Environment and Resource Efficiency Plans Waste Management

Transcription

1 Environment and Resource Efficiency Plans Waste Management

2 Welcome EPA Victoria Sustainable Learning Australia Participants Introduce yourself Name Where from - organisation and role

3 EREP Program Outcomes Identify types and causes for waste generation Capacity to undertake waste assessments Identify opportunities for reducing waste Develop waste reduction action plans Analyse waste costs Process for implementation of options Waste reporting Module 1 EREP Toolkit and Guidelines

4 Training Program Objectives Provide you with an understanding of the waste assessment process Provide tools to assist you to conduct waste assessments Assist you to identify better ways to manage waste and reduce costs Use of EREP Toolkit

5 German Manufacturing Costs Ot h e r C o s t s 13 % D e p re c i a t i o n, R e n t a l & Le a s i n g C o s t s 6 % P e rs o n n e l C o s t s 2 5 % Ma t e ri a l C o s t s 5 6 %

6 Discussion Auto industry supplier Identified scrap metal left over from stamping operations Metal in general waste stream What will you do? What are the options?

7 Activity How would you define waste? Do you think your clients/staff view waste differently? If so what would be their perspective?

8 What Is Waste? Something we do not need any more Stuff we throw out Items that need treatment / disposal No singular definition and/or meaning of what is waste! Legislation definition

9 What is Waste? Which of these would be classified as waste?

10 Reasons for Waste? Acceptance of waste as an outcome of the business Attitude Communication Practices Quality It is not measured.

11 Manufacturing is. Raw materials + labour + equipment + time + energy = products + waste Resource Efficiency Inputs = Products + Waste

12 Example 1 Pasta manufacturer pasta not packed due to bags/machine pasta recirculated through process repackaged business = no wastage but - bags, energy, pasta, staff time, water etc.

13 Example 2 Rubber products manufacturer Approximately 40 hoses rejected per day Value of these at market price (extrapolated) per annum = $600,000 No records of numbers disposed of (audit identified this) 42 pairs of gloves (in good condition) in waste container = $13,000 per annum Save $42,000 by more efficient recycling Some use for rubber off cuts as pallet protectors

14 Categorising Waste Inherent characteristics Physical Properties Hazardous; solid Source Domestic; C&I Stream or management process Recyclables; compostables Legal requirements Prescribed

15 Waste Management Hierarchy More desirable Less desirable

16 Where to Start Start at the beginning Keep it simple Accurate data Decisions based on potential to avoid waste Module 2 EREP Toolkit

17 Flow Charts Track waste from point of generation to a. Consolidation on-site b. Final disposal off-site What systems are in place Who does what a. Company staff b. Contractors c. Cleaners d. Waste contractors

18 Activity Map the flow of waste for a plastic bucket manufacturing factory Note the types of waste and points of generation. Map from source to disposal.

19 Benchmarking Essentially the comparison of one s own business practices with those of other organisations to generate ideas on how to make improvements. In the context of EREP, benchmarking refers to comparing waste type/quantity generation rates and potential for reduction of those waste types/quantities (ie., waste reduction targets/potential).

20 Benchmarking Data collected could be used to: Measure performance against industry sector norm(s) Help in developing realistic waste reduction targets for waste minimisation and recycling Enable measurement of progress towards those targets

21 Benchmarking Benchmark units should be collected in: A manner that is easy/simple Data units currently collected if possible Issues include: Quality assurance programs/procedures Number of employees Types of products manufactured Rate of manufacturing Different raw materials Implementation of waste management Data from contractors if in volume may only represent the volume of the waste container collected

22 2 Key Questions 1. Where are you now? what s in place; what do you do; what wastes do you generate? How are you performing? What are the opportunities?.. 2. Where do you want to be? what are your objectives/targets. What do you actually want to achieve? Compliance? Cost reduction? Waste reduction?..

