PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
ISO 14001 Requirements
4.1 General requirements
4.2 Environmental policy
4.3 Planning
4.4 Implementation
4.5 Checking and corrective action
4.6 Management review
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
4.1 General Requirements
• Establish and maintain an Environmental Management System.
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
4.2 Environmental Policy
• Top management defines and ensures policy:– is appropriate to environmental impacts– commits to
• continual improvement• prevention of pollution• comply with legal and other requirements
– provides framework for objectives and targets– is documented, implemented, maintained,
communicated– available to public
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
4.3 EMS Planning
4.3.1 Environmental aspects
4.3.2 Legal and other requirements
4.3.3 Objectives and targets
4.3.4 EM programs
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
EMS Definitions
ENVIRONMENTAL ASPECTElement of an organization's activities, products or
services that can interact with the environment.
ENVIRONMENTSurroundings in which an organization operates, including air, water, land, natural resources, flora,
fauna, humans, and their interrelation.
ENVIRONMENTAL IMPACTAny change to the environment, whether adverse or
beneficial, wholly or partially resulting from an organization's activities, products or services.
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
4.3.1 Environmental Aspects
• Procedure to identify aspects of activities, products, services.
• Aspects that can be controlled or influenced. • Determine aspects that have or can have
significant impacts.• Consider significant aspects in setting
environmental objectives.• Keep information up to date
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
4.3.2 Legal & Other Requirements
• Procedure to identify and access• Applicable to environmental aspects
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4.3.3 Objectives and Targets
• Documented objectives and targets• Relevant functions and levels• Consider:
– legal and other requirements– significant environmental aspects– technological options– financial requirements– operational and business requirements– views of Interested parties
• Consistent with environmental policy
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
4.3.4 EM Program(s)
• Plan for achieving objectives and targets
• Designate responsibility at relevant functions and levels
• Define means and time frame
• Amend as necessary
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
EMS Mentoring
Eaton Corporation, Supercharger Division
EMS Policy and Planning
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
Athens Plant EMS Policy
We are committed to maintaining an Environmental Management System that
promotes continual improvement, prevention of pollution, and compliance with applicable
legislation, regulations and other requirements pertinent to our operations. We will strive to use energy efficiently, to reduce, reuse, and
recycle materials in an effort to conserve natural resources, and minimize wastes from
the manufacture of superchargers.
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
Environmental Aspects
Assemble ResourceTeams
Brainstorming
Select an Approach(Initial Procedure)
Activities &Products
PotentialImpacts
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
Environmental Aspects
Apply approach &review results
Modify approach & / orCollect more data, as needed
Consolidate findings& review
Control orinfluence
Adjust as required
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
Environmental Aspects
Environmental Steering Team
• EHS Manager
• Engineer
• Quality Manager
• Training Coordinator
Process
1. List environmental categories and concerns
2. Identify Eaton activities that could have impact
3. Quantify impact
4. Determine significant aspects
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
List Activities, Aspects and Impacts
Environmental Category Impact/ConcernInterested Party View, Regulatory
Contributing Activity
Air Emissions Adverse health effect on employees,community, vegetation and soil.
Oil mist from machines and machining,exhaust from gas-fired equipment, anddusts.
Energy Consumption Undesirable atmospheric change andhealth effects from gases generated fromfossil fuel generated electric plants. Highcosts.
Factory Lighting, machine operation,process heaters, compressors,
Water Consumption Waste water generation, decreasingwetlands and wetland habitat for wildlife,resource conservation.
Coolant/cutting oil fluid, Paintline andsteel washer, Imprex bath, cleaning
Waste Water Water pollution – State Discharge PermitCompliance
Spent synthetic cutting fluids/oils,Paintline and steel washers, cleaning.
Solid Waste Landfill leachate and biodegradation,resource conservation – Liability(Superfund?)
Used oil, expired tooling, packaging,
Spills/Accidental release Soil and groundwater contamination,clean-up and liability.
Material handling of oils, coolants andfluids.
