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Cleaner Production Audit
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CP audit

• Knowing where you are and what you have got is
  the essence of good management and yet it is
  surprising how many organizations are not aware
  of their environmental positioning.
• Audio to listen

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Purpose of a CP audit

• Identify low hanging fruits to generate
  immediate savings and to motivate the project
  team
• Set priorities for the project

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Context of a cleaner production audit

• First company visit Convince the company to
  participate in a project with the NCPC.
• Start of the cleaner production projectCollect
  initial data for project planning, identify
  options to motivate the team.
• EMS initial reviewObtain an overview of
  environmental impacts and the organization.
• Within a cost reduction auditObtain an overview
  of the reduction potential.
• Within continuous improvementDetermine
  benchmarks and ask for an expert opinion.

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How to conduct a CP audit?

• Scope
• Technical (data, technology, special
  observations)
• Legal compliance
• Organization
• Preparation
• Team, participants
• Date
• Materials to prepare (company brochure, layout,
  flowcharts, etc.)
• Checklist

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The tasks of an audit
Planning
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Training
Learning
Identifying options
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Before the company visit

• Plan the first visit to the company
• Team
• Timing
• Questions
• Draw up a form for the documentation of the first
  visit
• Company information and data
• Flowchart
• Data
• Observations

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Three steps

• Step 1 PREPARE
• Define responsibilities
• Define the scope
• Collect documents
• Develop a schedule
• Prepare checklists and inform staff
• Step 2 CARRY OUT
• Audit
• Evaluate findings
• Organize a wrap-up meeting
• Step 3 FOLLOW-UP
• Follow up on corrective action
• Report to the management
• Document and report

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Key qualifications of auditors

• Diplomacy
• Ability to listen and good communication skills
• Attention to detail
• Flexibility in adapting to a companys culture
• Authority, acceptance and support within the
  organization
• Access to expert knowledge on relevant laws,
  regulations, codes and organizational standards
• Access to staff or advisors who are able to
  convert legal and other obligations into daily
  organizational procedures
• Access to all levels of the organization
• Access to senior decision makers

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Schedule for a quick scan

• Meeting with the director (company policy,
  products, plans)
• General technical introduction(introduction to
  site, responsibilities, layout, flowchart)
• Site visit (in operation)
• Take notes (preliminary data, flowcharts,
  pictures ASK FIRST!)
• Feedback session

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Audit checklist
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Question techniques

• Open questions
• Closed questions
• Mirror questions

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MATERIAL Raw material Process material Other
material
OBSERVEDSYSTEM
PRODUCTS Primary and coupled
MATERIAL EMISSIONS
ENERGY CARRIERS Fuels, e.g. gas, oil, coal
Solid waste Gases Wastewater
ENERGY Mass free, e.g. electricity or district
heating
ENERGY EMISSIONS Waste heat Noise
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Data sources
Accounting Receipts Records on waste Stock
Process data disposal Verbal information
Measurements
Office Process A Process B Process
... Energy balance
Materials Energy
Products Waste, emissions
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Audit

• Report completed within three weeks and submitted
  to the EMS coordinator
• Subsequent audits shall in particular address
  previous non-conformities and ensure that the
  corrective action taken prevents their recurrence
• The audit procedure should be reviewed annually

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Where auditors look ...

• Auditors will carefully check
• Stacks
• Waste pipes
• Storage locations for chemicals
• Non-labelled containers
• Contents of containers to find items that do not
  belong there
• Items that are not supposed to be thrown away
• Leaking valves, tanks and pipes, broken trays
• Storage of chemicals in their respective
  designated locations

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What auditors ask ...

• Who empties the containers?
• Where does the waste go?
• How are hazardous chemicals disposed of?
• How is their use monitored?
• What would you do if a container with a chemical
  was spilled onto the floor?

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Audit interviews

• Audit interviews are to check whether
• Rules and procedures are observed
• Operational controls are in place
• Employees understand their role in the EMS
• Significant impacts are addressed
• Important documents are accessible

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Audit outcomes

• Report to management
• Identification and implementation of corrective
  action
• Recording of audit results

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Quick scan Where to look 1 (General
information)

• Talk to staff (about training, experience, health
  and safety, problems, ideas, approximate data)
• Measuring equipment
• Storage (cleanliness, waste, losses)
• Logistics (handling losses, space, problems)
• Accounting (structure of accounts, figures)
• Cleaning (product recovery, time, chemicals,
  dosage)

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Where to look 2 (Plant and process)

• Plants and machinery (follow the process flow)
• Type
• Design
• Age
• Maintenance
• Control
• General impression
• Consumption of energy and water
• Waste generation per plant, type and quantity

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Where to look 3(Options and low hanging fruits)

• Heating system(piping, leaks, insulation,
  boiler, quantities of fuel, type, price)
• Cooling system(insulation, compressor, etc.)
• Compressed-air system(leaks, compressor, etc.)
• Water preparation and distribution(dosage of
  chemicals, leaks, quantities, costs)

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The audit iceberg
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Tips for auditees

• Understand the scope of the audit.
• Review and familiarise yourself with procedures
  and work instructions in your area.
• Familiarize yourself with the audit plan and find
  out at what point you may be involved.
• Be prepared for questions about your job as well
  as about the procedures and work instructions
  that you use.
• Ensure that you know the location of documents
  relevant to the audit.

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Listen, listen, listen!

• Listen to a question completely before answering
  it.
• Answer ONLY the question you are asked.
• Do not offer any additional information that you
  THINK the auditor might find interesting.
• Do not avoid questions, answer directly.

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Get help if you need it!

• Find the most competent person available for a
  certain area of expertise.
• Do not guess responses, try to find the person
  who can provide the answer.
• Ask supervisors or team leaders for assistance.

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Correct non-conformities

• If possible, correct minor non-conformities
  before the final meeting of the audit
• Thus you demonstrate your intention to comply
  with the requirements

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Its about time ...

• You have worked with your processes. The audit
  is the time for you to show how much you have
  done and how well you have done it.
• Enjoy the opportunity to demonstrate your
  professionalism.
• You have done everything you could do and now
  youre READY!

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Analysis of the sources of waste