First Prize Automobile Manufacturing

MAHINDRA & MAHINDRA LIMITED

Zaheerabad Unit, Medak (Andhra Pradesh)

Unit Profile

Mahindra & Mahindra Ltd. is a US $ 4.5 Billion group and is among the top 10 Industrial Houses in India.
With over six decades of manufacturing experience, the Mahindra Group has built a strong base in
technology, engineering, marketing and distribution.

MAHINDRA Automotive sector has five manufacturing units, three in the state of Maharashtra located at
Kandvili, Igatpuri & Nasik; fourth unit located at Zaheerabad, Medak- Andhra Pradesh and the fifth unit
located at Haridwar, Uttaranchal.

The Zaheerabad unit is a certified ISO / TS 16949 – 2002, ISO14001:2004 & OHSAS 18001:2007 unit.

Energy Consumption

Description Unit 2005 - 2006 2006-2007 2007-2008

Annual equivalent vehicles produced No's 17294 22152 28151

Total Electrical energy consumption per annum Lac. kWh 86 101.94 111.32

kWh/ equivalent
Specific electrical energy consumption 500 448 395
vehicle

Lakh M3 2.26 2.60 2.72

Total thermal (fuel) consumption per annum
Million K Cals/
3571 4102 4296
annum
Specific thermal energy consumption per Million K Cals/
0.206 0.185 0.153
annum equivalent vehicle

33
 Electrical energy Thermal energy

Year Consumption
Consumption % reduction
% reduction over Million K Cals /
kWh/ equivalent over
2005-06 equivalent
vehicle 2005-06
vehicle
2005 - 2006 500 Base 0.206 Base
2006-2007 448 10.40 0.185 10.19

2007-2008 395 21 0.153 25.73

Energy Consumption Trends

34
Energy Conservation Commitment, Policy and Set up

Mahindra & Mahindra Ltd., Automotive sector, Zaheerabad unit strongly believes that energy saving is a
multi disciplinary approach. The Plant’s energy profile consists of electricity, HSD, compressed air, LPG
and water. The LPG consumption is the major part of the energy consumption. Even smallest energy
conservation is going to add directly to its bottom line profits. Energy management policy, conservation
plans (ENCON), its implementation & periodic status reviews are closely monitored by the top
management. Energy audits are regularly conducted by external agencies like CII, Ingersoll-Rand,
synergy services etc. in addition to the in-house energy manager’s audits.

Energy Management policy is displayed everywhere in the plant for creating energy conservation
awareness. Every ENCON is taken to implementation and the best ENCON is identified and
rewarded/awarded accordingly. The company has adopted the TPM (Total Productive Management)
methodology for its excellence in performance. The company had formed cross functional teams (CFT)
headed by a senior executive as facilitator / mentor for cost reduction through energy savings. As many
as 1446 Kaizens (Double over F’06) like energy substitution, derating of the equipment suitable to site
conditions, Capacity utilization of the equipments, eliminating idle operation, optimization of air pressure
etc. have been done & implemented in F’07.

Energy Management Policy

• Benchmark specific energy consumption with national & international standards and setting up
systems to achieve them.
• Increase use of renewable energy & alternate fuel sources.
• Incorporate energy efficient designs & equipments in all projects.
• Conduct regular energy audits to optimize them.
• Form small group activities to increase employee involvement.
• Strengthen energy management program through the enhancement of skills & competence of our
employees.
• Reduce energy cost continuously every year by adopting effective “Energy Management system”
etc.

ENCON Cell formed by the top management to establish, implement and maintain the Energy
conservation initiatives.

35
36
37
Energy Management set up

Energy conservation & energy efficiency in all operations is a top management priority for the unit. The
below shows the set up following at the Zaheerabad unit for energy conservation.

Variability reduction team

(VRT)

electricity) consumption

38
Energy Conservation Achievements

1. Isolation of cooling tower from Body shop during non production hours

Before installation:

The existing cooling tower is common for both process

equipments & Compressor room. They need to run the 30
hp motor even in case of no process is running, thus
wastage of power.

After installation:

Energy efficient pump provided by modifying the water

circulation system which eliminates usage of cooling
tower during body shop non production hours.

No. of kWh Saved : 0.105 Lakhs Units

Savings per annum : Rs. 0.42 Lakhs
Investment : Rs.0.60 Lakhs

2) Reactive power optimization by installing 250 KVA Capacitor bank & Panel

Before:
Maximum demand recorded was 2739 KVA at power factor
of 0.96 lag.

After:
Maximum demand recorded was 2477 KVA at power factor
of 0.98 lag.

MD Saved per month : 56 KVA

Savings per annum : Rs.1.55 Lakhs

3) Auto voltage selection for Electro Deposition dip stage

Before:
In paint shop at electro deposition dip stage, due to manual selection of voltage & fixing it continuously for
3 Min, the power consumption was very high.

39
After:
Auto voltage & current selection system provided in turn vary voltage for the First 1 min & Next 2 Min
depending upon the surface area & thickness of the coating on the body.

Investment : Rs. 5.5 Lakhs

No. of kWh Saved : 0.40 Lakhs units
Savings per annum : Rs.1.62 Lakhs

4) Insulation replacement for the ED bring up & Holding zones

Before:
Electro deposition oven bring up zone oven insulation damaged results into wastage of heat through
ceiling & side walls

After:
Now the damaged insulation removed and replaced with new insulation eliminated heat losses.

Saving of Energy : 187 M KCal

Investment : Rs.1.5 Lakhs
Savings per annum : Rs. 6.67 Lakhs

Energy Conservation Plans

40
Energy Conservation Targets

Environment and Safety

Mahindra & Mahindra limited, Zaheerabad has a well-established Safety, Occupational and
Environmental Policy to ensure the optimum safety of the employees, public, plant and equipment, which
are embedded in the core organizational values. The Policy interalia necessitates necessary compliances
with all statutory rules and regulations, imparting training to employees, carrying out safety audits of the
various facilities of the company, conducting regular medical check up of our employees and promoting
eco-friendly activities. The M & M Ltd, Zaheerabad has been certified for Occupational Health and Safety
Management System (OHSAS 18001:2007) certification which aims to eliminate or minimize risk to
employees and other parties who may be exposed to Occupational Health and Safety risks associated
with the activities of the Company. Various safety promotion campaigns and special initiatives were
carried out in the plants. M & M Ltd, Zaheerabad of the Automotive Division have been certified with the
amended standards for Environmental Management System (ISO 14001:2004).

