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					                             Table of Contents
1       Introduction                                                   1
    1.1 Preface                                                            1
        1.1.1 Project objectives                                       2
        1.1.2. Organization of the inspection and self-monitoring
        manuals                                                            2
    1.2 Introduction to the Motor Vehicle Assembly industry                3
        1.2.1 Product characterization                                 3
        1.2.2 Egyptian particularities                                 3

2         Description of the industry                                  5
    2.1   Raw materials, chemicals and other inputs                        5
    2.2   Production processes                                             8
          2.2.1 Foundry operations                                      9
          2.2.2 Metal fabrication plant                                12
          2.2.3 Motor vehicle assembly                                 12
          2.2.4 Motor vehicle painting/ Finishing                      13
          2.2.5 Post production motor vehicle dismantling/shredding    20
    2.3   Service units: description and potential pollution sources      20
          2.3.1 Boilers                                                20
          2.3.2 Water treatment units                                  21
          2.3.3 Cooling towers                                         21
          2.3.4 Laboratories                                           21
          2.3.5 Workshops and Garage                                   22
          2.3.6 Storage Facilities                                     22
          2.3.7 Wastewater Treatment Plants                            22
          2.3.8 Restaurants, Washrooms and Housing Complex             22
    2.4   Emissions, effluents and solid wastes                           24
          2.4.1 Air emissions                                          24
          2.4.2 Effluents                                              24
          2.4.3 Solid wastes                                           25

3       Environmental and health impacts of pollutants                   28
    3.1 Top ten pollutants of the engineering industry                   29
    3.2 Impacts of the main pollutants                                   29
    3.3 Other pollutants and their impact                                35

4         Egyptian laws and regulations                                38
    4.1   Concerning air emissions                                       38
    4.2   Concerning effluents                                           39
    4.3   Concerning solid waste                                         44
    4.4   Concerning work environment                                    45
    4.5   Concerning hazardous material and waste                        46
    4.6   Concerning the Environmental Register.                         46




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5       Pollution abatement measures                                   47
    5.1 General concepts                                                 47
    5.2 Pollution prevention options                                     49
        5.2.1 Metal Shaping operations                                   49
        5.2.2 Surface Preparation Operatins                            50
        5.2.3 Surface Finishing Operatins                                54
        5.2.4 Auxiliary Equipment                                      59
    5.3 Possible pollution prevention future plans                       61

6         Industrial inspection                                         62

7       Inspection planning at the inspectorate level                  63
    7.1 Activities characteristic to motor vehicle assembly industry     63
    7.2 Providing information about the facility                         63
    7.3 Providing resources                                              64

8         Preparation for field inspection (inspection team)             65
    8.1   Gathering and reviewing information                            65
    8.2   Preparation of the inspection plan                           65
    8.3   Preparation of the required checklists                         66
    8.4   Legal aspects                                                  66

9       Performing the field inspection                                  68
    9.1 Starting the field visit                                       68
    9.2 Proceeding with the field visit                                  68
    9.3 Ending the field visit                                           71

1         Conclusion of the field visit                                 72
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10.1      Preparing the inspection report                               72
10.2      Supporting the enforcement case                               72
10.3      Following-up compliance status of violating facility          72

Annex 1. Inspection checklist for motor vehicle assembly industry




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posted:10/27/2011
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