PRODUCTIVITY EXCELLENCEIN

J.K.WHITE CEMENT WORKS, GOTAN

Presented by (Virendra Singh Rathore)Date of Presentation (15/10/2018)

Place of Presentation (QCFI, Hyderabad)

Sl. No. Parameters UoM Values

1 Capacity Utilization % 90%

2

Conservation of Raw Materials & Fuels % Alternative raw material used % Alternative fuel used Amount of Waste Heat recovery power generated

%% Alternative fuel used – 0.71%

3Approach to the Implementation of Best PracticesIf Yes, Please Specify.

Y/N

Yes, Separate management programmes taken for every aspect of productivity – Quality, Environment, Health & safety and energy

4DC in PAT CycleIf Yes , Specific Energy Consumption(Target & Achievement)

Y/N

TOE/T of Product

YesTarget in First Cycle- 1379 Kcal/Kg of cement Achieved- 1365 Kcal/Kg of cement

5

Do you have RPO obligation If Yes, Specify the obligation and measures taken to fulfill (Certificates procured or renewable energy used by purchase or by self generation)

Y/N

Yes, REC- solar purchasing is done at group level of J.K.Cement Ltd . The Unit is having 20KW Solar

Plant for office lightings and 150 KW solar plant is proposed on

roof of Admin Building

2017-18

Sl. No.

Parameters UoM Values

6Blended Cement Produced out of total production

% NA

7Low grade/sub grade limestone used out of the total limestone consumption

% NA

8% of Synthetic gypsum used out of total gypsum.

% of Fly ash used in cement.% of slag used in cement

% NA

9 Spares Consumption Rs/T of Product 189

10Man Power Utilization (Permanent & Contract)

T of Product/Man Power

1236

2017-18

Sl. No.

Parameters UoM Values

11Compliances with Environmental Norms (Dust, SOx & NOx Emission)

mg/Nm3Dust - <30 mg/Nm3SOx - <25 mg/Nm3NOx - <600 mg/Nm3

12 Industrial Relations Issues, Please Specify --

Not Faced any kind of problems /issues regarding industrialrelations till now (Since inception of Plant i.e. since last 34 Yrs.)

13Management System Implementation, Please specify the name of System(ISO/IS/IMS Systems etc)

Nos.

QMS Certification – 21-12-1993EMS Certification – 12-03-1998OHSAS Certification – 12-05-2005EnMS Certification – 19-03-2015SA 8000 Certification – 31-03-2006CE Mark (CPR) Certification- 13-04-2010 NABL accreditation – 18-03-2011

14Maintenance Practice(Preventive/Proactive/Condition Monitoring)

--All 3 Practices are being carried out

2017-18

SYSTEM APPROACH

Our journey towards international management systems started in 1993 . Our proactive approach & commitment towards adoption of management systems has a never ending journey towards continual improvement of system w.r.t Quality, Energy, Environment , Health and Safety & Social accountability.

1980

1985

1990

1995

2000

2005

2010

2015

2020

ISO 9001 ISO 14001 OHSAS 18001 SA 8000 CE Mark NABL ISO 50001

YEAR

MANAGEMENT SYSTEMS

MANAGEMENT SYSTEMS - JOURNEY - JK WHITE

IMS CERTIFICATION

HIGHLIGHTS

QMS Certification – 21-12-1993EMS Certification – 12-03-1998OHSAS Certification – 12-05-2005EnMS Certification – 19-03-2015

CERTIFYING BODY : LRQA , UK

AUDIT SCOPE :

1. Manufacturing of White Cement & Dry Mix Mortars .

2. Thermal Power Generation Capacity 7.5 MW

J.K.White Cement Works, Gotan is one of leader companies in the world to acquire SA-8000 (Social accountability) certification (March-2006) from RINA, Italy

SA 8000 CERTIFICATION

J.K.White Cement Works Gotan is the first company in the entire cement industry in India to have NABEL Accrediation.Our quality control laboratory achieved NABL accreditation under BIS as well as EN-197-1 on 18-Mar-2011.

