Key Lessons Learned from Visits to Companies – EMFACT

1. Key Lessons Learned from Visits to Companies – EMFACT Terri Goldberg, NEWMOA & Rick Reibstein, MA OTA

2. Contacts with Companies/Groups • MA OTA technical assistance staff • Devens redevelopment eco-efficiency group (variety of companies represented) • Toxics Use Reduction Planners Association (individual companies and consultants to companies represented) • Allegro Microsystems, Inc. • Wyman Gordon • Westfield Electroplating Co

3. Scope of Conversations • Existing EMFACT systems & capacity? • Motivation for creating systems? • Uses of system – reports & value? • Track energy use? • Track materials/energy costs? • Advice on EMFACT

4. EMFACT Users Continuum • Clear there is a continuum of EMFACT capabilities among the businesses and groups we talked to – • No tracking/reporting – particularly true for many very small companies • Some tracking/reporting – related to compliance • Extensive tracking – few companies • Not much reporting/analysis/presentation even among those tracking materials/energy/waste

5. Existing Systems • Devens & TURPA meetings – several participants in each meeting indicated that their company or clients do have some kind of EMFACT-like systems, but most do not • Visited three companies to see their existing system – one of these companies was recently acquired & no longer is able to track materials use

6. Motivations for Existing Systems • 2 Companies with EMFACT-like systems reported that they established their materials tracking systems because of compliance needs – air permits, TRI reporting, TURA compliance • Home grown systems – databases & spreadsheets

7. Use of Materials Tracking • The EHS staff use their materials tracking system to keep monthly or periodic tabs on the flow of materials in the facility & to report accurately on toxics use and releases for TRI & TURA • Also has value for some if doing an EMS & P2 Plan • Not used much for ongoing P2 analysis/decisions or cost analysis/decisions • Rapidly growing interest in energy evaluation & reduction; little routine energy tracking - not comprehensive • Not enough time to do reports/analysis except that which is required

8. Elements of Systems • Linked with purchasing • Use MSDS data to calculate/track individual chemical use • Track by CAS # • Quantity of each chemical/product • Sum quantities & track over time • Link with purchasing can track some costs

9. Elements of Systems • Waste/release estimates – separate but linked system • Process flow diagrams • By knowing what is coming in & what is going out in products/waste/releases gives some idea of what happens to materials in the process

10. Key Messages on EMFACT • Others have tried to develop similar generic systems for commercial sale with no real success • Need to address where users are currently and start from there • Need to provide guidance and training as much as software – balance emphasis

11. Key Messages on EMFACT • Critical elements for materials tracking – need way to access MSDS electronically • Need way to link to a wide array of purchasing systems • Modularize the system – enable linkages to be made among elements, but enable users to pick aspects they want to implement • Track scrap per unit of product or production line - demonstrate generation of scrap waste

12. Key Messages on EMFACT • Use standard spread sheet & database software that people already have – i.e., Excel & Access • Enable users to map process, but focus on materials use– treat the process as a black box • Create useful boiler-plate reports (i.e., using Access)

13. Key Messages on EMFACT • Provide guidance to existing commercially available software that has includes of EMFACT-like functionality • Create an online MSDS system so can be accessed electronically or let people know where they can get MSDS’ electronically

14. Key Functions • Easy way to develop/maintain process flow diagrams • Materials flow function – linking purchasing – MSDS – CAS – quantities for individual chemicals; Costs??? • Waste-release tracking system • Boiler plate reports using visuals (i.e., pie charts & graphs) & data presentations

15. EMFACT Vision that is Emerging • All components modular & optional  • Excel spreadsheet to track materials/water/energy – able to connect to purchasing system • Work with an MSDS system – a community web-based downloadable framework • Link to hazardous waste, other release outputs, & production & work areas so that user can normalize & produce reports • Create ready-made queries in database like Access that can help user build reports & prompt with the right questions; prompts can be in guidance or other formats   • Add module that prompts users to add in relevant costs • Link to Process Flow Diagram/s  • After all of this – compare impacts & costs of alternatives – NPV & Payback  

16. Key Questions for Advisory Group • What are the key reports that the EMFACT system should be designed to generate? • What are the key visual and numerical outputs? • What do you think about this idea of creating an online source for MSDS? Is that critical?