Mahindra & Mahindra Ltd - Nashik Plant - CII - Sohrabji Godrej ...

1Copyright © 2012 Mahindra & Mahindra Ltd. All rights reserved.

CII National Award for Excellence In Energy Management 2018

Journey Towards Sustainable Tomorrow

Mahindra & Mahindra Ltd - Nashik Plant

Presented By-

Novokesh Mishra

Deputy Manager

ECON

2

3

People ….. Passion…..Performance

Mahindra & Mahindra Ltd. Nashik Plant

• Plant Established : 1981

• Area : 47000 M²

• 40 % Greenery

• Employees : Avg. 7500 per day

• Innovative automation

• ZERO discharge plant

• Water Positive

4

Press Shop(Tandem line) Body Shop (Robotic Welding)

– 4 Body Shops

Paint Shop-CED Process

Paint Shop – Robotic

painting – 2 Paint ShopsConveyorised Assembly

Lines – 3 Lines

Nashik Plant : Key Manufacturing Facilities

5

Nasik Plant - Certifications

BS OHSAS 18001 ISO 9001 ISO 14001

Safety Quality Management Environment IT

ISO 27001

ISO 50001:2011 Documentation is in Process

6

The Core Values

Accepting No Limits

Alternative Thinking

Driving Positive Change

“We will challenge conventional thinking and innovatively use all our resources to drive positive change in the lives of our stakeholders and communities across the

world, to enable them to Rise.”

CORE PURPOSE

• Think big, think global• Challenge conventional

thinking• Agility with discipline• Reasoned risk-taking• Orientation for Excellence• Seek breakthrough

solutions

Rise by daring to disturb the universe

• Pursue new approaches

• Celebrate diversity• Focus innovation on

customer needs• Invent your way to

growth• Frugal mindset

Rise with your ingenuity

• Customer sensitivity• Build quality to

delight customers• Entrepreneurial

Engagement• Forge strong

relationships• Work hard. Have fun.

Rise by shaping destinies

Top 10 global Auto brands

Deliver Farm Tech Prosperity

CORE VALUES : Good Corporate Citizenship | Professionalism | Customer First | Quality Focus | Dignity of the Individual

BR

AN

D P

ILLA

RS

7

Mr.Darshan

(Thermal Energy)Mr. Atul Joshi.

(Water Mgnt)Mr. Mahadeo Salunkhe

(Energy Mgmt System)

Mr. Simon .

(Electrical System)Mr. Rushikesh Jadhav.

(Safety)

Mr. Harshad Kaduskar

(Environment)

Mr. Satish Bakare.

(Waste Mgnt)

Mr. Santosh Shingane

(Diesel & paper)Kamlakar Ghongader.

(ESOPS/CSR)Mr. Utkarsh Kulkarni

(Systems)

Mr. Ketan Wagh

(GSCM)

Mr. Mohan Chitnis

(Green IT)

Mr. H. D. Aher VP – Mfg. (NSK & IGT)

Mr. Norbert Desouza GM – CMD & SAFETY

Energy Conservation Team

8

53%

15%

13%

7%

12%Paint Group

AirCompressors

Body Group

AssemblyGroup

Others

Electrical

100%

@Paint

shops

24%

28%20%

11%

2%

Topcoat Oven

Surfacer Oven

ASU1

ASU2

ASU3

ASU4

ASU5

Plant Energy Stratification

Power Stratification

LNG Stratification

Fixed Load, 40.0%

Varaiable Load, 60.0%

Fixed Load Varaiable Load

Solar, 1.0%Wind, 5.0%

MSEB,

Solar Wind MSEB

9

Reduction in Specific Consumption (Year wise)

10

Kw

h/E

q V

eh

Specific Consumption BETTER

293

180 185181

140

190

240

290

340

F-08 F16 F17 F18

3% 2%

F17 Due to

expansion of 2 Major

Product Range SEC

increased hence

baseline revised

24.04

11

.05

12

.45

11

.33

0

5

10

15

20

25

30

F-08 F16 F17 F18

13% 9%

In F17 due to climatic

condition and product

trials the SEC

increased

49

2729

28

20

25

30

35

40

45

50

F-08 F-16 F-17 F-18

5%7%

Kg

/Eq

ve

h

In F16 & F17 Due

to expansion of 2

Major Product

Range SEC

increased hence

baseline revised 3.57

1.15 1.01 1.03

0

1

2

3

4

F-08… F-16 F-17 F-18

12% 2%

KW

H/E

qv

eh

38% Reduction

over F-08

0.5% increase

over F-16(Last

3 years)

53% Reduction

over F-08

3% Increase

over F-16(Last

3 years)

43% Reduction

over F-08

4% Increase

over F-16(Last

3 years)

71% Reduction

over F-08

10% decrease

over F-16(Last

3 years)

Electrical Thermal

Compressed Air Water

Cu

MT

/Eq

Ve

h

11

YearSavings in

RsInvestment

Rs. LacsPayback

FY - 16 61 170 2.7

FY - 17 111 106 1

FY - 18 87 192 2.2

Total 259 468 1.8

Energy Conservation Projects

Measures in Last 3 Years

No. of Projects

No/Low investment < 1 Lac 20

Medium investment < 5 Lacs 38

High investment > 5 Lacs 8

Total 66

0

50

100

150

200

250

300

F16 F17 F-18

61

172

259

Savings

0

50

100

150

200

250

300

F16 F17 F18

170

276468Investment

22930

24234

25198

21000

22000

23000

24000

25000

26000

FY - 16 FY - 17 FY - 18

MT of CO2 Mitigated

Savings of Rs

259 lacs with

Investment of

468 Lacs

12

Carbon Inventorisation

Energy Management

• Replaced conventional to IE3 motor of 260 KW to 200 KW at MQS

Paint shop ASU1 – Annualized saving 163730 KWh

Renewable Power

• Solar Generation – 86000 Kwh,

• Wind Power – With effect from June 2017

Waste Recycling / Reduction

• Corrugated containers – 149.3 Tons

• Wood recycled – 88.2 Tons

Tree Plantation

• Planted Trees (620 MT expected)