NABL ACCREDIATION OF QUALITY LAB

CE MARK: Achieved EN197-1 certification underConstruction Productregulation to produce twotypes of cements:

Portland cementCEM I 52.5 N

Portland compositecement CEM II / A-M (P-L) 42.5 N

After verification, LLODSRegister UK has certifiedour product and issued theCPD / CE certificate on 13-04-2010.

CE MARK (CPR) CERTIFICATION

Rajasthan Chamber Excellence Award 2017, by the Rajasthan Chamber of Commerce & Industry Jaipur on 1st

April, 2018 at Mohanlal Sukhadia Sabhagar Chamber Bhawan, Jaipur.

RAJASTHAN CHAMBER EXCELLENCE AWARD

J.K. White Cement Works, Gotan was adjudged 3rd position as Domestic Cargo owner of the year 2016-2017 on CONCOR DAY held at New Delhi on 02.12.2017

Domestic Cargo owner of the year 2016-2017

Productivity Super Excellence Award for the year 2014-15 awarded by the Rajasthan State Productivity Council on 28th May, 2017 at Jaipur. Honorable Industry Minister, Govt. of Rajasthan Mr. Rajpal Singh Shekhawat presented the prestigious award to Mr. B.K. Arora Business Head.

Productivity Super Excellence Award

Excellence Certificate – During Best Employers Award 2016, JKWC have been awarded “Certificate of Excellence” during the function on 24.11.2017. The award was organized by The Employers Association of Rajasthan, Jaipur.

CERTIFICATE OF EXCELLENCE

Dhanappa Limestone Mine of J.K.White Cement Works, Gotan have beenawarded First Prize in Overall Performance in 28th Mines Environment andMineral Conservation Week 2017-18 under the aegis of Indian Bureau ofMines Ajmer region; hosted by Shree Cement Limited, Beawar. Prize givingceremony held at Shree Cement Ltd., Beawar on 13.01.2018 and ControllerGeneral Indian Bureau of Mines, Shri Ranjan Sahai was the Chief Guest

First Prize in Overall Performance of Limestone Mine28th Mines Environment and Mineral Conservation Week 2017-18

Our Mines have been awarded First prize in OverallPerformance in 31st Mines Safety Week-2017 Final dayFunction on 24.12.2017 at Kota under the aegis ofDirector General of Mines Safety; hosted by ACC LimitedLakheri

First prize in Overall Performance 31st Mines Safety Week-2017

Life Time Achievement Award – The award was declared for Syt. Yadupatiji Singhania, CMD JK Cement Ltd. on 01.04.2018 by Shri Ram Charan Bohra, M.P. (Loksabha) and Award received by Shri Raghavpat Singhania, Special Executive on behalf of CMD.

Life Time Achievement Award

Reward to Dedicated Employees

MAINTENANCE BEST PRACTICES

1.Equipment wise Task list for Preventive Maintenance Activities

2. Walk By Inspection

3. Monthly Equipment Loading w.r.t Preventive Maintenance

4. Condition based Monitoring

5. Predictive Maintenance – External Agencies Involvement

6. Annual Inspection/Need Based Maintenance

7. AMC’s for Critical Equipment's to OEM’s

8. Equipment Efficiency Checking

1379

1365

1355

1360

1365

1370

1375

1380

1385

TARGET ACHIEVED

Kca

l/K

g of

Cem

ent

PAT FIRST CYCLE - TARGET V/S ACHIEVED

PAT Ist Cycle - TARGET V/S ACHIEVED

ENERGY PERFORMANCE – PAT CYCLE-1

431

0

50

100

150

200

250

300

350

400

450

500

2012-15

No.