41
Second Prize Automobile Manufacturing

GENERAL MOTORS (INDIA) PRIVATE LIMITED

Halol, Panchmahal (Gujarat)

Unit Profile

General Motors-Halol is having plant manufacturing capacity of 85,000 units per annum with a plant area
of 65000 Sq.Mtrs. It was started into production in June’1996.GM-Halol plant is a two shift operating plant
with an automation of medium level. The plant is certified for “GM Global Manufacturing System”, ISO
9001 and ISO 14001 management systems.

General Motors Corp. (NYSE: GM), the world's largest automaker, has been the annual global industry
sales leader for 77 years. Founded in 1908, GM today employs about 280,000 people around the world.
With global headquarters in Detroit, GM manufactures its cars and trucks in 33 countries. In 2007, nearly
10.2 million GM cars and trucks were sold globally under the following brands: Buick, Cadillac, Chevrolet,
GMC, GM Daewoo, Holden, HUMMER, Opel, Pontiac, Saab, Saturn and Vauxhall. GM's On Star
subsidiary is the industry leader in vehicle safety, security and information services.

42
Process Layout

• Halol unit is having Lean production process flow. This flow is same for all models.

Production Volume Trend

70000
M 200
60386
60000 (T-200
/250)

49616 48685
50000 Paint Shop
Top Coat Corsa
Line Phase-out
40000
Tavera
(I-163)
32298
30000
Optra 25907
J-200
Astra
20000
Astra Phase-out
Corsa 12046
10000 7633 8632
6794

0
2000 2001 2002 2003 2004 2005 2006 2007 2008
(Till Sep '08)

43
Energy Consumption

Description Unit 2005 2006 2007

Annual equivalent vehicles

No's 29608 34922 60414
produced
Total Electrical energy
Lac. kWh 223 245 322
consumption per annum
Specific electrical energy
kWh/ car 754 701 534
consumption
Lakh M3 0.028 0.029 0.048
Total thermal ( Fuel)
consumption per annum Million K Cals/
44.06 45.96 75.97
annum
Specific thermal energy Million K
0.00149 0.00132 0.00126
consumption per annum Cals/car
Electrical energy Thermal energy
%
Year Consumption % reduction
Consumption reduction
Million over
kWh/ car over 2004-
K Cals / car 2004-05
05
2005 - 2006 754 -- 0.00149 --
2006 - 2007 701 7.04 0.00132 11.57
2007 - 2008 534 29.20 0.00126 15.51

Down trend of resources consumption per car

Water consumption in 2007-08 has come down to 4.93 KL/Car, which is 5% lesser then the
consumption in 2006-07,This result of water conservation activities implemented in the plant.

44
LPG consumption in 2007-08 has come down to 33.28 KG/Car, which is 5% lesser than the
consumption in 2006-07.

Energy Saving Achievements

Project 1

Power Transformer 2no.’s of 30/40MVA was selected on the basis of energy efficiency & least losses.
Selected TELK make Transformer and inspected at regular intervals to ensure the Transformer delivering
to its design.

Benefits : - Least no load losses to the scale of 11KW

Investment : - Rs. 6.2 Crores
Savings : - Rs 1,252,680 per annum
Payback Period : - 2.5 Years (with respect to the differential amount between regular & energy efficient
transformer)

45
Project 2

Commissioned ES-8, Compressors energy managing device. It controls the 6 bar air pressure system
dynamically such a way loads the VFD on top priority and static speed drives on need basis.

Benefits : - Loads the VFD on top priority & smartly manages other fixed speed compressors.
Investment : - Rs. 4.2 Lakhs
Savings : - Rs. 3.51Lakhs
Payback Period : - 14 Months

Project 3

Details: - Utilizing LED based indication lamps across the plant. Energy meters provided on every feeder
to enable efficient energy management in the plant.

Benefits : - Measure the energy consumption feeder wise and enable to quantify the control
Measures taken.
Investment : - Rs. 3.56Lacs
Savings : - Rs. 2.3 Lakhs
Payback Period : - 1.5 years.

46
Project 4

Details : - Utilizing energy efficient capacitor banks. 0.2W per KVAR. This is best in class.
Benefits : - Reduced energy loss.
Investment : - Rs. 4.7 Lakhs
Savings : - Rs. 1.8 Lakhs
Payback Period : - 2 .5 Years.

47
Project 5

Details: - Utilizing regenerative type of drier in the Air compressors. Reduces the energy demand on the
system.

Benefits : - Reduced the energy required for drying process

Investment : - Rs. 1.2 Lakhs
Savings : - Rs. 0.94 Lakhs
Payback Period : - 15 Months.

Project 6

Details: - Utilizing Energy efficient boiler-Hot water generator. It has air sealing at the ends reduces the
heat dissipation to surrounding at the same preheats the return line.

Benefits : - Reduced the LPG requirement by Preheating the HWG return line.
Investment : - Rs. 12.34 Lakhs
(Only differential amount with respect to Conventional HWG)
Savings : - Rs. 9.23 Lakhs
Payback Period : - 15 Months

48
Energy Conservation Commitment and Policy

General Motors –India Pvt. ltd., strongly believes in the Energy saving is multi disciplinary approach.
Plants energy profile consists of electricity, HSD, compressed air, LPG and water. The LPG consumption
is the major part of the energy consumption. Even smallest energy conservation is going to add directly to
its bottom line profits. Energy management policy, conservation plans (ENCON), its implementation &
periodic status reviews are closely monitored by the Energy Auditor & top management. Energy audits
are regularly conducted.

Energy Conservation – Displays are displayed everywhere in the plant for creating energy conservation
awareness. Every ENCON is taken to implementation and the best ENCON is identified and
rewarded/awarded accordingly. The company has adopted the Global Manufacturing Practices (GMS)
methodology for its excellence in performance. The plant had formed cross functional teams (CFT) names
as “Urja Rakshak team” headed by a certified Energy Auditor as facilitator / mentor for cost reduction
through energy savings. More than 271 Kaizens (small improvements) like energy substitution, derating of
the equipment suitable to site conditions, eliminating idle operation, process optimization etc.

GMI-Energy Conservation teams is part of the GM-Global Energy Team (GET) is responsible for
implementing the company's global energy strategy. This team drives strategies to reduce energy use
and costs. The GET is composed of regional energy managers from GM North America (GMNA), GM
Europe (GME), GM Latin America, Africa and the Middle East (GMLAAM), and GM Asia Pacific (GMAP).
The team is coordinated by GMNA Worldwide Facilities Group, Energy and Utility Services, and meets
on a quarterly basis.

