Mahindra & Mahindra Ltd. Automotive Division, Kandivli Plant

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

53 Years & Going Strong..

Mahindra & Mahindra Ltd.

Automotive Division, Kandivli Plant

Sandip D. Priolkar – Head CMD/PPS/CECM & Energy Management

Nikhil Datar – Manager Heat Treatment & ENCON Member

Hemantkumar Joshi – Deputy Manager CMD/Utilities & ENCON Member

© Confederation of Indian Industry2

KND NSK IGT Zbad Hwar CKN

Foundry

Press Shop

Body Shop

Paint Shop

TCF

M/c Shop

Heat Treat.

Comparison of Activities of KND Plant

with Other Plants of Mahindra

Mahindra Group & Kandivli Auto Division

We are a 19 billion USD

conglomerate

We are a family of 2,00,000

employees with presence in

100+ countries

We are world’s #1 tractor brand

(by volume)

We are India’s #1 UV maker

We are India’s only OEM to

participate in Moto3TM &

Formula E racing

Started in 1964, Oldest Plant

Mother Plant of all Mahindra Auto Plants-

Supplies Aggregates to all other Plants

Only integrated Manufacturing Plant in

Mumbai (Foundry to Vehicle assembly)

4500+ Employees


Automotive Division

Area – 64 Acres

Max

Sanctioned

Demand

13,559 KVA

Connected

Load24,107 KW

Input Power @ 22 KV

Electrical

Consumption

55,00,000 KWH/

Mon.

PNG

Consumption

2,60,000

SCM/Month

LPG Consump. 3,000 Kg/Month

Kandivli Plant- Layout/ Process/ Energy Use/ Major Equipment

MAJOR EQUIPMENT

Foundry with 1750KWx2 Induction

Melting Crucibles, HPML, Sand

Plant, Pollution Control Equip.

(15000 Ton Dispatch Capacity)

Heat Treatment with 19 Furnaces

including Vacuum Furnace

Paint shop with PTCED facility

1100+ Machine Tool/Presses etc.

Screw Compressors with 12000CFM

demand

ENERGY USEKandivli Plant Process Flow

Vehicle PUPik-up & Thar Assembly

Axle PULive & Dead Axles

Machining & Assembly

Transmission PUGearboxes & Transfer case


Engine PUEngines


Foundry PUCylinder Head

Crankcase castings

Paint ShopBody & accessories

painting

Body ShopSpot welding

& finishing

Press ShopSheet metal

parts

Body PU

Other PlantsChakan

HaridwarNashik

Zaheerabad

Other PlantsIgatpuri

Farm Division

Vehicle Dispatch

ISO 9001 : 2015 BS OSHAS 18001 : 2007 ISO 14001 : 2015 TPM Consistency Award

Certification of Kandivli Plant


Axle, 6%

Body, 15%

Eng, 7%

Foundry, 32%

Transm, 19%

Veh, 1%

Others , 20%

Electrical ConsumptionCanteen

, 5% Café, 1%

Heat Treat., 53%

Paint Shop, 27%

Foundry, 14%

Thermal Consumption

Head UOM FY15-16 FY16-17 FY17-18

Revenue Budget for ENCON Project Rs. Lacs 66.00 26.29 33.05

ENCON Budget as % of Power Budget % 1.03 0.5 0.77

CAPEX for ENCON Project Rs. Lacs 243.78 746.53* 107.17

ECCON CAPEX as % of Total CAPEX % 8.73 33.9 1.5

1. Specific Energy Consumption in last 3 years

*- Includes Wind Mill Cost

Energy Resources

FY18

Electrical

DISCOM –

63.85%

OA SWPGL –

33.41%

Solar PV –

0.35%

Wind – 2.38%

ThermalPNG – 76.20%

LPG – 23.80%

Energy Cost 18.5% of Conversion Cost

Energy sources, stratification and budgets

Electrical88%

Thermal12%

Resource Cost Wise

Variable 88%

Fixed12%

Electrical Energy Stratification



Capacity utilization & Energy performance

Financial

Year

Installed

Capacity

Actual Roll

Down

%

Utilized

Eq.

