Top 25 India s best companies Mahindra & Mahindra Ltd. Nashik Plant Journey Towards Carbon & Water Neutrality

Transcription

1 Mahindra Group $17.8 billion Group (1.10+ Rs. Lac Cr.) Employees Worldwide countries CLEANTECH 10 Sectors In business for over 66 years Highly CSR focused One of the 1st signatories to UNGC in India CII 18th National Award for Excellence In Energy Management 2017 Top 25 India s best companies Mahindra & Mahindra Ltd. Nashik Plant Journey Towards Carbon & Water Neutrality Copyright 2012 Mahindra & Mahindra Ltd. All rights reserved. The Core Values Top 10 global Auto brands CORE PURPOSE to work for Mahindra & Mahindra Ltd. Nashik Plant Deliver Farm Tech Prosperity Plant Established : 1981 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. BRAND PILLARS Accepting No Limits 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 Alternative Thinking Pursue new approaches Celebrate diversity Focus innovation on customer needs Invent your way to growth Frugal mindset Rise with your ingenuity 2 Area : M² 40 % Greenery Driving Positive Change Employees : Avg per day Customer sensitivity Build quality to delight customers Entrepreneurial Engagement Forge strong relationships Work hard. Have fun. Innovative automation ZERO discharge plant Water Positive People.. Passion..Performance Rise by shaping destinies CORE VALUES : Good Corporate Citizenship Professionalism Customer First Quality Focus Dignity of the Individual 3 4 1

2 Nashik Plant : Key Manufacturing Facilities Nasik Plant - Certifications Safety Quality Management Environment IT Press Shop(Tandem line) Body Shop (Robotic Welding) 4 Body Shops Paint Shop-CED Process Conveyorised Assembly Lines 3 Lines Paint Shop Robotic painting 2 Paint Shops 5 BS OHSAS ISO 9001 ISO ISO 50001:2011 Documentation is in Process ISO Methodology Approach Act Plan Check Step 5 Do Step 3 Step 4 7 Step 2 Step 1 8 2

3 Energy Conservation Team Mr. H. D. Aher VP Mfg. (NSK & IGT) 7% 13% 12% Plant Energy Stratification 53% Paint Group Electrical Air Compressors Body Group shops Mr. Norbert Desouza GM Mfg. (NSK & IGT) 15% Assembly Group Others Power Stratification Topcoat Oven Mr.Darshan (Thermal Energy) Mr. Atul Joshi. (Water Mgnt) Mr. Mahadeo Salunkhe (Energy MgmtSystem) Mr. Simon. (Electrical System) Mr. Rushikesh Jadhav. (Safety) Mr. Harshad Kaduskar (Environment) 2% 11% 24% Surfacer Oven ASU1 ASU2 Varaiable Load, 60.0% Fixed Load, 40.0% Mr. Satish Bakare. (Waste Mgnt) Mr. Santosh Shingane Kamlakar Ghongader. (Diesel & paper) (ESOPS/CSR) Mr. Utkarsh Kulkarni (Systems) Mr. Ketan Wagh (GSCM) Mr. Mohan Chitnis (Green IT) 9 20% 28% LNG Stratification ASU3 ASU4 ASU5 Fixed Load Varaiable Load 10 Year Measures No/Low investment < 1 Lac Medium investment < 5 Lacs High investment > 5 Lacs Savings in Rs Energy Conservation Projects No. of Projects Investment Rs. Lacs Payback FY Total Savings F15 F16 F Savings of Rs 148 lacs with Investment of 305 Lacs Investment F15 F16 F17 MT of CO2 Mitigated Carbon Inventorisation Energy Management Replaced conventional to IE3 motor of 260 KW to 200 KW at MQS Paint shop ASU1 Annualized saving KWh Renewable Power Solar Generation Kwh, Wind Power Will be effective from June 2017 Waste Recycling / Reduction Corrugated containers Tons Wood recycled 88.2 Tons Tree Plantation Planted Trees (620 MT expected) CO2 emission reduced by 24% FY FY Total FY - 14 FY - 15 FY - 16 FY - 17 F14 F15 F16 F17 Total CO 2 e MT

