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GP for the Rama Phosphates Ltd.

GP for the Rama Phosphates Ltd. Case Study of Soy Oil Processing Industry (DOC Production). Group II - Philippines. Outline. Organization Data Collection Analysis GP Options Objectives & Targets Policy Statement. I. Organization. GP Team Composition Roles and Responsibilities.

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GP for the Rama Phosphates Ltd.

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  1. GP for the Rama Phosphates Ltd. Case Study of Soy Oil Processing Industry (DOC Production)

  2. Group II - Philippines

  3. Outline • Organization • Data Collection • Analysis • GP Options • Objectives & Targets • Policy Statement

  4. I. Organization GP Team Composition Roles and Responsibilities

  5. GP Team • Production Supervisor (Team Leader) • Engineer/PCO (Facilitator) • Quality/Environmental Mgmt. Representative • Finance/Accounting Officer • Human Resource Officer • Technical Consultant

  6. 1. Production Supervisor (Team Leader) • Preparation of agenda • Summarizing sessions and getting agreements • Working assignments for taking action • Setting and Conducting review procedures • Reports to Management • Communicating management’s views to team members

  7. 2. Engineer/PCO • Facilitates training and awareness programs • Facilitates legal and other requirements

  8. 3. Quality/Environmental Management Representative • Walking through the implementation of GP • Liaison officer between employee, middle level management, and top level management.

  9. 4. Finance/Accounting Officer • Planning and creation of feasibility studies and cost-benefit analysis

  10. 5. Human Resource Officer • Prepares training programs for workers • Coordinates trainings/seminars needed by the workers • Conducts training needs analysis • Acts as secretary during GP Team meetings.

  11. 6. Technical Consultant • Provides technical and legal assistance during the walk-through’s, identification of GP options, setting of objectives and targets. • Conducts training, awareness, certification of technical staff.

  12. II: Data Collection (Based on Case Study)

  13. Process Flow Diagram

  14. d

  15. III: Analysis Cause-Effect (Hexane Loss)

  16. Waste Stream

  17. Waste Stream

  18. Waste Stream

  19. Fishbone Diagram (Hexane)

  20. Possible Major Causes • No Quality Control on raw materials • Non-compliance to desired processing time • Lack of process control (i.e. desired thickness of DOC flakes is not attained) • Poor steam supply from old and inefficient boilers • Lack of priority for training of workers/skilled workers • Inappropriate/inefficient machines/systems (i.e. extractor, cyclone, chiller)

  21. IV: Objectives & Targets Addressing Hexane Loss

  22. Objectives and Targets To reduce Hexane loss by 10% by the end of the year 2007… Target Description: • Modification/review of current process specs by end of 2006 • Establish maintenance program for equipment by end of 2006.

  23. Objectives and Targets • Study equipment replacement options by end of 2006 and replace equipment, if possible, by mid of 2007. • Establish and improve processes by first quarter of 2007. • Establish training curriculum by 1st Quarter of 2007 and implement by 2nd Quarter of 2007.

  24. V: GP Options Options for Possible Major Causes (on Hexane Loss)

  25. Recommended GP Options for Major Causes (Hexane Loss) • Quality Control. Measures should define raw material quality specifications. • Process Improvement. Current process specifications should be reviewed/modified vis-à-vis process efficiency. Engineering control/TPM should be established. • Training and Development. Technical Training of workers should be pursued. • Repair and Maintenance. Equipment should be regularly checked to ensure maximum performance. Defective equipment should be replaced.

  26. VI: Policy Statement Rama Phosphates Ltd.

  27. Policy Statement RPL (Oil Division) is committed to protecting human health and the environment, meeting government and local/international laws, regulations and guidelines and employing sustainable Green Productivity practices whenever possible.

  28. Policy Statement RPL will utilize pollution prevention control and other GP initiatives as means for achieving compliance and strive to minimize impacts and continually improve its environmental performance.

  29. Policy Statement To achieve this, we aim to: • Maintain a policy committed to environmental excellence; • Comply with pertinent requirements in government, local/international laws and regulations; • Develop annually goals, objectives and targets to advance our program performance in terms of other regulated and unregulated impacts. • Improve level of efficiency in the use of all resources.

  30. Policy Statement • Institutionalize and deploy TPM and elimination of wastes to all levels of employees, processes and equipment. • Make personnel aware of the environmental roles and responsibilities by providing training and holding employees accountable for their performance including recognizing their outstanding performance.

  31. Policy Statement • Effectively communicate with employees, partners, stakeholders, customers and the general public, our commitment to the environment and solicit their inputs/suggestions in achieving our goals and objectives and work towards continuous improvement.

  32. Team 2 Philippines • Homer • Richard • Romy • Leila • Aileen • Emma • Claire • Norman • Iyam • Jackie • Donna • Nonoi • Remy • Dilson • Art

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