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
© Confederation of Indian Industry3
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
Machining & Assembly
Engine PUEngines
Machining & Assembly
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
© Confederation of Indian Industry4
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
© Confederation of Indian Industry5
1. Specific Energy Consumption in last 3 years
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
© Confederation of Indian Industry6
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
1. Specific Energy Consumption in last 3 years
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
© Confederation of Indian Industry7
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
© Confederation of Indian Industry8
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
© Confederation of Indian Industry9
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
© Confederation of Indian Industry10
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
No Energy Project Details Major Outcome CO2
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..
No Energy Project Details Major Outcome CO2
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
© Confederation of Indian Industry11
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
© Confederation of Indian Industry12
3b. Energy Saving projects implemented in FY 2016-17
Project Type No Investment
~ 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
Elimination Idle Running 28.99 7.54
Combine/Intermittent
Operation
Single Power pack for Multi
Machine
11.71 1.75
Efficiency Increase IE-2 to IE-3 Motor 29.46 46.37
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
© Confederation of Indian Industry13
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
Elimination Idle Running 7.9 4.30
Combine/Intermittent
Operation
Single Power pack for Multi
Machine
8.95 11.19
Efficiency Increase IE-2 to IE-3 Motor 12.03 20.70
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
Project Type No Investment
~ 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
© Confederation of Indian Industry14
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
© Confederation of Indian Industry15
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
© Confederation of Indian Industry16
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
© Confederation of Indian Industry17
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
4. Innovative Projects implemented
© Confederation of Indian Industry18
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
4. Innovative Projects implemented
Project -2 The Solution
© Confederation of Indian Industry19
4. Innovative Projects implemented
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
© Confederation of Indian Industry20
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
© Confederation of Indian Industry21
4. Innovative Projects implemented (Zero investment)
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
© Confederation of Indian Industry22
4. Innovative Projects implemented (Zero investment)
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
© Confederation of Indian Industry23
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
© Confederation of Indian Industry24
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
© Confederation of Indian Industry25
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
© Confederation of Indian Industry26
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
© Confederation of Indian Industry27
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
© Confederation of Indian Industry29
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
© Confederation of Indian Industry30
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
© Confederation of Indian Industry31
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%
© Confederation of Indian Industry32
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
© Confederation of Indian Industry33
9. Team work, Employee Involvement & Monitoring
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
© Confederation of Indian Industry34
9. Team work, Employee Involvement & Monitoring
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
© Confederation of Indian Industry35
9. Team work, Employee Involvement & Monitoring
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
© Confederation of Indian Industry36
9. Team work, Employee Involvement & Monitoring
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
© Confederation of Indian Industry37
9. Team work, Employee Involvement & Monitoring
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%
© Confederation of Indian Industry38
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.
9. Team work, Employee Involvement & Monitoring
WWC- War For Water Conservation C3- Cut Cost of Compressed Air
© Confederation of Indian Industry39
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
© Confederation of Indian Industry40
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
© Confederation of Indian Industry41
Thank You
Our Journey Continues to excel under
People, Planet and Profit ……...
High performance, time and again…
Step towards Excellence ………………..
Way Forward…