4 Industrial air Breezer - Bladeless Fan AFTER BEFORE Industrial Air Breezer Patent applied. (No 28335) Innovative Project Industrial fan Consumes 0.25 Units/Hrs Parameter Bladeless Fan 13 Bladeless Available on Total installed 30 Nos. Amazon conventional Air flow Uniform Breeze Non uniform and uneven Safety Highly safe Unsafe Noise level Lesser High Blades Absent No cutting of air Present Cutting of air Maintenance Not required Frequently required Cleaning During Running Need to switch off. Power (WATT) Air Flow 1m/sec at 5 Mtrs 0.3 m/sec at 5 Mtrs 38 Industrial fans replaced by 28 Bladeless fan 14 Layout of Industrial breezer in Scorpio TCF Before After Innovative Project FRP Impeller Investment Rs 3.22 Electrical Saving per year Units Cost saving Rs. 1.2 Lacs 38 Air circulators Copyright 2012 Mahindra & Mahindra Ltd. All rights reserved. 28 Industrial breezer

5 Idea Source Horizontal Deployment FRP Impeller & Exhaust Fan Almonard Metal Blade. FRP Blade. Before-Metallic Impeller After -FRP Impeller. 18 %POWER SAVING Implemented In F Nos. Total SCOPE: 800 Fans (575 Units / day) Implemented at Moist Sanding Exhaust Blower Capacity M3/Hr Weight Reduced by 20KG Investment Lacs FRP Blades for Almonard Fans. Annual Savings Lac Advantages of FRP Blades: Optimal aerodynamic design 23% Reduction in weight of the fan Blade( 1.3 to 1 kg ) Spares cost reduction. 18% power saving. 17% more air flow. Lower flow noise and mechanical noise. Unbreakable Blade. Why cant we do the same with Big Impellers??? Before-Cast iron exhaust fan After-FRP exhaust fan Total SCOPE: - 3NOS Exhaust fan at MQS - 6NOS Exhaust fan at NPS - 4NOS Exhaust fan at SBS Air conditioner Lubrication Enhancement System Unique Product Use Frigitech for Air Conditioners 19 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 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 Total Units Cost Sr.No Office installed Tons Saved saved 1 VP Office UVBody Shop UV Body Supply Module Total 118Ton Covered Haridwar Loading (Old Axle Shop) SCM + PPC Office+VC MQS Paint 6 Shop STCF Logistics Xylo Body Shop Total Saving Frigitech Total installed Units-67 Nos(118 Tons) Annual Savings - Saving of 1.49 L Power saving units/year Investment 3.31 L 20 5

6 Idea Genesis 12% Paint Group 7% 13% 53% Air Compressors 15% Body Group Optimisation Project DeRating of ASU Motor Power Stratification Of Plant Gap found in Air Supply units between Ideal & Actual Makigami Analysis 21 Can we Optimise and get Saving??? 22 Excess Flow in Existing Booth BEFORE AFTER Existing 260KW Motor was used for the Air Supply Unit to the Paint Booth(Circulation As Shown) Can we Optimise and get Saving??? No any changes in air flow No any change in air velocity distribution in spray booth. Parameter Before After Motor Rating in KW RPM Motor Efficiency IE1 IE3 Motor weight in Kg No. of groove of pulley 8 6 Motor Pulley weight in Kg Blower pulley weight in Kg Frequency in Hz Motor Current in Amp Spray booth should be positive. 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 Copyright 2012 Mahindra & Mahindra Ltd. All rights reserved. 23 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 Annual Savings - Saving of L Power saving units/year Investment L Copyright 2012 Mahindra & Mahindra Ltd. All rights reserved. 24 6

7 Existing Scenario Exhaust modification-before layout Earlier the Air Supply Unit of Surfacer Line was catering to 4 Zones Waste air Recovery Tack- O-rag duct modification The ASU Blower Motor was running at 32hz We found Air from two of our Booth were left to atmosphere Brainstorming was done how can we reuse this waste Air HOW DO WE USE THE WASTE AIR? Exhaust modification-after layout Reduction of torque of 250 kw main motor of press 1 Idea came why not to reuse this air Surfacer ASU BEFORE AFTER It was found in Surfacer ROBO zone we could use this air Ducting Modification were done and the air diverted to the Robot Zone Process Optimisation Description Before After Frequency 32 Hz 26 Hz KWH /annum Saving /annum Kwh Freq 26 Hz Surfacer Blower frequency could be reduced from 32Hz to 26Hz CO2 mitigation- 114 MT 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. Investment Rs. 6.5Lacs Electrical Saving-1.4 Lac KWH/Year Cost saving Rs. 9.8 Lacs 27 Annual Savings - Saving of 2.12L Zero Investment 28 7