23 Types of Waste Audits Compliance - legal or statutory Desktop Waste assessment Physical waste audit Mass balance Process Audit Module 3 EREP Toolkit

24 Types of (Solid) Waste Audits Compliance - legal or statutory identify compliance only Reviews actual practices/systems to standard (eg EPA license; Corporate Policy; EMS) Desktop provides basic information on waste composition and quantity more useful when industry information available Is based on a review of historical records and industry benchmarks

25 Types of (Solid) Waste Audits (cont) Waste Assessment Based on visual assessment of waste systems and materials plus desktop review of historical records. provides an indication of key issues and effectiveness of current systems Physical waste audit involves physical analysis of waste provides detailed information on composition and quantity Identifies WHY waste has been generated, by whom and how much

26 Types of (Solid) Waste Audits (cont) Mass (materials) Balance Determine inputs/outputs Uses information such as transport certificates and purchasing records Identifies materials entering waste stream Process Audit Visual observations of processes Combine with tools such as focus sessions Provides detailed cleaner production opportunities

27 Definition Waste Assessment It is a visual analysis of the types and quantities of waste found in the workplace. It will identify the main types of waste present; waste streams & systems in place and give an idea of quantities generated.

28 A waste assessment identifies the low hanging fruit of waste management. Relatively easy to identify, yet providing real waste reduction opportunities. The process is about how to select options to ensure that ripe opportunities are picked

29 Waste Assessment Constraints Waste assessments may not provide full identification of: Hazards Full profile (characteristics and weight/volume) of the waste stream Cost/benefit analysis All opportunities to reduce waste All legal compliance issues

30 Waste Assessment - Key Stages 1. Planning Scope & objectives Legislative impacts OH&S 2. Information Gathering Business specific Waste information Systems Licenses 3. Site Analysis Purpose Schedule wastes/activities to be viewed Conducting waste observations Recording information Data/Reports 4. Analyse the findings Waste Profile Identify reasons for waste Identify opportunities 5. Action Plan Prioritise actions Assign responsibilities & timing

31 Waste Assessment Materials leaving the Site Streams Why Generated Analysis Department Raw Materials

32 Planning

33 Waste Assessment Scope Establishment and agreement of clear objectives and outcomes why are we doing this? Allocation of resources to accomplish these Timeframes Responsibilities

34 Scoping Influences EREP program Legal obligations Costs associated with current management systems Corporate policies/procedures OH&S issues Shareholders / stakeholders External variables such as customer needs

35 Discussion Occupational Health & Safety What needs to be considered? What components of the waste assessment process could be hazardous? What do you need to prepare? Eg Risk assessment Site induction Others?

36 Information Gathering

37 Business/Site Specific Organisational information Site operational details Waste indicators EFT staff Turnover Size of facility Contractor details Site operating licences Corporate reports Policies / Procedures (environment/waste) Anything else..

38 Waste Information Waste streams onsite Quantities Systems in place Acceptance criteria/disposal pathway Types of waste expected Tonnes/volumes generated per annum (invoices) Current waste practices including all avoidance/minimisation practices

39 Discussion Accessing the information Where might you get this information?

40 Discussion Review the sample waste invoices provided What do they tell you? What information is not provided?

41 Conducting the Site Analysis

42 The Process Essentially a process of walking through all work areas and documenting waste issues Types of wastes Quantities volume/number Systems Practices Visual process do not physically sort waste May require a number of inspections and follow-up discussions

43 Purpose of Site Analysis Identify key waste issues identify the low fruit Inspect waste management systems are they working effectively? Are they suited to the waste/client? Issues of contamination/leakage? Review other issues eg.,signage / litter Identify any barriers that may impact on change ie space Observe material flows and potential sources of waste generation not all waste will be visible

44 Visual Inspections Look for: Prescribed Waste is it managed correctly Items being discarded in significant volume Costly/unused/valued items being discarded Product/raw materials or other inputs Reject/scrap/off-cuts Contamination of streams and leakage ie recyclables in general waste Housekeeping waste on floor/near drains Variations in waste stream between departments/shifts Opportunities to reduce/divert

45 Cleanups and other non-standard activities

46 Signage?

47 Are materials really being diverted?

48 Indications of waste types and quantities

49 Opportunities

50 How effective is diversion?

51 Are systems suitable?

52 Consistency of bins?

53 Loss of Raw Materials

54 Unexpected Waste

55 Site Analysis Plan Plan the site analysis process When is waste generated? In what areas? By what activities? When are bins cleared? Ensure ALL key activities and areas are covered You may have to inspect different departments several times Who do you need to speak to? Eg cleaners, night shift manager etc

56 Remember The site analysis is a critical component of the Waste Assessment. Ensure the inspections of departments cover the full waste flow and all key activities.

