PROJECT COMPLETION REPORT PROJECT TITLE: TRANSFER OF TECHNOLOGY AND PROMOTION OF DEMAND: ZINC GALVANIZING IN INDIA, BANGLADESH AND NEPAL DISSIMINATION OF TRAINING TOOLS (CFC/LZSG/08) I.

Project Summary 1.

Title: Transfer of Technology and Promotion of Demand: Zinc Galvanizing in India, Bangladesh and Nepal.

2.

Number: CFC/LZSG/08

3.

Project executing agency (PEA): International Zinc Association

4.

Location: Brussels, Belgium

5.

Starting date: September 2012

6.

Completion date: August 2014

7.

Financing (USD): Total project cost: -

II.

$65,000.00

CFC Financing (Loan/Grant):

$65,000

Background and context in which the project was conceived:

While it is not the intention of this report to provide a comprehensive preamble to the project, the following points should be noted: 1. Phase I of the project, “The Transfer of Technology and Promotion of Demand: Hot Dip Galvanizing (Phase III) (CFC/LZSG/08)” identified China as the largest market for batch hot dip galvanizing of six developing nations (China, India, Korea, Morocco, Peru and Russia) investigated. 2. Phase I concluded that for increased consumption to occur, technology transfer was required in the key area of production techniques and environmental controls. 3. Phase II of the project involved training of key identified industry personnel in the aforementioned countries. This was carried out in Europe. 4. At the end of Phase II it was concluded that a demonstration plan should be built to establish “best practice.”

5. Phase III proposed to carry out the recommendations of Phase II by either the establishment of a pilot demonstration plant or technology transfer to a number of identified plants, or both. The latter tactic met with great success, including development of a computer-based training tool for both managers and operators of galvanizing plants. Over 50 participants joined the training tool activity and many more were exposed to the advantages of using the training tool through four industry promotion meetings and workshops. Over 200 delegates attended the final workshop in November 2010. 6. Because of the success of this program and the training tool methodology, it was agreed to use surplus funding from the program to fund a successor workshops program with the Indian general galvanizing industry under the “Fast Track” framework of CFC to disseminate the use of the Interactive Management Training Tool The Fast Track project was developed through the process outlined below:

From the results of Phases I-III, together with inputs from Indian industry, it was decided to use the training tool in English and to conduct approximately 12 workshops, both inplant and also in public places that would be open to all interested in participating. Project Scope. The scope of the project was to disseminate previously developed training tools, pre-audit and audit protocols and benchmarks for hot dip galvanizing to the hot dip galvanizing industries in India, Bangladesh and Nepal. The training tools and training modules were created by the successful CFC-funded project in China (Transfer of Technology and Promotion of Demand: Zinc Batch Hot Dip Galvanizing

(CFC/ILZSG/12). The introduction of these training tools were expected to maximize overall plant performance and compliance with benchmarked norms, optimized energy use, minimized plant impact on the environment, improved operator and supervisor health and safety, and introduced a customer relations system based on total quality existence. The means of dissemination were to include both in-house and publiclyoffered workshops.

Outputs. India Lead Zinc Development Association (ILZDA), New Delhi, a 50-year-old technical body with close connections to the galvanizing industry, was chosen to plan the workshops. The initial plan was to conduct 12 workshops: 10 in India, 1 in Nepal and 1 in Bangladesh. Mr. Michael Ainsley, Project Consultant, with a long experience in the zinc/galvanizing industry, was retained as an expert facilitator and presenter. The English version of the interactive training tool, together with pre-audit and audit sheets developed for the CFC China General Galvanizing Program, were used in each of the workshops for the purposes of training. As further planning proceeded, it became clear that there was no reason to hold a general galvanizing workshop in Bangladesh because of the absence of a suitable general galvanizer in this country. All known Bangladeshi galvanizers are smallholders with no capacity for training or adoption of practices that are the subject of this project. Therefore, 12 workshops were held in India and 1 in Nepal. A table showing the location of each of the workshops, their dates and the attendance at each of the workshops is shown in Table 1. Table I. Workshop Locations, Dates and Attendance

Location First Series Mumbai - Public workshop Nagpur - Public workshop Chennai - Public workshop Delhi - Public workshop Jaipur - KEC International Ltd Second Series Kolkata - Public workshop Hyderabad - Public workshop Gandhinagar - M/s Kalpataru Power & Transmission Ltd Pune - M/s Valmont Structure Ltd

Date

Attendance

4-Dec-12 6-Dec-12 8-Dec-12 14-Dec-12 12-Dec-12

33 23 7 17 10

9-Apr-13 10-Apr-13

15 12

13-Apr-13 15-Apr-13

50 25

Third Series Simra, Nepal - Hulas Steel Industries Ltd Nagpur - Shilpa Steel & Power Ltd Raipur - Kapataru Power Transmission Ltd

21-Sep-13 30-Sep-13 1-Oct-13

20 22 14

The main objective of the workshops was to present, and raise awareness of, the interactive training tool. The contents of the ITT are:     

Pre-audit protocol Full audit methodology Supervisor interactive tool Quality control documentation (ISO 9001) Environmental management documentation (ISO 14001)

