This is a presentation from Ashok Leyland, Hosur I one of the finalists at the 5th CII-GBC National Award for Excellence in Water Management in 2008. The awards are in 2 categories, Within the Fence for work done on minimizing the organisations water footprint, and Beyond the Fence for work done in the community around the industry. This presentation was in the "Within the Fence" category. We thank CII and the respective companies for giving us permission to upload these presentations on the India Water Portal website for dissemination to a wider audience.

1. E-Comet (910) TAURUS 2214 - 22 Tons GVW REAR DUMPER (25 Tons)
New Gen 2518-H Inter Centur y- Luxur a
Stallion 4x4 Mk.III
“CII - Excellence in Water Management –2008”
Company Profile
v Spread of the Plant : 102.4 Acres.
v Built up area : 164 592 sq.mtr.
v Plant & Machinery : Rs. 645 Cr.
v Production Level/Day : 300 Engines & 44 Veh.
v Connected Load : 31924 Kva.
v Captive Power : 8750 Kva.
v Man power : 2740.
v Trees : 1850 nos.
“Every drop of water counts”
1

2. Manufacturing Process
Machining Heat Treatment
Engine assy
Finished Product
Cha ssi s assy
Fra me assy
Axle a ssy FES dre ssing
“Many drops of water will lead to a Ocean”
Water Management Structure
Unit Head
Divisional Heads
Utility Manager & Dept Managers
Shop Representatives
CFTs/SGAs
“Save every drop & save the Globe”
2

3. Water Management Planning
Review performance of last financial year
Set targets for Water conservation
Plan to achieve well within targets Try to achieve the stretched targets.
Develop projects towards Plan & implement
3R Initiatives WATCON projects.
“Every drop of water Recycl ed & Reus ed is water saved for
Others/Fu ture”
Water Management Policy
Mission :
To beco me the “Best wate r efficient unit a mong the automo bile industrie s”.
To mee t the abo ve objec tive by:
§ Scientific approach towa rds wa ter manage men t.
§ Mete ring of wate r con sumption a t micro le ve l.
§ Identi fy projec ts on 3R –Re duce, Reu se & Recyc le of water.
§ Encourage sugg estions & initia tive s taken by our e mploye es towards
water conservation.
“Avoid runoff of water .The wastage is 30%”
3

4. Energy Conservation & Employee Involvement.
Ø Monthly One day “Awareness Tr aini ng Prog ra m on Water / Energy
Conse rvation”.
Ø Water conservation initiatives are shar ed by Utilities team with particip ants.
Ø Need for water conservation & mon itoring syste ms are expl ained.
Ø SGAs(S mall G roup Activities) & CFTs( Cross Functio nal Tea ms)
Ø Suggestions fro m e mp loyees are e ncoura ged.
“Availability of Pure Water Scarce”
Specific Planned Step for Futurity Preservation of
Environment
v AL –H 1 is a signatory for MSG – “A im at Growth but Su stain Eco log y”.
v MSG – “T o pr omot e R esour ce Con ser vati on without co mpr omising H igh end
acceler ated Growth ”.
v Ten N atur al C ommandments (F oc us points) are:
(1) Specific Ener gy & W ater reducti on (2 –6%).
(2) Was te R edcution ( 2 –6%).
(3) R enew able energy incr ease (2 –10%)
(4) Specific GHG emis sion r educ tion(2- 6%) & CDM.
(5) Incr eased r ecy cling of materi als by 2- 10% .
(6) Rai n w ater harvesti ng incr ease by 2 –10%.
(7) Li fe Cycl e Ass ess ment of new pr oduc ts & new tec hnol ogies .
(8) Gr een Purc has e Policy.
(9) Pr oduc t s tew ar ds hip pr ogr am &
(10) R educti on of other natur al c apait als by 2 – 6%.
“Every drop of water counts”
4

