annual env. report

7/29/2019 Annual Env. Report

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AnnualEnvironmental

Report

Year 2001 ~ 2002

AnnualEnvironmental

Report

Year 2001 ~ 2002

Thal Engineering

Plot no. 1,2 Sector 22,

Korangi Industrial Area

Karachi.


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Contents

Company Profile

Company Milestones

Environment Management System

Companywide Environmental Management System

Objectives and Targets, Implementation and Operation

Training, Communication

Public awareness and promotion activities focusing on the environment.

Environmental Cost

EMS Organizational Chart

Environmental Policy

Total Environmental Aspects

TE Business activities and their effect on the environment

List of concerned Parties

Environmental Achievements

Results of Activities to fiscal year 2001~2002

Activities to reduces substances with environmental impacts

Case Study 1: Recovery Recycling Unit at DENSO AIRCON CENTER

Case Study 2 : TEC Recycling at Factory

Feedback Form


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Company Profile

Thal Engineering

Plant:

Thal Engineering

Plot 1,2, Sector 22,

Korangi Industrial Area,Karachi.Pakistan

Denso Aircon Service Centre:14, Banglore Town Housing

Society, Sharah-e-Faisal,

Karachi.

Number of employees:

194

Products:

Car Air Conditioner &

Wiring HarnessSales:

Rs. 627,351,000 p.a


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Company Milestones

Thal Engineering, was setup by the House ofHabib in 1995 as a division of Thal Jute Mills, tomanufacture auto parts.

The Company entered into a TechnicalAssistance Agreement with Denso CorporationJapan, in 1996 to progressively manufacturecar air conditioners. A localization plan,envisaging achievement of 52 % in five yearswas prepared and approved by the Ministry ofIndustries and the company started operationsin Aug,1996,supplying its air conditioners toToyota and Suzuki car manufacturers.

In late 1999 Thal engineering entered into aTechnical Assistance Agreement with FurukawaElectric Japan to manufacture wiring harnessand began supplies in March 2000. It nowsupplies for Toyota, Daihatsu, Hilux &Hondacars, Yamaha motorcycles and MF Tractors.The Company employs modern managementpractices and was awarded certificate ofExcellence by Management Association ofPakistan in 2000.It has also been certified forISO 9001-2000 and ISO 14001, the only auto

parts manufacturer to be certified in Pakistan.The company is young and youthful and theaverage age of the employees is 28.

The Company is service oriented. It hastaken upon itself the market discipline of totalsolution provider and has established a 3Scentre in the activity hub area, besides being indaily contact with the automakers.


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Environmental Management System

Company-wide Environmental Management

System (EMS)We established the Thal Environment Committee in Sept. 2000 as a

company-wide organization for promoting effectively our company

action plans of environment protection. The committee made a three

month action plan to achieve ISO 14001 certification.

Objective and TargetsIn setting the objectives and targets significant environmental aspects

are considered.We use and maintain a procedure for developing such

objectives and targets which accomplish the goals of the

Environmental Policy.At a minimum, our objectives and targets

comply with regulatory requirements but we strive wherever possible

to exceed this minimum requirements.

Implementation and OperationA procedure is used and maintained for DOCUMENTING ROLES,

RESPONSIBILITIES AND AUTHORITIES of various individuals, to

ensure that the structure and system of accountability for

implementation of EMS remains current and clear. Each individual

knows what his or her responsibilities are, as well as the authority

with which to fulfill them. Management has provided resources

including Human capital, Specialized skills training, and funds

essential for the implementation and control of the EMS.

NextNext


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TrainingEnvironmental training is conducted to ensure that all employees

are aware of the environmental issues, environmental policy,

significant aspects of activities, product and services and

requirements of EMS and have adequate training to deal with

responsibilities they are given. We are firmly committed to provide

all necessary training to employees.

Communication

We maintain a documented system for INTERNAL AND

EXTERNAL COMMUNICATION, which provides regular and timely

communication among Thal Engineerings Employees and to other

relevant persons as and when required. We arrange Management

review meetings to review the process for communication ( Internal

& External both) and record its decision. We believe thatmaintaining a high level of effective communication is essential for

good performance of the company and the community as well.

