Table 8.3 shows the results obtained from a scoping audit performed on seven quantities consumed and produced over one year.
Table 8.3 Scoping audit Resources &
Services Raw Materials
Steel Powder Paraffin Chemcoater
Utilities:
Water Waste:
Effluent Domestic waste
Factory waste
Quantity 1570668
24088 70800 2190 1953 1876 21 24
Units unit
kg L L kL kL kL skips
Cost (R)/
Year 8827154
825854 183372 18440 15070 6968 9196 3600
Priority (l=Highest)
1 2 4 8 3 5 6 7
Scope to Save %
1-5
20-80 20-80 10-50
Scope (min) 88272
8259 1834 184 3014 1394 920 360
Scope (max) 441358
41293 9169 922 12056 5574 4598 1800
Each resource in column 1 of Table 8.3 was allocated an annual production or consumption quantity and a costing. These values were obtained using the formula shown in Equation 8.3.
Annual quantity = Quantity for the monitoring period x Equation 8.3 Monitoring period
Only the purchased powder goes into the factory store from which it is requisitioned by the Paint Line. The steel purchased goes straight to the Roll Mill Department. The paraffin is delivered into an underground storage tank and the water is piped straight into Phosphating Line and to four taps situated around the factory.
The steel consumption was calculated from the quantity purchased from the supplier (see Table 7.5). This quantity was obtained for the full monitoring period and was then converted to an annual amount using Equation 8.3.
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The powder consumed during the monitoring period was assumed to be the same as the quantity of powder issued from stores to the Paint Line. The mass of powder used over the 236 days was based on that requisitioned by the Paint Line for the full monitoring period and calculated as that used for 236 days using Equation 8.3.
Paraffin readings were only recorded from the 28th of June to the 19th of July (16 days).
Thus, the amount used in the process was calculated by converting the quantity used during this time (4800 L) to an average quantity per day. This average was then scaled up to the amount used over 236 days (see Table 7.5).
The amount of Chemcoater used on the Paint Line was calculated from the chemical additions (see Table 7.4) and the amount used in the initial make-up and subsequent recharging of the tanks. Recharging took place once during the full monitoring period and the solution volumes used were equal to that used at the initial make-up. This value was then converted to an annual volume using Equation 8.3.
The water consumption was calculated from the Msunduzi Municipality Tax Invoices.
Five of these invoices were collected during the monitoring period. From these invoices a daily water consumption was then calculated. This value was then used to derive volumes that would have appeared in the first month of 2004 and the remaining seven months of the year. This was done because the tariff charged per kL of water increased from R6.45 to R7.10 during the last month of the monitoring period. The annual quantity and cost was based on the period starting from mid December 2003 to mid December 2004. The same procedure was followed for the effluent to account for this tariff rise from R3.16 to R3.38 per kL for the first 400 kL of effluent discharged. The amount of effluent discharged monthly is equivalent to the amount of water consumed.
The company produces three solid waste streams and one liquid waste stream. These are known as:
• factory waste
• domestic waste and scrap metal, and
• an effluent stream.
The factory and domestic waste constitutes the solid waste of the company. The upliftment and removal of the domestic waste is carried out by the City Engineers - Waste Management Department and the charges appear on the invoices. Upliftment is done on a weekly basis and the waste is disposed of at the landfill site situated on New England Road. The City Engineers Department charge a standard weekly tariff for uplifting a 1.75m3 bin. This tariff had a value of R144.30 for the period from the 1st of July 2003 to 30th of June 2004. On the 1st of July 2004 this tariff increased to R165.94.187 For invoicing these values are converted to a monthly value (see Equation 8.4) onto which VAT is added.
Cost of Removal = Tariff x Equation 8.4 12months
Thus the annual quantity of solid waste disposed was based on the upliftment of one 1.75 m3 bin per month. The total cost was calculated using the tariff of R 144.30 for the first six months of the year and the tariff of Rl 65.94 for the remaining six months.
Factory waste is collected in two skips and removed by a private contractor. No invoices were available for viewing during the monitoring period. However the line supervisor priced this service charge as R300 per month.
The scrap metal is sold on to a dealer and does not appear in the scoping audit.
Table 8.3 shows that the greatest financial savings, represented by the maximum scope to save, can be made through a reduction in the steel consumption. The second most significant waste problem appears to be caused by the powder. The third greatest scope to save can be achieved by reducing water consumption. This lowest scope to save is shown by the Chemcoater consumption. Most of the water and all of the Chemcoater are only used on the Phosphating Line.
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