Bosch, Jaipur
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Transcript of Bosch, Jaipur
1
Recieved - WATER EFFICIENT UNIT AWARD at the National Award for Excellence in Water Management – 2007 conducted by CII Sohrabji Godrej Green Business Centre, Hyderabad .
1
BOSCH - JAIPUREstablished : 1999Land Area : 202,350 m2
Product :Fuel injection pumps
ISO 14001:2004 TS 16949:2002
CERTIFICATIONS
Built Area : 30,834 m2
Employees : 1,383Turnover : 9,000 MINR
CO
MPA
NY
PR
OFI
LE
OHSAS 18001(Under implementation)
National Award for “Excellence in Water Management – 2008
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Recieved - WATER EFFICIENT UNIT AWARD at the National Award for Excellence in Water Management – 2007 conducted by CII Sohrabji Godrej Green Business Centre, Hyderabad .
2
MA
NU
FAC
TUR
ING
PR
OC
ESS
Production facility
Soft Stage
Hard stage
Calibration
Heat treatment Surface treatment
Assembly
Post Calibration
VE- Pump
* * *
*
Grinding, cleaning etc
Milling, boring etc
National Award for “Excellence in Water Management – 2008
Recieved - WATER EFFICIENT UNIT AWARD at the National Award for Excellence in Water Management – 2007 conducted by CII Sohrabji Godrej Green Business Centre, Hyderabad .
Internal JaP/TEF | 06-10-07 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
JaP/SAF-EPR 33
National Award for “Excellence in Water Management – 2008EN
VIR
ON
MEN
TAL
PR
ESER
VATI
ON
RESOURCE CONSERVATION
Reduce Fresh Water consumption within i.eadopting new technologies, utilizing rain water, and increase recycling
Community/employee empowerment
Introduce non- conventional Energy i.e Wind energy and Solar Thermal energy
Water Management in the local community
ENVIRONMENTPROTECTION
Eliminating hazardous chemicals and waste
Reducing carbon foot print
Tree plantation in the society
Society involvement through PPP
Sustainable Approach
3 Internal JaP/TEF | 06-10-07 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
3
Recieved - WATER EFFICIENT UNIT AWARD at the National Award for Excellence in Water Management – 2007 conducted by CII Sohrabji Godrej Green Business Centre, Hyderabad .
Internal JaP/TEF | 06-10-07 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
JaP/SAF-EPR 44
SPECIFIC WATER CONSUMPTIONNational Award for “Excellence in Water Management – 2008
439
285260
212
0
50
100
150
200
250
300
350
400
450
500
04-05 05-06 06-07 07-08
reduction in specific water consumption since
year 2004-05
51%
Specific Water consumption in Liters
44
5
Recieved - WATER EFFICIENT UNIT AWARD at the National Award for Excellence in Water Management – 2007 conducted by CII Sohrabji Godrej Green Business Centre, Hyderabad .
5
National Award for “Excellence in Water Management – 2008
List of few projects completed to reduce water consumption:
-Conversion of water cooled fan chamber in SQF to air cooled
-Conversion of conventional taps to sensor based
- Introduction of Zeriscaping in landscaping
- Water budgeting and audits
-Recycling of water after treatment in the resin treatment plant
- Up gradation of Sewage treatment plant
- Installation of dishwasher in canteen
- Leakage audits
EHS | 27/11/2008 | © Bosch Limited 2008. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
6
Recieved - WATER EFFICIENT UNIT AWARD at the National Award for Excellence in Water Management – 2007 conducted by CII Sohrabji Godrej Green Business Centre, Hyderabad .
6
24902093
14271275
667
0
500
1000
1500
2000
2500
3000
2005 2006 2007 2008 (Ytd) BM
3081
25802199
1275
0
500
1000
1500
2000
2500
3000
3500
NaP BanP NhP JaP
m3/MioEURBENCHMARKINGBosch Jaipur unit has already reached to a benchmark among the four BOSCH manufacturing units in India in water consumption against added value output.
i.e Bangalore, Nashik, Nagnathapura plants
BOSCH – Bari ( Italy) manufacturing unit is taken as
Benchmark
( Target 2013)
Water consumption in m3/MioEUR
National Award for “Excellence in Water Management – 2008
EHS | 27/11/2008 | © Bosch Limited 2008. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Recieved - WATER EFFICIENT UNIT AWARD at the National Award for Excellence in Water Management – 2007 conducted by CII Sohrabji Godrej Green Business Centre, Hyderabad .
Internal JaP/TEF | 06-10-07 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
JaP/SAF-EPR 77
Domestic sewage
WASTE WATER TREATMENT & DISCHARGEEFFLUENT TREATMENT PLANT
SEWAGE TREATMENT PLANT
Process Effluent
ULTRA FILTRATION PLANT
“ZERO DISCHARGE UNIT”
SINCE INCEPTION
National Award for “Excellence in Water Management – 2008
1 %Recycling and reusein gardening and process
77
Recieved - WATER EFFICIENT UNIT AWARD at the National Award for Excellence in Water Management – 2007 conducted by CII Sohrabji Godrej Green Business Centre, Hyderabad .
