This is a presentation from Mahindra & Mahindra Ltd, one of the finalists at the 5th CII-GBC National Award for Excellence in Water Management in 2008 The awards are in 2 categories, Within the Fence for work done on minimizing the organisations water footprint, and Beyond the Fence for work done in the community around the industry. This presentation was in the "Within the Fence" category. We thank CII and the respective companies for giving us permission to upload these presentations on the India Water Portal website for dissemination to a wider audience.

1. MAHINDRA & MAHINDRA LTD
AUTOMOTIVE SECTOR- PLANT I
SECTOR-
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 - 2005
27001-
1

2. 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
2

3. 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- 2004 To 2008
projects-
3

4. 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 ODI S
E 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 T nk
a
C ollecti on Ta nk
G at e Stor m Wat er Gu tter
Total Water Saved = 2971 M3
Investment = 0
4

5. 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
5

6. 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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7. 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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8. 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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9. 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
9

10. 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-house Project.
In - 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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11. 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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12. Green Areas in Nashik Plant
Green Areas in side Nashik Plant shop area
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13. 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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14. 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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15. 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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