EMRC Oct 2008

Transcription

EMRC Oct 2008

Environment Management Review
Committee Meeting
18th Oct 2008
AGENDA FOR EMRC MEETING
(To be held on 18th Oct 2008 at 11:30 AM)
Venue: Learning Centre [Main Conference Hall]
1. Developments in Legal & Other requirements…[PKN]
A. PFOS Directive
B. Overview of Flame Retardants Scenario
C. REACH Directive
2. Green Cell Initiatives :
A. Packaging Material Reuse/Recycling [Manmeet- Sales & Marketing]
B. Indoor Air Quality [ Sangeeta Bansal- Metalcan]
3. EHS Activities in CDIL Mohali: AVC
4. Internal Audit Findings & Evaluations of compliances with Legal Requirements..[Manasi Mehta]
A. General Audit findings …[Manasi Mehta]
B. Status of Corrective & Preventive Actions…[Manasi Mehta]
C. Evaluation of Legal Compliance ….[PKN]
5. Extent to which objectives & Targets have been met
A. Environmental Foot Printing of Production areas.[Pawan Tanwar]
B. Status of Environment Management Programmes
C. EMG Meeting Status
6. Follow up actions from EMRC Nov 07…[ PKN]
7. Recommendations for Improvement …[ PKN]
Development in Legal & other
requirements
An overview of
Flame Retardants (FR)
Deca BDE
TBT
PFOA
TBTO
POP
BFR
TPT
PoHS
PFAS
PFOS
ELINCS
EINECS
CFR
REACH
SVHC
TBBPA
HBCDD
PAH
RoHS
ANTIMONY
TOXIC
PBB
DEPH
WELCOME TO THE WORLD OF PBDE
ECHA
ENVIRO-LEGAL
REQUIREMENTS
CMRs
DSDMAC
TBBPA-A-BIS
An Overview of Flame Retardants
Flame Retardants (FRs)
These are Chemicals which is added to materials during or after the
manufacture, inhibit or suppress the combustion process.
Type of FRs
1.
2.
3.
4.
5.
Brominated Flame Retardants [BFRs]
Chlorinated Flame Retardants [CFRs]
Phosphorus Containing Flame Retardants
Nitrogen Containing Flame Retardants (Melamines)
Inorganic Flame Retardants
Flame Retardants
Standard for Flammability
UL 94 flammability testing
There are two types of pre-selection test programs conducted on plastic
materials to measure flammability characteristics. The first determines
the material’s tendency either to extinguish or to spread the flame once
the specimen has been ignited. The first program is described in UL 94,
The Standard for Flammability of Plastic Materials for Parts in Devices
and Appliances, which is now harmonized with IEC 60707, 60695-11-10
and 60695-11-20 and ISO 9772 and 9773.
The second test program measures the ignition resistance of the plastic
to electrical ignition sources. The material’s resistance to ignition and
surface tracking characteristics is described in UL 746A, which is similar
to the test procedures described in IEC 60112, 60695 and 60950.
Standard for Flammability
UL 94 flame classifications
There are 12 flame classifications specified in UL 94 that are assigned
to materials based on the results of small-scale flame tests. These
classifications, are used to distinguish a material’s burning
characteristics after test specimens have been exposed to a specified
test flame under controlled laboratory conditions.
Six of the classifications relate to materials commonly used in
manufacturing enclosures, structural parts and insulators found in
consumer electronic products (5VA, 5VB, V-0, V-1, V-2, HB).
For semiconductor products the applicable flammability standard is
UL94 V-0
UL94 V-0, V-1, V-2 Flammability Standard
Specimen
•
Length 125 mm (5 in) x Width 13 mm (0.5 in) x Thickness [typically 0.7 mm (1/32 in)
or 1.5 mm (1/16 in) or 3.0 mm (1/8 in)].
Procedure
1. A total of 10 specimens (2 sets) are tested per thickness.
2. Five specimens of each thickness are tested after conditioning for 48 hours at 23
degrees C and 50% RH.
3. Five specimens of each thickness are tested after conditioning for 7 days at 70 degrees
C.
4. Each specimen is mounted with long axis vertical
5. Each specimen is supported such that its lower end is 10 mm above Bunsen burner
tube.
6. A blue 20 mm high flame is applied to the center of the lower edge of the specimen for
10 seconds and removed. If burning ceases within 30 seconds, the flame is reapplied for
an additional 10 seconds. If the specimen drips, particles are allowed to fall onto a layer
of dry absorbent surgical cotton placed 300 mm below the specimen.
Requirements for V-0
1. The specimens may not burn with flaming combustion for more than 10 seconds after
either application of the test flame.
2. The total flaming combustion time may not exceed 50 seconds for the 10 flame
applications for each set of 5 specimens.
3. The specimens may not burn with flaming or glowing combustion up to the holding
clamp.
4. The specimens may not drip flaming particles that ignite the dry absorbent surgical
cotton located 300 mm below the test specimen.
5. The specimens may not have glowing combustion that persists for more than 30
seconds after the second removal of the test flame.
clamp.
4. The specimens may not drip flaming particles that ignite the dry absorbent surgical
cotton located 300 mm below the test specimen.
clamp.
4. The specimens can drip flaming particles that ignite the dry absorbent surgical cotton
located 300 mm below the test specimen.
Flame Retardants
Flame Retardants
Flame Retardants
Brominated Flame Retardants [BFRs]
1.
75 different products each with specific properties and Toxicological
behaviour.
2. Six product Families
1. TBBPA and its derivatives [Tetra Bromo Bisphenol A]
2. HBCDD [Hexa Bromo Cyclo Dodecane]
3. PBDE [Poly Brominated Diphenyl Ether]
a) Deca-BDE [Deca Bromo Diphenyl Ether]
b) Octa-BDE [Octa Bromo Diphenyl Ether]
c) Penta-BDE [Penta Bromo Diphenyl Ether]
4. PBB [Poly Brominated Biphenyl ]
5. Brominated Styrols
6. Pthalic Anhydrides
Flame Retardants
Flame Retardants
The PBDE & PBB group of flame retardants under most pressure for
restrictions and phase-out currently include:
PentaBDE -Pentabromodiphenyl ether ,
OctaBDE -Octabromodiphenyl ether ,
DecaBDE -Decabromodiphenyl ether ,
PBBs
-Polybrominated Biphenyl Ethers ,
Antimony trioxide, and, in some instances,
all brominated and halogenated flame-retardants.
PentaBDE – is the main flame retardant used in polyurethane foam
and furniture. It is highly toxic, persistent, and bioaccumulative and has
been banned by the European Union as of 2005.
OctaBDE is used in small amounts in wire and cable and other
products and was banned by the EU as of August 2005, because of its
high potential for bioaccumulation in the environment and humans.
Flame Retardants
DecaBDE
The concerns include the
possibility for debromination (degradation to
lower congeners of BDEs, such as penta),
formation of dioxins and furans in fires,
processing and end-of-life handling, as well as
its neurological effects and persistence.
Additional studies are underway to clarify these
uncertainties.
PBBs are highly toxic, persistent and
bioaccumulative chemicals that are no longer
manufactured in the United States or Europe.
Antimony trioxide is on the EPA’s
Toxics Release Inventory list and is classified
by the International Agency for Research on
Cancer (IARC) is a probable carcinogen.
Flame Retardants Legal Restrictions
Six product families of BFRs
Banned/Restricted
under
TBBPA and its derivatives [Additive]
[Tetra Bromo Bisphenol A]
WEEE,PoHS,IPC1752 JIGA, REACH,
HBCDD [Hexa Bromo Cyclo Dodecane]
WEEE, REACH, IPC1752 JIGA, PoHS
PBDE [Poly Brominated Diphenyl Ether]
RoHS, WEEE, China RoHS , IPC1752
JIGA, TRI, REACH,
PBB [Poly Brominated Biphenyl ]
RoHS, WEEE, China RoHS, IPC1752
JIGA, REACH,
Brominated Styrols
WEEE, REACH, IPC1752 JIGA,
Pthalic Anhydrides
WEEE, REACH, IPC1752 JIGA, PoHS
As of today, Deca-BDE can no longer be used in electronics and electrical
applications. This follows a European Court of Justice ruling from 1 April 2008.