8 Automatic Switching OFF stack lifter hydraulic motor Energy Efficient Motor at Shower top dryer BEFORE AFTER BEFORE AFTER Process Optimisation Energy Efficient Product 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 Before Shower top dryer had Earlier Motor with Lower Efficiency Now We have replaced it by IE3 Energy Efficient motor Annual Savings - Saving of 0.65 L Zero Investment 29 Annual Savings - Saving of Rs Lacs /annum Investment - Rs Lacs 30 Power Quality Enhancement by Use of RTPFC Panels Provision of air booster BEFORE AFTER Harmonic Compliance as per IEEE 519 Before 1. Air Compressor for 8 Bar Pressure Requirement 2. 45KW Compressor running. 3. Power per day-950 Kwh Now 1. 6 to 8 Bar Air Booster for 8 Bar Pressure requirement 2. No Extra compressor running 3. Power per day- 769 Kwh Use of RTPFC Panels to reduce the Harmonics & Maintain Unity PF Annual Savings - Saving of Rs. 3.8 lacs/year

9 No Air Loss Drain Valve BEFORE AFTER Measurement & Monitoring Timer based drain valve Before 1. Timer Based Solenoid Valve 2. Air also drained with moisture 3. High Noise during moisture drain. No air loss drain valve Now 1. No electricity required to operate 2. No air loss only moisture drained 3. No noise during moisture drain Annual Savings lacs/year Investment- 3.6 lacs Monitoring & Measurement Partnership with EESL Plant Lighting (Philips, Wipro, Goldwyn) Qty Nos. Budget 238 Rs. Lacs Completed Substation wise Online monitoring LNG Monitoring with SCADA IE3 Motors (Siemens - ACE LLP) Qty. 34 Nos. Budget 24 Rs. Lacs In progress Online Trend Analysis 100% Water Monitoring Air Conditioners (Blue star) Qty. 48 Nos. Budget 33 Rs. Lacs In progress Trend Analysis Compressed Air Monitoring with Flow Meters

10 Theme 1: Energy Conservation- Power Theme 2: Energy Conservation-Lighting Process optimization 98% efficiency Maximum envelope size Motor optimization High efficient motors Use of VFD s Solar Light Pipe in offices Uniform lux No heating Motion Sensors Use driven Supply Control Efficient use as per demand Power controls Unity power factor Harmonic distortion < 5 % Pump optimization High efficient pumps ZERO throttling Solar Power Power generation Lights BEE certified products Lower power Consumption 10-15% less Heat recovery 100% Zero heat losses ZERO pollutant Energy efficient chillers Water cooled VFD driven Hydro pneumatic control Demand supply Electrical interlocks Use of alternate methods LNG instead of LPG Wet on wet painting Energy management Daily power balance Immediate actions High Preventive maintenance Six monthly shutdowns Condition based tools Magnetic Induction lamps Lower power Used than Metal Halide lamps AC Energy Savers Controls Compressors 6-8% less consumption LED Lighting Lower power Consumption Higher Life of rods Automation of Assembly Lighting Lighting Automated with Conveyor Supply Street Lighting on Lux Sensors All Street lights On/off on lux sensor Nomenclature for Switching Effective Switching Zero Investment Saving Theme 3: Energy Conservation-Compressed Air Theme 4: Energy Conservation-Thermal Designed network Minimum pressure drop Ring loop Solenoid valves at user Off when not used Less demand Top to Bottom at CED oven Oven modified for air flow from top to bottom Sealer oven elimination Sealer oven eliminated in NPS Supply side control Compressor optimization Auto controls Localized compressor Air booster Stand alone compressor CED oven Heat recovery Heat recovery from air to water. WET ON WET Productivity increase of MQS TC Demand side control Variability control Less pressure Remote control Auto shut down Optimum usage PTCED 30JPH to 36 JPH Cab Cargo On single skid. Cargo from ATC bypassing drop lift. Bunty Bubbly Project at MQS Topcoat line. Productivity increase of Topcoat line by 10% ZERO air drain valves No air losses Auto control Air leakage management Air loss control User morale Project - SANGAM Utilizing NPS heat from oven to PTCED line Heat recovery from ovens Heat recovery from ovens to air supply units in NPS. Water Management Temperature control Scale control Air monitoring-scada Daily losses Immediate action Alternative fuel for LPG Changed over to LNG from LPG Wax oven elimination Introduction of air drying wax process change