Vehicle

% Change

2015-16 1,00,000 78,386 78.39% 214779 Base

2016-17 1,00,000 77,177 77.18% 202648 -5.64%

2017-18 1,00,000 82,001 82.00% 221952 3.33%

Equivalent Vehicle Calculation Equation:

Plant Equivalent Vehicles= Work content of Roll Down Vehicles +

Work content involved in Manufacturing other Aggregates

252240 240

25.4

27.9 27.9

FY16 FY17 FY18

Specific Electrical ConsumptionKWH/Eq. Vehicle

Impact of Additional Load

0.1091

0.1162

0.1093

FY16 FY17 FY18

Specific Thermal ConsumptionMkcal/Eq. Vehicle

Frequent

Start/Stop

of Furnaces


10

5.8

21

9.7

98

91

6.4

23

5.2

17

.6

98

.3 22

2.9

10

0.8

93

5.6

22

6.4

19

.2

0

200

400

600

800

1000

1200

Axle PU Body PU Eng PU Fdry PU TransPU

Veh PU

SEC Product Unit Wise

FY17 FY18 Plant FY17 Plant FY18


Analysis of Energy performance: Reasons for variation

Foundry Product Mix

has a Impact on SEC

1.951.34

0

1

2

FY17 FY18

Cylinder Head to Crank Case Ratio in

LMTCylinder Head

Less Wt, More EV

Crank Case

More Wt, Less EV

1

7.3% Increase in

Eq. Veh.

13% increase

in Tonnage

Increased Production in Foundry Pulls

up Avg Plant Consumption2

244.9 242.1

23 25.8

220

230

240

250

260

270

FY17 FY18

Holiday working SECDue to Non-availability of RM

Plant SEC Holiday Impact

3

Plant average


2. Information on Competitors, National & Global benchmark

(For vehicle assembly plants)

Source: Ernst Orlando National Lab.

Global Benchmarks

Application

SEC

KWH/

Car

M&M-KND

KWH/ Veh

FY17 Data

HVAC 160 13.92

Paint System 260 74.35

Lighting 130 19.47

Compressed Air 120 114

Material

Handling60 NA

Metal Forming

(Press+ Body)30 33.83

Miscellaneous 20 30.78

CompanyName

Sp. Carbon Footprint

(Scope 1 & 2 Emission)

KG/Unit of Production

Specific Water

Consumption

KL/ Unit of Production

FORD 670 3.70

GM 680 4.21

MERC 843 3.62

CHRYSLER 413 3.12

M&M-KND

690 2.99

Source: Sustainability Report 2017


2. Information on Competitors, National & Global benchmark

Parameter UOM C1 C2 C3 C4 C5 C6 M&M-KND

Manufacturing Capacity

Tons/ Year

36000 40000 75000 45000 120000 36000 20000

Major Product Cylinder Head/ Crank Case Brakes Part

Cylinder Head/ Crank Case

Rework/Rejection % 5% 5% 5.5% 3.5% 7.2% 6% 6.5%

Yield % 62~65 67~72 70 82 75 69 68

Melting Consumption

KWH/LMT

630 600 640 590 630 640 684

Overall Energy Consumption

GJ/LMT

3.42 3.49 2.3 3.89 4.39 2.3 4.14

Benchmarking Similar Processes – Grey CI Foundries

Since, the Product complexity of every Plant is different, Product Weight

Different, Capacity utilization is different, it is very difficult to compare on Apple

to Apple basis. hence all figures are indicative ones for reference

Z’ Bad NSK KND

0.012 0.008 0.007

PT-CED Process- Energy Usage GJ/m2

Z’ Bad NSK KND

0.03 0.07 0.055

Body Shop Energy Usage GJ/1000 Spots

NSK KND

0.71 0.15

Press Shop Energy Usage- GJ/1000 Strokes

Z’ Bad NSK-

BoleroKND

17.4 16.8 21.35

TCF Energy Usage- KWH/EV

Internal Benchmarking for Similar Processes


Process

FY17 Data

KWH/

LMT

Mkcal/

LMT

Tooling 22

Core Making 52 0.201

Sand Mixing 37

HPML 30

Melt Pouring 684 0.011

Fettling 12

Dispatch &

Others

136

Total FY17 981 0.213

Actions Taken in FY16 to FY18 Savings

With 2 Shift Operation, Optimize Cold Start up

Time of Furnace to avoid Holding of liquid

metal ( Furnace startup delayed by 30 Minutes)

