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These terms may be easier to understand with an example. A very straightforward and simple example involves a company that receives incoming raw material in cardboard packaging. Suppose the company is a metal stamping plant for the automobile industry. Below are situations where the company could apply the hierarchy: Eliminate the waste through engineering process modi cations. For example, the company could work with the vendor to eliminate the use of cardboard containers and switch to returnable plastic containers. This is the most preferred method and completely eliminates the problem of waste management and need for recycling. 2 In-process recycling. If waste is generated, develop a separation method to use the waste as a raw material for the same process. For example, the company could collect the metal scrap from the stamping process and attempt to process it again in the same process. 3 On-site recycling. If waste is generated, develop a separation method to use the waste as a raw material for another in-house process. For example, the company could use the cardboard packages to ship their own nal products.

1. Does your company have a written environmental policy Yes No If yes, does this policy include solid waste prevention Yes No 2. Is there a solid waste prevention program in place Yes No Is there a quality management program in place Yes No Is there an employee involvement program to improve operations Yes No If yes, please explain your employee involvement program: ____________________________________ _ _______________________________________________________________________________ ___ ___ 3. What are the priority areas where solid waste prevention efforts should be focused _____________ _ ____ ______________________________________________________________________________ ____ _ __ _______________________________________________________________________________ _____

FIGURE 5-5.

4. Please indicate any barriers to the procurement of recycled materials: Inadequate performance Corporate policy Engineering specifications Price Other __________________________________________________________________ 5. Please indicate any current procurement policies used by your company: Recycled content products Reusable containers Recyclability of materials concerns Environmental friendliness Minimum packaging Other __________________________________________________________________ Comments:

2

PROCESS DESCRIPTION: COMPANY/LOCATION: RECORDED BY: DATE:

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Core processes must be broken down into enough detail to understand, monitor, manage, and analyze performance. As a general rule, processes must be described using the three general steps to create a process map dissussed in the previous paragraph before improvement teams are able to deal with them adequately. Figure 8.14 shows a data collection form that can be used when creating the process map and owchart. Figure 8.15 shows the process charts that were created during the case study example. The primary purpose of the production analysis is to determine annual production rates (or capacities) and related cyclical patterns. These production rates will relate directly to the amount of waste generation by each cycle, whether the cycle is a week, month, or quarter. Figure 8.16 shows a capacity model worksheet that could be used to aid in this process. To calculate the capacity, the following information will be needed:

develop a detailed action plan that will achieve the desired objectives. This plan must be designed to accomplish the objectives and targets well not merely doing them to cross them off a list. Thinking about performing a task well as opposed to just doing it leads to a different set of actions and requirements. Critical resources required to complete the task well must be identified. This may include a commitment from engineering to use standard parts instead of unique parts for designs, a commitment from key suppliers to provide leadership in their areas of expertise during product development, or commitment from operations to gather information about the performance of parts and share it with the purchasing department to get accurate measures of suppliers performance.

Paste mixing and pasting material flow diagram Raw materials Expander fiber water acid lead oxide Grids paste expanded grids plastic sheeting Waste streams

Ef ciency (versus cycle time) Time available Utilization (uptime of the machine)

Some 9295 106 miles away from us, or for those working in metric 1496 106 km away from us is the sun (Figure 2-1) To imagine the magnitude of this great distance, think that light, which travels at an amazing 299,792,458 meters per second, takes a total of 831 minutes to reach us You might like to do a thought experiment at this point, and imagine yourself traveling in an airplane across America At a speed of around 500 miles per hour, this would take you four hours Now, if you were traveling at the speed of light, you could fly around the earth at the equator about seven and a half times in one second Now imagine traveling at that speed for 831 minutes, and you quickly come to realize that it is a long way away.

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