1. Sustainability Improvements - Packaging
Date : 19 October 2015

2. Objective
Conversion of Expendable Packaging for Inbound Parts into Returnable Packaging to achieve following benefits.
Improve Quality of component received
Improve sustainability by eliminating cardboard & wooden packaging
Improve operators Ergonomics
Optimise packaging itself & transportation
Cost Saving thru optimisation

3. Process for Inbound parts in Expendable Pack
Supplier
Unloading
M&M Plant
Mahindra
Opening of Box
in W/H
Staking on Rack
Issue on
Assy line
Waste Disposal
Re-Binning

4. Equipment Pooling for Returnable Packaging
Supplier Plant
Service Provider to issue Equipment on need basis
Service Center
near Supplier
Payment of Rental Charges to Service Provider for period of usage
Part Supplies to
M&M Plant
Service Provider to collect equipment when empty
Mahindra
Service Center
near M&M Plant
M&M Plant

5. Process for Inbound parts with Equipment Pooling
Supplier
Unloading
M&M Plant
Mahindra
Activities Eliminated
Opening of Box
in W/H
Staking on Rack
Issue on
Assy line
Waste Disposal
Re-Binning

6. Equipment Pooling of Returnable Packaging
Supplier Plant
Service Provider to issue Equipment on need basis
Implementation Status & Benefits :
Year No of Parts F
F 16 H
Total Saving achieved till date : Rs 275 Lacs.
Wood & Cardboard Reduction : 15%
Estimated Saving of 600 Ton Carboard/ annum
Service Center
near Supplier
Payment of Rental Charges to Service Provider for period of usage
Part Supplies to
M&M Plant
Service Provider to collect equipment when empty
Mahindra
Service Center
near M&M Plant
M&M Plant

7. List of Suppliers
Converted to Equipment Pooling Concept

8. M&M / Supplier owned to Rental Returnable
After
Before
M&M Plant
Local Service Centre
(3rd Party)
M&M Plant
Saving in Return Trip utilised partially for Rent payment
Rental Packaging
M&M Owned Packaging
Local Service Centre
(3rd Party)
Supplier
Supplier

9. M&M / Supplier owned to Rental Returnable
After
Before
M&M Plant
Local Service Centre
(3rd Party)
Implemented for 14 BIW Panels to Zaheerabad
Benefits
Avoid Long distance Return Trip resulting in Transportation Cost Saving
Avoid Co2 emission : 320 Kg per return trip.
Improved Cube utilization > 90%
Standard equipment
M&M Plant
Saving in Return Trip utilised partially for Rent payment
Rental Packaging
M&M Owned Packaging
Local Service Centre
(3rd Party)
Supplier
Supplier

10. Examples of Returnable Packaging
Part No & Description
0703CAK00330N
Assy Shift System W201
Used on Model
XUV 500
Supplier
Best Koki Automotive Pvt. Ltd, Gurgaon
Receiving Plant
Chakan
Earlier Packaging
Corrugated Box with pations & EPE inserts
Changed Packaging
PP Foldable Crates with Thermoformed trays
Before
After

11. Examples of Returnable Packaging
Part No & Description
0703CAK00330N
Assy Shift System W201
Used on Model
XUV 500
Supplier
Best Koki Automotive Pvt. Ltd, Gurgaon
Receiving Plant
Chakan
Earlier Packaging
Corrugated Box with pations & EPE inserts
Changed Packaging
PP Foldable Crates with Thermoformed trays
Benefits
Elimination of Cardboard waste: 3.2 Ton / Annum
Elimination of Wooden waste : 4.5 Ton/ Annum
Elimination of EPE Foam Inserts : 144 Kg/ Annum
Improved ergonomics
Cost saving : Rs 70 per vehicle set.
Before
After

12. Examples of Returnable Packaging
Part No & Description
0703CK0280N
Assy Shift Tower TX – 6S 400
Used on Model
XUV 500
Supplier
Best Koki Automotive Pvt. Ltd, Gurgaon
Receiving Plant
Chakan
Earlier Packaging
Corrugated Box with pations & EPE inserts
Changed Packaging
PP Foldable Crates with Thermoformed trays
Before
After