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
Impact - Evaluation Criteria
Evaluate manufacturing processes or equipment with respect to impact. A machine with a total of 10 or greater indicates a significant process. A category total of >50 indicates a significant environmental category. 0 = No negative impact - An event beyond Eaton's control or authority to manage, or a process that improves environment. Ex. - Water taken from river returned cleaner.
1 = Insignificant impact - No measurable effect or cost.
2 = Low impact - Minimal consequence or cost. Ex. A spilled chemical that is easily and quickly cleaned up.
3 = Moderate Impact - Activity with moderate cost of management, containment or clean-up.
4 = High Impact - Causes measurable and sustained harm to the environment or has high cost to manage. Ex. – extremely hazardous material.
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
Dept./Process
Machine Oil AirEmissions
EnergyConsumption
WaterConsumption
OilDischarge
SolidWaste
Spill toGround
TOTAL
G & S Gleason Tag 400 #1,2 & 3 1 1 0 0 2 0 4
Steel Washer (Better Eng) 1 1 2 2 0 0 6
Assembly M45 1 1 0 0 0 0 2
M90/M112 1 1 0 0 0 0 2
M62/M45 1 1 0 0 0 0 2
WWT Ultra-Filtration 0 1 2 2 0 0 5
Reverse Osmosis 0 1 2 2 0 0 5
Evaporator 1 1 0 0 2 0 4
Oil Separator 0 1 0 0 2 0 3
Ancillary Puckmaster 0 1 0 2 2 0 5
Steel Chip Slinger 0 1 0 2 2 0 5
Air Compressors 0 1 0 0 0 0 1
Product Supercharger 1 1 0 0 1 0 3
TOTALS 42 57 39 61 47 0 246
Evaluation Table
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
Significant Aspects
• Machine Fluid Management
• Energy Consumption
• Solid Wastes
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Legal and Other Requirements
• How do you identify which activities are covered by the regulations?
• How do you determine the relevant regulations?
• How do you keep track of the regulations?• What is the process to identify non-regulatory
requirements?• Are legal and other requirements factored into
your objectives and targets?
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
SC Legal Requirements
MEDIA REG./PERMIT NO. AUTHORITY DESCRIPTION REQUIREMENTS
Solid Wastes GAD981249709 USEPA/GaDNR Hazard wastesgeneration (small
quantity generator)
40 CFR 260 – 263, 26849 CFR 173
OCGA 391-3-11
Solid Wastes NA USEPA Universal Wastes 40 CFR 273
Toxic Substances30601TNSPR695IN USEPA Toxic Release
Inventory Reporting40CFR 370, 372
Water No-007Athens-ClarkeCounty WPC
GaDNR/USEPAIndustrial
Pretreatment Permit
ACC Sewer Use Ordinance Sec. 5OCGA 391-3-6.0840 CFR 122, 403
Water GA000000 Ga DNR/USEPAStorm Water
DischargeGeneral Permit
OCGA 391-3-6.1640 CFR 122.6
Land NA GaDNR/USEPA Spill Notification andReporting
OCGA 12-14-140 CFR 302
Chemicals NA USEPA Used OilManagement
40 CFR 279.22
Air None GaDNR Air Quality/PollutionControl
OCGA 391-3-1
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
Keeping Up to Date
• Internet sites - ganet, EPA, OSHA
• Industry/Trade Publications
• Regulation updates from BNA, Keller, Legal Reports, etc.