Internal JaP/TEF | 06-10-07 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
JaP/SAF-EPR 88
2008
Modify cleaning process in canteen
Introduce Zeriscaping in the lawns
Irrigation 100% by treated waste water
2013
Awareness among employees/contractors - Continuous
Recycling of treated wastewater in Secondary purposes
Technology up gradation for wastewater treatment
To become a benchmark plant in BOSCH - DS
Rain water utilization for Process and Cooling
RO
AD
MA
P T
O E
XCEL
LEN
CE
National Award for “Excellence in Water Management – 2008
Treat and utilize external drain sewage
88
Recieved - WATER EFFICIENT UNIT AWARD at the National Award for Excellence in Water Management – 2007 conducted by CII Sohrabji Godrej Green Business Centre, Hyderabad .
Internal JaP/TEF | 06-10-07 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
JaP/SAF-EPR 99
Sustainability tools
Kaizen
POKA - YOKE
Suggestion Scheme
Team Oriented Production
National Award for “Excellence in Water Management – 2008
Awareness campaigns
Leanstatts
Policy Deployment
Strategic Themes and Targets
99 EHS | 27/11/2008 | © Bosch Limited 2008. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well
as in the event of applications for industrial property rights.
10
Recieved - WATER EFFICIENT UNIT AWARD at the National Award for Excellence in Water Management – 2007 conducted by CII Sohrabji Godrej Green Business Centre, Hyderabad .
10
National Award for “Excellence in Water Management – 2008Monitoring and ReportingCONSUMPTION
-Daily consumption Monitoring by meters on various lines.
-Monthly review on consumption and conservation with Plant Management
-Half Yearly review through PDCA methodology
-Annual review with Bosch –India, Corporate Management
REPORTING
Quarterly reporting to Bosch – HSE :India
Annual reporting to Bosch – C/PSE :Germany
EHS | 27/11/2008 | © Bosch Limited 2008. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Recieved - WATER EFFICIENT UNIT AWARD at the National Award for Excellence in Water Management – 2007 conducted by CII Sohrabji Godrej Green Business Centre, Hyderabad .
Internal JaP/TEF | 06-10-07 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
JaP/SAF-EPR 1111
National Award for “Excellence in Water Management – 2008Utilization of Rain water in cooling towers
1. Diversion of roof top rain water after filtration to cooling tower water tank
2. Collection of Rain water and pumping it to cooling tower after filtration.
Benefit:
-Due to low TDS rain water the blow down frequency is reduced
- Saving of anti scaling chemicals in cooling tower and salt in softener
- Saving of fresh water, soft water, regeneration water
- Saving of power.WA
TER
CO
NSE
RVA
TIO
N P
RO
JEC
TS
EHS | 27/11/2008 | © Bosch Limited 2008. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Recieved - WATER EFFICIENT UNIT AWARD at the National Award for Excellence in Water Management – 2007 conducted by CII Sohrabji Godrej Green Business Centre, Hyderabad .
Internal JaP/TEF | 06-10-07 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
JaP/SAF-EPR 1212
National Award for “Excellence in Water Management – 2008Technology Up gradation in component cleaning process
WA
TER
CO
NSE
RVA
TIO
N P
RO
JEC
TS
No WastewaterGeneration
Upgraded TechnologyClosed loop system
Post projectDURR –EcocleanSingle chamber, Multistage Three cleaning Tanks
Heatingchamber
Sludge
Condenser
Chamber1
Wastewater to drain
Open loop systemPrevious Technology
Chamber2
Chamber3
Chamber1
Tank-1 Tank-2 Tank-3
Tank-1 Tank-2 Tank-3
Insight Cleaning m/cMulti chamber, Multistage
Pre project
‘NO’effluent
generated
Recieved - WATER EFFICIENT UNIT AWARD at the National Award for Excellence in Water Management – 2007 conducted by CII Sohrabji Godrej Green Business Centre, Hyderabad .
Internal JaP/TEF | 06-10-07 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
JaP/SAF-EPR 1313
National Award for “Excellence in Water Management – 2008
Water recycling in resin treatment plant
WA
TER
CO
NSE
RVA
TIO
N P
RO
JEC
TS
Filtration / treatment
Waste water
Aluminum castings
DM water Resin
Heat
Resin Treatment
Additional Unit added for clarification of waste water, which is now recycled back to the Resin Treatment Plant.
Now effluent is discharged only 3 -4 times a year
Recieved - WATER EFFICIENT UNIT AWARD at the National Award for Excellence in Water Management – 2007 conducted by CII Sohrabji Godrej Green Business Centre, Hyderabad .