PFOS Directive 2006/122/EC
12th Dec 2006
12th Dec 2006
PFOS directive came into existence after 30th amendment of
Restriction on the marketing of certain dangerous substances and
preparations EU directive 76/769/EEC 27 th July 1976
Perfluorooctane sulfonates (PFOS).
PFOS and their chemical variations were used historically as water, oil, soil and
grease repellents for carpets, fabric and upholstery and food packaging, and in
specialized applications such as fire-fighting foams, aviation hydraulic fluids, and
insecticides.
The definition of PFOS
- Title
: Perfluorooctane Sulfonates
- Structure : C8F17SO2X
[ X=OH, Metal salt(O-M+), Halide, Derivatives containing Amide
and Polymer]
PFOS is VpVb [Very Persistent Very Bioaccumulative Toxin] and
Banned worldwide under POP list of Stockholm Convention .
PFOS Directive 2006/122/EC 12th Dec 2006
PFOS:Perfluoro-octyl Sulfonate
C8F17SO3
surface treatment, paper protection,
performance chemical
e.g. Carpet; Cup & plate; Fire fighting
foam; Semi-conductor;
PFOA: Perfluoro-octyl Acid
C8F15OO
Emulsifier and surfactant
e.g.; Soap; Shampoo;
Teflon; Gore-tex
12th Dec 2006
1.
2.
3.
4.
5.
6.
7.
Main use of PFOS
Photoresists or anti reflective coatings for
photolithography process
Transcription belt and rubber roller coatings
for printer and combination printer.
Mist suppressants for chromium plating,
dehydrator for chromate treatment, etching
additives, pretreatment and post treatment
agent etc
Painting resin, Printed circuit board,
Ceramic board, PTFE, Fluoric Resin.
Paints, Colors, Pigment
Solder Flux, Cream Solder
Fluoric mold spatt etc
PFOS is used for a surfactant and a dispersion
agent etc besides the mentioned use above.
12th Dec 2006
The restriction limit
PFOS usage
As a substance or
constituent of preparation
In semi finished products or
articles
Limit
0.005 % by mass
0.1 % by mass
Photo resists or anti reflective coatings for photolithography process
are currently exempted under PFOS.
PFOS Directive 2006/122/EC 12th Dec 2006
REQUIREMENT FROM CDIL SUPPLIER
Material Declaration detailing
1. The prohibition of the usages and circulation of
the substance/preparations which have the over
0.005% concentration of the prohibited
materials by PFOS.
2. The prohibition of the usages and circulation of
the intermediate products which have over 0.1%
ratio of the prohibited materials by PFOS.
3. The coated materials such as textiles which
have PFOS 1 µgm/m2 of content.
ISSUE OF PFOS CERTIFICATE TO CUSTOMER
Continental Device India Limited
An ISO/TS 16949 and ISO 14001 Certified Company
Certificate of Compliance
Restriction on the use of certain dangerous Substances and Preparation
(perfluorooctane sulfonates)as per
Directive 2006/122/EC of the European Parliament and of the Council with the 30th
amendment of Council Directive 76/769/EEC
Continental Device India Limited (Supplier) certifies to HITEC RCD KOREA INC... and its
subsidiary and associated companies that, having made full and careful enquiry:
All CDIL products and processes are fully compliant with the PFOS regulations of the
EU. Directive 2006/122/EC
This is based on specific declarations from our suppliers of
( a ) Photoresist and
( b ) chemicals used in terminal finishing process --- plating solutions and fluxes .
(i)
all of the materials, components, assemblies, equipment or other products or any
parts of such products which are listed on the attached schedule (the Products) are
in full compliance with EU directive 2006/122/EC (the PFOS Directive), EC directive
76/769/EEC (Restrictions on the marketing and use of certain dangerous substances
and preparations), as amended and the national or regional legislation of member
states within the European Community implementing such directives (the Applicable
Legislation); and
The Supplier confirms that this certificate will apply to all future supplies of the Products to
HITEC RCD KOREA INC.. Unless the Supplier informs the relevant member of the HITEC
RCD KOREA INC.. in writing at the time of order of any non-compliant Products.
The
Supplier will inform the HITEC RCD KOREA INC.. immediately that it becomes aware that
any applicable exemption is being amended or withdrawn.
Continental Device India Limited confirms that HITEC RCD KOREA INC.. is entitled to rely on
this certificate for the purpose of providing information to its customers on the compliance of
products supplied by Continental Device India Limited with the Applicable Legislation and to
provide copies of this certificate to its customers and to authorities involved in the monitoring
or enforcement of the Applicable Legislation.
[signature]
for and on behalf of Continental Device India Limited
Date [
]
REACH Directive 1907/2006/EC
18th Dec 2006
Enhancing the competitiveness of
EU Chemical Industry
Risk of Chemicals
Non Systematic
Non integrated
legislations
Fragmented market
under EU
Registration Evaluation Authorisation & Restriction of Chemicals [REACH]
1. Protection of Human Health & Environment
2. Enhancing the competitiveness of EU
Chemical Industry
3. Prevention of fragmentation of internal market
4. Increased Transparency
5. Integration with International Efforts
6. Promotion of non animal testing
7. Conformity with EU obligation under WTO
18th Dec 2006
European Chemical Agency
ECHA
Helsinki (Finland)
Registration Evaluation Authorisation & Restriction of Chemicals [REACH]
Producers/
Manufacturers
Importers
Distributors
& Retailers
Downstream
Users
18th Dec 2006
SUBSTANCE: means a chemical element and its compounds in the
natural state or obtained by any manufacturing process, including any
additive necessary to preserve its stability and any impurity deriving
from the process used, but excluding any solvent which may be
separated without affecting the stability of the substance or changing
its composition;
ARTICLES:
Articles are products such as electrical equipment, sub assemblies,
components – items which have a “special shape,
surface or design which dictates its function to a greater degree than
does its chemical composition” – for example
•Clay is a preparation (a mixture of substances)
•A pottery mug is an article because it has a specific shape.
PREPARATION: means a mixture or solution composed of two or
more substances;
18th Dec 2006
SVHC [Substances of Very High Concern]
Substances which are considered to be
Carcinogenic (C);
Mutagenic (M);
Toxic for Reproduction (R);
Persistent, Bio-accumulative and Toxic (PBT);
Very Persistent and Very Bio-accumulative (vPvB).
ECHA has published a draft list of 16 such candidate
substances. Substances above 0.1% weight-byweight will be requiring AUTHORISATION after draft
is approved
The EU environmental NGOs through the International Chemical Secretariat
has released its "Substitute It Now" (or aptly acronymed "SIN") a list of 220
chemical substances considered to be possible Substances of Very High
Concern under REACH and submitted to ECHA.
ECHA expects the first candidate list to be approved on October 22.
18th Dec 2006
18th Dec 2006
REGISTRATION AND NOTIFICATION OF SUBSTANCES IN ARTICLES[Article 7]
1. Any producer or importer of articles shall
submit a registration to the Agency if both
the following conditions are met:
The substance contained in the product
a) More than 1 tonne per producer or
importer per year;
b) intended to be released under normal
or reasonably foreseeable conditions
of use.
1. Any producer or importer of articles shall
notify the Agency, if a substance is SVHC&
both the following conditions are met:
The substance contained in the product
a) More than 1 tonne per producer or
importer per year;
b) above a concentration of 0,1 % weight
by weight (w/w).
