sop for Scrap Management

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4 days ago

sop for Scrap Management

1.0 Objective
To lay down a procedure for handling and transfer the scrap from various departments to the scrap yard.
2.0 Scope
This Standard Operating Procedure is applicable for handling and transfer the scrap from various

departments to the scrap yard to be followed at formulation plants of abc Pvt. Ltd.
3.0 Responsibility
3.1 Officer / Executive concerned department shall be responsible for handling and transfer of scrap to scrap yard.
3.2 Officer / Executive QA shall be responsible for verification of scrap before transfer to scrap yard.
3.3 Officer / Executive HR Department shall be responsible for verification and shall receive the scraps in scrap yard.
3.4 Concerned department head and Head QA shall be responsible for compliance this SOP.
4.0 Abbreviations and Definitions
SOP : Standard Operating Procedure
QA : Quality Assurance
QC : Quality Control
No. : Number
NRR : Non Recoverable Rejects
HR : Human Resource Department

5.0 Procedure
5.1 Different type of scrap is generated in the plant. This scrap shall include empty

containers, gunny bags, plastic and rubber scrap, used polythene bags / used disposable

hand gloves / shoe covers / nose masks / lint free cloth, paper waste, waste of

corrugated box, stationary / carton / label, waste of broken ware, rejected glass

bottles, rejected blister / strips, NRR generated from capsule, QC department

and general waste generated in the plant.
5.2 Empty fiber container of raw materials / plastic container / empty reagent bottles:
5.2.1 Cross mark the empty containers / plastic containers by permanent marker

pen as ‘X’. Deface the labels of empty bottles. Rinse the bottles with water.

Collect them in a waste bin and label it as per Annexure-1.
5.2.2 Transfer scrap to the designated place of common scrap collection point

after recording the details in scrap transfer form (Annexure-2).
5.3 Empty Gunny Bags: Empty gunny bags of raw material are counted by warehouse and

the details are recorded in scrap transfer form and send to scrap collection point.
5.4 Plastic scrap / rubber scrap / used polythene bags / used disposable hand gloves / shoe covers / nose masks / lint free cloth:
5.4.1 Collect the scrap mentioned above in a polythene bag.
5.4.2 Affix the label after recording the details (Annexure-1).
5.4.3 Enter the details in scrap transfer (Annexure-2).
5.4.4 Transfer the bags to common scrap collection point.
5.5 Corrugated box / paper waste / stationary / carton waste into several parts and collect in a polythene bag.
5.5.1 Tear the waste / rejected corrugated boxes, paper waste into several parts and collect in a polythene bag.
5.5.2 Affix the label and record the details in scrap transfer note.
5.5.3 Transfer the bags to common scrap collection point.
5.6 Broken glass bottles
5.6.1 Collect the scrap containing broken glass of bottles from production area take out wash

with water and allow the water to drain by flushing after neutralization in designated area.
5.6.2 Collect it in a polythene bag. Affix the label and record its details in scrap transfer form.
5.6.3 Transfer the bag to common scrap collection point.
5.7 Rejected empty strips / blister
5.7.1 Collect the empty blister / strip, pieces of foils in a polythene bag after the defoiling procedure.
5.7.2 Affix the status label as per Annexure-1 on the bag and enter the details in scrap transfer

form (Annexure-2) and send to scrap collection point.
5.8 Non recoverable rejects generated from tablet and capsule department
5.8.1 Waste generated during in-process or in filling, sealing and packing operation, shall be

treated by taking out its liquid from filled bottle in a separate container and discard through Destruction Form.
5.8.2 Bottles and ROPP Caps shall be discarded through Scrap Form affixed with Scrap label.
5.9 Non-recoverable rejects generated from QC laboratories
5.9.1 First deface or destroy the label on sample poly bag after testing of capsules, raw material taken for

observation or conducting physical test in QC are treated as NRR are soaked in water in a plastic container.
5.9.2 Liquid waste like solution taken for analysis shall drained in sink by flushing with water.
5.9.3 Collect broken glassware & empty reagent bottles in a polythene bag. Affix the label after recording

the details. Enter the details in scrap transfer form and transfer them to scrap yard.
5.9.4 General waste generated in the plant
5.9.5 Collect all the general waste & segregate all the items like old slippers, torn booties, waste of lint free

cloth in a polythene bag. Transfer these bags to the scrap yard after recording the details
5.10 Scrap containing expired chemicals / reagent / solvent
5.11 After all the scrap is transferred to the scrap collection point, the responsible person in this area shall

check the scrap for following
5.11.1 All the Containers / Bottles / Labels shall be defaced.
5.11.2 No product or usable printed packaging (coated & uncoated) material is in scrap.
5.11.3 Segregate the bags containing scrap received as per the nature of the material as mentioned below
5.11.3.1 Glass
5.11.3.2 Plastic
5.11.3.3 Foil
5.11.3.4 Papers and others
5.11.3.5 Rejected strip / blister
5.12 After complete verification of the scrap, the person from Personnel & Administration

Department (HR) weighs the above segregated scrap and records its weight in Scrap Transfer Form.
5.13 Transfer the scrap from the collection point to common Scrap Yard and keep it till its disposal.
5.14 The scrap containing empty Blister / Strip shall be Shredded by means of Shredder / Crushing

Machine and filled in the bag and placed at designated place till its disposal.
5.15 Annexure -2 is the duplicate logbook one copy is HR department and second copy is initiator department.
5.16 Incase any filled Bottle / Strip / Blister / Coated / Uncoated / Printed Label found in scrap,

Scrap Yard person shall immediately inform to concern person / HR Department / QA Department.
6.0 Forms and Records
6.1 Scrap Label – Annexure-1
6.2 Scrap Transfer Form – Annexure-2
7.0 Distribution
7.1 Master copy – Documentation Cell (Quality Assurance)
7.2 Controlled copies – Quality Assurance, Quality Control, Production
Warehouse, Personnel & Administration.

8.0 History