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MANUFACTURING OPERATIONS & SUPPLY CHAIN Annual Conference'24 EHSS Occupational health & Safety + Environmental Sustainability 1st -3rd Aug 2024  OH & S highlights -FY’24 ( occupational health and Safety )...

MANUFACTURING OPERATIONS & SUPPLY CHAIN Annual Conference'24 EHSS Occupational health & Safety + Environmental Sustainability 1st -3rd Aug 2024  OH & S highlights -FY’24 ( occupational health and Safety ) Reportable Accidents (PIL UA/UC/NM Chart Title Show Cause Notice Non reportable Incidents units) Chart Title - 38 12 40 35 30000 +120 27000 10 25000 % 25860 6 5 ZERO 10 60 30 8 7 20000 18596 HARM % 20 15 4 3 6 8 9 4 10 5 4 15000 12181 2 4 2 2 0 0 0 0 0 0 10000 0 2 LTI First Aid & Fire Process 0 FY22 FY23 FY24 Target-FY25 0 Minor Incident Incident 5000 FY22 FY23 FY24 FY25- Injury 0 Reportable Incident Target FY22 FY23 FY24 Target-... LTIFR FY 23 FY 24 FY25 Target Top Initiatives- FY24 & to be continued BBS  What Went Well- 170 certified BBS mentors, Deployment at PIL Own units, Operation Leadership Engagement.  To be continued- Deployment of BBS at Warehouses, Offices & INO locations. My Setu EHS Software  What Went Well- 6 modules are launched with features of data analytics & exception management.  To be continued- Stabilization of the software & utilization of data analytics for defining initiatives & decisions. PLSR deployment  What Went Well- Seat belts to all vehicles, more than 3000 machine guarding, more than 1200 gaps closure related to PLSR’s.  To be Continued- Defensive driving training to all employees, monthly theme-based campaign related to PLSR’s. Analyze & action plans related to PLSR’s observations. EHS Audit Management  What Went Well- 96 Internal Audits including manufacturing & nonmanufacturing, 2200 external audits actions closure.  To be Continued- Timely closure of EHS Audit observations, no overdue actions, Certification training to new pool of auditors.  Environmental Sustainability Highlights – FY’24 KPI Performance (E) Total Energy Use Renewable Energy Total Waste Disposed Water Use [KL/MT] [GJ/MT] Mix [%] [Kg/MT] 1.33 56% 10.88 10.34 1.00 1.26 0.95 45% 47% 5.69 1.16 0.86 FY '23 AOP F... Actual FY '23 AOP F... Actual F... FY '23 AOP F... ActualF... FY '23 AOP FY'24 Actual F... F... What went well & to be continued  Delivered Water & Energy consumption and Waste disposal KPIs better than plan.  Released Environmental Sustainability KPI definition & calculation handbook.  BRSR Core: Independent assurance audit of environmental data completed.  First time Independent assurance of Sustainability Report for FY 22-23.  Launched Capability building on environmental risk assessment and ESG through Gurukool.  EcoVadis Score – 38 to 62 with Silver.  ISO 14001 re-certification completed and all new sites added into group certificate.  Ensured compliance to Plastic Waste Management Rules through multi stakeholder collaboration.  OH&S Key Challenges/gaps – FY’24 Gaps / Challenges Source Insights/learnings MI/KI Planned Repeated unsafe acts/unsafe EHS 1. All employee's conditions/incidents which involved At- Observation involvement/ownership & active risk behaviors by employees. s & incident participation is needed to statistics Eliminate ‘ At-risk behavior’ at MI- Behaviour Based Safety organization level & which will (BBS) help for safety cultural transformation. 2. Mentor/Gemba walks/TBTs Process safety aspects- 4 high potential Incident 1. Few design safety related issues process safety incidents e.g. reactor statistics e.g. interlocks non availability, over pressurized, hazardous materials PSV discharge not routed Process Safety Management in storage tank overflow etc. properly etc. certain identified areas- PSI, 2. Gaps in robust inspection Mechanical Integrity , MOC & mechanism system for safety CMR chemicals handling. critical equipment. Project Risk Assessment process- PSSR & 1. Simplified PRA guidance docume Gaps in PRA processes for few of the Internal/Exte nt with clear roles Strengthening Project Risk projects including PRA1, PRA 2 & PSSR. rnal Audits & responsibilities. Assessment process including 2. Gaps in competency to PRA & competency enhancement. PSSR team members. EHS Infrastructure & competency in few EHS 1. Mandatory safety requirements of the job works e.g. Kukreja, Welsun Inspections clause during contract agreement Mandatory Safety