Strategies for Identifying Pollution Prevention Opportunities via Lean Manufacturing

Pacific Northwest Pollution Prevention Resource Centerpractical solutions for economic and environmental vitality

November 2010

Sleuthing for Pollution Prevention Opportunities

Why?What and Where?

How?

Adding the Green to Lean

Prevention and Avoidance Trumps (The Environmental Hierarchy)

BPEO = Best Practicable Environmental Option

Why Look for Waste and Toxics? $$

Do you give a 2nd thought to the true cost of “wastes”? – What is the cost to pre-treat wastewater?

• permitting fees• buffering chemicals• energy • sampling & testing time and expense• disposing of any dewatered or filtered solids• filtration supplies• disposal of packaging from purchased supplies• maintenance of the pre-treatment system

– What is the annual cost of lighting and heating unused space?– What is the cost of discarding unusable packaging

• Really paying supplier• Pay for disposal ($200/ton in Seattle)

Why Look for Waste and Toxics?

• Reduce Toxics – Human, Environmental, Business Benefits– Indoor air quality at the workplace– Effluent and emissions released to the environment – Exposure to employees and end users of products

containing potentially toxic materials (Phthalates in your shower curtain)

– Reduced liability – Reduced permitting or regulatory burden

Where to Look for Waste and Toxics?

• Production• Facility • Grounds• Maintenance • Pollution control and waste management

systems• Office/administrative operations

Where? In Production

– Waste process heat – Inefficient use or overuse of water, energy, compressed

air, materials– Overspray or over-applied coatings– Overprocessing (e.g., curing parts longer than necessary)– Scrap and rework– Inventory that is unusable or expired– Idle equipment – Other non-product output (filters, cutting fluids, tumbling

media, floor coverings, cleaning or processing solvents)

Where? At the Facility (Inside and Out)

– Facility drains – Storm drains– Floors– Chemical and raw material inventory– Dumpsters, garbage cans, scrap piles– Material movement equipment (forklifts, cranes,

fleets)– Unnecessary lighting– Lush, green landscaping (pesticides, water use)

Where? In Maintenance

– Lubricants– Hydraulics– Machine shop – Cleaning materials, chemicals and rags

Where? In Pollution Control and Waste Management

– Bag house dust– Filtrates from stills, baths, wastewater treatment– Dewatered solids– Hazardous waste collection or accumulation area– Throughout production and chemical management

or storage areas

Where? In Administration

– Paper and office supply use– Printing and copying “culture”– Employee cafeteria or food consumption (including

packaging)– Unused space heating and cooling– Employee commute

How to Look for Wastes and Toxics? • P2 audit or checklist templates• VSM / Process mapping adding inputs/outputs• Invite the third party inquisition on a walkthrough

or assessment (Someone not familiar with day to day)

• Material balance• Scrap rates• Dumpster dive (and other solid waste

piles/collections)• Purchasing records and bills (materials, all utilities)• Senses: Smells, Sights, and Sounds• Publically available emissions or materials data

Examples: Process Specific P2 Checklist Excerpt for Metal Finishing

Parts Cleaning: Mechanically pre-clean parts as much as possible first. Determine level of cleaning needed. Work with the supplier to use a corrosion inhibitor more easily removed or

compatible with the cleaning system used on site. Arrange for JIT delivery to reduce or eliminate need for corrosion protection. Use a lower vapor pressure cleaner. Use an aqueous cleaner.Reduce Drag Out Losses: Extend drip time; install drip racks. Install drainage boards between tanks to route drag out into the correct

process tank. Reduce workpiece withdrawal rate from the chemical bath. Install air knives or water misters to remove drag out. Lower the concentration of plating bath constituents, increase the plating

solution temperature. Both actions will reduce solution viscosity to enhance runoff.

Rack workpieces being plated so that cavities open downward to promote draining.

Use non-ionic wetting agents ….