Content of the Communiqué’ to all suppliers of articles or preparations for REACH compliance
Form no: CDIL/PUR/OCP 01/F08
Ref no: CDIL/PUR/OCP 01/R08
Date:
To, [Name & Address of Supplier]
Dear CDIL Supply Chain Partner,
This communiqué is in response to the latest EU regulation on REACH 1907/2006/EC of 18 December 2006. The
st
regulation was adopted on 18 December 2006, and came into force on 1 June 2007. The acronym REACH stands for
Registration – the necessity to submit a (technical) dossier on the properties of a substance. Evaluation – of the dossier
by the authorities. Authorization and restriction – on the use of a substance or preparation of Chemicals. The purpose of
this Regulation is to ensure a high level of protection of human health and the environment, including the promotion of
alternative methods for assessment of hazards of substances, as well as the free circulation of substances on the internal
market while enhancing competitiveness and innovation.
You need to register with ECHA [European Chemical Agency] located in Helsinki Finland.[if you are a supplier outside
EU ,you may appoint an only representative to fulfil the obligation.] in the following main conditions of Article 6 &7:
1. Save where this Regulation provides otherwise, any manufacturer or importer of a “substance“, either on its own or
in one or more preparation(s), in quantities of 1 tonne or more per year shall submit a registration to the Agency.
2. Any manufacturer or importer of a polymer shall submit a registration to the Agency for the monomer substance(s)
or any other substance(s), that have not already been registered by an actor up the supply chain, if both the
following conditions are met:
a) the polymer consists of 2 % weight by weight (w/w) or more of such monomer substance(s) or other
substance(s) in the form of monomeric units and chemically bound substance(s);
b) the total quantity of such monomer substance(s) or other substance(s) makes up 1 tonne or more per year.
3. if you are a supplier of “articles“ containing “substances“ totalling over 1 tonne to CDIL and if the substances is
intenteded to be released under normal or reasonably forseeable conditions of use .
4. Any producer or importer of articles shall notify the Agency, in accordance with paragraph 4 of this Article
(Producer’s identity ,Registration no, classification,tonnage, & identity of SVHC etc), if a substance meets the
criteria in Article 57 [SVHCs] and is identified in accordance with Article 59(1)[Annexure XV Dossier as prepared by
ECHA], if both the following conditions are met:
i.the substance is present in those articles in quantities totalling over 1 tonne per producer or importer per year;
ii.the substance is present in those articles above a concentration of 0,1 % weight by weight (w/w).
It is our duty to ask you as our supplier to list up all chemical substances or preparations which you produce, import or
market in your company – no matter if you deliver them to CDIL or to other companies – and to pre-register (If the above
conditions are met) them at the ECHA.
In addition to this, it is your duty as a supplier, to ask your own suppliers for similar request.
The registration, authorization, restriction and information provisions according to the REACH Regulation, CDIL requires
you as supplier to submit the attached Confirmation on REACH Compliance and expects you to provide responses to
the issues addressed in the attached questionnaire
Most of CDIL customers are requesting for this information to ensure their product compliance towards these legislative
requirements and hence, we need to ensure that our supply chain is prepared for the changes that are required to
comply with REACH regulation. In order for CDIL to be able to monitor its own compliance with REACH, this information
is being requested on behalf of Continental Device India Ltd or any of its subsidiaries that purchases or may purchase
materials from your company.
Therefore, we need assistance from our valued supply chain partners to help us in meeting the compliance
requirements.
To facilitate you in furnishing the relevant data and information for compliance please find in the attachment a send back
Certificate on REACH Compliance which you need to countersign and the provide responses to the questionnaire to the
undersigned no later than six weeks after receipt of this letter and update the information asked for in the questionnaire
regularly.
Thank You. We appreciate your cooperation in this important initiative.
Best Regards,
[Purchase Executive]
Continental Device India Ltd
C-120, Naraina Industrial Area, Phase-1
New Delhi-110028
18th Dec 2006
Information in the supply chain [Article 31]
Supplier shall provide safety data sheet if the
article or preparation include any
substance :
1. From the SVHC list
2. Meets the criteria for classification as
dangerous substances according to
Directive 67/48/EEC or 1999/45/EC
[Packaging & labeling of dangerous
substances]
3. Declared as dangerous by ECHA.
4. Which is not classified as dangerous but
having a concentration of >=1% by weight
and >=0.2% by volume and at least one
substance posing human health or
environmental hazard.
5. For which there is a community workplace
exposure limit.
REACH TIME SCHEDULE
Green Cell Initiatives
Manmeet Kaur
Sangeeta Bansal
Scope of Reduction of Packaging
Material in CDIL
MANMEET KAUR
Sales & Mktg
CONTENTS
Ø What is packaging
Ø Type of packaging materials
Ø Three 'R's of waste reduction
Ø Relevance of waste reduction
Ø Legislations on packaging waste
Ø Good practices by some to semiconductor manufacturers
Ø Use of packaging material in CDIL.
Ø CDIL Practices for reuse
packaging material
Ø Recommendations
What is Packaging?
A wrapping, container, or other protective holder for a
product that keeps it fresh (in the case of food or
beverages) and unharmed until it is sold or conveyed
Type of Packaging Material
Weight of
packaging
material %
% of
packaged
goods
Paper/ Board
43%
25%
Plastic
20%
53%
Glass
19%
10%
Aluminium/ Steel
14%
7%
Tetra Pak
(75% paper+
20% polyethylene +
5% aluminium foil )?
4%
5%
Material
Three “R’s” for Waste Prevention
v Reduce
Reduce means try to avoid
goods that they consider are
'over-Packaged'.
Example:
The use of standardized
packaging boxes can lead to
void space in the package,
which is both a wasteful use
of resources and misleading
for consumers
v Reuse
The most direct way to recover
packaging is by reusing it in its
original form because recyclables
need to be transported, cleaned
and re-processed before they can
be turned into new products.
Example:
Ø The Body soap, and cleaning liquids
are sold in refillable or returnable
containers.
Ø Buying milk in returnable bottles
avoids the creation of plastics waste.
v Recycle
Transporting, cleaning and re
Processing of the used
packaging material before it can
be turned into new products.
Example :
Recycled cardboard boxes.
Relevance of recycling of packaging material
Ø No waste of packing
received from external
suppliers.
Ø There is no need to use
new packing material.
Ø Shipping costs have
been reduced.
Ø Total shipping weight has
been decreased as
compared to traditional
shipments.
Ø Reduce burden on
environment.
Directives on Packaging Waste
EC Directive on Packaging and Packaging Waste 94/62/EC
or Packaging Directive:
u Sets targets for the recovery and recycling of packaging
wastes.
u It sets minimum design standards.
u The combined ppm by weight of three banned
substances (Pb, Hg, Cr6+) must not exceed 100ppm and
Cd alone should not exceed 5ppm
China RoHS
u Include general rules for handling and utilization of packaging
refuse.
u Stipulates that the type, name, size & colours for marks of
recyclable, reusable and packaging should be as per GB18455 standard
Good Practices of some
Top Semiconductor
Manufacturers
ST Microelectronics
l They continue to pack their products in homogeneous materials, not in composite
material
l In wafer packing, Single wafer containers are designed to be reusable after
cleaning.
l In some regions, ST and other semiconductor manufacturers in the area have
contacted recycling companies.
NXP Semiconductors
• Reducing the amount of packing material by switching to 'one
piece' boxes (instead of boxes with upper and lower parts)
• Switched to 'mono material' to aid recycling. For example, from
aluminium-lined boxes to carbon-coated boxes.
• Switched from white boxes to natural brown boxes to eliminate the
use of bleach (chlorine) in their manufacture.
Use & Reuse of Packaging
Material in CDIL
Packaging Material used in CDIL in
last three year
Year
Weight
(Tones)
Cost (Rs in
Lakh)
2006-07
18.93
11.64
2007-08
9.17
6
2008-09*
2.24
1.5
* Till July' 08
MAJOR PACKAGING MATERIAL USED IN
CDIL
Outer Carton
POLYTHENE BAG
STICKERS
Inner Carton
CONSUMPTION OF MAJOR PACKAGING
MATERIALS IN CDIL
Item Type
Weight (Tones)?
