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