Excellence in Water Management · 12/9/2008 2:40:06 PM cc_20082 Heary PPT-2498 JC CEHS-2.01...
Transcript of Excellence in Water Management · 12/9/2008 2:40:06 PM cc_20082 Heary PPT-2498 JC CEHS-2.01...
12/9/2008 2:40:06 PM cc_20082 Heary PPT-2498 JC CEHS-2.01
Excellence in Water Management@
GlaxoSmithKline Consumer Healthcare LtdRajahmundry
EHS V isio n
To achieve
Compet it ive Business
advant age t hrough
Lead ership
and Exc ellenc e
in EHS
Rajahmundry
GSKCH, IndiaØ Indian br anch of Glax oSmithKline plc U.K.Ø Manufactur ing sites at Nabha, Rajahmundr y and Sonepat
About RajahmundryØ Commer cial pr oduction star ted in 1973Ø Capacity Installed – 24 KT Ø Pr oduct Portfolio: Hor licks, Choco late Hor licks, Boost ChocoblastØ Employees ~ 1500 (Incl. contr actor employees)
www.gsk.com
Site Profile
12/9/2008 2:40:06 PM cc_20082 Heary PPT-2498 JC CEHS-2.02
Mfg Process & Water IPO
HORLICKS - Manufacturing process flow diagram
Mash sep aration
Mash ing
W ort hol ding
Milk h oldin g
Weak Wort
Malt Ext ract
Sa lts & Min e rals
Evaporat ion- 1st st age
Food Transfer for sp read ing on trays
Oven dryi ng
W heat Flour
Malted Barely
CCP - 2
CCP - 1
Wh ea t Glu te n
Hu sk w ashi ng Milk recep tion
Milk Pasteurizat ion
Milk sta ndard iza tion
IS P
SMP
FCS
Dry Vit amin ( B- Comp lex & C)
PART - B
Trays s crap ping
Grind ing
Mixing
Packing i n Drums
O ily Vit amin (A,D ,E,K )
Ir on contaminat ion
Evaporat ion 2 n d s tag e
Steam
Chill water
Raw water
Filtered water
Condensate
Condenser
Waste water
Hot water
Water Out flow
Condensate
Hot water
Condenser water
Waste Water• Util it ies• Other Fu nctio ns• Manufactur ing
Reuse , Recycl e
Reuse
Reuse , Recycl e
Recycl e
3 R (Zero Discharge) - 100% Compliance
Gr o u n d W a t er fr o m Bo r e we ll s
Do m e s ti c P r o d u c ti o n Co o li n g &
B o i l e r fe e d
R e c h a rg e o f wa t e r t o
g r o u n d
Ra i n w a te r
h a rv e s t in g p it
Us e d i n c a n t e e n f o r f o o d p r e p a ra t io n
W a te r r e u s e d f o r g a rd e n i n g
T re a t ed W a t er st o r ed
in la g o o n
E f f lu e n t
Tr e a tm e n t P la n t
Me t h a n e
Ga s
F is h c u lt u re
R e so ur ce su b st i tu t i on ( R e p la c in g LP G )
R e u se
R e so ur ce co n ser va t i on
B i o - di v er si ty
Recharging of ground water
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Resource Conservation Strategy
Top Down Bottom up
EHS Plan for
Excellence
GMS – India Strategy
EHS program & procedures at site
Functional & Indiv idual objectives
Idea Cam ps, Suggestion boxes/JDIs
Kaizens & Projects
Baselining & Benchmarking
Innovatio n & Collaboratio n
Corporate program s
Employee Engagement
Training & Education
Visual displays/Controls
Idea Camps
Competitions – Posters/Slogans
Suggestion Boxes
Just Do Its
Rewards & Recognition/ Spirit AwardsAware ness ca mpai gn
Rewar d to Employe e
Site Director observ ing the entries i n Slogan Compe titi on
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Brainstormi ng session on water c ons erv ation
Soluti on ide nti ficati on for the opportuni ties
Water Kaizen
Process follow ed
Key Result Areas
Benefits
• Basel ining t he Current performance. • Studied consumption pattern for la st 1 y ear• Identified cros s functional team • Conducted Kaizen event on 21st Sep’06
• End hose control systems put in use• Replacing ra w water points wit h treated ones• Providing push type cocks in toilets • Leak/ spil l contro l clamps • Rational ization of wash po ints (63 to 48)– need based
• 48 UDE’s Identified• Implement ed all Quick win so lutions in
3 months• Water consumption is reduced by 30%
per TOP
Community Involvement
Imbibed EHS concepts in 1550young “ Ignited
Minds”
Slide from ‘Connecti ng LittleHearts’ on wate r conservation
Students witnessing a demonstration during the session
Site Director administering oath to Conserve Natu ral Resources
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Monitoring & Review system
Month YTDKPI UOM
2007 actual s
2009 Target
2008 Target
2008 actual s2006 actua ls
Traff ic Light
2010 Target
Month YTD2008 FCSite 2007 Target Q3 2008 Plan
2008
Format for monitoring Specific water consumption
Format for monitoring Absolute water
consumption
Repor ting Water
Consumption
List of Water Conservation Projects
End of hose control
660
365
75
-
5
12
3
-
-
5
1
InvestmentRs. in ‘000
20
55
30
5
20
2
3
100
130
5
5
Water Savings (m3/day)
9782
26900
14673
4891
9782
978
1467
105668
60262
4891
4891
Annual Saving (Rs.)
