WASTE REDUCTION - COST OPTIMIZATION PROJECT

files image. WASTE REDUCTION - COST OPTIMIZATION PROJECT.

Kaizen Team. 2. Exec. Sponsor. picture. “I fully empower this team to pursue the goals of kaizen in a manner consistent with EBX’s values, and I will support all decisions made by the team.”.

Kaizen Introduction. 3. .…………………..……………………..... .………………..……..…………………….

Investigate Causes (Root Causes). 4. 0742b -uSU», 43 MT _ - 1700v. 9 _ MT - 41 950 202 ft- bTltu• 95 T.

Overview of Major Solid Waste Contributors. 5. 2024 Total in MT WOODEN SCRAP PAPER SCRAP GUNNY BAG SCRAP 94.16 54.16 27.608000000000001 2025 Total in MT WOODEN SCRAP PAPER SCRAP GUNNY BAG SCRAP 95.61 55.231999999999999 46.36.

Implemented actions. 6. S. No Issue Description Kaizen Action Points / Interim Proposals Responsible 1 RM wooden pallets & boxes scrapped after unloading 🪵🔁 Import pallets ✅ Venus boxes collected → repaired → reused for EWAC and Logistics Stores / Logistics 2 Excess wooden pallet procurement 📊📦 Pallet ordering aligned → excess & scrap reduced Purchase / Stores 3 Handling wastage in JLC wooden box 50kg packaging ⚙️ JLC box size changed → less damage & waste Purchase / Stores 4 Fresh A4 papers usage with carbon paper in weighing processes 📄♻️ A4 paper recycled → carbon paper removed Stores 5 Hard copy Manual BTC issuance 📧🔄 BTC process automated via soft copies emailing IT / Logistics 6 PP carton disposed as no value scrap ♻️💰 PP carton & film scrap → segregated → sold Stores 7 Reclaim powder disposed as no value scrap 🔄⚙️ Reclaim powder recycled → reused in production Production / Stores.

Process Approach comparison (Before and After). 7.

Objectives and Results (Financial and Non-Financial).

Kaizen Improvement- Wooden Pallets recycle. 9. Before After Problem Improvement / Benefit Damaged Wooden pallets and boxes were treated as scrap and removed through disposal processes. leading to waste, unnecessary purchases, and higher environmental impact. Discarded wooden materials are now collected, segregated, and repurposed into usable pallets. reducing scrap generation, lowering purchase costs, and minimizing environmental impact.

Kaizen Improvement- Salable scrap improved. 10. Before After Problem Improvement / Benefit PP carton and Vac pack pouch scraps are presently disposed of under the non‑salable scrap category. Initiated a new authorized vendor to classify PP carton & Vac pack pouch scrap under the salable scrap category . Dispose of it through a structured scrap‑sale process instead of treating it as waste and resulting cost savings ` INSERT PHOTO INSERT PHOTO.

Kaizen Improvement- BTC digital Automation. 11. Before After Problem Improvement / Benefit Process of BTC issuance relied on manual methods. consuming over 2500 sheets of A4 leading to high costs and paper waste. By automating BTC issuance via email and digitalizing records paper consumption was reduced to zero, saving over $3000 annually and increasing process efficiency..

Kaizen Improvement- Venus Wooden box reusage. 12.

Kaizen Improvement- Weighing Digital systems integrated.

KPI Dashboard – Waste Reduction Cost Saving 2026.

Warehouse cost savings funnel-2026. 15. [image] 2026 Plant Sl.N0 1 2 3 4 5 6 7 8 Warehouse cost Saving Project - Project Identifier Optimization of Container Storage Release Project Funnel -Monthly cost saving in kUSD Business Region Segment Monthly Target Yearly Ta rget 3.70 5.89 2.39 2.65 2.00 3.20 0.53 1.01 21 JAN 0.16 0.49 0.20 0.02 0.21 0.24 0.26 0.07 1.65 FEB 0.31 0.49 0.20 0.17 0.19 0.28 0.27 0.08 2.00 MAR APR Diesel forklift c onsumption restriction through plant forklift Forklift operation cost saving by shifted Godrej vend or Reuse ofvenus supplier box to ewac dispatch BTC automation- Paper cost saving Waste reduction ofwooden pallets through RM Import Pallets PP carton recycle- Salable Carbon Paper Restriction by using a Digital Weighing Machine Warehouse cost Savings per Month in K USD s s s s s s s 0.31 0.49 0.20 0.22 0.17 0.27 004 0.08 1.78 s s s s s s s s s S s s s s s s s S s s s s s s 0.31 0.49 0.20 0.08 0.27 0.17 0.04 0.09 1.65 s S s s s s s s 0.31 0.49 0.20 0.26 0.23 0.17 0.01 0.08 1.75 MAY s 0.31 s 0.51 s 020 s 029 s 028 s 006 s 001 $174 YTD $ 139 2.47 $ 100 $ 082 $ 119 $ 091 $ 060 $ 041 8.80.

Sustainment. 16. sustainment of the Kaizen To ensure long-term success, the improvements have been embedded into our standard operating procedures Follow Standard Work for all new processes. Continue the reuse of wooden boxes and pallets, reducing packaging waste. Maintain digital documentation to reduce paper consumption Continuously monitor ergonomics to enhance workplace safety..

30 Day Homework List. 17. Kaizen Newspaper Month Milestone Action Who When WK1 WK2 WK3 WK4 Phase 1 Observation & Baseline 1.- Identify wooden packaging usage areas Stores Day 1–2 ✔ 2.- Record scrap generation data Stores Day 3 ✔ 3.- Study BTC & weighment process Logistics Day 4 ✔ 4.- Measure paper consumption Logistics Day 5 ✔ 5.- Capture baseline cost data Warehouse Day 6–7 ✔ Phase 2 Implementation 1.- Reuse Venus wooden boxes for EWAC Logistics Day 11–12 ✔ 2.- Reuse RM pallets for logistics operation Logistics Day 13–14 ✔ 3.- Standardize pallet handling Logistics Day 15 ✔ 4.- Implement BTC email automation IT / Logistics Day 16–17 ✔ 5.- Segregate PP carton & vac film scrap Stores Day 18–20 ✔ Phase 3 Sustain & Results 1.- Digitalize weighment records Stores Day 21–22 ✔ 2.- Recycle reclaim powder via pulverization Production & Stores Day 23–24 ✔ 3.- Validate waste reduction cost savings Warehouse Day 25–26 ✔ ✔ 4.- Prepare Kaizen results Kaizen Team Day 27–28 ✔ 5.- Standardize & communicate practices Management Day 29–30 ✔.

Lessons Learned. List any Lessons Learned from the Kaizen ♻️ Waste Management and Recycling Efforts Environmental (BRSR Principle 6): Embedding reuse and recycling practices directly improves environmental performance and supports the circular economy. 🧹 Cleanliness and Green Campus Drives Social (BRSR Principle 3): Ergonomic and process improvements enhance employee safety and well-being. 🌍 Sustainable Workplace Practices Governance (BRSR Principle 1): Clear role ownership and cross-functional coordination are critical for accountability and success. 📄 Reduction of Paper and Plastic Usage Integrated ESG: Digitalizing manual processes improves transparency and demonstrates organizational maturity to all stakeholders. 📚 Environmental Learning & Awareness Sessions Knowledge Sharing: Successful recycling practices have been transferred to the IGT plant and extended to SHARP,NGP plant, enabling standardize and wider impact..

SOCIAL SUSTAINABLE TOMORROW ESG GOVERNANCE STRONGER PLANET STRONGER SOCIETY STRONGER FUTURE YOU.