Mahindra & Mahindra Ltd.

Farm Division
Nagpur Unit

Welcomes

MAHINDRA & MAHINDRA, NAGPUR

Our Product

FD - NAGPUR

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

MAHINDRA & MAHINDRA, NAGPUR

Achievements
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

FD - NAGPUR

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

Our scope of operations

FD - NAGPUR

Hydraulics Plant Hydraulics Plant

Tractor Plant Tractor Plant

TransmissionPlant Transmission Plant

Engine Plant Engine Plant

Warehouse

Each Unit consist of Assembly, Testing and Raw material Stores

Machining Activities in Hydraulics, Transmission and Engine Ware House for Material Storage

MAHINDRA & MAHINDRA, NAGPUR

Nagpur Plant : Schematic Layout

Total Land -1,73,000 Sq. mtr. (@ 42 acres) Built-up Area 42,378 Sq. mtr. (@ 10 acres)

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Excise

Transmission Plant Tractor Plant

Tractor Parking

Admin Block

Warehouse
Old Office

Open Dock

Engine Plant

Canteen
Open Dock

TEST TRACK

Hydraulics Plant
Road Plants/Bldg

Trainin g Center

Society

Garden

Open Area

MAHINDRA & MAHINDRA, NAGPUR

Process Flow Diagram

Control valve component machining VTU component cleaning Transmission component machining

FD - NAGPUR Engine component machining

Control Valve component cleaning Control Valve Assembly & Testing

VTU Assembly

Transmission component cleaning

Engine component cleaning

VTU Testing

Transmission Assembly & Testing

Engine Assembly & Testing

Tractor Testing

Tractor Post Painting Operation

Tractor Painting operation

Tractor Pre Painting operation

MAHINDRA & MAHINDRA, NAGPUR

FD - NAGPUR

MAHINDRA & MAHINDRA, NAGPUR

Functional Team for Energy Conservation

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Leader
S. W. Mahabal

DGM Central Services

Member D. K. Shrivastava

Member P. Wakankar

Member

Member S. R. Khedikar

Member M. N. Joshi

V. V. Deshpande Manager Engine Maint.

Manager
Tractor Maint.

Manager
Transmission Maint.

Manager
Hydraulic Maint.

Manager
Central Services

MAHINDRA & MAHINDRA, NAGPUR

Specific Energy consumption

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SEC Per Tractor

300

250
200 150

231

243

169

SEC Per Tractor

100 50 0 F08 F09 F10

MAHINDRA & MAHINDRA, NAGPUR

Projects Implemented through Engineering Control

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Sr No
1 2 3 4 5

Projects
Incorporation of Energy efficient Pumps in Place of Conventional Pumps at 18 Locations Use of Turbo ventilators' in place of exhaust Pumps Use of Natural Lighting by using Poly carbonate sheets on Roof Timers to Package Airconditionars Solar Heating for Kitchen

6
7 8 9 10 11 12 13

Compressor Air Management

Incorporation of Heat Pump Water siphon & Timer circuits for OH water Tanks Using Electrical Motors in Star connections as possible. Improving the design of the Hot air circulation on ovens Monitoring the Heat loss from all Hot air circulations fans & improving the Insulation Incorporation of VFDs for major induction motors Replacement of Conventional lamps with LED lamps

MAHINDRA & MAHINDRA, NAGPUR

Incorporation of Energy Efficient Pump

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BEFORE
with Energy Efficient Pump

AFTER

Optimizing power by Replacing Conventional Pump

MAHINDRA & MAHINDRA, NAGPUR

Incorporation of Energy Efficient Pump

FD - NAGPUR

BEFORE
Booster Pump

AFTER

Optimizing Power by replacing conventional pump with

MAHINDRA & MAHINDRA, NAGPUR

Incorporation of Energy Efficient Pump

FD - NAGPUR

BEFORE
with Energy Efficient Pump

AFTER

Optimizing power by Replacing Conventional Pump

MAHINDRA & MAHINDRA, NAGPUR

Use of Natural Resources

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Maximum Usage
of Natural Lights

Use of Eco Friendly Ventilation System

MAHINDRA & MAHINDRA, NAGPUR

Timer on ACs

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BEFORE

AFTER

PACKAGED AC WITH NO TIMER

PACKAGED AC WITH TIMER

MAHINDRA & MAHINDRA, NAGPUR

Solar Heating for Canteen

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Piping re-layout and Compressor Shifting

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BEFORE

AFTER

Earlier Two Compressors of 900 CFM & one Compress or of 200 CFM was required.