Cost (Rs In Lakh)?
06-07
07-08
08-09*
06-07
07-08
08-09*
06-07
07-08
08-09*
Outer
Carton
9
9
9
9.6
4.8
0.96
1.67
1.99
0.6
Inner
Carton
4
4
1
5.5
2.92
0.7
3.6
2
0.5
Polythene
Bags
10
6
6
1.72
0.47
0.24
1.67
0.47
0.28
Stickers
4
3
1
0.34
0.23
0.1
0.65
0.38
0.13
17.32
8.42
2
7.59
4.84
1.51
* Till July' 08
Material Shipped vs Major Packaging
Material Used
Packaging Material
Year
Total Material
Shipped (in
Tonnes)
2006-07
153.53
17.32
7.59
2007-08
134.11
8.42
4.34
Weight (In Tonnes) Value (In Lakhs)
EXPORT FREIGHT CHARGES
USA
Weight (KG)?
0.1-10
11-45
46-100
101-250
Cost (in Rs)* Normal
2500
250
210
155
Cost (in Rs)** Courier
1895/KG
251-300
301-500
> 500
* Additional Tax: Rs 50.10
** Additional Tax : 12% Service Tax + 20% Freight Surcharge
HK
Weight (KG)?
0.1-10
11-45
46-100
101-250
251-300
301-500
> 500
1200
92
-
63
-
50
30
1669/KG
CHINA
Weight (KG)?
0.1-10
11-45
46-100
101-250
251-300
301-500
> 500
1200
114
100
80
-
63
50
1948/KG
Country Wise % Share of
CDIL’s Total Exports
Country
% Share of Total Export
Hong Kong
30
China
30
US
10
Africa
10
Europe
20
Case Study - Export
Case Study: Packaging material fright cost in total
shipment fright cost
60000
50000
Cost in
Rs
3143
40000
Freight Cost for packaging
(in Rs)
1886.05
30000
Total Freight Cost ( in Rs)
46912
20000
28150
10000
377.32
5717
0
Case 1
Case 2
Case 3
CDIL Practices for Reuse of
Packaging Material
In-House Production
• At present Packaging material is reused
only as 'BUFFER PACKAGING'.
BUFFER PACKAGING:
Packaging material used to fill void space in
standardized packaging boxes.
As per ITRS norm recycle of packaging
material as a percentage of total
packaging material is 80%
SUBCON / TG
For inner packing
Past Situation
Initially as we have our own standards we repack (inner as well as outer
carton) all the supplies from the subcon/ TG material in our own standard
packages Which causes below mentioned problems.
a) Packaging Cost
b) Manpower Cost
c) Disposal of scrap packaging from subcon.
d) Environmental Burden.
Present Situation
Now we start using subcontractors packaging by sending material as it is to
avoid above mentioned problems.
Now 70% packaging material of subcontractors
has being reused.
REASONS WHY 30% OF TG/SUBCON
DEVICES STILL REPACKED
è
Tube packing from some vendors.
Inner carton from vendor
CDIL Standard inner carton
è
HFE Group not mentioned on CFL Devices from some
vendors.
è
From some vendors Quality of polythene bags is not
good.
PACKAGING PERFORMANCE INDICATOR
Shipment weight vs Procured Packaging material weight
14
10
12.11
11.51
10.12
8
Devices Shipped by weight in Tonnes
(Naraina Plant)
6
Major packaging material procured by
weight in tonnes (Naraina Plant)
4
2
0.9
0.8
1.01
0
July' 08
Aug' 08
Sept' 08
Month
% of packaging weight in total shipment weight
9.00
8.00
7.00
Weight (%)
Weight in (Tonne)
12
8.2
8.1
6.00
6.2
5.00
% of packaging material used in total
shipment weight
4.00
3.00
2.00
1.00
0.00
July' 08
Aug' 08
Month
Sept' 08
Recommendation to increase reuse
of packaging material
1.Types of outer carton can be reduced & limited
to 2-3 types.
2. Set packaging standard at vendors end to avoid
repacking at our end .
CHANGE...........
Before you have to.
Earlier EMP taken by Sales & Mktg.
Non Moving Stocks Lying in FG (Domestic), DTA+EHTP
14.00
12.00
11.76
10.12
10.00
8.98
Qty in Million
8.41
8.26 8.14
7.81
8.00
7.47
7.26
7.12
6.91 6.74
6.55
6.08
6.00
5.35
4.89
3.97
4.00
3.65
3.43 3.41 3.35
3.09
2.87
1.85
2.00
1.17 1.09 1.11 1.05 1.04
0.99 0.98 0.94 0.94 0.94 0.94 0.93
0.00
Mar' 05
June' 05
Sept' 05
Dec' 05
Mar' 06
Jun' 06
Sept' 06
Month
Dec' 06
Mar' 07
June' 07
Sept' 07
Dec' 07
THANK YOU
INDOOR
AIR QUALITY
Presented by : Sangeeta Bansal
Date: 18th October 2008
Overview
•
•
•
•
•
•
What is IAQ?
Indoor sources of pollutants
Causes of indoor air pollution
Various Researches
Effects of polluted air on health
Various techniques of analyzing IAQ
•
•
•
•
What is NAAQS?
Mitigation techniques
Delhi Factory Rules 1950
IAQ survey in CDIL
What is IAQ?
Indoor Air Quality (IAQ)
• Deals with the content of interior air
that could affect health and
comfort of building occupants.
• The IAQ may be compromised by
microbial contaminants (mold, bacteria), chemicals
(such as carbon monoxide,
radon), allergens, or any mass or
energy stressor that can induce health
effects.
Various Researches
• The air within homes and other buildings can be more
seriously polluted than the outdoor air
• People spend approximately 90 percent of their time
indoors.
• Risks to health may be greater due to exposure to air
pollution indoors than outdoors.
Sources of Indoor Air Pollution
• Combustion sources such as oil, gas,
kerosene,coal,wood and
tobacco products
• Building materials & furnishings
• Asbestos containing insulation,
wet carpet, furniture
• Products for cleaning & maintenance
• Central heating & cooling systems.
• Radon pesticides
In developing countries like India
the most important indoor air pollutants
are combustion products of unprocessed
biomass fuels used by poor urban & rural
folk for cooking and heating.
Causes of indoor air
pollution
• Indoor pollution sources that release
gases or particles into the air are the
primary cause of indoor air quality
problems in homes.
• Inadequate ventilation can increase
indoor pollutant levels by not bringing
in enough outdoor air to dilute emissions
from indoor sources and by not carrying
indoor air pollutants out of the home.
• High temperature and humidity levels also
increase concentrations of some pollutants.
Effects of polluted air on
Health
• Immediate effects -may show up after
a single exposure or repeated exposures.
These include irritation of the eyes, nose
& throat, headaches, dizziness, and fatigue.
• Other effects-may show up only after long or
repeated periods of exposure. These effects include
respiratory diseases, heart disease, and cancer.
Indoor Exposures & Asthma
• -- Confirmed known indoor triggers
-- New triggers : ETS,high level of
NO2
-- Possible triggers: formaldehyde,
fragrances
• Recent studies VOCs,formaldehyde,workplace
cleaning products may be associated
LEGIONNAIRES’ DISEASE
• It is an infectious disease caused by bacteria
“Legionella pneumophila” .
• It is an aquatic organism that thrives in warm
enviornments(25°C - 45°C).
• Infection occurs after inhaling water droplets
originated from a water source contaminated with
‘Legionella’.
• It takes two distinct forms:
a. Legionnaires’ Disease
b. Pontiac Fever
Techniques for analyzing
IAQ
• Collection of air samples
• Collection of samples on
building surfaces
• Computer modeling of air
flow inside buildings.
These samples can be analyzed for mold, bacteria,
chemicals or other stressors and ultimately lead to an
understanding to strategies for removing the
unwanted elements from the air.
