Waste Minimisation Strategies in a Ceramic Tile Factory in Edo State

This project investigates waste generation patterns and minimisation strategies within a ceramic tile manufacturing facility in Edo State, South South Nigeria. Solid waste from ceramic production, including reject tiles, kiln dust, and slurry residues, poses significant environmental and economic challenges, particularly given growing regulatory attention to industrial waste management in Nigeria. The study adopts a quantitative descriptive approach, employing waste audit techniques to measure waste volumes at each stage of the production process over a six-week monitoring period. Data collection involved direct weighing of discarded materials, review of production logs, and structured interviews with production and quality assurance staff. Analysis reveals that breakage during the pressing and glazing stages accounts for approximately fifty-five percent of total solid waste generated per production cycle. Lean manufacturing principles, specifically the 5S methodology and kaizen practices, are assessed for their applicability in reducing waste at source. Recommendations include revised material handling procedures, operator training in careful tile handling, and the re-integration of certain reject materials into raw material batches where technically feasible. This research provides a practical waste audit framework adaptable by other ceramic and building materials manufacturers across Nigeria's South South zone and beyond. Keywords: waste minimisation, ceramic tile, 5S methodology, lean manufacturing, Edo State