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    Ashok Leyland IAQ Quality Sustainability Award Summary

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    Sudhagar
    This project aimed to reduce phosphate sludge generation at an automobile manufacturing plant. Phosphate sludge generation was nearing the authorized limit set by the state. The project team used Six Sigma DMAIC methodology to analyze the problem. They found high moisture content was a key cause of sludge. Installing a drying bed reduced sludge from 6.92g/sqm to 5.22g/sqm. Using a more compact phosphate coating chemical further reduced sludge to 4g/sqm, keeping generation under the limit. This improved productivity while reducing water and energy use, saving over $70,000 annually.

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    Ashok Leyland IAQ Quality Sustainability Award Summary

    Uploaded by

    Sudhagar
    99 views1 page
    This project aimed to reduce phosphate sludge generation at an automobile manufacturing plant. Phosphate sludge generation was nearing the authorized limit set by the state. The project team used Six Sigma DMAIC methodology to analyze the problem. They found high moisture content was a key cause of sludge. Installing a drying bed reduced sludge from 6.92g/sqm to 5.22g/sqm. Using a more compact phosphate coating chemical further reduced sludge to 4g/sqm, keeping generation under the limit. This improved productivity while reducing water and energy use, saving over $70,000 annually.

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    This project aimed to reduce phosphate sludge generation at an automobile manufacturing plant. Phosphate sludge generation was nearing the authorized limit set by the state. The project team used Six Sigma DMAIC methodology to analyze the problem. They found high moisture content was a key cause of sludge. Installing a drying bed reduced sludge from 6.92g/sqm to 5.22g/sqm. Using a more compact phosphate coating chemical further reduced sludge to 4g/sqm, keeping generation under the limit. This improved productivity while reducing water and energy use, saving over $70,000 annually.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    99 views1 page

    Ashok Leyland IAQ Quality Sustainability Award Summary

    Uploaded by

    Sudhagar
    This project aimed to reduce phosphate sludge generation at an automobile manufacturing plant. Phosphate sludge generation was nearing the authorized limit set by the state. The project team used Six Sigma DMAIC methodology to analyze the problem. They found high moisture content was a key cause of sludge. Installing a drying bed reduced sludge from 6.92g/sqm to 5.22g/sqm. Using a more compact phosphate coating chemical further reduced sludge to 4g/sqm, keeping generation under the limit. This improved productivity while reducing water and energy use, saving over $70,000 annually.

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    One Page Summary

    Phosphate Sludge Generation Reduction


    Name of the Project: Phosphate Sludge (hazardous waste) generation reduction in Cabin pre-treatment line
    Name of the Organization hosting the project: Ashok Leyland Ltd. (India)
    UN Sustainability Development Goal affected: Goal 12: Responsible Consumption and Production
    Introduction:
    In Commercial Vehicle manufacturing, painting is one of the important process which generates sludge (hazardous
    waste). At Ashok Leyland, we comply with all transportation and disposal rules related to the waste management
    standard (prevalent in the country). While adhering to compliances, being a responsible organization, we are
    continually innovating to reduce waste generation. One such project at our Hosur-2 plant is explained here.
    Essence of the project and Problem statement:
    In its regulation, State has given the authorized limit for waste generation which is 300MT/annum for paint sludge
    and 24 MT/annum for phosphate sludge. At Hosur plant, Paint sludge generation was well within the authorized
    limit whereas, Phosphate sludge generation (Hazardous Waste) was a concern nearing to the authorized limit.
    Going forward, there was a risk to cross this limit as production volumes were predicted to be higher by 20% in
    FY20. Project has been started with the objective of reducing Mean Phosphate sludge generation from 6.92 g/sq.m
    to 4 g/sq.m.
    Methodology used: Six Sigma DMAIC
    Observation and Analysis :
    We performed Measurement system analysis (MSA) for
    titration checking method (Phosphate sludge measurement
    process) to verify whether the measurement system is
    capable. Results suggests that the measurement system is
    capable as Gage R&R is 0.66% and No. of distinct categories
    (NDC) are 214 i.e. project metric data is accurate & precise.
    Nine probable causes are identified for high phosphate
    sludge generation. Detailed cause validation reveals that
    moisture content present in Phosphate sludge is very high
    (61% of sludge weight).
    Improve (Finding, Implementing the solutions with
    resource used):
    1. To address this issue of high moisture content in
    Phosphate sludge, drying bed is installed, and drying process
    is continued. As a result, Mean Phosphate sludge generation
    reduced from 6.92 g/sq.m to 5.22 g/sq.m.
    2. Even with improved performance, projected annual Pp = 1.98
    sludge generation level will be 26 MT against the Govt. Ppk = 1.83
    regulation of 24 MT considering 20% higher production
    volumes.
    To further reduce sludge generation, we went for an
    innovative solution of using less coating weight, which was
    possible with usage of a different ‘Pre-treatment Chemical’.
    From our research, ‘compact & fine phosphate coating chemical’ was found most suitable for this process. After
    implementation, Mean Phosphate sludge generation is reduced to 4 g/sq.m. With this, estimated annual sludge
    generation will be 20 MT against the Govt. regulation of 24 MT even for 20% higher production volume.
    As part of risk analysis, we checked if there’s any adverse impact on Consequential metric (Phosphate coating
    weight). Phosphate coating weight process is stable and capable as Ppk is 1.83.
    Results and Effects (few):
    Phosphate Sludge generation
    1. Mean Phosphate sludge generation reduced from 6.92 g/sq.m to 4 8
    g/sq.m 55% Reduction

    2. Phosphate coating weight process is stable and capable as Ppk is 1.83. 6 6.9 6.8
    g/sq.m

    3. Phosphating process time reduced from 90 sec. to 60 sec. Productivity


    4 5.2 4
    improved by 12%. 4.8
    4. DM water requirement reduced from 180 KL to 120 KL per annum.
    2
    5. Financial benefit of INR 5.25 Million.
    Jan'19

    Feb'19
    Before

    FY19Q2

    FY19Q3

    6. Reduction of carbon footprint because of energy consumption


    reduction.
    Resources used: Expenditure of INR 0.1 Million for Phosphate sludge
    drying bed construction.
    Locking & Cloning the Improvements: Operation controls procedures are changed, and training has been given
    to all associated members. Detailed case study is shared and communicated to all plants of Ashok Leyland.
    Tools used in the project: Variable MSA (GRR study), Pugh matrix, Test of Hypothesis (2 sample t-test), Process
    capability studies, Variable Control charts, Risk analysis.

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