
4.6.2 Copy No. Status
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Manu Yantralaya Pvt. Ltd. EnMS-4.6 EnMS-4.6 EnMS-4.6 EnMS-4.7 EnMS-4.5 EnMS -4.7 EnMS -4.7
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Energy Management System Manual
Internal audit of the EnMS Nonconformities, correction, corrective action and preventive action Control of records Management review General Input to management review Output to management review
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4.6.3
31
4.6.4
32
4.6.5 4.7 4.7.1 4.7.2 4.7.3
33 34 34 34 35
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INTRODUCTION : Company Profile & Important Details Establishment
2007
Contact Person
Mr. Mahendra Banthia, MD
Weekly Off Day
Sunday
SSI Registration No.
080121205515
T.I.N.
8551653324
Export Import No.
1399008331
Connected Load
850 KVA
Major Customers
SKF, NBC, NRB, TATA, CMSP-USA, TOHO, SKF-Indonesia, FAG-UK,NSK,NACHI
ECC No.
AACCM0082FXM002
Generator Capacity
380 KVA and 625 KVA
ESI Registration No.
15000168960000500
PF Registration No.
RJ14_13605
Factory Registration No.
RJ28712
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Energy Management System Manual
Process Chart :
Pre Riveted Cage RAW MATERIAL
BLANKING
STORAGE
INSPECTION & PACKING
TRANSFER LINE
TUMBLING
OILING
PRE BENDING
50% FEMALE CAGES
(RUST PREVENTIVE)
MALE CAGES
RIVET INSERTION
POCKETING
PIERCING
ORIENTATION
TUMBLING
50%
Dust Shield - On Transfer Press (In House) TRANSFER LINE
STORAGE
BLANKING & NOTCHING
PRE BENDING
INSPECTION & PACKING
OILING (RUST PREVENTIVE OIL)
CURLING
VISUAL INSPECTION & ORIENTATION
ZINC PASSIVATION
NO
ZINC PASSIVATION
RAW MATERIAL
YES
(Sub Contrator)
Seal Insert - Washer
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RAW MATERIAL
BLANKING
TUMBLING
STORAGE
INSPECTION & PACKING
OILING (Rust preventive)
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SCOPE AND BOUNDARIES:
This Energy Management System Manual aims at ensuring compliance to the requirements of ISO 50001: 2011 at the manufacturing site situated at F-701,702 Sitapura Industrial Area, Jaipur. The scope covers all the activities carried out in the physical boundary at this site.
Scope of Registration : Manufacturing and Supply of Sheet Metal Components
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Amendment Record Issue No. 1 Section No.
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Title & Details of Revision
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Energy Management System Manual List of Abbreviations
Abbreviated Name CFT CP ECN EnMP EnMS EnSP FM FMEA IPC IQA MR NC OCP PO PR QA SI SPC SR WI EnPIs
Expanded Name Cross Functional Team Control Plan Engineering Change Note Energy Management Program Energy Management System Energy System Procedure Factory Manager Failure Mode & Effect Analysis Interested Party Concern Internal Quality Audit Management Representative Non-conformity Operational Control Procedure Purchase Order Primary Responsibility Quality Assurance Store In-charge Statistical Process Control Secondary Responsibility Work Instruction Energy Performance Indicators Document Distribution List
Copy No. Master Electronic
Distributed To MR Accessible To All (Protected, Electronic Copy On Server)
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Procedure No.
Procedure Title (Procedure For)
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ISO 50001:2011 Clause No.
EnSP-1
Legal Requirements and Other Requirements
4.4.2
EnSP-2
Internal And External Communication
4.5.3
QSP-1
Control of Documents
4.5.4.2
QSP-2
Control of Records
4.6.5
QSP-3
Internal Audit
4.6.3
QSP-4
Control of Non-Conforming Products
......
QSP-5
Corrective And Preventive Actions
4.6.4
QSP-6
Purchase
......
QSP-7
Training
4.5.2
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4.1 General Requirements : The organization has established an Energy Management System capable of continually improving the energy performance and prevention of wastes of Energy. It is the responsibility of every employee to ensure compliance to the established system. This EnMS enables the company to:
established, document, implement, maintain and improve an EnMS in accordance with the requirements of this International Standard;
defined and documented the scope and boundaries of its EnMS;
determined how it will meet the requirements of this International Standard in order to achieve continual improvement of its energy performance and of its EnMS.