NextNext PreviousPrevious


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Public Awareness

and PromotionActivities Focusingon the EnvironmentOur view is that action is

needed to generate agreater awareness ofenvironmental concernsamongst all employees. To

achieve this widerrecognition we are engagedin company-wide awarenessand promotion activities.Year 2001~2002 has beendesignated The RecyclingYear of Thal Engineering.During this year we carriedout an intensive program of

awareness building activitieson a company-wide basis,including practical actionprograms for cleaning-upand greening our plantsites as well as awarenesscampaigns directed at thegeneral public through ourproduct booklet, CDs and

website.Environmentalawareness-building has alsobeen an important subject ofour initial training programfor newly recruitedemployees since 2001.

Employees With

Environmental related

Qualification (as of July 2002)

6Internal Environment

Auditors

1Lead Auditor

NumberQualification

68Training of new

employees

228General Training on

Environment

Number ofattendees

Course

Curriculum ( classes in FY

2001~2002)

NextNext PreviousPrevious


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EnvironmentalCostsFor the ongoingdeployment of ourenvironmental protection

activities, it is essentialto make an accurateassessment of the costsinvolved and of theeffects achieved and tocommunicate the costinformation to all

concerned both insideand outside thecompany.

650,000R & D Costs

Costs for product

development, researchand capital investment for

environmental protection

1,700,000Total

550,000Indirect Costs

Management,

environmental education,certification and other

costs

500,000Direct CostsPollution prevention,

industrial waste disposal

and recycling costs

Amount

( Rs.)

Category and Primary

Expenses

Environmental Protection

Costs In FY 2001~2002

PreviousPrevious


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Approved By

Issue Date: 27-06-2001

Issue No. 01

- Transport- others

Chief Executive

MR Committee

EMR

- Scrap yard

- Main Store

- Incoming Store

- Raw Material

store

- Air Con Centre- WH Plant

- TFW

- Canteen

- Security

- Sanitation


DMC SM Task TeamGMP

- Plantation

M(Finance) M(PE) MAP

-

of A/C Plant

- Ist floor office


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ENVIRONMENTAL POLICY

"Fulfill Environmental

Obligation toCommunity, Countryand Mother Earth ."

We shall commit toprevent pollution and

continually improveour environmentalperformance byregularly settingobjectives against

significantenvironmentalimpacts, conductingaudits, managementreview and

complying withlegislative andregulatoryrequirements.


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S.

No.No. % Cum %

1 98 57.3 57.3

2 39 22.8 80.13 34 19.9 100.0

171Total

Remarks

Objectives & targets are made to minimize HSHigh Significance (HS)

Medium Significance (MS)

Graphical Representation of Total

Environmental Aspects / Impacts

Low Significance (LS)

TE

spec s

Issue date: 20-9-01, No: 02

Aspects

Pie Chart for Aspects

57%

23%

20%

1

2

3

PARETO ANALYSIS

98

3

9

34

80.1

57.3

ASPECTS

No

0

50

100

CUM

Environmental Aspects

No. No. % Cum %

1 Land Pollution 22 46.8 46.8

2 Hazardous Waste 7 14.9 61.7

3 Wastewater Discharge 7 14.9 76.6

4 Non-Hazardous Waste 4 8.5 85.1

5 Energy use/ Consumption 3 6.4 91.5

6 Air Emissions 4 8.5 100.0

47

Graphical Representation of Significant

Ervironmental Aspects / Impacts

Aspects Register

Issue date: 20-9-01, No: 02TE

Description Remarks

Total

Pie Chart for Aspects

28%

19%24%

14%

10%

5%1

2

3

4

5

6

PARETO ANALYSIS

22

7 7

43

4

46.8

61.7

76.6

85.191.5

1 2 3 4 5 6

ASPECTS

No

0

50

100

CUM


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Business Activities

ProcurementResource and energy

consumption

Industrial waste generation

Use of substances with anenvironmental impact

Air pollution

Noise pollutionWater

contamination

Global warming

Depletion of

resource

Destruction of

ozone layer

ProductionIndustrial waste generationUse of substances with an

environmental impact

DistributionGas emissions

Fuel consumptionNoise pollution

Product packaging waste

Product useGas Emissions

Noise pollution

Product

development

Recycling and

scrappingDischarge of industrial

waste

Use of substances with an

environmental impact

Thal Engineering Business Activities and Their Effect on the Environment

Thal Engineering Environmental

Protection Activities

Environmental protection in

production

Social contribution activities


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LIST OF CONCERNED PARTIES

1. CUSTOMERa) Indus Motor Company

b) Pak Suzuki Motor Company

c) Authorized dealers

d) Direct customer (A/C purchase directly from Service Center)

2. VENDORS AND SUPPLIERSA) List of vendors available with our Development Department.

3. NEIGHBOURING COMPANIES

a) Atomic Energy Commission (New-2)Plot no. 3 & 4, sector 20,

Korangi Industrial Area Karachi.

b) K.E.S.C Work Shop.

