1. Protecting our planet is a group project 2003 Earth Award Team Name : TEAM PAINT SHOP Contact no: 91- 595 - 2357152 Primary Contact: Iqbal Khan Mail : ( Iqbal.khan@ind.xerox.com ) TEAM NAME Nominator information: Abhay Deep Mail : ( abhay.deep@ind.xerox.com )

2. Protecting our planet is a group project 2003 Earth Award PROJECT GOAL Project Goal: Reduction of Natural Resources Usage ( Low Density oil ) Reduction in Power Consumption Overview: XIND Paint shop has conveyorised spray type pre-treatment plant having 7 tank process followed by drying oven. Wet spray painting is used for both Metallic and plastic ( ABS ) parts. Baking oven is used for baking of painted parts. Both Pre-treatment plant & drying oven are heated through close loop Thermic fluid heating system ( Thermax plant ) for which input is liquid LDO ( Low density oil ). Air / chemical circulation, air curtain, blower etc. are driven through electricity.

3. Protecting our planet is a group project 2003 Earth Award Thermic fluid heating system (Thermax Plant) INPUT: Electricity for Air curtain, air circulation & chemical circulation Degreasing ( 2 tanks ) Phosphating ( 1 tank ) Passivation ( 1 tanks ) Drying oven Baking Oven Heat Rinsing ( 2 tanks ) Rinsing ( 1 tank ) PRE TREATMENT PLANT BAKING OVEN PROJECT GOAL Overview cont. Target : Consumption Reduction INPUT : Liquid LDO

4. Protecting our planet is a group project 2003 Earth Award Plastic parts Phosphating plant Drying oven Baking Oven Painting of parts LDO is used to heat drying oven of pre-treatment plant & Baking oven. Plastic( ABS ) parts are painted and are baked in baking oven. Metallic parts are phosphated, dryed, painted and then baked Output Process : Before Input LDO + Electricity Heat Loss Heat Loss HOW WAS THIS ACHIEVED

5. Protecting our planet is a group project 2003 Earth Award Plastic parts Phosphating plant Drying oven Baking Oven Painting of parts Input LDO + Electricity Residual heat of drying oven used to heat Baking oven. No baking of Plastic parts. Output Process : After Partly heat diverted from drying oven Residual heat Heat Loss HOW WAS THIS ACHIEVED Heat transferred through mechanical valve Baking eliminated by usage of air dry paint hence reduce usage of baking oven HOW WAS THIS ACHIEVED

6. Protecting our planet is a group project 2003 Earth Award XIND Paint supplier With help of our paint supplier, various paint samples were developed and tryout were conducted to get desire quality. XIND Paint shop team Paint shop team observe that residual heat of Pre-treatment plant used to get waste so they fitted mechanical valve by operating which, heat is getting transferred to baking oven. Since initial firing of Oven consume lot of consumable ( LDO ). Hence paint shop team increased batch size to minimize this consumption. JAN 02 Fitting of mechanical valve to transfer residual heat. To optimize batch size MAY-JUNE 02 Development of air dry paint. Trial and tryout on paint and cut-in for production. RESOURCES TIMING : RESOURCES AND TIMING

7. Protecting our planet is a group project 2003 Earth Award LDO consumption in Ltr / per m/c Yr. 2001 = 1.77 Ltr/ per m/c Yr. 2002 = 0.93 Ltr / per m/c Cost of PU paint Earlier = Rs. 326 per Ltr After = Rs. 215 per Ltr. (Air Dry) Power consumption ( paint shop only ) in unit / per m/c Yr. 2001 = 7.6 unit/ per m/c Yr. 2002 = 5.4 unit / per m/c Cycle time of PU paint parts Earlier = 24 hrs After = 8 hrs. 29 % Reduction66 % Reduction47 % Reduction34 % Reduction SAVING TOTAL LDO SAVED IN Yr. 2002= 7190 Ltr TOTAL ELECTRICITY SAVED IN Yr. 2002= 18.8 kWH MONETARY SAVING( in Yr. 2002)= $ 4430 RESULTS AND BENEFITS

8. Protecting our planet is a group project 2003 Earth Award ABHAY DEEP ASHOK SHARMA AMIR NISHAT ZAFAR KHAN BABU KHAN MUNEER KHAN MANOJ KR. DAS TEAM MEMBERS