13. Examples of Returnable Packaging
Part No & Description
0703CK0280N
Assy Shift Tower TX – 6S 400
Used on Model
XUV 500
Supplier
Best Koki Automotive Pvt. Ltd, Gurgaon
Receiving Plant
Chakan
Earlier Packaging
Corrugated Box with pations & EPE inserts
Changed Packaging
PP Foldable Crates with Thermoformed trays
Benefits
Elimination of Cardboard waste: 5.6 Ton / Annum
Elimination of Wooden waste : 7.2 Ton/ Annum
Elimination of EPE Foam Inserts : 256 Kg/ Annum
Improved ergonomics & Elimination of Transit damages
Cost saving : Rs 41 per vehicle set.
Before
After

14. Examples of Returnable Packaging
Part No & Description
0305BAB02030N
MDI LCCR Assy Fuel Pump with Cam Box
Used on Model
MDI Engine
Supplier
Delhi TVS Diesel System Ltd. Kanchipuram,
Receiving Plant
Igatpuri
Earlier Packaging
Corrugated Box, LDPE bag, Wooden base & top
Changed Packaging
PP Foldable Crates with Thermoformed trays
Before
After

15. Examples of Returnable Packaging
Part No & Description
0305BAB02030N
MDI LCCR Assy Fuel Pump with Cam Box
Used on Model
MDI Engine
Supplier
Delhi TVS Diesel System Ltd. Kanchipuram,
Receiving Plant
Igatpuri
Earlier Packaging
Corrugated Box, LDPE bag, Wooden base & top
Changed Packaging
PP Foldable Crates with Thermoformed trays
Benefits
Elimination of Cardboard waste: 5.65 Ton / Annum
Elimination of Wooden waste : 16 Ton/ Annum
Elimination of LDPE waste : 600 Kg/ Annum
Improved ergonomics, Elimination of Transit Damages
Cost saving : Rs 24 per vehicle set.
Before
After

16. Examples of Returnable Packaging
Part No & Description
EGR Cooler
Used on Model
W201, Mhawk, Mustang, NEF, NEF CRDi Engines
Supplier
BorgWarner Emissions, Gurgaon.
Receiving Plant
Igatpuri
Earlier Packaging
Corrugated Box with partitions.
Changed Packaging
PP Foldable crates with partitions.
Before
After

17. Examples of Returnable Packaging
Part No & Description
EGR Cooler
Used on Model
W201, Mhawk, Mustang, NEF, NEF CRDi Engines
Supplier
BorgWarner Emissions, Gurgaon.
Receiving Plant
Igatpuri
Earlier Packaging
Corrugated Box with partitions.
Changed Packaging
PP Foldable crates with partitions.
Benefits
Elimination of Cardboard waste: 6.1 Ton / Annum
Elimination of Transit Damages
Improved ergonomics
Cost saving : Rs 11 per vehicle set.
Before
After

18. Examples of Returnable Packaging
Part No & Description
Fuel Lid & Fuel Box
Used on Model
Scorpio, Xylo, Quanto, XUV 500
Supplier
Dhanjal Engineers
Receiving Plant
Nasik, Chakan
Earlier Packaging
Corrugated Box with corrugated board partitions.
Changed Packaging
PP Crates with PP Partitions
Before
After

19. Examples of Returnable Packaging
Part No & Description
Fuel Lid & Fuel Box
Used on Model
Scorpio, Xylo, Quanto, XUV 500
Supplier
Dhanjal Engineers
Receiving Plant
Nasik, Chakan
Earlier Packaging
Corrugated Box with corrugated board partitions.
Changed Packaging
PP Crates with PP Partitions
Benefits
Elimination of Cardboard waste: 2.33 Ton / Annum
Elimination of Transit Damages
Improved ergonomics & Storage
Direct feeding on lineside w/o Re-binning
Before
After

20. Thank You !