ems implementation and operation

EMS Implementation and Operation

ISO 14001 Requirements

4.4 Implementation and Operation

4.4.1 Structure and responsibility

4.4.2 Training, awareness, competence

4.4.3 Communication

4.4.4 EMS documentation

4.4.5 Document control

4.4.6 Operational control

4.4.7 Emergency preparedness/response

4.4.1 Structure and Responsibility

• Roles, responsibility and authorities defined, documented and communicated

• Management provide essential resources

• Appoint management representative– Ensure EMS requirements are established,

implemented and maintained– Report to top management on EMS

performance

4.4.2 Training, Awareness, Competence

• Identify training needs

• Personnel performing work which can cause significant impacts:– require appropriate training– competent based on appropriate

education, training and/or experience

(cont’d)

4.4.2 Training, Awareness, Competence

• Procedures for employee awareness of – importance of conformance – significant impacts of work activities and

benefits of improved performance– roles and responsibilities in achieving

conformance– potential consequences of departure from

operating procedures

(cont’d)

4.4.3 Communication

• Procedures for:– internal communication– receiving, documenting and

responding to external interested parties

• External communication processes on significant aspects must be recorded

4.4.4 EMS Documentation

• Information to:– describe core elements of the EMS– provide direction to related documentation

• Can be paper or electronic

Document Organization Scheme

Proof that system works

Records

1.EMS

Manual

3. Work instructionsBOM’s, specs, drawings,

visual standards

4. External Documents

6. Completed Forms & Other Records

Policy

Implementationof policy

“How to” for procedures

ControlledDocuments

5. Blank Forms

2. Procedures, programs, permits

4.4.5 Document Control

• Procedures for controlling documents to ensure that:– they can be located– they are periodically reviewed, revised, and

approved– current versions available at essential locations– obsolete documents are promptly removed– any obsolete documents retained for legal and/or

knowledge preservation are suitably identified

(cont’d)

4.4.5 Document Control

• Legible

• Dates of revision and readily identifiable

• Maintained in an orderly manner

• Retained for a specified period

• Creation and modification procedures

(cont’d)

4.4.6 Operational Control

• Identify operations and activities associated with significant aspects

• Plan activities, including maintenance• Ensure activities are carried out under specified

conditions:– Documented procedures where absence could lead

to deviations– Stipulate operating criteria– Procedures related to significant aspects of goods

and services purchased from suppliers

4.4.7 Emergency Preparedness and Response

• Procedures to:

– identify potential for and respond to accidents and emergencies

– prevent and mitigate environmental impacts.

• Review and revise

• Periodically test

EMS Mentoring

Eaton Corporation, Supercharger Division


ISO 14001 - Continuous Improvement Cycle

EMS Responsibility Matrix

?ACTIVITY DEPT/POSITION? PLANT

MGR

EHS QUAL. HR ENG. MFG.

ENG.

MFG. PURCH. ACCT. MAINT. IT

4.2 ENVIRONMENTAL POLICY

Define policy – DRAFT R R P P P P P P P P

Ensure policy is appropriate and includes requiredelements.

R P P P P P P P P P

Ensure policy is available to Public P P R

4.3 PLANNING

Determine and document facility’s environmentalaspects

P R P P R R P

Determine and document legal and otherrequirements applicable to the Env. Aspects

P R

Set objectives and targets R P P P P P P P P P

Environmental management program to meetobjectives and targets. (identify and establishprojects to minimize or eliminate impact of significantenv. aspects.)

P R R R R

4.4 IMPLEMENTATION

Structure and responsibility – appoint mgt. Rep. Whoshall have defined resp. and authority for ensuringthe EMS is established and implemented; reports onprogress and performance of EMS to top mgt.

R P

Training – Determine individuals in roles that impactor influence significant env. aspects.

