Norbert De Souza Avinash Wagh Prasanna Kulkarni. CII National Award for Excellence in water Management th Dec 17 th Dec 2008 CII-Hyderabad

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1 MAHINDRA & MAHINDRA LTD AUTOMOTIVE SECTOR- PLANT I NASHIK Norbert De Souza Avinash Wagh Prasanna Kulkarni CII National Award for Excellence in water Management th Dec 17 th Dec 2008 CII-Hyderabad Occupational Health & Safety C E R T I F I C A T I O N Environment Quality Information Security OHSAS 18001:2007 ISO 14001:2004 ISO TS ISO/IEC

2 Water saving projects Press Shop Process flow Customer Body Shop Dispatch Paint Shop Assembly Think outside the sink Water Management Process Cooling/Distribution Domestic ETP STP Garden

3 Water audits 1. For total plant audit by CII in For treated water distribution by MMK in For Sewage distribution system by C11 in For rain water harvest by Greenfield technology in For ground water survey by GSDA in For total plant water balance by Technogreen in For sustenance by internal audits. [ Water saving projects To

4 Water saving projects Specific water reduction by process optimization ED B50 STAGE ELIMINATION PT Electrocoating BODIES Dip tank ENTERING PT BODIES ENTERING Electroco ating Dip tank BEFORE: UF spray UF spray Rinse Rinse UF Dip Rinse tank 1 2 ELECTROCOAT PROCESS UF spray Rinse 1 AFTER: UF spray Rinse 2 UF Dip Rinse tank ELECTROCOAT PROCESS DI Spray Rinse DI Spray Rinse ED B50 stage DI Spray rinse was running Fresh DI Spray also was running ED B50 stage & Fresh spray are Kept OFF Total Water Saved = M 3 Investment = 0 Water saving projects Rain water harvesting at paint shop Paint Sho p Sof t Wat er Ta nk C ollecti on Ta nk Gate Stor m Wat er Gu tter Total Water Saved = 2971 M 3 Investment= 0 4

5 Water saving projects Rain Water Harvesting Project for cooling tower ponds Compressor cooling tower Body-shop tower Water Saved : 1253 m 3 this monsoon Investment : Rs 0.2 lacks Water saving projects Water distribution through gravity & all pipes are above the ground. No underground leakages Before Variable Pressure 12 Pumps Water Savings : m 3 / Annum Investment : 30 lacks After Uniform pressure 2 Pumps Savings lac Kwh/annum 5

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

7 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 Specific Water Consumption National Benchmark * International Benchmark* MPCB Benchmark** Specific Water Consumption M3/vehicle Tata Motors 5.23 Ford India GM Toyota Motor Benchmarks for Wastewater Discharge National Benchmark* International Benchmark* MPCB Benchmark** Specific Water Consumption M3/vehicle Ford India Renault *:- Source from CII, Hyderabad. **: Mahar ashtra Pollution Control B oard 7

8 Per Capita consumption Improvement by 43 % Better M 3 /Capita *4% 21% 35% % * % Reduction with the base y ear 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

9 Treated Water Balance CMD 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

10 Recycling of treated water Raw water inlet Raw water Recycle Waste water recycled Waste Water Tank m 3 Water consumption M m 3 Before After Water Saving: M3 Investment: 0.2 Lacks In-house Project. Monitoring system 30 meters across the plant. Daily morning meter reading. Daily MIS report to top management. Daily shop consumption published. Variability captured by departments. Daily water management. Fortnightly CFT meets for opportunities. 10

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

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

13 Awareness & Involvement within the Plant Celebration of Water Conservation week-24 th to 30 th March Organizing Slogan, Poster Competition for Employees and their families. Awareness session to workmen through Workers Training Course. ECON stall on Founders Day(2 nd Oct)- visited by 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

14 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

15 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