ISO 14001 Requirements

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EMS Policy and Planning
ISO 14001 Requirements
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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
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4.1 General Requirements

• Establish and maintain an Environmental
  Management System.

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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

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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

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EMS Definitions

• ENVIRONMENTAL ASPECT
• Element of an organization's activities, products
  or services that can interact with the
  environment.
• ENVIRONMENT
• Surroundings in which an organization operates,
  including air, water, land, natural resources,
  flora, fauna, humans, and their interrelation.
• ENVIRONMENTAL IMPACT
• Any change to the environment, whether adverse or
  beneficial, wholly or partially resulting from an
  organization's activities, products or services.

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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

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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

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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

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EMS Policy and Planning
EMS Mentoring
Eaton Corporation, Supercharger Division
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ISO 14001 - Continuous Improvement Cycle
Management Review
Checking Corrective Action
Commitment Policy
Implementation Operation
Planning
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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.

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Environmental Aspects
Assemble Resource Teams
Activities Products
Brainstorming
Potential Impacts
Select an Approach (Initial Procedure)
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Environmental Aspects
Apply approach review results
Modify approach / or Collect more data, as
needed
Control or influence
Consolidate findings review
Adjust as required
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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
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List Activities, Aspects and Impacts
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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 gt50 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.

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Evaluation Table
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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?

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SC Legal Requirements
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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

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Setting Targets
Policy Commitment
Significant Aspects
Objectives and Targets
Legal Other Requirements
Business Considerations
Interested Parties
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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

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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

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EMP-1
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EMP-2
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EMP-3
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EMS Policy and Planning
Questions?
Eaton Corporation, Supercharger Division
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EMS Policy and Planning
EMS Mentoring
Yamaha Motors Manufacturing Corporation of
America
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Environmental Aspects and Impacts


--Target(
purpose) --




Production System
..considering for Environment
Strengthening Cost
Competitiveness

• Improvement strategies
• and techniques
• Resource conservation
• Prevention of pollution
• Design for environment

• 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 standards
Product life cycle Material Selection
Transportation Manufacturing
Transportation Use/Reuse/Recycling
/Maintenance Transportation
Disposal
Inputs Materials Energy
Outputs Products Air emissions Water
effluents Waste materials Other releases
Environmental impactsResource depletion
Ozone depletion Smog formation
Eutrophication Climate change
Alteration of habitats Reduction of
biological diversity etc.
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Aspects and Impacts Inventory
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Identify Aspects
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Identify Impacts
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Aspects and Impacts Inventory
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Rate for Significance
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Significant 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
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Identify Legal Requirements
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Reviewing Legal Requirements
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YMMC 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!
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YMMC Integrated Policy - Check
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YMMC 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
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YMMC Objectives and Targets
1. Objective Improve Air Quality Target -
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
Landfilled Target Reduce Landfilled Solid
Waste 20
ENVIRONMENTAL
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YMMC Objectives
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Select Registrar
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EMS Policy and Planning
Questions?
Yamaha Motor Manufacturing
Corporation of America
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EMS Policy and Planning
EMS/P2 Integration
P2
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Incorporating Pollution Prevention Tools
Process Mapping
Waste/Resource Management Hierarchy
Develop EMS Policy 1.0
Identify Activities/ Products/Services 2.0
Identify Aspects and Impacts 3.0
Root Cause Analysis Brainstorming/ Prioritization/
Pareto Analysis
Full Cost Accounting
Set EMS Targets 6.0
Establish EMS Objectives 5.0
Determining Significance 4.0
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EMS/P2 Environmental Policy
Waste/Resource Management Hierarchy
Dont focus all your efforts on the backend!

