Bosch, Jaipur

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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 .

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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

2


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



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



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


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

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


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





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


1 %Recycling and reusein gardening and process

77



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


Treat and utilize external drain sewage

88



JaP/SAF-EPR 99

Sustainability tools

Kaizen

POKA - YOKE

Suggestion Scheme

Team Oriented Production


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.

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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




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




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



JaP/SAF-EPR 1313


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



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



JaP/SAF-EPR 1515


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



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




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.


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.


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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




JaP/SAF-EPR 1919


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

Education

Bosch, Jaipur