Environmental Management Systems:

Systematically Improvingyour Performance

Metal Finishing Sector

American metal finishers are facing a period of intensedomestic and international competition. As an importantmanufacturing industry that puts a premium on productquality, metal finishers must find ways to continuouslyimprove their operational efficiency.

Within this highly competitive setting, metal finishing facili-ties face a wide range of federal, state, and local environ-mental requirements. Over the past 25 years, the metalfinishing industry has made great progress in improving itsenvironmental performance. The most progressive firmshave recognized that improved operational efficiency canlead to reduced environmental impacts, better regulatorycompliance, and an improved bottom line.

A growing number of metal finishing companies haveturned to Environmental Management Systems (EMS) tohelp achieve continuous performance improvement. Thesefirms have discovered that by using an EMS to improve theefficiency of their everyday operations, they can:

• Reduce costs;

• Improve regulatory compliance;

• Stay competitive;

• Enhance operational decisions; and

• Improve their public image.

If your company is looking for a proven, efficientway to enhance your environmental performancewhile improving your bottom line, an EMS may beright for you.

Finish First in the Face of IncreasedCompetition

An EMS weaves environmental decision-making into thefabric of a metal finisher’s business, facilitating compliancewhile improving overall performance. Like the QualityManagement Systems used at many metal finishingfacilities, the systematic approach of an EMS canhelp metal finishers conserve resources,enhance product quality, and adapt tochanges in today’s competitive market-place. Each facility’s EMS is unique, butfollows a simple Plan-Do-Check-Act model.

Environmental Management System (EMS)Fundamentals

A Plan-Do-Check-Act approach creates a simple frame-work to examine the many ways in which your facility canaffect the environment. You use this knowledge of yourcompany’s environmental ‘aspects’ to develop, implement,

monitor, review, and revise your environmental proce-dures over time to promote continual improvement.

Many metal finishing facilities already have com-ponents of an EMS in place, such as best man-agement practices and safety procedures.Since an EMS is a flexible tool, your facility maywant to consider integrating safety, quality,maintenance, public relations, and other facets

of your business into one integrated system.

The metal finishing industry has taken an active role inEMS development, with positive results. Metal finishingfacilities that have implemented EMSs have achieved costsavings ranging from $10,000 to more than $100,000.Geoff Blake of All Metals Processing noted that his facilitydeveloped an EMS “and saved $55,000 in the first year!”

Metal finishers can recover the up-front costs of an EMSthrough improved process efficiency and resource con-servation. Savings can be achieved through:

• Reduced energy and water usage;

• Less waste generation and emissions;

• Fewer raw material inputs; and

• Reduced sludge generation and shipments.

An EMS can help metal finishers achieve long-term costsavings through pollution prevention, beneficial reuse ofmaterials, and installation of high efficiency equipment.Metal finishers can also use their EMSs to reduce futureliability costs by managing workplace risks through earlydetection and action.

“We saved over $72,000, primarilythrough the identification of highnatural gas and electricity use causedby an obsolete gas boiler. Our EMShas kept our heads above waterduring these tough economic times.” —Carol McCracken, Foss Plating

“Since [implementing an EMS],Quaker City has experiencedremarkable success, starting with a68% reduction in water usage.” —Nick Avedissian, Quaker City Plating

“Since the start of the [EMS] inOctober 2001, Gene’s Plating hasseen reductions of 62.5% in kilowatt-hours and 70% less process waterused. At our new plating shop, thecompany has realized savings of 33%less kilowatt-hours and 50% lessprocess water usage.”— Jayne Lecy, Gene’s Plating Works, Inc.

Evaluate Your Operations for Opportunitiesto Reduce Costs

Metal finishers face a wide array of environmental regula-tions. Maintaining compliance with these requirementsrequires significant effort and diligence. The systemsapproach of an EMS can bring a reassuring sense oforder to the environmental compliance process. Accordingto Willie Bell of Metal Surfaces, Inc., an EMS “increasesawareness of how to manage our environmental issues.”

The Plan-Do-Check-Act framework of an EMS can helpensure that you comply with your environmental require-ments in a timely manner, avoiding violations and fines thatcan damage both your public image and the bottom line.The comprehensive nature of an EMS helps to improvecommunication and employee understanding of environ-mental requirements throughout your company.

