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Bombay Chapter of Commerce
Sustainability Case Study
MET Institute of Management ,Mumbai
Team: Blaze
Shruti Railkar [email protected] +91 9969004297
Kunal Thakur [email protected] +91 8879118457
First time Bottom Ash used in Bricksby
QC Team TATA Power
Philanthropy without scale and sustainability is like any other bad business that will simply wither and die on the vine.-Naveen Jain
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Our Approach
Company Analysis
PDCA Cycle
Benefits
Future Plans
3
Company Analysis
PDCA Cycle
Benefits
Future Plans
4
Company Analysis
PDCA Cycle
Benefits
Future Plans
5
Company Analysis
PDCA Cycle
Benefits
Future Plans
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VISION
• To be the most admired and responsible Integrated Power Company with international footprint, delivering sustainable value to all stakeholder.
MISSION
• We will become the most admired and responsible Power Company delivering sustainable value by:• Operating our assets at benchmark levels• Executing projects safely, with predictable benchmark quality, cost and time• Growing the Tata Power businesses, be it across the value chain or across geographies, and also in allied or new businesses• Driving Organizational Transformation that will make us have the conviction and capabilities to deliver on our strategic intent• Achieving our sustainability intent of ‘Leadership with Care’, by having leading and best practices on Care for the Environment, Care for the Community,
Care for the Customers and Shareholders, and Care for the People
Company PDCA Cycle Benefits Future Plan
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TOTAL GENERATION CAPACITY 6999MW
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Company PDCA Cycle Benefits Future Plans
QUALITY CIRCLE TEAM
QC TEAM
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Company PDCA Cycle Benefits Future Plans
PROBLEM SOLVING CONTENTS
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STEP 1: Identification of problemBRAINSTORMING
TOTAL NO OF PROBLEMS
IDENTIFIED=60*
*List of problems provided in appendix
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STEP 2: Selection of Problem
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Selection Of Problem
The problems were categorized in A,B,C categories (A,B,C analysis)
A category-Which can be solved by QC circle
B category-Which can be solved by other department
C category-problems which require management approvalA
68%
B17%
C15%
Percentage
Category A = 41Category B = 10Category C = 9
Company PDCA Cycle Benefits Future plans
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Selection Of Problem QC TEAM DECIDED -CATEGORY A STRATIFICATION
A CATEGORY
Environment : 4
Safety/Health :
13
Cost:6
Moral:6
Quality :12
Selection Of theme
Sustainability/environment was selected since plant is located in heart of Mumbai city which is densely populated
Directly linked to MISSION statement
• Slide 2 of 59
Environment
Company PDCA Cycle Watch Industry Cost analysis
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STEP 3: DEFINING THE PROBLEM
Company PDCA Cycle Benefits Future plans
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Defining The Problem
Reason• In Trombay Thermal Power Station, Coal is used as major
fuel for Power generation .• Ash is a byproduct
Type• Fly Ash-which is total burnt coal and which resale to
Cement construction company • Bottom Ash –No resale value. Therefore we have to
dispose it off.
% Content • The total % of Ash is divided in to two parts i.e. around 80% Fly Ash & 20% Bottom Ash
Requirement • Coal requirement for Trombay is around 9000 MT per day.
Company PDCA Cycle Watch Industry Marketing strategy Cost analysis
Company PDCA Cycle Benefits Future Plans
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Defining The Problem Ash • They are using good quality Imported Indonesian
coal, it contains around 1-2% of ash content.
Content • Bottom Ash Generated: 7500 MT/yr. (625 MT/month)• Fly Ash generates: 37500 MT/year.
Future • After conversion of U#6 from Oil to coal, Bottom ash generation may increase by 5000 MT/year
Company PDCA Cycle Benefits Future plans
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Defining The Problem
Company PDCA Cycle Watch Industry Marketing strategy Cost analysis
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Defining The Problem
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Environment pollution
Huge amount disposable bottom ash 625 T/month(65trucks)
Disposable at the distance of 30KM
People have to work at night since transportation is at night.
Expenses Incurred on transportation 3,00,000/- month
Lack of space for storage Bottom ash.
Affect Green Manufacturing Index(GMI)4
IMPACT OF PROBLEM (Bottom Ash)
Defining The Problem
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Company PDCA Cycle Benefits Future plans
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Impact of problem (Bottom ash)-StorageAs per Central Electricity Authority of India ‟Per Megawatt(MW) area calculation required for imported coal is:0.47Acre/MW
But our plant is running/installed at the ratio of :0.27Acre/MW (Situated in Mumbai (Metro city)
Already they are running their plant with lesser area.
Cleanness/healthiness or up keeping of the plant area got affected due continues storage of the Bottom within plant area.