CO2

emission

reduced by

24%

F16 F17 F18

Total CO2e MT 43145 40710 32790

13

Benchmarking of Energy Conservation Norms

14

National level Bench Marking

Nashik Plant

498

205

507

181

0

100

200

300

400

500

600

TATA Pune Mahindra kndivli Fiat Mahindra Nashik

SEC Values for FY18

LOWEST IN GROUP

38% Reduction

over F-08

293

180 185 181

140

190

240

290

340

F-08 F16 F17 F18

15

CO2 Emissions Benchmarking

Nashik Plant

25% Reduction by F19

Parameter Volkswagen Ford BMW General Motors

Carbon Intensity40% reduction by 2020 (Baseline:

2010)

30% reduction by 2025 (Baseline:

2010)


2006)


2010)

Water Footprint25% reduction by 2018 (Baseline:

2010)NA


2006)


2010)

We are committed to Move towards carbon Neutrality.

16

Low Temperature Heat Recovery

Innovative Project

17

Paint shop – LNG Cons & Heat Sources

Heat Sources for

Recovery in Paint Shop

18

Can We Re-Use Rejected Heat?

What are the sources?

Cooling Tower arrangement for heat rejection

What can be

the

application?

Areas of Heat Rejection

PT line Rinse 1 stage

45 deg. 35 deg.

PT line Rinse 3 stage

35 deg. 30 deg.

ED chiller Condenser 35 deg. 30 deg.

• High capex required.

• High time for implementation

• High IRR

Elevating this heat by Heat Pump

and use in PT process bath heating

Where else this low temperature heat can be used?

Process where Heat can be Rejected

19

• In Pre treatment line BIW Body is

processed in Degreasing tank (@

50 ⁰C).

• BIW Body is then rinsed by soft water

in rinsing stages.

• Rinse tank temp rises due to warm

BIW Body.

• Rinse tank temp is to be

maintained below 35°c.

• This is achieved by rejecting the

heat in cooling tower.

• In Topcoat spray painting process,

Air supply units (ASU) supply

conditioned air (22⁰C - 25⁰C & 65% -

75% RH) to spray booth.

• In winter, due to cold & dry climatic

conditions, ASU Burners are operated

with humidifier to maintain required air

quality.

• Water temperature drops from 25⁰C to

20⁰C during humidification process.

• Thus burners keep on running

continuously.

Analysis

20

Implemented Scheme - Phase I

Process pump

• Less running of ASU

burners

• Reduced LNG

consumption.

• Water saving in winter

season due to no

evaporation losses

PT Rinse 1 heat rejection in

ASU humidifier tank

M/s Durr (OEM) approval taken before changes

Total Investment = 2.2 Lakhs

21

Results

• Reduction in Thermal Energy consumption = 45070 kg/ year

• Reduction in Thermal Energy Cost = Rs. 16.22 Lakh/annum

Total cost saving of Rs 17.30 Lakh/annum

• Reduction in Water consumption = 850 KL/ year

• Reduction in Water consumption Cost = Rs 0.29 Lakh/annum

• Reduction in C02 Emission = 98.63 M Ton/annum

• CO2 saving due to energy = 9.20 M Ton/annum

• Total CO2 Saving = 107.83 M Ton/annum

22

Phase II

Air supply

Unit 1

Rinse 1

45 deg cent

Cooling tower

pump

Heat recovery

pump 1 & 2

1 2

3

4

Cooling tower

HE 1

Heat

Sink

Warm water

Heat rejection in ASU humidifier tank

32 deg 21 deg

Rinse 3

36 deg cent

HE 2

Heat

Source

1

Heat

Source

2

PT Line Rinse 3 Stage heat

also cascaded.

• Total 427500 Kcal Heat

Recovery with Rinse 1

• 563 kg/day saving of LNG

• Equivalent to Rs. 20.26

Lakhs

First time in

automobile industry

23

Future scope in Nashik Plant for low temperature heat

recovery

All

manufacturing

industries

Other

Automobile industries

M & M

Manufacturing

plants

2

4

3

Paint

Shop

1. ED Chiller cooling

tower – 450000

Kcal/Hr.

2. Scorpio body shop

cooling tower – 280000

Kcal / Hr

3. UV Body shop cooling

tower – 350000 Kcal/Hr

4. Compressor house

cooling tower 550000

Kcal / Hr1

Applied for Patent

Heat Available - 13 Lakh

Kcal/Hr.

(Equivalent LNG saving -

172 M Tons / year)

24

Parker Membrane

Energy Efficient Product

25

Ultra filtration – Parker Membrane

Project Theme Observation

ED Line Power Reduction ED Process requires the separation of Filtrate from CED Paint. Existing UF

membrane efficiency was lower hence Low flux rate within 3 months of

installation Requirement-7000LPH

Two Type Product Trial Done

Inference – F155 pump running on high frequency to maintain required flux rate(48 Hz). Sepro make UF

membrane flux rate reduced after a month. Initial it sustain at 1000 LPH then reduced up to 240 LPH.

