Issue:
High water usage and wastage in the powder coating pre-treatment line.

Current Situation:
Fresh water is used to rinse the product and is then discharged into the sewerage system. At the same time fresh water is also being used to top up the chemical wash tanks.

Objective:

• Reduce the use of fresh water
• Eliminate regular water discharge into the sewerage system
• Reduce the amount of chemicals used in the rust inhibiting pre-treatment of product

Improvement Initiative:
Change the water pipe system to reuse the fresh water after it has rinsed the product to top up the chemical wash tanks. This would reduce the fresh water usage and eliminate the amount water being discharged into the sewerage system. Installation of a system to control the water levels across all tanks. Reduced chemicals will be used due to less dilution of the chemical wash tanks by fresh water.

Timing:
Pipe changes and electrical control system to be modified during Christmas factory shutdown. Project to be completed by end January 2005.

Measurement:
Financial Controller to measure total water usage billed for quarter prior to project and after for comparison.
Pipe to sewerage will be capped and therefore discharge to sewer will be eliminated.