Containing Cost Through Iso14001 2003
- 1. 2003 Containing Cost through ISO 14001 Environmental Management System Review November 2003
- 2. Agenda Introductions Review and Status of 2002 OTMP Recycling and Conservation Efforts and its Pay Back Legal Requirements Aspects - Significant Changes EMS BSI Audit Summary EMS CARs and PARs Safety Update OTMP 2004 Environmental Policy Review
- 3. Review of 2002 OTMP’s 1. Objective: Health and Safety of Workers Goal: We will eliminate pinch and laceration injuries on Machines beginning July 30, 2002. By installing light curtains on three Bag Machines. Status: Complete
- 4. Machine Injures The one pinch injury in 2003, occurred during a maintenance operation. Operator was assisted in a kapton change when the helper inadvertently leaned against the manual actuator resulting in the injury. We request sign-off on this OTMP
- 5. Review of 2002 OTMP’s (continued) 2. Objective: Legal Compliance Goal : We will train backup personnel to perform hazardous waste handling functions. Completed Education and on the job learning – on going We request sign-off on this OTMP
- 6. 3. Objective: Conservation of Natural Resources Goal : We will reduce the consumption of electricity per liner sold by 1% from the previous year Missed target! Review of 2002 OTMP’s (continued)
- 7. Electricity Per Liner Sold 31% Savings
- 8. Contributing Factors Ramped up Poly Nylon, which required: Less energy to manufacture liners Short cycles Cooler welds We request sign-off on this OTMP
- 9. 4. Objective: Conservation of Natural Resources Goal : Set up a building assessment of the electrical use for the purpose of energy reduction. We identified some short term - low cost reductions and have implemented many of them. We also identified a long term – capital intensive reduction Energy control plan with an on-site backup generator This has been put on hold until we complete our lease negotiations. Review of 2002 OTMP’s (continued)
- 10. Sneak Preview - Payback 800 kW Diesel – 2.7 years 1000 kW Diesel – 3.4 Years
- 11. Review of 2002 OTMP’s (continued) 5. Objective: Waste Reduction Goal: To reduce non-manufacturing waste Status: Complete Paper use was reduced by 1 ream per week – total cost savings for 2002 – $113.10!! Ink and toner cartridges are recycled Additionally, UPW use has been monitored and the results are:
- 12. City Water Used / Per Package Sold We request sign-off on this OTMP
- 13. Review of Recycling and Conservation Efforts and Its Pay Back Chris - you’re up
- 14. Water Use Drops!
- 15. Background to Water Savings Efficient running R.O. Fine Tuned Water Reclamation System
- 16. What We Recycle A quick survey of interesting data…. Cans Paper Cardboard Wooden Pallets Thin Films Regulated Waste Computers Oil and oil filters Fluorescent Batteries Scrap metal
- 17. Tons Recycled
- 18. Recycling – It Pays
- 19. Money Received from Recycled Scrap and Paper Does not include Teflon Film
- 20. Money Received from Teflon Film
- 21. Money Saved by Recycling Cores and End Caps
- 22. Disposal Costs Avoided by Recycling and or Reuse
- 23. Total Money Received, Saved and/or Cost Avoided by Recycling and or Reusing
- 24. Trees Saved
- 25. Environmental Performance and Compliance (Legal requirements) SARA Tier II ( The Federal Superfund Amendments and Reauthorization Act) Tier II reporting of Extremely Hazardous Chemicals: Liquid Nitrogen and Sulfuric Acid All License and Permits are: Current as of November 20, 2003
- 26. Aspects-Significant Changes Aspect=Any activity, product or service with the potential to impact (+/-) the environment. There have been no significant changes to the environmental aspects of this facility in the past year. Significant impact to the environment: No change.
