Mahindra & Mahindra Ltd
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Waste Management & Improved performance
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Mahindra & Mahindra Ltd
- 1. National Award on Energy Conservation Mahindra & Mahindra Limited Top Rank Award in Automobile Manufacturing Sector
- 2. Location Zaheerabad, Medak District (Andhra Pradesh)
- 3. USD 16.2 billion multinational group based in Mumbai, India Employs more than 155,000 people in over 100 countries
- 4. Power Mobility Enhance Urban lifestyles Increase business efficiency Drive rural prosperity Priorities
- 5. Pillars of guidance Accept No limit Alternative Thinking Driving Positive change in everything
- 6. About the Zaheerabad factory ISO 14001:2004 (Environmental Management) 2500 Employees OHSAS 18001:2007 (Occupational Health and Safety Management) ISO 27001:2005 (Information Security Management System)
- 7. Products LCVs Buses UVs 3 Wheelers
- 8. Water Conservation Measures Rain-Water Harvesting ETP & STP Green Belts Development Bio-Filter Treatment
- 9. Total Energy Consumption (MTDE) 2404.5 8.4 % 2202 2011-12 2012-13
- 10. Absolute Power Consumption (Lakh units) 97.9 0.85 % 97.07 2011-12 2012-13
- 11. Absoute Thermal Consumption (Tonn/…..) 1250.07 12.5 % 1093.76 2011-12 2012-13
- 12. Specific Electrical Consumption (Kwh/ Eq. Veh) 95.72 78.32 18.2 % 2011-12 2012-13
- 13. Specific Thermal Consumption 0.4142 0.2901 (M Kcal/ Eq. Veh) 30 % 2011-12 2012-13
- 15. 1st Idea Energy conservation by Optimal use of space
- 16. Initial Situation Processing of sheet metal body Cargo Cabin Skid 1 2 4 Skids used for processing 4 BMT trucks 3 4
- 17. After Improvement 3 Skids used to process 4 BMT trucks
- 18. Savings No. of kWh Saved : 1.42 Lakhs kWh Thermal Savings : 210 M k Cal Savings per annum : Rs. 23.82 Lakhs Investment : Rs. 0.8 Lakhs
- 19. 2nd Idea Energy conservation by new lighting systems
- 20. Old systems replaced by more effective and efficient 28 W-T5 150 W SV/MV 45 W CFL 43 W LED 40W-T8 250 W MV/SV 250 W MV/SV 150 W MV/SV
- 21. Savings No. of kWh Saved : 1.78 Lakhs kWh Savings per annum : Rs. 17.21 Lakhs Investment : Rs. 9.45 Lakhs
- 22. 3rd Idea Energy conservation by changing a method of cleaning
- 23. Paint Booth grills cleaning Before • High pressure Water Jet system used to clean Paint Booth Grills • Physical forces produced by 110kW Motor After • Chemicals used to remove paint from booth grills • The chemicals used are environment friendly • No compromise on quality • Chemical reactions are self-sustaining and do not require any power source
- 24. Savings No. of kWh Saved : 1.50 Lakhs kWh Savings per annum : Rs. 14.51 Lakhs Investment : Rs.7.2 Lakhs
- 25. 4th Idea Choosing the equipment according to requirement
- 26. Retro fitment of screw chilling compressor in place of reciprocating compressor Before • 98 TR air cooled reciprocating chilling compressor • 110 KW motor along with forced draft cooling tower • Water circulation pump in throttled condition After • Replaced reciprocating compressor with 125 TR screw compressor (75 kW motor) • Natural draft cooling tower & VFD controlled water circulation pump
- 27. Savings No. of kWh Saved : 1.02 Lakhs kWh Savings per annum : Rs. 9.91 Lakhs Investment : Rs. 14.9 Lakhs
- 28. Enhancing Energy Efficiency – ENCON Cell • Suggestion Schemes • Small Group Activities • Total Productive Maintenance • Low Cost and No Cost automation Techniques 2013-14 Targets • Anticipated Investment – Rs. 58 lakhs • Targeted Savings – Rs. 64 lakhs
Editor's Notes
- Ministry of Power, Govt. of India
- Mahindra Automotive sector has six manufacturing units, four in the state of Maharashtra located at Kandvili, Igatpuri, Chakan & Nasik; fifth unit located at Zaheerabad, Medak- Andhra Pradesh and the sixth unit located at Haridwar, Uttaranchal.
- To enable people to rise through solutions that power mobility, drive rural prosperity, enhance urban lifestyles and increase business efficiency Zaheerabad plant also takes various initiatives towards community development in the areas of Health, Education and Environment.
- Internally, Mahindra Group follow three basic tenets-Accepting no limits, Alternative Thinking, and Driving positive change in everything we do. These brand pillars guide all our actions and business decisions from deciding whether or not to enter a new field or planning a portfolio of services.
- The Zaheerabad unit is a certified ISO14001:2004 & OHSAS 18001:2007, ISO27001:2005 unit. Employees 2500 people Planning an information security management system; risk assessment; risk treatment It exists to help all kinds of organizations put in place demonstrably sound occupational health and safety performance.
- manufacture of LCV's, Buses, UV's & 3 wheelers.
- One of the unique features of this plant is its total dependence on ground water as it does not get water supply from the state administration. The plant has taken measures to become self sustainable by conserving water through rainwater harvesting, ETP & STP -Waste water treatment, Bio filter treatment plant, Green belt Development & Environmental projects etc.
- Processing of 2 BMT cabins on one skid 4 cargos on one skid (one 2 ka 4)
- Before: Earlier the plant used to process One BMT cabin and one cargo on one skid
- Now plant is processing 2 cabins on one skid and 4 cargos on one skid meeting without compromising product quality resulting in 4 BMT's processing in 3 skids against 4 skids earlier
- No. of kWh Saved : 1.42 Lakhs kWh Thermal Savings : 210 MkCal Savings per annum : Rs. 23.82 Lakhs Investment : Rs. 0.8 Lakhs
- 2. Introduction of Energy Efficient lighting system across plant
- 3. Paint Booth Grills cleaning with chemicals instead of high pressure water jet system thereby elimination of 110 kW motor
- No. of kWh Saved : 1.50 Lakhs kWh Savings per annum : Rs. 14.51 Lakhs Investment : Rs.7.2 Lakhs
- 4. Retro fitment of screw chilling compressor in place of reciprocating compressor