Plot no. 23 & 24, sector 22,

Korangi Industrial Area Karachi.

4. ENVIRONMENTAL PROTECTION AGENCY

1) ASSOCIATIONSa) The Federation of Pakistan Chambers and Commerce.

b) The Karachi Chambers and commercec) Korangi Industrial Estate Association

d) Pakistan Association of Automotive Parts & Accessories Manufacturers

2) CONTRACTORSa) Industrial Power (Tech)

b) Fahad Enterprises

c) Star Contractors

d) Al-Hina Architect Engineers & Constructors

e) MHM Builders

f) Noor Khan Scrap Contractorsg) EMC

5. EMPLOYEES OF THAL ENGINEERING

We also publicize our Quality and Environmental Policies and

Objectives to Public through Web site.


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The proper areas will be identified anddesignated by Dec-2001.

TARGET

completed

Improve existing oil, chemical andhazardous material storage anddesignate proper area for used chemicals/ hazardous material.

OBJECTIVE7

The proper areas will be designatedaccording the types of scraps by Dec-2001.

TARGETcompleted

Improve and designate proper area forscrap from its

existing condition.

OBJECTIVE6

The Water treatment facility be operatedby June-2003.

TARGET60% completed

To design and install the watertreatment facility.

OBJECTIVE5

04 Vehicles will be converted to CNGfrom petrol by Dec-2001.

TARGET

75% completed

To conserve energy by replacing Petrolwith CNG in company vehicle.

OBJECTIVE4

All THAL ENGINEERING staff be givenbasic training on EMS elements andenvironmental awareness by Dec-2001.

TARGET Completed

Training on Environmental awareness &EMS elements to all TE employees.

OBJECTIVE3

TCE will be collected, Stored andrecycled offsite by Dec-2001.

TARGETCompleted

Used Trichloroethylene ( Hazardouschemical) will be recycled.

OBJECTIVE2

Gases R-12 & R134a will be recycled inorder to save the Ozone depletion bySep-2001.

TARGETCompleted

To prevent the escape of Ozonedepleting substances completely atDenso Aircon service centre. We will notfit any new aircon with R-12 after sep,

2001.

OBJECTIVE1

ResultsACTIVITIES FY 2001~2002S.No

Achievements


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Activities to Reduce Substances With

Environmental Impact

Specified CFCs (Substances

Destroying the Ozone layer)

We discouraged specified CFCs (R-

12), used as a refrigerant for

automotive air-conditioners, with R-

134a from the first day of production.

The management also decided not

to fit any air-conditioner with R-12

gas, even if it means loss of

business.

We are also striving to reduce the

consumption of R-134 by taking

more effective steps for preventing

leakage when filling the refrigerant in

the system.


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Environmental Achievement (Case Study 1)

It is a common practice that whenever the car is brought at the

Denso aircon service centre for servicing of the A/C system,

the gas (refrigerant) has to be discharged into the atmosphere

because it becomes difficult to restore it in another container.

When it is discharged, it poses threat to the operator working

on the vehicle and finally to the ozone layer.

After thoughtful evaluation of the means available for

preserving the refrigerants escaping out into the atmosphere , it

was decided to procure a machine which can recover as well

as recycle the refrigerants and then safely recharge them into

the A/C system. This would not only prevent loss of gases into

the atmosphere but also save cost.In the light of above facts recovery recycling unit had been

purchased as per plan.

PROJECT

DESCRIPTION

Global warming is one of the most dreadful threat to all of us

these days. Reason being that ice glaciers and the ice bergs

will be melted in no time flooding the entire mother earth if

preventive measures are not taken. Most of know that the sun

radiates energy in the form of ultraviolet radiations. These

radiations are spread out through the entire universe and are

extremely harmful to human body (can cause severe burns,

skin cancer, skin irritation etc) therefore nature has created a

protective shield (Ozone Layer) around the global which doesnot allow these radiations to penetrate through. But

unfortunately there are some gases (CFCs) which they

escaped into the atmosphere, can damage Ozone Layer letting

the UV radiations to pass through and thus raising the

temperature of the earths environment as well as causing

harm to the human beings.

WHY WAS

PROJECT

PERFORMED?