49
Second Prize Automobile Manufacturing

LUCAS-TVS LIMITED
Padi, Chennai (Tamil Nadu)

Unit Profile

Lucas-TVS is a part of the TVS group. It was setup in 1961 as a joint venture of Lucas Industries plc, UK
and TV Sundaram Iyengar and Sons at Chennai to manufacture automotive electrical systems.

Lucas-TVS is a leader in Auto-electrical manufacturing. Lucas-TVS manufactures a complete range of

auto electrical products consisting of direct drive and gear reduction Starters, internal and external fan
alternators, wipers, fan motors, blower motors, window lift motors, mechanical and electronic distributors,
cam sensors, headlamps etc. The mother plant, being at padi - chennai, LTVS has its manufacturing units
at Rewari, Pondicherry, and Chakkan & Rudharapur.

Energy Consumption

E N E R G Y C O N S U M P T IO N U N IT IN L A C S

250

200

150

100

50

0
9 8 '- 9 9 9 9 '- 0 0 0 0 '- 0 1 0 1 '- 0 2 0 2 '- 0 3 0 3 '- 0 4 0 4 '- 0 5 0 5 - '0 6 0 6 - '0 7 0 7 - '0 8

U N IT IN L A C S 186 172 163 162 163 180 193 203 220 230

50
Specific Energy Consumption

S P E C IF IC U N I T S P E R P R O D U C T

20

18

16

14

12

10
YEA 9 8 '-
9 9 '- 0 0 0 0 '- 0 1 0 1 '- 0 2 0 3 '- 0 4 0 4 '- 0 5 0 5 - '0 6 0 6 - '0 7 0 7 - '0 8
R 99
S e rie s 1 0 22 21 19 18 15 1 4 .5 1 3 .4 1 3 .2 13

O V E R A L L E L E C T R IC A L U N IT S & P R O D U C T IO N

300 25
20
200
15
10
100
5
0 0
9 8 '- 9 9 9 9 '- 0 0 0 1 '- 0 2 0 2 '- 0 3 0 3 '- 0 4 0 4 '- 0 5 0 6 - '0 7 0 7 - '0 8

U N IT IN L A C S 186 172 162 163 180 193 220 230

U N IT S /PR O D U C T 22 21 18 16 15 1 4 .5 1 3 .2 13
PR O D .ES U IN L A C S 8 .4 5 8 .2 9 .0 5 9 .8 7 1 1 .3 4 1 3 .5 16 1 6 .1

Energy Conservation Commitment

“Energy Management Objectives”

The unit is committed to reduce the Specific Energy consumption per product on continual basis by
various continuous improvements and projects.

Such as:

1. Optimum capacity utilization

2. Elimination of unwanted machine movements / Elements
3. Introduction of VFD & optimizing motors depending on load
4. Waste elimination – reduce reuse and recycling critical resources.
5. Technology up-gradation with energy efficient processes and equipment’s.
6. Continuous awareness / training programs for employees and suppliers.
7. People involvement through suggestion schemes and small group activities
8. Manufacturing relay out and cell formations to reduce lighting and ventilation load.
9. Strict adherence to Government norms & regulations

51
Energy Conservation Achievements

During the period 2007 – 2008 Lucas – TVS Ltd has implemented around 12 projects through
Engineering initiatives and workman’s suggestion schemes resulting into total saving of Rs. 195.55 Lakhs
with an investment of Rs. 431.81 Lakhs. This has been resulted in a reduction from 13.2 units per product
to 13.0 units per product in specific electrical energy consumption.

Energy conservation for the year 2007 – 2008

Investment
Sl. No Title of Energy Saving Projects Implemented Savings In Lacs
In Lacs

1. Energy conservation through power factor

14.4 3.2
improvements

2. Reduction of Fuel consumption by increasing Grid

8.0 84.0
power

3. Energy conservation through distribution loss 60.0 23.0

reduction
4. Street Light Energy Saver 1.0 0.50

5. Replacing of Diesel Fork lifter by Electric battery

3.2 14.4
operating Fork lifter

6. Energy Conservation through Load Sharing 6.0 4.0

7. Replacement of 1 H.P wall mounting fan into

3.2 5.6
180Watts pillar type fan

8. Reduction of Fuel Consumption 17 9.6

9. Temperature Reduction in shop floor 300 25

10. Introduction of Air cooled Screw Compressor 12 5.0

11. Energy conservation through gravity force

introduced for sewage collection by removing 3.34 1.9
motors.

12. Energy conservation through conversion of Mono-

1.5 2.5
block pump to Submergible pump

13 Automatic Heat Treatment Process 2.17 16.85

TOTAL 431.81 195.55

52
Project 1

Energy conservation through power factor improvements and tail end voltage improvements/distribution
loss reduction

Total investment, Rs. 3.2 Lacs

First year energy cost savings, Rs. 14.4 Lacs
BEFORE AFTER

Project 2

Energy Saver system introduced for a group of street lights to regulate the voltage / wattage based on
programmable timers

Total investment, Rs. 1.0 Lac

First year energy cost savings, Rs. 0.50 Lac

BEFORE Street light connected through the energy

saver

• Direct supply to street lights from 6

p.m. to 6 a.m.

53
Project 5

Replacement of wall mounting fan (1H.P) into pillar type fan (180Watts) (30 numbers)
Total investment, Rs. 3.2 Lacs
First year energy cost savings, Rs. 5.6 Lacs

Wall mounting 3-phase fans for the

Task oriented ceiling mounting fan
operator convenience

Project 6

Energy conservation through gravity force for sewage collection by removing motors.

Total investment, Rs. 3.34 Lacs

First year energy cost savings, Rs.1.9 Lacs (Recurring savings)

Back Pressure due to operation of pump at Introducing of Gravity flow instead of

different Location pumping

BEFORE AFTER

55
Project 7

Replacement of diesel forklifts by electric battery forklifts

Total investment, Rs. 6.0 Lacs

First year energy cost savings, Rs. 4.8 Lacs

Diesel operated fork lift for material Battery operated fork lift for material
movements movements

Project 8

♦ Consumption of energy for shop lighting is reduced by introducing Transparent Roof sheet
♦ Consumption of energy for Exhaust fan to reduce the roof temperature is fully eliminated by
introducing Turbo–Vents.

