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Waste Minimization: Yachts of Opportunity

Waste Minimization: Yachts of Opportunity. Marquis Yachts, LLC. Founded in 1954 in Pulaski, WI Past up to 1400 employees at Pulaski, WI 15 – 43 - >700,000 Vertically Integrated (wood, metal, fiberglass, coatings) 13 Buildings of Operations. Opportunity. 146 hoist lifts rated up to 40 tons

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Waste Minimization: Yachts of Opportunity

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  1. Waste Minimization:Yachts of Opportunity

  2. Marquis Yachts, LLC • Founded in 1954 in Pulaski, WI • Past up to 1400 employees at Pulaski, WI • 15 – 43 - >700,000 • Vertically Integrated (wood, metal, fiberglass, coatings) • 13 Buildings of Operations

  3. Opportunity • 146 hoist lifts rated up to 40 tons • 56 industrial vehicles with continuous education • Respiratory fit testing for 350 employees • Elevated surfaces of heights over 30 feet • Needle-sharp fiberglass and razor blades • Eye contaminates from sand blasting, grinding, sanding, spraying, polishing, drilling and cutting. • OSHA VPP guidelines

  4. What does ‘WASTE’ mean to you?

  5. Seven Types of Wastes • Overproduction • Unnecessary Inventory • Transport • Process • Rejected Product • Waiting • Unnecessary Motion

  6. Process Wastes • Chemicals • Energy • Temperature • Water • Industrial Waste Disposal

  7. Chemical Management • Types of chemicals utilized • Wood, metal, fiberglass coatings • Resin • Emission sources • By-product development • Alternative Process Options • Alternative Chemicals

  8. Alternative Chemicals • Cross Linking vs. Carriers • Acids vs. Bases • Heavy Metal Elimination • Solvent vs. Water-based

  9. Energy Management • Natural and Propane Gas • Fossil Fuels • Electricity • Air compressor leaks • Computers left on

  10. Temperature Management • Heating Ovens • Air Conditioning • Natural Sources of Heat • Air compressors • Computers • Water • Boilers

  11. Water Management • Sinks, Toilets, Bubblers • Rain • Condensation

  12. Industrial Wastes • Hazardous • Non-hazardous • By-products • Metal • Paper, cardboard, plastics, etc. • Electronics

  13. Alternative Process Options • Closed Molding • UV Light Ovens • Re-circulating Exhausts • Monitoring Sensors • Application Process • Light Sensors, fluorescent • Wind Turbine Generators

  14. Waste Reductions • EPA Clean Air Excellence Award in 2002 • Green Tier Induction Ceremony in 2006 • Air Emission Reduction (> 40%) • Small Quantity Generator (>60%) • Process Waste Water Reductions (> 80%) • Real Time Air Emission Tracking (>50%) • Labor Reductions (16%) • Cost Savings over $4,000,000

  15. Management Tools EMS Lean Manufacturing Six Sigma

  16. What are the basic elements of an EMS? POLICYAdoption of an environmental policy that includes a commitment to compliance with environmental requirements, pollution prevention, and continual improvement in environmental performance. FOOTPRINTAn analysis of the environmental aspects and impacts of an entity’s activities. COMPLIANCEPlans and procedures to achieve compliance with environmental requirements and to maintain that com­pliance. REQUIREMENTSIdentification of all environmental requirements applicable to the entity. ACTION PLANSA process for setting environmental objectives and developing appropriate action plans to meet the objec­tives. CONTROLEstablishment of a structure for operational con­trol and responsibility for environmental performance. TRAININGAn employee training program to develop aware­ness of and competence to manage environmental issues.

  17. RESPONSEA plan for taking actions to prevent environmental problems and for taking emergency response and correc­tive actions when environmental problems occur. COMMUNICATIONA communication plan for collaboration with employees, the public, and the department on the design of projects and activities to achieve continuous improve­ment in environmental performance. RECORDSProcedures for control of documents and for keeping records related to environmental performance. AUDITSEnvironmental management system audits. Housekeeping IMPROVEMENTA plan for continually improving environmental performance and provision for senior management review of the plan.

  18. Improvement Methodologies • Lean Manufacturing • Six Sigma (DMAIC) • Define the problem (D) • Measure the extent of the problem (M) • Analyze the sources of variation (A) • Improve the process (I) • Control the process for sustained improvements (C)

  19. Thank You for Your Time! Any Questions?

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