Kirloskar Brothers Limited, Kirloskarvadi Plant

This is a proprietary document of Kirloskar Brothers Ltd. 111/25/2008

Presentation by ,

KIRLOSKAR BROTHERS LIMITED Kirloskarvadi Plant

National Award for “ Excellence in Water Management 2008 “

( Confederation of Indian Industry)


Water is Life , We give life to water

VALUES• Developing and working with mutual trust.? Building and nurturing teamwork.? Assessing and enhancing employee satisfaction level.? Giving the best to customer and giving value for the money.? Enhancing relation with stakeholders.? Maintaining fairness in dealing with customers and suppliers.

MISSION Kirloskar Brothers Limited shall be known globally as a reliable, innovative and cost effective solution provider in hydraulic machines & systems and in water business.

VISION Kirloskar Brothers Limited shall be amongst the first five pump companies in the world by the year 2015 and become the preferred choice of customers as well as employees.


Products – Pumps for Various Applications

Pumps range from 1/10 kW to 12,000 kW

Monobloc Domestic PumpsCapacity up to 0.28 m3/hr.

A man standing at the discharge pipe of a Concrete Volute Pump, KBL’s biggest pump (126000 m3/hr ), holding KBL’s smallest pump (0.28 m3/hr.)


Manufacturing Plants

Overseas Customers Overseas Offices

Global Presence Over 70 Countries Worldwide

SPP - Pumps England

Shirwal

Kondhapuri

Dewas

Kirloskarvadi


Integrated Plant(Processes )

? Research and Engineering

? System Engineering

? Procurement

? Manufacturing – Pattern Shop, Foundries , Machining

? Testing - Asia’s biggest Pump Testing Lab

? Quality Assurance

? Project management

? Erection and Commissioning

? Operation and Maintenance

? After Sales & Product Support


Need for Water Saving

Scarcity Global Warming

• Impact of water cost on Product cost

• Stiff competition in Market


Water consumption

65%9%

13%

13%

Process Drinking/domesticColony resident Gardening

Water Consumption Distribution


Water Saving - Approach

New Idea Generation from Employees

Auditor / Assessor Feedback / suggestion

Auditor / Assessor Feedback / suggestion

Last Year Analysis -Opportunities

Last Year Analysis -Opportunities

Search for New Technology Source, Benchmarking with National and International processes

Search for New Technology Source, Benchmarking with National and International processes

Conceptualization of Projects

Conceptualization of Projects

Detail Study, trial , approval , Plan & Executation , closing & Measure & Monitor Savings

Detail Study, trial , approval , Plan & Executation , closing & Measure & Monitor SavingsCapturing

Learning , Correction , Review

Capturing Learning , Correction , Review


Water Saving - Team

Manufacturing Head

Process Water Cell

1.Foundry2.Hydro testing3.Pump testing4.Coolant

Drinking Water cell

1.Shop floor2.Office

Hand wash & bathing cell

1.Shop floor2.Foundry

Champion

Colony1.Drinking2.Gardening


Certification

• ISO 9001 :2000

• ISO 14001:2004

• ISO 18001 :2007 ( Audit Completed , Certificate awaited )


Water Saving - Awareness

Daily Sun Rise Meeting Colony Meeting Contractor Training


Water Saving – Monitoring & Reporting

• Daily reading of incoming water meter

• Daily reading of water consumption for Factory

• Daily reading of water consumption for Colony

• Monthly reading of process water – 18 Meters

Monthly Review of Water consumption and Water Saving Projects


Water Saving Projects


1.Sensors for Hand Wash & Urinals

REPLACED – 20 NOS


2. Close Loop Hydro Testing

SAVINGS – 6 Lac Litres /Month


3.Drip for Garden

800 Sq. M


4.Sprinklers for Lawn

Area – 27000 Sq.M


5. Push type tap

Total tap- 200


6.Float Valves for old Overhead tank

Adopted – 225 Nos


Saving 4 Lac Litre / Year

7.Use of percolated rain water for process


Saving 10,000 Litre / Year

8.Use of A.C. condensed water


Saving - 18 Lac Litre / Year

9. Replacement of water cooled compressor by air cooled


Waste Water Treatment

2007-08Zero

Waste Water Discharge


Waste Water

Waste water Discharge Cum / Pump (used for Gardening)

2.72

4.46

3.03 2.80

012345

04-05' 05-06' 06-07' 07-08'


Per Capita Consumption

Colony per capita ( Litres/Day)

160 140 155115

90135

55

050

100150200

04-05' 05-06' 06-07' 07-08' 08-09'Target

National Global


Per Capita Consumption

Industry per capita ( Litres/day)

3832

24 23 20

45

0102030405060

04-05' 05-06' 06-07' 07-08' 08-09'Target

National


Specific Water Consumption

Process Water per Pump ( Litres)

8100 71005600 4710

3000

02000400060008000

10000

04-05' 05-06' 06-07' 07-08' 08-09'Target


Environment

More than 3000 Trees


Water Saving Project 08-09

• 100% Rain water harvesting

• Replacement of old pipeline by new APVC piping

• Adoption of close loop tanks for pump testing

• Cooling tower for Cupola wet scrubber water

• Separate Piping for Factory gardening & toilet flushing

Kirloskar Brothers Limited, Kirloskarvadi Plant

Education

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