• Eaton EHS Network
• Company News letters and alerts• Professional publications .. Occupational
Health & Safety, Environmental Engineering
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
Setting Targets
SignificantAspects
Legal & OtherRequirements
BusinessConsiderations Interested
Parties
Policy&
Commitment
Objectives and Targets
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SC Objectives and Targets
• Energy Consumption – Reduce by 5% per supercharger produced
• Machine Fluid Management– Reduce by 10% per supercharger produced
• Solid Wastes– Reduce by 20% per supercharger produced
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
Environmental Management Program(s)
Establish and maintain program(s) for achieving objectives and targets. Designation of responsibility at each relevant
function and level The means and timeframe by which they are to
be achieved. Method to amend program(s) as new products
and/or programs are added to assure conformance to the EMS
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
EMP-1
EATON CORPORATIONEnvironmental Management Program Form
Facility Name:__Athens Supercharger Plant
Related Function/Process/Activity: Supercharger Parts Manufacturing Aspect:Energy Consumption
Objective TargetMeasurable steps (whenever possible) to achieve objective
Reduce 2001 energy consumption 5%(KW)/ supercharger produced, less than 2000
Action Plan Method Time-FrameFor achievement of
goal
ResponsiblePerson/Team
Comments/Results
Develop strategy to replace old equipment withimproved efficiency equipment.
Q1-Q4 2000
Q4 – 200
G. Wasielewski
G. Wasielewski
Replacementequipment to beobtained as productionrequirements allow.
Replace plant lightswith high effic. Pulselights.
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
EMP-2
EATON CORPORATIONEnvironmental Management Program Form
Facility Name:_____Athens Supercharger
Related Function/Process/Activity: Supercharger Parts Machining Aspect: CuttingFluids Management
Objective TargetMeasurable steps (whenever possible) to achieve objective
Reduce used oil shipments 10%(wgt.) /SC less than 2000 shipments
Action Plan Method Time-FrameFor achievement of
goal
ResponsiblePerson/Team
Comments/Results
1. Improve WWT effectiveness by refining oil-split technique and Increasing ultra-filtrationefficiency through improved filter cleaning.Determine best filter cleaning detergent.
2. Implement transition from Elf coolants toHoughton biostable product.
Q4 2001
Q4 – 2001
Ricky Kemp
Engineering
WWT improvements will reducewater and thus volume of used oilshipped.
Biostable coolants will reducemachine changouts due to fluidspoiling, thus preventing orminimizing waste disposal.
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
EMP-3
EATON CORPORATION Environmental Management Program Form
Facility Name:__Athens Supercharger Plant
Related Function/Process/Activity: Supercharger Parts Manufacturing Aspect: Solid Wastes Disposal
Objective
Target Measurable steps (whenever possible) to achieve objective
Reduce solid wastes shipped to landfill
20%(wgt)/supercharger produced, decrease from 2000 shipments.
Action Plan Method
Time-Frame For achievement of
goal
Responsible Person/Team
Comments/Results
Form a recycling team to develop recycling programs for:
1. Paper
2. Cardboard
3. Plastics
4. Cans
5. Pallets
Q4 2001
R. Eaton
Team formed in Feb. 2000. Paper, cardboard and consumer plastics and cans program implemented March 11, 2001. Pallet recycling opportunities currently being investigated. (4/27/01)
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
Questions?
Eaton Corporation, Supercharger Division
EMS Policy and Planning
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
EMS Mentoring
Yamaha Motors Manufacturing Corporation of America
EMS Policy and Planning
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
Environmental Aspects and Environmental Aspects and ImpactsImpacts
--Target ( purpose ) --
Production System
..considering for Environment
StrengtheningCost Competitiveness
Product life cycle Material Selection Transportation
Manufacturing Transportation
Use/Reuse/Recycling /Maintenance Transportation
Disposal
Product life cycle Material Selection Transportation
Manufacturing Transportation
Use/Reuse/Recycling /Maintenance Transportation
Disposal
Inputs ・ Materials ・ Energy
Inputs ・ Materials ・ Energy
Product concept/need• Function• Performance• Safety and health• Cost• Environment• Legal and regulatory requirements
Product concept/need• Function• Performance• Safety and health• Cost• Environment• Legal and regulatory requirements
Product design• Material selection• Energy efficiency• Material efficiency• Maintainability• Ease of Disassembly• Recyclability• Reuse
Product design• Material selection• Energy efficiency• Material efficiency• Maintainability• Ease of Disassembly• Recyclability• Reuse
Productstandards
Improvement strategies and techniques• Resource conservation• Prevention of pollution• Design for environment
Improvement strategies and techniques• Resource conservation• Prevention of pollution• Design for environment
Outputs ・ Products ・ Air emissions ・ Water effluents ・ Waste materials ・ Other releases
Outputs ・ Products ・ Air emissions ・ Water effluents ・ Waste materials ・ Other releases
Environmental impacts ・ Resource depletion ・Ozone depletion ・ Smog formation ・ Eutrophication ・ Climate change ・ Alteration of habitats ・Reduction of biological diversity etc.