11 Sustainable Manufacturing Green Projects Theme 5: Environment impact reduction Drying of Paint Sludge Drying of sludge reducing weight Recovering Thinner Use of Filter press To remove maximum water & liquid contains from Sludge Recuperate- Incinerator Burning of all flue gases Reduction in air pollution Milk run for material supply Fuel saved Reduction of Co2 emission Fuel saving & emission reduction Compacting by belling M/c. Reduces the trips Electrical Removal of access water paint sludge Filling of sludge in gunny bags instead of drums Canteen waste utilization Bio- gas plant generating LPG- used in canteen waste used as manure Use of Battery Fork lifts Replacement of Diesel Forklifts with Battery operated. (emission reduction) Empty trolley project Returned trolleys in MLL Save fuel & reduction in Co2 emissions Waste thinner reduction Waste thinner distillation Reuse in to process Thermal 602 projects since F08 Solar & wind energy Day lighting LED lighting Efficient pumping Efficient motors Compressed air boosters Compressed air management 36 projects since F ton fuel saved 4721 MT of CO2 mitigated 100% heat recovery Clean fuel LNG Recuperate for all ovens Water 89 projects since F M3 saved 16 RWH Projects KL saved since F08 Water by gravity Daily water balance ZERO water discharge HDPE pipes for sewage TW for fire fighting & gardens Waste 100% recycling of non hazardous waste Eska for paint sludge Paint sludge drier machine 100% Paint sludge recycle Filter press for Phosphate and ETP sludge Solvent recovery Renewable Energy Water positive plant Water positive plant Water beyond fence Capacity of Plant : 302 KWp Installation : Carport Structure Generation(Annual) : 4.08 Lacs KWh Annual CO2 reduction : 383 tons Water within fence Solar sky light for shop floor Solar Power Check Dams River widening Water reservoir Rain water harvesting Solar Power Plant 7 Villages, 7 check Dams 7 Villages Water requirement 191 K (Cu.Mtr) Water returned to society 252 K (Cu.Mtr) 1 village Solar light tube for office Pond for rain water harvesting Solar lighting for office Solar Water Heating system Wind Power Water Positive Plant 43 Capacity of Plant : 1050 KW Installed : At Jath Sangli Generation(Annual) : 20 Lacs KWh Annual CO2 reduction : 1880 tons Solar diesel dispensing Solar lighting for ETP & RWH 44 11

12 Non Hazardous waste Green SCM Initiatives Hazardous waste Green spots at shop floor Reduce Manual to Robotic painting 23% Reduction in paint consumption Baltimore cooling Natural cooling tower Office solar light pipe Dept Waste 3R Resource Conservation Renewable Energy Safety & Ergonomics Total Shop solar Sky shade Press shop Verito Body Sc Body Reuse Spent solvent Recovery & Reuse 1.8 lac lit /year saving fresh solvent Xylo Body MQS Paint Shop NPS Paint Shop Bolero TCF Canteen Canteen solar water heater Office solar PV Cell Recycle Bolero Body Verito TCF Sc TCF Eliminate Dewatering & drying of paint sludge Recycling project in process 45 SCM CMD Common MDC Total Canteen bio gas plant 46 Digitization (Industry 4.0) Innovation Steps - Digitization Approach No. of Patents filed Themes - Digitization Digitization projects Plant Innovation Gallery 100 No.of projects FY15 BM2 FY16 FY

