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Organization of the GP Techniques

Organization of the GP Techniques. Improved Operating Procedures. Example of Improved Operating Procedures. Waste Stream Segregation. Good Housekeeping. The 5S Technique. 7 Wastes. Preventive and Productive Maintenance. The Preventive Maintenance comprises of the following active items:

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Organization of the GP Techniques

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  1. Organization of the GP Techniques

  2. Improved Operating Procedures

  3. Example of Improved Operating Procedures

  4. Waste Stream Segregation

  5. Good Housekeeping

  6. The 5S Technique

  7. 7 Wastes

  8. Preventive and Productive Maintenance • The Preventive Maintenance comprises of the following active items: • Cleaning • Lubrication • Inspection of protective coating • Replacement of parts & overhauls • Design of a Cost Effective Maintenance System: • These are the following steps in designing a cost-effective maintenance system: • Classification and identification of equipment • Collection of information • Selection of maintenance policies • Preparation of preventive maintenance program • Preparation of corrective maintenance guidelines • Organizing for maintenance

  9. Recycle, Reuse and Recovery

  10. On-site Recovery and Recycle

  11. Off-site Recovery and Recycling

  12. Energy Conservation

  13. Input Material Changes

  14. Input Material Changes Dunalakk Paint Producing and Servicing Ltd., Hungary

  15. Process / Equipment Changes

  16. Industry: Textile printing and finishing Size: Medium Scale Push Factor: Inferior product quality and health and safety concerns for the workers. Measures: Modification of the acid ageing process during dyeing using azoic dyes. Control charting used to identify and implement minimization of usage of toxic substances like acetic acid during dyeing. Productivity Benefits: Product quality improved extensively; Improved worker health and safety. Economic Benefits: Reduction of acetic acid procurement costs by over $33,280 annually. Total savings in chemical costs approx . $78,520 while wastewater treatment costs have been saved by $200,000. Environmental Benefits: Effluent quality improved. Reduction in air emissions Example of Process/ Equipment Changes Print Works, Massachusetts, USA

  17. Pollution Control

  18. Air Emission Control  Particulates  Gaseous pollutants • Industrial Boiler emissions • Acid Bath Fumes • Chemical Odours • Gravitational settlers • Cyclonic collectors • Bag filters Techniques for Air • Wet scrubbers Emission Control • Electrostatic precipitators • Adsorption towers • Adsorption columns

  19. Effluent from Effluent from Process Domestic Process Domestic Utilities (e.g. Utilities (e.g. Effluent Effluent Effluent Effluent cooling etc.) cooling etc.) Degritting / Selective segregation for screening and recovery / detoxification Heat Recovery equalization Optional Return Equalization / effluent Equalization / Neutralization Neutralization Thickener / Thickener / Clariflocculation Clariflocculation Filtration Filtration Biological treatment Biological treatment aerobic / anaerobic aerobic / anaerobic Disposal Disposal Optional Tertiary treatment Tertiary treatment For recycling Wsatewater Management

  20. Industry sector: Food Processing ( dessicated coconut production) Size: Medium scale Push Factor: Serious environmental non- compliance due to very high levels of Biological and Chemical Oxygen Demand (BOD and COD). Measures: Utilization of 80,000 liters of wasted coconut water through a recovery process to produce a commercial drink; improvement of operational practices. Productivity benefits: Profitability due to new by-product; Increase in production of dessicated coconut. Economic benefits: Annual savings of US $ 370,000 due to increased production; treatment cost savings of US $ 3700 per year. Environmental benefits: Regulatory compliance possible due to reduction in effluent BOD by 50%. Example of Wastewater Management Peter Paul Philippines Corporation, Philippines

  21. Solid Waste Management

  22. Lower production costs through efficient resource utilization Reduction in production cost Reduce environmental impact Achieve higher performance Improve product performance CONVENTIONAL PRODUCT DESIGN DESIGN FOR ENVIRONMENT Design for Environment

  23. Design for Environment (DFE)

  24. DfE for TV sets • Reduced the number of materials used; • Plastic parts marked with the symbol of plastic to assist recyclers in identifying the parts; • Water based lacquers for finishing; • Snap and slide connections to facilitate easy disassembly; • Only a small part of the TV cannot be recycled. DfE for monitors Take Back • “take back” label part of every SONY monitor sold in Germany. DfE for loudspeaker cabinets • Cabinet for a new line of speakers is made out of recycled tetrapak cartons; • Better sound quality. Design for Environment -Illustration from SONY

  25. Life-Cycle Assessment Goal definition and Scope Inventory analysis Process flow chart; data collection; system boundary defined and data processing Impact Assessment Classification and characterization of effects of resource use; valuation Improvement Assessment Reporting; evaluation of the need and opportunities to reduce impact

  26. Establishment of the Life Cycle Assessment Society of Japan in 1995 with the support of the Keidanren and the Ministry of International Trade and Industry. Almost all industries have assisted in its activities. The basic premise is that product design should take LCA and environmental advantage into account and life cycle engineering approach should be adopted to maintain sustainable development. MANUFACTURING using clean technology Renewable reduced resources UTILIZATION Durable, repairable and necessary products Base Materials MINIMAL WASTE Cycle1: Waste prevention, long life products Cycle 2: Waste reduction, recycling of useful material Life-Cycle Assessment - Illustration from Japan

  27. Three basic principles of Green Purchasing • Consideration of product cycle GREEN PURCHASING • Management policies and practices regarding Green Purchasing • Availability of eco-related information to evaluate products manufacturers and distributors Procurement of safer eco-friendly materials, technology etc.by the producers Green Purchasing is at two levels Consumers seeking ecofriendly products Green Purchasing

  28. GP Techniques, Cost and Level of Efforts Cost Design for Environment and Level Process and Equipment Change Pollution Control of Effort Input Material Changes Resource Conservation Recycle, Reuse and Recovery Improved Operating Procedures Housekeeping (5S) and 7 Wastes GP Techniques GP Techniques, Cost and Level of Effort

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