After comparing the technical data of 2 suppliers found Parker Make module efficiency is higher than existing module.

26

Before After

Action Taken – Parker make membrane used & frequency reduced to 40 Hz .

Low flux rate 420

LPH

high flux rate 1000 LPH

Freq-48Hz Freq-40Hz

Results After Replacement

Investment-3.9 LacsSaving of 8.65 lacs/year

Payback-6 Months

Supplier-Geofluid Processors Contact no- 022-61555888

Total Flow rate was 7.3 M3/H. ED F155 pump running @ 48 Hz. Power consumption was 52.11 kwh.

After replacing UF module with Parker make, ED F155 pump running @ 40 Hz. By keeping the same flow rate (7.3 M3/H). Power consumption is 35.59 kwh.

27

Energy Reduction Initiatives In F18

Sr. Initiative ( Brief discription)

Annaulized

Units saved

( 12 mths)

LNG

Saved

Rs Lacs

@Rs 7/Kwh

Investment

Rs LacsPayback

1 To reduce energy consumption of Chilled Water Cirulation Pump for ED Chiller 10680 0.7475664 0.00 0.00

2 Energy Efficient motor IE3 for ASU-1 blower 187956 13.15692 3.76 0.29

3 LED Street and office Lights 345258 24.168088 83.27 3.45

4 High Volume Low speed Fan 6266 0.4386201 2.97 6.76

5 Energy Efficient AC for Offices 69264 4.84848 14.82 3.06

6 Zero Air Leakage Month Celebration 93000 6.51 0.18 0.03

7 Refurbishment of Compressor No-2 287040 20.1 74.16 3.69

8 Water lifting pump for Material gate domestic water storage tank 30264 2.1 2.00 0.95

9 Common blower for spot repair exhaust blower at NPS 14760 1.0 2.30 2.38

10 Energy Efficient Pump for Coagulation 54793 3.8 6.00 1.56

11 Low Temperature heat Recovery by using PT Line RC 1 Tank Heat to Top Coat ASU 1. 28820 10.1 2.20 0.22

11 29 87 192 2.20

Year No of Projects

Achievement of energy savings per year basisInvestment

incurred on the

project (Rs.

lakhs)

Electricity Fuels*

Total savings in (Rs. lakhs)Lakhs (kWh) LPG (Ton)

FY - 18 11 11 29 87 192

28

Compressor no.02 refurbishment (installed in 2006)

1. Cartridge type coolers-Air through tubes,

water over tubes. Heavy scaling, high

temperatures

2. Maintenance time – min 48 hours

3. Reduced efficiency -83%

1. External type coolers- Water through

tubes, air over tubes. Lower scaling, Low

temperatures

2. Maintenance time – Max 16 hours

3. Improved efficiency -98%

BEFORE AFTER

Annual Savings - Saving 920 Unit/Day

Investment - Rs 74.16 lacs with payback in 3.7 yrs

29

Central control of dryer

• Benefits :- Units saving : 23 unit/day

Manual Switching Operation

Compressor OFF/dryer ON

Excess running

Auto Operation of Dryer with Comp.

Compressor OFF/dryer OFF

Only required running

Main

Compr

essor

House

Remote Connection

Remote Panel at Main

Compressor House For

switching remote

compressor

•Air Flow

•Air FlowMain

Compr

essor

HouseNo

•Air Flow

•Air Flow

We are

hereDistance between 2

compressor house

- 500 mtrs

Air-Dryer1 Air-Dryer1

Main

Compr

essor

House

Remote Connection

•Air Flow

•Air FlowMain

Compr

essor

HouseNo

Provi

sion•Air Flow

•Air Flow

We are


compressor house

- 500 mtrs

Main

Compress

or House

Paint shop

Compresso

r

Remote Connection

•Air Flow

•Air FlowMain

Compress

or House

Paint shop

Compressor

No

Provision

of

Remote

Panel

•Air Flow

•Air Flow

We are


compressor house

- 500 mtrs

Mfg. Shops Mfg. Shops

BEFORE AFTER

30

Compressed air-Future plan

59%

reduction

Initiative Investment

Saving

Estimated

Kwh/day

Target

DateStatus

Refurbishment of

ZR-03 compressor81.7 350 F-19 Approved

Shop wise Air Flow

Controllers-Phase-0111.45 150 F-19 Approved

Refurbishment of

ZR-110 compressor81.7 350 F-20 Planned

Shop wise Air Flow

Controllers-Phase-0220.9 199 F-20 Planned

VFD screw air

compressor90.0 1220 F-21 Planned

71

61.8

56.65

45.648.7

39.3

34.732.4

29.4 29.426.6 27.3

29.228.80

1

0

10

20

30

40

50

60

70

F-05 F-06 F-07 F-08 F-09 F-10 F-11 F-12 F-13 F-14 F-15 F-16 F-17 F-18

Axis Title

Lowest specific power ever of

21 Kwh/Eq.veh

in

Jan-18

31

Replacement of Air Circulators with High Volume Low Speed (HVLS) Fan.

ECO AIRALMONARD

• 9x4 Kwh/Day • Safety risk• Moderate noise

• 1x15.9 KWh/Day• Three Dimensional Natural Breeze with

low noise• Reduced safety risk

Savings of 4770 Units/Fan

Planned to replace 28 Nos.

32

Partnership with EESL

Plant Lighting(Philips, Wipro, Goldwyn)

IE3 Motors

(Siemens - ACE LLP)

Air Conditioners(Godrej)

Planned through EESL - 37150 Nos.

Completed so far – 32011 Nos.