requirements  OH&S Key Challenges/gaps – FY’24 Gaps / Challenges Source Insights/learnings MI/KI Planned Warehouse safety aspects related to Fire, Internal 1. Few cases Fire NOCs are not Electrical & transportation safety Audits & available. Fire, Electrical & Transportation Incident 2. Safety infrastructure gaps & Safety infrastructure upgradation. statistics nonadherence of SOPs. Deployment of PTSR’s at offices & Inspections/ Awareness gaps related to Safety among sales force staffs. Interactions hazards & controls among Commercial Safety- with employees. Strengthening EHS adoption. stakeholders. Permit to Work (PTW) conditions are not Incident 1. Permit conditions are not verified deployed effectively in few cases Statistics at filed. Strengthening Permit to Work particularly in hot work activities. 2. Gaps in competency related to (PTW) management system. PTW system. Gaps in EHS system adoptions in few Internal 1. Need to Strengthen EHS critical areas e.g. PTW, Machine Audits, systems/processes at INO Guarding, PLSR’s at INO locations. Inspections. locations. Strengthening of Safety System 2. EHS Competency gaps among at all INO locations Critical roles at few of the locations.  Environmental Sustainability Key Challenges/gaps– FY’24 Gaps / Challenges Source Insights / Learnings MI / KI Planned Achievement of FY’25 Data analytics More than 50% of resource sustainability targets. consumption and waste MI - Implementation of identified Power generations occurs in IP plants, fuel & water conservation projects. major contribution from Vapi 23. Road map to net zero not Stakeholder Scope 3 GHG emissions yet to Establish a system to update and track available. requirement be quantified. GHG emissions. Environment data Internal Audit SOPs / key controls not Standardize environmental data management and ensuring defined. recording process and standardize data accuracy. Internal audit process yet to logbook formats. be established. Establish process for internal audit for sustainability data. Fit for Purpose assurance Show Cause Change in product / process Design adequacy through MOC / PRA for ETPs Notice resulting into change in ETP inlet process. MS List parameters. Journey to zero waste to Data analytics Identify opportunities for implementing landfill 20% of wastes are disposed to 3R’s. landfill Identify alternate method of waste disposal. Competency in ISO certification Gap in understanding ISO system Review and update documentation of the implementing and audit requirements. ISO 14001:2015 and 45001:2018  MAJOR INITIATIVE- OH&S Support MI Name Measurable Outcomes Current level Target level Timeline Required Deployment of BBS at  50% reduction in 0.120 < 0.060 31.03.25 Cluster Organization level reportable accident Chiefs/EHS/Log  30%-40% reduction in 1800 < 1200 31.03.25 istics at risk behaviors Chiefs/ZLMs. Milestones- BBS deployment is done at all PIL Own units. last 4 months observations of BBS – Overall Safe habits 73%, At-Risk behaviours- 27%. Top 3 At-Risk behaviours PPEs, Non-Adherence of Procedures & Material handling. Need to focus in these areas to convert safe habits from 73% to at least 90% within next 6- 8 months' time by positive reinforcement. BBS deployment at all Warehouses ,Offices & INO will be started from Aug’24 onwards. TTT(Train the trainer) - 100 employees are trained as ‘BBS Mentors”. BBS mentors must take lead to train the BBS observers at respective locations & subsequently start BBS observations. Timeline- 30.09.24 BBS mentors & observers should involve in task-based BBS to identify safe habits as well as at risk behaviours effectively.  TOP KEY INITIATIVES- OH&S KI Name & Measurable Outcome Current level Target level Timeline Support Milestones required Process Safety 1. Process Safety Incident 4 0 31.03.25 Unit Management in few key 2. Overflow protection- Heads/Cluster areas. storage tanks. 21 64 31.01.25 EHS/Cluster PSI at selected sites 3. As built P&ID Chiefs/PED/Eng ( Vapi 78, Mahad A22, availability (Nos) ineering. Dahej D3). 31.03.25 70 350 31.12.24 Mistake proofing for hazardous process. 31.08.24 Safe handling of CMR chemicals. 31.03.25 Effective MOC deployment. 31.12.24 Strengthening Project PSSR compliance (%) 80 95 31.03.25 Project/PED/ risk assessment(PRA) Plant EHS process. Revised PRA guidance document. 31.12.24 Competency enhancement for PRA 1, PRA 2 & PSSR process. 