Also as per MOEF (Ministry Of Environment & Forest ) notification we can store the Bottom Ash(solid waste) upto:3Months only
Defining The Problem
Company PDCA Cycle Watch Industry Marketing strategy Cost analysis
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Defining The Problem To Improve:•Green Manufacturing Index (GMI) . (Directly linked to Companies “MISSION”)
To redu
ce
Environment
pollution
Storage & Transport
ation problem
Expenses incurred for disposable of bottom
ash
Working at night
shift
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Defining Of Problem (Goal setting)
Disposing at present (MT/Month)
Planned disposal (MT/Month)
Bottom ash in MT
625 300
50
150
250
350
450
550
650
Bottom ash in MT
Bott
om a
sh In
MT
To reduce disposable of bottom ash from 625MT/Month to 300MT/Month
Company PDCA Cycle Benefits Future plans
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STEP 4: Analysis of Problem
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ANALYSIS OF PROBLEM 5W & 1H TOOL
What? • 625MT/month-transportation• Around Rs.3.2 Lakhs per month expenses
Where?• Plant situated at trombay in Mumbai• Transported outside the plant area as permitted by
MPCB(Maharashtra pollution control board
When? • Ash generated 365 days of the year• Transportation in late hours
Who ? • Problem is irrespective of person –Process related
How?• Transported at late night by dumpers .• Spillage• Environmental pollution
Summery of SAP report
Year Bottom ash qty in MT/year
Amount spent for disposal in lakhs
2007-08 7000 35
2008-09 8600 44
2009-10 7500 40.5
2010-11 7350 37.5
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Step 5: Identification of causes
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Company PDCA Cycle Benefits Future plans
Identification Of Causes
Environment
Person
System
Material
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Company PDCA Cycle Benefits Future plans
Identification Of Root Causes By Why-Why Analysis
Ash Content in
100% pure coal is not available
Available from natural mines
Why ?
Why ?
Coal
Economically & easily available than Oil & Gas
Why ?
Transportation By Road
Disposal yard is 30KM away from plant
Only MPCB approved dumping yard
Why ?
Why ?
Company PDCA Cycle Benefits Future Plans
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Identification Of Root Causes By Why-Why Analysis
Space constraint
More generation in small space
Generation has been increased from 180MW to1580MW
Need for power
Industrial growth
Dumping
Environmental Constraint
Mumbai (Metro city)
Today TATA power have dumping permission but they are not sure about tomorrow
Why ?
Why ?
Why ?
Why ?
Why ?
Why ?
Why ?
Company PDCA Cycle Benefits Future plans
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STEP 6: DATA ANALYSIS
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Company PDCA Cycle Benefits Future plans
Data Analysis
Total amount spent
in last 4 years- 157 lakh
Avg amt spent till date-39.25 lakh/yr
Total Bottom Ash disposed-30450MT(FOR LAST 4 YRS)
Avg bottom ash disposed-7612 MT/yr
SAP REPORT
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Data Analysis
Disposal area is far away from plant 30 km
• Bottom ash needs to be disposed at MPCB approved are
Ash Content in a Coal
• Indian coal has 30-40% ash content
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STEP 7: DEVELOPING SOLUTION
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Some of the solution listed down
Sr No Description Statement Remark
1Use of other fuels like gas/oil instead
of coal Coal is economical than other fuel Rejected
2 Transfer the plant at a remote location
Very costly. Not possible at this
momentRejected
3 Use of 100% pure coalGot the coal from
natural mines. 100% pure coal not
availableRejected
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Developing SolutionPossible usage of bottom ash
Non structuring work like PCC, Plastering
Leveling Bed for Paver blocks
Molding of bricks
Paver blocks
Structural/Masonary work
Company PDCA Cycle Watch Industry Marketing strategy Cost analysis
Company PDCA Cycle Benefits Future plans
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STEP 8: TRIAL IMPLEMENTATION
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Company PDCA Cycle Benefits Future plans
Developing solution
Sr. No Solution Statement Remark
1 PCC and plastering work
We can replace bottom ash
instead of sand in the PCC & plaster
Selected
2 Bottom Ash Bricks As per result we can use it Bricks Selected
3 Leveling bed for paver block
We can use it for leveling of paver
blockSelected
4 For masonry work Ash can be used instead of sand Selected
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TRIAL IMPLEMENTATAIONCompany PDCA Cycle Benefits Future Plans
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TRAIL IMPLEMENTATAION
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Company PDCA Cycle Benefits Future plans
Trial Implementation Sample
NoRatio
(by volume)Proportion Weight
(KG)Strength
Cement Bottom Ash %(Kg/brick)
Fly Ash
StoneDust
MPA(N/mm2)
1 1:4:6 7.5% 42.50%(1.35) 50% Nill 4 7.52
2 1:5:4 8.6% 51%(2.04) 40.4% Nil 4 15.64
3 1:6:3 8.6% 61.13(2.44) 30.29%
Nil 4 11.70
4 1:8:3 7.12% 67.71%(2.84) 25.16%
Nil 4.2 11.4
5 1:8:2 7.18% 73.91%(2.83) 18.31%
Nil 3.8 15.67
6 1:10:3 6.1% 72.4%(2.78) 21.5% Nil 3.84 6.24
Company PDCA Cycle Benefits Future Plan
Comparison Between Clay Brick & Bottom Ash Brick
Sr No Property Clay Brick Bottom Ash Brick
Remark
1 Compressive strength
5-6MPA 15-16MPA 3 time more
2 Density 1800-1900Kg/cm2
1900-2000Kg/cm2
Acceptable
3 Water Absorption
10-20% 10-20% Ok
Company PDCA Cycle Benefits Future Plan
STEP 9:REGULAR IMPLEMENTATIONCompany PDCA Cycle Benefits Future plans
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REGULAR IMPLEMENTATION
• During trial implementation it was confirmed that we will continue with the proportion 1:8:2 having an un expected strength value of 15.67MPA.