NAAQS
National ambient air quality standards
•
The Central Pollution Control Board (CPCB) in
collaboration with State Pollution Control Boards
(SPCBs) initiated National Ambient Air Quality
Monitoring (NAAQM) programme in 1984.
• To assess quality of air and to take steps for
prevention, control and abatement of air pollution
• an attempt is made to define air quality status as low,
moderate, high and critical based on the
concentration of pollutants with respect to notified
standards.
Ambient Air Quality Standards &
Actual values in CDIL 07-08
Actual Values
S.No. Parameter Units
3
µg/m
1 SO2
2
3
4
5
6
7
CO
Nox
SPM
RSPM
Lead(Pb)
Ammonia
Tolerance
Limits
Security Gate Backside Main Park
120
12
11
10
3
µg/m
3
µg/m
3
µg/m
3
µg/m
3
µg/m
mg/m3
BDL:Below detection limit
SPM:Suspended Particulate Matter
RSPM:respirable Particulate Matter
5000
120
500
150
1.5
0.4
1252
31
332
112
BDL
BDL
1119
29
309
102
BDL
BDL
1002
26
296
94
BDL
BDL
Death, Disease and Irritant Effects
• PM-respiratory & cardiovascular effects
• Carbon Monoxide-Death & Flu-like symptoms
• NO2, respiratory disease
• Communicable Diseases
• Irritant Effects
• Sick Building Syndrome
IAQ SURVEY IN SENSITIVE
AREAS OF CDIL
Major chemicals / solvents used in CDIL for which there
exists exposure limits as per Delhi Factories Rules
1950.
• ASSEMBLY AREA – Glycol, Acetone, TCE
• LF(YM area) – Ammonia, Nitric acid, Sulphuric acid,
HCL
• LEAD FINISH – Oxalic acid, Nitric acid, Sulphuric
acid, Sodium hydroxide, Solderon Tin conc., Flux,
Reflow paste.
Permissible Limit Exposure
(Delhi Factory Rule 1950)
Substance
acetic Acid
ammonia
n-butyl acetate
cyanides
ethyl alcohol
methyl alcohol
nitric acid
sulphuric acid
trichloroethylene
xylene
Time Weighted
Average
Concentration
mg/m 3
ppm
10
-150
-1000
200
2
-100
100
25
10
710
5
1900
260
5
1
535
435
Short Term
maximum
Concentration
mg/m 3
ppm
15
35
200
--250
4
-150
150
37
27
950
--310
10
-800
655
Permissible Limit Exposure
(Delhi Factory Rule 1950)‫‏‬
Substances
ppm
Mg/m3
Hydrochloric Acid
5
7
Potassium Hydroxide
--
2
Sodium Hydroxide
--
2
“Air Quality in Clean Rooms”
The Clean Room is an environment which potentially
supports the growth of Micro organisms ;
Air Quality of clean rooms does not only mean
control of Dust, temperature & Humidity.
Classification of Clean Rooms
Federal Standard 209(E)‫‏‬
Class Name
SI
English
Fresh
Class Limits Air
Air
Air
(no per Cuft) Velocity Intake Change
0.5µ
5.0µ
M5.5 10,000 10,000 70.5
fpm
%age Per hr
10-15 10-15% 50-75
Human Interface In Clean Room
• There are various ways of microorganisms
to enter into a ‘clean room’:1.On Skin – a. Transient Resident
b. Temporary Resident
2. Skin Cells – Oil and salt residues
3. Hair – Dandruff,Scalp Flakes,Keratonin
4. Coughs, Colds, Sneezes
5. Wounds, Boils, Medicaments
Mitigating Techniques Used In
CDIL
• VENTILATION SYSTEM – Exhaust is there to
control the emission & dispersion of contaminants.
• FUME SCRUBER – Dilution of hazardous fumes with
water vapors to control their direct exposure in air.
• High efficiency Exhaust fans are installed in Zener
Area for reducing solvent vapor / reactant gases
concentration discharge into the work place and
ambient atmosphere.
• Regular check and maintenance of all exhaust fans is
being carried out within department.
Mitigating Techniques Used In
CDIL
• GASTEC gas detection tube system is installed in
yellow room and metallization areas for the analysis
of Xylene / Acetone concentration
• Personal protective Equipment are being issued to
employees for the particular work to be perform.
Concentration limits checked by
GASTEC in Zener Area WF
• Xylene (standard ppm
level=100)‫‏‬
Date
Measured
27/10/05
50
14/06/06
40
•Acetone (standard ppm
level = 500)‫‏‬
Date
Measured
22/02/06
310
29/02/06
310
09/05/06
135
EHS Activities in CDIL Mohali
Avinash Chadha
EHS PRESENTATION
CDIL Mohali
'Avinash Chadha
CDIL Mohali
GAS STORAGE AREA SHED
SCRAP YARD SHED CONSTRUCTED
REGULARY MAINTAINED SCRAP YARD
IPA DISTILLATION INITIATED
EHS CERTIFICATION AUDIT
NCs
NCs
= 7 ( 5 CLOSED)‫‏‬
OBSERVATIONS
=1 (CLOSED)‫‏‬
OPPORTUNITY FOR IMPROVEMENT=2 (CLOSED)‫‏‬
NOTEWORTHY EFFORTS
=1
PENDING NCs =2
1. Training of Internal Auditors.
2. (a) Acoustic enclosure of DG SET
(b) Stack Ht. of DG Set
Details of Waste IPA Distillation
Expenses
Good IPA
Produced
(Lts)
Rate of
IPA/Lt(Rs)
Saving(Rs)
Manpower
Electricity
Nett Saving
Cumm
Saving
22nd Apr to
31st May
2008
Jun 2008
627
80
50160
4878
2640
42642
42642
762
80
60960
5365
2904
52691
95333
Jul 2008
1118
94
105092
5952
3422
95718
191051
Aug 2008
Upto 24th
sep 08
1055.5
94
99217
5592
3215
90410
281460 2 holidays
773
94
72662
4496
2585.2
65581
347041
Month
Mar 2008
Apr 2008
May 2008
Jun 2008
Jul 2008
Aug 2008
Upto 24th
sep 08
Waste IPA Stock Status
Distillation
Opening Stock
Waste IPA recd Closing Stock
done
15391
0
1260
16651
16651
0
728
17379
17379
1204
784
16959
16959
1090
394
16263
16263
1729
692
15226
15226
1494
582
14314
14314
1135
318
13497
Rs 3,47,041.00 saving done in 5 months against investment of Rs 59,000.00 0nly.
Notes:
1) Apart from Nett Saving as above, we are able to reduce the quantum of
Hazardous Waste accumulated in our premesis, thereby reducing chances of
Fire Hazards.
2) We have not bought fresh IPA after 1st June 2008.
Rate of fresh
IPA has
increased
RESOURSE CONSERVATION(ENERGY)
TO REPLACE CONVENTIONAL TUBE LIGHTS WITH T5 ENERGY EFFICIENT TUBE LIGHTS
Type of Lamp
Existing
Unit
Proposed
689
Nos.
589
Effective consumption per point
50
Watts
29
Av operating hours
18
Hours
18
Cost per point/day
4.14
Rs
2.4
Total Cost per day
2852.46
Rs
1414.31
Total cost per month(25 days)
71311.5
Rs
35357.67
Total Cost per year(12 months)
855738
Rs
424292
Saving per year
431446
To be paid to Asian
144000
No of existing points
Saving for CDIL per year
Maint cost per year(free by Asian)
Total saving for CDIL per year
Saving in 4 years(contract period)
After 4 years total saving for CDIL per year
287445.96
39180
326625.96
1306503.84
431446+39180= 470626
EHS ISSUES
RENEWAL OF HAZARDOUS WASTE AUTHORISATION
SLUDGE DISPOSAL
SANCTION FOR DISTILLATION PLANT & IPA
RESIDUE DISPOSAL
WASTE FLUX DISPOSAL
FURTHER IMPROVEMENT PROJECTS
ENERGY CONSERVATION
WATER CONSERVATION
REDUCTION IN OCCUPATIONAL HEALTH & SAFETY
HAZARDS AND RISKS.