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Energy Management System Manual
4.2 Management Responsibility: 4.2.1 Top Management: Top management demonstrate its commitment to support the EnMS and to continually improve its effectiveness by:
Defining, establishing, implementing and maintaining an energy policy.
Appointing a management representative and approving the formation of an energy management team.
Providing the resources needed to establish, implement, maintain and improve the EnMS and the resulting energy performance..
Identifying the scope and boundaries to be addressed by the EnMS.
Communicating the importance of energy management to those in the organization.
Ensuring that energy objectives and targets are established.
Ensuring that EnPIs are appropriate to the organization.
Considering energy performance in long-term planning.
Ensuring that results are measured and reported at determined intervals.
Ref. MRM
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4.2.2 Management Representative: The documents are controlled.
Internal audits are properly planned and executed and necessary Corrective actions are effectively taken.
Control of records is proper.
Liaison with third party on matters relating to management system of the organisation.
Preparation and review of documents in accordance to the standards and organisational requirements.
Ensuring that corrective and preventive actions taken are effective.
Collection and presentation of information relating to management system performance for regular review
The MR is authorised to schedule audit any time against and activity or department, based on non conformances observed against it.MR is authorised to change system documents or may recommend, delay in document changes based on its effect on other functions in the organisation.
Ref. Master File
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4.3 Energy Policy: We at Manu Yantralaya Pvt. Ltd. are committed to efficient use of various forms of energy to produce and deliver products and services to our customers, minimize cost and enhance competitive position. To accomplish this we will:
Monitor closely and control the consumption of various forms of energy through an effective energy management system.
Make energy conservation a mass movement with awareness and involvement of all employees
Adopt appropriate energy efficient technology to reduce consumption.
Maximise use of cheaper and easily available or alternative forms of energy and implement contingency plans to protect operations from energy supply interruptions.
Maintain a clean environment and conserve natural resources.
Cooperate with governmental agencies and utility companies on energy programs
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4.4 Energy Planning 4.4.1 General: The organization conduct and document an energy planning process. Energy planning consistent with the energy policy and lead to activities that continually improve energy performance. Energy planning involved a review of the organization's activities that can affect energy performance. Below figure provides a conceptual diagram intended to improve understanding of the energy planning process.
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4.4 General 4.4.2 Legal & Other Requirements: The organization procedure:
has
established,
implemented
and
maintained
a
a) To identify and have access to the applicable legal requirements and other requirements (e.g. SKF Code of Conduct, CO2 monitoring) to which the organization subscribes related to its significant of energy uses. b) To determine how these requirements apply to its significant of energy uses. The organization ensures that these applicable legal requirements and other requirements to which the organization subscribes are taken into account in establishing, implementing and maintaining its energy management system Refer : 1.
EnSP-1 Procedure for Compliance to Legal Requirements
2.
MRM Minutes
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4.4.3 Energy review : Our organization developed, recorded, and maintained an energy review. The methodology and criteria used to develop the energy review documented. To develop the energy review, the organization is:
Analyzed energy use and consumption based on measurement and other data,
Identify current energy sources. Evaluate past and present energy use and consumption.
Based on the analysis of energy use and consumption, identify the areas of significant energy use,
Identify the facilities, equipment, system, processes and personnel working for, or on behalf of, the organization that significantly affect energy use and consumption. Identify other relevant variables affecting significant energy uses. Determine the current energy performance of facilities, equipment, system and processes related to identified significant energy uses. Estimate future energy use and consumption.
Identify, prioritize and record opportunities for improving energy performance.
Ref. Monitoring sheet
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4.4.4 Energy baseline : The organization established an energy baseline(s) using the information in the initial energy review, considering a data period suitable to the organization's energy use and consumption. Changes in energy performance measured against the energy baseline(s). Adjustments to the baseline(s) shall made in the case of one or more of the following: ⎯EnPIs no longer reflect organizational energy use and consumption, or ⎯ there have been major changes to the process, operational Patterns, or energy system, or ⎯ According to a predetermined method. The energy baseline(s) is maintained and recorded
Ref. EnPIs sheet
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4.4.5 Energy performance indicators :
The organization identified EnPIs appropriate for monitoring and measuring its energy performance. The methodology for determining and updating the EnPIs recorded and regularly reviewed. EnPIs reviewed and compared to the energy baseline as appropriate.
