m&mnagpur
TRANSCRIPT
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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
MAHINDRA & MAHINDRA, NAGPUR
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FD - NAGPUR
MAHINDRA & MAHINDRA, NAGPUR
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
MAHINDRA & MAHINDRA, NAGPUR
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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MAHINDRA & MAHINDRA, NAGPUR
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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MAHINDRA & MAHINDRA, NAGPUR
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MAHINDRA & MAHINDRA, NAGPUR
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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MAHINDRA & MAHINDRA, NAGPUR
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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MAHINDRA & MAHINDRA, NAGPUR
BEFORE AFTER Optimizing power by Replacing Conventional Pump
with Energy Efficient Pump
Incorporation of Energy Efficient Pump
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MAHINDRA & MAHINDRA, NAGPUR
BEFORE AFTER
Optimizing power by Replacing Conventional Pump
with Energy Efficient Pump
Incorporation of Energy Efficient Pump
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MAHINDRA & MAHINDRA, NAGPUR
BEFORE AFTER
PACKAGED AC WITH NO TIMER PACKAGED AC WITH TIMER
Timer on ACs
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MAHINDRA & MAHINDRA, NAGPUR
Solar Heating for Canteen
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MAHINDRA & MAHINDRA, NAGPUR
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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MAHINDRA & MAHINDRA, NAGPUR
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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MAHINDRA & MAHINDRA, NAGPUR
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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MAHINDRA & MAHINDRA, NAGPUR
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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FD - NAGPUR
MAHINDRA & MAHINDRA, NAGPUR
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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MAHINDRA & MAHINDRA, NAGPUR
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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MAHINDRA & MAHINDRA, NAGPUR
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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MAHINDRA & MAHINDRA, NAGPUR
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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MAHINDRA & MAHINDRA, NAGPUR
Idea Generation Campaign
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FD - NAGPUR
MAHINDRA & MAHINDRA, NAGPUR
Banner Display
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FD - NAGPUR
MAHINDRA & MAHINDRA, NAGPUR
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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FD - NAGPUR
MAHINDRA & MAHINDRA, NAGPUR
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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FD - NAGPUR
MAHINDRA & MAHINDRA, NAGPUR
THANKS