THANK YOU
Audit Findings & Status of corrective &
Preventive actions
Manasi Mehta
AUDIT REPORT
FIFTEENTH EMS INTERNAL AUDIT
At
Continental Device India Ltd
C-120, Naraina Industrial Area, New Delhi
Conducted During Mar - May 2008
For the period (JAN – JUN'2008)?
By EMS Internal Auditors
MANASI MEHTA
V P MATHEW
S.P.JOSHI
MANMEET KAUR
SANGEETA NEGI
MITA CHATTOPADHYAY
PRIYANKA VATS
BABITA KAKKAR
Criteria: ISO 14001: 2004 standard system manuals/Departmental manual & Policy
Methodology: Site Visits, interviews; documentary review and Data analysis/physical tests
EMS 15th INTERNAL AUDIT SUMMARY
(JAN-JUN'2008)
Conclusion and Recommendation
Environment Performance Indicators needs to be analyzed for setting of Objectives, Targets and
Programme(s)?
Mock Drill Training to be imparted to various departments like EHTP, Assembly, Facilities etc
Corrective Actions against the Observations & Minor Non Conformities raised in the Re
Certification Audit by DNV has been submitted to the Certification Agency (DNV).
Special emphasis is required for Closure & follow up of activities as mentioned in respective
Environment Manangement Programme(s)
Efforts to be done for follow up of actions as discussed in respective EMG meetings at department
level.
Procedure for rating system of Environmental Assessment of Vendors generated and implemented
by Purchase dept for strengthening of Supply Chain Management System
Queries related to Environmental legislations – PFOS, REACH Directive, Flame Retardants are
being asked by major Customers like Emerson & ST Microelectronics.
DNV AUDIT OBSERVATIONS (Nov 07)
S.NO
ISO 14001 ISO CLAUSE
CLAUSE
REF.
PROCESS/ AREA/
DEPARTMENT
Observation
Stores
4.4.6
2
4.4.7
Emergency The spent solvents are categorised as hazardous
Preparedness waste in category 20.2, Schedule 1 of Hazardous
& Response Waste Rules. For ensuring safe transport of
these hazardous wastes which are highly
inflammable, company needs to give TREM
cards to the carrier and also check that the driver
has received training for transport of hazardous
goods
Observation
Personnel & Admin
3
4.4.7
Emergency 1) In mock drill reports, the action plan and
Preparedness action taken report for closure of the observations
& Response are not recorded.
2) For evacuation effectiveness, the head count
should also be tallied with the attendance and
visitors record.
Observation
Personnel & Admin
3) Gangway / Pathway for Shop floor & Office
may be demarcated.
4) Emergency Exits may be identified &
illuminated.
Opportunity for
Improvement
Personnel & Admin
1) For monitoring performance of the cooling
tower of chilling system, the approach of cold
water temperature to the wet bulb temperature
should be monitored and controlled within 3 °C.
2) Monitoring CO2 in water after degasser and
controlling it within 5 PPM.
Opportunity for
Improvement
Facilities
4.4.6
Operational
Control
The MSDS for various solvents / chemicals kept
in Stores does not give details about required
storage conditions as well as PPE's required for
safe handling.
CATEGORY OF
FINDING
1
4
Operational
Control
DESCRIPTION & CONSEQUENCE
S.NO
ISO 14001 ISO CLAUSE
CLAUSE
REF.
Operational
Control
DESCRIPTION & CONSEQUENCE
PROCESS/ AREA/
DEPARTMENT
Opportunity for
Improvement
Facilities
5
4.4.6
6
4.4.7
Emergency 6) Audibility of Siren to be checked in all
Preparedness production areas. In case, the siren is not audible
& Response in any production room, individual hooter in
parallel with siren needs to be installed over
there.
7) The hydrant pressure should also be checked
and recorded.Presently, there is no pressure
gauge in the line.
Observation
Facilities
7
4.4.7
Emergency 1) No obstructions should be kept in front of the
Preparedness emergency exit doors.
& Response 2) Emergency Procedures may be established &
Implemented in Shopfloor where hydrogen &
oxygen gases are consumed.
Opportunity for
Improvement
Production (Wfr Fab)
8
4.5.2
Opportunity for
Improvement
Management
Representative
Evaluation of
Compliance
3) The dissolved gas analysis of transformer oil
may be got done once in 5 years to diagnose
any developing problems in the transformer
winding / insulation.
4) Analysis of ETP sludge to know the main
constituent, for easier sludge disposal.
5) The direction of flow may be marked on the
various pipelines in the ETP for easier control.
CATEGORY OF
FINDING
In the Register of Regulations, the evaluation
status of the all the legal and other applicable
requirements may be incorporated and the same
may be discussed in the EMRC meeting
NOTEWORTHY EFFORTS
n
The general understanding and compliance of legislation pertaining to
environmental rules is found quite good.
n
The company has effectively implemented the green supply chain
management system as more than 50% suppliers are ISO 14001
certified and further pontential green suppliers are being identified.
n
The company has effectively complied with the POHS requirements
of the client M/s Super Victory, China.
NO OF NC'S / OBSERVATIONS
0
DEPT
EDP
Sales and Mktg
Purchase
Assy / Diode Assy
EHTP
WF Engg
Lead finish
Test/Print/Pack/CS/FG
MR section
Assy Engg
Accounts & General Stores
Facilities
Exports & PPC
Research & Development
Wafer Fab
Personnel & Administration
DEPARTMENTWISE NCR’s / OBSERVATIONS
DEPTWISE NCR'S / OBSERVATIONS
5
4
3
2
1
CLAUSES
4.6
4.5.5
4.5.4
4.5.3
4.5.2
4.5.1
4.4.7
4.4.6
4.4.5
4.4.4
4.4.3
4.4.2
4.4.1
4.3.3
4.3.2
4.3.1
4.2
NO OF NC'S / OBSERVATIONS
ISO 14001 CLAUSEWISE NCR’s / OBSERVATIONS
CLAUSEWISE NCR'S / OBSERVATIONS
5
4
3
2
1
0
Evaluation of
Legal Compliance
Evaluation of Legal Compliance
Status of Licences/authorisations:
NO. OF LICENSES /
CONSENTS /
AUTHORISATION
VALIDITY DATE
RESPONSIBILITY
1
License to work a
factory from Chief
Inspector of Factories.
One
31/12/2008
Admn
2
“Consent to Operate”
from DPCC (Air/Water
Consent)
One
05/08/2009
Admn
3.
Authorization to
operate a facility for
storage of hazardous
waste
One
17/09/2009
Admn
4.
License to store Liquid
Nitrogen
One
31/03/2010
Admn
5.
License to store
Mixture gas &
Hydrogen
One
30/09/2008
Admn
S.NO.
TITLES OF LICENSES /
CONSENTS /
AUTHORISATION
Due to shifting of production units the cylinder storage for Hydrogen
And forming gas has come down within the legal limit of 25 cylinders.
Therefore the applicability of gas cylinder rules ceases to exist.
Evaluation of Legal Compliance
Verification of Compliance with respect to Procedural Requirements
Water Cess return submitted regularly.
“Environment Statement" was submitted to DPCC on
24.9.08
All outlet effluent and ambient air quality parameters are
well within the prescribed standards.
