Zamzam Drinking

Water Factory

August 2014

 SCOPE
Production

of high quality drinking

water according to ASTM .

 POLICY
Zamzam is committed to delivering a high quality
standard drinking water to comply with our
customers requirements.
This can be achieved by continuous improvement and
applying advanced process technologies and
involvement of all employees regarding their safety in
the first place with provide safe work environment and
welfare facilities.
Zamzam is also committed to prevent any kind of
environmental pollution and to protecting the health &
Safety of communities surroundings the areas of our
work.
C.E.O
August 2014



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August 2014

C.E.O

 OBJECTIVES:

1.To increase the production rate

toward the designed capacity by 50%
by the last quarter of this year.
2.Improve our health and safety to our
people to eliminate accidents by 30%
annually .
3.To utilize an advanced waste
treatment system in order to minimize
industerial waste by 75% by the end of
this year.

PROCESS FLOW CHART

INTAKE
FROM
WELLS
NO
PH
CHEC
K

YE
S

PURIFICATIO
N
NO
TURBIDI
TY
CHECH

YE
S

Sludg
e
waste

FILTRATION

Solid
wast
e

NO
COD /
BOD
CHECK

YE
S

DISINFECTION
NO
CHLORID
E
RESIDUE

YE
S

CL2
INJECTION
UV SYSTEM

FILLING &
PACKAGING

MINERALS

NO
WEIGHT /
APPEARA
NCE
CHECK

INVENTOR
Y & SALES

Markets

YE
S

 Quality Plan:
Process

INTAKE FROM
WELLS
PH
CHECK

PURIFICATION
TURBIDI
TY
CHECH

FILTRATION
COD /
BOD
CHECH

Stage

W.I

Q. Charactestics

Responsibilities

Raw water feed

WI-PR-01

Flow Rate

Production Operator

Determination of raw
water PH

WI-QC-01

PH

Quality Inspector

WI-PR-02

Flow Rate

Production Operator

Inspection of purified
water Turbidity

WI-QC-02

Turbidity

Quality Inspector

Filtration of water
from fine
suspended solids

WI-PR-03

Flow Rate

Production Operator

Determination of
COD and BOD of
water

WI-QC-03

COD / BOD

Quality Inspector

Purification of
water from large
suspended solids

Process

DISINFECTION
CHLORID
E
RESIDUE

FILLING &
PACKAGING
WT /
Appearan
ce
CHECK
INVENT
ORY &
SALES

Stage

W.I

Q. Charactestics

Responsibilities

Disinfect of water
from germs and
bacteria

WI-PR-04

Cl2 Flow Rate

Production Operator

To check chloride
concentration in
water

WI-QC-04

Chloride Residue

Quality Inspector

Inject of minerals ,
filling and
packaging of the
product

WI-PR-05

Minerals Dose and

speed of Filling
Machine

Production Operator

Ensure the weight

and appearance of
the product

WI-QC-05

Weight /
Appearance

Quality Inspector

Storing ,
selling and
marketing of
product s

SMP-01

Batch Size

Production Operator

Hazard Identification & Risk Assessment

(HIRA)
HAZARD

R.R

CONTROL

CL2 Inhalation

1. Use high standard fittings.

2. Provide air dilution ventilation
system with gas detector.
3. Using warning signs.
4. PPEs (Muzzle respirator)

Back injuries
from manual
handling

1. Utilizing belt conveyor

mechanical handling system.
2. Conduct safety training course
for handling procedure.

High noise from

pumping units

1. Isolation of pumping area.

2. Instructions for time limited
working area.
3. Provide PPEs (ear plugs).

 Environmental Aspect & Impact Assessment (EAIA)

ASPECT

I.R

CONTROL

Chemical Leak
(anti-Scaleior)

1. Continual inspection and PreMaintenance for chemical unit.

2. Design of concrete trench
around the chemical tank.

Sludge waste
from purification
unit

1. Utilizing highly effective

drainage system.
2. Reuse of this rich muddy
minerals sludge for agricultural
purposes.

Plastic waste
from packaging
unit

1.Applying recycle unit to reuse the

waste.

NCRS

CORRECTION

CAUSE

CORRECTIVE ACTION

Manual
handling used
due to lack of
handling
equipment's
according to
the clauses
(5.1(e)) , (7.5.1
(c))

Provide
handling
machine such
as fork lift as
soon as
possible

- Lack of
handling
equipment's
- Lack of
reporting
system

Applying of
Automatic handling
system with next
production order
(conveyor
mechanical )

-Availability of
data records
Misunderstandin
g of reporting
system

-Activation of
reporting format
system.
- Developmental
training for
employees on data
analysis techniques

Accidents and Issue immediate

near misses
order to do the
data not
analysis
analysis as
required by
clause (4.5.3.1)

Mock drill for

ERP not conduct
2 years ago as
required by
clauses
(4.4.7(a),(b))

-Perform fire
drill next week

-ERP plant not

implemented.

- Lack of
management
commitment

- Conduct the mock

drill for ERP before
any MRM

 Analysis of Internal Environment:

Factor

Strength

Weakness

Governance

Application of powerful
regulations

Less Supervisory

Policies

Management commitment

Capabilities

Resources availability

Information
System

Good communication channels

Abuse of IT System

Cultural

Great response to training and

developmental programs

Lack of awareness
and culture

Standards

Following the standards firmly

Difficulty in applying
modified standards

 Analysis of External Environment:

Factor

Opportunity

Threat(s)

Legal

Conforms with governmental

rules and regulations

Bad abuse of power

Economic

Considerable increase of voice

of the markets to our product

Prices fluctuations

Technological

Utilizing an advanced process

technologies

Political

Good relations with local and

central authorities

Difficulties of importing
spare parts due to the
international
restrictions

Environment

Friendly production plant toward

environment

Contamination of the
ground water by
external factors

 Interested Parties
Stakeholders

Needs

Employees

Comfort working environment and satisfying

wages

Board members

Short pay back period , high profitability and

achieving company goals.

Government

Following legal requirements and paying taxes

Customers

Quality and price of the product

Contactors

Terms of payment and sustainability

Agency

Quantity and quality of the product and

commission

MRM AGENDA

Outstanding status of previous MRM.

Performance of IMS system including
trends , NCRs ,CA and audit result.
Opportunities for continually improvement
at (technology ,social) issues.

Thank you for

attension
Any Question?