National Award on Energy Conservation

Top Rank Award in Automobile Manufacturing Sector

Mahindra & Mahindra Limited

Location

Zaheerabad, Medak District

(Andhra Pradesh)

USD 16.2 billion multinational group based in Mumbai, India

Employs more than 155,000 people in over 100 countries

Power MobilityEnhance Urban

lifestyles

Increase business efficiency

Drive rural prosperity

Priorities

Pillars of guidanceAccept No

limit

Alternative Thinking

Driving Positive change in everything

About the Zaheerabad factory

ISO 14001:2004(Environmental Management)

2500 Employees

OHSAS 18001:2007(Occupational Health and Safety Management)

ISO 27001:2005(Information Security Management System)

Products

LCVs

Buses

UVs

3 Wheelers

Water Conservation Measures

Rain-Water Harvesting ETP & STP

Green Belts Development Bio-Filter Treatment

2404.5

2202

2011-12 2012-13

Total Energy Consumption (MTDE)

8.4 %

97.9

97.07

2011-12 2012-13

Absolute Power Consumption (Lakh units)

0.85 %

1250.07

1093.76

2011-12 2012-13

Absoute Thermal Consumption (Tonn/…..)

12.5 %

95.72

78.32

2011-12 2012-13

Specific Electrical Consumption (Kwh/ Eq. Veh)

18.2 %

0.4142

0.2901

2011-12 2012-13

Specific Thermal Consumption(M Kcal/ Eq. Veh)

30 %

Energy Conservation Ideas

1st IdeaEnergy conservation by Optimal use of space

Processing of sheet metal body

4 Skids used for processing 4 BMT trucks

Cargo Cabin

21

3 4

Skid

Initial Situation

3 Skids used to process 4 BMT trucks

After Improvement

Savings

No. of kWh Saved : 1.42 Lakhs kWhThermal Savings : 210 M k CalSavings per annum : Rs. 23.82 LakhsInvestment : Rs. 0.8 Lakhs

2nd IdeaEnergy conservation by new lighting systems

Old systems replaced bymore effective and efficient

28 W-T5150 W SV/MV

45 W CFL43 W LED

40W-T8250 W MV/SV250 W MV/SV150 W MV/SV

SavingsNo. of kWh Saved : 1.78 Lakhs kWhSavings per annum : Rs. 17.21 LakhsInvestment : Rs. 9.45 Lakhs

3rd IdeaEnergy conservation by changing a method of

cleaning

Paint Booth grills cleaningBefore• High pressure Water Jet system used to clean Paint Booth Grills• Physical forces produced by 110kW Motor

After• Chemicals used to remove paint from booth grills• The chemicals used are environment friendly• No compromise on quality• Chemical reactions are self-sustaining and do not require any

power source

SavingsNo. of kWh Saved : 1.50 Lakhs kWhSavings per annum : Rs. 14.51 LakhsInvestment : Rs.7.2 Lakhs

4th IdeaChoosing the equipment

according to requirement

After• Replaced reciprocating compressor with 125 TR screw compressor (75 kW

motor) • Natural draft cooling tower & VFD controlled water circulation pump

Before• 98 TR air cooled reciprocating chilling compressor• 110 KW motor along with forced draft cooling tower • Water circulation pump in throttled condition

Retro fitment of screw chilling compressor in place of reciprocating compressor

SavingsNo. of kWh Saved : 1.02 Lakhs kWhSavings per annum : Rs. 9.91 LakhsInvestment : Rs. 14.9 Lakhs

Enhancing Energy Efficiency – ENCON Cell

• Suggestion Schemes• Small Group Activities• Total Productive Maintenance• Low Cost and No Cost automation Techniques

2013-14 Targets

• Anticipated Investment – Rs. 58 lakhs• Targeted Savings – Rs. 64 lakhs