All stack monitoring parameters are well within norms
Extent to which Objectives & Targets
have been met
Ecological FootPrints of
Production Areas
Pawan Tanwar
ECO FOOT PRINT WAFERFAB
ECOFOOTPRINT WAFER FAB (2007-08)
ECOFOOTPRINT WAFER FAB (2006-07)
Energy
Energy
95
Effluent
75
95
Water
55
Effluent
35
15
Haz Waste
GW
15
HSD
Chemicals
Gases
Water
55
35
-5
75
Haz Waste
-5
GW
HSD
Chemicals
Gases
ECO FOOTPRINT METALCAN
ECO FOOT PRINT ASSY- 1 (2007-08)
Haz Waste
ECO FOOT PRINT ASSY- 1 (2006-07)
Energy
Energy
55.0
55.0
45.0
45.0
Water
35.0
Haz Waste
25.0
25.0
15.0
15.0
5.0
5.0
-5.0
-5.0
GW
Chemicals
Water
35.0
Gases
HSD
GW
Chemicals
Gases
HSD
ECO FOOTPRINT EHTP
ECO FOOTPRINT EHTP
( FY 07-08)
ECO FOOTPRINT EHTP
( FY 06-07)
Energy
Haz Waste
7.0
5.0
3.0
1.0
-1.0
-3.0
-5.0
GW
Energy
Water
Gases
HSD
Haz Waste
7.0
5.0
3.0
1.0
-1.0
-3.0
-5.0
GW
Water
Gases
HSD
ECO FOOTPRINT LEAD FINISH
ECO FOOT PRINT LF 07 - 08
Effluent
Haz Waste
ECO FOOT PRINT LF 06 - 07
Energy
Energy
1.3
0.8
0.8
0.3
Effluent
Water
Chemicals
Water
0.4
0.2
HSD
Haz Waste
-0.2
GW
0.6
0.0
HSD
-0.2
Aq Eutrph
Aq O2 Dmnd
GW
Chemicals
Aq Eutrph
Aq O2 Dmnd
ENVIRONMENTAL BURDEN PRODUCTION AREA
(2006—07)
Metal
EHTP /
Wafer
Can/
1000
Fab/
Devices
[1000 wfr] (1000
Devices)
LF/
1000
Devices
BURDEN
POTENTIAL
EFFECTS
UNITS
Global
Warming
Climate
change
Kg
CO2 Eq
44664.7
43.92
5.44
0.46
Ozone
Depletion
Climate &
health
Kg R11 Eq
0.22
--
--
--
Total VOC
emissions
Urban smog;
health &
safety
Kg
VOC
106.42
0.0152
--
0.0023
Atmospheric
acidification
Acid rain;
health
Kg SO2
Eq
2.02
0.042
0.000029 0.0004
(2006—07)
BURDEN
POTENTI
AL
EFFECTS
UNITS
Wafer
Fab Per
1000wfr
Photochem
ical Ozone
Creation
Urban
smog;
health
Kg
Ethylene
Eq
2606.2
Aquatic
Oxygen
Demand
Threat to
fish and
aquatic life
Kg BOD
15.42
Aquatic
Eutrophica
tion
Removes
oxygen
from water
METAL
CAN per
K Devices
EHTP
per K
Devices
LF
Per K
Devices
--
--
--
--
--
0.0014
--
--
0.0002
Kg
Phosphate
Eq
7.38
(2007—08)
Wafer
Fab Per
1000wfr
Metal
Can
Per K
Devices
EHTP
Per K
Devices
LF
Per K
devices
25.3
4.88
0.7656
--
--
--
--
0.0017
BURDEN
POTENTIAL
EFFECTS
UNITS
Global Warming
Climate
change
Kg CO2
Eq
91219.7
Ozone Depletion
Climate &
health
Kg R-11
Eq
0.36
Total VOC
emissions
Urban smog;
health &
safety
Kg VOC
149.34
0.0139
Atmospheric
acidification
Acid rain;
health
Kg SO2
Eq
4.45
0.0032
0.000034
0.0003
(2007—08)
POTENTI
AL
EFFECTS
UNITS
(Per K
Wafer)
Photochemi
cal Ozone
Creation
Urban smog;
health
Kg
Ethylene
Eq
Aquatic
Oxygen
Demand
Threat to fish
and aquatic
life
Kg BOD
Aquatic
Removes
Eutrophicati oxygen from
on
water
Kg
Phosphate
Eq
BURDEN
Wafer
Fab
METAL
CAN
EHTP
LEAD
FINISH
3881.5
--
--
12.22
--
--
0.0012
4.9
--
--
0.0002
--
ENVIRONMENTAL BURDEN WAFER FAB. PER 1000 WAFERS
2006-07
2007-08
91219.7
44664.7
Aq.Eutro.
AOD
3881.5
POCP
Atm.Acid.
VOC
OD
2606.2
GW
100000
90000
80000
70000
60000
50000
40000
30000
20000
10000
0
Global warming(KgCO2Eq) per K devices
45
43.9
06--07
07--08
40
35
30
25
25.3
20
15
10
5.44
5
0
4.88
0.46
Metalcan
EHTP
LF
0.76
Energy Consumption (KWH/K devices)
50
45
40
35
30
25
20
15
10
5
0
46.95
06--07
07--08
31.89
6.29
5.99
Metalcan
0.645 1.03
EHTP
LF
Atmospheric Acidification (Kg SO2 Eq )per K devices
0.0045
0.004
0.0035
0.003
0.0025
0.002
0.0015
0.001
0.0005
0
06--07
07--08
0.0042
0.0032
0.000029 0.00003
Metalcan
EHTP
0.0003
0.0004
LF
Ozone Depletion( Kg R-11 Eq.) per 1000wafer
0.4
0.36
0.35
0.3
0.25
0.22
0.2
0.15
0.1
0.05
0
Diff
06--07
07--08
Foot Print Analysis
Wafer Fab.
1. Aquatic Oxygen demand & Aquatic Eutrofication has
decreased due to more Re-cycling of water .
2. Global warming has been increased per wafer due to
fixed consumption of energy for air conditioning, lighting,
for compressed Air etc.
3. O3 dep., VOC,AA & POCP has increased due to fixed
chemical change frequency of the chemical bath
irrespective of the production quantity.
Metal Can
1. The Global warming, VOC , and AA has been decreased
due to more production.
EHTP
Foot Print Analysis
1. Global warming has been reduced marginally may be due to
Energy consumed by machine depends on the production
and the fixed energy for air conditioning/ lighting have less
impact on total energy consumed i.e. low fixed/ variable
energy ratio.
Lead Finish
1. Global warming has been increased per K devices of
production due to fixed consumption of energy for air
conditioning, lighting, for compressed Air etc.
2. VOC has been decreased due to usage of old/liquidated stock
of organic chemicals.
3. Aquatic Oxygen demand has been reduced due to more
water Re- cycling done in 2007--08.
Extent to which objectives are met
Dept
Wafer
Fab
Wafer
Fab
Objectives/Targets
To assess manufacturing phase
of Life cycle assessment of
Schottky diode CB-21
To recycle used Millipore DI
Water from Rinser Dryer
Status as on 1.10.08
All data regarding energy ,water &
chemicals, gases & metals have been
collected. EMP closed due to production
stoppage.
Water from GMN contained organic solid
impurities(11mg/ltr) when mixed with
recycled millipore DI water from Rinser dryer
was causing adverse effect on MPDI plant.
EMP closed due to production stoppage
Facilities
Facilities
To reduce consumption of
compressed air usage by 5% wef
Sep 07
About 13.4% reduction in air consumption
has been achieved since Sep
07.Corresponding power consumption
reduced by 17.8%.KWH/CFM reduced by
6.21%
To initiate vermicomposting of
canteen food waste
Prepared vermicomposting beds, installed
procedure. Composted 45 days Canteen’s
food waste with earth worms. The manure
produced was used in gardens. The
procedure gets validated.EMP stands
closed.
Dept
EHTP
Objectives/Targets
To reduce percentage lead
frame rejections from 2.04 % to
1.5 % by Jun 08
Lead frame rejections increased steadily since
the change of the supplier from APL(Ag) to
NINGBO(Cu). Rejection for Jul 08 ( 2.07%)
,Aug 08(2.06%), & Sep 08 (3.42%) .Ordered
for bearings to realign Indexers. Extension
sought till Mar 2009.
