This document summarizes a continuous process improvement project at a powder plant to address high dust emissions and overflow of powder. Several countermeasures were implemented, including adding reclaim stations, selling reclaim material, optimizing grinding acid dosing, and practicing 5S. These measures led to a 71% reduction in dust emissions and overflowed material. The project cost $8,880 to implement and saved $53,910.14 per month, with additional intangible benefits like an improved work environment and knowledge gains.

1. Continuous Process Improvement Project PLANT PROCESS IMPROVEMENT DUST EMISSION RECYCLE OF POWDER QIT Powder Buster

2. Milling Process had continuously encountered High “Dust Emission” since the commissioning of New Classifiers and High frequencies of overflow Powder to floor which has resulted much recycle Material placed around the plant. Problem Statement

3. Overflow powder in Bulk Bags placed all over the production floor. (Packing area) Problem Statement Dust Emission can be seen in plant

4. Team Members

5. Baseline Counter Measure #1 (Administration Control) Sold recycle material to KPM Added recycle station Improve PM actions Basic Housekeeping Actions Measure Phase Counter Measure #2 (Engineering Control) change the GRINDING ACID Dosing Rate 5S practice (Seiri / Seiso) Manual Tracking by Packing Department

6. Analysis We had found the higher incidents of overflow powder coincide with the Start up and commission- ing of the New Classifiers. A lot of trials were tested during March – August 2007.

7. Counter Measure # 1 As the commissioning of New Classifiers were on going, the process team look at short term to minimize the reclaim material quantity Action implemented (Administration Control) Set up additional reclaim station Sold reclaim material Started to look at leakage (PM) Basic Housekeeping Actions

8. Counter Measure # 1 1 2 3 Reclaim station at Ball Mill 1 Reclaim station at Packing Reclaim Material to be sold

9. Counter Measure # 2 During the commissioning period, we have also observed that when an optimum Grinding Acid was dosed, the dust emission seemed to have vanished and later we verified that Grinding Acid has direct impact through records. Action implemented (Engineering Control) Dosing rate set at optimum (Auto set to Manual) (from 4 L/H to 3.0 L/H or 80 ppm) 2. Started practicing 5S (Seiri / Seiso)

10. Counter Measure # 2 # 1 Engineering Control Change to Manual Mode Set the Dosing Rate to 3.2 L/H to 3.5 L/H

11. Counter Measure # 2 # 2 Administration Control Employ contract cleaner 2x

12. Action Plan

13. Control - Trial Result We achieved good results after we managed to get 40% of the reclaim material sold to another powder supplier. The Engineering / Administration Control had helped to make the plant area cleaner. Further result When we started to control on the Grinding Acid Dosage at agreed Setting, we observed tremendous Improvement on DUST EMISSION and Overflowed material from Plant. Reduction Of 71%

14. Cost of Implementation

15. Cost Saving - Calculation NET SAVINGS :- GROSS SAVINGS - COST OF IMPLEMENTATIONS = ( RM 62,790.14 - RM 8,880 ) RM 53,910.14

16. Project Savings Current Status After Implementation Cost Saving/month $ 53,910.14 Cost Saving/YEAR $ 646,921.68 20 bags / month

17. Intangible Benefits QIT Powder Buster Improve on Project Management Better cooperation with other departments Exposed to show their abilities and talents Meets IMERYS Corporate Goals Environmental Friendly Plant Create world-class manufacturing processes Lead in the Minerals Industry Improve knowledge on Problem Solving Decision Making Promote Continuous Improvement Activities

18. Plant at Glance BEFORE AFTER Dusty Environment Reclaim bags everywhere

19. Thank you…….. And to those who contributed direct or indirectly to make this project a Success