Ref. 1.EnPIs 2.MRM
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4.4.6 Objectives And Targets: The organization has established, implemented and maintained documented energy objectives and targets, at relevant functions and levels within the organization. The objectives and targets are measurable, where practicable, and consistent with the energy policy, including the commitments to prevention of energy losses, to compliance with applicable legal requirements and with other requirements to which the organization subscribes, and to continual improvement. When establishing and reviewing its objectives and targets, an organization has taken into account the legal requirements and other requirements to which the organization subscribes, and its significant energy uses. It has also considered its technological options, its financial, operational and business requirements, and the views of interested parties. The organization has established, implemented and maintained programs for achieving its objectives and targets. The programs include : a) Designation of responsibility for achieving objectives and targets at relevant functions and levels of the organization b) The means and time-frame by which they are to be achieved Refer : 1.
Energy Objectives
2.
EnMPS (Energy Management Programs)
3.
MRM Minutes
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4.5 IMPLEMENTATION AND OPERATION 4.5.1General: The organization used the action plans and other outputs resulting from the planning process for implementation and operation. The implementation of an energy management system specified by this International Standard is intended to result in improved energy performance. Therefore, this International Standard is based on the premise that the organization will periodically review and evaluate its energy management system in order to identify opportunities for improvement and their implementation. The organization is given flexibility in how it implements the EnMS.
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4.5.2 Competence Awareness & Training: The organization ensured that any person(s) working for or on its behalf, related to significant energy uses, are competent on the basis of appropriate education, training, skills or experience. The organization identified training needs associated with the control of its significant energy uses and the operation of its EnMS. The organization provided training or take other actions to meet these needs. Appropriate records is maintained. The organization ensured that any person(s) working for or on its behalf are aware of:
the importance of conformity with the energy policy, procedures and the requirements of the EnMS;
their roles, responsibilities requirements of the EnMS;
the benefits of improved energy performance;
the impact, actual or potential, with respect to energy use and consumption, of their activities and how their activities and behaviour contribute to the achievement of energy objectives and targets, and the potential consequences of departure from specified procedures.
and
authorities
in
achieving
the
Refer : 1. QSP-7 Procedure For Training 2. Training Records 3. Training Plan 4. MRM Minutes
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4.5.3 Communication
The organization communicated internally with regard to its energy performance and EnMS, as appropriate to the size of the organization. The organization established and implemented a process by which any person working for, or on behalf of, the organization can make comments or suggest improvements to the EnMS. The organization decided whether to communicate externally about its energy policy, EnMS and energy performance, and documented its decision. If the decision is to communicate externally, the organization established and implement a method for this external communication. Refer : 1.
EnSP-2 Procedure For Communication
2. Feedback Through Interested Party Concerns 3. MRM Minutes
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4.5.4 Documentation 4.5.4.1 Documentation requirements : The organization established, implemented and maintained information, in paper, electronic or any other medium, to describe the core elements of the EnMS and their interaction. The EnMS documentation included:
the scope and boundaries of the EnMS;
the energy policy;
the energy objectives, targets, and action plans;
the documents, including records, required by this International Standard;
other documents determined by the organization to be necessary.
Ref.
EnMPs
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4.5.4.2 Control of documents: Documents required by International Standard and the EnMS are controlled. This includes technical documentation where appropriate. The organization established, implemented and maintained procedure(s) to:
approve documents for adequacy prior to issue;
periodically review and update documents as necessary;
ensure that changes and the current revision status of documents are identified;
ensure that relevant versions of applicable documents are available at points of use;
ensure that documents remain legible and readily identifiable;
ensure documents of external origin determined by the organization to be necessary for the planning and operation of the EnMS are identified and their distribution controlled;
prevent the unintended use of obsolete documents, and suitably identify those to be retained for any purpose.
Refer : 1. QSP-1 Procedure For Control of Documents 2. Master List of Documents
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4.5.5 Operational control: The organization identified and planned those operations and maintenance activities which are related to its significant energy uses and that are consistent with its energy policy, objectives, targets and action plans, in order to ensure that they are carried out under specified conditions, by means of the following:
establishing and setting criteria for the effective operation and maintenance of significant energy uses, where their absence could lead to a significant deviation from effective energy performance;
operating and maintaining facilities, processes, systems and equipment, in accordance with operational criteria;
appropriate communication of the operational controls to personnel working for, or on behalf of, the organization.