“[Our EMS includes a] compliancecalendar [that] lists all regulatoryprograms, permits and reports dueeach month. Another EMS tool is amonthly environmental and safetyaudit. During the internal audit, alldocuments required to remain incompliance are reviewed andcompliance log sheets andprocedures are updated to reflectnew rules and regulations. EMSprovided motivational tools to remain in compliance with federal,state, and county agencies.”—Jayne Lecy, Gene’s Plating Works, Inc.

“The EMS program helps achievecompliance and improve our bottomline. We set our objectives andtargets, and raised our level ofawareness and team efforts in areaslike pollution prevention. It gave ustools to communicate our progress,successes, and the hurdles to ourobjectives.” —Filomena Bundang, Crown City Plating

Systematically Achieve EnvironmentalCompliance

In today’s global marketplace, many customers requiretheir suppliers to incorporate an EMS into their operationsas a condition of doing business. This trend is becomingcommon for suppliers to such industries as automobilemanufacturing, telecommunications, and aerospace.

By putting an EMS in place, your metal finishing facility cananticipate customer demands for a more systematicapproach to environmental management. A flexible EMScan enable you to achieve performance results that arewell-measured and easily demonstrated. The voluntaryadoption of an EMS can position your company to achieveISO 14001 certification if your customers require it.

Many metal finishers, especially those that supply theautomotive industry, have already implemented an ISO9000-certified Quality Management System. ISO 9000shares many elements with effective environmental man-agement systems. Both systems place a strong emphasison evaluating current processes and thinking strategicallyabout how things can be done better. Companies thatalready have ISO 9000 certification are well situated totake a ‘systems approach’ to environmental management.

“Recognizing that our customers wereunder pressure to improveenvironmental managementthroughout their supply chain, wewanted them to further count on us.Developing an EMS was in alignmentwith our goal to become a world classorganization, and it put our firmahead of the curve. In today'seconomy, any metal finisher who isn'tworking toward this environmentalsystem could be left behind in themarketplace and quite possibly goout of business.”

—James Hammer, Imagineering FinishingTechnologies Worldwide

Stay Ahead of the Curve in a CompetitiveMarketplace

The process of developing an EMS for your facility can alsocontribute to improvements in process line operations andoverall product quality. The Plan-Do-Check-Act approachhelps company owners and plant managers stay abreastof improvement opportunities. It opens valuable lines ofinternal communication with employees. It promotes long-term planning that integrates all aspects of a company’soperations, from product QA/QC to resource conservationand recovery. According to Geoff Blake of All MetalsProcessing, “setting up an EMS planted valued seeds. Itprovides a good matrix [for environmental management].”

“The EMS gave Artistic Plating a bettergeneral awareness about theenvironment. [It] was instrumental inthe identification of significantimpacts, the setting of objectives toreduce those impacts, andestablishing metrics for measuringperformance improvements. Ithelped us look at ways of reducingnot only the cost, but the amount ofhazardous materials used.” —Ruben Angel, Artistic Plating

“One of the immediate benefits of[EMS] is the tool aspect/impactanalysis. It clarifies to [companymanagement] and our employeeshow to approach new technologiesand even everyday tasks. I amconfident that as times goes on we willcontinue to improve ourenvironmental footprint.” —Brenda Zemo, Polaris Plating

“I credit [EMS] with sharpeningawareness in the plant and providinghelpful analytical tools to put newenvironmental strategies to work. TheEMS approach has helped us reducesolvent usage by 50%, recycle 99% ofscrap and 98% of paper-relatedproducts, and reduce non-productionenergy consumption by nearly 25%.” —John Marrs, Chrome Craft

Enhance Operational Decisions

As citizens take greater interest in the environmental well-being of their communities, factors like public trust andcredibility become even more significant to the success ofyour business. By putting an EMS in place, you demon-strate to regulators and the general public your commitmentto a clean environment and a healthy economy.

An EMS can help you maintain good lines of communica-tion with those who are directly impacted by your facility’soperations, including customers and the surrounding com-munity. The EMS emphasis on performance metrics canput your company in a better position to share informationon compliance and environmental stewardship, providing astrong foundation for greater trust and cooperation.

Your relationship with regulators can improve as well. “OurEMS has helped us establish a great relationship with ourlocal POTW,” noted Carol McCracken of Foss Plating.Inspectors are likely to spend significantly less time review-ing the records of a facility with an EMS in place, preferringinstead to focus on the facilities with known problems andlax management.