Environmental impacts ・ Resource depletion ・Ozone depletion ・ Smog formation ・ Eutrophication ・ Climate change ・ Alteration of habitats ・Reduction of biological diversity etc.
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
Aspects and Impacts InventoryAspects and Impacts Inventory
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
Aspects and Impacts InventoryAspects and Impacts Inventory
Y M M C I S O 1 4 0 0 1
D e p a r t m e n t E n v i r o n m e n t a l A s p e c t A c t i v i t y / T a s kV o l u m e
U s e d
P a i n t C / D L i n e P a i n t S t a t i o n
W a s t e M E K F l u s h i n g g u n s2 5 0 0
g a l / m o n t hI I 2 2 5 0 0 9 0 9 0 3 6 0 0 1 5 0 0 5 0 0
P l a s t i c s W a s t e M E K F l u s h i n g P r e s s L i n e s3 0 0
g a l / m o n t hI I 2 2 5 0 0 9 0 9 0 3 6 0 0 1 5 0 0 5 0 0
P a i n t C / D L i n e D u s t O f f S t a t i o n
I P A ( A l c o h o l ) D u s t i n g p a r t s4 0 0
g a l / m o n t hD I 2 2 5 0 0 6 0 6 0 3 6 0 0 6 0 5 0 0
P a i n t / M i x R o o m P a i n t M a t e r i a l s p a i n t m i x i n g / s t o r a g e2 3 0 0
g a l / m o n t hD I 2 2 5 0 0 9 0 9 0 1 5 0 0 5 0 0
F o r m u l a :
I m p a c t R a t i n g = S e v e r i t y x F r e q u e n c y x S c a l e x P r o b a b i l i t y x R e g u l a t i o n S t a t u s x P r o d u c t i o n x I n t e r e s t e d P a r t y x S o u r c e s
( e a c h s e c t i o n i s r a t e d o n a s c a l e o f 1 – 5 )
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Rate for SignificanceRate for Significance
YMMC ISO 14001 Environmental Impacts Rating Chart
Rating Severity Frequency Scale ProbabilityRegulation
StatusProduction Interested Party
Sources of Impacts
To what degree can the impact
affect the environment?
How often does the impact occur?
What physical area is or could be
affected by the impact?
How likely is the impact to occur?
Is the impact subject to legal or
other requirements?
How does the impact affect production?
Is the impact of concern to
interested parties?
In how many departments does the impact occur?
1Harmless
No potential for harm
Rarely Occurs less than once per year
Isolated Impact is
contained on-site
Remote Very Unlikely 10% or less
Non-Regulated Not subject to government or
other requirements
Minimal No down time
Little or No Concern
1 - 4 Departments
2Mild
Little potential for harm
Intermittently Occurs 2-4 time
per year, on average
Confined Impact migrates
off-site but is contained in small
adjacent area
Low 11% - 33%
Voluntary Standard practice
but not formal policy
Limited Less than 1 hour
of down time
Some Concern Secondary concern
to one or a few interested parties
5 - 8 Departments
3Moderate
Somewhat harmful
Regularly Occurs on a
monthly basis
Local Impact migrates off-site into local
community
Moderate Reasonable probability 34% - 66%
Company Policy Formal policy or industry standard
Moderate 1 - 4 hours of
down time
Moderate Secondary concern
to most or all interested parties
9 - 12 Departments
4Severe
Harmful but not potentially fatal
Repeated Occurs on a weekly basis
Regional Impact migrates
outside of the local community
Likely Strong probability
67% - 89%
Potential to Become
Regulated Possible future
regulation
High 4 - 8 hours of
down time
Concern Primary concern to
one or a few interested parties
5
Extremely Severe
Very Harmful or potentially fatal
Continuous Ongoing
occurrence
Global Impact migrates outside of the
region
Very Likely High probability 90% or more
Regulated Mandated by federal, state and/or local government
agency
Substantial more than 8 hours
of down time
Concern Primary concern to
most or all interested parties
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
Significant AspectsSignificant Aspects
1. MEK - Methyl Ethyl Ketone - chemical used primarily for line flushing and cleaning
2. IPA - Isopropyl Alcohol - alcohol wipe used in surface cleaning and preparation
3. Paint Products - Liquid Solvent Paints - paint used mainly on golf cars and water vehicles
These listed chemicals are flammable liquids that when used or disposed of improperly can negatively impact our air quality, ground water, surface water, soil, and human health.