P R P P

Training – Define and document roles andresponsibilities in achieving EMS goals and targets atall levels of org. P R

Training – Develop training P R P P P

Training

• Steering Team

• Internal Auditors

• Awareness Level

• Job Specific Training

• Utilized existing system to track and document

Communications

• Postings

• Training (refresher and new employee)

• Progress Reports (goals and targets)

• Incident Reports• Surveys, suggestion program, committee

participation, e-mail, open door policy.

• External communications (inquiries, compliance reports, and regulatory inspections)

Documents and Document Control

• Used existing system for QS 9000.• Keep EMS documents separate from QS

documents within the system, but all documents are controlled in the same manner.

• Develop a matrix of important documents and retention times.

Operational Controls

Significant Aspect Objective/Target Environmental Program Operational Control

Energy Use 5% reduction/SC= 58 KW/SC

EMP-1, Replace equipment withhigher efficient models.

Lighting Control Schedule

Maintaining proper fluidconcentrationPer Method SheetMachine coolant change outand disposal per CMS#214086Waste Water Treatment

Preventative Maintenance(filter changes, machinecleaning)

Cutting FluidManagement

10% reduction/SC

= 0.9 lbs/SC

EMP-2,a. Switch machines to

biologically stable coolant.b. Improve WWT efficiency by

improving oil split and filtercleansing.

Purchasing –New EquipmentChemical approval

Solid Wastes 20% reduction/SC= 1.3 lbs/SC

EMP-3a. Form Recycle Team toimplement paper, cardboard,plastics and pallet recycling.

Waste segregation anddisposal

Questions?

Eaton Corporation, Supercharger Division


EMS Mentoring Workshop Day 2

Day 1 Review and Day 2 Overview

EMS Implementation and Operation Elements Cont.

EMS Checking and Corrective Action Elements

EMS Management Review Elements

EMS SWOT Analysis/Planning Group Exercise

EMS Mentoring

Yamaha Motors Manufacturing Corporation of America


ISO and 8-step Process

Align ISO program with current processes

Step 1: Problem Statement

“YMMC generates and ships hazardous waste off-site for disposal.”


Project selection – ISO objective

ISO 14001 Objective

“Reduce amount of hazardous waste shipped off-site.”


Step 2: Current Level Attributes –

Loss Tracking MEK Usage Tracking

Step 2: Current Level Attributes –

Loss Tracking Hazardous Waste Disposal Tracking


Step 3: Setting Baseline and Target Hazardous Waste Disposal

MEK/Paint Hazardous Waste Shipments

4235

3135

2530

19801815

2255

2860 2915

1980

3520

2585

0

500

1000

1500

2000

2500

3000

3500

4000

4500

Apr

-00

May

-00

Jun-

00

Jul-0

0

Aug

-00

Sep

-00

Oct

-00

Nov

-00

Dec

-00

Jan-

01

Feb

-01

Mar

-01

Gal

lon

s o

f H

azar

do

us

Was

te

MEK/Paint Generated (gallons)

Average 2,900 gallons/month


Step 3: Setting Baseline and Target

Monthly Hazardous Waste Disposal

0

500

1,000

1,500

2,000

2,500

3,000

3,500

Current Goal


50% Reduction

($84,000/yr or 17,000 gal/yr)

Improvement Approach

Methodology:

• Data Analysis

• Chemical Analysis

• Case Studies - Pollution Prevention

• Brainstorming

• Site Visit to US Can - observe onsite distillation


Step 4: Root Cause Analysis

Other2%

Waste MEK and Paint85%

Waste MEK and Styrene

3%

Waste IPA10%

YMMC Hazardous Waste Generation


Brainstorming Results:

1. Non-hazardous Line Cleaner - Pilot

2. Off-site distillation - Quotes

3. Purchase Distillation Equipment - Quotes

4. Mobile on-site distillation - Pilot


Step 5: Countermeasure

Distillation Process


Step 5: Countermeasure


Step 6: Implementation of Critical Path


Step 7: Confirmation of Effects and Results

Lab Analysis Results of Distilled MEK:• Outside Lab• PPG Lab Analysis

Conducted Onsite Pilot Distillation with First Source:


