Cp gp day02 session 8 waste cause analysis & cp techniques2012

1. Waste Cause Analysis and
CP Techniques
Samantha Kumarasena
Deputy Director
National Cleaner Production Centre, Sri
Lanka
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2. Option generation
An organized, participative
activity!
Brainstorming is a good
tool!!
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3. Cause Analysis
(Reasons for Waste)

4. How Do We Find Waste Causes
 Ask Questions
 What, Why, Where, When, How
 Never WHO
 Make Observations with CP Team
 Conduct Brainstorming sessions
 Use suitable Tools such as
 Fishbone Diagram

5. Is the
waste
caused
due to…
Choice & quality
input material
Choice of
technology
Technical status
of equipment
Operation &
maintenance
Personal skills &
motivation
Product
specification
Management
planning &
information
systems
Design &
layout of plant
& machinery
Waste Cause Categories
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6. Choice & Quality of Input Material
• low quality
• Impurities
• Composition
• Size of material
• Cleaning requirement
• Toxicity / hazardousness
IS THIS THE BEST RAW MATERIAL?

7. Choice of Production Technology
 Obsolete technologies
 Available technologies
 Modern technologies
 Appropriate technology

8.  Obsolete equipment
 Absence of indicator instruments
 Improperly working controllers
Technical Status of Equipment

9. Design and Layout of Equipment
 Arrangement at the
production floor
 Placement and arrangement
of stores
 Material conveying method
 Long distance distribution
 Capacity balance
 Service / utility needs

10. Product Specification
 Dimensions (size)
 Colors
 Surface finish
 Packaging requirement
 Performance properties

11. • Inefficient process controls
• Cleanliness / housekeeping
• Correct load / parameters
• Frequent down time
• Power failures
• Improper maintenance / lack
of maintenance planning
Operation & Maintenance

12. • Lack of production planning
• Wrong information
• Inadequate information
• Inventory management
• Absence of record keeping
culture
Management Planning & Information
Systems

13. • Attitudes
• Carelessness
• Short cuts
• Incomplete work
Personal Skills & Motivation

14. Cleaner Production
techniques
 Input substitution
 Good housekeeping
 Better process control
 Product modification
 Equipment modification
 Technology change
 On-site recovery/reuse
 Creation of useful by products
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15. 15
Classification of CP Techniques
CP TECHNIQUES
PRODUCT
MODIFICATION
RECYCLING
Onsite
recovery
and reuse
Creation of
Useful by-
products
SOURCE REDUCTION
Process
Changes
Good
House-
Keeping
Input
Material
change
Better
process
control
Equipment
modification
Technology
change

16. Good housekeeping
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17. Good Housekeeping
Take appropriate operational actions
to prevent:
- leaks
- spills
Formulate & enforce to practice
appropriate operational instructions

18. • Tighten valves, check & repair leaking
pumps, valves, pipes to reduce/ avoid
leaks
• Store chemicals in appropriate places
• Insulate steam pipes and design
proper steam distribution system

19. 19
Spills
The spilling of dyes and chemicals at a
washing plant amounted to Rs 37,600/- per
month
Drips
In a rubber factory the dripping of a chemical
was estimated to be Rs 46,000/- per month
Leaks
The steam leaks in a textile industry was
equivalent to 9300 liters of furnace oil (Rs
67,000/-) per month (23% of total cost)

20. Input substitution
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21. Input Substitution
 Substitute input materials where ever
possible with
- less toxic materials
- renewable materials
- materials with longer lifetime

22. 22
• Replace organic solvents with water
• Replace Formic acid by Hydrochloric Acid in
textile dyeing
• Replace chlorine bleaching with O3 bleaching
• Use of soft water for preparation of dye bath:
Higher dye exhaustion levels lower dye
consumption

23. Better process control
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24. Better Process Control
Modify:
- operational procedures
- equipment instructions
Process record keeping in order to
run the processes more efficiently
and at lower waste and emission
generation rates

25. Improving process controls – e.g.
25
• Optimize and control operating parameters
in the plant to reduce product reprocessing
rate
eg: pH, temperature, time
• Optimize the boiler operations
Combustion (CO2> 12%, O2< 2%)
Reduce heat losses (surface, flue gas)
therefore reduce fuel consumption
• Optimize fabric : liquor ratio for dyeing
Reduce energy, water and chemical consumption

26. Equipment modification
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27. 27
Equipment Modification
 Modify the existing production equipment
and utilities to
- run the processes at higher efficiency
- lower waste and emission generation
rates
 Repair faulty equipment to reduce losses
and rejects
 Replace obsolete equipment or parts

28. 28
• Multiple countercurrent rinsing
• Installation of hood above dryer drums for
faster moisture withdrawal
• Replace solvent cleaning with mechanical
cleaning
• Use of high pressure jet nozzles for for
screen washing in printing
- efficient cleaning and save water

29. Technology Change
Change the product & process
technology in order to minimize
waste and emission generation
and optimize the resource
efficiency

30. Technology change
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31. Product
modification
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32. Product Modification
Modify the product characteristics
in order:
- to minimize the environmental
impacts of the product during or
after its use (disposal)
- to minimize the environmental
impacts of its production

33. 33
Product Modification
Raw Material
Extraction
Manufacture Transportation Use End-of-life

34. On-site recovery/reuse
Water, Packaging, containers !!!!

35. On site Recovery/Reuse
Reuse/recovery or recycling of the
wasted materials in the same
process or outside, for same or
another application

36. Recovery, reuse, recycle
• Water of last rinse for the first rinse
• Chrome recovery in leather industry
• In plastic injection moulding the waste
is recycled
• Condensate recovery in boilers

37. 37
Production of Useful By-products
Reuse of the wasted materials for
manufacturing of another product.
eg:
• Waste tyres are used for energy recovery
• Use of fabric cuttings for mattress manufacturing
• Coconut water from DC mills
- Juice Preparation
- Vinegar production

38. Creation of useful by products
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39. Your
Questions
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?

40. Thank
you!
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