57 Items in the Waste Stream Always assume that all waste bags or containers may contain hazardous materials - NEVER PLACE HANDS INTO A WASTE/RECYCLING CONTAINER. Never try to move a waste container

58 Waste Systems What types of systems are in place Are they effective Where are they located Do they efficiently manage the various waste streams Are they cost effective

59 Waste Contractors Types of services they can provide include: Systems Containers Collections Advice Data on generation/disposal pathways Reports Education

60 Density Conversions The waste assessment is a visual process Observed waste will be in a volume measurement Other data may be in a weight measurement Data allows for conversions and thus consistency See attached density conversion data

61 Decision Making Waste management hierarchy It s about questioning why wastes are generated, not how do we manage what we have

62 Analysing the Findings

63 Waste Profile From the observations you should be able to develop a rough waste profile This profile should be by department and stream within each department Can then be consolidated for the entire site For each stream, list the main components with estimates of approximate percentage (these will not be accurate they are to give an overall impression only)

64 By Department 25% 20% 15% 10% 5% 0% Plate scraps (K) Prepared (K) Cardboard (K) Co-mingled (K) Breakages (K) Other (K) Comingled (HK) Paper (HK) Other (HK) Glass (B) Cardboard (B) Other (B)

65 By Waste Type Kilograms Compostable 2.50% True General Waste 18.38% Listed Waste 0.78% Manufacturing Waste 31.91% Listed Waste Manufacturing Waste Manufacturing Packaging Other Packaging Reusable Materials Gloves PPE Recyclables Compostable True General Waste Recyclables 9.29% PPE 0.16% Gloves 2.37% Reusable Materials 0.56% Other Packaging 0.49% Manufacturing Packaging 33.56% 100% 90% 80% 70% 60% 50% 40% Plastic Samples Paper Extrusion Cardboard Metal Plastic Wrap Chemical 30% 20% 10% 0% Feb - F'night 1 Feb F'night 2

66 Data Validation Does the information make sense? Is it typical of other businesses from this sector? Were any unexpected wastes observed? Were any expected wastes NOT observed? The analysis MUST relate back to the waste assessment scope

67 Root Cause Analysis

68 Finding The Right Answer A sustainable and effective Waste Reduction program is dependent on identifying the right solutions What is really causing the waste to be generated? What is really leading to contamination/leakage of the recycling system? Root Cause

69 Basic Principles Never assume you know the answer Question everything you are told Validate conclusions first hand observation Observe behaviour at different times and during different stages

70 Key Tools Focus Groups Teams Staff awareness surveys 6 Whys

71 Root Cause - The 6 Whys Ask why is the waste item being generated need to go back through the process Choose one reason and ask why - more reasons will be given For one, ask why again and do so 6 times in total Doing so and repeating for some of the responses for the first set of answers usually results in the same answer eg. lack of communication or management issues

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74 Activity The 6 Whys Refer to the video clips. After each, note the cause of the waste and solution. Cause Solution

75 Waste Costing

76 Cost Of Waste Disposal Food Manufacturer (Mixed) Disposal & Transport $ 89,000 Cost of Product $890,999 Cost of Packaging $ 50,568 Cost of Consumables $100,000 Cost of Labour $ 42,000 Site Overheads $ 10,000 Safety/Management??? Downtime???

77 Real Cost of Waste $1,182,567 + or 13.3 times cost of transport & disposal

78 Cost Of Waste Disposal Rubber Products Manufacturer Disposal & Transport $ 60,697 Cost of Rubber Product $600,000 Cost of Gloves $ 13,000 Cost of non-compliance??? Cost of Labour??? Site Overheads??? Safety/Management???

79 Real Cost of Waste $673,697 + or 11.1 times cost of transport & disposal

80 Other Studies Sustainability Victoria Resource Efficiency Program in 2004/05 12 companies $23 million in lost value through nonproductive resource flows Waste costs: 12,500 tonnes per annum $950,000 per annum Loss of resource value of 23:1 Previous case studies conservative

81 Options - Feasibility

82 Moving Forward Ignore waste focus on resource efficiency Measure efficiency of input resources measuring inputs rather than waste Bring waste to front of the process not hidden away behind the process How efficient are resources converted to product?