60000 KWH

Refractory Brick Lining for Press Pour VAT 69120 KWH

Avoid Heat loss from LM during Ladle transfer

by providing better insulation inside MS Lid and

for Lids of Crucibles

10155 KWH

Sand Plant Conveyor Modification- 2 to 1 36300 KWH

Better Insulation of Ducting in Core Ovens 87.15 MKcal

Cold Box Process established on Existing

Susha Machines using Resin Coated Sand and

Amine Gas

276.77 MKcal

Energy Efficient Pumps/VFDs, Tapered Runner

Risers to improve yield etc.

183000KWH

2. Foundry Energy Consumption Optimization

FY17- 4.42 GJ/TonFY18- 4.14 GJ/Ton

FY16- 4.42 GJ/Ton


No Energy Project Details Major Outcome CO2

Mitigation

Investment

in Rs. Lacs

Target

Date

01 Cold Box Equipment for

Barrel Core in Foundry

Saving of PNG

132000 SCM/Year

289.08 280.00 Sep 2018

02 Waste Heat Recovery from

Compressors

Electricity Saving

600000 KWH/Year

492.00 54.00 Sep 2018

03 Centrifugal Compressor

4800CFM Capacity

Electricity Saving

665000 KWH/Year

545.30 150.00 Dec 2018

04 Replacement of Old Motors

with IE3/IE4 Motors - 126

Motors Targeted

Electricity Saving

290000 KWH/Year

237.80 56.26 Jan 2019

05 Inverter Based Split ACs

208 ACs Targeted

Electrical Saving

171000 KWH/Year

140.22 113.00 Feb 2019

06 Energy Efficient Ceiling

Fans- 110 Fans Targeted

Electrical Saving

10160 KWH/Year

8.33 3.63 Oct 2018


Mitigation

Investment

in Rs. Lacs

Target

Date

07 Thyrister Based Panels in

place of Conventional Panel

in Foundry

Electrical Savings

119700 KWH/ Year

98.15 20.56 Nov 2018

08 HVLS Fans

4 Fans Targeted

Electrical Savings

63000 KWH/Year

51.66 10.37 Aug 2019

09 Pumps, VFDs etc Electrical Saving

20000 KWH/Year

16.40 3.00 Sep 2018

10 Robotic Painting in Paint

Shop

Electrical Saving

283200 KWH/Year

PNG Saving

68000 SCM/Year

381.14 1160.00 Jan 2019

11 1.05 MW Wind Mill Clean Electricity

1700000 KWH/Year

1394.00 700.00 FY 2020-

Q1

3. Strategy for next 2 years..


Mitigation

Investment

in Rs. Lacs

Target

Date

12 Tri-Gen Project in

Collaborating with EESL

(24 Hrs x 350 Days

Operations Considered)

Electricity Saving

6856800 KWH/Year

with use of Additional

PNG @

1512000 SCM/Year

2311.29 800.00 FY2020-

Q1

13 1Ton Bio-Gas Plant Electricity Saving

54000 KWH/Year

44.28 50.00 FY2020-

Q2

Electrical Savings

107,78,860 KWH/Year

Use of Additional PNG

13,12,000 SCM/Year

Total Carbon Foot

Print Reduction

5965 Tons/ Year


Tangible:

1. Electrical Energy Saving 13200 KWH/ Year

2. Cost Saving-Rs. 1.06 Lacs/ Year

Problem

Definition

BenefitsAfterBefore

To reduce power consumption on grinding machines in

Gear & Shaft Line Cell

M/C 1109 M/C 1639

Chiller Tank TankChiller

2 Identical M/c s having Chiller

& Coolant Transfer Tanks for

Chilled Coolant for ID Spindles.

Total Connected power- 4.75KW

for Chiller/Coolant Pump / M/c.

Both Machine consumption :

132 KWH

Cost Per Day: Rs 1056

M/C 1109 M/C 1639

Coolant

TankChiller Unit

Modified Electrical, Piping Arrangement so as to cater Both Equipment with Single Chiller and Coolant Transfer Unit .