Total investment, Rs. 300 Lacs

First year energy cost savings, Rs. 25 Lacs

30 nos. of Ventilation fan used for

temperature reduction and shop floor Ventilation fan eliminated through Turbo-
roof day(70KW) lights were working in vents. Transparent roof sheets eliminates
day in shifts the shop floor lights

56
Project 9

Introduction of Air Cooled Screw Compressors

Total investment, Rs. 12 Lacs

First year energy cost savings, Rs. 5.0 Lacs (Recurring savings)

BEFORE AFTER

125 HP Motor with Screw compressor air-

150 HP Motor with reciprocating cooled
compressor water –cooled Energy consumption- 90 units/hr
Energy consumption- 110 units/hr
Cooling tower 10HP motor Cooling tower eliminated

Project 10

Conventional manual HT furnaces replaced by automatic Sealed Quench Furnace

Total investment, Rs. 2.17 Lacs

First year energy cost savings, Rs. 18 Lacs

BEFORE AFTER

57
Environment and Safety

“The unit is committed to Protection, preservation and improvement of the environment by

continually orienting the activities, products and services.”

INNOVATIVE TECHNOLOGY FOR ENERGY AND ENVIRONMENT

One of the remarkable contributions this year was the establishment of indigenous waste coolant
treatment system, which was not done before by any of the industries in the world, which involves
recovering waste oil from waste coolant, thereby the quantity of waste disposed has reduced by 55%
compared to last year.

ENVIRONMENTAL AND ENERGY BENEFITS

¾ This process is unique one. It uses RO Rejection water & solar evaporation for coolant
oil treatment process.
¾ No Chemical treatment is involved in this process whereas other companies are using
chemicals & Electrolysis for treatment.
¾ High TDS water (RO Reject) disposal problem is solved.
¾ Meeting out the PCB standard to sell the oil for recycling (0.8% water & 99.2% oil
against PCB norms of 15 % water & 85% Oil)
¾ Cost saving Rs 6.52 lacs per annum.
¾ Energy Consumption is very less
RO REJECTION

TDS OF 5000
WITH HIGH

SUN RO PLANT

FACTORY WATER TREATMENT

PLANT
LUCAS - TVS
UNLOADING
WASTE COOLANT WITH OIL
USED COOLANT OIL
FACTORY FROM FACTORY

LUCAS - TVS
WATER OIL BARREL

VALUE YARD
STORAGE TANK
COOLANT OIL ( 2 LAKH LITRE CAPACITY )
STORAGE AREA
DISPOSAL TO RECYCLER
WITH PAYMENT

CPCB
&
TNPCB HAZARDOUS WASTE
STORAGE AREA SOLID SOLAR POND
STOPPED & VALUE YARD
POWDER
( FOR SALE OF
OIL )

BEFORE IMPROVEMENT AFTER IMPROVEMENT

58
Project 3

Re-distribution of the load to optimize transformers capacity utilization

Total investment, Rs. 6.0 Lacs

First year energy cost savings, Rs. 4.0 Lacs (Recurring savings)

BEFORE AFTER

♦ Transformer of starters / Alternators

production lines overloaded
♦ Frequent failures and line stoppages
♦ Energy Loss

Load Sharing based on load current on

the transformer & optimizing

Project 4

Factory load re-distributed after study with formation of an additional 11KVA substation resulting in
reduction of transmission loss by 3%

Total investment, Rs. 60.0 Lacs

First year energy cost savings, Rs. 23 Lacs

Substation for manufacturing & Formation of New additional substation

process, Engineering for Engineering
REQUIREMENT OF POWER FROM TNEB
POWER FROM TNEB CURRENT MAXIMUM DEMAND
4600
KVA

SUB STATION - 1 SUB STATION - 2 SUB STATION - 3

3000 KVA
900 KVA 700 KVA
BACK UP GENSET 2400 KVA
BACK UP GENSET 640 KVA BACK UP GENSET 520 KV

OPERATIONS Process ENGINEERING

3000 KVA 900 KVA 700 KVA

ADDITIONAL LOADS ADDITIONAL LOADS ADDITIONAL LOADS

PROPOSED PROPOSED PROPOSED
200 KVA 400 KVA 150 KVA

2007-08 2008-09 2009-10 2007-08 2008-09 2009-10 2007-08 2008-09 2009-10

80 KVA 100 KVA 100 KVA 370KVA 300 KVA 100 KVA 50KVA 100 KVA 50KVA

54
 Next to this the reduction of lead soldering stations for armatures by the introduction of brazing method,
and also a new system for solder recovery from waste lead solder dross where by we can able to reduce
the solder waste disposed.

ENVIRONMENTAL AND ENERGY BENEFITS

¾ Elimination of usage of lead in product

¾ Power consumption is reduced from 0.7 units to
0.3 units per armature
¾ Design scraps reduction (Copper saving) due to
raiser less commutator from 60% to 33%.
¾ Total energy savings of Rs. 1.8 Lacs units/year

BRAZED ARMATRE LEAD SOLDERED

AFTER ARMATURE BEFORE
IMPROVEMENT IMPROVEMENT

ENERGY CONSERVATION AND ENVIRONMENT AWARENESS PROGRAM

Periodical training of employees & awareness programs for employees families, contractors and suppliers
are done by LTVS on continuous basis

RAIN WATER HARVESTING

59
Development of greenery, rainwater harvesting, water conservation are an important part of their routine
activities with significant increase in production and man power, the overall water consumption of the
factory has been reduced by 5% by rain water harvesting, improved ground water levels and greenery
development.

GREENERY DEVELOPMENT

Total requirement of gardening water is managed by recycling the sewage water 100%. About 300
numbers of tree saplings were added to their green belt this year.

. INTRODUCTION OF FLUIDIZED AREATION BED IN PLACE OF SURFACE AGITATOR

FOR SEWAGE TREATMENT

The unit could able to save a considerable amount of energy by the introduction of Fluidized aeration bed
in sewage treatment plant in place of surface aeration by agitator.

ROOTS AIR
BLOWER -
POWER CONSUMPTION IS 2WORKING
25 KW/HOUR

60
Safety

Ensuring employees safety and safe work place is one of the major objectives of the company.
Maintenance of safety standards, adherence to safety rules and regulations are prime responsibility of
Human Resources, Works Engineering, Safety and Manufacturing Departments.

Periodical audits to identify the areas for improvement are done by each department’s safety teams.
Major safety improvement projects are triggered by Safety department, whereas the day to day
improvements related to machinery & work places are identified and implemented by active involvement
of employees through small group activities and TPM movement.

Some of the safety improvements in 2007 – 08 are:

¾ Introduction of Photo guards in 125 presses / machines.

