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Mahindra & Mahindra Ltd.

Farm Division

Nagpur Unit

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FD - NAGPUR

MAHINDRA & MAHINDRA, NAGPUR

At Nagpur we produce 14 Models and 86 Variants on a single assembly line

Our Product


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2001 - ISO 14001 Certification (Environment Management System)

2003 Deming Application Prize for FES

2004 ISO/TS 16949:2002 Certification

2005 OHSAS 18001 Certification

2007 Japan Quality Medal for FES

2008 - Awards for Best Energy Management System from Government of

Maharashtra

2009 Golden Peacock Award in Safety & Health by world Environment Forum

2009 Frost & Sullivan Golden Award

2009 Award for Water Efficient Unit by CII


Achievements

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Our scope of operations

Each Unit consist of Assembly, Testing and Raw material Stores

Machining Activities in Hydraulics, Transmission and Engine

Ware House for Material Storage

Hydraulics Plant

Hydraulics Plant Tractor Plant

Tractor Plant

Transmission Plant

Transmission Plant Engine Plant

Engine Plant

Engine PlantWarehouse

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Control Valvecomponent

cleaning

Control valve

componentmachining

Control ValveAssembly &

Testing

VTU component

cleaning

VTUAssembly

Transmission

componentmachining

Enginecomponentmachining

Enginecomponent

cleaning

Tractor PrePainting

operation

Transmissioncomponent

cleaning

TransmissionAssembly & Testing

EngineAssembly &

Testing

Tractor

Testing

TractorPainting

operation

Tractor PostPainting

Operation

VTUTesting

Process Flow Diagram

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Leader

S. W. Mahabal

DGM Central Services

Member

D. K. Shrivastava

Manager

Tractor Maint.

Member

P. Wakankar

Manager

Transmission Maint.

Member

V. V. Deshpande

Manager

Engine Maint.

Member

S. R. Khedikar

Manager

Hydraulic Maint.

Member

M. N. Joshi

Manager

Central Services

Functional Team for Energy Conservation

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Sr No Projects

1 Incorporation of Energy efficient Pumps in Place of Conventional Pumps at 18

Locations

2 Use of Turbo ventilators' in place of exhaust Pumps

3 Use of Natural Lighting by using Poly carbonate sheets on Roof

4 Timers to Package Airconditionars

5 Solar Heating for Kitchen

6 Compressor Air Management

7 Incorporation of Heat Pump

8 Water siphon & Timer circuits for OH water Tanks9 Using Electrical Motors in Star connections as possible.

10 Improving the design of the Hot air circulation on ovens

11 Monitoring the Heat loss from all Hot air circulations fans & improving the Insulation

12 Incorporation of VFDs for major induction motors13 Replacement of Conventional lamps with LED lamps

Projects Implemented through Engineering Control

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BEFORE AFTER Optimizing power by Replacing Conventional Pump

with Energy Efficient Pump

Incorporation of Energy Efficient Pump

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BEFORE AFTER

Optimizing power by Replacing Conventional Pump

with Energy Efficient Pump

Incorporation of Energy Efficient Pump

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BEFORE AFTER

PACKAGED AC WITH NO TIMER PACKAGED AC WITH TIMER

Timer on ACs

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Solar Heating for Canteen

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BEFORE AFTER

Earlier Two

Compressors of900 CFM & oneCompress or of200 CFM was

required.

Now One Compressors of 900CFM & one Compress or of 200

CFM is required

Piping re-layout and Compressor Shifting

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BEFORE AFTER

Heat Pump installed

Heaters panel

(6 x 4 =24KW)

HeatersPower MCB

ON

New Heat

Pump

(6KW)Heaters Power MCB off

High consumption Electrical Heater

Optimization of Power by replacing Heaters with Heat Pump

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BEFORE AFTER

Unnecessary Running Ofpump eliminated.

Unnecessary Running OfWater pump while

overflowing.

Siphon system for OH water Tanks with Level sensors

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BEFORE AFTER

Improvement in hot air circulation inside oven system for faster baking

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Induced draft fan removing the heatfrom the combustion chamber

Method of Testing:

Checked the Flue gas temperature.

It is observed that the temperature of Flue Gas

is 220 degree centigrade which reduces below

180 degree when ID fans is kept OFF.

Recommended Flue Gas temperature

is 190 degree C.

CHIMNEY

2200

C

Heat Recovery

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Thermal Insulation of 4 has

been

provided on the Circulation FAN.

Skin temperature is reduced

from

90 degree centigrade to

40 degree centigrade.

BEFORE

AFTER

950 C

400 C

Heat Loss Reduction

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Induced draft fan removing

the heat from

the combustion chamber

Induced draft of one Burner stopped

and chimney directly connected so

that Flue gas can move with

Natural Draft.

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Variable frequency

Drive installed for

blower motors

Before After

(1) Dampers with 40% throttle. (1) Dampers fully open & VFD installed.

(2) Power consumption

Units 2,20,000 Kwh / annum

Cost - Rs. 10,56,000 / annum

(2) Power consumption

Units 1,80,000 Kwh / annum

Cost Rs. 8,64,000 / annum

(3) Air velocity 2.4 m / sec (3) Air velocity 2.4 m / sec

VFD installation for exhaust blowers in paint booth

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Sr No Projects

1 Energy conservation Audits

2 Training on Energy conservation to all Employees

3 Awareness through Banners & Poster

4 Idea Generation campaigns

5 Implementation of all Feasible Energy saving Ideas

6 Rewards & Recognitions for all participants contributing to Energyconservation drive.

Energy Saving Through Administration control & People Involvement

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Idea Generation Campaign

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Banner Display

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11

2831

38

50

0

10

20

30

40

50

60

F07 F08 F09 F10-H1 F10-

Total

NumberofIdeas

8.93

7.89

1.28

4.57 4.99

0

1

2

3

4

5

6

7

8

9

10

F07 F08 F09 F10-H1 F10

Total

SavinginKwh/Yea

r

42.87

37.87

6.14

21.93

23.95

0

5

10

15

2025

30

35

40

45

50

F07 F08 F09 F10-H1 F10

Total

SavinginRs

.Lacs/Year

Better Better

Better

Consistent Performance by the Team Since F07

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Stabilized supply to

plant

for saving Energy

during

Non Peak Hours

Installation of 3.2 MW

Wind Mill Projects for

Power Generation

Future plans

& G

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THANKS

m&mnagpur

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