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

MAHINDRA & MAHINDRA, NAGPUR

Optimization of Power by replacing Heaters with Heat Pump
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BEFORE

AFTER

Heaters Power MCB ON

Heaters panel (6 x 4 =24KW)

New Heat Pump (6KW)

Heaters Power MCB off

High consumption Electrical Heater

Heat Pump installed

MAHINDRA & MAHINDRA, NAGPUR

Siphon system for OH water Tanks with Level sensors
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BEFORE

AFTER

Unnecessary Running Of Water pump while overflowing.

Unnecessary Running Of pump eliminated.

MAHINDRA & MAHINDRA, NAGPUR

Improvement in hot air circulation inside oven system for faster baking FD - NAGPUR

BEFORE

AFTER

MAHINDRA & MAHINDRA, NAGPUR

Heat Recovery

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Induced draft fan removing the heat from the combustion chamber
Method of Testing: Checked the Flue gas temperature.
CHIMNEY

It is observed that the temperature of Flue Gas is 220 degree centigrade which reduces below 180 degree when ID fans is kept OFF. 2200 C

Recommended Flue Gas temperature

is 190 degree C.

MAHINDRA & MAHINDRA, NAGPUR

Heat Loss Reduction

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BEFORE

Thermal Insulation of 4 has been 950 C AFTER

provided on the Circulation FAN.

Skin temperature is reduced from 90 degree centigrade to 40 degree centigrade. 400 C

MAHINDRA & MAHINDRA, NAGPUR

FD - 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.

MAHINDRA & MAHINDRA, NAGPUR

VFD installation for exhaust blowers in paint booth

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Variable frequency Drive installed for

blower motors

Before
(1) Dampers with 40% throttle. (2) Power consumption Units 2,20,000 Kwh / annum Cost - Rs. 10,56,000 / annum (3) Air velocity 2.4 m / sec

After
(1) Dampers fully open & VFD installed. (2) Power consumption Units 1,80,000 Kwh / annum Cost Rs. 8,64,000 / annum (3) Air velocity 2.4 m / sec

MAHINDRA & MAHINDRA, NAGPUR

Energy Saving Through Administration control & People Involvement FD - NAGPUR

Sr No
1 2 3 4 5 6 Energy conservation Audits

Projects

Training on Energy conservation to all Employees Awareness through Banners & Poster Idea Generation campaigns Implementation of all Feasible Energy saving Ideas Rewards & Recognitions for all participants contributing to Energy conservation drive.

MAHINDRA & MAHINDRA, NAGPUR

Idea Generation Campaign

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MAHINDRA & MAHINDRA, NAGPUR

Energy Saving - Idea Generation Campaign

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The Campaign received euphoric response from the employees and contract labor as well.

MAHINDRA & MAHINDRA, NAGPUR

Banner Display

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Consistent Performance by the Team Since F07

60 50 50 40 30 20 10 0 F07 F08 F09 F10-H1 F10Total 11 28 38 31
Better

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Better

10 9 8 7 6 5 4 3 2 1 0

Number of Ideas

Saving in Kwh / Year

8.93 7.89 4.57 4.99

1.28

F07

F08

F09

F10-H1

F10 Total

Better

50 45 40 35 30 25 20 15 10 5 0

Saving in Rs. Lacs / Year

42.87 37.87 23.95

21.93 6.14

F07

F08

F09

F10-H1

F10 Total

MAHINDRA & MAHINDRA, NAGPUR

Future plans

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Stabilized supply to plant for saving Energy during

Installation of 3.2 MW

Wind Mill Projects for

Power Generation

Non Peak Hours

MAHINDRA & MAHINDRA, NAGPUR

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THANKS