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Identify processes that generate
pollution. Draw chalk line – figurative, or literal. Look at everything around the
process/activity - people, vehicles, cleaners, equipment.
Coffee is batch process. What if have multi-step?.........metal parts
degreasing and coating operation
If you’re Starbucks what are you making
the money on? Yet you have all these non-product
outputs. You’re spending money on many
things that are just being thrown away, not sold. And your employees have to spend time picking up the trash and
taking it out to the dumpster when they could be making more coffee. Money’s going to waste. Try to make more coffee for less money.
When you draw a chalk line, you want to be careful and be aware of things outside
the chalkline that can have a significant affect on this process.
you back up, you see things that can have a significant affect on your process.
You want to also look at indirect
What are some of the indirect inputs?
(WAIT) In this case, this company likes a little Almond flavor in their coffee.
As an example of an unsuspected
influence to a process, let’s looking at a metal machining process. Here we have a drill bit that bathed in
coolant that is used in manifold production.
The coolant is collected in a trough on the floor and reused until it
goes bad. The company is having a big
problem – the coolant is going rancid and losing its ability to cool so
quickly that they can’t replace the coolant fast enough. The drill bit gets too hot and breaks. They have to fly a new bit down from
Michigan and the plant is located near Brownsville, TX. It’s a $1million/day operation so down time
is really costly. Let’s compare to pictures
of the process area. How does the floor
look different from one picture to the next?
Why does the area look cleaner now?
Here’s what the plant operators think
Turns out there was some surprise
input! The phosphate soap used by
janitorial staff who clean the floors causes microbes/bacteria to grow in the
coolant. This makes it go rancid so
Increase coolant life to months instead
of weeks by switching to Dawn dish detergent.
Save $300,000 just in coolant purchasing.
ALSO Al chips don’t smoke when melted for recycling!
We have created a special portal into
the TCEQ website specifically dedicated to Pollution prevention. I think you
will find it easier than trying to remember http://www.tceq.state.tx.us/assistance/P2Recycle/wrpa/p2planning.html
So let’s go through some of these resources.
Here is a snapshot of what is included.
The left column is resources for meeting the requirements. What is WRPA, the
APR, and planning and Executive Summary fall below the screen. The center
column is for current hot topics. And the right column will help guide your
internet search. For instance if you were to click on p2 resources you would
find links to information like:
P2pays.org is the largest online library
of pollution prevention information. Use it to search for published materials
of interest to your specific topics. You’ll hear us mention many types of p2
equipment and you are likely to find references to others as you prepare your
plan. You can use IWRC.org and EPA VendInfo to identify vendors of the
equipment. I have two cautions to go with this information. We are not
recommending any equipment as a cure all for everyone. Please use the same
caution in investigating these options as you would in investigating all
others. And secondly Epa’s sight specifically note verified versus not
verified. This is the sign for not verified. Verified does not equal an
endorsement of a particular product.
One of the most commonly identified
Hazardous Wastes is a companies solvents. A hazardous solvent can be
considered hazardous because are designed to taking anything off anything. You
can use the Solvent Alternatives guide to help you find a less hazardous
solvent and the coatings alternative guide to find a less hazardous coating.
These are tools that step you through the process of identifying the right
alternative for you. This is possible because it asks a series of questions
about what you are currently using and how you are currently using it. In
other words it will help you find a solvent or coating alternative for your specific
While I would tell you that p2plan is
best website around Thomas would argue that zerowastenetwork is clearly the
superior website. The funny thing is that he created them both. The southwest
network for zero waste is one of eight regional centers that work together to
promote P2 on a national scale.
They work within their regions to
identify successful practices that can then be transferred to the national
level and then promote on the regional level those tools identified in other
regions. Key focuses are training and assistance while providing an on-line
presence. Of particular note this service is free to all here except those
from the EPA.
The EPA maintains a collection of sector
guides. The guides provide BMP and pollution prevention options for their
If you can’t find your sector there Try
the P2Rx Topic Hubs. These resources are updated by the centers. They have
links to p2 documents and fact sheets about each subject.
If you still can’t find what you are
looking for you can send an email to P2Tech. There are over 150 p2
professionals associated with this website. It is free to all. If you are new
to this resource you can go to the archive, most all topics have been
discussed over the last 14 years.
Moving away from the internet
information. We’ve all heard the saying “one man’s trash is another man’s
treasure.” Renew proves that point year in and year out. The program acts a
sort of match.com for materials. It can be viewed online or by picking up a
copy of the semi-annual catalog.
Here is an example of a recent success
from Renew. A wire manufacturer uses sulfuric acid to clean the wire.
Eventually the sulfuric acid gets to dirty and must be dumped. A chemical
company identified this off spec sulfuric acid as a pre-cursor to one of their
products Ferrous Sulfate. As a result of this exchange the company not only
saves 2.5 million in disposal fees but they also earned 315000.
We won’t be able to help everyone and
that is ok. There are other organizations available to provide assistance.
TMAC goes beyond environmental constraints in providing manufacturing
Of particular interest to Texas and
possibly this group is Virgil our virtual engineer. The P2planner is an online
tool designed to walk you through the process of preparing a plan. It acts as
a virtual engineer by providing a set of options for a particular process and
by collecting specific options suggested by other users of the tool.
150 options were originally entered,
while users of the planner many unlike yourselves have enter 5 times more. The
planner in many ways has become a virtual think tank. Allowing engineers and
p2 professionals around the nation to interact and develop more and better
options. Similarly we have found that the mini think tanks that are developed
as part of the day 2 exercise will identify a number of very exciting and
encouraging p2 opportunities as you share with one another.
Here is a sampling of the user submitted
ideas. We see a wide range of ideas being presented from A C C ,and of course
they were choosing composting as there option, to foaming process. Now foaming
process is one that caught our eye because it was entered by one company and
then quickly utilized by several others. Upon further investigation we found
that this was being evaluated because of regulatory changes that were phasing
out the old cfc materials being used.
This is the case study database. There
are over 445 case studies available. You can search by industry process or by
company. These are developed in conjunction with the companies and are
maintained using their own words.
Results and savings are always real. We
may misspeak in describing them to you but we have tried to include most of
them in the printed documents.
For example. Fibergrate came to this
workshop two years ago and found out about the p2planner. One of those things
is this robo recycler. Not quite as impressive as a robocop but it does the
job. They reduced their emissions and saved 14,000.
Because of the choice they made they
were able to maintain their operations here and remain competitive.
Now I would like you to think about this
a minute. If you were one of the companies who moved offshore how would an
event like this affect your business? How would you get your product here to
help get this industry back online? Remember all the ports were closed.
Fibergrate was the only company who had made the commitment to stay here and
was the only company able to respond to this need. That 14000 dollars may have
been extremly minor but the opportunity to capture market share might just be
1.Overproduction (production ahead of demand)
2.Transportation (moving products that is not
actually required to perform the processing)
3.Waiting (waiting for the next production
4.Inventory (all components, work-in-progress
and finished product not being processed)
5.Motion (people or equipment moving or
walking more than is required to
perform the processing)
6.Over Processing (due to poor tool or product
design creating activity)
7.Defects (the effort involved in
inspecting for and fixing defects)