13 Energy Audit Compliance Scope of major energy saving options as per the external energy audit report S.N. Energy Audit Proposal Status 1 Voltage optimization across the plant Completed 2 Installation of demand side controller on compressed air system 3 Phase out of old inefficient comfort air conditioners 4 Installation of VFDs on under loaded motors and blowers. Completed Completed Completed 5 Waste heat recovery projects in Paint Shops Completed 6 Installation of Tuned Harmonics filters Completed 49 Copyright 2012 Mahindra & Mahindra Ltd. All rights reserved. 50 Specific Consumption BETTER 340 Electrical 30 Thermal Reduction in Specific Consumption (Year wise) Kwh/Eq Veh % Reduction over F-08 In F16 & F17 Due to No decrease over F-14(Last expansion of 2 Major 3 years) Product Range SEC increased hence baseline revised 5% 3% 3% Kg/Eq veh % Reduction over F-08 1% Increase over F-14(Last 3 years) % 1% 9% In F17 due to climatic condition and product trials the SEC increased F-08 F-14 F-15 F16 F17 Compressed Air 0 4 F-08 F-14 F-15 F16 F17 Water KWH/Eq veh % Reduction over F-08 No Increase over F-14(Last 49 3 years) 29 In F16 & F17 Due to expansion of 2 3 Major Product Range SEC increased hence baseline revised CuMT/Eq Veh 5% 2% 7% % Reduction over F-08 18% Increase over F-14(Last 3 years) 4% 11% 5% F-08 F-14 F-15 F-16 F-17 0 F-08 F-14 F-15 F-16 F

14 International Benchmarking Benchmarking of Energy Conservation Norms 1% Reduction 14% Reduction 15% Increase Nashik Plant F-08 F-14 F-15 F16 F17 37% Reduction Over F National level Bench Marking TATA Pune Mahindra kndivli Volkswagen Pune Mahindra Nashik FY14 FY15 FY16 F LOWEST IN GROUP CO2 Emissions Benchmarking Parameter Volkswagen Ford BMW General Motors Carbon Intensity Water Footprint Nashik Plant 40% reduction by 2020 (Baseline: 2010) 25% reduction by 2018 (Baseline: 2010) 30% reduction by 2025 (Baseline: 2010) NA 25% Reduction by F19 25% reduction by 2020 (Baseline: 2006) 45% reduction by 2020 (Baseline: 2006) 20% reduction by 2020 (Baseline: 2010) 15% reduction by 2020 (Baseline: 2010) Nashik Plant F-08 F-14 F-15 F16 F17 37% Reduction over F We are committed to Move towards carbon Neutrality

15 Assurance & Sustenance EC Week Celebration Daily Work Management TUV Audits TPM Assessment EC Oath with HOD s EC WEEK Banners at Gates & Canteen KPMG Assessment BEE, CII & MEDA Awards Recognitions 57 Energy Efficient Product Display & Sale Solar Panel Sale in plant 58 LED Sale for Employees I4 Concept to Encourage Employees In this drive total LED bulbs of 7 Watt were purchased by employees which accounts for saving of KWh units/year Plan Policy, Envt Aspects Continual Improvement Do - Procedures i4 Software for idea Entry Act Management Reviews Check Measurement & Monitoring

16 Implementation & Monitoring Felicitation of i-point Gainers. 62 Recording & monitoring i 4 ideas through specially developed software Implementation through CFT approach. Half yearly Event of i-point distribution Quarterly review of i 4 teams by Plant Head 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 Beyond Best Innovative Kaizen Award for Vendor

17 Connect to society Prayas War against Aids Project Rakhee Drive against Thalassemia Nanhi Kali Girl child support 120 K Sahayog Knowledge Sharing Reach out > 12 Lacs Mahindra Hariyali 228 Childs >1499 employees Tribal Athelits Talent Search Adopted 4379 Nanhi Kalis Swaccha Bharat Abhiyan 66 Sessions, 12 NMC Schools Water beyond fence Future Plans about Energy Conservation 3 Lacs tree plantation Arjun Award winner (Kavita Raut) Clean India Mission 7 Villages, 7 check Dams Future Projects Achievements Sectorlevel State level National level Rise- Safety 2016 MEDA Award last 6 yrs CII Energy Award 2016 Rise- ESOPS 2015/16 Maharashtra State Level Fire Drill CII Water Award Rise- Sustainability 2016 We want to make Mahindra globally admired brand Vasundhara Award 67 Founders day award 14/15/16 Seem NationalAward 68 17

18 Thank You Copyright 2012 Mahindra & Mahindra Ltd. All rights reserved