ENVIRONMENTAL
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
Identify Legal RequirementsIdentify Legal Requirements
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
Reviewing Legal RequirementsReviewing Legal Requirements
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YMMC Integrated PolicyYMMC Integrated Policy
The future is in our hands...
Take action to meet or exceed
requirements and regulations!
Promote quality and prevention of
pollution!
Make and design products
that impress our customers!
Realize success by achieving
our goals!
Plan, Do, Check, Act is our
process for Continual Improvement!
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
YMMC Integrated Policy - CheckYMMC Integrated Policy - Check
4.2 Environmental Policy
No. Question Y N Comments
1 Has the environmental policy been defined and approved by top management (at this site)?
2 Is (or does) the policy –
a) appropriate to the nature, scale and environmental impacts of its activities, products and services?
b) include a commitment to continual improvement?
c) include a commitment to the prevention of pollution?
d) include a commitment to comply with relevant environmental legislation and regulations?
e) include a commitment to comply with other requirements to which the organization subscribes?
f) provide the framework for setting and reviewing environmental objectives and targets?
g) documented, implemented and maintained,
h) and communicated to all employees?
i) available to the public?
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
YMMC Environmental ObjectivesYMMC Environmental Objectives
Considerations to Align Environmental Objectives and Targets with YMMC Business Improvements:
• Maintain or improve regulatory compliance
• Reduce environmental impact
• Provide a positive return on investment (ROI) within the first year of implementation
ENVIRONMENTAL
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
YMMC Objectives and TargetsYMMC Objectives and Targets
1. Objective : Improve Air QualityTarget - Reduce VOC Emissions 10%
2. Objective : Reduce Amount of Hazardous Waste Shipped Off-Site
Target - Recycle 30% of Waste MEK Shipped Off-Site
3. Objective : Reduce Amount of Solid Waste
which is LandfilledTarget – Reduce Landfilled Solid Waste 20%
ENVIRONMENTAL
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
YMMC ObjectivesYMMC Objectives
YMMC ISO 14001 Environmental Objectives
Objective:
Selection Consideration: Yes No Comments:
1.) Would this improvement help meet the requirements of the IMS policy?
2.) Would this improvement help meet legal and/or other requirements?
3.) Are the options for this improvement technologically feasible?
4.) Are the options for this improvement financially feasible?
5.) Would the community/interested parties consider this improvement beneficial?
6.) Were the significant aspects considered in this improvement?
7.) Do the options for this improvement provide a commitment to pollution prevention?
8.) Is this improvement in line with business and operational requirements?
Objective Selection Approved By:
_______________ISO 14001 Management Representative Date
_______________General Manager Date
_______________President Date
FRM-0269, Rev. 1
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
Select RegistrarSelect Registrar
DNV QSR Smithers AQA
Ability to perform Integrated Audit Yes Yes
Sufficient Qty of Auditors Yes (Contract)
6 month Survelliance Audit Yes Yes Yes No
Interpretation of Standards OK ( Strong Ref)
References Not Provided Yes
Customer Satisfaction High Good Good Good
Quoted Costs
Estimated Expenses Low $3,850 Max Avg. Unknown'
Estimated Total 3 yr. Costs
Strength's:Largest RegistrarWorld Wide Recognition
Registrar Selection Matrix
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
Questions?