- 27. EMS Audits by BSI Assessment summary 03/18/2003 David - you’re up
- 28. BSI Audit Summary The Environment Management System for remains effective and sustainable. Audit Conclusions: Continued certificate was confirmed EMS Certificate No; EMS 53764 28 th February 2002 remains valid for the scope of registration
- 29. Status of EMS CAR System
- 30. CAR Status 42 issued
- 31. PAR Status 34 Issued
- 32. Safety Update
- 33. Worker’s Comp- Process Efficiency (Time to submit First report of Injury) 2002 Target is < 10 days
- 34. Worker’s Comp Cases-Severity 2003
- 35. Number of Workers Comp Claims 46% Less Workers Comp Claims than 2002 Otherwise: 2003 – 8 39% Less Claims than 2002
- 36. Days away 94% Less Days Away than 2002 2002 * : 2003 claim placed on OSHA 2002 Log 2003 * : 2003 claim moved to 2002 (year injury was first reported) Otherwise: 2002 – 55 2003 – 25 55% Less Days Away than 2002
- 37. Restricted Days 98% Less Restricted Work Days than 2002 Otherwise: 2002 – 216 2003 – 181 17% Less Restricted Days
- 40. Ergonomic Issues We identified a hit list of the “Low Hanging Fruit” Ergonomic abatement progress report: Status: Diptube flaring operation for 3/8 diptube - Outsourced 200 Ltr. diptube flaring - Outsourced Mandrel pulling - Outsourced Smart cap press - modifications 100% completed Aluminum closure cleaning - Handling trays ordered Breakseal loading - Project approved and in process Liner folding – on hold
- 42. Breakseal Loading Observations: Risk Factor: Frequency of repetition 1500 – 2000 movements per hour is considered excessive This process requires hand motion 3 X what is considered excessive. Risk Factor: Contact stress Pinching force Three employees have reported discomfort in performing this loading operation. Corrective action: Neutralize breakseal loading Option: Automate loading process. Currently employees are rotated. However, this remains an issue.
- 43. Liner Folding
- 44. Liner Folding Observations: Risk Factor: Frequency of repetition 1500 – 2000 movements per hour is considered excessive This process requires hand motion 2 X what is considered excessive. Employees have reported discomfort in performing this assembly. Corrective action: Neutralize work station Option: Resolve issues with an automated bag folding fixture. In the short term, employees are rotated. However, this remains an issue.
- 45. 2004 OTMP’s
- 46. Legal Compliance Objective: Legal Compliance Goal: Complete assessment of flammable chemical storage by December 31 2003. Install sprinkler system in new warehouse space by December 31, 2003. Goal: Perform toxic dust and fumes exposure testing in manufacturing by April 31, 2004. 2004 OTMP’s
- 47. Objective: Health and Safety Goal: Implement a new proximity security system for employees by December 31, 2003. Goal: Reduce workers compensation claims in 2004 by 20% from 2003. Goal: Perform decibel testing in work areas and test each employee to obtain baseline data by March 31, 2004 Health and Safety of Workers 2004 OTMP’s
- 48. Waste Reduction Objective: Waste Reduction Goal: Reduce waste associated with destructive testing from 6.4% to 4.4% by the end of 2004 Goal: Reduce liner waste from 9% to 7.5% by the end of 2004. 2004 OTMP’s
- 49. Environmental Policy We commit to conduct its business in ways that respect the environment. Enhancing and protecting the environment is integral to our continual improvement. We seek to ensure that our products meet our customers’, employees’, and communities’ environmental expectations. Review
- 50. Continually Improve We will continually enhance and improve our Environmental Management System to ensure that our environmental performance is consistent with applicable laws, regulations, and our environmental goals and principles. Internal and external audits, with periodic executive management review, will monitor our Environmental Management System performance. Prevent Pollution We will identify, then make all reasonable efforts to avoid, reduce, or control processes, materials, or products that may cause pollution. Environmental Policy
- 51. Comply with Legislative and Regulator Requirements We subscribe to, and comply with environmental laws, regulations, contracts, and other requirements. We will establish objectives and targets to achieve and maintain compliance. Be Aware We will communicate our environmental policy by training employees, and informing suppliers and contractors to ensure continuing awareness. Our environmental policy is available to any interested party. Focus on the Customer We will help customers to prevent pollution and to comply with environmental laws and regulations for our products. New product designs will consider features to improve their environmental performance. Environmental Policy
- 52. This Concludes the 2003 Environmental Management Review November 2003