Investment – 217 Rs. Lacs

Savings – 13.34 Lac Units

Payback - 2.33 Years

Completed – 95%


Investment – 18.31 Rs. Lacs

Savings – 40622 Units

Payback –2.2 Years

Planned through EESL - Qty. 160 Nos.


Payback – 1.85 Years



Savings – 69264 Units/Annum

Payback – 3 Years

Planned through EESL Qty. 110 Nos.

Budget 41 Rs. Lacs

Payback – 2 Years

33

SUMMARY SHEET FOR F17 POWER SAVINGS

Sr. Initiative ( Brief discription) PU

Annaulized

Units saved

( 12 mths)

Rs Lacs @Rs

7/Kwh

Investment

Rs LacsPayback

1 LED Project Plant CMD 1118360 78.29 86.00 1.1

2 ASU -3 & ASU-5 auto switch off after shift end NPS 5120 0.36 6.00 16.7

3 IE3 motor for Spray booth exhaust no-2 Blower NPS 87463 6.12 2.50 0.4

4 IE3 motor for ASU2 NPS 27475 1.92 2.50 1.3

5 22 nos. sodium vapor lamp ( 250W) to be replaced with MAG crupled lamp (150 W) STCF 3960 0.28 2.42 8.7

6 Trim 3 lime replace with the fan STCF 10973 0.77 1.58 2.1

7 Eenrgy saver 36 KVA for overhead lamp. STCF 2052 0.14 1.20 8.4

8 Replacement of Air circulator MS fan blade with FRP blades. STCF 8640 0.60 1.15 1.9

9 Energy efficient IE3 motor for sealer Oven heat up zone motor NPS 29091 2.04 0.75 0.4

10 VFD for DI water transfer Pump NPS 19319 1.35 0.50 0.4

11 VFD for water degrease Pump NPS 13329 0.93 0.50 0.5

12 Use of new parker make membrane to increase the flow rate of ultrafiltrate generation NPS 123702 8.66 0.39 0.0

13 RBT blower mototr from contactor logic to VFD. STCF 1584 0.11 0.30 2.7

14 Elimination of 25 nos of tube lights by Lowering the height of overhead lamps BTCF 9600 0.67 0.20 0.3

15 Replacement of ED main tank exhaust fan SS Impeller with FRP Impeller NPS 17148 1.20 0.10 0.1

16 Timer Circuit provided for Overhead lamps to switched off during dinner time BTCF 750 0.05 0.10 1.9

17 Timer Circuit provided for snacks table to switched on only during lunch & dinner time BTCF 9450 0.66 0.10 0.2

18 To Reduce the Energy Consumption of Emergency Tubelights by optimising Lux level in night shift VBS 1584 0.11 0.01 0.1

19To Reduce the Energy Consumption of Loading Area Tubelights by switching off VERiTO Tubelights while

Xylo Loading in 2nd shift.VBS 2112 0.15 0.01 0.1

20 Automatic Switching OFF stack lifter hydraullic one motor during auto mode Press 9360 0.66 0.00 0.0

21 Reduction of torque of 250 kw main motor of press 1 Press 30420 2.13 0.00 0.0

22 Switch off cooling zone supply fan during last running & start the fan after temperature achieved NPS 26695 1.87 0.00 0.0

23 Major repair booth tube light to be switched off. NPS 265 0.02 0.00 0.0

24 Work area ex. To be switched on during start up. NPS 6905 0.48 0.00 0.0

25 NPS Excess tube light fixture elimination NPS 10149 0.71 0.00 0.0

26 NPS clear coat water greating pump start delay one hour. NPS 5988 0.42 0.00 0.0

27 Elimination of 6 Nos of fan by re arranging BTCF 4800 0.34 0.00 0.0

28 Elimination of over head lamps in Bolero TCF by re arranging. ( 5 Nos ) BTCF 3000 0.21 0.00 0.0


Year No of Projects

Achievement of energy savings per year basis

Investment

incurred on the

project (Rs.

lakhs)

Electricity Fuels*

Total savings in (Rs. lakhs)

Lakhs (kWh) LPG (Ton)

FY - 17 28 16 0 111 106

34

Parameter Bladeless conventional

Air flow Uniform Breeze Non uniform and uneven

Safety Highly safe Unsafe

Noise level Lesser High

Blades AbsentNo cutting of air

PresentCutting of air

Maintenance Not required Frequently required

Cleaning During Running Need to switch off .

Power (WATT) 315 250

Air Flow 1m/sec at 5 Mtrs 0.3 m/sec at 5 Mtrs

Industrial fan

Consumes 0.25 Units/Hrs

BEFORE AFTER

38 Industrial fans replaced by

28 Bladeless fanTotal installed 30 Nos.

Industrial air Breezer - Bladeless Fan

Industrial Air Breezer

Patent applied.

(No 28335)

Available on

Amazon

35

Before• DF hydraulic two motors switched on

automatically during press line auto mode

Now• Modified DF hydraulic electrical circuit so

that one motor out of two will get switched off automatically during press line auto mode. Resulted into saving of 900 KWH per year

• Annual Savings - Saving of 0.65 L

• Zero Investment

BEFORE AFTER

Automatic Switching OFF stack lifter hydraulic motor

Process Optimisation

36Copyright © 2012 Mahindra & Mahindra Ltd. All rights reserved. 36

Derating of Paint Booth Motor

Existing 260KW Motor was used for the Air Supply

Unit to the Paint Booth(Circulation As Shown)

If booth is unbalanced

quality concern arises.