Your company’s image can be further enhanced throughparticipation in programs that recognize good performersthat have an EMS in place. EPA’s National EnvironmentalPerformance Track and similar state programs offer benefitsranging from public recognition to regulatory flexibility fortop performing companies.

“[EMS] has helped Lincoln Plating geta better handle on our processesbecause we can monitor all the dataand see where improvements needto be made. In addition, thecompany earns recognition for itsefforts. Typically, we receive an awardevery year.” —Ray Dickey, Lincoln Plating

Maintain a Positive Public Image

Once you have made the decision to develop an EMS,there are a number of free tools and resources available tohelp you get started.

Use the EMS Template, a ‘How To’ GuideTailored to Metal Finishing ProcessesTo begin developing your facility’s own customized EMS,visit EPA’s Sector Strategies Program Web site atwww.epa.gov/sectors/metalfinishing/. There you willfind a step-by-step EMS guide created specifically for themetal finishing industry. This plain language templatefocuses on everyday metal finishing operations, andincludes many easy-to-use tools and EMS process steps.The Metal Finishing Implementation Guide has beenthoroughly pilot-tested by metal finishing companies andconforms with Performance Track requirements.

There are More Resources to Help YouGet StartedAn expanded EMS business guide produced by theGlobal Environment and Technology Foundation is alsoavailable at www.epa.gov/sectors/metalfinishing/.This in-depth guide includes business tools, case studieson EMS best practices, and promotional material formetal finishers.

You can find other resources for EMS development andimplementation, including a list of Technical AssistanceProviders near you, on EPA’s EMS Web site atwww.epa.gov/ems/.

Start Small and Build MomentumAn EMS is based on common sense and intuitive businessdecisions. Learn from the tools listed above, then start bytaking small, doable steps and build momentum fromthere. To be effective, you’ll need proactive involvementfrom senior management, front-line workers, and supervisorsthroughout your facility. Keep the big picture in mind, butdefine reasonable expectations. Set goals and timeframes in line with your expectations, then monitorprogress, making corrections where necessary. Capitalizeon any elements of an EMS that your facility may alreadyhave in place.

It’s Easy to Get Started with EnvironmentalManagement Systems

The metal finishing industry has taken a proactive role inEMS development, starting with the successful pilottesting of the EMS template by members of the MetalFinishing Association of Southern California, supported byTetra Tech, Inc. Industry leaders have long recognized thevalue of EMSs to the continued progress and competitive-ness of metal finishers in the United States.

In 2003, the major metal finishing trade associationsformed a Metal Finishing EMS Partnership with EPA, theGlobal Environment and Technology Foundation, severalstate environmental agencies, technical assistanceproviders, and other public and private organizations. Thispartnership reflects the industry’s continuing commitmentto the voluntary adoption of EMSs by metal finishersnationwide. By 2003, over 100 metal finishing companieshad put EMSs in place or were working to do so.

“I have yet to go to a place [thatimplemented an EMS] where at theend of the day they didn’t save[money]…a place where at the end of the day they didn’t findopportunities for greater utilizationof human capital.” —Jim Connaughton, Chairman, White House Council on Environmental Quality

The Metal Finishing Industry Endorses EMS Development

GETF

Photos for this business case were provided by: Patrick Wooliever, Tetra Tech, Inc.; Plating and Surface Finishing; and Finishers’ Management.

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Discover what other leading metal finishersacross the country are finding—

EMS is a Good Business

Decision

There is a positive trend in cost savings as a result of EMSimplementation. When costs and savings are projected overa 10-year period, Artistic will realize over $1,000,000 insavings, after deducting one-time costs. —Ruben Angel, Artistic Plating

Implementing an EMS helped us realize huge cost savings andsignificant reductions in water use and waste generation. Butby far the biggest benefit was the increased sense of control I got from more proactively addressing my company’senvironmental issues. Bottom line? I slept better at night.—Ken Harel, Continuous Coating Corp

December 2003

Printed with Vegetable-Oil Based Inks on Recycled Paper (Minimum 50% Post-Consumer) Process Chlorine Free

EPA’s Sector Strategies Program is a cooperative working relationship among government, trade groups, and other stakeholders to

reduce pollution and ease the burden of regulation. For more information, visit www.epa.gov/sectors or contact your trade association.