Justice Tshifularo, Senior Manager: Productivity ... - wastex africa

upsetsubduedManagement

Nov 9, 2013 (3 years and 8 months ago)

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The “closed
-
loop economy”

Minimising

waste & improving
resource efficiency



Presented @ Waste Indaba

by Justice Tshifularo, Senior Manager

30 May 2013

1.
What is Waste

2.
Productivity vis
-
à
-
vis Waste

3.
Increasing Productivity
through Waste Reduction

4.
Seven Wastes

5.
Integrated Waste
Management

6.
Job Creation from Waste

7.
Case study

8.
Conclusion



PRESENTATION OUTLINE

Vision


To
lead and inspire a productive

and competitive South
Africa
.

To improve productivity by advising,
implementing, monitoring and evaluating
solutions aimed at improving South Africa’s
competitiveness


Mission

WHAT IS WASTE


The definition of waste is an on
-
going debate because of increasing
global trend to reduce, re
-
use, rework, and recycle the waste
products.



Waste
refers to all non
-
value adding activities that consume
resources.



Anything
that that does not add value to the end product or service
and something for which the customer is not willing to
pay
.




Something
that nobody wants at a particular moment in time and
that needs to be disposed
of.


WHAT IS WASTE


What
waste is in one process could become raw material to another
process
.



The understanding of waste have given birth to many management
philosophies whose ultimate objective is to improve productivity and
competitiveness such as Just in Time (JIT), Lean Thinking and
Continuous improvement (Kaizen).



PRODUCTIVITY
vis
-
à
-
vis
WASTE


Productivity entails converting resources (inputs) into products and
services (outputs) efficiently, effectively and with optimum utilisation
of human capital and physical resources for the benefit of society, the
economy and the environment
.



Productivity is a mind
-
set that embraces the value of “doing what I do
today better than I did yesterday, and even better tomorrow”,
continuously finding better ways of doing things and tracing improved
performance through accepted measures
.



Thus productivity is related to the use and availability of
resources
with minimal wastage.


INCREASING PRODUCTIVITY THROUGH
WASTE REDUCTION


One of the many options available for how to improve productivity is
to reduce waste, be it time or
materials.


Waste can occur at any stage in delivering a product or service to a
customer.


Waste has
a significant impact on productivity levels


on unit costs
as
well as
profit margins
.


A simple, proven technique known as “seven wastes” developed by
the famous Toyota Motor of Japan has been used by many companies
all over the world to improve the productivity of their operations.





DEFINITIONS
OF THE SEVEN WASTES


Type

of Waste

Definition

1. Waiting

Resources waiting during operations

2. Transporting

Moving materials unnecessarily in the workplace

3. Processing

Waste inherent in the process or design itself

4.

Inventory

Keeping high inventory or work in process

5. Motions

Unnecessary movements of

workers during operations

6. Defects

Producing defective parts or poor service

7. Overproduction

Producing more than

necessary


DEFINITIONS
OF THE SEVEN WASTES



This may sound very manufacturing oriented, but over the years many
service
-
sector companies have adapted the concept in their
operations to help them improve productivity and profitability
.



The seven wastes technique is a good framework to help companies
identify opportunities for elimination of waste in operations.



The technique can be implemented either as a driver or as a tool, to
complement
other productivity improvement programs like
Lean
Management
,
5S
,
Quality Circles
, Green Productivity
.





INTERGRATED WASTE MANAGMENT



Integrated Waste Management became mandatory with the coming
into effect of the National Environmental Management: Waste Act,
2008 on 1 July
2009.



