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Bosch, Jaipur

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This is a presentation from BOSCH, Jaipur one of the finalists at the 5th CII-GBC National Award for Excellence in Water Management in 2008....

This is a presentation from BOSCH, Jaipur 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.

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Bosch, Jaipur Bosch, Jaipur Presentation Transcript

  • National Award for “Excellence in Water Management – 2008 Established : 1999 BOSCH - JAIPUR CERTIFICATIONS Recieved - WATER EFFICIENT UNIT AWARD at the National Award for Excellence in Water 2 Management –Areaconducted by CII Sohrabji Godrej Green Business Centre, Hyderabad . Land 2007 : 202,350 m ISO 14001:2004 Built Area : 30,834 m2 PROFILE Employees : 1,383 TS 16949:2002 Turnover : 9,000 MINR OHSAS 18001 (Under implementation) Product :Fuel injection pumps COMPANY 1 1
  • National Award for “Excellence in Water Management – 2008 Soft Stage* * Heat treatment * Surface treatment MANUFACTURING PROCESS Recieved - WATER EFFICIENT UNIT AWARD at the National Award for Excellence in Water Grinding, cleaning etc Management – 2007 conducted by CII Sohrabji Godrej Green Business Centre, Hyderabad . Hard stage * Milling, boring etc Assembly Calibration Post Calibration Production facility VE- Pump 2 2
  • National Award for “Excellence in Water Management – 2008 ENVIRONMENTAL PRESERVATION Reduce Fresh Water consumption within i.e Recieved - WATER EFFICIENT UNIT AWARD at the National Award for Excellence in Water adopting new technologies, utilizing rain water, Management – 2007 conducted by CII Sohrabji Godrej Green Business Centre, Hyderabad . RESOURCE and increase recycling CONSERVATION Community/employee empowerment Introduce non- conventional Energy i.e Wind energy and Solar Thermal energy Sustainable Approach Water Management in the local community Eliminating hazardous chemicals and waste ENVIRONMENT PROTECTION Reducing carbon foot print Tree plantation in the society Society involvement through PPP JaP/SAF-EPR 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 3 disposal such as copying and passing on to third parties.
  • National Award for “Excellence in Water Management – 2008 SPECIFIC WATER CONSUMPTION Recieved - WATER EFFICIENT UNIT AWARD at the National Award for Excellence in Water Management – 2007 conducted by CII Sohrabji Godrej Green Business Centre, Hyderabad . 500 450 439 51% reduction in specific 400 water consumption since 350 year 2004-05 285 300 260 250 212 200 150 Specific Water consumption 100 in Liters 50 0 04-05 05-06 06-07 07-08 JaP/SAF-EPR 4 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 4 disposal such as copying and passing on to third parties.
  • National Award for “Excellence in Water Management – 2008 List of few projects completed to reduce water consumption: Recieved - WATER EFFICIENT UNIT AWARD at the National Award for Excellence in Water Management – 2007 conducted by CII Sohrabji Godrej Green Business Centre, Hyderabad . -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 5 EHS | 27/11/2008 | © Bosch Limited 2008. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well 5 as in the event of applications for industrial property rights.
  • National Award for “Excellence in Water Management – 2008 3500 3081 BENCHMARKING 2580 3000 m3/MioEUR Recieved - WATER EFFICIENT UNIT AWARD at the National Award for Excellence in Water 2500 2199 Management – 2007 conducted by CII Sohrabji Godrej Green Business Centre, Hyderabad . Bosch Jaipur unit has already reached 2000 to a benchmark among the four BOSCH 1500 1275 manufacturing units in India in water 1000 consumption against added value output. 500 0 i.e Bangalore, Nashik, Nagnathapura plants NaP BanP NhP JaP 3000 2490 BOSCH – Bari ( Italy) 2500 manufacturing unit is taken as 2093 Benchmark 2000 1427 ( Target 2013) 1500 1275 1000 667 500 Water consumption in m3/MioEUR 0 2005 2006 2007 2008 (Ytd) BM 6 EHS | 27/11/2008 | © Bosch Limited 2008. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well 6 as in the event of applications for industrial property rights.