Of E

scer

ts

PAT FIRST CYCLE

No. Of Escerts Earned

PAT Ist CYCLE – EsCERTS EARNED

0

0.71

1.50

0

1

2

3

2016-17 2017-18 2018-19

% A

FR

YEAR

USE OF AFR

MATERIAL CONSERVATION

Management Programmesfor Productivity Enhancement

17

35

41

0

5

10

15

20

25

30

35

40

45

50

ENERGY QUALITY ENVIRONEMENT , HEALTH &SAFETY

No.

of M

anag

emen

t Pro

gram

mes

SEGMENT

MANAGEMENT PROGRAMMES 2017-18

TRAININGS TO ENHANCE PRODUCTIVITY

1052

1245

0

250

500

750

1000

1250

1500

EXTERNAL TRAININGS INTERNAL TRAININGS

TRA

ININ

G H

RS.

SEGMENT

TRAINING HOURS 2017-18 1. In-House Trainings

2. External Trainings

3. Core Job Trainings

4. On-Job Trainings

5. Orientation Trainings

6. Health & SafetyTrainings

7. SA -8000 Trainings

8. ISO awarenesstrainings

INDUSTRIAL RELATIONS ISSUES

J.K.WHITE CEMENT WORKS HAVE NOT FACED ANYKIND OF PROBLEMS / ISSUES REGARDING INDUSTRIALRELATIONS TILL NOW ( SINCE INCEPTION OF PLANTi.e. LAST 34 YEARS)J.K.WHITE CEMENT WORKS HAVE STRONGSTAKEHOLDER IDENTIFICATION AND ENGAGEMENTWITH PROPER RISK ANALYSIS

ADEQUATE SAFETY MEASURES FOR EMPLOYEES

Convex mirrors at road turnings Regular medical check ups for employees and their family members Annual Spiro-metery / Lung Function Test for employees Audio-metery test for employees to assess noise induced hearing loss Ergonomics training Pathological laboratory having auto analyzers Awareness on blood pressure, diabetics and cardiovascular ailments, as these

diseases are silent killers PDCA approach for continual improvement All the welding/cutting sets have been provided with flash back arresters at both the

ends to ensure safety. Industrial Gas Cylinder transportation trolleys have been provided Isolated gas cylinder Godown for industrial use has been constructed as per Gas

Cylinder rules. Exhaust chimneys have been installed in the mess. DGMS approved Safety shoes have been provided to our complete work force.

PPEs like Helmets, Safety Belts, Nose Masks, and Safety Shoes etc. have beenprovided to all the work force as per their job requirement.

Warning and safety signage have been installed for road safety as well as industrialsafety.

Fire extinguisher has been installed at all the places and audit and Mock Drill isconducted as per the established policy.

Emergency preparedness plan is displayed at all locations and regular training hasbeen given.

Some of the persons are trained for first aid by Red Cross and list of such persons isdisplayed at all locations to care in case of emergency.

Ambulance has been purchased equipped with appliances to take care inemergencies.

Deployment of sweeping machines for road cleaning in factory and colony campusto give dust free environment.

ADEQUATE SAFETY MEASURES FOR EMPLOYEES

Work Permit System Circulating Safety Flash for awareness. Regular Job Specific Safety Training (Internal / External). Monthly Safety Meeting with department HOD’s. Regular Safety Inspection / Audit. Circulating Safety Statistics Electrical Shut Down System (Log – Out / Tag – Out).

ADEQUATE SAFETY MEASURES FOR EMPLOYEES

PARTICIPATIVE WORK SYSTEM AND CULTURE/ FEEDBACK

We have an established system of employee involvement which is through various committees and functions etc. as mentioned below:

Safety Committee Canteen Committee Kaizen Schemes Suggestion Schemes Feed Back from Employees Town Hall Meetings Energy Management Team Meetings (EnMGMT) Social Performance Team Meetings (SPT) Management Review Meetings (MRM) Monthly Safety Meetings

JOURNEY CONTINUES………….

THANKS!