The Institute of Waste Management of Southern Africa recognizes the
importance of a broad hierarchy of preferred options that look at the
waste stream in a cradle
-
to
-
cradle approach,
namely:






INTERGRATED WASTE MANAGEMENT


Waste Avoidance: The reduction of waste source

Re
-
use: The utilization of a waste product without further

transformation

Recycling: The manufacturing of a product that is made from waste

material

Treatment: The process of changing the physical and/or chemical

Properties of a waste product)

Disposal: The final and least desirable step in the hierarchy; involving

land filling of wastes in a controlled manner

Resource Recovery: The recovery of recyclable material out of the

waste stream


JOB CREATION FROM
WASTE










Minister
Edna
Molewa,
Dept. of
Water and Environment
Affairs:
“Waste is wealth and we aim to
prove that in line with our
efforts to reduce, re
-
use and
recycle waste, we could create
job opportunities for all our
young people”.




JOB CREATION FROM WASTE



There has been an increase in recycling across South Africa which has led to
job creation and economic growth
-

direct formal employment and informal
employment.


Whilst
waste collection or management’s benefits may be on the
environmental impact, it is job creation and the economy which benefits
most
.


Enterprises
that are not recycling companies can through their innovations
provide self
-

employment to people in the informal sector through
involvement in the recycling industry
.



Recyclables like paper, glass, plastic, metal and even vegetable remains can
be sold or produce other material out of it.




JOB CREATION FROM WASTE



Productivity SA’s Workplace Challenge Program (WPC) is a world
-
class
manufacturing / service or best operating practice programme aimed at
helping manufacturing / service companies in SA to become more
competitive.



One of the model companies involved in WPC is
Adcock Ingram Critical
Care (AICC) (Pty)
Ltd.



AICC is
an integrated facility for manufacturing healthcare products
and manufactures various Medical solutions bags and final finished
products.





CASE STUDY

Adcock Ingram Critical
Care
(Pty)
Ltd

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1
.
Sorting of various grades of material

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2. Reject Ampoules

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3. The grinding process of IV Ampoules

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4. Cut PVC Bags and grinded Ampoules is then sold to


Riggs Waste Plastics

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5
.
All components that cannot be recycled is removed

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6. The cut IV Bags are grinded to form PVC regrind

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7.

Regrind material sent to Tongi
-
Yi Footwear



Regrind mixed

with master batch colour to form a blend

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8. Blended materials used for moulding sandals

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9. Moulding of sandals

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10. Sandals passing through the dye bath

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11. The drying process

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12. Packaging Process

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13. Proudly made in the Republic of South Africa

32



The cost of not recycling material disposed of:


PVC Material





74,370
kg

=

R 303,798



Other Grades of Material


14,942 kg

=

R 90,797


Total






89,312
kg

=

R 394,595


To dispose:





89,312
kg x R
14.02









= R 1,252,333

Benefits
of Recycling:


Saving on disposing



R1,252,333



Revenue generated




R394,595


Value
generated




R1,647,948



33


















































































As a direct result of the waste material generated by AICC,
Riggs Recycling

employs
25
people for sorting and grinding.



As a direct result of the waste material generated by AICC,
Tongi
-
Yi Footwear employs
45

people for the manufacture of
the footwear.



A further
40
customers have become entrepreneurs selling this
footwear.



Product proudly bears the mark
“MADE IN SOUTH AFRICA”.

34



AICC won the
2011 National
Productivity
Award



JOB CREATION FROM WASTE



Other companies involved in Workplace Challenge Programme that put
waste to work are:



Company

Primary Product

Waste

Waste

Produce

Granor Passi

Fruit juice

Fruit peels

Essential Oils

Green Farm Nut Company

Macadamias

Hard shells

Macadamia oil

Merensky

Timber

Timber cuts

Furniture

Adcock Ingram Critical
Care (Pty) Ltd

Pharmaceutical
products

Rubber

Shoes


CONCLUSION



We
should not limit our thinking on the current products and services
because we might as well discover future products and services from
today’s waste.


We need to
think
of innovative ways of converting the “waste” back
into value before disposal because we might be missing out on a
wonderful opportunity that mother earth and its citizens might be
grateful of
.


These examples shows that innovation could lead to “waste”
becoming essential in meeting needs of the customers, Job creation
and GDP growth
.




THANK YOU