Now the Consumption:88 KWH

Horizontally Deployed for 17 different units!Total cost savings worth Rs. 17 Lacs/annum

Project Category Project Details Saving In Lacs Investment In lacs

Low Investment Timer –Manual to Auto 7.80 1.36

Elimination Idle Running 16.99 1.5

Combine/Intermitten

t Operation

Single Power pack for Multi

Machine

11.71 3

Efficiency Increase IE-2 to IE-3 Motor 29.46 23.37

Renewable Energy Solar System 23.23 94.62

Paint Chemical

Process

PTCED bath by altering

the chemical composition

42.50 51

New Technology Variable Frequency Drive/

LED Lights

15.13 18.74

De-rating Machine coolant Pump 0.75 0

3a. Energy Saving projects implemented in FY 2015-16

Project Type No Investment

~ Rs.10K

Investment

Rs.10K~ Rs. 2L

Investment

> Rs. 2L

Total Savings

Rs. L

Investment

Rs. L

No of Projects-54 16 24 15 134.27 139.78

Electrical Savings

1066000 KWH/Year

Total Carbon Foot Print

Reduction – 1187Tons/ Year

Tangible:

1. Eliminated air consumption

2. Annual Saving – Rs 1.8 Lacs

3. One man saving

Intangible:

Unsafe condition

eliminated.

Problem

Definition

To eliminate use of compressed air for Ring gear tap

hole cleaning

Post Shot Blasting, On Ring Gear

Air blowing m/c ring gear’s 8 tap

holes cleaned by compressed Air

.

1. Time - 5 sec per Ring Gear

2. Compressed Air Cost per day:

Rs 606 (28500 KWH/Year)