  • National Award for “Excellence in Water Management – 2008 WASTE WATER TREATMENT & DISCHARGE “ZERO DISCHARGE Recieved - WATER EFFICIENT UNIT AWARD at the National Award for Excellence in Water EFFLUENT TREATMENT PLANT Management – 2007 conducted by CII Sohrabji Godrej Green Business Centre,UNIT” Hyderabad . SINCE INCEPTION Process Effluent Domestic sewage SEWAGE TREATMENT PLANT 1 % Recycling and reuse ULTRA FILTRATION PLANT in gardening and process JaP/SAF-EPR 7 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 7 disposal such as copying and passing on to third parties.
  • National Award for “Excellence in Water Management – 2008 To become a benchmark plant in BOSCH - DS Recieved - WATER EFFICIENT UNIT AWARD at the National Award for Excellence in Water ROADMAP TO EXCELLENCE Management – 2007 conducted by CII Sohrabji Godrej Green Business Centre, Hyderabad . Treat and utilize external drain sewage 3 Rain water utilization for Process and Cooling 201 Technology up gradation for wastewater treatment Recycling of treated wastewater in Secondary purposes Irrigation 100% by treated waste water Modify cleaning process in canteen 8 Introduce Zeriscaping in the lawns 200 Awareness among employees/contractors - Continuous JaP/SAF-EPR 8 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 8 disposal such as copying and passing on to third parties.
  • National Award for “Excellence in Water Management – 2008 Sustainability tools Recieved - WATER EFFICIENT UNIT AWARD at the National Award for Excellence in Water Management – 2007 conducted by CII Sohrabji Godrej Green Business Centre, Hyderabad . Kaizen Suggestion Scheme Team Oriented Production POKA - YOKE Awareness campaigns Leanstatts Policy Deployment Strategic Themes and Targets JaP/SAF-EPR 9 Internal JaP/TEF | 06-10-07 | © Robert Bosch GmbH reserves all rightsregarding any disposal, exploitation, reproduction, editing, distribution, as well EHS | 27/11/2008 | © Bosch Limited 2008. All rights reserved, also even in the event of industrial property rights. We reserve all rights of 9 disposal such as copying and passingindustrial property rights. as in the event of applications for on to third parties.
  • National Award for “Excellence in Water Management – 2008 Monitoring and Reporting Recieved - WATER EFFICIENT UNIT AWARD at the National Award for Excellence in Water CONSUMPTION Management – 2007 conducted by CII Sohrabji Godrej Green Business Centre, Hyderabad . -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 10 EHS | 27/11/2008 | © Bosch Limited 2008. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well 10 as in the event of applications for industrial property rights.
  • National Award for “Excellence in Water Management – 2008 Utilization of Rain water in cooling towers Recieved - WATER EFFICIENT UNIT AWARD at the National Award for Excellence in Water WATER CONSERVATION PROJECTS Management – 2007 conducted by CII Sohrabji Godrej Green Business Centre, Hyderabad . 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. JaP/SAF-EPR 11 Internal JaP/TEF | 06-10-07 | © Robert Bosch GmbH reserves all rightsregarding any disposal, exploitation, reproduction, editing, distribution, as well EHS | 27/11/2008 | © Bosch Limited 2008. All rights reserved, also even in the event of industrial property rights. We reserve all rights of 11 disposal such as copying and passingindustrial property rights. as in the event of applications for on to third parties.
  • National Award for “Excellence in Water Management – 2008 Technology Up gradation in component cleaning process Recieved - WATER EFFICIENT UNIT AWARD at the National Award for Excellence in Water WATER CONSERVATION PROJECTS Previous Technology Management – 2007 conducted by CII Sohrabji Godrej Green Business Centre, Hyderabad . Open loop system Chamber Chamber Chamber 1 2 3 Tank-1 Tank-2 Tank-3 Wastewater to drain Pre project Insight Cleaning m/c Multi chamber, Multistage Upgraded Technology Closed loop system No Wastewater Chamber Generation 1 Condenser ‘NO’ effluent generated Heating chamber Tank-2 Tank-3 Post project Tank-1 Sludge DURR –Ecoclean Three cleaning Tanks Single chamber, Multistage JaP/SAF-EPR 12 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 12 disposal such as copying and passing on to third parties.
  • National Award for “Excellence in Water Management – 2008 Water recycling in resin treatment plant Recieved - WATER EFFICIENT UNIT AWARD at the National Award for Excellence in Water WATER CONSERVATION PROJECTS Management – 2007 conducted by CII Sohrabji Godrej Green Business Centre, Hyderabad . DM water Resin Aluminum Resin castings Treatment Waste water Heat Filtration / 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 JaP/SAF-EPR 13 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 13 disposal such as copying and passing on to third parties.
