Transcript Document

Case study
Implementation of EMAS in plastic manufacturing industry
Project
ETIV – EMAS TECHNCAL
IMPLEMENTATION AND
VERIFICATION
Prepared by: VUSTE ENVIS, spol. s r.o., Prague, CZ
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Case study
Implementation of EMAS in plastic manufacturing industry
This project has been funded with support from the European
Commission. This publication reflects the views only of the
author, and the Commission cannot be held responsible for any
use which may be made of the information contained therein.
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Objectives
ETIV Project
Development of didactical training material to promote,
stimulate and support the implementation of EMAS II
Regulation
Case study
Supply information on EMAS implementation in a
plastics manufacturing enterprise, representing a „Case
Study“ on EMAS implementation
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Object of the case study
Implementation of EMAS in the KASKO Ltd., Slavkov
Summary of the case study:
This case study is divided in four main parts:
•
Introduction
•
General data
•
EMAS implementation – Analysis
•
EMAS implementation – Evaluation and conclusion
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INTRODUCTION
Massive environment pollution as the negative subsequence of the
communistic regime in the Czech Republic
A noticeable improvement of environment after the year 1989:
• Equipment renovation
• Progressive technologies
• Positive changes in the legislation
• Ecological thinking in the whole Czech society.
Considerable funds in the area of SMEs
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INTRODUCTION
• Integration of the Czech Republic into E.U. on the 1st of May 2004
• Participation in the environment protection systems
• Aim of EMAS system - to support constant progress of influence
on the environment made by organisations acting
• EMAS system - convenient for use in SMEs
• Bad knowledge of principles and implementation conditions
amongst the SMEs´ managers in the Czech Republic
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DESCRIPTION OF THE TYPE OF THE COMPANY
•
Criteria for a Small and Medium Enterprise in the Czech
Republic according the definition of the Ministry of Industry
and Trade of the Czech Republic
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CHARACTERISTICS OF THE ENTERPRISE
• The KASKO Company Ltd. was established in 1992
• Czech company with no participation of foreign capital
• Main business programme of the company: development
procedure, production, assembly and distribution of plastic
constituents, design and production of injection forms
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CHARACTERISTICS OF THE ENTERPRISE
Building a quality system in KASKO Ltd. :
• 1998, re-certification in 2001: ISO 9002 and the VDA 6.1
• 2000: Preparation for the certification according to the ISO
Standard14001
• 2000: EMAS implementation started
• 2002: Gaining certificate according to the ISO
Standard14001 and validation
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CHARACTERISTICS OF THE ENTERPRISE
Company location
• Company is situated in Slavkov, which is located
approximately 10 km away from Uherský Brod in Moravia –
East part of the Czech Republic.
• Nearest source of drinking water defensive zone is 5 km
away from the company precinct. Company precinct is
located very nearby to the Protected Land Area of the
Carpathian Mountains.
• The entire KASKO Ltd. precinct are situated in an area of 5
724 m2
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CHARACTERISTICS OF THE ENTERPRISE
Workers
• 103 employees, from which 5 deal with the design and
development of plastic products
Structure of the company
• Production area
• Stocks
• Working and technical divisions
• Administration
• Social services
• Others
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CHARACTERISTICS OF THE ENTERPRISE
Production
• Injected plastic pressed pieces till the weight of 1 100 g and
assembly of them. Products are assigned for automobile
industry.
• Share of products for electrical engineering enterprises is
increasing.
• The production is realized in the pressing plant, where are:
• 12 injection moulding presses and
• 1 extrusion press
• Production of KASKO Ltd. is increasing year by year
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CHARACTERISTICS OF THE ENTERPRISE
Raw materials
Granulated plastics
Colourings
Metal components
Helping materials
Energy
Electrical power
Water
Natural gas
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ENVIRONMENTAL POLICY
•To provide training of the staff oriented on encouraging the mental attitude
to the environment protection
•To reduce use of raw materials and energy usage on production by
permanent, consistently persuade analysis
•To inform employees and the public about the influence of your production
on the environment
•To promote introduction of the environmental management system to
business partners
Environmental policy is carried out by means of the environmental
system management. This system is being supervised by the
company management in internal, also in external audits.