Arrangement on Shot Blasting

M/c

1. Ring gear hole caps made

to block shots & dust

entering in holes

2. No air blowing required

3. 100% Cost saved

BenefitsAfterBefore

Thermal Saving

1189Mcal/Year


3b. Energy Saving projects implemented in FY 2016-17


~ Rs. 10K

Investment

Rs.10K~ Rs. 2L

Investment

> Rs. 2L

Total Savings

Rs. L

Investment

Rs. L

No of Projects-50 29 33 11 480.47 242.82

Electrical Savings

14,69,000 KWH/YearTotal Carbon Foot Print

Reduction - 1521Tons/ Year

Thermal Saving

1040 Mcal/Year

Project Category Project Details Saving

In Lacs

Investment In

lacs

Low Investment Timer –Manual to Auto 15.70 0.75


Combine/Intermittent

Operation


Machine

11.71 1.75


Renewable Energy Solar System 23.23 100.62

Cold Box Conversion of Hotbox to ColdBox 50.13 65

New Technology IGBT Based Welding machine/

LED Lights

45.13 28.74

De-rating Machine coolant Pump 5.5 0


3c. Energy Saving projects implemented in FY 2017-18

Project Category Project Details Saving In Lacs Investment In lacs

Low Investment Conversion from Star Delta 4.80 1.01


Combine/Intermittent

Operation


Machine

8.95 11.19


Air cooling HVLS Fan 7.8 11.05

Waste Heat Recovery Compressor Waste Heat Recovery 8.5 8.0

New Technology Variable Frequency Drive/ LED

Lights

16.05 26.74

De-rating Machine Hydraulic Motor 0.75 0


~ Rs. 10K

Investment

Rs.10K~ Rs. 2L

Investment

> Rs. 2L

Total Savings

Rs. L

Investment

Rs. L

No of Projects-46 10 24 12 60.456 107.34

Electrical Savings

13,53,075 KWH/YearTotal Carbon Foot Print

Reduction - 1109Tons/ Year


Energy Saving Projects

Variable Frequency Drive- 80+ Nos

VFD IE3 Motor LED Lights

Energy Efficient Motor- 120+ Nos

LED High Bay lamps & Tube Lights 10200 + Nos

Energy Saving – 780000Kwh/Annum


Energy Saving Projects

100% LED Lights in Kandivli Plant

HVLS FAN Wireless OccupancyInduction High Bay Light

HVLS FAN - 6 Nos

Energy Saving – 565000Kwh/Annum

Induction High Bay Lamps -350+Nos

Wireless Occupancy 90 + Nos

Learning

From CII

Learning

From CII


4. Innovative Projects implemented

Project-1 -Introduction of Refractory Bricks on Press Pour

Before

A B DC

Furnace 1

1500KW

3 T/Hr

Furnace 2

1750KW

3 T/Hr

HPML

Press

Pour

170 KW

Autopour

Furnace

Liquid metal Transfer

through Ladle Using

Forklift

OEM DesignMore Surface Temperature and High radiation Losses

After

Low Surface Temperature due to Refractory BricksSavings- 69120KWH/Year

Trigger

Heat Treatment

Furnace Surface

Temp. Low due to

Refractory Bricks

59.5

51.1

FY17 FY18

SEC/LMT

This successful Experiment was done for the First

Time in Foundry Industry


Project -2 Unique solution

Mould Making - HPML

Foundry study: (Energy Consumption & Process

stage wise)

Carbon Footprint Mapping Cell Wise

* 12* 851

* 401

* 1051

* 10125* 124

* 0.8 * 5.5

CFT -1 working

Manual vent poking operation

Cross PokingMetal rod stuck in water passage

Vent

Moulding Process

En

erg

y L

eve

l

Auto Poking - Innovation



18

Auto Poking - Innovation

Unique Features of the Patent

Electro-Pneumatic Principle for Vent poking 1st time across Globe on HPML

Poking with Drilling 1st time across Globe

Salient Highlights

Conventional method used for vent poking across industry is Manual Poking

(High Fatigue) & Hydraulic Poking machines (High CAPEX cost)

Developed Auto Poking solution (Frugal Solution) is unique to M&M as well as

Foundry industry


Project -2 The Solution



Project -2 Benefits of the innovation

People

• Green manufacturing

• Enhanced safety & Fatigue Elimination

Planet

• Electrical Energy Saving 55000Kwh/Year

• Carbon Footprint Reduction 45Tons/Annum

• Water saving 14KL/Annum

Profit• Energy Cost Saving 5.5Lacs/Annum

• Total Cost saving -29Lacs/Annum


4. Innovative Projects implemented (Zero investment)

Project-3 -Process optimization on Vacuum Carburizing

Furnace

CGC-12%

CGC-25%

RHF-10%

RHF-20%

UBQ-13%

UBQ-21%

UBQ-31%

HA-20%

HTSQF13%

VCF75%

Heat Treatment, Furnace-wise Electrical Consumption

CGC = Continuous Gas Carburizor

RHF = Rotary Hearth Furnace

UBQ = Universal Batch Quench Furnace

HA = Horizontal Atmotrol

HTSQF = Hightemp Sealed Quench Furnace

VCF = Vacuum Carburizing Furnace

Idling2%

Heating36%

Controlling15%

Accessories*10%

Chiller32% Miscellaneou

s5%

Vacuum Furnace Energy Consumption Break-up

Heating segment is responsible for highest

energy consumption.

Furnace heating system is responsible for

heating & controlling(maintaining temperature)

segment & both put together amount to 51 % of

energy consumption



0

200

400

600

800

1000

0 50 100 150 200 250

Tem

per

atu

re in

°C

Time in minutes

Typical Heat Treatment Cycle

HT Cyclebreak-up

Heating Heating Soak Carburizing Temperature Drop

Hardening Soak

Quenching

Function of each stage

Achieving processtemperature

Attaining temperature uniformity in components

Achieving case depth

Distortion Control

Attaining temperature uniformity in components

Achieving transformation & strength

ASM Metals Handbook Volume 4 states heating soak

should be 30 minutes for a component with

1 inch thickness

Heater

current

Heating soak

Stabilized heater

current

Project-3 -Process optimization on Vacuum Carburizing

Furnace



0.8834080140.779630231

-0.805258591

0.248851088

0.59901434

-0.817668248-1

-0.5

0

0.5

1

Heating ramp Heating soak uptodrop of heater current

Heating soak withstabilized heater

current

Carburizing & diffusionTemperature dropping Hardening soak

CORRELATION WITH CHARGE WEIGHT

HT Cycle

break-up

Heating

rampHeating soak

Carburizin

g &

diffusion

Temperatur

e dropping

Hardening

soak

Total cycle

time

Set time in

minutes52

6363 10 20 208

37 26

Average 55.4 36.4 26.8 62.6 17.8 8.9 -

Proposed

time in

minutes

5248

63 15 10 18840 8

BENEFITS

Tangible benefits:

1. Electrical consumption reduced by 3,44,500 KWH per annum.

2. Electricity cost saved by Rs. 31,00,000 per annum.

3. Specific Electrical Consumption reduced by 5.3%.

Intangible:

1. CO2 emissions reduced by 186 Metric tons, which is equivalent to

saving 186 trees.