¾ Introduction of two hand safety on all hydraulic & pneumatic presses.
¾ ELCB introduction on all mobile electrical equipment’s and hand tools.
¾ Double solenoid Brake clutch valve for all mechanical presses as an additional safety.
¾ Remote operation of High voltage switch gears in substations
¾ Ring main earthling stations for the electrical installations.

61
Certificate of Merit Automobile Manufacturing

MAHINDRA & MAHINDRA LIMITED

Nashik Plant
Satpur, Nashik (Maharashtra)

Unit Profile

Mahindra & Mahindra, automotive division is in the business of manufacturing Utility vehicles, SUV’s,
LCV’s and Cars. Nashik unit manufactures market leaders products in their respective segment; Scorpio,
Bolero, Logan (JV with RENAULT FRANCE) and spares for these vehicles. M&M’s R&D centre, where
new product design activities carried out, is also located at Nashik. The total sales turnover of the Nashik
unit is around Rs. 5015 Cr.

Energy Consumption

Annual electricity and LPG consumption for last three years is as follows

Annual Energy Consumption

Year Electrical* Thermal (LPG)

(FY) Lakhs kWh Rs. Lakhs Tons Rs. Lakhs

FY 05 – 06 364.41 1227.97 2805.10 701.28

FY 06-07 406.16 1637.77 3112.54 930.28

FY 07-08 470.91 1989.34 3949.59 1343.99

* Including DG Generation

Specific Energy Consumption (SEC)

Description Unit FY 05 - 06 FY 06- 07 FY 07- 08

Electrical Energy kWh/Eq. Vehicle 346 316 290

Thermal Energy M KCal/Eq. Vehicle 0.35 0.32 0.28
Total Energy Bill Rs. Lakhs 2530.29 3248.63 4029.05
Energy as % of Total mfg cost % 9.74% 9.5% 13.57%

62
 SEC (Electrical) SEC (Thermal)

390 0.45
387
25% decrease in 4 years 0.45 36%decrease in 4 years
370
0.40
350
346
330 0.35
0.34
310 316 0.32
0.30
290 0.28
290
0.25
270

250 0.20
2004–05 2005–06 2006–07 2007–08
2004–05 2005–06 2006–07 2007–08

Energy Conservation Policy and Organizational Set up

Mahindra & Mahindra Ltd, Automotive Sector, Nashik emphasises on all types of energy (Electrical,
Thermal and Compressed air.) conservation. Energy conservation measures are identified, reviewed
periodically for techno-commercial viability in ECON Cell, implementation & verification strategies are
made. ECON meeting is held on every alternate Tuesday of the month to review the action plan. The unit
has an active “ENERGY MANAGEMENT POLICY.

63
Organizational Setup

Plant Head

Chairman
Projects through
ECON Cell CFT
Energy Manager
Secretary ECON Cell Horizontal
ECON Member Body Function
Deployment
through Sector
ECON Member Paint Function
Level
Synergy Teams
ECON Member TCF & Assembly
Improvements
ECON Member Utility through Operator
Level
I4 Teams
ECON Member Support services

ECON Member Finance Function

Energy Conservation Achievements

Achievement of energy savings per year basis

Investment on projects
Year Electricity Fuels Total savings
(Rs. lakhs)
(Lakhs kWh) LPG Ton HSD (KL) (Rs. lakhs)
FY 06-07 39.34 250.68 *25.6 244.12 525.15
FY 07-08 28.99 317.08 *114 266.51 146.9

1. Painting on cab & cargo on one skid in MQS Paint Shop

Stopped painting of cab & cargo on separate

skids & started painting on one skid –
• Increase in productivity by 20 body
shells/shift
• Savings in electricity by 40 kWh/body shell
• Savings in LPG by 13 kgs/body shell

Annual savings – Rs. 71 Lakhs

64
2. Optimization of LPG burners during winter

SEASONAL SETTING FOR AIR SUPPLY UNITS W. R. T. TEMPERATURE & HUMIDITY

Changed humidity setting of ASU units
Max. temp. Min. temp. Average Max. Min. Average Humidity setting (Rh value)
in paint shop as per season as against Month deg. Cent deg. Cent temp Rh (Rh) Humidity ASU 01 ASU 02 ASU 03 ASU 04 ASU 05
constant setting earlier Jan 33.5 5.5 12 96 16 48 70 70 65 70 65
Feb 33.8 9.7 21 85 15 50 70 70 65 70 65

• Savings in LPG by 125 MT/yr Mar 39.3 15 27 82 7 52 70 70 65 70 65

worth Rs. 42.5 Lakhs/yr Apr 38.6 16 32 94 13 53 75 75 75 75 75
May 40.8 19.5 37 89 12 56 75 75 75 75 75
Jun 37.5 20.2 30 97 34 70 75 75 75 75 75
Jul 29.9 20.4 25 98 63 80.5 75 75 75 75 75
Aug 29.5 21.5 23 97 63 80 75 75 75 75 75
Sep 33.7 15.7 22 98 37 75 75 75 75 75 75
Oct 35.4 14.6 25 98 25 60 75 75 75 75 75
Nov 32.4 10.8 16 96 25 55 70 70 65 70 65
Dec 31.8 9 12 87 12 49 70 70 65 70 65

3. Replaced CT pumps with energy efficient ones fitted with VFD drives

Replaced conventional pumps with energy

efficient pumps fitted with VFD drives –
• Savings in electricity worth Rs. 6.48
Lakhs/yr
• Investment – Rs.14.5 Lakhs

Energy Conservation Plans and Targets

Description Unit FY 08-09

Electrical Energy kWh / Eq. Vehicle 280

Thermal Energy (LPG) M KCal/ Eq. Vehicle 0.25

Water consumption KL / Eq. Vehicle 2.8

65
Environment and Safety

Environment

Mahindra & Mahindra Ltd. is committed to “Protect the Environment, Prevention & Control of Pollution,
Minimise the Waste Generation, Promote Energy Saving and Conservation of Resources”. An
“Environmental Policy” duly signed and documented is provided expressing the commitment towards the
EMS. Following are some of the initiatives taken by the management towards Environment protection

1. Installed Effluent Treatment Plant and the treated effluent are being used for Gardening spread over
the area of about 1.00 Lac M2.
2. Installed Bio-Gas plant for processing Canteen solid Waste to generate a cooking gas for its use at
canteen
3. Installed Solar Water Heating Systems for canteen hot water requirement.
4. Around 25% of the electricity requirement for the FY 06- 07 is met by clean energy i.e. wind power.
5. For FY 07-08 massive plantations of 1 Lakh trees in the Nashik has been planned in association with
Forest department & Air Force.