Examples (How)Pre-Assessment Baseline Metrics

Sales Revenue (Annual) Units Produced

Working Days / Year

Number of Shifts / Day

SITE & PROCESS EQUIPMENT DESCRIPTION OF USE / TYPE OF EQUIPMENT

QUANTITY

TOTAL VOLUME

Number of Buildings

Delivery Vehicles -

Fork Lifts -

Water Treatment

Nitrogen Assist spray equipment

Cure ovens

Other

INPUTS – ANNUAL QUANTITY U/M EXPENSE DESCRIBE USE / LISTConsumables (List metrics for any commodities you might want to look at)

Paint $

Degreaser

Other Solvents

Process Additives/Consumables $

Water Treatment Chemicals $

Abrasives & Polishes

Public Water Consumption

Water Source:

Gal $

Diesel Fuel - Gal $

Gasoline Fuel - Gal $

Propane Fuel - Gal $

Bio Fuels $

Etc. Etc. ,

(See Handout)

Current State Value Stream Map (Unmodified)

Market Forecast

Total Lead Time = 10 days Value Added Time = 15 min

CustomerA

2 people

C/T = 4 minC/O = 3 hrUptime = 61%

Assembly &Inspection

2 people

Milling

C/T = 2 minC/O = 2 hrUptime = 74%

3 people

C/T = 7 minC/O = 4 hrUptime = 48%

Painting

I I I3 people

Shipping

7 min4 min2 min

1 day 2 days2 days 3 days

Production ControlAnnual Production Plan

Weekly delivery schedule

Wee

kly

sche

dule

Daily schedule

Daily scheduleWK

I

5 days

D ID

30 daysWK

Receiving

C/T = 2 minC/O = 30 minUptime = 93%

Welding

2 days

2 min

CustomerBSupplier

1Supplier

2

Current State Value Stream Map (Modified with Materials)

Materials lines can be developed for any major material source used in processes and products

2 people2 people

Milling

II

Welding

EHS EHS

5 lbs8 lbs

10 lbs12 lbsMaterials Used = 22 lbs Materials Needed = 13 lbsMaterials Wasted = 8 lbs

Top line: Materials Used by Process

Bottom line: Materials Added to Product During the Process

Current State Value Stream Map (Modified with Water & Materials)

1 person1 person

Surface Prep

II

Paint

EHS EHS

7 lbs2 lbs

10 lbs5 lbs

Materials Used = 15 lbs Materials Needed = 9 lbsMaterials Wasted = 6 lbs

Water Used

5 gal2 gal

Water Used = 14 gal Water Needed = 10 galWater Wasted = 4 gal

4 gal

1 personI

Purge Spray Line

EHS

Materials Used

Materials Needed

Water Needed

5 gal

N/A

0 lbs

3 gal

5 gal

Solvent (with paint residuals)

Air leaks, GHGs

Current State with Inputs/Outputs(Akin to Process Mapping)

Surface Prep Paint Purge Spray Line

Grit & additives

EnergyWater

Compressed Air

Spent grit

Contaminated water

Fugitive dust

Greenhouse gases (GHG)

Paint & Solvent

Compressed Air/Energy

Filters, Nozzles, Masking,

Rags

Air leaksSpent

filters, masking tape and paper,

nozzles, rags

Air leaks, GHGs

Surplus paint &

solvent, & solvent-

laden rags

Overspray

SolventCompressed

Air/Energy

Hazardous/toxic Water Related Non-haz Waste Energy

Wastewater Pre-treat

Filters Buffer chemicals

EffluentSolids, filters

Examples: Diagram Inputs/Outputs

Super Sleuthing for Opportunities• PPRC or other facility walkthrough list (handout)

• Research the process beforehand, especially common wastes, emissions, effluent, etc.

• Research available emissions or waste data (TRI, Fire Marshal, state data)

• Research their permit status

• Identifying potential opportunities is not (usually) rocket science, moreso an inquisitive way of thinking about pollution and avoidance.

