MRM pg 16-20.pdf - Mabati Rolling Mills

Commisioning misioning of Pickling plant at Mariakani
MABATINEWS
In the true spirit of Kaizen principles of continuous improvement,
MRM invested over US$9 million last year to create a new
pickling line that was commissioned on October 3, 2006 this
year by the Minister for Finance Hon. Amos Kimunya. In his key
note address Hon. Kimunya, acknowledged the huge investment
the shareholders had made into the state-of-the-art technology.
He recognised that the results of the new line will shift the level of
manufacturing to a completely new level of competitiveness. He
noted and appreciated the advantages of the new line. MRM will
now widen its raw material sources, particularly in the hot rolled
coils. It was hitherto confined to a few selected suppliers. He also
noted that the investment will give the company the advantage of
flexibility, innovation and creativity in a very competitive market.
He acknowledged that such an investment demonstrated
the confidence MRM shareholders had in doing business in
Kenya. Hon Kimunya noted with appreciation that the plant took
into consideration environmental concerns and made further
investment in Acid Regeneration Plant which allows the acid to be
completely recycled. The facility has a capacity to handle and treat
coils up to 200,000 tonnes per year.
The minister observed that MRM’s overall business operations
make a significant contribution to the country’s economic growth
and development. He said that the government is committed to
creating a conducive and enabling environment where businesses
will find it easier and more friendly to do business.
Since private sector plays and important role in the country’s
economic development the government is committed to support
private sector investment initiatives. Appropriate legislation and
streamlining of administrative bottlenecks will continue to be
introduced at various levels of operations of government to make
it easier for businesses to operate.
The Minister pointed out how Kenya has gained high rating
by where it was rated 4th in the Sub-Saharan Africa behind
Botswana, South Africa and Nigeria. The World Bank has rated
Kenya 6th in Africa in respect of doing business. Obviously there
is going to be increased government effort to consolidate what
is good and improve on areas that can facilitate private sector
investment in the country.
The government is also investing in ICT and communications
connectivity to make it easier for businesses to share vital
information necessary for growth and global trade. The Minister
spoke about refunds and said the government has scaled up from
KSh614million to KSh900million. He also said there is a provision of
KSh1.5billion for KRA to clear the backlog.
The Minister praised the MRM management and welcomed
the opportunity to officially visit the plant and commission the
Pickling Line. The inauguration ceremony was attended by among
others: the Board Directors,
Managers, Workers,
Customers, Well wishes and
community leaders.
After
the inauguration ceremony
Hon. Kimunya visited and
toured the nearby Kaluworks
Plant which is also owned
by the same shareholders
of MRM.
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Continued on page 18>>

awards
MABATINEWS
OVERALL CORPORATE CP AWARD:
awarded to the organization with
outstanding cleaner production
management initiatives
CP LEADERSHIP AWARD:
given to the company that demonstrates
its openness and communication
regarding cleaner production and other
environmental matters to workers and
the surrounding community
SOLID WASTE REDUCTION AWARD:
given to the company that has achieved
significant solid waste reduction in
the implementation of its cleaner
production initiatives
REDUCTION IN GASEOUS EMISSIONS:
given to the company that has achieved
significant reduction in gaseous
emissions through implementation of
cleaner production initiatives
WASTEWATER REDUCTION AWARD:
given to the company that has achieved
significant wastewater reduction in
the implementation of its cleaner
production initiatives
CP INNOVATION AWARD:
given to the company that promotes voluntary
complementary initiatives like designing products
for environment, EMS, green supply management
and other innovative eco-efficiency principles.
KRA 2006 DISTINGUISHED
TAXPAYER AWARD
OCCUPATIONAL HEALTH AND
SAFETY AWARD:
given to the organization with most
significant reduction in occupational
health and safety risks and hazards
M A B A T I N E W S 17