Monthly Hazardous Waste Disposal

0

500

1,000

1,500

2,000

2,500

3,000

3,500

BaselineCurrent

Step 7: Confirmation of Effects and Results


73% Reduction($126,000/yr or 25,500 gal/yr)

Intangible Results:

• Reduction in Risk and Liability

• Improved YMMC’s Environmental Image


Step 8: Prevention of Reoccurrence

Created ISO Operation Standard:


ISO 14001 Training Needs Matrix

Environmental Training

General ISO (IMS) Awareness

Initial

Emergency Response / Evacuation

Initial

RCRA / Emergency Response

Initial and Annual

Initial and Annual

External Annual

External Annual

Initial and Annual

HAZWOPER 40 hourInitial

CertificationInitial

Certification

HAZWOPER 8 hour Refresher

Annual Annual

Wastewater Treatment Training Credits (external)

6 credits / 2yrs

6 credits / 2yrs

Environmental Training (external)

24 hours/yr minimum

24 hours/yr minimum

Significant Environmental Impact Operation Standard Training

Initial

Training

Communication

Document Creation Schedule

Document Control

• Contingency Plan

• Emergency Evacuation

YMMC Contingency Plan TestSOP-0082

Scheduled Date Test Date Test Type Attendees Comments

4Q2000 12/13/00 Spill Response J im Gentryidentified possible future release risk - PAR #004 (work order) will be issued to Maintenance to repair pavement

12/13/00 Lonnie Booth Good ResponseJerry PuckettBill BohachJodie Jackowiec

2Q2001 8/2/01 Evacuation All Facility8/2/01 create flow chart responsibility

create emergency kit for executivesincorporate into EHS Yamaha Video

Emergency Preparedness & Response

Questions?

Yamaha Motor Manufacturing Corporation of America


EMS/P2 IntegrationP2


Structure and Responsibility

Require representation from all departments and business units on EMS Team

Make process supervisors and department managers responsible for the environmental performance of their units.

Use full-cost accounting to link P2 and resource use efficiency performance to operating budget and employee compensation rules.

Structure and Responsibility

Where feasible, rotate staff between environmental and production responsibilities.

Integrate quality and environmental improvement teams into one single workgroup focused on production efficiency.

Give highest decision-making priority to projects with significant P2/resource conservation benefits.

Include P2 and resource management performance in job descriptions and employee evaluations.

EMS Communication

EMS bulletin boards, company newsletters, company meetings and training

Communicate how and where P2 and resource conservation is integrated within your EMS

External Open houses, press releases, focus groups, annual reports, advertising, community meetings, permit applications, industry mentoring

Internal

Training, Awareness & Competence

Training on the waste/resource management hierarchy and the use of “systems approach” tools within the EMS Basic training - P2 and resource conservation concepts

All Employees

Develop an EMS employee incentive program

Specific training - P2 resources and solutions applicable to employee functions

Create friendly competitions for environmental improvement between departments and shifts

Training, Awareness & Competence

Understanding of P2 measures with potential to reduce or eliminate the aspect . Use the Internet to tap into the local and global network of practical P2 and resource conservation solutions.

Staff performing or managing an activity linked to a significant environmental aspect

Post process maps in work areas w/ environmental aspects

Highlight significant aspects

Use as visual element of standard operating procedure

EMS Operational Controls

Document all P2 and resource conservation suggestions, implemented or not.

Create a standard form

Collate the form as a reference tool for staff



Develop a written procedure for:

Using the Waste/Resource Management Hierarchy

Reporting P2 and resource conservation progress to senior

management

Monitoring, recording and posting the full cost of

significant aspects

Ensuring that aspects with written procedures required

because their absence could cause a significant environmental

impact receive the highest P2 priority

ems implementation and operation

Documents

ems performance4

ems documentationinformation

ems documentation4

ems manual3

significant aspects

maintenanceensure activities

procedurescontrolled

document control4