Quality Circle Forum of India

Environment Health and Safety

Improvements Success Story.
TEAM MEMBERS:-
1) SHREYAS KULKARNI
2) YUVRAJ JADHAV
3) AJINKYA GAIKWAD

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FORBES MARSHALL PVT.LTD
Manufacturing Footprints

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OUR PRODUCTS

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 Energizing Businesses
We build long-term, collaborative partnerships with customers

1955: Amul Dairy Company 2015: Amul Dairy Company

Coal Boiler Inauguration by the Prime Minister. Biomass Boiler Inauguration by the
President.
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Control Instrumentation Solutions

Chemicals Pharmaceuticals Power Oil and Gas Water

We help customers build and sustain

highly efficient plants by reducing waste,
optimising process and energy efficiency,
and complying with regulatory
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requirements.

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r Tyre
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 INDEX

Sr. No. Content Page No.

1.0 History. 8
2.0 Introduction. 9
3.0 Case- 1 Problem Description. 10
4.0 Case- 1 Problem Solution & Tools Implemented. 11
6.0 Case- 2 Problem Description. 12
7.0 Case- 2 Problem Solving Tool Step / Procedure. 13
8.0 Case- 2 Problem Solution Implemented. 14
9.0 Case- 3 Problem Description 15
10.0 Case- 3 Problem Solution A] 15
11.0 Case- 3 Problem Solution B] 16
12.0 Case- 3 Problem Solution C] 17
13.0 Case- 3 Problem Solution D] 18
14.0 Case- 4 Problem Description & Solution. 19
12.0 Results Of The Successful Safety Improvements. 20
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 1.0 History-

• This study aim towards the Kaizen in safety by constructing a safe structure for cleaning and
preventive maintenance of solar panels (Case 1) i.e. Staircase and Safety Walk Ways at Roofs.

• Employees health safety enhancing through improvement in drinking water quality (Case 2)
i.e. As scientifically proven and WHO (World Health Organisation) stated that RO water is
health hazardous as it deprives us from essential minerals, also RO water production cause
large amount of water wastage which may leads to water scarcity and cause environmental
hazard thus need to provide substitute to RO water.

• Systematic strategy towards the protection of environment (Case 3) i.e. Energy Conservation,
Reduce emission of harmful gases and carbon foot print and prevention of noise pollution using
Reduce – Reuse – Recycle mind-set.

• Transition to renewable green energy source (Case 4) i.e. Solar power plant installation.

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 2.0 Introduction :-

• The enhancement in safety against physical hazard in “Roof Solar Panels” while maintenance
& Cleaning activity, these kaizen initiative reduces the risk level substantially.

• Bubble top or bottom loading RO water dispenser discarding as RO water can cause physical
hazards if consumed for prolong period thus providing substitute for the same, also RO water
plant causes large amount of water wastage which may leads to drinking water scarcity and
result in Meteorological Hazard

• Reuse and recycle of the industrial wastes such as Glass, foam, metal scrap which can leads
to land pollution and reuse it in such a way to reduce or control another pollution like noise
and enhance human comfort which results in overall increase in productivity.

• Transition to renewable green energy to reduce emission of harmful gases during electrical
energy generation, which enhance greenhouse effect and contributes to global warming.

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 Improvements in Safety :

1.0 Case-1 Problem Statement:-

• The R&D building roof solar panels did not have any provision to reach for cleaning and PM
activity, the roof had substantial height of 30 feet.
The time period consumed for implementation 90-100 days
Hazard Type- Physical Hazard.
Consequence:-
1. Body Stress .
2. Lack of confidence.
3. Fear / Acrophobia
4. Dizziness.
Risk level Score of previous procedure:- Likelihood x Severity
Legends

Risk level Score:- 4x4= 16 Brainstorming Session

Tool / Technique Used To Solve The Problem:- Brainstorming. 10

 Improvements in Safety :
1.0 Case-1 Solution to the Problem:-
• Constructed the safety walkway at the R&D building
roof to reach the solar panels location.
Top Ideas Obtained during brainstorm session are as follows:-
1) Permanent Scaffolding erection.
2) Scissor lift
3) Cherry Picker
4) Staircase and safety walkway construction.

Advantages:-
1) Enhanced safety.
2) Improved confidence.
3) Hazard minimized.
4) Peace of Mind.
5) Improved work quality.
6) Easy for maintenance and cleaning, this increased life cycle of
the machine.

Risk level Score of after improvement:- Likelihood x Severity

Risk level Score:- 2x2= 4 i.e. 75% reduced NOW- Staircase & Safety Walk way to roof solar.
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 Improvements in Safety :
2.0 Case-2 Problem Statement:-
• “RO water bottles usage in bubble top & bottom loading water Bubble Top Water Dispenser
dispenser machines”. As it is scientifically proven & WHO stated that
RO water is harmful to human body as it deprives us from essential
minerals like calcium, magnesium, fluoride etc.
Hazard Type- Physical Hazard, Meteorological Hazard.
Consequence:-
1. It is already known that RO (Reverse Osmosis System) gives only 30 %
product water (Drinkable water) and 70 % wastage water, thus it is a
huge concern to drinking water scarcity in India and which can cause
meteorological hazard.
2. Prolong drinking RO water causes bone diseases like Osteoporosis
and tooth weakness due to deficiency of calcium and fluoride.
3. Prone to motor neuron disease due to deficiency in magnesium.

Risk level Score of previous procedure:- Probability x Severity.

