Mahindra & Mahindra Ltd

1. Brief Description of the project :

To Reduce Specific Carbon Footprint by using Waste to
 Wealth, TPM (Breakthrough Technology) and Industry 4.O Concept at Compressor House

1. What made your company to take up this Project? Describe briefly :

Mahindra AD Kandivali Plant: - Background

We have a Dream - To be amongst the Top 10 Global Automotive Brands. To Achieve this we had started Journey in 2007 with Milestones in the form of Promise 2010, 2013, 2016, 2019 ,2022 and so on. Currently Promise 2019 is in force. Since, promise we have declared is to reduce Specific Caron and water Footprint by 15% as compared to FY16 Level. Sector specific Energy Management Policy and Plant Specific Water Management Policy are the guiding documents.

Leadership Commitments on Climate Change….

Climate change is a major challenge for developing countries like India that face large scale climate variability and are exposed to enhanced risks from climate change

Our Chairman At UN

Automotive Industry plays major role in Indian industry. It Contributes 12% of the Indian GDP.

Mahindra Automotive Plant (52 Years Old) being in the heart of the Mumbai city surrounded by residential area with high rise building faces the challenge of being sustainable model on People Planet and Profit front

Automotive Industry by nature of its process considered to be most rigid and rigorous workplace, consuming large amount of natural resources in terms of Water, Electricity, Gas, Air etc.

To overcome it M&M started looking for Innovative and sustainable and Productivity project for moving towards Improving quality of life, improving business performance, making technology affordable and

Green process to achieve sustainable business model, a positive step towards achieving an inclusive growth.

Kandivali Plant -

The team challenged the conventional process of Heat treatmant washing machine making changing the Heating design and thereby moving towards green product with determination for:

• Safety first.
• Crusade for natural resource conservation
• The urge for continuous improvement.
• Unprecedented challenge.

Energy Consumption is the highest contributor for Natural Resource Consumption

At Air compressor Only 10-30% of energy reaches the point of end-use, and balance 70-90% of energy of the power of the prime mover being converted to unusable heat energy

At Kandivali Plant Heating Furnace and Washing Machine Contributes the Highest for Energy Consumption i.e. 34% of the Total Energy Consumption

2. How did you generate the solution which you implemented?

Team with innovative approach thought of exploring other ideas i.e. Waste Heat Recovery from Air Compressor.

Recovery of waste heat from screw air compressor and utilised it for heating purpose on 8 washing machine

Currently there is one base load screw compressor in Utility department is having around 355123 Kcal/kw potential thermal energy available that is unutilised

As per Our Company Rise philosophy-Green products / services

Improving Energy Security through less consumption

To reduce carbon footprint reduction –Make technology affordable -Improve Business Performance

Waste to Wealth -Unique concept, First time adopted in Mahindra on Compressors

Huge Potential for saving as can be deployed in all plants

 

Schematic Diagram of System -

 

Team Came up with Multiple Ideas : -

 

4. Describe how the selected solution was implemented. Some of the aspects could be :

We have many challenges in the plant. Our connected load is steadily increasing due to addition of equipment for Quality, Safety, Compliance. Still we have taken a target of 15% Reduction for Plant and for foundry.

We have a well-established ENCON Cell. This is our approach- Data Collection, Stratification, Analysis, Developing project Proposal, Budgeting and implementation., The low hanging fruits with low payback Period are catered to through Plant revenue Budget. Then comes the CAPEX Investment and for Higher Payback period coupled with high investment, we go for ESCO Model where 3^rd party invests and savings are shared as per agreed terms.

Here is one project which is done for the first time in Mahindra Group. Waste Heat recovery from compressors. As you are aware, hardly 15% of input energy is delivered in form of compressed air at point of usage. Rest 85 % gets consumed to overcome friction and dissipation as heat. We have harnessed this heat for heating solutions of 8 washing machines. This is interfaced with Industry 4.O for online monitoring of various parameters.

 

Following are the Challenges faced while Project Implementation : -

1. Air Compressor Oil Ckt  Modification
2. Washing Machine Heating Ckt  Modification
3. Laying of Insulated Pipes in Running Production
4. Heat Exchanger Installtion
5. Intigration of Washing machine And Air Compressor
   

 

 

With each project, certain risk are involved For mitigating the risk, i.e. Irreversible machine modifications been done offline and only reversible machine Modifications done on machine.

 

Results / Impact. Value Creation and Business Impact :

 

Training to Associates and Officers for New Technology : -

1. Machine Working Principals and on job training

 

2. Safety Training

2. Value Creation and Business Results.

Benefits under PQCDSME : 

P :

Machine Start Up time reduced from 45 min to 30 operators working in min. (Productivity improvement by 33%).

Q : 

1. Customer End rework reduced by 5%.
2. Washing Machine Solution Temp band eliminated

C : 

   1) Electrical Energy Cost saving 60Lacs/Annum

   2) PNG Cost Saving of 3.282 Lacs/Annum

   3) Rejection Cost saving of 8.91 Lacs/Annum

   4) Manpower cost saving of 0.83 Lacs/Annum

   5) New Capacity Generation of 1.2 Cr/Annum

   6) Opportunity Cost saving of 1.8Cr/Annum (New Machine Procurement)

D :

1. Opportunity to generate new business .
2. Retaining existing cost completeness in the market

S : 

1. Elimination of unsafe working condition of environment where Associates was working at 110°C.
2. Created Many Happy Stakeholders

2. Environmental considerations: (if any)

1. Carbon Foot Print saving of 513 Tons/Year
2. PNG consumption eliminated from 41 Tones/Annum to Zero
3. Associates morale improved due to safe & Tension free working environment.
4. Can the ideas, principles, concepts or techniques developed by you be implemented in other areas in your company and in similar / other industry? Describe.

Shared this Idea with the following Industry

1 - In 34^th Kaizen Conference

2 - Across the Mahindra Group During our Energy Conservation week, E –Energy conference held on 21^st Dec. 2018

Other Information : -

Won Third Prize in Mahindra AFS Best Energy Efficient Project :-

 

 

 

External Award

KND Plant Bagged 1^st Prize at 34^th Kaizen Conference in Breakthrough Kaizen Category for its entry on “ Reduction of Carbon Footprint using Waste to Wealth and Industry 4.O.”

 

Any other merits.

This type of concept was developed first time across the Group. Looking at its uniqueness, we have applied for patent. It is under consideration with IPR cell.

Patent registration number is 2478 / PAT / 2019 .