National Award for Excellence in Water Management 2008

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1 Established : 1999 BOSCH - JAIPUR anagement Land Area 2007 conducted : 202,350 by CII Sohrabji m 2 Godrej Green Business Centre, Hyderabad. COMPANY PROFILE Built Area : 30,834 m 2 Employees : 1,383 Turnover : 9,000 MINR Product :Fuel injection pumps CERTIFICATIONS ISO 14001:2004 TS 16949:2002 OHSAS (Under implementation) 1 1

2 MANUFACTURING PROCESS ecieved Grinding, - WATER cleaning EFFICIENT etc UNIT AWARD at the National Award for Excellence in Water 2 Soft Stage * * * Heat treatment Production facility 2 Surface treatment Hard stage Milling, boring etc Assembly Calibration Post Calibration VE- Pump *

3 ENVIRONMENTAL PRESERVATION RESOURCE CONSERVATION Sustainable Approach ENVIRONMENT PROTECTION Reduce Fresh Water consumption within i.e adopting 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 Eliminating hazardous chemicals and waste Reducing carbon foot print Tree plantation in the society Society involvement through PPP 3 JaP/SAF-EPR 3

4 SPECIFIC WATER CONSUMPTION % reduction in specific water consumption since year Specific Water consumption in Liters 4 JaP/SAF-EPR 4 4

5 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 5 EHS 27/11/2008 Bosch Limited All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. 5

6 m3/mioeur ecieved - WATER EFFICIENT UNIT AWARD at the National Award for Excellence 2580 in Water BENCHMARKING Bosch 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 NaP BanP NhP JaP BOSCH Bari ( Italy) manufacturing unit is taken as Benchmark ( Target 2013) (Ytd) BM Water consumption in m 3 /MioEUR 6 EHS 27/11/2008 Bosch Limited All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. 6

7 WASTE WATER TREATMENT & DISCHARGE ZERO DISCHARGE UNIT SINCE INCEPTION ecieved - WATER EFFLUENT EFFICIENT TREATMENT UNIT AWARD PLANT at the National Award for Excellence in Water Process Effluent Domestic sewage SEWAGE TREATMENT PLANT ULTRA FILTRATION PLANT 1 % Recycling and reuse in gardening and process 7 JaP/SAF-EPR 7

8 ROADMAP TO EXCELLENCE 8 To become a benchmark plant in BOSCH - DS Treat and utilize external drain sewage Rain water utilization for Process and Cooling Technology up gradation for wastewater treatment Recycling of treated wastewater in Secondary purposes Irrigation 100% by treated waste water Modify cleaning process in canteen Introduce Zeriscaping in the lawns Awareness among employees/contractors - Continuous JaP/SAF-EPR

9 Sustainability tools Kaizen Suggestion Scheme Team Oriented Production POKA - YOKE Awareness campaigns Leanstatts Policy Deployment Strategic Themes and Targets JaP/SAF-EPR 9 Internal EHS JaP/TEF 27/11/ Bosch Robert Limited Bosch GmbH All rights reserves reserved, all rights also regarding even the any event disposal, of industrial exploitation, property reproduction, rights. We editing, reserve distribution, all rights of as well 9 disposal as in such the event as copying of applications and passing for industrial on to third property parties. rights.

10 Monitoring and Reporting CONSUMPTION -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 All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. 10

11 WATER CONSERVATION PROJECTS Utilization 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. 11 JaP/SAF-EPR 11 Internal EHS JaP/TEF 27/11/ Bosch Robert Limited Bosch GmbH All rights reserves reserved, all rights also regarding even the any event disposal, of industrial exploitation, property reproduction, rights. We editing, reserve distribution, all rights of as well disposal as in such the event as copying of applications and passing for industrial on to third property parties. rights.

12 Technology Up gradation in component cleaning process Previous Technology anagement 2007 conducted by CII Sohrabji Open loop Godrej system Green Business Centre, Hyderabad. WATER CONSERVATION PROJECTS Upgraded Technology Closed loop system Tank-1 Chamber 1 Chamber 2 Chamber 1 Chamber 3 Tank-1 Tank-2 Tank-3 Tank-2 Tank-3 Condenser Three cleaning Tanks Wastewater to drain Heating chamber NO effluent generated Sludge Pre project Insight Cleaning m/c Multi chamber, Multistage No Wastewater Generation Post project DURR Ecoclean Single chamber, Multistage 12 JaP/SAF-EPR 12

13 Water recycling in resin treatment plant DM water Resin WATER CONSERVATION PROJECTS Aluminum castings Heat Resin Treatment Filtration / treatment Waste water 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 13 JaP/SAF-EPR 13

14 WATER CONSERVATION PROJECTS 14 Rain water Harvesting system Collection of surface/rooftop runoff and recharging Water collection system having total volume of 1,200 m 3. A set of pumps with meters provided Harvested rain water charged back to recharge well in premises Pumps and collection system JaP/SAF-EPR 14 Recharging well

15 Emulsion Oil replacement in Machining processes WATER CONSERVATION PROJECTS PROCESS: Water + Emulsion Oil (Coolant) used in grinding/machining 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 Saving Payback period = Immediate = Nil = 348 m 3 liters /annum fresh water 15 JaP/SAF-EPR 15

16 Modification In cleaning process before heat treatment WATER CONSERVATION PROJECTS PROCESS: Water + chemical used to remove oil from components Pre- modification Components Cleaning machine Post - modification Oil Skimmer Components Cleaning machine Holding Tank Oil Holding Tank Waste Water Waste Water Investment = INR 39,000 Saving = 96 m 3 liters /annum fresh water Payback period = 2.8 years 16 JaP/SAF-EPR 16

17 PLC controlled Irrigation system ( Sprinkler & Drip) : WATER CONSERVATION PROJECTS Irrigation automatically through -PLC controlled -pop-up sprays sprinklers -Drippers. Waste water after treatment is used for landscape irrigation Investment Benefits: = Rs.11 lakhs -Less water consumption in irrigation. - Evaporation losses minimized as programmed to work in late night hrs. 17 JaP/SAF-EPR 17 Internal EHS JaP/TEF 27/11/ Bosch Robert Limited Bosch GmbH All rights reserves reserved, all rights also regarding even the any event disposal, of industrial exploitation, property reproduction, rights. We editing, reserve distribution, all rights of as well disposal as in such the event as copying of applications and passing for industrial on to third property parties. rights.

18 RO cascading with DM combination WATER CONSERVATION PROJECTS Pre- modification anagement 2007 conducted R.O. by CII Sohrabji Godrej Green Business Centre, Hyderabad. Raw Water Permeate DM To Inlet Plant process Post - modification Raw Water Inlet R.O. Reject 45 % Permeate DM Plant Reject as inlet Reject 11% To process Investment = negligible (system was available) Saving Payback = immediate = 3,200,000 liters /annum Post project 18 EHS 27/11/2008 Bosch Limited All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. 18

19 WATER CONSERVATION PROJECTS -3 ENVIRONMENT CONSERVATION PROJECTS Other projects and Milestones -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) 19 JaP/SAF-EPR 19