MAHINDRA & MAHINDRA LTD

AUTOMOTIVE SECTOR-
SECTOR- PLANT I
NASHIK

Nor bert De Souza Av inash Wagh Prasanna Kulkarni

CII National Award for

Excellence
in water Management 2008
16th Dec – 17th Dec 2008
CII-Hyderabad

C E R T I F I C A T I O N
Occupati onal Heal th & Safety

Env ironment

Quality
Infor mati on
Security

OHSAS
18001:2007
ISO 14001:2004

ISO TS 16949

ISO/IEC 27001-
27001 - 2005

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 Water saving projects Process flow
Pre ss
Shop

Body
Shop
Customer

Di spat ch

Paint
Shop

A sse mbly

Think outside the sink

Water Management 1350

280

Cooling/ Distri bution

Process Domestic

430 800 400

ETP STP

Garden
430 400

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Water audits
1. For total plant audit by CII in 2006

2. For treated water distribution by MMK in 2006

3. For Sewage distribution system by C11 in 2008

4. For rain water harvest by Greenfield technology in

2007

5. For ground water survey by GSDA in 2007

6. For total plant water balance by Technogreen in 2007

7. For sustenance by internal audits.

[ Water saving projects-

projects- 2004 To 2008

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Water saving projects
Specific water reduction by process optimization
ED B50 STAGE ELIMINATION
ED B50
BEFORE: stage DI
Spray rinse
X XX X X X X XX X
was running
X XX X X X X
X XX X X X XX X X X X XX X X
X
X XX X X XX X X X X XX X
X X X
X XX X X XX X X X X XX X
X X X
X XX X X XX X X X X XX X X
X X
X X X
X X
UF spray UF spray DI
PT Electrocoating UF D ip
Rinse Rinse Spray
B ODIE S Dip tank Rinse tank
1 2 Rinse Fr esh D I
ENTE RING E LE CTROCOAT PROCESS Spr ay also
was running

AFTER:
X XX X X
X X XX X X
X ED B50
X XX X X X
X
X X XX X X stage &
XX X X X XX X X
X XX X X
X
X
X F resh spray
X X XX X X
X XX X X X XX X X ar e Kept
X X

X
X
X X OFF
X
UF s pray UF spr ay
PT Electroco ating U F Dip DI
Rinse Rinse
B ODIE S D ip tank Rinse tank Spray
1 2
ENTE RING Rinse

E LE CTROCOAT PROCESS

Total Water Saved = 13490 M3 Investment = 0

Water saving projects

Rain water harvesting at paint shop

Pain t S ho p

Sof t Wat er Ta nk

C ollecti on Ta nk

G at e Stor m Wat er Gu tter

Total Water Saved = 2971 M3

Investment = 0

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Water saving projects
Rain Water Harvesting Project for cooling tower ponds
Compressor cooling tower Body-shop tower

Water Saved : 1253 m3 this monsoon

Investment : Rs 0.2 lacks

Water saving projects

Water distribution through gravity & all pipes are above the
ground. No underground leakages

Before After
Variable Pressure Uniform pressure
12 Pumps 2 Pumps
Savings- 1.15 lac Kwh/annum
Water Savings : 30000 m3/ Annum
Investment : 30 lacks

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Water saving projects
Optimizing the painting process by combining cab & cargo on
single fixture.

Before
After
Two fix tures required
Single fix ture
Electricity – 207 kWH/body - 167 kWh/ body
LPG – 26 kgs/body - 13 kgs/body

Water Savings 10 CMD OR 2880 m3/annum

Water saving projects

Replacement of inefficient pumps with efficient Hydro MPC for air
compressor water circulation .