The workshops showed how to apply the ITT to achieve consistent process efficiency and sound environmental management. Ways in which it would enable the galvanizing units participating in the workshop to maximize overall plant performance and compliance, with benchmarked norms with respect to galvanizing process control, energy optimization, kettle management, sound environmental management, health and safety aspects and other key points for success were presented. An overall emphasis on achieving “total quality” in all aspects of galvanizing plant operation and management was presented. All the participants were given computer usb memory sticks containing the presentations for their study and reference. Copies of these files are available from the PEA. Follow-up to the workshops was enabled by use of a Technical Auditor who visited and audited select galvanizing units, followed by practical suggestions to achieve the benchmark norms. R. Srinivasan, an engineer with over 35 years shop floor experience in galvanizing plants in India and several overseas countries, was selected as the Technical Auditor. The technical auditing task is outside the scope of the CFC-funded project, which included only the workshops and is being sponsored independently by the galvanizers themselves, with support from the zinc industry. KEC and Kalpataru have so far availed themselves of the services of the Technical Auditor.

Outcomes The workshops were all well attended and witnessed interesting questions and answers between the presenters and participants. Two of the plants have engaged the Technical Auditor; additional engagements with other workshop participants are expected.

Finance Original Budgeted Costs

Final Expense Status

Stage I workshops Stage II workshops Stage III workshops

USD $36,000 $9,000 $20,000

USD $26,679.36 $21,519.45 $16,801.19

Total Project Cost

$65,000

$65,000

Notes: Stage I workshops were originally planned as 6 public workshops in Delhi, Mumbai, Chennai, Kolkata, Hyderabad and Nagpur Actual Stage I workshops included 4 public workshops in Delhi, Mumbai, Chennai and Nagpur and an in-plant workshop in Jaipur Stage II workshops were originally planned as 3 in-plant workshops in Ahmedabad, Jaipur and Pondicherry Actual Stage II workshops included 2 public workshops in Kolkata and Hyderabad and 2 in-plant workshops in Gandhinagar and Pune Stage III workshops were originally planned as 2 public workshops in Bangladesh and a public workshop in Nepal Actual Stage III workshops included an in-plant workshop in Simra, Nepal and 2 in-plant workshops in Nagpur and Raipur, India

Project Management Structure

III. Project Implementation and Results Achieved 1. Project Implementation. This phase of the project was structured as 3 rounds of workshops, divided as follows and summarized in Table I above: Round 1: 4 common workshops: Mumbai, Nagpur (first seminar), Chennai and Delhi. In-house workshop in Jaipur at KEC International Limited. All of these workshops were carried out during December 2012. Round 2: 2 common workshops were held in Kolkata and Hyderabad, 2 in-house workshops were performed in Gandhinagar and Pune. The Gandhinagar workshop was held at M/S Kalpataru Power Transmission Ltd. and the Pune workshop at M/S Valmont Structure Ltd. These were all carried out during April 2013.

Round 3: 3 common workshops were carried out in the third round, but at hosted locations within galvanizing plants. These were held at Hulas Steel (Nepal), Shilpa Steel & Power (Nagpur – second seminar) and Kalpataru Power Transmission Ltd. (Raipur). These were held during September and October 2013. Organizing and promoting of these seminars was mainly done by ILZDA with the assistance of the Project Consultant. ILZDA also reproduced the usb computer memory sticks that were distributed to each of the project participants. During each of the workshops, the presentation material was shown, generating questions in each case as to its applicability toward the situation of each of the participating galvanizing plants.

2. Project Results Achieved. The training of each of the 248 workshop participants and transmittal of the workshop presentation material to them was the principal outcome of this project. Many of the galvanizing plants expressed interest in implementing the interactive training tool in their plant and were given the opportunity to do so by offering of passwords to the sites to enable them to enroll as students in the interactive training tool. Also, the opportunity to engage the technical auditor was offered. Several of the plants have taken up this offer, engaging the technical auditor. 3. Dissemination of Project Results. The workshops conducted for this project enabled dissemination of the project results. In addition, the workshop presentation material is available via a link provided by the PEA that can be used for further training in the Indian milieu. IV. Lessons Learned It was learned that there is no Bangladeshi galvanizer operating in the organized sector; our plans to conduct a workshop were therefore changed and an additional India workshop conduced in its place. No significant problems were otherwise encountered during this phase of the project. Both ILZDA and the consultant were well known to the PEA and had a good record of program performance. V. Conclusions and Recommendations Twelve workshops were carried out to assimilate the interactive training tool for general galvanizing plants developed under the CFC program, “Transfer of Technology and Promotion of Demand: Zinc Hot Dip Galvanizing (Phase 3) in China (CFC/LZSG/08).” These seminars were held at 11 locations in India and 1 in Nepal. Each of the workshops drew delegates from a good fraction of the general galvanizing industry located in its locality. The participants received the workshop materials enthusiastically and in many cases indicated that follow-up

work with the Technical Auditor, funded independently by the galvanizers themselves and the zinc industry, was likely to occur. Several technical audits have already been accomplished by this technical auditor. The presentation material prepared for these workshops is available electronically from the project-executing agency. VI. Future Actions The zinc industry plans to work with the galvanizers participating in these workshops to implement the interactive training tool in their works. It is also expected that continued engagement of the Technical Auditor with the various participating galvanizers will be continued to support the use of the interactive training tool.