• Give highest priority to
• Waste reduction at the source
• Better resource management
• Improved process efficiencies

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Waste/Resource Management Hierarchy
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Identifying Environmental Aspects
Aspect Chemicals, Water, Electricity
Process Mapping
Process, Activity or Service
Schematic depiction of a process, activity, or
service
Product
Product
Aspect Product Scrap, Wastewater, Emissions

• 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

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Identifying Environmental Aspects
Process Mapping - Metal Finishing Example
Service Program
Support Activity
Primary Processes/Activities
Parts Assembly 3.0
Liquid Painting 2.0
Surface Preparation 1.0
Subcontract Maintenance 4.0
Just-In-Time Delivery 5.0
Process Map Sublevel
Hot Water Seal 1.5
Counterflow Rinse 1.4
Conversion Coat 1.3
Counterflow Rinse 1.2
Degrease/ Clean 1.1
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Identifying Environmental Aspects
Alkaline Chemicals
Energy
EMS/P2 Aspects Mapping
Water

• 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
Product
Product
Solution Evaporation
Bath Dump Wastewater
Bath Dragout
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Identifying Environmental Impacts
Activity
Aspects
Impacts
Potential for groundwater contamination
Subcontract Maintenance
Solvent use (MEK and Xylene)
Ozone generation from VOC emissions
Liquid paint use (Xylene and Toluene)
Worker exposure to VOC and HAP emissions
Depletion of non-renewable resource
High-pressure spray washwater
Depletion of critical natural resource
Potential for water pollution from oils/metals in
washwater
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Determining Significance
Environmental Cost Impacts

• 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

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Determining Significance
Using an Integrated EMS/P2 Approach
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Full Aspect Cost Accounting
Aspect/Cost Material Balance
Energy Loss
Air Emissions
Material Utility Inputs
Product Output
CHEM-X
Wastewater Discharge
Hazardous Waste
Solid Waste
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Full Aspect Cost Accounting
Full Cost Categories

• 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

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Cost Accounting Approaches
Traditional Cost Accounting System
Overhead
Direct Costs A
Direct Costs B
Process A
Process B
Full Cost (Activity-Based) Accounting System
Activity Cost Pools A
Activity Cost Pools B
Direct Costs A
Direct Costs B
Process A
Process B
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Uncovering Supporting Activities

• Review process maps
• 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?

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Processing a Drum of Hazardous Waste

• 1. Supervisor stages labels drum for collection
• 2. Operator fills secures drum
• 4. Environmental manager arranges for disposal
• 5. Environmental manager supervises
• pick-up processes paperwork
• returned from contractor

• 3. Transfer of drum from accumulation point to
  designated storage point

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Full Aspect Cost - Drum of Waste Ink

• Disposal 50
• Handling 47
• Ink thinner 819
• Waste management 369
• Hazardous waste tax 16Total cost per
  drum 1,301

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Determining Full Aspect Cost

• Identify direct aspect cost categories
• Determine direct aspect costs
• Identify all supporting activities (process map)
• Determine the cost of supporting activities
• Attribute the indirect supporting cost to
  responsible aspects
• Attribute full aspect cost to responsible
  activity, product or service (refer to process
  maps)

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Pareto Analysis (80/20 Rule)
Be efficient with your time and resources!

Aspect
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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
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Root Cause and Effect Analysis
Cause and Effect Fishbone Diagram
Equipment
Materials
PROBLEM
Methods
People
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Root Cause and Effect Analysis Example
Min./Max. Flow Not Established
Methods
Quality Concerns
Rinsewater Flow Too High
Cleaner Bath Dumps
(once/3 weeks)
Quality Concerns
No Set Procedure
Trial Error
Thats the way it has always been
Short Drain Time (5 seconds)
Supplier Recommendation
Nickel Bath Dumps
(monthly)
Salts/Oils Contamination
Wastewater Generation
Quality Concerns
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Selecting Pollution Prevention and
Resource Conservation Measures
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Prioritizing Pollution Prevention and
Resource Conservation Measures
Bubble-up/Bubble-down Use a forced pair
comparison
Provokes extensive team discussion
No
alternative is completely eliminated
Quick wins and crown jewels
bubble up
Multi-voting
Team members allotted a
certain number of votes More time
efficient prioritization
Requires upfront research by team
members Produces winners
and losers