Our impact, Their voices

Exceeding production targets through waste reduction in Ghana

Participation in SCORE Training enabled Carmeuse Lime Products Ghana Ltd. to reduce waste and exceed production targets, while stepping up on safety issues and improving environmental impact.

Article | 28 July 2019
The operational results reported following the Sustaining Competitive and Responsible Enterprises (SCORE) Training at Carmeuse Lime Products (GH) Limited (Carmeuse) highlighted a sharp reduction in waste generation, alongside an increase in overall production. Additional results indicate that Carmeuse exceeded production targets whilst raising the profile of safety related policies and environmental impact of the company.

City Takoradi(Sofokrom)
Region West
Country Ghana
No of Employees 58
Male 54
Female 4
Year Founded 1993
Product
QUICK LIME AND HYDRATED LIME used in steel, mining for ore processing, road construction & asphalting, paper, agro-food, water treatment, chemicals
MarketsDomestic  and export markets of Mali, Niger, Burkina Faso
SCORE Training modules completedWorkplace cooperation, Quality Management, Cleaner Production, Managing the Human
Resource, and Health and Safety Management.

Carmeuse Ghana also known as Carmeuse Lime Products (Gh) Ltd. was established in 1993 in the port city of Takoradi, Ghana. Carmeuse Ghana is specialized in the production and sale of high grade Quicklime and Hydrated lime in West Africa. With the present production capacity of 100,000 metric tonnes per annum.

Carmeuse initially signed up to SCORE Training to build the skills and capacity of their workforce. SCORE was introduced to the company by Sekondi-Takoradi Chamber of Commerce Industry (STCCI) and they embraced it with open arms.

Having completed all 5 modules, the benefits to the company, workers and managers following SCORE Training were wide reaching, however this case study focuses on some key results gained from the single module: Productivity Through Cleaner Production. The company used the new knowledge gained from this module to ensure that waste was controlled and brought to the barest minimum. Coupled with an employee financial incentive scheme, production increased tremendously. Compared to a peak production level of 132 units (of lime packaged in bags) in 2018, figures for 2019 after SCORE Training increased to 144 and beyond.

Less Time, Less Waste
Following the training, workers and managers agreed that changes needed to be made to the production process. It spurred the company to implement a number of changes to existing processes...

Bags for packaging had been identified as an area that could be improved. Describing the situation prior to the training programme, Francis Ntarma, Production Supervisor explained that “our one metric ton packages were too small and operators struggled to meet the exact weight that was required”.
Building on the insights provided through the training programme, the company requested an increase in the dimension of the bags in size and width, in order for the operators to work with ease, while avoiding spillages due to overfilling, which can lead to accidents. Health, Safety and the Environment are important issues for Carmeuse and its workers.

The new strategy delivered immediate, tangible improvements, for both the workers and the bottom line, and therefore the staff were keen to follow the new bagging process which was quicker and safer than previously, and also makes it easier to meet client quality specifications.

Another example comes from the new approach taken to waste management. Under new procedures, product waste is now kept at the environ lime shed, a place designated to receive waste of lime and mixed with water to settle. The end product of the mixture is a local paint which is now sold to the communities around. The waste lime again has other uses. It is mixed with clay to repair roads, for soil stability and to balance the PH (the acidity and alkalinity) of the soil for preparing paints.

“We have been able to achieve our targets because time and waste is reduced in the packing process since we had training from SCORE; we have also been exceeding our targets which is a plus to us” Ebenezer Owusu, Operations Manager.

Productivity through Cleaner Production training can be used to ensure that waste is controlled and brought to the barest minimum. Production has increased and if workers exceed their production targets, a bonus is paid.

Getting everyone involved in problem solving

Workers have also been involved through their “tool box meetings” - a platform where staff and managers meet and discuss issues concerning the company and the way forward. The need to recycle waste has been enhanced through these meetings in all areas of the company – in the office as well as the production line. One other way Carmeuse found to reduce waste in the system through the ‘’tool box meeting’’, explains Ebenezer Owusu, Operations Manager "Everyone is encouraged to turn the air conditioners and lights off when they are out of the office / area in order to reduce waste, which has also reduced our bills”.

Regarding continuous improvement Francis Ntarmah; Production Supervisor comments,“Relationship and communications with each other has improved greatly; we also get to talk to our clients often to get feedback from them. We are so happy SCORE has been introduced in the company.” 

Ebenezer Owusu, suggested that ILO-SCORE Training should be introduced to more organizations to help production, and for organizations to know if they are on the right track in terms of their activities and programmes as well as enable them ensure best practices on Health, Safety and Environmental at all time. “Our workers are pleased SCORE was introduced to the company; we are ready to be involved in any new module which will be introduced to us in future." He continues “we will also encourage other companies to sign up for the benefit of all to improve socio-economic development of the country.”