1225

1160

1120

1140

1160

1180

1200

1220

1240

F'17 F'18

Specific Electrical Consumption (KWH/Ton)

Project-3 -Process optimization on Vacuum Carburizing Furnace


Waste Heat Recovery from Air Compressor – Units saved 1,01,000 KWH/annumLocalization of Suction at Roller Tester – Units saved 37000 KWH/annumIncreased components to fixture weight ratio for Heat Treatment – Energy saved – 0.6 MKCal/Ton

4. Unique Projects implemented Some Unique Projects executed for First time in Mahindra Group at

Kandivli Plant

Sharing of ideas for Horizontal deployment at other plants

Tempering

Washer

machine

7283

Electrical

Water Heater

Water inWater out

Oil

Air out

90 Deg C

Heat exchanger

Air oil

separator

Oil Cooler

In

Motor

Heat Treatment ShopCompressor House

Compressor Tempering Washer Machine

80 Deg C

70 Deg C

90 Deg C

Screw Compressor

55 Deg C

75 Deg C

Unique project

First time in

Mahindra Group


4. Unique Projects implemented

Using Predictive Maintenance Tool for Energy Optimization Through

Breakdown Elimination

Line Stoppage

M/c Idling

M/c Breakdown

Spindle Motor

Winding Open

Motor Overloaded for

Extended time due to

various reasons

Thermal Overload

Response Poor

Digital Overload Relay

Quick reponse for high Current

Temp. Sensor interlocked with

Control- Alarm for Heating due to fan

Failure, bearing jam etc

Implemented at 24 Locations

on 13 Equip.-

HD in Progress

43 Incidents of

Unplanned stoppages

Eliminated

63 hours of Idling Time

Saved

18973 KWH of Energy

Saved

Loss of Energy


4. Unique Projects implemented

22 KV

Rec. St.

11 KV

Unmanne

d Station

Fault

Carbonisation of

HT Cable Joint

Leading to Spark

Response

time to attend

10 Minutes

Distance

600Mtrs

Rectification

0.5 Hrs to

3 Hrs

Loss of Prodn.

Leading to

Partial working

on Holidays

Th

erm

og

rap

hy

@ P

eri

od

ic

Inte

rval

Before After

Use of Thermistor close to

cable for sensing the

temperature

and generating signal if

temp >75 Deg C

Thermistor

Interfaced

with PLC

and GPRS

to generate

SMS alert to

multiple

persons SMS On

Mobile

Benefit

Online Monitoring

Proactive Approach

Optimized Maint.

No Unscheduled

D/T

Leveraging iOT and

Digitisation


5. Utilisation of renewable energy sources

Solar Thermal at

Canteen

200KWp Solar PV

Generation

FY17- 164,812 KWH

FY18- 218,869 KWH

1.05 MW wind Mill at

Jath, Sangli

Generation

FY18- 14,92,993 KWH

1 more 1.05 MW

Planned in FY20

Impact on Specific Carbon Footprint- Excluding Scope 3 Emission

294.7 Kg/ Eq. Veh. 282.7 Kg/ Eq. Veh. 255 Kg/ Eq. Veh.

Upto FY16 FY17 FY18


6. Utilisation of waste material as fuel

Bio-gas Plant – 1Ton

Upgradation

Planned in FY20

Vented ENDOTHERMIC Gas

redirected to and burnt in burners

Waste

Material

FY-16 FY-17 FY-18

Organic Waste 0.0127 0.0127 0.0127

Vented Gas 0 0.36 0.42

Energy saved

in Million

KWH


7. GHG Inventorisation

• At M&M, we have adopted GRI G4 Guidelines for GHG inventorisation

• We are monitoring & analyzing GHG data through SoFi portal, across

all M&M locations

• GHG are monitored under scope 1 ,scope 2 and scope 3 for all

locations and it is externally assured through authorized and

competent agency every year .