Yamaha Motor Manufacturing Corporation of America
EMS Policy and Planning
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
Incorporating Pollution Prevention Tools
Waste/Resource Waste/Resource Management HierarchyManagement Hierarchy
DevelopEMS Policy
1.0
Identify Activities/Products/Services
2.0
Identify Aspects and Impacts
3.0
Process Process MappingMapping
Determining Significance
4.0
EstablishEMS Objectives
5.0
SetEMS Targets
6.0
Full Cost Full Cost AccountingAccounting
Root Cause Analysis Root Cause Analysis Brainstorming/Brainstorming/Prioritization/Prioritization/
Pareto Pareto AnalysisAnalysis
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
Don’t focus all your Don’t focus all your efforts on the efforts on the backend!backend!
Waste/Resource Management Hierarchy
Give highest priority toGive highest priority to::Waste reduction at the Waste reduction at the source source Better resource Better resource management management Improved process Improved process efficienciesefficiencies
EMS/P2 Environmental Policy
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Waste/Resource Management Hierarchy
Waste Minimization/Resource Conservation
Pollution Prevention Recycling
Source Reduction
In-Process Recycling
Use/Reuse/
Reclaim
Energy Recovery
Pollution Control
Treatment Disposal
Decreasing Operating Costs, Decreasing Environmental Liability
Decreasing Process Efficiency, Increasing Raw Material Loss
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Identifying Environmental Aspects
Process Mapping
Created by cross-functional EMS team Can be used as a resource accounting template
Visualizes P2 and resource conservation opportunities
Provokes questioning and open communication
ProductProcess,Process,Activity or Activity or
ServiceService
Product
Aspect: Chemicals, Water, Electricity
Aspect: Product Scrap, Wastewater, Emissions
Schematic depiction Schematic depiction of a process, activity, of a process, activity, or serviceor service
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
Conversion Coat1.3
CounterflowRinse
1.4
CounterflowRinse
1.2
Hot Water Seal1.5
Degrease/Clean
1.1
Process Mapping - Metal Finishing Example
Liquid Painting
2.0
Parts Assembly
3.0
Surface Preparation
1.0
Identifying Environmental Aspects
SubcontractMaintenance
4.0
Process Map Sublevel
Just-In-Time Delivery
5.0
Primary Processes/ActivitiesSupport Activity
Service Program
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
EMS/P2 Aspects Mapping
Identifying Environmental Aspects
Water
EnergyAlkaline Chemicals
ProductProduct
Bath Dump Wastewater
Solution Evaporation
Bath Dragout
Attribute aspect inputs/outputs
to process map worksteps
Collect aspect usage and
generation data
Link process map to spreadsheet
for aspect usage, generation and
cost characteristics
Degreasing/Cleaning
1.1
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
Identifying Environmental Impacts
Subcontract Maintenance
Activity Aspects
Solvent use (MEK and Xylene)
Liquid paint use(Xylene and Toluene)
ImpactsPotential for groundwater contamination
High-pressure spray washwater
Ozone generation from VOC emissions
Worker exposure to VOC and HAP emissions
Depletion of non-renewable resource
Depletion of critical natural resource
Potential for water pollution from oils/metals in washwater
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
Environmental Cost Impacts
Determining Significance
Why include cost in determining significance?
It make the EMS more practical and efficient
To avoid overlooking an aspect for improvement that could add business value (cost savings!)