Floor cleaning ma chine
Tray cleaning mach ine
Improving con densate reco very
Use of nozzles for drum washing
Modification of flushing at Amen ity blocks
Auto flush for toilets at Admin blo ck
Treated Water for flushing of toilet
Optimization of water pressure
Use of Cooling Tower water for va cuum pump sealing
Introduction of self closing taps
Project/JDI
Floor cleaning ma chine
Treated water for coal wetting
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Initiatives : Floor Cleaning machine (2006)
Wastage of water arising fr om conventional floor cleaning is eliminated thr ough use of Floor Cleaning machine
Investment : 6.6 Lakhs
Water savings per annum : 7300 m3
Before
Mechanized Cleaning using Floor Cleaning machine
After
Initiatives : Mechanization of Tray cleaning (2007)
Manual cleaning of food tr ays was r eplaced w ith mechanized cleaning
Investment : Rs. 3.65 Lakhs
Water savings per annum : 20000 m3
Before
After
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Initiatives : Optimization of Water pressure
1.5 Kg / cm2
0.9 Kg / cm2
• Reduction of Water pr essur e : 1.5 to 0.9 Kgs/Sq cm• Use of Var iable Fr equency Drive
Investment : Nil
Water savings per annum : 36500 m3
Initiatives : Improving Condensate Recovery
Impr ovement of Condensate r ecover y : 61.7 to 75 %
Resu lt : Reduction in DM water consumption by 28.7 Cu. M / Day
Investment : Rs. 0.75 Lakhs
Befor e implementation : 84.3 m3/day
After implementation : 55 m3/day
Water savings per annum : 10700 m3
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Initiatives : Cooling Water for seal cooling of Vacuum pumps
Cooling Tower water was reused for seal cooling of Vacuum pum ps in place of Fresh water
Investment : Insignif icant
Before im plementation : 130m3/day
After im plem entation : Nil (As C ooling Tower water is reused)
Water sav ings per annum : 47450 m3
Fresh water l ine disconnec ted and c onnecte d with Cooli ng water
Initiatives : Auto flush for toilet
Every drop counts …
Small change …
Sustained improvement
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Initiatives : Sprinkler & Drip Irrigation
Sprinkler i n use Drip irriga tion on-si te
Performance delivered
Speci fi c Water consumption
38% reductionIn 3 yrs span
21.117.3 15.5
13
0
5
10
15
20
25
KL
per T
on
2004 2005 2006 2007
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Performance delivered
Per capit a Water consumption
45% reductionIn 3 yrs span277
255
172 152
0
50
100
150
200
250
300
Lit.
per D
ay
2004 2005 2006 2007
Waste Water Treatment - Process
KITCHEN
Fat Trap
(25 KL)
Eq. Tank
(200 KL)
UASBR
(287 KL)
Aerati on Tank - I
(510 KL)
Clarifier
(271 KL)
Treated Water to Green Bel t
Bio-gas Dome (50 Cu.M)
ProcessAerati on Tank – II (1013 KL)
Canteen / Domestic
Not in use
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Waste Water Treatment - Facility
Equalisation Tank UASBR (Anerobic Dig estion) Bio-gas Collecti on Dome
Treated Water S torage Pon d Clarifier Aerati on Tank (A erobic Sys tem)
Supply to Canteen
Green Bel t
Bio-gas Collection
Rain Water Harvesting
Objective :
GSKCH, Ra jahmundr y uses bor e well water for its oper ation. In or der to avoid adverse effect of the oper ations on the water table, implemented Rain water har vesting.
Rain Water Collection Rain Water Harvest ing
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Waste Water Generation
22% reductionIn 3 yrs span9.4
8.17.7 7.5
456789
10
KL
per T
on
2004 2005 2006 2007
Laurels
National Energy Conservation
Award 2005
Director of Factories Award’ 05
for “OHSAS 18001”
CEO’s Award 2005 - Vanguard Award presented by JIM in Aug’ 06
CEO’s Award 2005 – First Place
honor for U SE Methane- Aug’ 06
APPC B Award 2004
CEO’s Award 2007 – Special commendation Awards
FAPCCI Award -2008
Internal
External
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Way forward…
Installation of s ub me ters at ide ntifie d areas
Conducting Water balance regularly
Year on year stretche d targets
Innov ativ e suggestions / ideas from employees
20 %Reduction
by 2010
20 %Reduction
by 2010