• From Past 10 years , these GHG emissions are reported in annual

sustainability report

Public discloser

• M & M reports its GHG emissions in following platforms –

1. Annual sustainability report

2. Annual report

3. DJSI (Dow Jones Sustainability Index)

4. CDP (Carbon Disclosure Project)

Scope 1

6921 TCO2

Scope 2

49663 TCO2

Scope 3

42119 TCO2


8. Green Supply Chain Policy, Target Suppliers and Activities

• Development of

Management System for

Sustainability/ Energy

• Reduce Carbon footprint-

Material/ Energy/Water

• Logistics Optimization

• Zero Wood Waste

Focus on Tier-1 Suppliers across AFS

Sustainability AwarenessTotal 345 Suppliers trained on

Sustainability since 2016.

LED InstallationLED installed at 101 supplier location

through EESL and Mahinda & Mahindra.

Energy EfficiencyCollaboration with EHS+ centre for Energy

audit and handholding for energy

reduction at 9 Suppliers

Wood reduction in Packaging15% wood reduced in AD and 62% wood

reduced in FD packaging through Supply

chain

Projects Implemented at Suppliers’ End


8. Green Supply Chain Policy

Monitoring and Outcome

Monitoring through

Balance Score Card

Sustainability Performance Monitored for 80 Suppliers

across AFS

Major Performance MonitoredEnergy/ Water/ Diesel/ Waste/

Safety

Sustainability Assessment

On-site Assessment done for 43 Suppliers

On-site Assessment done for 43 Suppliers

Results

Monitoring Energy/Water footprint of 75 Suppliers of AD (42), FD(22)

and SD (16)

Sustainability Parameter No of Supplier Reduction in %

Specific Electricity Reduction 34 More than 3% - 5%

Specific Diesel Reduction 35 More than 3% - 5%

Specific Water Reduction 40 More than 10%


9. Team work, Employee Involvement & Monitoring

By 2030, we will reduce emissions

by 33 to 35% of 2005 levels,40% of

our installed capacity will be from

our non- fossil fuels.

Committing to Join EP 100- double

energy productivity by 2030 or RE

100 -100% renewable energy in the

future.

Sector Specific Energy

Management Policy Plant Specific 3-Years

Promise Statement

Reduce Carbon/Water Footprint by

15% in FY19 wrt FY16

Leadership Vision, Policy and Plant Specific Promise



ENCON Structure, Review Mechanism

Approach

Mahindra EnMS

Take Stock of Current

Energy Scenario

Stratification of Data

Micro-Analysis

Theoretical V/s Actual

Idea Conceptualization

Technical/Economic

Feasibility & Prioritization

Implementation/ Monitor

and Horizontal

Deployment

Saving on 22,00,000+ KWH

&

2393 Mkcal Saved in Last 24

Months



Sharing of

Resources

interlocking

VFD

Energy

Efficient

appliance

Waste Heat

Recovery

Solar PV

Wind Energy

Low

Temperature

De-greasing

Solution

Energy

Efficient

Motors

Harnessing

Rain Water

Ground

Water

Recharging

Wireless

Occupancy

Sensors

Elimination

LED Lights

Paint Sludge

Reduction

Rework-

Rejection

Reduction

Paper

Reduction

Corrugate Box

Reduction

Wood

Reduction

Improve Yield

of Sheet

Metal

Recyclable

Packaging

Elimination of

Compressed

air leak

Water

Efficient

Taps

Max. use

of Treated

water

Timer

Based

Shutoff if

idling

Karakuri

Kaizens

Stoppage of

Leakages Leveraging

IoT

Various initiatives



Metering, Online Monitoring and Reports for Analysis

Electricity 27 KEY Meters connected EMS Sys. 100 meters on DB Total 300 Meters

Compressed Air 13 Air Flow Meters to Capture Air Consumption data PU wise

Gas 9 Gas Meters Capturing Gas Consumption Department Wise (Manual)

