34 Revamping of B2B & PCO cleaning methodology Introduced a modified clean-up methodology based on a comprehensive risk assessment and avoided batch to batch cleaning whenever the equipment is known to be taken for PCO Impact • Obtained savings on solvent cost from cleaning method revamp of primary solvent cycle & elimination of B2B cleaning before PCO • Tracked & estimated solvent consumptions of reactor PCO’s - annualized savings are over Rs. 1.1 Crore Re-use of oil in Patkar pumps following heating and filtration Oil consumption in Patkar pumps (used for PFO high vacuum distillation process) was reduced by reusing used oil through heating and filtration Impact • Reduction of fresh oil consumption in Patkar pumps • Oil recovery of 95% was achieved Employee Involvement in meeting sustainability goals Kaizen Blitz is our ‘continuous improvement program’ implemented throughout our Indian sites where the ideas are generated as well as implemented by employees. Kaizens are referred as the building block of lean production methods and cover a broad spectrum encompassing areas such as waste elimination, efficiency improvement, operating cost optimization and process improvements. The second edition of Kaizen Blitz received over 450+ Kaizen ideas. As a result of implementing the selected ideas, the annualized savings from the program stood at nearly Rs. 4 crore. 22% 40% 23% 26% 45% 66% 0% 10% 20% 30% 40% 50% 60% 70% FY 22 FY 23 Processing time Cleaning + Waiting time Establishing process excellence: Process time reduction & yield improvement As part of SFTI, Batch Cycle Time (BCT), and Batch Charge Frequency (BCF) are monitored continuously and steps are taken for improvement in case challenges observed in the production process. We took a series of initiatives for productivity enhancement through process modifications and improved yield and cost efficiency. Such productivity enhancement initiatives on BCT and BCF have resulted in higher capacity utilization of our equipment. In one of the products manufactured, we achieved a reduction of 35% BCT and 33% BCF. It resulted a yield improvement and cost efficiency. Such productivity enhancement initiatives on BCT and BCF have resulted in higher capacity utilization of our equipment.
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