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SIGNIFICANT ENVIRONMENTAL ASPECTS
Environmental aspect – component of activity, products or service of the
organization, which might have an influence on the environment
Direct environmental aspects – aspects referring to the organization
activity of which the progress is being controlled
Indirect environmental aspects – aspects referring to activity of the
organization, which can not be fully controlled by the organization
Register of environment aspects - contains processes, company
activities with its rating of environmental aspects and impacts
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SIGNIFICANT ENVIRONMENTAL ASPECTS – cont.
The register of environment aspects is being continuously checked
by internal audits and once a year examined by management.
In the KASKO Ltd. are specified environmental aspects in
processes:
• Supply, stocking and manipulations
• Granulates for the press preparation
• Exchange of form and switch to another material
• Starting up the production
• Moulding
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SIGNIFICANT ENVIRONMENTAL ASPECTS – cont.
Band sawing
Work in the finishing workshop
Using the compressor
Mould maintenance
Machines’ maintenance and mending
Work in adjusters’ workshop and in the tool room
Administration, cleaning works
Others
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SIGNIFICANT ENVIRONMENTAL ASPECTS – cont.
The environmental aspects introduced above have following
impacts on the environment:
• Refuse production
• Processing waste production
• Dangerous waste production
• Primary resources consumption
• Downgrade of work environment
• Soil and water contamination
• Air pollution
• Waste water production
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LEGAL AND OTHER REQUIREMENTS
Registers created in the KASKO Ltd., containing obligatory legal
and other requirements to environmental protection:
Register of relevant legal requirements
in the area of:
 Waste and Containers
 Water Management
 Protection Of The Air
 Treatment of Chemical Substances and Chemical Preparations
 Prevention of Major Accidents
Register of relevant technical standards
Register of external decisions
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OBJECTIVES AND TARGETS AND THEIR FULFILLMENT
1. Decrease the amount of material to crush gradually by 5% on
every100 kg of production The target was not fulfilled
2. Decrease the production of further on unused plastic waste
gradually by 5% on every 100 kg of production Target was not
fulfilled
3. Decrease the electricity consumption gradually by 3% on every 1
kg of production The target was not fulfilled
4. Decrease the consumption of drinking water gradually by 5% in 1
working hour Target was fulfilled
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OBJECTIVES AND TARGETS AND THEIR FULFILLMENT- cont.
5. Decrease the production of hazardous waste (absorbing reagents,
contaminated metal containers) gradually by 5% on the number of
mould exchanges Target was partly fulfilled
6. Decrease the consumption of container materials (paper, plastic
containers) gradually by 3% on every 100 kg of production Target
was fulfilled
7. Improve the appearance of company’s surroundings with
appropriate modification and planting of green plants Target was
fulfilled
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ENVIRONMENTAL MANAGEMENT PROGRAMME
The KASKO Ltd. introduced the Environmental Management System in
February 2001 following the international directive ISO 14001
The management system is based around the procession-oriented
approach. The processes they were divided into:
• Main processes
• Managing processes
• Supporting processes
The processes are described in detail in the Management Handbook
elaborated on the basis of ISO 9002 and later also the requirements ISO
14001 and EMAS were incorporated.
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DEFINITON OF STRUCTURE AND RESPONSIBILITY
Responsible persons:
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General manager of the company
The authorized representative for EMS
Financial manager
Technical director
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TRAINING, AWARENESS AND COMPETENCE
Department managers in cooperation with the personal
management and possibly the authorised representative for quality/
EMS identify training needs on all levels. The training needs are to
be identified in this case:
• For new employees
• For employees transferred to a new work position
• For employees transferred to a different kind of work content
• For permanent current employees at least once a year
• For temporary employees
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COMMUNICATION
Targets:
Internal communication
To ensure efficient communication among various levels and functions
taking into account the customer’s requirements, QMS and EMS
External communication
Ensure the reception of incentives the involved parts
Establish contacts with the public
Provide te cooperation with expert companies
Provide the cooperation withj rescue teams (fire-fighters, gas workers,
emergency health aid, policy)
Means of communication
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DOCUMENTATION
Structure and content of documents
• Management handbook
• Declaration on the environment
• Directive
• Work instruction
• Regulation
• Design documentation, forms
Approving process and issuing of documents
Documents modification
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MONITORING AND MEASUREMENT
The KASKO Ltd. monitors, measures and evaluates its behaviour in the
area of EMS in the following fields:
• Functionality and efficiency of the system of environmental management
• Meeting the environmental policy and objectives
• Environmental awareness of employees
• Monitoring and measuring of activities in the frame of selected indicators.