5. Specific Water Consumption : 2004 -08
25% redn over
4 years.
10
8 9.72
6
8.73
KL/ECU s
7.28
7.51
4
2
0
2004-05 2005-06 2006-07 2007-08
“Many drops of water will lead to a Ocean”
Year
Per Day Water Consumption : 2005 -2008
4.6% reduction
in abs olute
v alue ov er 3
years
678
656
680
647
660
KL/Day
640
620
2005-06 2006-07 2007-08
Year
“Save every drop & save the Globe”
5

6. Water Consumption Vs Production Increase
WATER CONSUMPTION vs PRODUCTION 68% INCRE AS E
INCREASE IN PRODN
35000 12
PRODUCTION IN
30000 27972
31806 32571 10
25000 9.72
ECU
8.73 8
KL/ECU
20000 7.51 7.28 6
15000 19375
10000 4
5000 2
25% REDN IN
0 WA TER 0
CONS U MP TI ON
2004-
2005-
2006-
2007-
05
06
07
08
YEAR
“Every drop of water Recy cl ed & Reus ed is water saved for O thers/Fu ture”
Water Conservation –Last 4 years : 2004 -08
Water sav ings Water sav ings
Year
(M3/Annum) (M3/Day)
2007 - 08 45270 124
2006 - 07 18000 49
2005 - 06 15156 41
2004 - 05 26100 71
“Avoid runoff of water .The wastage is 30%”
6

7. WATCON INITIATIVES: 2007-08
“Availability of Pure Water Scarce”
Y ea r
Sl. Title o W
f ater s aving of Annual Water Savings . Invesem ent Payback
No imple Made period
. Proje t implemented
c (Months)
m enta
ti on M3 R s. Lakhs Rs Lakhs.
Ins tallation of " Z ro Disc harge
e
F acility" at ETP area tow ards
1 reducing raw w ater 2008 15000 292500.00 21500000.00 882
cons um ption by 50 kl/day .
Elimination of water s eepage
thro' underground w ate r
2 s torage tank s by rec oncreting 2008 3300 64350 300000 55. 9
the tank bottom portion- 2
nos .
Water atomis ation in engine
3 w as hing ac tiv ity after testing 2008 1350 26325 20000 9.1
of engines in test cells along
w ith us age of c ompress ed air.
Replacement of damaged
pipelines at underground fire
4 hy drant ines & thereby
l 2008 1500 29250 25000 10. 3
eliminate w astage of water in
f r e hydrant lines.
i
Recy cling of c ondensate water
from mechanical ev aporator
thro' RO Plant & the reby
5 ensure us age of additionally 2008 4500 87750 25000 3.4
treated RO water for cooling
tow ers & washing m ac hines .
Proc urem ent of w ater pumps
w ith m ec hini al seals instead
c
6 of gl nd rope to eliminate
a 2008 1800 35100 200000 68. 4
w astage of water f orm pum p.
Identi ication of old gate
f
7 v alv es le ading to wastage of 2008 3000 58500 48000 9.8
water thro' leak s & replac e
them w ith butterfly v alv es .
WATCON INITIATIVES: 2007-08
“Availability of Pure Water Scarce”
Filling o f co oling tow er s umps
at Generator house from
8 extra make up water s ump, 2 008 6000 117 000 1 0000 1 .0
therby ensuring no feeding of
w ater during 1s t s hift fr m
o
main overhead tank.
Blowdown c ontr l of co oling
o
towers based on TDS
9 monitoring & thereby red e uc 2 008 30 0 58 50 600 0 12.3
water c ons umption towards
top up quantity of water.
B ending of raw water with RO
l
w ater fo r engine tes t bed
10 appli ations at shop5 engine
c 2 008 1500 29250 2 0000 8 .2
shop & al o still ensure
s
required water parameter.
Idenitific ation water leaks
aro u all shops thro' holiday
nd
11 2 008 3600 70200 4 8002 8 .2
patrolling & arres t leakage o f
water.
Laying o f DM water d istribution
s ystem from Gen erator house
DM plant to shop4 MDV
as sembly for mixing with
12 2 007 1320 25740 2000 00 93.2
radi to r coolant & fiiling o n
a
C h s i , thereby reducing
as s
frequ enc y o f filling for the end
c usto mer.
Intermittent sup ply of water
during s ummer to all s hops by
13 2 007 9000 175 500 0 -
s topping s upply from OHT
during ean hours.
l
I talation of " Pu type tap
ns l sh s"
at urinal po in for fl s hing at
ts u
14 2 007 114 00 22 2300.00 75 000.00 4
s hop3, s hop9, s hop7 & sho p 1
areas.
7