Green Procurement in 2007-08:
Purchase
To increase the Green
procurement for (RM+Pkg) and
consumables by 5% with respect
to 2007-08 by Dec 2008
a) RM: Total 15462.66 Kg., Non-Green: 28.60 Kg.
RM% - 99.98%
b) PKG: Total 4302.0Kg., PKG%: 100%
Green Procurement in 2008-09:
a) RM: Total 10432.33 Kg., Non-Green: 33 Kg.
RM% - 99.68%
b) PKG: Total 3387.33 Kg., PKG%: 100%
LF
LF
To reduce the water
consumption at least by 7% with
respect to consumption of 04-05
To study the feasibility of
recycling and reuse of solvents,
acetone and IPA from various
production processes.
The water consumption reduced by 5% [from
0.0407 KL/K in 04-05 to 0.0377 in 07-08] due to
optimization in water rinses, arresting leakages,
optimizing production timings and increasing
operator awareness
Recycling of Acetone & IPA was found feasible
and is being deployed in testing and
Mohali.EMP stands closed
Dept
Exports
Objectives/Targets
To liquidate non moving FG
Export stock [Non RoHS] by Dec
2007 by at least 95-100 %
Total [DTA+EHTP] Reduced from 10.93
million to 0.57 million.[94.3%]
EMP stands closed
Total [DTA+EHTP] Reduced from 11.68
million to 1.01 million.[91.4%]
Sales &
Mktg
To liquidate non moving FG
Local stock [Non RoHS] by Dec
2007
DTA stock reduced from 8.42 million to 1.01
million [88%]
EHTP FG stock was completely
liquidated by June 2007
EMP stands closed
Sales &
Mktg
To study the feasibility of
reduction of packaging material
by Dec 2008.
Packaging material consumption as a %age
of total shipment [Domestic +Export] is
monitored since Jul 08.Study is in progress.
Power & Fuel [ 2004 to 2008]
Total Power Consumption (KWh)
5500000
5087032
5039028
5019314
5000000
4529700
Total power consumption
Reduced by 11% since
2004
4500000
4000000
Total Power
Consumption (KWh)
2004-05
2005-06
2006-07
2007-08
5087032
5039028
5019314
4529700
Qty of Diesel Procured (Ltrs)
Total Diesel consumption
Reduced by 91.8% since
2004
600000
390053
444000
400000
72000
200000
0
Qty of Diesel Procured
31800
2004-05
2005-06
2006-07
2007-08
390053
444000
72000
31800
Power & Fuel [ 2004 to 2008]
Total Raw Water consumption (KL)
80000
70139
59934
45551
60000
35977
40000
Total raw water
consumption
2004
20000
0
Total Raw Water
2004-05
2005-06
2006-07
2007-08
70139
59934
45551
35977
Power & Fuel Cost (In Rs)
39496247
Total Power & Fuel Cost
2004
40000000
35077071
28055435
25201310
30000000
20000000
10000000
0
Power & Fuel Cost
2004-05
2005-06
2006-07
2007-08
35077071
39496247
28055435
25201310
Power & Fuel [ 2004 to 2008]
Annual Average Power Factor
0.990
0.986
0.983
0.972
Power Factor maintained
above 0.98 for two
consecutive year by close
Monitoring of capacitor
performance
0.980
0.960
0.970
0.960
0.950
0.940
2004-05
2005-06
2006-07
2007-08
Power & Fuel Cost/Ton-Hour
Total Power & Fuel
Cost Per ton-hr
reduced by 76.9%
[From Avg Rs 11.13
in 2005-06 to Avg
Rs 2.57 in 2008] by
Continuous
optimization of
chillers.
P&F Cost (Rs/Ton-Hour)
20.00
18.38
18.00
16.00
14.00
11.54
12.00
12.03
2005-06
2006-07
2007-08
2008-09
13.48
11.78
11.52
11.79
10.00
10.72
10.61
8.00
8.24
7.82
6.00
5.70
3.57
4.00
3.16
2.00
3.60
3.17
2.72
2.49
Apr
May
3.83
3.15
2.41
3.88
3.10
2.61
4.02
3.37
3.56
3.20
3.04
2.6
3.16
3.27
3.03
2.79
2.92
3.05
3.09
2.71
2.68
3.01
3.00
0.00
Jun
Jul
Aug
Sep
Oct
Nov
Dec
Jan
Feb
Mar
Optimization of Screw Chillers
0.716
0.635
0.62
160
150
140
130
120
110
TR
200
190
180
170
160
0.634
0.619
0.644
150
140
130
0.603
0.592
120
0.57
0.576
TR
110
0.554
90
100
0.582
0.576
0.646
60
50
40
30
20
10
0.625
0.689
0.673
0.716
0.73
0.72
0.71
0.7
0.69
0.68
0.67
0.66
0.65
0.64
0.63
0.62
0.61
0.6
0.59
0.58
0.57
0.56
0.55
0.54
0.53
0.52
0.51
0.5
0
IKW/Ton
The operating curve of
the 182 TR screw chiller
shows max efficiency at
50% loading of 91 Ton.
Good operating efficiency
obtained by maximizing
the running the chiller in
the range of 65 to 90 TR
load
IKW/TR 4185.1
80
100
90
80
70
60
50
40
30
20
10
0.553
0.577
0.583
0.604
0.647
0.674
The operating curve of the
150 TR screw chiller shows
max efficiency at 50%
loading of 75 Ton.
Good operating efficiency
obtained by maximizing the
running the chiller in the
range of 80 to 110 TR load
70
0.73
0.72
0.71
0.7
0.69
0.68
0.67
0.66
0.65
0.64
0.63
0.62
0.61
0.6
0.59
0.58
0.57
0.56
0.55
0.54
0.53
0.52
0.51
0.5
0
IKW/Ton
IKW/TR 4155.1
Naraina’s AC load Profile
Typical AC Load Profile at Naraina (TR)
350
300
300
241
Tonnage
250
200
50
100
40
100
100
325
308
143
142
130
Max
Min
240
152
150
100
310
100
130
110
103
137
107 110
83
80
50
DEC
NOV
OCT
SEP
AUG
JUL
JUN
MAY
APR
MAR
FEB
JAN
0
The size of the screw chillers allows to optimize the loading up to
200 TR throughout the year [for 83% of the time]. During remaining
17 % of the time the load crosses 200 TR and runs at slightly higher
IKW/Ton.
EMG Meeting Status since Dec 07-Sep 08
Departments
Scheduled
No of
Departments
Scheduled
Meetings
No of
Meetings
Facilities/ General
Stores
10
10
Test/Print/Pack/CS
10
9
Metal Can
10
10
Purchase
10
8
R&D
10
10
P& A
10
5
EHTP
10
10
LF
10
4
Sales & Mktg
10
10
Exports & PPC
10
2
7
7
Wafer Fab
HODs of Key supply chain areas need to actively drive holding of
EMG Meetings
Follow up Actions from EMRC Nov 07
Issues
Actions Taken
Specific Work related Training
(SET) needs strengthening
HR prepared detailed competency based
SET training modules
Green procurement to be
expanded
Purchase took an EMP on increasing the
green procurement. A comprehensive
document for management of product
oriented legislation was introduced as
part of Purchase OCP.
NON-GREEN VENDORS
NUMBER OF GREEN PARTNERS
NO. OF GREEN PARTNERS
60
50
40
30
20
10
0
20
20
15
35
35
40
Oct 07
Jan 08
Apr 08
13
8
42
47
July 08 Sept 08
57
Total
Vendors
Recommendations
for Improvements
Recommendations for Improvement
ISSUES
PRESENT
STATUS
Frequency of Once in six
EMRC
months
Training
Training on
product related
legislations
ACTION REQD
To be done once in a year
SET training modules on
management of product
related legislations to be
increased
RESPONSIBIL
ITY
MR
HR
THANKS

EMRC Oct 2008

Transcription

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