MRM pg 16-20.pdf - Mabati Rolling Mills

More documents

Recommendations

Info

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 18 M A B A T I N E W S
Page 1: Commisioning misioning of Pickling
Page 5: 20 M A B A T I N E W S

MRM pg 16-20.pdf - Mabati Rolling Mills

Create successful ePaper yourself

Delete template?

Save as template?