83 Feasibility Analysis Each potential recommendation needs to be assessed in terms of its feasibility. This should include: Environmental evaluation Economic impacts Organisational issues Impact on quality of product or service OH&S impacts Social impacts Integration with existing systems eg management; quality; EMS

84 Investigating Issues Each issue can now be investigated to see what can actually be achieved: Are there any constraints within the business eg space, language etc What services are available in the region Are there suitable re-processing methods available Are there any legislative issues which will impact on the recommendation

85 Waste Disposal Options

86 Options Waste avoidance primary option Diversion from landfill opportunities Need to consider Reuse Waste to energy Recycling Treatment Systems Containers Collections Space Costs

87 New Systems Must ensure no contamination Involve waste contractors Correct placement Staff education Signage Monitoring Staff feedback

88 Savings

89 Tracking Savings Calculate true cost of waste management and resource usage Identify potential savings Calculate payback period Payback period (years) = Initial investment ($) Net annual savings ($ per year) Module 4 EREP Toolkit

90 Cost/Benefit Example Meat manufacturing plant required to upgrade on-site wastewater treatment plant Cost of approximately $2,000,000 Waste audit conducted Identified meat wastage on bacon line Solutions cost $60,000 Additional $20,000 in product saved per annum Need for treatment plant upgrade avoided

91 Action Plan

92 EREP Requirements Supporting documentation Waste assessment report Opportunities Actions Template

93 Template

94 Goals and targets Where do you want to be The most important thing about having goals, is having one Geoffrey F Albert

95 Goals Avoidance/Reduction in waste generation Reduction in waste to landfill Reduction in operating costs Improved workplace safety Cleaner workplace Reduce environmental impacts Compliance with Legislation Increased employee environmental awareness Improved Corporate Image

96 Prioritising Actions Based on the waste issues identified and reasons for the waste, priorities can be set Compliance issue due diligence aspects Cost savings potential Volume of waste Toxicity of waste OHS&E Ease of change required Cost/resources required to make change Meets corporate objectives i.e. image, neighbours/odour Impact of employees positive Technology required

97 Setting Targets Specific Measurable Achievable Realistic Timetabled

98 Prioritising Actions Limited resources cannot do everything at once Focus on a manageable number of actions at any point in time Better to be in control of a few actions then to be overwhelmed by too many Helps employees by pacing changes

99 Exercise A manufacturer generates large quantities of cardboard packaging which is discarded in the general waste stream. What might be a suitable Goal; Action and Target for the company to set in regards improving this aspect of their waste stream Goal Target Action(s)

100 Implementation

101 The biggest hurdle CHANGE Changing attitudes; habits; practices. Empowering people to take ownership and control. Change takes time.

102 Requires Effective leadership Policy and objectives Management of change Communication Organisation Resources Employee involvement Implementation Monitoring Review - Improvement

103 Implementation Identify any training needs or other support requirements Create awareness of the change and promote benefits Assist acceptance; take-up & compliance Involvement All stakeholders

104 Implementation Identify and access necessary resources People/equipment/information/capital Identify key stakeholders How will they be impacted by the planned action? How should this be managed? Communicate, communicate, communicate Planned changes, reasons, progress, outcomes.. Invite input from stakeholders

105 Successful Implementation Strategic level Policies Risk based Integration Corporate governance Operational level Resourcing Strategies Procedures Training Review

106 The Hurdles Recognising that waste exists Understanding the causal relationship between waste and other areas eg OHS; quality; cost; etc Identifying the real cost of waste Establishing ownership at senior level

107 Implementing the Action Plan Why, who, when Waste management committees Staff education

108 Waste Reporting

109 EREP Waste Reporting - Conducted annually Must include: type and quantity of waste generated actions that have been fully implemented actions that have been partially implemented costs of implementing actions waste efficiency gains made by implementing actions financial savings of implemented actions. Appendix 7 EREP Guidelines

110 Monitoring

111 Monitor, Review & Evaluate Waste Assessment Review and Improvement Analysis Implement

112 Monitoring Basis is continual improvement Ensures actions work Allows for adjustments Meet reporting requirements Dates and data Allocate responsibility Module 5 EREP Toolkit

113 Questions