Dalmia Cement ‘s kaizen approach to solar panel cleaning

Dalmia Cement (Bharat) has demonstrated ingenuity by addressing a critical issue within its solar power plants through an in-house innovation - the Dalmia Robotic Cleaner. This semi-automatic cleaning solution, crafted by the internal Research and Development (R&D) team at the Rajgangpur plant, Odisha not only addresses operational challenges but also embodies a culture of innovative thinking, skill development, team building and motivation.

The challenge at hand was the detrimental impact of dust deposition on solar panels, causing a substantial daily generation loss. The conventional manual cleaning method not only proved inefficient but also raised safety concerns for the maintenance team. Facing this challenge, the R&D team embraced the Kaizen methodology, focusing on continuous improvement through incremental changes. Rather than seeking external solutions, the team aimed to develop an in-house, semi-automatic robotic cleaner to enhance solar plant performance.

The Dalmia Robotic Cleaner Solution

The Dalmia Robotic Cleaner, a product of internal innovation, is a lightweight system (less than 40 kg) designed for easy assembly, installation, maintenance and shifting to other location. It has fully remote-controlled operation within 50 metre range, operates on rechargeable battery and runs continuously for three hours in single charge. It operates with a 24 V DC work voltage and a 60 W cleaning motor. It is made up of complete aluminium frame, fibre electrical control panel, and a fabricated trolley, which makes it 100% weather-proof for trouble-free outdoor use. This device ensures a safe working environment with minimal human intervention.

Performance metrics

The successful integration of the Dalmia Robotic Cleaner resulted in a noteworthy enhancement of solar plant performance, elevating efficiency from 66% to 75%. This internally engineered solution not only effectively tackled the immediate issue of dust deposition but also demonstrated the organization's adeptness in innovation within its existing capabilities. Furthermore, a reduction in manual cleaning translated into substantial savings in manpower costs, while increased operational safety was achieved by minimizing the need for manual intervention during the cleaning process.

Key benefits of in-house innovation

Operational cost savings: Internal expertise resulted in substantial savings on inhouse manufacturing of Robotic device totaling 26.9 lakh, as well as saving in manpower cost of 11.7 lakh at one of DCBL plant at Rajgangpur unit itself.

Enhanced safety: The in-house developed robotic cleaner minimized the need for manual intervention, reducing safety risks associated with traditional cleaning methods.

Scalability and adaptability: The success of the prototype paved the way for the installation of the Dalmia Robotic Cleaner in seven different plants, demonstrating its scalability and adaptability across various operational settings.

The creation of the Dalmia Robotic Cleaner underscores Dalmia Cement's dedication to promoting an environment of innovative thinking, urging employees to explore and apply creative solutions to operational challenges. Acting as a catalyst, the project provided a foundation for skill development, team building, and motivation within the R&D team. This initiative aligns with Dalmia Bharat’s commitment to driving transformative changes through its internal resources and capabilities, cultivating a culture of sustainability and excellence within the renewable energy sector. The Dalmia Robotic Cleaner has won Platinum and Jury Champion Award for "In house design, & development of Robotic cleaning device for solar panels" under Innovative Kaizen category in the year November, 2023.

Rotary brush cleaners

Dalmia Cement has also developed inhouse rotary brush cleaners for wet cleaning of sticky materials/scales deposited over solar panels in due course of operation. This cannot be cleaned through dry cleaners and needs cleaning through chemical mixed water and brushing by using this device which runs on 2 x 30 watt DC motors.