31.12.24  TOP KEY INITIATIVES- OH&S KI Name & Measurable Current level Target level Timeline Support Milestones Outcome required Safety infrastructure & 1. High potential 4 0 31.03.25 Unit competency enhancement at incidents/near Heads/Plant identified JWs- Kukreja, Welsun misses. 70% 31.03.25 EHS/Cluster Wada & Silvasa, Falna, Godhra, 2. EHS Internal Chiefs/Cluster ROFF JWs. Audit Scores Engineering. Mistake proofing - 31.03.25 Effective deployment of EHS SOPs & PLSRs. 31.12.24 Fire , Electrical & transportation 1. High Potential 4 0 31.03.25 Logistics safety infrastructure upgradation Incidents/near Chiefs/EHS/ZL at warehouses misses. 10 0 31.12.24 Ms/RLMs. 2. No overdue audit observations Commercial Safety-  No of defensive 1200 4000 31.03.25 ZSMs/Office In Strengthening EHS adoption driving trained charges/CBOs. (Branch/Corporate Offices, Sales employees. Not measured 0 31.12.25 force employees)-  No high Defensive driving training potential 31.03.25 incident. Incident Management System 31.12.24  TOP KEY INITIATIVES- OH&S KI Name & Support Measurable Outcome Current level Target level Timeline Milestones required Strengthening Permit High potential incident 5 0 31.03.25 Unit Head/Unit to Work System. related to PTW activities Engineering/Pl  Gap assessments of ant EHS PTW system. 31.10.24  Gap closures. 31.03.25 Strengthening of Safety No High potential incident 2 0 31.03.25 INO Unit System at INO at INO locations. Heads/EHS/Co locations. untry Heads.  PLSRs call to actions & No of MOCs 0 >10 gap closure. 31.10.24  MOC implementation. 31.12.24  EHS trainings to all critical roles as per matrix.31.03.25  MI: Implementation of identified Power fuel & water conservation Current Target Measurable Timeli Initiatives level level Support Required Outcomes ne (FY’24) (FY’25) Water intensity reduction: Installation of ETP treated water recycling unit at Dahej D3.31.12.24 Process Engineering STP installation and reuse of treated effluent at CIPY Reduction in (for finalising Shirwal, Litokol Amod, SSCPL, SHIEL. 31.12.24 Water treatment scheme). Installation of closed loop cooling towers at consumption 1.16 1.09 HO / Unit Engineering Secundrabad. 30.04.24 Intensity 31.03.2 (for project Water recovery from RO Plant at Vapi 23 (AZO ML [KL/MT] execution) 5 recycle & reuse). 28.02.24 Freshwater Consumption reduction in MEE plant by using STP treated water at Vapi 23. 31.01.24 Energy Consumption Intensity Reduction: Heat pump for hot DM water generation at Dahej D3. 31.03.25 Reduction in HO / Unit Engineering Heat pump 40 TR chilling mode for BFS-3&4 Hydraulic Energy 31.03.2 (for project chiller and BFS-3&4 AHU Coil at Kalamb -1. 31.03.25 Intensity 0.86 0.80 execution) Consumption 5 Waster Heat recovery from Air compressor at Baddi-4 31.03.25 [GJ/MT] IE4 motors for Vapi-78 and A-22. 31.12.24 Increase Renewable Energy Mix: Upleta -1805 KWp - 30.04.24 Increase in Phase 2 roof top solar of 1293 KWp at 07 units – Renewable 31.08.2 31.07.24 47% 56% HO Engineering Energy Mix  Key Initiatives - Environmental Sustainability Measurable Current Target Timelin KI Key Initiative outcome level Level es Owner Establish a system to update and track An online GHG Emission Not in place Available Mar’25 Arun GHG emissions. monitoring dashboard. Engage consultant to develop performance dashboard – 30th Aug’24 Lead discussions with different functions and collate data for all 15 categories for previous 01 year – 30th Nov’24 Establish baseline emissions and finalise relevant and major scope 3 emission categories – 15th Dec’24. Establish continuous monitoring dashboard – 15th Jan’25. Training of identified personnel from respective functions on data entry – 15th Feb’25. Standardize environmental data SOP for documenting Different Standard Sep’24 Arun recording process and standardize environmental data. processes process and logbook formats. and formats similar Develop data recording SOP template and share to in use formats units – 30th Aug’24. across units Develop logbook formats for capturing water, energy and waste data as per BRSR reporting requirements – 30th Aug’24. Training to site teams on implementation of SOPs and use of logbook formats – 30th Oct’24.  