Early cost reduction success stories can enhance buy-in from the company EMS “pessimists”
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
Determining Significance
Using an Integrated EMS/P2 Approach
Process, Activity or Service
Environmental Aspect
EcosystemDegradation
Human Health Risks
Natural Resource Depletion
RegulatoryCompliance
Waste/Resource Management
Quantity Used or Generated
Full Aspect Cost
Overall Significance
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
CHEM-X
Material & Utility Inputs
Air EmissionsEnergy Loss
Solid WasteWastewater Discharge
Product Output
HazardousWaste
Aspect/Cost Material Balance
Full Aspect Cost Accounting
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
Direct Costs
process materials, equipment, labor, energy, water Indirect Costs (Supporting Activities)
equipment cleaning, process bath dumps, waste handling,
waste treatment and disposal, auditing, reporting, lab testing
Liabilities
fines, property damage, personal injury, spill cleanup Social Costs
consumer response, employee relations, company image
Full Cost CategoriesFull Cost Categories
Full Aspect Cost Accounting
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
Full Cost (Activity-Based) Accounting System
Direct Costs A Direct Costs B
Process A Process B
Activity Cost Pools A
Activity Cost Pools B
Traditional Cost Accounting System
Process A Process B
OverheadDirect Costs A Direct Costs B
Cost Accounting Approaches
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
Uncovering Supporting Activities
1. Review process maps
2. Conduct personnel interviews• Determining time spent on supporting activities• Questions to ask....
– What activities are you involved in?– How much of your time does each activity
require?– How does the level of resource use or
waste generation effect each activity?
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
Processing a Drum of Hazardous Waste
1. Supervisor stages & labels drum for collection2. Operator fills & secures drum
4. Environmental manager arranges for disposal5. Environmental manager supervises pick-up & processes paperwork returned from contractor
3. Transfer of drum from accumulation point to designated storage point
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
• Disposal $50• Handling $47• Ink & thinner $819• Waste management $369• Hazardous waste tax $16
Total cost per drum $1,301
Full Aspect Cost - Drum of Waste Ink
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
1. Identify direct aspect cost categories
2. Determine direct aspect costs
3. Identify all supporting activities (process map)
4. Determine the cost of supporting activities
5. Attribute the indirect supporting cost to
responsible aspects
6. Attribute full aspect cost to responsible activity,
product or service (refer to process maps)
Determining Full Aspect Cost
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
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10
A B C D E F G H
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Pareto Analysis (80/20 Rule)
Aspect
Be efficient with your time and resources!
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
EMS Objectives and Targets
Establish general EMS objective significant aspects.
Ex. Reduce wastewater generated from metal finishing processes
Use P2/EMS Integration Tools Perform root cause analysis on chosen aspects
Conduct brainstorming with cross-functional team
Conduct prioritization with cross-functional team
Establish achievable and quantifiable % reduction or conservation goals to use as EMS targets.
Ex. Reduce alkaline cleaner and nickel plating wastewater by 40% by 2003
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
Root Cause and Effect Analysis
Cause and Effect Fishbone Diagram
PROBLEM
Equipment Materials
Methods People
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
WastewaterGeneration
Methods Quality Concerns
Cleaner Bath
Dumps (once/3
weeks)
No SetProcedure
Nickel Bath Dumps
(monthly)
Min./Max. Flow Not Established
Rinsewater Flow Too High
Salts/OilsContaminationQuality
Concerns
Short Drain Time (5 seconds)
Trial & Error
Quality Concerns
Root Cause and Effect Analysis Example
Supplier Recommendation
“That’s the way it has always been…”
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
Selecting Pollution Prevention and Resource Conservation Measures
BrainstormingBrainstorming
Open forum for generating alternatives; everyone speaks
Ground Rules Required
1. No criticism/idea evaluation
2. Think “outside of the box”
3. Go for quantity over quality
4. Build on the ideas of others
BrainwritingBrainwriting
Eliminates inhibition; fear of expressing ideas
Works well with teams that are less familiar with one another
Ground rules becomes less significant
Does not allow for open discussion
PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1
Bubble-up/Bubble-downUse a forced pair comparison Provokes extensive team discussion No alternative is completely eliminated Quick wins and crown jewels bubble upMulti-voting Team members allotted a certain number of votes More time efficient prioritization Requires upfront research by team members Produces “winners” and “losers”
Prioritizing Pollution Prevention and Resource Conservation Measures