Internal JaP/TEF | 06-10-07 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
JaP/SAF-EPR 1414
Rain water Harvesting system Collection of surface/rooftop runoff and rechargingWater collection system having total volume of 1,200 m3. A set of pumps with meters providedHarvested rain water charged back to recharge well in premises
Pumps and collection system Recharging wellWA
TER
CO
NSE
RVA
TIO
N P
RO
JEC
TSNational Award for “Excellence in Water Management – 2008
Recieved - WATER EFFICIENT UNIT AWARD at the National Award for Excellence in Water Management – 2007 conducted by CII Sohrabji Godrej Green Business Centre, Hyderabad .
Internal JaP/TEF | 06-10-07 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
JaP/SAF-EPR 1515
National Award for “Excellence in Water Management – 2008
Emulsion Oil replacement in Machining processes
WA
TER
CO
NSE
RVA
TIO
N P
RO
JEC
TS
Pre- modification
Post modificationFrequency of changing the coolant - Monthly
Frequency of changing the coolant – Once in 6 months
PROCESS: Water + Emulsion Oil (Coolant) used in grinding/machining
Features:
Reduction in water consumption
Investment = Nil
Payback period = ImmediateSaving = 348 m3 liters /annum fresh water
Less hazardous waste generationEnergy saving in Ultra Filtration of wastewater
Recieved - WATER EFFICIENT UNIT AWARD at the National Award for Excellence in Water Management – 2007 conducted by CII Sohrabji Godrej Green Business Centre, Hyderabad .
Internal JaP/TEF | 06-10-07 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
JaP/SAF-EPR 1616
Modification In cleaning process before heat treatment
WA
TER
CO
NSE
RVA
TIO
N P
RO
JEC
TS PROCESS: Water + chemical used to remove oil from componentsPre- modification
Cleaningmachine
Holding TankComponents
Waste Water
Cleaningmachine
Holding TankComponents
Waste Water
Post - modificationOil Skimmer
Oil
Investment = INR 39,000
Payback period = 2.8 yearsSaving = 96 m3 liters /annum fresh water
National Award for “Excellence in Water Management – 2008
Recieved - WATER EFFICIENT UNIT AWARD at the National Award for Excellence in Water Management – 2007 conducted by CII Sohrabji Godrej Green Business Centre, Hyderabad .
Internal JaP/TEF | 06-10-07 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
JaP/SAF-EPR 1717
PLC controlled Irrigation system ( Sprinkler & Drip) :
WA
TER
CO
NSE
RVA
TIO
N P
RO
JEC
TS
Irrigation automatically through
-PLC controlled -pop-up sprays sprinklers-Drippers.
National Award for “Excellence in Water Management – 2008
Waste water after treatment is used for landscape irrigation
Investment = Rs.11 lakhsBenefits:
-Less water consumption in irrigation.
- Evaporation losses minimized as programmed to work in late night hrs.
EHS | 27/11/2008 | © Bosch Limited 2008. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
18
Recieved - WATER EFFICIENT UNIT AWARD at the National Award for Excellence in Water Management – 2007 conducted by CII Sohrabji Godrej Green Business Centre, Hyderabad .
18
Raw Water Inlet
PermeateR.O.
To
process
To
process
PermeateR.O.
WA
TER
CO
NSE
RVA
TIO
N P
RO
JEC
TS
Post - modification
Reject as inlet Reject 11%
DMPlant
Pre- modification
Post project
Raw Water Inlet
Reject 45 %
DMPlant
Investment = negligible (system was available)Saving = 3,200,000 liters /annum
RO cascading with DM combinationNational Award for “Excellence in Water Management – 2008
Payback = immediate
EHS | 27/11/2008 | © Bosch Limited 2008. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Recieved - WATER EFFICIENT UNIT AWARD at the National Award for Excellence in Water Management – 2007 conducted by CII Sohrabji Godrej Green Business Centre, Hyderabad .
Internal JaP/TEF | 06-10-07 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.
JaP/SAF-EPR 1919
National Award for “Excellence in Water Management – 2008
WA
TER C
ON
SERVA
TION
PRO
JECTS -3
ENVI
RO
NM
ENT
CO
NSE
RVA
TIO
N P
RO
JEC
TS
-Installation of Non Cyanide Alkali based Zn Plating line.
- Elimination of Hexavalent chrome Cr+6 in electroplating process
-Elimination of Ozone Depleting substances ( Total 347 units)..
-Up gradation of Sewage treatment Plant.
-Solar water heating system installation for canteen.
-Change of conventional faucets to sensor based.
-Conversion of water cooled fan chamber in SQF to air cooled.
- Elimination of lapping paste ( Hazardous waste)
Other projects and Milestones