Risk level Score:- 4x3= 12 BEFORE – RO water bottled

Tool / Technique Used To Solve The Problem:- PDCA / Deming dispenser. 12
Cycle.
 Improvements in Safety :

2.0 Case-2 Problem Solving Tool Steps / Procedure :-

Identified Problem:- RO Bottled Water Hazardous For Employees Health.

PDCA / Deming Cycle Implementation
Procedure:-
1) PLAN Created an action plan to remove “RO Bottled Water
Dispenser Unit” and Install “Hot & Cold UV Water Dispenser
Unit in its place” i.e. defined a schedule & people responsible
to perform the task.
2) DO Execute the action plan of the task.
3)CHECK Take a trial to confirm the Hot & Cold UV Water Dispenser
Unit is working as per its objective & water quality as
4) ACT required.
After successful trial and achieving desired water quality
PDCA / Deming Cycle ( Plan,
results, replaced Hot & Cold UV Water Dispenser at 16
Do, Check & Act )
location throughout the factory.

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 Improvements in Safety :
2.0 Case-2 Solution to the Problem:- Hot & Cold UV Water Dispenser

• “Replaced all the bubble top and bottom loading RO water

dispenser machines With Hot & Cold UV water dispensers”.
Total 16 Nos Hot & Cold UV water dispenser installed at various
location throughout the factory.
Time period consumed for implementation-90-100 days

Advantages:-
1) Water with natural essential Minerals.
2) Good TDS counts i.e. 150 to 250 ppm, with relative to RO water
which is below 30 ppm.
3) Less water cost with respect to RO water.
4) No water wastage as compared to reverse osmosis system.
5) No water loss which is caused in RO water bottle replacement.
NOW- Normal Tap water is
Risk level Score of after improvement:- Probability x Severity passed through Carbon,
Sediment Filter of UV water
Risk level Score:- 4x1= 4 i.e. 65% reduced dispenser.
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 Improvements in Safety :
3.0 Case-3 Problem Statement:-
• “Energy Conservation, Reduce emission of harmful gases and carbon foot print and prevention of noise
pollution using Reduce – Reuse – Recycle.

3.0 Case- 3 Solution Of the

Problem:-
A] R&D partition wall sound Insulation

• Re-use of 100 kg’s waste Foam which would have gone

to landfill.

• It was generated from our FGS packing facility.

• Foam being porous and acts as a good sound insulator.

• Monitory benefits of INR 2800.

• Sound level dropped from 87Decibles to 62Decibles.

• Increment in user comfort and focus in work.

• Aesthetics improved
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 Improvements in Safety :
3.0 Case- 3 Solution Of the Problem:-
B] Glass Reuse at R&D partition

• • Used scrap glass and doors removed from cabins.

It take 4000 years for glass to decompose.
• • 1 ton glass saved from landfill.
Previous EIA score – 16
• New EIA score -- 1
• Around 1025 kg co2 emissions saved. 16
 Improvements in Safety :
3.0 Case- 3 Solution Of the
Problem:-
C] Scrap Material reuse for R&D Visitor meeting rooms at R&D.

• Used scrap glass for partitions.

• Reused 90k of Scrap Glass material.

• Reused 10 nos. scrap roof sheets for ceiling from

demolition scrap.

• Environmental impact reduced as below.

• 500 kg of waste diverted from landfill.

• 600 kg of raw materials saved.

• 150 kg less of CO2 emissions.

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 Improvements in Safety :
3.0 Case- 3 Solution Of the
Problem:-
D] Using Cement Aerocon panels for Guarding of office area.
Boiler Sales office Aerocon Wall SSD 1st Floor sales office Aerocon wall

• Noise pollution reduced by 15 Db.(81 db to 66 db.)

• Simultaneous working of Infra Team and Office area achieved.
• Risk of direct injury due to any objects falling from the area under redevelopment avoided.
• Risk score previous -16 ( High risk) After partition risk score – 4(low risk). 18
 Improvements in Safety :
4.0 Case- 4 Problem Statement :-
Heavy CO2 emission from the worlds electrical power industry. This results in an increase in the Earths
level of atmospheric carbon dioxide, enhances the greenhouse effect and contributes to global warming.
4.0 Case- 4 Solution Of the Problem:- Transition to renewable green energy source

SOLAR PLANT : - Roof top solar power plant installation at Forbes Marshall Chakan unit with M/s Amplus
Energy Solution on Operating Expenses Model, Operational Date 15 Aug 2021.
Plant Capacity – 1050Kwp (800 KW A/C)
Total Panels – 2500 Nos
Total Inverters – 8 nos.
CO2 emissions due to electricity generation 0.23314 kg CO2e per kWh,Therefore reduction of 1873 metric
tones of CO2 emission in 16 months 19
 Results of the Successful Safety Improvements :

• The effectiveness or successfulness of any kaizen done to enhance safety can measured on account of the number
of users and the ease to restrict hazard to their working environment.
• Thus below are the of number users whose working environment hazard ease off by the following improvements

Risk Level Reduced 75%

1) Staircase & Safety Walkway At Roof 10
50+ 5
Solar Location. 0
Users DG Sets

BEFORE NOW
No. Of Users
Risk Level Reduced 65%
2) Replacement of RO water dispenser
with Hot & Cold UV water dispenser 500+ 20
10
machine. Users 0
Water Dispenser

No. Of Users BEFORE NOW

Risk Level Reduced 50%

3) Insulated wall, Scrap glass reuse, 500+ 20
10
cement Aerocon panels . Users 0
Industrial DB RCCB

No. Of Users BEFORE NOW

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• Thank you !

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