Flow Requirement was 0.4

m/s

Existing Flow was 0.5 m/s

Motor VFD in Place with

Frequency 40Hz

Can we

Optimise and

get

Saving???

37Copyright © 2012 Mahindra & Mahindra Ltd. All rights reserved. 37

Parameter Before AfterMotor Rating in KW 260 200

RPM 1475 1490

Motor Efficiency IE1 IE3

Motor weight in Kg 1600 1360

No. of groove of pulley 8 6

Motor Pulley weight in Kg 165 110

Blower pulley weight in Kg 355 260

Frequency in Hz 44 44

Motor Current in Amp 285 229

No any changes in air flow

No any change in air velocity distribution in

spray booth.

Spray booth should be positive.

No any quality issue to be arise.

No any change in motor VFD frequency.

New motor should take starting torque of

blower.

New motor frame should match with

existing motor frame

BEFORE AFTER


• Power saving - 163730 units/year

• Investment - 7.25 L

38

Sl.

No.Title of Energy Saving project implemented PU

Achievement of Annual energy savings in 2015-16

Annual Electrical Savings

achievedAnnual thermal savings

Total

Annual

Savings

Invest.

Made

Units Lakhs Rs. LakhsTons of

LPGRs. Lakhs

Rs.

LakhsRs. Lakhs

1 Project Snagam for heat recovery in paint Shop Paint 47 27 27 62

2 VFD Installed in BTCF roller Tester exhaust Blower BTCF 0.02 0.12 0.12 1.21

3 Limit Switch for Roller Tester Pit Lighting BTCF 0.01 0.07 0.07 0.13

4 Conventional choke replacement by Electronic choke CMD 0.10 0.67 0.67 3.72

5

3 stage filteartion at MQS paint shop (4 stage filtration for Paint booth - one stage removed &

air pressure drop eliminated, Air quality - No change (Filtration grade changed at input as per

grade) (ASU frequency reduced

PAINT 0.82 5.77 5.77 2.08

6 LED tube lights to installed at NPS selaer line (VERITA) 40W to 18W PAINT 0.46 3.23 3.23 0.60

7 Surfacer cooling zone blower to be switched off during lunch time PAINT 0.07 0.46 0.46 0.00

8 Energy efficient motors (6 NOS.) EEF2 & IE3 PAINT 0.08 0.58 0.58 2.99

9 VFD for Moist Sanding PAINT 0.16 1.13 1.13 0.00

10 NPS Oven cooling zone blower to be switched off last running time PAINT 0.13 0.92 0.92 0.00

11 LED tubelights in MQS spot repair (GIBBS) PAINT 0.16 1.12 1.12 1.03

12 Energy Saver at café 4X4 Press PU 0.14 0.98 0.98 3.26

13 Energy Saver in front of LNG Yard SBS 0.09 0.62 0.62 2.88

14 Energy Saver at Materal Gate SBS 0.02 0.14 0.14 8.35

15 Energy Saver at BTCF SBS 0.21 1.44 1.44 1.82

16 Automatic switch off Control panel AC of Destack Feeder with hydraulic motor SBS 0.01 0.07 0.07 0.00

17 Removal of unwanted tube light SBS 0.06 0.44 0.44 0.00

18 Blower motor replacement with energy efficient motor(11Kw & 15 Kw) STCF 0.08 0.59 0.59 1.63

19 Use of motion sensor in pump house area VTCF 0.02 0.11 0.11 0.00

20 Use of magnetic lamps in place of 400w conventional lamps VTCF 0.03 0.18 0.18 3.00

21 Use of electronic chokes instead of conventional chokes XBS 0.14 1.01 1.01 3.47

22 Replacement of Roller tester Blower motor 9.3 KW with Energy efficient of same rating. 0.03 0.24 0.000 0.24 1.75

23 Energy Effiency Motor for Paint Exhaust 0.04 0.26 0.26 0.00

24 Energy Effiency Motor for After Dryer 0.03 0.18 0.18 0.00

25Fogger installed below condensor coil of chiller & water curtain made near condensor coil to

maintained ambiet for chiller (Delta T is 2 deg. Cel.)0.37 2.60 2.60 0.00

26 Occupancy Sensor Installation 0.01 0.06 0.06 1.94

27 LED installation in Plant 1.92 13.41 13.41 47.00


Year No of Projects

Achievement of energy savings per year basis

Investment

incurred on the

project (Rs.

lakhs)

Electricity Fuels*

Total savings in (Rs. lakhs)Lakhs (kWh) LPG (Ton)

FY - 16 27 3 73 61 170

39

Before• Shower top dryer had Earlier Motor

with Lower Efficiency

Now• We have replaced it by IE3 Energy

Efficient motor

• Annual Savings - Saving of Rs. 0.18 Lacs /annum

• Investment - Rs. 0.31 Lacs

BEFORE AFTER

Energy Efficient Motor at Shower top dryer

Energy Efficient

Product

40

Before• Torque limit set at 110 % as per

standard value

Now• Reduced torque limit of press 1 motor

from 110% to 90% so that peak current reduce to 340 Amp to 300 Amp.

• Annual Savings - Saving of 2.12L

• Zero Investment

BEFORE AFTER

Reduction of torque of 250 kw main motor of press 1

Process Optimisation

41

Advantages of Frigi-Tech:

Saves 15 % KWH in AC’s

One time Installation .

No Interruption to Equipment.

Reduces Friction.

Protects against Oxidation and wear.

Enhances Equipment Life.

