1. 1
Presented byPresented by
Rebecca MorganRebecca Morgan
Masonite CorporationMasonite Corporation
Laurel, MSLaurel, MS
Components DivisionComponents Division
601-422-2304601-422-2304
2. 2
• Ash is generated at the Boilers
• Sludge is generated at the Centrifuge Building
• Ash is mixed with Sludge at the Staging Area
• Masonite’s main goal is to decrease the cost of disposal
By utilizing Beneficial Re-Use
• Approximately 1100 tons per month are generated
• The new process will require man hours for loading, staging, and maintaining
The new staging area for “give-aways.”
• Front end loaders and bulldozers will be required to maintain
This area.
• The estimated savings could exceed $300,000 a year with
Minimal overhead cost.
3. 3
SIPOC
Boiler Room
Water Rec
SMC
Cut/Coat
Lines
ASH
Sludge
(wood fiber)
Calcium
Carbonate
(Lime)
Paint Solids
ASH /
SLUDGE
@1100 tons
per month
Water Rec
Centrifuge
Building /
Staging Area
Ultimate
Disposal
Facility
Ash/Sludg
e
Generation
Ash/Sludg
e
Ultimate
Disposal
Facility
Ash/Sludge
Disposal
Suppliers Inputs Requirements Process Outputs Requirements Customers
Amounts to
support
analytical
Amounts to
support
analytical
Disposal is
as needed
only
Disposal is
as needed
only
Beneficial
Re-use to
NON-
Disposal
4. 4
How do we
decrease the cost
of disposal of
ash/sludge?
Employee/Outside Give-away
Outside Facilities
Employees Landscapers
Paver/Asphalt
Companies
Flowerbeds
Fill
Cover
Loading? Staging? Times? Manpower?
What if we have too much? Not enough?
Horne?
Eakes?
City of Laurel
Sims Bark
If we have more than we
can ger rid of, can we
go back to disposal?
Horne? Coleman? Laird’s?
6. 6
Cost of Disposal of Ash/Sludge
2007
0
5000
10000
15000
20000
25000
30000
35000
40000
May June July August
Dollars
7. 7
Wood fiber is
burned in the
boiler for fuel.
Ash is continually
dumped from the
downspouts.
The downspouts
empty into waiting
hoppers.
Hoppers are
transported
by truck and
dumped
at Water Rec
Staging Area.
ASH GENERATION
8. 8
Sludge Generation
Water is pumped
from the clarifier.
The water goes
through the
centrifuge.
Solids are removed
and dropped out.
Excess water is
pumped back to
the clarifier.
Removed solids
are transported
by truck to the
staging area.
9. 9
Ash/Sludge Mixing
After both ash and
sludge are dumped
In the staging area.
A front end loader is
used to thoroughly
mix both streams.
After mixing, the
Ash/sludge is
moved
by front end loader
to a waiting trailer
for haul to a local
Landfill.
10. 10
Proposed New Process
After mixing at
the current staging
area, the waste
would be moved to
the new staging
area for “give-away”
11. 11
Cost of Disposal of Ash/Sludge
2008
0
5000
10000
15000
20000
25000
30000
Aug Sept Oct Nov
Dollars
12. 12
Failure Modes and Effects Analysis (FMEA) Form
Severity (SEV) : How severe is the effect on the customer? (5 = Most Severe, 1 = Least Severe)
Probability of Occurrence (OCC) : How often does the cause or FM occur? (5 = Highest Occurrence, 1 = Lowest Occurrence)
Detectability (DET) : How well can you detect the cause or FM using the current controls? (5 = Most Difficult to Detect, 1 = Easily Detected)
Risk Priority Number (RPN) : What is the measure of process risk related to the effects, causes & controls? (RPN = SEV. x OCC. x DET.)
Process Step/Input
Which process step is being
addressed? (Must appear on
PMAP)
Potential Failure Mode
What can go wrong with the
process step output? - little y's
gone bad - converse of outputs
in PMAP
Potential Failure
Effects
What is the impact of the
failure mode to the internal
and/or external customer(s)?
(team determination or
customer input)
S
E
V
Potential
Causes
What input went bad
and how (root cause of
input going bad)?
O
C
C
Current
Controls
What controls exist
that prevent or detect
either the cause or the
FM prior to leaving the
process step?
D
E
T
R
P
N
Actions
Recommended
What are the actions for
reducing the SEV. of the
effect, the OCC. of the cause
or improving DET.?
Plans /
Responsibility
What is the target completion
date and who is responsible?
ash generation
the boiler is down lower volume of ash 1
mill down time (market
driven) 3 scheduling dept 1 3
none-the periodic testing is
required by the state
partial completion/proceeding
with other ideas
chemical comp.change return to disposal 4 process changes 1
periodic testing and
process change
approval tracking 2 8
none-the periodic testing is
required by the state
partial completion/proceeding
with other ideas
market demand increase in disposal $ 2
not planting/fertilizing
season 1 return to disposal 1 2
have alternative methods for
give-away
partial completion/proceeding
with other ideas
sludge generation
the mill is down lower volume of sludge 1
mill down time (market
driven) 3 scheduling dept 1 3 NONE
partial completion/proceeding
with other ideas
chemical comp. change return to disposal 4 process changes 1
periodic testing and
process change
approval tracking 2 8
none-the periodic testing is
required by the state
partial completion/proceeding
with other ideas
market demand increase in disposal $ 2
not planting/fertilizing
season 1 return to disposal 1 2
have alternative methods for
give-away
partial completion/proceeding
with other ideas
ash/sludge mixing 0
the mill is down lower volume of combo 1
mill down time (market
driven) 3 scheduling dept 1 3 NONE
partial completion/proceeding
with other ideas
chemical comp. change return to disposal 4 process changes 1
periodic testing and
process change
approval tracking 2 8
none-the periodic testing is
required by the state
partial completion/proceeding
with other ideas
market demand increase in disposal $ 2
not planting/fertilizing
season 1 return to disposal 1 2
have alternative methods for
give-away
partial completion/proceeding
with other ideas
13. 13
Areas at Masonite’s Laurel Mill
Where Ash/Sludge have been used: Pond 1 Closure Pond 1 Closure
Pond 1 Closure after bush hog
14. 14
•Disposal was decreased in 2008 by $105k (June-Dec) and there is
an estimated $104k saving to be delivered Jan-June in 2009.
•We are working with a local group who would like to mix our ash
with chicken litter to benefit local farmers.
•The City of Laurel Horticulturist has expressed interest in using our
de-watered fiber in city flower beds and landscaping projects.
