Cp gp day02 session 8 waste cause analysis & cp techniques2012
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Transcript of Cp gp day02 session 8 waste cause analysis & cp techniques2012
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Waste Cause Analysis and CP Techniques
Samantha KumarasenaDeputy DirectorNational Cleaner Production Centre, Sri Lanka
05/03/2023 1Samantha Kumarasena
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Option generation
An organized, participative activity!
Brainstorming is a good tool!!
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Cause Analysis (Reasons for Waste)
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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
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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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Choice & Quality of Input Material
• low quality• Impurities• Composition• Size of material• Cleaning requirement• Toxicity / hazardousness
IS THIS THE BEST RAW MATERIAL?
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Choice of Production Technology
Obsolete technologies Available technologiesModern technologies Appropriate technology
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Obsolete equipment Absence of indicator
instruments Improperly working
controllers
Technical Status of Equipment
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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
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Product Specification
Dimensions (size) Colors Surface finishPackaging
requirementPerformance
properties
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• Inefficient process controls
• Cleanliness / housekeeping
• Correct load / parameters• Frequent down time• Power failures• Improper maintenance /
lack of maintenance planning
Operation & Maintenance
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• Lack of production planning
• Wrong information• Inadequate information• Inventory management• Absence of record
keeping culture
Management Planning & Information Systems
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• Attitudes• Carelessness• Short cuts• Incomplete work
Personal Skills & Motivation
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Cleaner Production techniques Input substitutionGood housekeepingBetter process control Product modification Equipment modification Technology change On-site recovery/reuse Creation of useful by products
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Classification of CP Techniques
CP TECHNIQUES
PRODUCT MODIFICATION
RECYCLING
Onsite recovery and reuse
Creation ofUseful by-products
SOURCE REDUCTION
Process
Change
s
GoodHouse-Keeping
InputMaterialchange
Better process control
Equipment
modification
Technology change
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Good housekeeping
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Good Housekeeping
Take appropriate operational actions to prevent:
- leaks- spills
Formulate & enforce to practice appropriate operational instructions
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• 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
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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)
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Input substitution
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Input SubstitutionSubstitute input materials where
ever possible with- less toxic materials- renewable materials- materials with longer
lifetime
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• 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
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Better process control
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Better Process ControlModify:
- operational procedures- equipment instructions
Process record keeping in order to run the processes more efficiently and at lower waste and emission generation rates
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Improving process controls – e.g.
• 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
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Equipment modification
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Equipment ModificationModify the existing production
equipment and utilities to- run the processes at higher
efficiency- lower waste and emission
generation ratesRepair faulty equipment to reduce
losses and rejectsReplace obsolete equipment or parts
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• 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
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Technology Change
Change the product & process technology in order to minimize waste and emission generation and optimize the resource efficiency
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Technology change
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Product modification
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Product Modification
Modify the product characteristicsin order:
- to minimize the environmental impacts of the product during or after its use (disposal) - to minimize the environmental impacts of its production
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Product Modification
Raw Material Extraction Manufacture Transportation Use End-of-life
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On-site recovery/reuse
Water, Packaging, containers !!!!
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On site Recovery/Reuse
Reuse/recovery or recycling of the wasted materials in the same process or outside, for same or another application
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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
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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
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Creation of useful by products
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Your Questions
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?
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Thank you!
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