The Good The Bad The Ugly

Developing & Implementing Quality

Management Systems:  Overcoming the

Challenges.

To Be Discussed…

• Focus on Biodiesel’s BQ9000 Standard– Producer, Marketer & Labs

• Implementing at operating level• Challenges with a new standard &

young industry• Information on the current industry

History of BQ9000

• Created in coordination with OEM’s (operating equipment manufacturers) & National Biodiesel Board

• Effort to eliminate same problem Ethanol had in the 70’s

• NBB created National Biodiesel Accreditation Commission, hired 3rd party auditors & review applicants for certification

BQ9000 Standard

• Basics are same as ISO9001:2000– Control of inspection, measure & test

equipment– Document & Data Control– Records Control– Corrective & Preventive Action– Control of Nonconforming Product– Internal Audits– Quality Manual

• Quality Policy, Objectives, Management rep., Management Rev., Org. Chart

BQ9000 Standard Applies to both

– Lab• Training for lab personnel only• Verification of External Lab capabilities, BQF-1• ASTM cross check proficiency, quarterly (internal

& external labs)

– Commingling of B99/B100• Oxidative Stability & Cold Soak test (Cloud point

also for producer)• Tank Homogeneity testing

– Storage• Inactivity Testing (water & oxidative stability)

– Blending (diesel & biodiesel) & Cleanliness of tanker at loadout

BQ9000 Standard Differences

Producer• Process Change• Assign Production Lot #

– Differs from batch to continuous flow

• Storage– Procedure must note if stored

in agitated/non-agitated tanks

• Initial Consecutive 7 must past ASTM D6751, then biannually, 3 consecutive if changes to process or testing requirements

• Monthly tests

Marketer• Receipt of product

– From BQ9000 certified with COA– From Non-BQ9000, lot # must

be certified prior to off loading & commingling

• Multiple Tank Holders (must be handled the same)

• Cleanliness & Inspection of Storage Tank if changed from other use

• Blending- Diesel Bio Content, Homogeneity (storage tank & tankers, % methylester after blend

Key Words

• Corporate Procedures• Task Analysis (Work Instruction,SOP)• Drivers (Behaviors and conditions )• Leading & Lagging Indicators• Continuous Process Improvement

They Must Make It Truly Their System

• Although templates were provided from RCI…– Broke it down into departments– Established procedures in each dept.– Wrote the procedures with employee input– Reviewed & revised, sometimes more than 20

• Cross referenced to standard to ensure requirements were being met

– Ensured forms for records were developed* Some choose to include WI, some do not

Challenges & Solutions

• Challenges with Personnel– Some catch on quicker than others– Some adjust to change easier than others– Didn’t want to be held responsible for negative issues– Fear of the unknown, at the beginning

• Solutions– Excellent leadership supporting middle management &

employee group through effort & today!– Middle management embraces, understands &

communicates to employee group advantages of program

• Clearly defined, step by step procedures, rewards for above grade & ID of issues prior to finished or delivered

Quality Management for BQ9000

Core Modules• Procedure Administration

w/Audits• Task Analysis (WI)• Training Management• Observations (future)• Incident Reporting,

Investigations, Corrective Actions

• Reports• Change Request

RCI’s Web Based Program Helped

• Almost everything is customizable to the clients’ needs, with corporate over site throughout– Location, Departments– Users/ Employees & the job titles– Incidents & the info collected for the incident

(sometimes more than 100!)– Procedures & Work Instructions specific to their

facilities– Audits set by them, they determine where, when & who

• RCI supported throughout the entire process, but the client had to Implement

Current Industry

• Feedstocks– Soy– Waste Grease– Canola/Camelina– Jatropha– Palm– Tallow– Future- Algea

Current Industry

• Plants-500,000 to 110 MGY

• Most use multiple feedstocks

• Pipeline-??• Ingenuity &

Perseverance

Overcoming Challenges

• February 2009 @ 30% capacity (US is 2.69 BGY)

• Multiple commodity product• Consumer Fears

– Filter, cold weather, etc

• Govn’t Usage is increasing• B2/B5 Mandates