Safety

Industrial Safety is an integral and essential part of every operation / process in Mahindra & Mahindra at
Nashik. The Industry is certified for OHSMS as per OHSAS 18001:2007 since February 2007.
Following practices are used to motivate Safety in plant:

1. Behaviour based safety (BBS) for people’s involvement has been started.
2. Staff / workers involvement in safety committee. Regular meetings are conducted to review the
Safety concerns and accident reduction.
3. Product Unit head is involved during the Safety Patrol rounds. Line managers and operators
motivate reduction in accidents.
4. Yearly Safety and HAZOP studies are conducted. The report is reviewed to take corrective action for
the observations in report.

66
Certificate of Merit Automobile Manufacturing

IP RINGS LIMITED
Maraimalai Nagar, Distt. Kancheepuram (Tamil Nadu)

Unit Profile

IP Rings Ltd., a member of Amalgamations Group of Company and having a Collaboration with Nippon
Piston Rings, Japan is producing Piston Rings for Automobile Applications to cater the needs of the
various prestigious customers like TELCO, Ashok Leyland, Mahindra & Mahindra, Simpson, Hindustan
Motors, Eicher, Maruti, Hyundai, Royal Enfield, TVS Motors.

Established in 1991, IP Rings manufactures a variety of Steel, SG Iron, Cast Iron Compression Rings with
intricate geometries and profiles. It is equipped with facilities for Surface Treatments like Plasma Spraying,
Flame Spraying, Gas Nitriding & Chromium Plating. For Leyland products, It has the facility of “All over
Width Chrome Plating” which is rare of its kind in the Country. For the Three Piece Oil ring, IP Rings has
the facility to manufacture both Nifflex H & S type rings, which is a unique specialty under one roof.

Turnover of 56 crores from its Piston Rings operations, IP Rings has now diversified its business
operations to the manufacture of Synchrocones and Bevel Gears through Cold Forming Technology.

67
Energy Consumption

By implementing various energy conservation projects there has been a consistent decrease in the
Specific Energy consumption.

Description Unit 2005 - 2006 2006 - 2007 2007 - 2008

No. of Rings /
Piston Rings produced 83,34,735 10,195,190 10,619,621
annum
Electrical energy
Units / annum 38.37 38.6 37.12
consumption in Lakhs
Specific Electrical energy
Units / Ring 0.42 0.35 0.30
consumption

Year Electricity Consumption (Units / Ring) % Reduction over 2005 - 2006

2005 - 2006 0.42 ---

2006 - 2007 0.35 16.7 %
2007 - 2008 0.30 14.3 %

68
Specific Energy Consumption

Energy Conservation Cell Structure

Director

ENERGY
CONSERVATION
TEAM chaired by
AVP (Operations)

Environment Maintenance Electrician / Fitters Cell Engineer / Cell

Management Rep. Engineers Leaders
& Safety Officer

Energy Conservation Achievements

During the period between 2005 ~ 2008, IP Rings Ltd., has implemented around 34 proposals through
Engineering initiatives, suggestion schemes, Auditors recommendations and TPM methodology resulting
in a total savings of Rs.23 lakhs. This has resulted in a reduction of 28 % on the electrical energy
consumption.

Energy Conservation Commitment

IP Rings is committed to conserve energy in all aspects. Towards this, many initiatives like getting the
inputs from the visitors, visiting other factories, sharing the improvements to the cluster members and
learning from them, benchmarking with companies like Mico Bosch, GKN Driveline, training of the
employees, implementing suggestions from the employees and creating awareness to them.

In this process, many initiatives like power generation thro’ wind-mill, solar energy are under
consideration. The TPM initiatives are helping to march towards the objective.

69
Energy Conservation Policy

The IP RINGS LTD, is committed to conserve its Electricity Consumption in all the activities through
™ Selection of Energy Efficient Equipments.
™ Continuous improvements to reduce Specific Energy Consumption by at least 10 % every year.
™ Increase the use of non–conventional sources of Energy.
™ Creating Energy Conservation awareness among employees.

Energy Conservation Measures implemented in 2007-2008

Project 1

In Administrative office, CFL Lamp fittings, working with Copper choke were replaced with Electronic
Ballast

Total investment, Rs. 15750

First year energy cost savings, Rs. 5250

Project 2

Fixed capacitor were used for PF correction in the Load centre and replaced by APFC unit to maintain
unity power-factor to avail incentive from EB.

Total investment, Rs. 28800

First year energy cost savings, Rs. 150000

70
 Fixed Capacitor at six locations Dedicated APFC at six locations

Project 3

In Lapping machine, diaphragm air pump was working during machine idle time and lunch time. By
interlocking the pump with the machine, the air loss and hence the power loss is minimized in 5 locations

Total investment, Rs. 10000

First year energy cost savings, Rs. 34500

Diaphragm pump working all the time Diaphragm pump interlocked with
even when the machine was not the lapping machines
loaded with products
Loss of Power is minimized
Loss of Power

Project 4

In Drinking water cooler, Digital temperature controller provided instead of conventional Thermostat for
better control in 5 locations

Total investment, Rs. 15000

First year energy cost savings, Rs. 18333

Thermostat to control the water Digital Temperature Controller fixed

cooler temperature
Variation in temp. is 2’ C
Variation in temp. is 5` C

71
Project 5

In Chrome plating section, improper joints in bus bar results in power loss. To eliminate power loss in each
bus bar joint, bolts and nuts are replaced periodically as per the maintenance plan

Total investment, Rs. 50000

Energy Conservation Plans and Targets

Anticipated
Energy
Savings in Approx.
Conservation Project
Energy Investment Completion year
measures Rs. Commencement
Value (Rs. Lakhs)
(Planned) Lakhs
(KWh)
Reduce weight of
Basket - 6 in HT 2314 1.18 0.1 Jul-08 Aug-08
furnace
High Efficiency Fan
94118 4.8 3 Oct-08 Dec-08
for Scrubber
Cogged V belt in
place of V belt for 13137 0.67 0.58 Oct-08 Nov-08
all machine
Replace 750W fan
to 240W EE fan for 26471 1.35 1.2 Nov-08 Feb-08
man cooler
Energy saver (210
7255 0.37 0.47 Sep-08 Nov-08
V) for OCF lighting
Minimize Radiation
1569 0.8 1 Apr-08 Apr-08
Loss in HT furnace
VSD Compressor -
98039 5.04 7 Apr-08 Jun-08
Rings
VSD Compressor -
98039 5.04 7 Jan-08 Mar-08
OCF

72
 Replace Brick
insulation to
34706 1.77 2.5 Feb-08 May-08
Ceramic Fibre in
HT furnace
VFD for Motor -
15686 0.8 1.4 Nov-08 Jan-08
Plating Compressor
HPMV 250W to
MHL 150W for 19608 1 2.1 Jul-08 Oct-08
shop floor lighting

Environment and Safety

Various initiatives on Safety Awareness including Safety Audit, Risk Analysis, Monitoring and
Measurement, Health Check-ups of all employees.