Saving Higher in Older AC Units

Lubrication Enhancement System- Frigi-Tech’s Containing anti-oxidation, anti wear systems, which gives coating on inner surface to

reduce friction and improves heat transfer efficiency

• Total installed Units-67 Nos(118 Tons)


• Power saving - 21330 units/year

• Investment – 3.31 L

Air conditioner Lubrication Enhancement System

Sr.No Office installed

Total

Tons

Units

Saved

Cost

saved

1 VP Office 8 14.5 2610 18270

2 UVBody Shop 8 15 2700 18900

3

UV Body

Supply Module 5 9.5 1710 11970

4

Haridwar

Loading (Old

Axle Shop) 2 3 540 3780

5

SCM + PPC

Office+VC 22 43 7740 54180

6

MQS Paint

Shop 12 19 3420 23940

7 STCF Logistics 4 4 720 5040

8 Xylo Body Shop 6 10.5 1890 13230

Total Saving Frigitech 67

118.

5 21330 149310

Total

118Ton

Covered

42

• Use of RTPFC Panels to reduce the Harmonics & Maintain Unity PF

Power Quality Enhancement by Use of

RTPFC Panels

Harmonic

Compliance as per

IEEE 519

43

Process optimization

• 98% efficiency• Maximum envelope size

Heat recovery 100%

• Zero heat losses

• ZERO pollutant

Energy efficient chillers

• Water cooled

• VFD driven

Hydro pneumatic control

• Demand supply

• Electrical interlocks

Motor optimization

• High efficient motors

• Use of VFD’s

Pump optimization

• High efficient pumps

• ZERO throttling

Use of alternate Source

• Vaporiser Elimination

Power controls

• Unity power factor

• Harmonic distortion < 5 %

High Preventive

maintenance

• Six monthly shutdowns

• Condition based tools

Energy management

• Daily power balance

• Immediate actions

Theme 1: Energy Conservation- Power

44

Solar Light Pipe in offices

• Uniform lux• No heating

AC Energy Savers

• Controls Compressors• 6-8% less consumption

Motion Sensors

• Use driven Supply Control

• Efficient use as per demand

Magnetic Induction lamps

• Lower power Used than

Metal Halide lamps

Nomenclature for Switching

• Effective Switching

• Zero Investment Saving

Automation of Assembly

Lighting

• Lighting Automated with

Conveyor Supply

LED Lighting

• Lower power Consumption

• Higher Life of rods

Street Lighting on Lux

Sensors

• All Street lights On/off on

lux sensor

Solar Power

• Power generation

• Lights

BEE certified products

• Lower power Consumption

• 10-15% less

Theme 2: Energy Conservation-Lighting

45

Designed network

• Minimum pressure drop• Ring loop

Supply side control

• Compressor optimization• Auto controls

Air monitoring-SCADA

• Daily losses• Immediate action

Demand side control

• Variability control• Less pressure

ZERO air drain valves

• No air losses• Auto control

Water Management

• Temperature control• Scale control

Solenoid valves at user

• Off when not used• Less demand

Localized compressor

• Air booster• Stand alone compressor

Remote control

• Auto shut down• Optimum usage

Air leakage management

• Air loss control• User morale

Theme 3: Energy Conservation-Compressed Air

46

Top to Bottom at CED oven

• Oven modified for air flow from top to bottom

CED oven Heat recovery

• Heat recovery from air to water.

Heat recovery from ovens

• Heat recovery from ovens to air supply units in NPS.

Sealer oven elimination

• Sealer oven eliminated in NPS

PTCED – 30JPH to 36 JPH

• Cab Cargo On single skid.• Cargo from ATC bypassing

drop lift.

Project - SANGAM

• Utilizing NPS heat from oven to PTCED line

WET ON WET

• Productivity increase of MQS TC

Wax oven elimination

• Introduction of air drying wax – process change

Theme 4: Energy Conservation-Thermal

Bunty Bubbly Project at

MQS Topcoat line.

• Productivity increase of Topcoat line by 10%

Alternative fuel for LPG

• Changed over to LNG from LPG

47

Canteen waste utilization

• Bio- gas plant generating LPG- used in canteen

• waste used as manure

Recuperate- Incinerator

• Burning of all flue gases• Reduction in air pollution

Waste thinner reduction

• Waste thinner distillation• Reuse in to process

Fuel saving & emission reduction

• Compacting by belling M/c.• Reduces the trips

Empty trolley project

• Returned trolleys in MLL • Save fuel & reduction in

Co2 emissions

Removal of access water paint sludge

• Filling of sludge in gunny bags instead of drums

Theme 5: Environment impact reduction

Milk run for material supply

• Fuel saved • Reduction of Co2 emission

Use of Battery Fork lifts

• Replacement of Diesel Forklifts with Battery operated. (emission reduction)

Drying of Paint Sludge

• Drying of sludge reducing weight

• Recovering Thinner

Use of Filter press

• To remove maximum water & liquid contains from Sludge

48

Capacity of Plant : 302 KWp

Installation : Carport Structure

Generation(Annual) : 4.08 Lacs KWh

Annual CO2 reduction : 383 tons

Solar Power Plant Solar Water Heating system

Solar lighting for ETP & RWH Solar diesel dispensing

Solar light tube for office

Solar sky light for shop floor

Capacity of Plant : 1050 KW

Installed : At Jath Sangli

Generation(Annual) : 20 Lacs KWh

Annual CO2 reduction : 1880 tons

Solar lighting for office

Wind

Power

Solar

Power

Renewable Energy

49

Maximizing Use of Natural Resources

Bio Gas plant

Light Pipe in SCM Office Nori Kool roof sheets

Painting Structure & Roof Sheets

50

Use of Day Light maximization

Before Painting Structure &

Roofsheets

Before Painting Walls & Columns After Painting Walls & Columns

After Painting Structure & Roof

Sheets

51

Water positive plant

Water positive plant

Check Dams River widening Water reservoirRain water

harvesting

Water beyond

fence

Water within

fence

7 Villages,

7 check Dams7 Villages 1 village

Pond for rain

water harvesting

• Water requirement – 191 K (Cu.Mtr)

