CLEAN BAG INITIATIVE IN ACC

ACC Limited

Reasons for Dirty Bags

Packing and Loading (controllable)

In – transit (difficult to control)

Unloading at rail siding (difficult to eliminate

but manageable)

Improper de-dusting of bags

Damages to Cement bags at Transfer points

Jamming of Cement bags at Diverter

Due to sharp edges/ opening or loosening of nuts n bolts

Wear n tear/holes on side-guards of conveyor belt

Loading in unfit wagons, Improper stacking inside wagons and pilling of bags near wagon doors

Non compliance of SOP

Poor stacking leads to higher frictions enroute casuing damages to bags

Exposure to rain /moisture enroute if loaded in wagons having damages/holes

Improper wagon sealing

Improper covering of cement if dispatched in rainy season /areas getting unseasonal rains like North East

Not sticking to SOP while unloading cement

Lack of 24*7 supervision

Use of undesirable hooks while unloading

Unloading Cement in wet /dirty wharf

Loading cement in unfit trucks

One “leaky bag” spoils the look of other bags

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Bags speak to Customers

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Bags speaks to customers when we are not around

Bags represent us in the customer shop/market place

Shop keeper prefers to store clean bags in the front

Clean bags means fuller bags – higher customer acceptability

Leads to less wastages One “leaky bag” spoils the

look of other bags Clean bag meets customer’s

expectations ultimately leading greater satisfaction & repeat purchases

ACC Limited

Clean bag Initiative processes

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The four buckets Cleaning & de_dusting facilities available

SustainabilityScalability

Innovative practicesNew/sustainable practices adopted to

bring about changes having (High/Medium/Low)impact

SOP- wagon loading The rigour of documentation (measurable)

& adherence to SOP Guidelines Customer feedback

Feedback from cross section of users

Project objectiveTo deliver Clean

Bags to our valued customers

ACC Limited

Initiatives Taken

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Man

Every one, from packing house personnel to wagon loaders, own the process

It is a Commitment from entire Team not from couple of individuals

Loaders have been sensitized regarding drop heights

Machine

Suction system has been installed at packer discharge belt which removes loose cement dust from bag’s surface

Small quantity of cement that remains on the bags is then brushed off

The cement dust is collected by the dust collector system reducing fugitive dust in the packing house

Process

The conveyor belts are kept clean of any spilt cement leaking from damaged bags

While loading, the height from which the bags are dropped is being reduced.

ACC Limited

Clean Bag Project: Plant Visit

To observe the cleaning & de-dusting facilities available

The best/ innovative practices being adopted

SOP-Wagon loading implementation status

Plant’s readiness to deliver clean bags to our esteemed customers

Objective

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Good Practices in cleaning & de-dusting

Clean and smooth packer area

Bag transfer points with minimum fall Small drop at turning

Hazards aer clearly marked High level of housekeeping in PH area

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Dealer/Customer feedback

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Other Initiatives: Sensitizing rail head labours at U/L point Engaging Rail Head Labours for smooth /hooks free unloading of cement bags, ensuring delivery of clean bags to customers & enhancing the sales of premium cement(25%) Unique and first of its kind activities undertaken at Rail sidings The Team members of Sales Unit-Sales & Logistics , CFAs were there in

full strength at the rail Head site. They engaged the Rail Head Labours , discussed with them regarding

the best unloading /loading practices , distributed ACC Caps, Food Coupons, offered sweets

Obtained their consent NOT to use hooks for unloading of premium cements and minimal use of hooks for handling normal cement.

ACC took initiative & all the labours of Cuttack Rail Head were group insured( Mediclaim)

ACC Limited

Steps for SustainabilityLoading point Unloading point

Plant Coordination: Packing house in-charge Periodic check and regular

maintenance of De-dusting machines

Cleaning of conveyor belt, checking of Transfer point

Regular maintenance of path from bag dropping point to till truck/wagon loading machine

Regular interaction with packing house supervisors/ labours to sensitize them

SOP Wagon Loading Implementation & sending the filled up Wagon Check List to SUL

SU Coordination: SU Logistics Manager Strict enforcement of SOP Sending Back the Wagon

check list to Packing House I/C with comments

Effective communication Program with unloading labour at Railhead & our warehouse

Insurance of Unloading labours Regular feedback from

dealers/customers/sales. SU Logistics Managers to meet min 2 big multiband retailer/wholesaler in a month, take his feedback on standard template & send to Regional Team