  • National Award for “Excellence in Water Management – 2008 Rain water Harvesting system Recieved - WATER EFFICIENT UNIT AWARD runoff and recharging Collection of surface/rooftop at the National Award for Excellence in Water WATER CONSERVATION PROJECTS Management – 2007 conducted by CII Sohrabji Godrej Green Business Centre, Hyderabad . Water collection system having total volume of 1,200 m3. A set of pumps with meters provided Harvested rain water charged back to recharge well in premises Pumps and collection system Recharging well JaP/SAF-EPR 14 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 14 disposal such as copying and passing on to third parties.
  • National Award for “Excellence in Water Management – 2008 Emulsion Oil replacement in Machining processes Recieved - WATER EFFICIENT UNIT AWARD at the National Award for Excellence in Water WATER CONSERVATION PROJECTS Management – 2007 conducted by CII Sohrabji Godrej Green Business in grinding/machining PROCESS: Water + Emulsion Oil (Coolant) used Centre, Hyderabad . Pre- modification Frequency of changing the coolant - Monthly Post modification Frequency of changing the coolant – Once in 6 months Features: Reduction in water consumption Less hazardous waste generation Energy saving in Ultra Filtration of wastewater Investment = Nil Saving = 348 m3 liters /annum fresh water Payback period = Immediate JaP/SAF-EPR 15 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 15 disposal such as copying and passing on to third parties.
  • National Award for “Excellence in Water Management – 2008 Modification In cleaning process before heat treatment Recieved - WATER EFFICIENT UNIT AWARD at the National Award for Excellence in Water WATER CONSERVATION PROJECTS PROCESS: Water + chemical used to remove oil from components Management – 2007 conducted by CII Sohrabji Godrej Green Business Centre, Hyderabad . Pre- modification Components Cleaning Holding Tank machine Waste Water Post - modification Oil Oil Skimmer Components Cleaning Holding Tank machine Waste Water Investment = INR 39,000 Saving = 96 m3 liters /annum fresh water Payback period = 2.8 years JaP/SAF-EPR 16 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 16 disposal such as copying and passing on to third parties.
  • National Award for “Excellence in Water Management – 2008 PLC controlled Irrigation system ( Sprinkler & Drip) : Recieved - WATER EFFICIENT UNIT AWARD at the National Award for Excellence in Water WATER CONSERVATION PROJECTS Management – 2007 conducted by CII Sohrabji Godrej Green Business Centre, Hyderabad . Irrigation automatically through -PLC controlled -pop-up sprays sprinklers -Drippers. Waste water after treatment is used for landscape irrigation Investment = Rs.11 lakhs Benefits: -Less water consumption in irrigation. - Evaporation losses minimized as programmed to work in late night hrs. JaP/SAF-EPR 17 Internal JaP/TEF | 06-10-07 | © Robert Bosch GmbH reserves all rightsregarding any disposal, exploitation, reproduction, editing, distribution, as well EHS | 27/11/2008 | © Bosch Limited 2008. All rights reserved, also even in the event of industrial property rights. We reserve all rights of 17 disposal such as copying and passingindustrial property rights. as in the event of applications for on to third parties.
  • National Award for “Excellence in Water Management – 2008 RO cascading with DM combination Recieved - WATER EFFICIENT UNIT AWARD at the National Award for Excellence in Water Pre- modification WATER CONSERVATION PROJECTS Management – 2007 conducted by CII Sohrabji Godrej Green Business Centre, Hyderabad . R.O. Raw Water Permeate To DM Inlet Plant process Reject 45 % Post - modification R.O. Raw Water Permeate Inlet To DM Plant process Reject as inlet Reject 11% Investment = negligible (system was available) Saving = 3,200,000 liters /annum Payback = immediate Post project 18 EHS | 27/11/2008 | © Bosch Limited 2008. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well 18 as in the event of applications for industrial property rights.
  • National Award for “Excellence in Water Management – 2008 WATER CONSERVATION PROJECTS -3 Other projects and Milestones ENVIRONMENT CONSERVATION PROJECTS Recieved - WATER EFFICIENT UNIT AWARD at the National Award for Excellence in Water Management – 2007 conducted by CII Sohrabji Godrej Green Business Centre, Hyderabad . -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) JaP/SAF-EPR 19 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 19 disposal such as copying and passing on to third parties.