8. WATCON INITIATIVES: 2006-07
“Availability of Pure Water Scarce”
Eliminat ion of wat er wash for
concret e floors in shop floor &
15 2007 1200 23400 0 0
resorting to dry floor cleaning
using scrubbers.
Eliminat ion of raw wat er use
for gardening by ext ending t he
pipeline of treated water
16 2007 3600 70200 50000 8.5
supply from ETP/STP areas,
thereby raw reducing wat er
cons umpt ion.
Piping modification for us age
of "Localised 15 k l
capacity c oncrete overhead
17 t ank" at shop5 machine s hop, 2006 4500 87750 15000 2.1
t o rest rict wat er supply to
only 2 bays of s hop5 machine
shop, in first s hift .
Piping installation for using
reject water of drinking wat er
18 2006 2400 46800 190000 48.7
Purifiers at urinal points for
flushing.
Int roduction of fourt h pipeline
source from private agency
for supply of pot able water,
19 2006 6300 122850 0 0.0
towards reduc tion in water
receipt from tanker t o MOQ
level of 100 kl.
WATCON INITIATIVES: 2005-06
“Availability of Pure Water Scarce”
Installation of "Kent" make 6"
dia water flow met ers at main
20 & shop5 pump houses, t o 2006 - - 100000 -
direc tly quant ify water
cons umed at the plant level.
Ins tallat ion of "Air cooled
Refrigerated t ype compressed
air Dryers" - 2nos, to eliminate
21 2006 1800 35100 400000 136.8
use of wat er t hro' cooling
tower incase of w ater cooled
machines.
Extension of "RO water usage"
for compressor cooling wat er
circ uit , t owards reducing
22 2006 2250 43875 10000 2.7
descaling frequency of
intercooler & after cooler tube
bundles.
Introduct ion of "Foam t ype
taps" at all high consumption
shops( shop5, shop1 & 2 &
23 2005 11100 216450.00 150000.00 8
employees canteen) of t he
plant & t hereby reduce 37
kl/day.
8

9. WATCON INITIATIVES: 2004-05
“Availability of Pure Water Scarce”
Im proving cooling effic iency on
com pr sor c oolng tower ,
es i s
by replacement of fills,
24 reconditi ning of sprinkler
o s 2005 1500 29250 75000 30.8
etc., & thereby reduce
evaporation loss . Spillage loss
& m ake up water quantity.
C ons truction of "Rain water
c oll c tion Sum ps " - 10 nos at
e
plant level, towards c hargi gn
25 2005 6000 117000 1000000 102.6
the ground l vel & thereby
e
helping to the water supplying
agenc y towards better yield.
Reduc n g water consumption
i
at m ai canteen by ins tallation
n
of 2 nos 5 kl storage tanks on
26 2004 7200 140400 50000 4.3
top of c anteen building,
towards reduc ing head from
20 metres to 9 metr e.
Introduction of "RO water" for
was hing m ac hine & coolant
27 2004 11700 228150.00 700000.00 37
mixing applications in
machines hops 1&2
Intr oduction of "new induction
hardening machine for shop1
cam shaft line with closed
28 2004 11700 228150.00 600000.00 32
c ir uit RO water utiis ation" as
c l
against c onventional cooling
tower instalation.
l
Piping line installation to ensure
water supply from s hop5
O verhead tank, instead of
29 2004 9900 193050 400000 24.9
main overhead tank, by
reduc ing head from 40 m etres
to 20 m etres.
Bench-marking with other AL Units: 2007-08
25 Lowest
among AL
21.6
units
KL/ECU
15 13.0
7.28
5
Hosur-1
Hosur-2
AL -
AL -
Bhandara
AL -
Units
“Every drop of water counts”
9