• Water returned to society – 252 K (Cu.Mtr)

Water Positive

Plant

52

Rain Water Harvesting

1025 3666

25619

4749760800

75334

97155105814

-5000

20000

45000

70000

95000

12000015 RWH Projects

10 Crore Lits

Achieved1 Lac KLs in Rain water harvesting

Summary of Water saving

Initiatives

YearNo of

projects

Annual Water Savings Invest. Made

Kls Rs. Lakhs Rs. Lakhs

F-08

- F-1895 331228 62 81

3.57

1.03 1.00

0

1

2

3

4

F-08 F-18 F-19 Target

75% Reduction

over F08

Sp. Water consumption-Kl/ Eq.Veh

Avg Water consumption – 600-700 KL/day

53

Green SCM Initiatives

54

Green SCM Initiatives

Non Hazardous waste Hazardous waste

Manual to Robotic painting 23%

Reduction in paint consumption

Spent solvent Recovery & Reuse

1.8 lac lit /year saving fresh solvent

Dewatering & drying of paint sludge

Recycling project in process

Recycle

Reduce

Eliminate

Reuse

55

Eliminate….by Accepting No Limits

Wooden Packaging Recyclable Packaging

Theme: Elimination of Wooden Packaging Of

Steering Column By Plastic Crates.

Without PackagingPolybag Packaging

Theme: Elimination of Polybag Packaging From

Deflector.

Packaging Waste Reduction

Wood Packaging Recyclable Packaging

Theme: Elimination Of wood Packaging by

returnable crate

Bubble BagCorrugated Packaging

Theme: Elimination of Corrugated Packaging By

Bubble Bag .

112 KAIZENs

Implemented

56

Recycle Packaging Of Instrumental panel

Corrugated Packaging Recyclable Packaging

Theme: Corrugated Packaging of IP Replaced with

Recyclable Packaging

Recyclable PackagingWooden Packaging

Theme: Wooden Packaging Replaced By Returnable

crates .

Packaging Waste Reduction

Corrugated Packaging Recyclable Packaging

Theme: Corrugated Packaging of Footstep

Replaced with Recyclable Packaging

Recyclable TrolleyCorrugated Packaging

Theme: Corrugated Packaging Replaced By

Returnable Trolley Of radiator .

53 KAIZENs

Implemented

57

Waste Management

58

Before-Untapped heat of hot body shells.

-Exhaust air directly left to atmosphere

Now• Tapping the latent heat from hot body

shells.

• Waste heat from the exhaust captured and used in ASU

• Annual Savings - Saving of Rs.14 Lacs /annum

• Investment - Rs. 4.45 Lacs

BEFORE AFTER

Heat recovery from Hot Body shells at Cooling Zone

Heat Pipe

Technology

System supplied by: M/s Apex Eng.Pune

59

Before• LPG Driven Hot Water Generator

(HWG) used at paint pretreatment process

. Nearby ED oven operating and exhaust gas released in atmosphere

Now• Installed Heat Recovery Unit (HRU)

recovers the heat from the ED Oven exhaust

• Exhaust gas temperature is reduced from 2200C to 950C

• Annual Savings -LPG saving of Rs. 36 Lacs /annum

• Investment - Rs. 95 Lacs

(Additional Stand by capacity – 225000 Kcals/hr of heating at Hot water Generator)

BEFORE AFTER

220 OC

Exhaust

ED OVEN

energy is

wasted

LPG

BURN

ER

ED oven Heat recovery and Reuse in PT

Process

WHR Project

System supplied by: M/sThermax Pune

60

Paint Sludge

Disposed as

hazardous Waste to

MPCB

Paint sludge recycled

into powder. Sludge

Disposal Process

Eliminated.

Powder Used in

coating Process of

internal vehicle

components

Powder Used as

Extender for Powder

coating Process

Action1: Metallic Container replaced with Gunny bag.

2: By Using “ Paint Sludge Recover Unit” ,% Of

Sludge reduced & Converted into powder for Powder

Coating Application.

Benefits:

Planet: No Disposal of paint Sludge due to

Recycling.

People: Hazardous waste handling reduced for

people.

Profit: Sludge Disposal Cost Rs30.24 Lacs Saved.

Hazardous Waste reduction (3R Approach)

61

A4 paper Saving in logistics area

Logistic area is prime contributor in A4 paper consumption.

Average monthly consumption - 70 A4 paper rims.

Average 24000 papers (48 A4 paper rims) required to print

the vehicle specifications to feed the material to the

production line.

Papers coming along with glass pallets as partitions were thrown as waste.

Idea generated to use these unused glass partition papers

Glass coming with paper

partitions

A4 template made in-

house for resizing

Trials taken using resized

papers and were found ok.

