A) Identify three internal issues and three external issues of the case study organization. Everest Chemicals Limited

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A) Identify three internal issues and three external issues of the case study organization.

Everest Chemicals Limited was established in May 2008 and situated at the Tarapur Industrial estate in the Palghar district of Maharashtra state. The major production of the company is the Phosphoric acid and design capacity for the production of Phosphoric acid is 200MTPD. For manufacturing the Phosphoric acid, the organization has a setup of 60 acres and all the plants, tank farms; utilities are situated within the defined boundary.
The organization has obtained the consent for establishment before erecting of the plant, and obtained the consent to operate in Jan.2008. Subsequently it was renewed and current consent is valid till end of December this year.
Organization consists of the two manufacturing units and utilities like DM water plant, cooling towers, chilling plant, air compressors, Nitrogen plant & boiler house, and vapor scrubbers within the defined boundary. The organization has implemented Quality Management System, Environmental Management System and OH&S management system according to the ISO 9001:2015, ISO 14001:2015 & ISO 45001:2018 respectively.
Everest Chemicals Ltd is headed by Mr. Peter Robinson as the chairman & Managing Director and is the top management. Mr.Peter Robinson is visiting the factory once in a month for reviews and directing and addressing the employees on company performance. For effective implementation of ISO 9001, ISO 14001 & ISO 45001, he has appointed Mr.Rakesh Gupta (Head-Commercial) as the Leader for implementation and maintenance of QMS, EMS & OH&SMS. Mr.Gupta is supported by the team of the department heads.
As a policy, organization is outsourcing the operations of the Boiler house and nitrogen plant to Ms.Jagannath Enterprises. Also organization has outsourced their services for the unloading of the rock phosphate and transportation of the phosphoric acid. The selection of the contractor is being done by the Purchase department. Purchase department has established the procedure for the Selection and evaluation of the external providers. The preventive maintenance and statutory compliances for infrastructure is being done by third party.
Sales and marketing department are regularly carrying out the market survey and based on that they are finalizing the monthly production projections. While receiving the enquiries and order, marketing head is reviewing the requirements and accordingly communicate with the customer. Customer satisfaction is being monitored through tele-communication with customers.
The major raw materials used by the organization are: Rock phosphate, Sulphuric acid.
PHOSPHORIC ACID:
Major raw material for the manufacturing of the Phosphoric acid is Rock phosphate, which is obtaining from the various mines situated in Rajasthan and other part of Gujarat.
Rock phosphate is being received by road and rail wagons and unloaded in silos through belt conveyor system. Sometimes this process involves contractor’s workers. The unloading area for the rock phosphate is in open yard. Required Personal Protective Equipment are provided based on the needs raised by those contractor’s workers. The silos are provided with the dust collectors for collecting the dust particles emitted during the unloading of the phosphate. The monitoring and maintenance of the dust collectors is being carried out by the maintenance department during the preventive maintenance schedule.
The raw material (Phosphate) is then fed to plant through belt conveyor according to plant load. The transferred phosphate then charged to the Ball Mill at the controlled rate to reduce the dust emission. The ball mills are situated in the isolated place. The grinding of rock phosphate, charged in the ball mill , is done to make it to fine particle sizes so that digestion efficiency can be improved in later stage. The hot air is blown through rock phosphate to remove moisture. The dry ground rock phosphate is then fed to digester unit along with Sulfuric Acid. The filter cake is composed primarily of gypsum (CaSO4 2H2O). The product phosphoric acid is concentrated to 75-100% by a series of evaporators and then cooled before entering storage.
For evaporators, steam is being used as a utility. The vapors escaped from the condensers are being collected in the secondary condenser where chilled water is being used for condensing the vapors.
Air vents of the condensers are connected to the emergency scrubber to deal with any emergency emissions of vapors.
The final product, Phosphoric acid is being collected in the collection tanks where the quality of the product is being tested by quality control department and approved material is being forwarded to the final product storage tanks with the help of the pumps.
The utility section is situated in the center of the plant. Organization is provided with the electrical supply with express feeder and also has four numbers of DG sets which are used in emergency. All the emergency services e.g. Utilities, DCS control room, fire pumps etc. are provided with the DG supply.
Organization is having full-fledged effluent treatment plant where the effluent generating from the plant is being treated to required quality and discharged to the CETP. (Common effluent treatment plant.).The sludge generated from the ETP process is being sent to the authorized agency for disposal and records are being maintained.

