ems implementation drivers

PP22AD GA MFI - 34303 Rev.1AD GA MFI - 34303 Rev.1

EMS Implementation Drivers

•Minimize Waste and Prevent Pollution

•Increased Operational $ Cost Savings

•Greater Process Efficiencies

•Improved Environmental Compliance

•Reduced Future EH&S Liability Risk

•Improved Competitiveness in Supply Chains

•More Attractive to New Customers/Investors

•Improved Community Relations

•More Efficient Use of Company Resources



EMS Mentoring

Eaton Corporation, Supercharger Division


Eaton Supercharger

• Located in Athens

• 325 Employees

• 100,000 sq. ft.

• Aluminum and steel machining

• Epoxy Powder Coating

• UF/RO WWT


• Use the EMS to drive improvements in the bottom line;

• Design the EMS to act as a tool to improve operating efficiencies;

• Use the EMS as a function of your organizations overall marketing strategy.

• Design the EMS to act as a compliance assurance tool;

• Use the EMS as a tool to reduce legal liability risks; and

• Design the EMS as a public relations tool.

Reasons to Implement an EMS


Improve Bottom Line

0

20

40

60

80

J F M A M J J A S O N D

kw/UNIT

Goal

Energy

YTD = 52 KW/SC GOAL = 58 KW/SC 2000 = 61 KW/SC

14.75% Reduction

14.75% Reduction


Improve Operating Efficiency

Used Oil

YTD = 0.73 lb/SC GOAL = 0.9 lb/SC 2000 = 1.1 lb/SC

05

101520253035


0

1

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3

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6

total tons

per unit

Goal

33.6% REDUCTION

33.6% REDUCTION


Market/Customers

• FORD Motor Company Announces ….• 150 facilities to be Certified by 1998• They Will Encourage Suppliers to Follow Suit

• Others Include: GM, Chrysler, Toyota

– International Paper– US Steel– EXXON– Procter & Gamble– Kodak– United Technologies

– Xerox– Honda of America– Lucent Technologies– British Airways– Dupont– Akzo Nobel– and more …...


Regulatory Compliance

Solid Wastes

YTD = 1.67 lb/SC GOAL = 1.3 lb/SC 2000 = 1.6 lb/SC

0

10

20

30

40


0

0.5

1

1.5

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total tons

per unit

Goal


Public Relations

• Athens-Clarke County Industrial Recycler of the Year

• Industry of the Year• ISO 14001 Certified• QS 9000 Certified


Driver

Eaton Corporation mandated that every manufacturing plant be ISO 14001 certified by the

end of 2000!


EMS Mentoring


Getting Started With Your EMS


ISO 14001 Implementation Trail

AppointManagement

Representative

EstablishImplementation

Team

Provide Implementation

Training andDefine Roles

ConductReview& Gap

Analysis DevelopImplementation

Plan andAssign

ResponsibilitiesEstablishManagement

Programs

SetObjectives& Targets

DefineOrganizational

Structure & Assign

Responsibilities

DevelopDocumentation

ProvideJob

RelatedTraining

ConductInternalAudit

Review

InitiateCorrective

Action

Pursue Certification

Identify Aspects

Identify Legal & OtherRequirements

Environmental Policy


Getting Started

• Assign Responsibility/Champion

• Perform a Gap analysis– Must be knowledgeable of environmental

regulations and ISO 14001 requirements

• Identify Resource needs– Establish Steering Team– Select a registrar


Gap Analysis

Section 4.4.3 Requirement

With regard to its environmental aspects and EMS, the

organization shall establish and maintain procedures for:

a) internal communications between the various levels and functions of the organization;

b) receiving, documenting and responding to relevant communication from external interested parties.

The organization shall consider processes for external

communication on its significant environmental aspects and

record its decision.

Existing Communications Program

A procedure does exist to communicate information on the facilities

environmental aspects to relevant functions and levels of the organization.

Review of the procedure does not include a process for responding to

external communications from external interested parties.

The organization has not recorded a decision on external communication of its

significant environmental aspects.

GAP?

NO

YES

YES


Resource Needs

• Steering Team– Environmental– Quality– Production/Manufacturing– Engineering– Purchasing/Materials

• Consultant• Reference Materials

– Consensus/Industry Standards– Regulations


Questions?