For an investment of Rs. 399,000/= Thal would see annual

operating saving ranging about Rs. 137,700/= per year.BUSINESS

ENVIRONMENT

BENEFITS

CAPITAL INVESTMENT

To prevent the escape of Ozone depleting substances

completely at Denso aircon service centre. In the early days

R-12 gas was not being recovered from vehicle when the A/C

was repaired. R-12 gas is very harmful for environment so the

management decided to buy a recovery recycling unit to

avoid releasing the harmful gas into the atmosphere. The

management also decided not to fit any air conditioner with

R-12 gas, even if it means loss of business.

BUSINESS

DECISION


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Ejaz Rizvi,

DM QA,

Thal Engineering,

Korangi industrial Area,

Karachi.

Ph. No. 5897608

Fax no. 5888539

E mail [email protected]

CONTACT

This recovery recycling unit showed a positive impact on cost. Now

gas is being fully recovered and recycled. Project saving has been

calculated on yearly basis, about Rs. 137,700/= for which the

payback will be achieved in three years time approx.

A number of critical assumptions underlying the analysis were

individually tested to determine their effect on profitability. These

included the expected cost of the gases, the cost of rework, and thedepreciation method.

FINANCIAL

RESULTS

The investment in a recovery recycling unit was evaluated to enhance

capital budgeting decisions in connection with environmental safety.

the initial investment cost which include not only equipment and

material but also training of operators. The saving would result from

not discharging R-12 gas into the atmosphere.

ANALYSIS


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978,000Total saving over ten years

1,377,000Total cost saving over ten years

399,000Cost of recovery unit

137,700Annual cost saving of gas

Rs.

Cost Considerations

Cost Considerations


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WE contacted to PCSIR to recycle the TCE. Finally they agreedto recycle TCE. After several attempts they succeeded to get

good results of recycled TCE.

PROJECTDESCRIPTION

This chemical is being used to degreasing the aluminum tubes,

which use in air-conditioner production. There are two bath of

TCE. in first bath aluminum tubes are dipped for degreasingheavy oil and chips. And in second bath tubes are dipped for final

degreasing. Normally after one month, TCE of first bath is

disposed off and TEC of second bath is transferred into first bath.

Disposed TCE was stored that could not be disposed on land

because it is very harmful chemical. Final management decided

to search the sources to recycle that chemical.

WHY WAS

PROJECT

PERFORMED?

Company will save about Rs.60,000 per year to recycle this

chemical.BUSINESS

ENVIRONMENT

BENEFITS

Product/ Process Costing

Trichloroethylene TCE (Hazardous Chemical) will be recycled by

Dec-2001.

BUSINESS

DECISION


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To recycle the TCE, we saved about Rs.60,000 per year.FINANCIAL

RESULTS

The investment in a recycling of TCE was evaluated to enhance

budgeting decisions in connection with environmental safety. theinitial investment cost which include not only material but also

transportation of material. The saving would result from not

disposing the hazardous chemical on land.

ANALYSIS

59,940Yearly Saving

4,995Monthly Saving

Rs.

Cost Considerations


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Feed Back

Environment Protection Dept.Thal Engg.Pvt.Ltd.

Please complete this questionnaire and return it to us by fax.

Your comments will help us make further improvements and prepare our next Environment Reports.

Q1. How would you evaluate this report? Q5. What do you expect Thal Engg.to do concerning

(Please circle only one.) the environment?

Please give specific reasons.

Why did you choose the answer above?

Pleas give specific reasons (e.g,topics covered

or simplicity) Q6. Why did you receive this report and how did youbecome aware of it?(Circle as many as relevant)

Why did you receive the report.

Q2. What impressed you the most about this report?

What information did you find most interesting?

Q3. Is there any part of this report that should besupplemented with more information or

improved in any other way?

How did you become aware of the report?

Q4. After reading this report,how do you feel about

Thal Engg's environment-related activities?

Why did you choose the answer above?

Please give specific reasons.

Sex 1. Male 2. Female Age

AddressOccupation and employer Department and title

Your Comments or opinions on this report would be much appreciated.

FAX 021- 5888539

Name

1.Excellent 2.Good 3.Average

4.Unsatisfactory 5.Poor

1.Excellent 2.Good

3.Unsatisfactory 4.Poor

1.Have transactions with Thal Engg.

2.Member of Government or administrative office.

3.Member of the press.

4.Thal Engg. Employee or family member.

5.None of the above

(Be specific)

1.Thal Engg Web Site 2.Thal Engg.dealer

3.Heard from a friend or acquaintance

4.None of the above

(Be specific)


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annual env. report

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