Refer : 1. Master List of EnMS Documents
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1.5.6
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Design:
The organization shall consider energy performance improvement opportunities and operational control in the design of new, modified and renovated facilities, equipment, systems and processes that can have a significant impact on its energy performance.
The results of the energy performance evaluation shall be incorporated where appropriate into the specification, design and procurement activities of the relevant project(s).
The results of the design activity shall be recorded.
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4.5.7 Procurement of energy services, products, equipment and Energy : When procuring energy services, products and equipment that have, or can have, an impact on significant energy use, the organization informed suppliers that procurement is partly evaluated on the basis of energy performance. The organization established and implemented the criteria for assessing energy use, consumption and efficiency over the planned or expected operating lifetime when procuring energy using products, equipment and services which are expected to have a significant impact on the organization's energy performance. MANU defined and documented energy purchasing specifications, as applicable, for effective energy use.
Ref.
QSP-7
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4.6 CHECKING 4.6.1 Monitoring, Measurement and Analysis : The organization ensured that the key characteristics of its operations that determined energy performance are monitored, measured and analysed at planned intervals. Key characteristics shall include at a minimum:
significant energy uses and other outputs of the energy review;
the relevant variables related to significant energy uses;
EnPIs;
the effectiveness of the action plans in achieving objectives and targets.
evaluation of actual versus expected energy consumption.
The results from monitoring and measurement of the key characteristics are recorded. An energy measurement plan, appropriate to the size and complexity of the organization and its monitoring and measurement equipment, defined and implemented. Refer: 1. Test Reports 2. Objective’s Review And Status
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4.6.2 Evaluation of compliance with legal requirements and other requirements Organization evaluated compliance with legal requirements and other requirements to which it subscribes related to its energy use and consumption. Records of the results of the evaluations of compliance maintained.
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4.6.3 Internal audit of the EnMS The organization conducted internal audits at planned intervals to ensure that the EnMS:
conforms to planned arrangements for energy management including the requirements of this International Standard.
conforms with the energy objectives and targets established.
is effectively implemented and maintained, and improves energy performance.
An audit plan and schedule developed taking into consideration the status and importance of the processes and areas to be audited as well as the results of previous audits. The selection of auditors and conduct of audits ensure objectivity and impartiality of the audit process. Records of the audit results maintained and reported to top management.
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4.6.4 Nonconformities, correction, corrective action and preventive action The organization addressed actual and potential nonconformities by making corrections, and by taking corrective action and preventive action, including the following:
reviewing nonconformities or potential nonconformities.
determining the causes of nonconformities or potential nonconformities. evaluating the need for action to ensure that nonconformities do not occur or recur.
determining and implementing the appropriate action needed.
maintaining records of corrective actions and preventive actions.
reviewing the effectiveness of the corrective action or preventive action taken.
Corrective actions and preventive actions appropriate to the magnitude of the actual or potential problems and the energy performance consequences encountered. The organization ensured that any necessary changes are made to the EnMS.
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4.6.5 Control of records The organization established and maintained records, as necessary, to demonstrate conformity to the requirements of its EnMS and of this International Standard, and the energy performance results achieved. The organization defined and implement controls for the identification, retrieval and retention of records.
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1.6
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Management review
4.7.1 General At planned intervals, top management reviewed the organization's EnMS to ensure its continuing suitability, adequacy and effectiveness. Records of management review maintained.
4.7.2 Input to management review Inputs to the management review include:
follow-up actions from previous management reviews.
review of the energy policy.
review of energy performance and related EnPIs.
results of the evaluation of compliance with legal requirements and changes in legal requirements and other requirements to which the organization subscribes.
the extent to which the energy objectives and targets have been met.
EnMS audit result.
the status of corrective actions and preventive actions.
projected energy performance for the following period.
recommendations for improvement.
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4.7.3 Output from management review Outputs from the management review included any decisions or actions related to:
changes in the energy performance of the organization.
changes to the energy policy.
changes to the EnPIs.
changes to objectives, targets or other elements of the EnMS, consistent with the organization's commitment to continual improvement.
changes to allocation of resources.
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