• There’s never a stupid question! Leave no stone unturned.– Even if a question or idea turns out to be infeasible, it spurs further thinking

and a possible trail to other opportunities or solutions

Opportunities – Understand their Emissions

Super Sleuthing for Potential Solutions

• Contact PPRC to help research • Contact material or equipment suppliers for feasibility and potential cost savings• Review MSDS or other product specs on chemicals of potential concern• Utilize free tools and services

• WSU Energy Extension• Energy Star Profile• Alternatives databases (EPA DfE, SAGE, Cleaner Solutions)

• Additional expertise may be necessary for more in-depth analysis or feasibility evaluation of findings and recommendations– energy auditing and analysis expertise, – wastewater engineering, – chemical engineering, – extruding equipment– Spray paint efficiency training

www.cleanersolutions.org

www.p2pays.org/ref/19/18161/index.cfm.htm

www.pprc.org/hubs

Maximize Paint Transfer EfficiencyFinding: Poor painting techniques and transfer efficiency

Solution: STAR Spray Efficiency Training

Results: Woodfold Mfg. in Oregon has shown a minimum savings of $34,000 in paint costs and $4,000 savings in reduced filter changes.

Maximize Transfer EfficiencyFinding: Variability in application of fiberglass and less than optimal transfer efficiency Results: Reduced overspray and variability in material thickness

Material Use

Minimum Fill Line for Gun Operation

Before After

• Finding: Waste of about 1 gallon of paint with each custom color mix

• Solution: Alternative container

• Result: Reduced overproduction of custom color paints by 48 gallons/year

Material Consumption (and Time)Canyon Creek Cabinet Company-Wood Waste (Washington)

Before: Lots of waste wood 368 sheets/day cut @ 120 sec/sheet = >12 hours

Solution: 3 new crosscut saws• Results: 219 cuts @ 21 sec/cut = 1 hour 17 minutes-----------------------------------------------------------------------• Reduction in time: 90% = $31,000• Reduction in sheets required: $194,000/year• Reduction in waste removal: 580,000 lbs/year

and $58,000/year

Finding: Poor visibility and ergonomics resulted in inadequate detection of defects to repair prior to coating.

Solution: Hang panels in-line, better lighting, stand inspect

Results: Changes reduced cost of rework by $208,000/year, improved ergonomics, reduced material travel and handling.

Scrap and Rework (Lean Waste)Before After

After

Scrap and ReworkPlastic Food Package Manufacturer

• Finding: 30% finished-product scrap rate and a “culture” that this is OK because they just regrind and put it back into the process. After all, it’s “recycling”!

We demonstrated the cost of this practice: “Back of envelope” calculation including material handling, grinding time, energy to re-extrude, grind, grinder maintenance, material: >$600k /year

A “lightbulb” moment

• Solution: Just communicating this cost to staff and the expectation to minimize this “scrap culture”, is expected to achieve 5% scrap reduction. They are working on optimizing downstream processes to maximize quality of the finished product and reduce the amount of rework.

Water Use at a Food Processor

Finding: Use of heated water, with high-volume hoses and nozzles to clean up residual food processing waste from vessels and floor. (Especially intensive water use before processing Kosher foods).

Solutions: • Manual pre-cleaning• Some mechanical vessel cleaning• Switch to low-volume-high-pressure hoses and nozzles•Harder employee access to hoses; easier access to brooms/squeegies• Changed standard operating procedure.

Water Use at a Food Processor

Results:

Found local composter to take all recovered solids – diverting at least 50% of previous volume from landfill

Projected reduction of heated water, and wastewater generation by 30%. This also reduces the amount of pre-treatment, treatment chemicals, water sampling and testing, and energy to heat cleaning water and run the pre-treatment system.

Wastewater savings are projected at 6 gallons/minute and $15,000 per year.

Water Reuse

Nature’s Path (Washington project) -Finding: Trucked collected oven condensate to wastewater treatment facility over 100 miles away. -Solution: Condensate recapture system for reuse onsite as makeup water. -Result: Savings of >$12,000 per year in wastewater treatment costs (plus reduced time and expense of trucking the water)

Columbia Paint (Washington Project)Finding: Vessel wash water containing white pigment discharged to wastewaterSolution: Collection of white and off-white wash water to use for tank cleaningResults: Avoid annual use of 36,900 gallons of city water

Toxics & Emissions Reduction

Canyon Creek Cabinet Company

Finding: >150,000 pounds volatile organic compound (VOC) emissions per year – pushing close to Title V air permit limits. One high VOC source was topcoat material for finished cabinets, which was applied twice to each panel.