Safety

Safety audits are being conducted by both external and internal parties in order to achieve and sustain
zero accident. Periodic Health Check-ups like Audiometry tests, Dermitology tests are carried out for the
operators. Special type of PPEs is given to the operators for the betterment of the Occupational hazard.
Training programs like Awareness on Hygiene, Art of living are given to the operators. To move further,
they have adopted Occupational Hazard and Safety Management OHSAS 18001 Certification.

Environment

The unit has been implemented various waste reduction activities and resource saving projects to sustain
and maintain the ecological balance in and around the premises. They have planted 1000 trees and 1.5
acres of the lawn is developed in their factory premises to improve the greenery. It has been certified for
ISO 14001 for ensuring Environment Management Standards.

73
Certificate of Merit Automobile Manufacturing

MINDARIKA PRIVATE LIMITED

Village: Nawada Fatehpur, Distt. Gurgaon (Haryana)

Unit Profile

Mindarika Pvt. Ltd. Is indo- Japanese joint venture Company with Tokairika Japan. It is a unit of Minda
Group of Industries. Mindarika is an India lead manufacturing of the all types of automobile electro –
mechanical switches for four wheelers. Mindarika is ISO TS -16949, ISO14001 & Ford Certified.

Company is fully equipped in product Development engineering (Auto-CAD, Pro-E, Unigraphing, Mould
flow analysis etc.) tool design cell with modern tool room equipped with CNC & Cam wire cut, milling EDM
etc. molding section process engineering for developing of P.L.C. Base assy. Line setup & with Assy.
shop. Mindarika have a special switch testing Laboratory & Standard Room for Technical, Electrical
Environmental INDURANCE Testing etc & plastic raw material also.

Mindarika product are used by most of the O.E.M. for 4 wheelers in India like Maruti, Toyota (TKML)
Honda (HSIL), Tata Motors, General Motors (GMIL), Ford India Ltd. M & M, Eicher Motors etc. it is
exporting to ford (USA), lvoco (Italy), Troika (Japan) etc.

Energy Consumption

Considering the cost saving potentials, energy conservation is promoted by management as continual
improvement area. Last three years specific energy consumption, plant energy performance and energy
cost % of manufacturing cost consumption, figure’s are shown below, which depicts continual reduction in
energy consumption over last two years due to each person involvement and sustained efforts & ideas to
increase efficiency of equipments are from:-

(a) Optimum utilizations.

(b) Capacity utilizations.
(c) Technology up-gradation.

74
 DESCRIPTION UNIT 2005~06 2006~07 2007~08
SPECIFIC ENERGY CONSUMPTION KWH / SW 0.27 0.26 0.24
SEC % REDUCTION OVER BASE YEAR 2005 ~
% 0 3.7 7.69
06
TOTAL MANUFACTURING COST RS. LAKHS 6245.41 8192.16 9460.1

TOTAL ENERGY BILL RS. LAKHS 153.19 193.52 190.34

ENERGY AS %AGE OF TOTAL COST OF

% 2.4 2.3 2
PRODUCTION

CONNECTED LOAD KW 1052 1670 1821

Connected Load
CONNECTED LOAD VS ENERGY AS %AGE OF TOTAL COST OF Increase Trend
SPECIFIC POWER CONSUMPTION PRODUCTION but %age Energy
Reducing Trend
1 2000 2.4 1821 2.5
1670
C O N N E C T E D L O A D (K W )

E NERGY AS % AGE OF
2.3 2.4
1500

TO TAL CO S T O F
2.3

P R O D U C T IO N
KW H/ S W

1052 2.2
1000
2 2.1
0.27 0.26 0.24 2
500
1.9
0 1.8
0 2005~06 2006~07 2007~08
2005~06 2006~07 2007~08 YEAR CONNECTED LOAD KW

ENERGY AS %AGE OF TOTAL

YEAR COST OF PRODUCTION %

Energy Conservation Commitment, Policy and Set up

Mindarika follows an Integrated Management System and this concept has enriched the company to have
a balanced focus on all the area whether it had to be Energy Conservation or Quality Improvement; it has
never left any area behind.

Even its Environmental Policy gives a major emphasis on the Energy Conservation. Energy Conservation
movement was started in the year 2001 by the Plant Maintenance Force and today it has the entire team
of Mindarika, jointly upgrading this Mission.

Mindarika Management has never put its foot back in promoting and upgrading the Energy Conservation
activities and has very serious reviews in this area. To mention a few of the activities carried out in this
area are:

• Development of Energy Skill Champions for up-gradation

• Deployment of this skill along with allocation of yearly Energy Saving targets in all the functions.
• Budget allocation for installing Energy saving devices in various process & machines. New Machines
and New Process line setups are being reviewed for Energy saving efficiency.

75
Promotion of effective Energy Management System are through

1) Regular Training on EMS, Energy Management, Equipment efficiency and Efficient Maintenance of
Machines and Processes.
2) Continually Skill Up gradation of the Energy Cell thru’ Internal and External Trainings.
3) Facilitating the Energy Skill Champions to qualify for Certified Energy Managers.
4) Reviewing the Environmental and Energy Conservation Performance thru’ Morning Meetings,
Weekly meetings and group wide quarterly meetings.
5) Celebration of Environment Month.
6) Regularly awarding and Rewarding the Associates and Staff for the Best Improvements done in
the Environment and Energy Management Areas.
7) Promoting the associates to get involved in this mission by setting the Quality Circle and EMP
targets of a particular function.
8) Not limiting the attitude within the unit Mindarika Management is promoting its group units to also
focus on this area by having constructive deployments of their learning’s and creating Energy Skill
Champions in other units as well.