Before

Before After
3.22 Lacs Units/Year 1.60 Lacs Units/Year
Water Savings /annum 1500 m 3
Investment Rs.14.5 Lacks

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Water saving projects
Fire hydrant line above the ground

Before After

Water Saving: 250 m3 leakage losses eliminated

Investment : 40 Lacks

Global Norms / Bench mark

Benchmarks for S pecific Water Cons um ption

Nation al International MPCB

Benchm ark * Benchm ark* Benchm ark**

Specific Ta ta Motors – 5.23

Water Toyota Motor-
Consum pti on Ford I ndia- 2.56 1.97
2.74
M3/v ehicle GM- 7.56

Benchmarks for Wastew ater Disc harge

Nation al International MPCB

Benchm ark* Benchm ark* Benchm ark**

Specific Water
Consum ption Ford India- Renault-
0
M3/vehicle 0.67 0.5
*:- Source from CII, Hydera ba d.
**: Mahar ashtra Po lluti on C ontrol B oard

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Per Capita consumption

Improvement by 43 % Better
187
2 00 180

1 48
1 50
121
*4%
10 7
M /Capita

21%
1 00
35%
3

43%
50

0
2004 2005 2006 2007 2008

* % Reduction with the base y ear 04-05

Sustainability
F Daily input and output water monitoring.

F Tighter consumption control in the high

consumption shop

F Internal water management team.

F Continuous improvements through team

review.

F Internal and External audit for improvement

validation.

F Monthly water quality analysis.

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Treated Water Balance CMD

830

430 400

•Treated water reuse for the Press shop car body panel
washing.
• Investment: Zero
• Water Saving: 1560 m 3/annum
• Implemented in Nov 2008

• Investment: Zero
• Water Saving: 120 m 3/annum
• Implemented in Oct 2007

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Recycling of treated water
Raw water inlet
R aw w at er

Recycle
Recycle

Wa ste Water Tank

Waste water recycled
recycled

3
3 000 0 m

consumption
Water

M3
3
15 600 m

Befo re After

In-
In -house Project.
Project.

Water Saving: 15600 M3

Investment: 0.2 Lacks

Monitoring system

Ø30 meters across the plant.

ØDaily morning meter reading.
ØDaily MIS report to top management.
ØDaily shop consumption published.
ØVariability captured by departments.
ØDaily water management.
ØFortnightly CFT meets for
opportunities.

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Monitoring system

ØMonthly treated water balance charts.

ØMonthly water balance charts.
ØMonthly specific water trends.
ØWater testing as per MPCB norms.
ØWater testing as per ISO10500 STD.
ØMonthly water cooler management.
ØMonthly management review.

Monitoring &Reporting
Ø Water meters at user
interface

Ø Daily monitoring &

analysis

Ø Daily Pressure Monitoring

Put a Stop - to the Drop

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 Green Areas in Nashik Plant

Green Areas in side Nashik Plant shop area

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Awareness & Involvement within the Plant
ØCelebration of Water Conservation week-24th to 30th
March

ØOrganizing Slogan , Poster Competition for Employees

and their families.

ØAwareness session to workmen through “Workers

Training Course”.

ØECON stall on Founders Day(2nd Oct)-

visited by 15-20 thousand people.

Preservation Towards Environment

• Expertise team for EMS

• Tree plantation target - 1 Lac / year
• Special team in R&D working for
Alternative fuel
• Rain water harvesting for paint shop.
• Formation of vendor cluster to reduce
transportation
• New research on non ODS refrigerant

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Preservation Towards Environment

• Special management programs to

reduce hazardous waste
• Introducing energy efficient equipment in
new projects/expansions.
• Involving employee in environment
preservation program.
• Maximize use of treated water.

Environmental projects

• Planting of 1 Million trees

• Planting of “Jatropha”Plant
• Use of Bio Diesel
• Use of Renewable energy
• Use of Treated water

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 Environmental projects

• Recycle of used thinner

• Recycle of Exhaust gases in paint shops
• Scrubber chambers for spray booths
• Reduction/Reuse of effluent sludge.

At Mahindra we follow Five Mantras

vLEADERSHIP

vCOST EFFECTIVE

vCUSTOMER CENTRIC

vGLOBALISATION

vINNOVATION

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