7/12/2018 1 “Resource Efficiency Through Operational Improvement” CII- GREENCO SUMMIT 2018 An Industrial Garden Township of 3000 acres in Mumbai, India ABOUT GODREJ 14 SBUs with Corporate Offices & Manufacturing Facilities Employee Welfare through Residential Facilities Employee Welfare through Company Schools Commitment to Society through Godrej Memorial Hospital Commitment to Sustainability through 1800 acres of Mangrove Plantation 118 YEARS OLD- EMPHASIS ON CUSTOMER CENTRICITY & OTHER STAKEHOLDERS NEEDS
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7/12/2018
1
“Resource Efficiency Through Operational Improvement”
CII- GREENCO SUMMIT 2018
An Industrial Garden Township of
3000 acres in Mumbai, India
ABOUT GODREJ
14 SBUs with Corporate Offices &
Manufacturing Facilities Employee Welfare through
Residential Facilities
Employee Welfare through
Company Schools
Commitment to Society through
Godrej Memorial Hospital
Commitment to Sustainability
through 1800 acres of Mangrove
Plantation
118 YEARS OLD- EMPHASIS ON CUSTOMER CENTRICITY & OTHER STAKEHOLDERS NEEDS
7/12/2018
2
One of the largest divisions of G&B
Market leader. Crossed Milestone of 2000 Cr revenue in 17-18
Heading towards 2500 Crs Business in 18-19 with a growth of over 20%
Unmatched reach. 16 Branches & over 700 Dealers
Supported by 7 manufacturing locations and over 100 major suppliers
ABOUT GODREJ INTERIO
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4
Vision : Godrej – The choice for home and workspace solutions
Mission : Enriching life by transforming home and work spaces
Integrity Trust To Serve
Respect Environment
OUR VALUES
OUR MISSION, VISION, VALUES…
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INTERIO
B2B
(60%)
Products
Desking
OPOS
Storage
Seating
Healthcare
Projects
Interiors
Laboratory
Marine Accommodation
Vending Services
Audio Video Solutions
B2C
(38%)
Products
Home Furniture
Home Storage
Mattress
Kitchen
Projects
U & US
Service
(2%)
AfterSales
Services
OVERVIEW OF OUR OFFERINGS3 STREAMS OF REVENUE
ABOUT OUR GREENCO CERTIFIED PLANTS
Shirwal plant(Relocated from Vikhroli, Mumbai in 2011)
Total Area – 24,420 SQM
Total Strength
• Management Staff : 119
• Total Workers: 298
Plant 13&14, Vikhroli
Total Area – 38,734 SQM
Total Strength• Management Staff : 183
• Total Workers: 1070
GREENCO PLATINUM RATED GREENCO GOLD RATED
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FOSTERING A CULTURE OF SUSTAINABILITY
National and International Green certifications
Green Buildings IGBC GOLD certified
showroom
IGBC Green Factory Platinum
Rating
Green Company Rating
7
2
GREENPRO
certified
products
Green Products
9
BIFMA Level
certified
products
78
GREENGUARD
certified
products
Plant Vikhroli Silver rating June 2014
Plant Shirwal Gold rating May 2015
Plant Vikhroli Gold rating March 2016
Plant Shirwal Platinum rating May 2016
Plant Chennai-Registered for GreenCo (Target-Platinum Rating)
Continual
improvement
beyond
Platinum
OUR GREENCO PLATINUM JOURNEY
Green
thinking
culture
Understanding the rating system Creating a
focused central task force Plant wise
GREENCO parameter champions for EE, RE, Water, WM, MCR
Capacity/
capability
enhancement
through total
employee
involvement
(TEI)
Focused
improvements to
achieve and
surpass
stretched targets
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Resource efficiency through operational improvement
BRAND
LEADERSHIP
OPERATIONAL
EFFICIENCY
LEADERSHIP
DESIGN
LEADERSHIPChannel
Vitalization
Supplier
Capability
Management
STRATEGIC DIRECTION – GODREJ INTERIO6 focus areas to achieve market leadership & profitable growth with innovations and sustainability as
the central focus
Employee
Competency
Development
INNOVATION
&SUSTAINABILITY Green Certified
Products-
BIFMA Level,
GreenPro
30% revenue from
Good and Green
product
Yield Improvement
Energy Efficiency
Water Conservation
Waste Management
Design for Environment, LCA
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PROCESS OVERVIEW AT SHIRWAL
Raw materialWood, Steel
Wood workingCutting, edge banding,
routing, drilling
Paint shopPTL, Powder coating
Press shopNotching, punching,bending
laminationImpregnation, lamination
Packing Panel packing
Finishedgoods
Wood Steel
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LIST OF MATERIALS USED AT PLANT SHIRWAL
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BOARDS- PPB (80%)
BOARDS- MDF (7%)
BASE PAPER(1%)
LIPPING(1.5%)
STEEL (10%)
POWDER (0.5%)
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APPROACH ADOPTED FOR MATERIAL CONSERVATION
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Yield Improvement
Reduction in Design
Reduction in process rejection
Reuse in alternate products
Use of alternate size raw material
Re-Optimize
the product
Approach towards
enhancing yield
improvement
5 R Approach-
Reduce
Reuse
Recycle
Recover
Redesign
BEFORE AFTER
Design Waste Optimising BST from waste
Reutilization Design Waste for other products
Utilizing Design Waste for optimising - 2 BST are made from off-cuts of 1 Bed
YIELD IMPROVEMENT PROJECTS
Approach 1: Reduce design Waste
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• LVD Sheet Utilization increased from 74.1 % to 76.3%
Approach 1: Reduce design Waste
Net saving of metal is 1.2 Tons
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BeforeAfter
Lesser utilization Better utilization
by optimizing
side flanges
YIELD IMPROVEMENT PROJECTS
Approach 2:Reduce in-process rejection
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Major Steps to reduce Rejection:
• Change in resin formulation
(Modification in chemicals compositions)
• Change in impregnation process parameters (reduction in Resin content and Volatility of impregnated paper)
• Change in process parameters of Short cycle lamination m/c ( Pressure and temperature settings w.r.t Paper thickness and shade