Cleaner Production Initiatives at
Mabati Rolling Mills Ltd
By Francis Muthama
Cleaner production is a preventive
environmental management strategy
that focuses on products, processes
and services. Cleaner Production aims to
reduce waste generation at source leading to
economic savings as well as protection of the
environment. Its techniques of application can
be broadly classified as waste minimization at
source, on-site recovery and reuse, recycling,
good house keeping, energy efficiency, risk
management, equipment modification,
input substitution, better process control,
technology change, product modification and
responsible corporate management.
Cleaner Production describes a preventive
approach to environmental management.
It is called a “win–win” strategy, because it
protects the environment, the consumer
and the workers while at the same time
improving industrial efficiency, profitability
and competitiveness. It focuses on processes,
productivity and services.
Reduce the consumption of raw materials
and energy
Eliminate as far as possible the use of toxic
and dangerous materials
Reduce at source the quantity and toxicity
of all emissions and waste generated and
released
Principles of Cleaner Production
Prevention: Preventing as much as possible
the generation of waste at source
Source reduction: Waste is reduced at
every process stage or service step
Raw material optimization: Conserving
raw materials and switching to renewable
resources
Substituting toxic inputs with less toxic
ones
To recover, recycle and re-use of byproducts
and waste
Reducing environmental, health and safety
impacts
MRM production processes aim for:
1. Waste Management and control Systems
Energy Conservation: An energy audit is
performed identifying areas where there
are high power consumption and giving
solutions on minimizing losses.
Key performance Indicators: the company
has formulated objectives and targets
for minimizing waste, reducing resources
depletion.
Methodology or a procedure for identifying
areas of inefficient use of resources and
poor management of waste: This is done
through internal audits, Systems audits and
Monitoring of consumables.
Material Balance: this helps to explain
unaccounted raw materials that end up as
waste and the yield.
Housekeeping: Implementation of Kaizen
Tools such as 5K’s help control wastes and
keeps the plant neat and tidy
2. Process Performance, Monitoring and
control
Equipment performance: measured and
monitored via the overall equipment
efficiency analysis which takes into account
the performance factor, availability & quality
factors.
Machine down time: Logged and analyzed
with reasons.
Rejections and Rework: Minimal rejections
and rework is generated.
Process Monitoring: Automation &
computerization of the Plants, Calibration of
measuring equipment / instruments, planned
maintenance and in-house Laboratory
analysis.
3. Systems to improve services
Maintenance: Autonomous Maintenance, And
Periodic maintenance schedule is followed.
Cross Functional Teams: These are groups
working as a team on any areas of improvement
i.e. different experts from different departments
coming together to brainstorm on a common
problems in TQM projects, Gemba – Kaizen
projects / interventions ISO 14001 continual
improvement programs.
Computerized systems of data acquisition,
storage and reporting: These include
Production Management System (PMS) and
Coil tracking software (Access)
4. Fire, Health and Safety
Fire
A general fire fighting procedure is
available throughout the factory. However
at departmental levels, detailed fire control
procedures specific to the particular type of
fire are available.
Health
There is periodic medical examination incase
of workplace sickness. Occupational Health
and Safety procedure is followed.
Safety
Workers are provided with personal protective
equipment which are relevant to their areas of
operation.
Issuance and compliance of use of Personal
Protective Equipment is at 100%.
First aiders have been trained and
allocated to cover 24 hours plant operation.
Well stocked first aid kits have been placed at
strategic areas in the plant
5. Environmental Practices
1. Environmental Impact Assessments before
commencing any new project
2. Corporate Reporting
IFC reports and NEMA environmental
assessments (self audits)
3. Measuring and Monitoring
4. Continual Improvement Programmes
These are done as Gemba Kaizen
Interventions and Continual Improvements
under ISO 14001
6. Innovation
Recover, recycle and re-use wastes
Product water from the reverse osmosis
plant is used as boiler feed water. This
water is recovered as condensate and
used as Rinse water and Scrubber water at
the Pickling Line. This water is collected as
rinse water for use in the Acid Regeneration
process to Produce Regenerated Acid.
Reject water from the reverse osmosis
plant is collected and used in toilets and
cooling water for mechanical seals of
pumps at Pickling and Acid Regeneration
Plants. This cooling water is collected
treated at the Pickling line ETP and used
as water for flushing in Toilets.
Recovered water from the Sewerage
treatment plant is recycled for use in toilets
within the factory and at the technical
school.
Treated Water from the CRM effluent
treatment plant is used for Agriculture
within the plant.
Rain water is Harvested and stored in
ponds. This water is utilized as process
water.
Hydrochloric acid is recovered from used
waste acid form the pickling line through
the process of regeneration and re-used in
the Pickling Process.
Waste Minimization at Source
This done through continual improvement
programmes , raw material substitution and
use of better technologies.
Awards won
Occupational Health and Safety Award
CP Innovation Award
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