ON

LIN

E M

ON

ITO

RIN

G



Capability Building for Officers and Associates

No FY Topic BY Persons Duration Type

1 FY18 Sustainability Conference Internal 6 2 Days External

1 FY18 Energy Efficient Motors EESL 10 1 Day External

2 FY18 ISO 50001 Lead Auditor BSI 2 5 Days Out-bound

3 FY17 Energy Management MIQ 4 3 Days Out-bound

4 FY17 ISO 50001 Awareness DNV 7 1 Day External

5 FY17 ISO 50001 Lead Auditor BSI 1 5 Days Out-bound

6 FY17 Energy Conservation Laws EESL 20 1 Day In-House

7 FY17 Energy Efficient Motors EESL 5 1 Day In-House

8 FY17 Energy Efficiency CII 2 2 Days Out-bound

9 FY16 Rain Water Harvesting NIVRON 1 2 Days Out-bound

10 FY16 Energy Efficiency CII 2 2 Days Out-bound

11 FY16 Green Building Godrej 10 1 Day In-House

12 FY16 Sustainability Conference Internal 3 2 Days In-House

53 Associates and 18 Officers are covered in FY18Capability Building For Associates



Energy Audit By External Agency and Management programmes

2014

Energy Audit By

PPS, Electrical/

Thermal & Power

Quality

2015

Energy Audit By

Spectrum,

Efficiency of

Foundry

2016

Motor audit By

TAACT,

Energy Efficient

Motors

2017

Audit By EESL,

Potential for

WHR

Major Energy Management Programs Taken in Last 4 Years

No Energy Management

Program

Major Activities Done %

Compl.

1 Compressed air

Consump. optimization

Screw Compressors, Upstream Air Controllers, Parallel lines-

Pressure opt., Leakage arresting

100%

2 VFD Identify and Implement 98%

3 Waste Heat Recovery Identify and Implement 93%

4 Energy Cost

Optimization

Electrical to Gas Conversion, Develop Low Temp Degreasing

Solution, Compressor Heat Recovery

86%

5 Energy Efficient Motors Conversion of IE1/IW2 Motors with IE3/IE4 motors 4%

6 Mahindra Towers as

Green Building

Implemented various measures- Awarded Platinum Rated

Green Bldg. in Existing Building Category

100%

7 LED Lamps LED Lamps in place of MH/MV Lamps 94%


A Theme Based Approach for Proactive/Focused Working with Union

support

UNITe- Unite to Save UNIT Green Manufacturing

Engagement of Everyone including Families of EmployeesFounders’ Day Celebration with Employees’ families- Sustainability

Theme

Tree Plantation to Mitigate CO2, Involvement of StakeholdersReward, Recognition for the Achievers- Inter PU Competition, Individuals

Best Product Unit

Best Support Dept.


WWC- War For Water Conservation C3- Cut Cost of Compressed Air


10. Implementation of IGBC rating

Mahindra Towers- Green Platinum rated Building in Existing Building

Category

32 Years Old Building- G+4

Rain Water Harvesting to

Recharge Borewell

22 KWp Solar PV Roof Tops

arrangement

Energy Efficient LED

Lighting

Reverse Umbrella for RWH

+ Solar Electricity

Paver Blocks for

LandscapingWaterless

Urinals

Energy Efficient Pumps with

VFD for Central AC Plant

Energy Efficient Air Handling Units


7th Manufacturing Supply

Chain Award for Best Practices

SEEM- Gold Award for ENCON

3rd Year in Row

Green Foundry of the Year at

Indian Foundry Congress 2018

Awards and Accolades (FY17-FY18)

Associate Level i4 Competition

Award on Energy Topic

Best Energy Efficiency Project

Competition by AFS

Sustainability Team

Internal RecognitionExternal Recognition

SOPEP Awards for Waste

Heat Recovery Case Study

SOPEP Awards for Energy

saving using iOT

1st Prize at 2nd CII National

Energy Circle Competition,

Best Case Study

Corp. Sustainability Award for

AV on Water ConservationApex Award of Excellence at

State Level ENCON CompetitionSOPEP Awards for Water

Conservation Case Study


Thank You

Our Journey Continues to excel under

People, Planet and Profit ……...

High performance, time and again…

Step towards Excellence ………………..

Way Forward…

Mahindra & Mahindra Ltd. Automotive Division, Kandivli Plant

Documents

Transcript of Mahindra & Mahindra Ltd. Automotive Division, Kandivli Plant