62

Ribbon-less Stickers

Printer

With

Ribbon

Printer

Without

Ribbon

BEFORE AFTER

Sticker

output

Sticker

output

Unique Initiative

at M&M in such a

small item

Carbon footprint

reduction 1.8

tons/year i.e

476 Kgs CO2

reduction

Annualized cost saved Rs. 9 lacs

Cost Saving Potential

AcrossM&MRs. 45

Lacs/Annum

100% Ribbons

elimination

Elimination of

Waste (10000

Ribbons/Annum

)

Printing area is first heated on ribbon and then

printing image is created on sticker-Thermal Transfer

Printing area is directly heated on sticker and then printing image is created on

sticker-Direct Thermal

63

DeptWaste

3RResource

ConservationRenewable

EnergySafety &

ErgonomicsTotal

Press shop 0 11 1 6 18

Verito Body 0 8 0 0 8

Sc Body 0 6 0 0 6

Xylo Body 0 1 0 1 2

MQS Paint Shop 0 11 0 4 15

NPS Paint Shop 2 12 0 2 16

Bolero TCF 13 17 0 12 42

Canteen 0 7 0 5 12

Bolero Body 0 16 1 0 17

Verito TCF 0 7 0 34 41

Sc TCF 23 70 1 20 114

SCM 4 1 0 3 8

CMD 0 2 1 0 3

Common 0 18 1 7 26

MDC 0 17 0 0 17

Total 42 204 5 94 345

Green spots at shop floor

Baltimore cooling Natural cooling tower Office solar light pipe

Canteen solar water heater Office solar PV Cell

Canteen bio gas plant

Shop solar Sky shade

64

Assurance & Sustenance

Daily Work Management TUV Audits TPM Assessment

KPMG Assessment BEE, CII & MEDA Awards Recognitions

65

Digitization (Industry 4.0)

Steps - Digitization

7582

89

50

60

70

80

90

100

FY16 FY17 FY18

No.o

fpro

jects

Digitization projectsThemes - Digitization

66

Training & Awareness

• Training need

Identification

• 100% officers coverage

on E Portal

Employee

s

Suppliers

Community

67

EC Oath with HOD’s

Energy Efficient Product Display & Sale Solar Panel Sale in plant

EC Week Celebration

EC WEEK Banners at Gates & Canteen

68

In this drive total 10212 LED bulbs of 7 Watt were purchased by employees

which accounts for saving of 149095 KWh units/Year

LED Sale for Employees

69

Software for idea Entry

Plan – Policy, Envt Aspects

Do -Procedures

Check –Measurement & Monitoring

Act –Management

Reviews

Continual Improvement

i4

I4 Concept to Encourage Employees

70

Sustainability Ideas Drive in i-4 Forum at all Canteen location on scheduled days

Total 2410

Associates

involved in all

PU

39 Feasible&

9 shortlisted

Sustainability coupon for Associate for Suggestion

SN Name PU Idea

1 D.S.Patil

BTCF-SCM-Log

Kandivili Axle Plastic to be convert in Reuse Material

2 Ajinkya WaghB-TCF Eliminate Plastic wrapped for lock set of

Steering Column in Box

3 R.D.Sonawane

SCTCF-SCM-Log

Eliminate the Wood packaging with PP Recyclable type box

4 K.T.Sumbh

SCTCFMultiple packing in one Pack instead of Every Mud flap to avoid Plastic of Each Flap

5 D.C.BedseBTCF Hardware supply in Plastic Bag to be

convert into Gunny Bag

6S.N.Gandalwad

B-TCF Eliminate Plastic cover for Seatbelt & Supply in Cloth bags

7 D.K.Mahapadi

Bolero Trim Eliminate the Plastic for Each Cylinder In

one Box-4 Bags Eliminated

8 Vinod Wilson

Bolero Trim Eliminate the Plastic of IP Caps

9Yogesh.K.Thakre

SCTCF Eliminate Plastic of Bezel & supply in Bins

“Santulan” Idea Generation I4 for associates

71

71

Half yearly

Event of

i-point

distribution

Felicitation of ‘i-point’ Gainers.

72

Identified 4 top Energy Use Supplier

Plant Data Collection for Various Energy

parameters

Plant Site Visit For Energy Audit(Within

ECON Week)

Report Preparation and Submission

Supplier End Energy Audits & Awards

Best Sustainable Kaizen

Award for Vendor

Best Innovative Kaizen

Award for Vendor

73

Substation wise Online monitoring

Trend Analysis

Monitoring & Measurement

Online Trend Analysis

LNG Monitoring with SCADA

100% Water Monitoring

Compressed Air Monitoring with Flow Meters

74

Beyond…

75

Connect to society

PrayasWar against Aids

Project RakheeDrive against

Thalassemia

Nanhi KaliGirl child support

SahayogKnowledge Sharing

Mahindra

Hariyali

Tribal Athelits

Talent Search

Swaccha Bharat

Abhiyan

Water beyond

fence

7 Villages,

7 check Dams

Adopted 4379

Nanhi Kalis

Arjun Award winner

(Kavita Raut)

Clean India

Mission

228 Childs

>1499 employees

Reach out

> 12 Lacs

66 Sessions,

12 NMC Schools

120 K

3 Lacs tree

plantation

76

Future Plans about Energy Conservation

77

Innovation & Benchmark - Patent filing

Process- Identification of Shop Champions Training on IPR Identification of IPR proposals Shop round with IPR cell TCA for shortlisted proposals Proposal submission on iolite TCA by IPR cell Patent filing for TCA qualified

proposals

Patents

IP Licensing Agreement executed to

produce & sale

78

Future Projects

79

Sector level State level National level

Rise- Sustainability F18Rise- Sustainability F18 MEDA Award F18 (last 8 yrs) CII Energy Award F18

Founders day award F18 Maharashtra State Level Fire Drill CII Water Award

Vasundhara Award

Seem National Award

Achievements

We want to make

Mahindra globally admired

brand

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