Mahindra & Mahindra Ltd,Nashik

MAHINDRA & MAHINDRA LTD AUTOMOTIVE SECTOR- PLANT I SECTOR- NASHIK Nor bert De Souza Av inash Wagh Prasanna Kulkarni CII National Award for Excellence in water Management 2008 16th Dec – 17th Dec 2008 CII-Hyderabad C E R T I F I C A T I O N Occupati onal Heal th & Safety Env ironment Quality Infor mati on Security OHSAS 18001:2007 ISO 14001:2004 ISO TS 16949 ISO/IEC 27001 - 2005 27001- 1

Water saving projects Process flow Pre ss Shop Body Shop Customer Di spat ch Paint Shop A sse mbly Think outside the sink Water Management 1350 280 Cooling/ Distri bution Process Domestic 430 800 400 ETP STP Garden 430 400 2

Water audits 1. For total plant audit by CII in 2006 2. For treated water distribution by MMK in 2006 3. For Sewage distribution system by C11 in 2008 4. For rain water harvest by Greenfield technology in 2007 5. For ground water survey by GSDA in 2007 6. For total plant water balance by Technogreen in 2007 7. For sustenance by internal audits. [ Water saving projects- 2004 To 2008 projects- 3

Water saving projects Specific water reduction by process optimization ED B50 STAGE ELIMINATION ED B50 BEFORE: stage DI Spray rinse X XX X X X X XX X was running X XX X X X X X XX X X X XX X X X X XX X X X X XX X X XX X X X X XX X X X X X XX X X XX X X X X XX X X X X X XX X X XX X X X X XX X X X X X X X X X UF spray UF spray DI PT Electrocoating UF D ip Rinse Rinse Spray B ODIE S Dip tank Rinse tank 1 2 Rinse Fr esh D I ENTE RING E LE CTROCOAT PROCESS Spr ay also was running AFTER: X XX X X X X XX X X X ED B50 X XX X X X X X X XX X X stage & XX X X X XX X X X XX X X X X X F resh spray X X XX X X X XX X X X XX X X ar e Kept X X X X X X OFF X UF s pray UF spr ay PT Electroco ating U F Dip DI Rinse Rinse B ODI S E D ip tank Rinse tank Spray 1 2 ENTE RING Rinse E LE CTROCOAT PROCESS Total Water Saved = 13490 M3 Investment = 0 Water saving projects Rain water harvesting at paint shop Pain t S ho p Sof t Wat er T nk a C ollecti on Ta nk G at e Stor m Wat er Gu tter Total Water Saved = 2971 M3 Investment = 0 4

Water saving projects Rain Water Harvesting Project for cooling tower ponds Compressor cooling tower Body-shop tower Water Saved : 1253 m3 this monsoon Investment : Rs 0.2 lacks Water saving projects Water distribution through gravity & all pipes are above the ground. No underground leakages Before After Variable Pressure Uniform pressure 12 Pumps 2 Pumps Savings- 1.15 lac Kwh/annum Water Savings : 30000 m3/ Annum Investment : 30 lacks 5

Water saving projects Optimizing the painting process by combining cab & cargo on single fixture. Before After Two fix tures required Single fix ture Electricity – 207 kWH/body - 167 kWh/ body LPG – 26 kgs/body - 13 kgs/body Water Savings 10 CMD OR 2880 m3/annum Water saving projects Replacement of inefficient pumps with efficient Hydro MPC for air compressor water circulation . Before Before After 3.22 Lacs Units/Year 1.60 Lacs Units/Year Water Savings /annum 1500 m 3 Investment Rs.14.5 Lacks 6

Water saving projects Fire hydrant line above the ground Before After Water Saving: 250 m3 leakage losses eliminated Investment : 40 Lacks Global Norms / Bench mark Benchmarks for S pecific Water Cons um ption Nation al International MPCB Benchm ark * Benchm ark* Benchm ark** Specific Ta ta Motors – 5.23 Water Toyota Motor- Consum pti on Ford I ndia- 2.56 1.97 2.74 M3/v ehicle GM- 7.56 Benchmarks for Wastew ater Disc harge Nation al International MPCB Benchm ark* Benchm ark* Benchm ark** Specific Water Consum ption Ford India- Renault- 0 M3/vehicle 0.67 0.5 *:- Source from CII, Hydera ba d. **: Mahar ashtra Po lluti on C ontrol B oard 7

Per Capita consumption Improvement by 43 % Better 187 2 00 180 1 48 1 50 121 *4% 10 7 M /Capita 21% 1 00 35% 3 43% 50 0 2004 2005 2006 2007 2008 * % Reduction with the base y ear 04-05 Sustainability F Daily input and output water monitoring. F Tighter consumption control in the high consumption shop F Internal water management team. F Continuous improvements through team review. F Internal and External audit for improvement validation. F Monthly water quality analysis. 8

Treated Water Balance CMD 830 430 400 •Treated water reuse for the Press shop car body panel washing. • Investment: Zero • Water Saving: 1560 m 3/annum • Implemented in Nov 2008 • Investment: Zero • Water Saving: 120 m 3/annum • Implemented in Oct 2007 9

Recycling of treated water Raw water inlet R aw w at er Recycle Recycle Wa ste Water Tank Waste water recycled recycled 3 3 000 0 m consumption Water M3 3 15 600 m Befo re After In-house Project. In - Project. Water Saving: 15600 M3 Investment: 0.2 Lacks Monitoring system Ø30 meters across the plant. ØDaily morning meter reading. ØDaily MIS report to top management. ØDaily shop consumption published. ØVariability captured by departments. ØDaily water management. ØFortnightly CFT meets for opportunities. 10

Monitoring system ØMonthly treated water balance charts. ØMonthly water balance charts. ØMonthly specific water trends. ØWater testing as per MPCB norms. ØWater testing as per ISO10500 STD. ØMonthly water cooler management. ØMonthly management review. Monitoring &Reporting Ø Water meters at user interface Ø Daily monitoring & analysis Ø Daily Pressure Monitoring Put a Stop - to the Drop 11

Green Areas in Nashik Plant Green Areas in side Nashik Plant shop area 12

Awareness & Involvement within the Plant ØCelebration of Water Conservation week-24th to 30th March ØOrganizing Slogan , Poster Competition for Employees and their families. ØAwareness session to workmen through “Workers Training Course”. ØECON stall on Founders Day(2nd Oct)- visited by 15-20 thousand people. Preservation Towards Environment • Expertise team for EMS • Tree plantation target - 1 Lac / year • Special team in R&D working for Alternative fuel • Rain water harvesting for paint shop. • Formation of vendor cluster to reduce transportation • New research on non ODS refrigerant 13

Preservation Towards Environment • Special management programs to reduce hazardous waste • Introducing energy efficient equipment in new projects/expansions. • Involving employee in environment preservation program. • Maximize use of treated water. Environmental projects • Planting of 1 Million trees • Planting of “Jatropha”Plant • Use of Bio Diesel • Use of Renewable energy • Use of Treated water 14

Environmental projects • Recycle of used thinner • Recycle of Exhaust gases in paint shops • Scrubber chambers for spray booths • Reduction/Reuse of effluent sludge. At Mahindra we follow Five Mantras vLEADERSHIP vCOST EFFECTIVE vCUSTOMER CENTRIC vGLOBALISATION vINNOVATION 15

Mahindra & Mahindra Ltd,Nashik

by India Water Portal on Nov 16, 2009

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