Key Initiatives -Environmental Sustainability Measurable Current Target Timelin KI Key Initiative outcome level Level es Owner Establish process for internal audit for SOP for internal audit. Not in place Available Aug’24 Arun sustainability data. Internal audit calendar. Develop SOP for environmental sustainability data audit – 30th Aug’24. Identify internal auditors and build capability – 30th Oct’24. Develop calender for internal audit – 30th Oct’24. Review and update documentation of Updated ISO 14001 and 4 Non - 0 Non - December Cluster the ISO 14001:2015 and 45001:2018 45001 documentation Conformity Conformity -24 Chief and standard addressing the changes EHS / Uni Update the Apex manual and SOP /Format such as Climate change t Training to employees and revision of Apex Head documents including new sites etc. Develop E-learning module on advanced Capability building of 0 Training Mo 1Training M January-25 Cluster E treatment technology on ETP in employees on effluent dule odule HS Gurukul. Treatment technology and L&D Devolvement of Training Content and operation Convert into Training Module Upload into Gurukul  Key Initiatives -Environmental Sustainability Measurable Current Target Timelin KI Key Initiative outcome level Level es Owner Reuse of process effluent and reactor Reduction of effluent O KL/Month 60 December Cluster wash water and treated ETP water. generation and KL/Month -24 Chief and ( Vizag-1 , Nalagarh , SSCPL, Patalganga , freshwater EHS and Paria, Hybrid, Vizag-2, Mahad A-22, Dahej D-3 consumption. PED etc.) Identification of Unit Check the feasibility and Trials with process and unit team. Approval from R&D Reduction the Hazardous waste Reduction of Hazardous O MT/month 26 January-25 Cluster generation through shifting the Raw waste generation MT/Month Chief and material from drums to bulk storage Unit head tank. and (Mahad A-22, Vapi-78, Kalamb-3, Mahad C-59, Project Shirwal, Vizag-1, ICA Pidilite, Litokol, Goodwill Team GOA, Kukreja etc.) Identify the units Assessments and availability of RM in tanker Proposal approval and executions Reduction of Hazardous waste disposal Reduction in waste 223 kg/MT After Study March-25 Cluster at Vapi-23 disposal intensity and Chief Hire the expert for study the waste source Zero waste to landfill Vapi-23 and reduction and  Environmental Sustainability Targets – FY’25 Company Environment KPI Cluster wise Targets & Key Targets Initiatives Actual Plan FY 24- Improveme 2030 KPI FY'24 25 nt Target* Water Use Intensity 1.16 1.09 -6% 1.19 [KL/MT] Total Energy Use Intensity 0.86 0.80 -7% 0.96 [GJ/MT] Renewable Energy Mix [%] 47% 56% 9% 80% Scope 1&2 Emission 0.062 0.0518 16% 0.03 Intensity [tCO2/MT] Total Waste Disposal 5.72 5.32 -7% 0 Intensity [Kg/MT] (click the above to see cluster wise targets) *As per public disclosure  Environmental Sustainability Targets – Cluster wise BACK Water Use Total Energy Use Total Waste Disposed [KL/MT] [GJ/MT] [Kg/MT] Actual Plan Reductio Actual Plan Actual Plan Cluster Cluster Reduction Cluster Reduction FY'24 FY’25 n FY'24 FY’25 FY'24 FY’25 Himachal 0.98 0.95 -3% Himachal 0.51 0.50 -2.2% Himachal 2.79 2.75 -2% Vapi 1.02 0.99 -3% Vapi 0.76 0.76 -0.6% Vapi 2.54 2.46 -3% Dahej & Dahej & Dahej & 1.07 1.01 -5% 0.61 0.60 -1.6% 1.71 1.27 -26% Amod Amod Amod Maharashtr Maharashtra 0.46 0.45 -3.5% Maharashtra 5.04 4.59 -9% 1.20 1.17 -3% a South & South & 0.52 0.51 -2.0% 1.56 1.30 -16% South & East East 0.90 0.87 -3% East ROFF 0.03 0.02 -22.0% ROFF 0.18 0.16 -11% ROFF 0.04 0.03 -23% 65.5 Pigments 513.59 480.71 -6% Pigments 66.14 -0.9% 64.5 58.5 7 Pigments -9% PIL 5.69 5.32 -7% Major Initiatives 1 3 Planned Installation of RO & ultrafiltration at PIL 0.86 0.80 -6.7% OFR planned at Baddi2, Guwahati, Mahad 1.1 1.0 Shifting to bulk storage tanks / sourcing in PIL Dahej D3. -6% A21 & A22, Vapi 78, Panoli, Vizag. 6 9 IBCs for raw materials at multiple locations. STP treated water recycle and use for VFD for High-Capacity Motors are planned at Moisture reduction of ETP sludge at Dahej flushing & gardening at multiple multiple locations. SEZ. locations. Cooling tower automation and change on CT Spent solvent (acetone) recovery and reuse Process effluent reuse in fresh batches fan MOC to FRP are planned multiple at multiple locations. at Vizag1, Nalagarh. locations. Salt recovery from hazardous waste & Vapi 23: Recycled water use for MEE Heat Recovery from air compressors planned reuse in process at Vapi 23. vacuum pump. at Baddi. Reduction of waste drums generated due to Vapi 23: Water recycling through RO. Vapi 23: Multiple projects identified and internal transfer of materials