EMS Mentoring

Yamaha Motor Manufacturing Corporation of America


YMMC Total Headcount

0 200 400 600 800

F & A

MFG

ENG

person

Salary

Hourly

Temp

Total 864 person

Yamaha Motor Manufacturing Corp.


3.4 million lbs of Waste Reduced/year!Landfilled Solid Waste

253 258230

339 321

160198 189 207

161135

176136 132 131 119 135

87

169140 157 145

101

0

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100

150

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400

Feb-0

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To

ns

Historically 280 tons/month went to the landfill

ReduceReduce

ReuseReuse

RecycleRecycle

EMS Results


Monthly VOC Emissions

8.0

7.0

6.3

7.6 7.7

8.3

9.6

6.87.2

8.68.2

7.9 8.0

5.3

2.2

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5.6

6.8 6.7

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-00

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00

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-00

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-00

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-00

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-00

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-01

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02

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-02

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-02

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-02

To

ns

/ VO

C

VOC Emissions (tons/month) VOC Emission Limit 12 Month Average Goal

EMS Results


Activity AnnualSavings

Annual Sales

Waste Management $200,000

Cardboard Recycling $75,000

Paper Break Even

Aluminum Cans Break Even

Plastics $10,000

Metals $ 5,000

Pallets $ 4,000

Unnecessary Item Sales $ 6,000

Metal and Plastic Drums $2,000

MEK Distillation $126,000

TOTAL $326,000 $102,000

$428,000 savings through environmental program implementation this year.

Additional cost savings through regulation compliance - no fines

EMS Results


Back to YMMC33.3%

YMMC Employee Programs

33.3%

Community Improvements

CCS33.3%

Recyclable Sales =

YMMC 33% Program


Funding for local classroom environmental projects

Grant cycle is 2 times per year

Grants awarded to 12 local schools

Environmental programs will benefit over

3,000 Coweta County School Children

Funding - Community Involvement


• Community Improvement and Beautification

• Community Recycling Programs

• Public Education and Scholarships

Keep America Beautiful - nonprofit federal environmental program



January 2002

Sponsored Christmas Tree Recycling

Coweta County Adopt-A-Stream equipment funded by

YMMC 33% Recycling Program



Through YMMC’s EHS programs we are able to make positive impacts on our company, our employees, our community and our customers.

• Improves Business / Cost• Improves Environment• Creates “Kando”

EMS Results



EMS Mentoring



ISO 14001 Certification


Why Quality Why Quality andand Environmental?? Environmental??Both Strive for ZERO:Both Strive for ZERO:

QualityQuality EnvironmentalEnvironmental

Zero ScrapZero Scrap Zero Waste Zero Waste

Zero DefectsZero Defects Zero Pollution Zero Pollution

““EveryEvery use of a resource represents an opportunity to conserve. use of a resource represents an opportunity to conserve.

Every loss of a resource represents an opportunity “ Every loss of a resource represents an opportunity “

Pojaseck, Harvard.eduPojaseck, Harvard.edu

Implementing an Integrated System


ISO 9001ISO 9001UniqueUnique

ISO 14001ISO 14001UniqueUniqueSharedShared

Customer FocusCustomer FocusProduct RealizationProduct RealizationDesign and DevelopmentDesign and DevelopmentProduction and ServiceProduction and ServiceCustomer SatisfactionCustomer SatisfactionControl of NCMControl of NCM

Aspects and ImpactsAspects and ImpactsEmergency ResponseEmergency ResponseInterested PartiesInterested PartiesRegulatory auditsRegulatory audits

Policy Manual and StatementPolicy Manual and StatementDocument ControlDocument ControlObjectives and TargetsObjectives and TargetsTrainingTrainingInternal AuditingInternal AuditingMeasuring and MonitoringMeasuring and MonitoringCalibrationCalibrationCAR/PAR SystemsCAR/PAR SystemsManagement ReviewManagement Review

Implementing an Integrated System


• Designate Management Representative

• Perform GAP Analysis

• Designate Implementation Team

Management Commitment

You Must Have Management Commitment!


Quality EngineerManuf. EngineerProduction Lead

Supervisor

Plastics


Supervisor

Welding


Supervisor

Paint


Supervisor

W/V Assembly


Supervisor

T/V Assembly

Standardization Team

One elected repfrom each dept.

team.

Use representatives from each area:

Form Implementation Team


Questions?



ems implementation drivers

Documents