The objective is to monitor:
•The activities, through which the company can influence the environment
•The real state of EMS in comparison to the set targets and legal duties.
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MONITORING AND MEASUREMENT – cont.
The monitored indicators:
• Waste production (including dangerous waste)
• Production of recycled material (shatter)
• Electrical energy consumption
• Water consumption
• Packing materials consumption
• Natural gas consumption
• Consumption of all inputs substances and materials
• Monitoring of noise level at the work place
• Production, man-hours, number of moulds replacements
• Environmental costs
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OPERATIONAL CONTROL
Inspections are performed on several levels:
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Company management
Manager of the production department
Auditor
Master craftsmen
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EMERGENCY PREPAREDNESS AND RESPONSE
Emergency readiness
Identification of potential emergency situations
The danger of a possible occurrence of emergency situations is
related mainly to the following activities:
• Storage of oil
• Matters and chemical substances and handling with them
• Usage of oil matters and chemical substances in production and
maintenance
• Operation and maintenance of machines and forklifts
• Storage of combustible substances and handling with them
• Collecting dangerous wastes
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EMERGENCY PREPAREDNESS AND RESPONSE – cont.
Emergency instructions
Emergency instructions have been elaborated for the following emergency
situations:
• Leakage of oil substances – oils – for the department: work shop of
adjusters
• Leakage of natural gas – for the department: boiler house
• Leakage of combustibles – for the department: store of chemical
substances
• Mercury leakage – fluorescents storage – store of chemical substances
• Occurrence of fire – for the department – pressing shop
Emergency management
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INDUSTRIAL RISK ASSESMENT
In the KASKO Ltd. a material concerning the risks identification has
been developed
The following objects have been assessed: Working machines,
hydraulic machines, and hydraulic press for working of thermoplastics.
The identified dangers have been assessed from the standpoint of risk
level.
Procedure of analysis of potential risks and defects
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NON CONFORMANCE AND CORRECTIVE AND PREVENTIVE
ACTIONS
In the KASKO Ltd. a directive has been developed and approved, which
should be instrumental in determining procedures applied in identifying the
causes of occurrence of defects in products, procedures, work system and
customer complaints aimed at adopting, documenting and verifying the
efficiency of preventive measures and corrections.
• Responsible persons:
• Managers
• Appointed workers
• The quality and environment manager
• The coordinator of the quality and environment
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NON CONFORMANCE AND CORRECTIVE AND PREVENTIVE
ACTIONS – cont.
Preventive measures are issued in order to prevent re-occurrence
of defects and discrepancies.
Preventive measures are designed in advance before a potential
occurrence of the defect or discrepancy
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NON CONFORMANCE AND CORRECTIVE AND PREVENTIVE
ACTIONS – cont.
In the KASKO Ltd.it is possible to make use of the method 8D for solutions
to defects re-occurrence.
Procedure of 8D solution:
1. Handle the problem in team work
2. Describe the problem
3. Give an incentive to a temporary measure and verify it’s efficiency
4. Identify the essential cause/causes and verify, whether it represents the
real cause
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NON CONFORMANCE AND CORRECTIVE AND PREVENTIVE
ACTIONS – cont.
5. Determine corrections and verify its efficiency by a test
6. Implement correction /corrections and verify it’s efficiency
7. Determine measures allowing preventing re-occurrence of the
problem.
8. Assess the performance and achievements of the team
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RECORDS
Records (QMS and EMS) represents part of respective documentation,
where the topics concerning individual records are described
(directives, work instructions, etc.)
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Records concerning inspections and tests, carried out activities,
materials and equipment are mainly issued on standardised company
forms; all originals of forms (thus also forms concerning records QMS
and EMS) are stored in „The Catalogue of forms”.
•
Each record has to be properly identified (date, name of worker,
relation to the respective product or activity, order number, etc. It has to
be readable and permanent. Records have to be stored in to be
prevented any damage to them, ensuring an easy access and make it
easy to find.