As a requirement, organization is regularly monitoring the quality for ambient air, workplaces, Noise monitoring, stacks monitoring etc. on quarterly basis. The quality of effluent is being monitored online as per the MPCB requirements.
According to the plant layout, on one side of the organization various industries using and manufacturing various flammable chemicals are situated and on another side residential colonies of other companies are there.
The effluent discharge is being transferred to CETP through the closed underground pipeline which is travelling through the no man’s land between the organization and other industries, and at some areas through the nearby farming land.
The finished product i.e. phosphoric acid is supplied to the customers in various packing as per the requirement of the customer. Various packing includes 50kg carboys, 200kg drums and bulk container which are generally transported through roadways. The transportation is arrangement is being done by the organization, however, occasionally customers are arranging for the transportation. For transportation, organization is having the vendor selection procedure and regular trainings are being conducted for the tanker and vehicle drivers. Organization has established the communication with the vendors for the handling and usage of the products. Organization is providing the information relevant to the environmental aspects of the products and operational measures for safe handling and disposal of the product.
Company has maintained a Register for the interested parties at the reception. Here the visiting interested parties are encouraged to write their suggestions and concerns related to Quality of products/services, environmental issues and Health and safety system in the Company. Some of these suggestions and concerns have been listed below:
1. Neighbours (Industries and community): Company shall not cause any nuisance to the neighbours through high noise, foul smell, release of harmful air pollutants, fire, smoke, unruly movement of transport vehicles, toxic gas release, untreated effluent or sewage discharge outside Company premises, and unscientific disposal of hazardous waste outside the Company premises.
2. Department of Industrial Safety & Health: Company should comply with all the applicable legal requirements. Company should contact the authorities in case of any legal problems / complications. Company should not cause any nuisance to the neighbouring communities / Factories. Company should submit the legal compliance report once in a year.
3. Pollution Control Board: Company should comply with all applicable legal requirements as mentioned in approved consent. Periodical Air Quality, Water Quality, Discharge details shall be submitted on periodic basis and shall not cross the specified limit as mentioned in consent

4. Stakeholders (Financial Institutions): Company should not face any problems due to EMS and OH&S legal issues. Company should implement QMS, EMS & OHSMS as per ISO 9001, 14001 & ISO 45001, respectively and ensure that they comply with all applicable legal requirements and ensure that they have adequate fire prevention system. Company should obtain a Fire NOC and also get insured against natural & man-made disasters. Company should conduct mock drills at regular intervals and submit their reports to the Financial Institutions. Company should also submit the legal compliance report every 6 months. Company to ensure good quality of products and address the customer complaints issues for proper resolution in time.
Visitors: Company should maintain their workplace in a healthy and safe manner. Also Company should provide appropriate PPEs to the visitors during their visits to the Factory.

QUALITY,ENVIRONMENTAL AND HEALTH & SAFETY POLICY
Everest Chemicals Limited, located at plot No.3/1, MIDC Industrial Area Tarapur, engaged in business of manufacturing of Phosphoric Acid is committed to satisfaction of domestic and international customers, prevention of pollution and continual improvement in effectiveness of our Quality ,Environmental and Occupational Health & Safety Management System.
To achieve this, we commit ourselves to :
a. Comply with all environmental requirements and with other requirements to which we subscribe, including those related to environmental aspects.
b. Comply with all requirements related to products and services to enhance customer satisfaction,
environmental performance and occupational health & safety performance of the organization.
c. Eliminate, minimize, or control the environmental aspects.
d. Incorporate suitable technologies and global best practices for quality improvement, energy conservation, and prevention of pollution by adopting the reduce, reuse, and recycle policy, and proper disposal of hazardous waste. Manufacturing quality products is the priority of the organization to prevent product nonconformities. Also, the organization will focus on the health and safety of its employees and contract workmen by promoting safe work practices.
e. Strengthen skills, competencies, and safety awareness of all employees and contract workmen by regular training.
f. Periodically review adequacy, suitability, and effectiveness of Quality, Environmental, and Occupational Health & Safety Management System.