10. Bench- marking with Competitors : 2006 -07
8.50
8.10
8.00
KL/ECU
7.51
7.50
7.00
Hosur-
- CVBU
Motors
AL -
TATA
1
Units
“Every drop of water counts”
Monitoring & Reporting System
M S
E A
A V
S e
U
R W
E A
W T
A E
T R
E
R.
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11. Monitoring & Reporting System
M S
E A
A V
S e
U
R W
E A
W T
A E
T R
E
R.
Innovative Projects:
Scope For water conservation is mainly looked at in
3 areas:
(1) Recycling & reuse of waste water.
(2) Reduce water consumption by process change.
(3) Study water intensive areas & Introduce water
efficient products.
Water is Scarce ….. Save it.
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12. Innovative Project No: 1
Water is Scarce ….. Save it.
Project : Water conservation by 50 kl/day thro’ recycling of ETP waste water.
Methodolo gy :
§ ETP waste water which was earli er used f or gardenin g,was in excess of STP
waste water wh ich was also used f or Garden ing.
§ RO Plant (Rochem make) & Mecha naical Ev aporator ( Tech nof orce make) were
installed to ensure reuse of process waste water.
§ This treated water was used f or industrial applicati ons like washi ng m/cs, cooling
towers, test beds & f or coolant mixing, thereby reducing ra w water consumption.
§ Zero discharge of process water was alos ensur ed.
§ 95 % water recov ery was ensured thro’ recy cling.
Benef its:
§ Sav ed raw water pr ocureme nt to the extent of 50 kl/day .
§ Process water qual ity was enhanced to all shops.
§ Industrial RO plants av l in shops became standby f acilities.
Start Date: 05/07/200 7 Co mpl n. Date: 15/03/20 08
Innovative Project No: 2
Water is Scarce ….. Save it.
Project : Water ato mization in en gine washin g activity at testbeds.
Methodolo gy :
§ After testing of engines in test beds, engines need to be washed.
§ Direct washing with water jet was consuming water by 12 kl/day .
§ Introduced water wash gu n to minimise water consumptio n by mixing compressed
air at low pressur e, to create atomized water wash.
§ Extended to all testbeds of shops 2 & 5.
Benef its:
§ Sav ed water consumption to the extent of 4.5 kl/day.
§ Engine washin g quality was not compromised.
§ Reduced wate r consumption by 2/3 rd.
Start Date: 10/05/200 7 Co mpl n. Date: 31/05/20 07
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13. Innovative Project No: 3
Water is Scarce ….. Save it.
Project : Water conservation thro’ introduction of “Air coole d Air Dryers“ in place of
“Wate r cooled Air Dryers”.
Methodolo gy :
§ 2 nos Water cooled Compressed air dry ers at shop5 required water circulatio n f or
cooling of hot air passing thro’ dry ers.
§ This deman ded exclusiv e av ailability of a cooling tower f or cold water circulation.
§ Apart f rom water consumption, water wastage in terms of ev aporation loss, spray
loss etc., are inev itable.
§ while or derin g additio nal air dry ers f or shop2, Air cooled air dry ers which do n ot
requir e cooling to wer were or dere d.
§ Hot air is cooled thro’ a f an arrangement, in air coole d air dry ers.
Benef its:
§ Sav ed water consumption to the extent of 6 kl /day .
§ Cooling tower oper ation & mainten ance elimin ated.
§ No compromise was made on dry air quality .
Start Date: 01/07/200 7 Co mpl n. Date: 31/12/20 07
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