Energy conservation team structure

UBH

EC CELL HEAD UNIT CHAMPION

DGM (CERTIFIED ENERGY FOR OTHER
MANAGER) GROUP
COMPANIES

MANAGER
PLANT MAINTENANCE

ACCOUNTS DY. MANAGER MAINT. OTHER FUNCTION HRM

TQM DEPTT. (FOR
(FOR (RESPONSIBLE FOR RESPONSIBLE FOR
(RESPONSIBLE TRAININ
ACCOUNTING SUGGESTIONS SUGGESTIONS THROUGH
FOR PROGRESS G OF
AND SAVINGS IMPLEMENTATION AND KAIZEN SCHEME ASSY. /
MONITORING HUMAN
VARIFICATION) UTILITY SERVICES) P. PRODUCTION/ OFFICE
THROUGH RESOUR
AREA
DEPARTMENTAL CE)
TARGETS

76
Energy Conservation Achievements

With best support & contribution of all employees’, Unit generated many ideas. Out of which 20 ideas
considered during the period 2005~08 & Achieved Annual savings of Rs. 34.7 Lakhs with an investment of
Rs. 8.6 Lakhs. It has resulted in “PLANT ENERGY PERFORMANCE IMPROVEMENT BY 7.69%” as
shown below

Plant Energy Performance

2005~06
DESCRIPTION UNIT 2006~07 2007~08
Base Year
No. of
PRODUCTION 8004580 8765315 10402288
Switch
PRODUCTION FACTOR =
Current Year Production / Reference - 0 1.09 1.30
Year Production
Reference Year Equivalent = Ref.
Lakh
year Energy use X Production 21.62 23.56 28.10
kWh/Year
Factor
Lakh
Current Year Energy 21.62 22.84 25.88
kWh/Year
Energy Performance = (Ref. year
Equivalent – Current Year Energy ) % 0 3.05 7.90
X 100 / Ref. year Equivalent

PLANT ENERGY PERFORM ANCE

E%

10
T

7.9
N
C

E
Y

8
M
G

E
M
R

6
V
E

3.05
N

FO

4
R
E

P
R

IM

2 0
PE

0
2005~06 2006~07 2007~08
BA SE Y EA R YEAR

Energy conservation measures for the year 2007 –2008

Project 1

Optimum water circulation by stopping one chilled water pump for centralized air conditioning system

Total investment, Nil

First year energy cost savings, Rs. 0.46 Lac

77
 BEFORE AFTER

Project 2

Installed VFD on air compressors to save load by speed/ frequency reduction

Total investment, Rs. 2.6 Lakh

First year energy cost savings, Rs. 2.83 Lakh

Project 3

AHU by pass valve closed for chilled water circulation to reduce energy consumption by pump

Total investment, Nil

First year energy cost savings, Rs. 1.78 Lakh

BEFORE AFTER

78
Project 4

Used insulation jackets on heating barrel of moulding m/c to avoid heat dissipation

Total investment, Rs. 0.75 Lakh

First year energy cost savings, Rs. 8.91 Lakh

BEFORE AFTER

Project 5

Saving in electricity bill every month by improving power factor from 0.70 to 0.99 after installation of digital
apfc relay in power factor panel

Total investment, Rs. 0.20 Lakh

First year energy cost savings, Rs. 2.3 Lakh

79
Project 6

Operation of FDV system by timer control in whole plant to avoid wastage of energy.

Total investment, Rs. 0.21 Lakh

First year energy cost savings, Rs. 1.17 Lakh

BEFORE AFTER

Energy Conservation Measures Implemented

Sl. Saving in Savings Investment

Description
No. lakh kWh (Rs. In lakhs) (Rs. In lakhs)
Using of CFL in place of bulbs on m/c’s, toilets,
1 0.06497 0.42 0.02
passages & street lights etc.
Using electronic blast with t5 lamp m/c’s office
2 0.08640 0.52 1.4
area, tool room, lab area & part prod etc.
Switched off all computer monitors when not in
3 0.04320 0.28 0
used in whole plant
4 Arresting air leakages in whole plant 0.13291 0.87 0
De energizing the servo stabilizers during non
5 0.07245 0.47 0
working hrs in molding and tool room area
Installation of appropriate capacity of capacitor
banks with APFC relay at utility area and plant
6 distribution panels for electrical power & d.g. 0.23320 1.53 0.15
set close to load.
Replacing of metal halides street lighting by
7 0.21024 1.38 1.15
CFL sets of 72 watts from 450/250 watts
Installation of soft starter with energy saver in
8 molding m/c by input voltage and current 0.79200 5.22 2.3
control at different loading conditions.
9 Used fuel additive for d.g. segr improvement 0.29508 1.94 1.54
Installed movement detector for air-curtain at
10 0.02592 0.17 0.05
assy. area entry gates

80
 Installed load controller to stop hydraulic pump
11 0.82125 5.42 0
motor at no load condition in molding shop
Installed VFD on chiller pump of centralised air
12 conditioner chiller of VFD on chiller pump of 0.03650 0.24 0.15
10hp
Use of free air cooling through AHU’s to purge
13 hot air of assy. area to reduce heat load on ac 1.27000 0.95 0
system
Optimum water circulation by stopping one
14 chilled water pump for centralised air 0.07020 0.46 0
conditioning system
Installed VFD on air compressors to save load
15 0.42924 2.83 2.6
by speed/ frequency reduction
AHU, by pass valve closed for chilled water
16 circulation to reduce energy consumption by 0.27000 1.78 0.0
pump
Used insulation jackets on heating barrel of
17 1.35000 8.91 0.75
moulding m/c to avoid heat dissipation
Provided energy efficient air guns in whole
18 0.01488 0.09 0.03
plant
19 Conversion of delta to star mode for AHU no-6
& 7 of centralised air conditioning system 0.08760 0.05 NIL
20 Replacing water urinals by aqua free urinals at
0.18203 1.12 0.76
tool room, account and engg. area toilets

Energy Conservation Plans and Targets

Saving Investment
S. Savings
Description in lakh (Rs. In
No. (Rs. In lakhs)
kwh lakhs)
Provide sun glass film on assy. area window to
1 5475 0.34 0.22
reduce heat load on centralised a.c. system

Cover all outdoor units of split a/c. provide shed on

outdoor units of splits a.c. conditioners to reduce
2 1500 0.07 0.1
heat load in accounts/ engineering/ tool room
design/ pad printing area.

3 Using magnetic resonator for dg sets 49400 4.4 0.4

Providing natural mechanical ventilator in place of

4 98550 6.09 2.25
roof exhaust fan

To reduce fan speed of FDV forced draft ventilation

5 15120 0.7 0.5
system – 04nos. to avoid throttling

TOTAL 170045 11.60 3.02

81
Environment and Safety

82