A Path to Lean and Green Manufacturing Excellence

KOpEx, short for K. K. Nag Operational Excellence, is a holistic approach that blends lean methodologies with green manufacturing principles. This initiative focusses on efficiency, sustainability and member involvement to optimise resources and maximise productivity.

A Path to Lean and Green Manufacturing Excellence

KOpEx, short for K. K. Nag Operational Excellence, is a holistic approach that blends lean methodologies with green manufacturing principles. This initiative focusses on efficiency, sustainability and member involvement to optimise resources and maximise productivity.

The GreenCo Journey at K. K. Nag Private Limited

All 5 of our Eligible Plants
are GreenCo Certified

GreenCo (Green Company Rating System) is a comprehensive framework designed by the Confederation of Indian Industry to evaluate and encourage sustainable manufacturing practices across various industries. The GreenCo Rating is a certification that reflects a company’s commitment to environmental sustainability, energy efficiency and resource conservation.

Captured

65%

of our rain water
harvesting potential

Installed over

500 kW

of solar panels at our
foam moulding plants

Zero Effluent Discharge

Reduced hazardous and
non-hazardous waste generation by

25%

Reduced GHG
emissions by

38%

Reduced specific
water consumption by

25%

Compete,
Collaborate
and Excel

Through cross-functional teamwork, KOpEx drives continuous improvement and sustainability, boosting both performance and environmental responsibility.

01

Compete

All of our manufacturing units compete against each other every month and showcase their improvements and best practices

02

Collaborate

The forum promotes inter-divisional learning and teaching as the plants give each other suggestions for improvement

03

Excel

As a result, all the initiatives and best practices are horizontally deployed and we excel as an organisation

Coming Together

Through cross-functional teamwork

KOpEx unites employees and departments, promoting teamwork and shared responsibility in achieving sustainability goals. Total Employee Involvement (TEI) and leadership-driven collaboration ensure every individual contributes to the initiative’s success.

Learning Together

KOpEx drives continuous improvement and sustainability

KOpEx emphasizes ongoing learning and knowledge-sharing through custom training programs, monthly reviews, and Gemba walks. This objective equips employees with the skills to innovate and optimize resources efficiently.

Excelling Together

Boosting both performance
and environmental responsibility

The ultimate goal of KOpEx is operational and environmental excellence. Through GreenCo ratings, cross-functional teamwork, and reward systems, KOpEx drives continuous improvement and sustainability, boosting both performance and environmental responsibility.

Pillars of

Energy
Efficiency

Waste
Management

Renewable
Energy

Green Infrastructure
and Ecology

Material Conservation
and Recycling

GHG
Mitigation

Water
Conservation

Green
Supply Chain

Circle
Adaptability to Customer
Requirements

Our agility helps us to adapt to even last-minute customer requirements with just-in-time supplies

Helping Customers with their
Carbon Neutral Journey

Through reduced carbon foot-print per unit of production

Cost Competitive Products

Optimum use of resources through resource management allows for win-win partnerships with customers on conversion costs

Protection of Customer Property

Safety and cleanliness at all of our manufacturing facilities are maintained through 5S that ensures our customers' assets are in our safe custody

Ability to Cater to Increased Demands

Improved productivity through higher machine uptime using Total Productive Maintenance techniques in our "My Machine" programme allows us to meet customer’s demanding schedules

High Customer Satisfaction

Zero defects, Zero customer complaints and Zero field complaints

Benefits for Our Customers

Adaptability to Customer
Requirements

Our agility helps us to adapt to even last-minute customer requirements with just-in-time supplies

Protection of Customer Property

Safety and cleanliness at all of our manufacturing facilities are maintained through 5S that ensures our customers' assets are in our safe custody

Helping Customers with their
Carbon Neutral Journey

Through reduced carbon foot-print per unit of production

Ability to Cater to Increased Demands

Improved productivity through higher machine uptime using Total Productive Maintenance (TPM) techniques in our "My Machine" program allows us to meet customer's demanding delivery schedules

Cost Competitive Products

Optimum use of resources through resource management allows for win-win partnerships with customers on conversion costs

High Customer Satisfaction

Zero defects, Zero customer complaints and Zero field complaints

Transforming Operations

Key
Initiatives

Productivity Improvement

  • Implementing work studies to analyze and enhance workflows.
  • Balancing production lines for optimal efficiency.
  • Utilizing low-cost automation to streamline processes.
  • Applying SMED (Single-Minute Exchange of Dies) for faster changeovers.

Zero Defect

  • Measuring and monitoring resource usage to identify inefficiencies.
  • Conducting variance analysis to detect discrepancies.
  • Launching initiatives aimed at resource optimization.

Resource Management

  • Measuring and monitoring resource usage to identify inefficiencies.
  • Conducting variance analysis to detect discrepancies.
  • Launching initiatives aimed at resource optimization.

5S & Safety

  • Practicing Red Tagging to remove unnecessary items.
  • Ensuring a place for everything and maintaining organization.
  • Setting up jogging tracks to promote safety and movement.
  • Standardizing processes to maintain a clean and safe workplace.

My Machine

  • Promoting “Cleaning with Meaning” for regular maintenance.
  • Identifying abnormalities and implementing countermeasures.
  • Establishing CLITA schedules (Cleaning, Lubrication, Inspection, Tightening, Adjustment) for machine upkeep.
  • Utilizing a General Inspection Manual for consistent checks.

Continual Improvement
Ensures ongoing process enhancement

Change Culture
Promotes innovation and adaptability

Total Employee Involvement
Engages all employees in achieving goals

Resource Optimisation
Ensures ongoing process enhancement

Bottom Line Improvement
Enhances profitability through lean practices

Empowerment in Change-Making
Enables active participation in decisions