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EMS INTERNAL ENVIRONMENTAL AUDIT
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Internal audit – independent inspection of the system of quality guarantees,
revealing of shortcomings and adoption of corrections and preventive measures.
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Internal audits represent a systematic analysis of objective facts, recorded in the
form of audit protocols. Inspection team delivers to the management a truthful
and undistorted record about inspected facts
Responsible persons:
General manager
Manager of Quality and Environment Department
Chief auditor
Manager of inspected
Project manager
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EMS INTERNAL ENVIRONMENTAL AUDIT – cont.
Internal audits are carried out according to audit plan in each
department of the KASKO Ltd. through comparing the implemented
activities with statements included in the management handbook,
directives, work instructions, work procedures and other relevant
management and technical regulations.
The plan of internal audits is set by the manager of Quality and
Environment Department (chief auditor) and approved by the general
manager of the company always by the end of the month of January of
the upcoming year at the latest.
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EMS INTERNAL ENVIRONMENTAL AUDIT – cont.
• Every area (department) of the company is inspected at least once a year.
In areas of particular importance audit can be executed more often.
• Audits are carried out by auditors, without any direct responsibility for the
activities performed by the department subjected to inspection and have no
ties to the function, where the audit is executed.
• Auditors are qualified to audit the requirements ISO / TS 16949 and are
familiar with company systems of quality and EMS, its documentation and
requirements of relevant regulations.
• The manager of the inspected area is responsible for implementation of the
correction.
• Implementation of correction and elimination of discrepancies id monitored
by the chief auditor.
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MANAGEMENT REVIEW
• Discussion about the current information, tasks and problems takes place at
regular meetings at least twice a month. Minutes are recorded from the meetings.
• Management is informed about outcomes of internal audits by the authorised
representative on the basis of respective protocol.
• Management is informed about outcomes of internal audits by the authorised
representative carried out in individual departments/sections.
• A complex report on verification of management system is submitted jointly a
member of quality management and the authorised representative for EMS to the
company management at least once a year.
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ENVIRONMENTAL STATEMENT
• Elaboration of environmental statement is based on the
Regulation of the European Parliament and Council n.
761/2001 of voluntary participation of institutions in the system
of company management and the audit in terms of
environmental protection (EMAS).
• The statement is developed for the interested public in order
to provide all interested parties with concise and sensible
information
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BASIC DIFFICULTIES FOUND DURING EMAS II IMPLEMENTATION
Within the process of implementation of the environmental management
system following the regulation ISO 14001 and the directive EMAS the
KASKO Ltd. did not encounter bigger difficulties.
Some partial problems occurred during EMAS implementation:
•The lack of literature and other supporting materials on EMAS
implementation.
•To persuade regular employees of the benefits of the system and make
them implement the modification deriving from implementing EMS (e.g.
sorting of waste, records of monitoring into forms etc.)
•Access of external companies carrying out e.g. reconstruction activities
within the area of the KASKO Ltd.
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EXPERIENCE COLLECTED BY THE COMPANY KASKO S.R.O.
DURING EMAS II IMPLEMENTATION
Quality and Environment Department staff acquired largest experience
Experience in all areas has been acquired:
• Especially experience with assessing activities and their impact of the
environment
• Experience with waste handling and incorporating legal duties is to be
highlighted
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ENVIRONMENTAL IMPROVEMENTS ACHIEVED BY THE COMPANY
KASKO LTD.
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Reducing of electrical energy consumption, soil and water
contamination, noise level
Better organisation of produced waste, improved record of waste
Improvement of work environment
Usage of waste, compliance with legislative duties
Gaining space in store, simplifying manipulation
More transparent record, reduction of shatter production
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CONCLUSIONS
BENEFITS AND NEGATIVES OF EMAS II IMPLEMENTATION
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Implementation of the environmental management system in compliance
with ISO 14001 and EMAS proves to be indisputably beneficial for the
KASKO Ltd.
Implementation of EMS was a good choice as well as investment into the
future development of the company.
The most significant benefit is certainly environmental protection in itself
– the management of the KASKO Ltd. have always been aware of the
impact of production on the environment and came to the conclusion that
the best way how to manage the activities affecting the environment is to
implement the environment management system.
Other benefit can be seen in raising awareness – stronger presentation of
the company to the public eye and other interested parties.
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