• Decided, we will implement the trial proportion 1:8:2 on regular basis. • Consumption of Bottom Ash per Brick is 2.83KG. • 250 bricks per Day. • We have increased our brick molding from 250 bricks/day to 350 Bricks/day. • Utilizing 990KG Bottom Ash daily for molding of 350 Bricks. • Bottom Ash Consumed for PCC work per meter cube (M3) = 765KG
• (APPENDIX-84)
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Regular Implementation
Bottom Ash Brick
Company PDCA Cycle Watch Industry Marketing strategy Cost analysis
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TROMBAY PLANT AREA
Company PDCA Cycle Benefits Future plans
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TANGIBLE BENEFITS
Cost Benefit Analysis:• After installation of Pilot Brick plant Bottom Ash is used in making of Bricks, PCC (Plain cement
Concrete), Plaster & masonry work and curbing work for all new Gardens developed - total Bottom Ash Consumed within 6 and half month = 875 MT (Metric Ton)
• Saved the transportation cost for 875 MT
• Transportation and Disposal cost of Bottom Ash per Ton is Rs. 510.
• Direct saving in the transportation cost of Bottom Ash = 875 X 510 =4,46,250/-
• As we had replaced the natural sand by using Bottom ash, we saved the cost of procuring Natural Sand for 875 Metric Ton.
• Cost of 1 Ton sand = 2100/- (if easily available, but now a day‟s natural sand is not easily available)
• Cost of 875 Metric Ton Sand saved = 875 X 2100 = 18,37,500/- Saving due to utilization of Bottom Ash instead of Sand in Bricks and civil work i.e. if we had
purchased the sand for above work we would have to spend around: Rs. 18,37500/
Company PDCA Cycle Benefits Future plans
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INANGIBLE BENEFITS Care of Environment &contribution to wards sustainability:
• As in this project we are able to reduce the storage and disposal problem of Bottom Ash. • Reduction of pollution in transport of Bottom Ash • Reduction in fuel cost and saving precious resources (diesel) for the transport of Bottom Ash ,
Bricks & natural sand. • Reduction in carbon foot print of the company. • Fatigue of workers reduced in the transportation of Bottom Ash , Natural sand and Bricks. • Reduction in mining of natural sand • Reduce, Reuse and Recycle .Contribution to wards Greenolution . Reusing the Bottom Ash in Civil
work. • Team work Experience As a team we worked together to achieve our goal.
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Company Pen Industry Benefits Future plans
FUTURE PLAN
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Future PlanTo achieve our goal of reducing disposal of Bottom Ash from 625 MT/months to 300MT/month & zero disposal by 2020 following are the future plans:
•Taking Clearance for the Radioactivity test to use the Bottom Ash Bricks for Structural and in-house. work : Samples submitted on 12/10/12 to BRIT office (Department of Atomic Energy, Radio analytical laboratory , Govt. of India, Mumbai ) for testing . Waiting for the results.
•Installation of Large capacity Brick plant having the capacity around 2000 to 3000 numbers of bricks per day.
•Utilization of Bottom Ash for the structural use.
•Making of Paver blocks by using Bottom Ash.
•After successful implementation of above plans we can reduce our Bottom Ash disposal to 300MT/months within next two years.
•Horizontal Deployment all over the TATA POWER.(Already Started)
•100% Utilization by 2020.
•Will be one of the future economical and eco-friendly construction materials
Company Pen Industry Benefits Future Plan
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Thank you!!
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APPENDIX
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Appendix60 problems
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Contd….
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Contd…
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Selection of Problem-RATING METHOD
Problem 3 Problem 5 Problem 17
Problem 34
0102030405060
Rating
Rating
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Appendix
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