Solution: Alternatives assessment and evaluation for substitute product. Identified a one-coat product that resulted in less overall VOC content for their coatings

Results: Reduced VOC emissions by 114,535 pounds/year. Now will not need to file for Title V air permit even with a 70% increase in production.

Energy Efficiency

Paint CuringFinding: Neanderthal 60’ gas convection oven running 24/7Potential Solution: Replace with infrared or halogen curing system that can potentially save the energy cost per part by 20 %.

Utility Pole – Kiln DryingFinding: Inadequate kiln drying resulted in running poles through kilns twice because pole surface areas facing inward to the log stack were not drying.

Potential Solution: Optimize fans and air flow, add additional spacers between logs in the stack, to optimize drying around the entire circumference of the pole. (Unconfirmed if implemented or amount of energy reduced).

ReuseFinding:

- Company purchase $18,000/yr. in biodegradable peanuts to ship products out, and -$Paid 280/month for two containers for recycling cardboard

Solution: - Shred cardboard and use in place of peanuts

Results: -Eliminated one recycling container- Annual savings $19,680 (after paying for the cardboard shredder)

Source: ConnStep Manufacturing Resource - Connecticut MEP)

Reuse

• Booty recycling at ON• Multiple lab refrigerators in a

refrigerated room – adding heat • Record storage in an unused building heated in

winter (in Idaho) for no other purpose than to keep fire sprinkler lines fluid in event of fire. (Suggestions? Transfer to e-data storage, or move records to another room in a building that requires heat anyway and has sprinklers).

Other Examples

What to do with All The Great Ideas?

Low hanging fruit or Low-tech solutions?- JUST DO IT!!!! - Schedule a mini-kaizen event – internal or with

TechHelp to assist and facilitate- Have company establish an internal Green

Team to work on opportunities over time- PPRC’s rapid response service for potential

solutions

Potential Metrics

Energy Metrics:

Environment Metrics:

Economic Metrics:

• Environmental savings identified• Lean savings identified• Other cost savings• One time potential cost savings

identified• Individuals trained• Jobs created• Jobs retained• Total annual potential impact identified• Number of small businesses engaged• Percentage of small businesses engaged• Number and value of SBA loans granted • Capital infusion dollars invested• Hours of counseling provided

• Air emissions reduced (lbs)• Solid waste reduced (lbs)• Material intensity per unit of production• Hazardous waste reduced (lbs)• Hazardous materials reduced (lbs)• Water pollution reduced (lbs)• Water used/conserved (gal)• Water intensity per unit of production

• Energy conserved (MM BTU/kWh)• Energy intensity per unit of production• Carbon reductions (tons)• Carbon intensity per unit of production

Environment Metrics & Some Suggestions for Data Sources (Baseline):

• Air emissions (lbs)• Air permit – monitoring, reporting

• Solid waste (lbs)• # of dumpsters (density conversion)• Garbage can /dumpster dive

inspections• Rejected product• Recycling or composting bills

• Material intensity per unit of production• Hazardous waste (lbs)

• Waste manifests• TRI Data• Logs

• Hazardous materials (lbs)• MSDS• Purchasing records• Inventory records

• Water pollution (lbs) or wastewater (gal)• Storm water

• NPDES Permit• Wastewater

• Pretreatment Permit• Sewer Records

• Water consumed (gal)• Point of use or flow meters (if

available)• Utility Records

• Water intensity per unit of production

• Energy consumed (MM BTU/kWh)Defer to NEEA

• Energy intensity per unit of production

Resources – Where to Get Help

• UW Industrial Assessment Center• Northwest Energy Efficiency Alliance • PPRC (Michelle)• Utilities• SBDC – Environmental Assistance Coordinator• City Public Works Staff• County

Breakout Exercise

MetalTek (A “fabricated” metal fabrication and coating company)

Exercise: Review description of company, baseline metrics, and current state VSM

1) What obvious and potential opportunities do you see?

2) What questions would you ask the company?

Thanks for your Time

Contact PPRC at:

1402 Third Ave, Suite 1420 | Seattle, WA 98101T 206.352.2050 | F 206.352.2049| www.pprc.org

Michelle Gaither | Environmental Engineer | mgaither@pprc.org

Pacific Northwest Pollution Prevention Resource Centerpractical solutions for economic and environmental vitality