Module 7

Application of GP Tools to achieve

EMS
Getting Started
Getting Started
Planning
Planning
Planning
Generation and
Evaluation
of GP Options
Generation and
Evaluation of
GP Options
Generation and
Evaluation of
GP Options
Sustaining GP
Sustaining GP
Monitoring and
Review
Monitoring and
Review
Implementation
of GP Options
Implementation of
GP Options
Implementation of
GP Options
I
II
III
IV
V
VI
Comparison of GP & EMS Methodology
Getting Started
Commitment
Planning
IER & Planning
Generation and
Evaluation
of GP Options
Generation and
Evaluation of
EMS
Documentation
Sustaining GP
Certification
Monitoring and
Review
Auditing and
Review
Implementation
of GP Options
Implementation of
GP Options
Awareness
Creation
I
II
III
IV
V
VI
ISO
14001
GP Methodology
EMS Methodology
HOW GP I S DI FFERENT FROM
I SO 14001 (EMS)
GP GOES BEYOND COMPLIANCE
EMS IS DOCUMENT ORIENTED WHILE GP IS
PRACTICE ORIENTED
EMS DOES NOT INCLUDE HEATH AND SAFETY
ASPCTS WHILE GP INCLUDES
Green Productivity-Methodology
Barriers to Commitment of Top Management
Attitudinal barriers
Information related barriers
Technical
Financial barriers
Green Productivity-Methodology
Means of Achieving Commitment of Top Management
Awareness programs
Visits to Industries that have
successfully implemented GP
Tools, techniques & methodologies
used in conjunction with the framework
Management
Engineering
Environmental
Economic etc.
Green Productivity-Methodology
GP Methodology- Components:
Tools for GP
1. Form a GP Team
2. Walk through survey &
information collection
3. Identification of
problems & causes
4. Setting Objectives &
Targets
5. Generating GP
Options
6. Screening &
Evaluation of GP
Options
7. Preparation of
Implementation Plan
Tools for GP
Methodology
STEP - I: GETTING STARTED
CHECKLISTS, TALLY CHARTS
PLANT LAYOUT
FLOW CHARTS & PROCESS FLOW DIAGRAMS
MATERIAL BALANCE
BENCH MARKING
STEP - II: PLANNING
BRAINSTORMING
CAUSE & EFFECT ANALYSIS
CRITICAL PATH ANALYSIS
ECO MAPPING
GANTT CHART
STEP - III: GENERATION & EVALUATION OF GP OPTIONS
BRAINSTORMING
COST BENEFIT ANALYSIS
ECO MAPPING
FAILURE MODE & EFFECT ANALYSIS
PARETO CHART
PROGRAMME EVALUATION REVIEW TECHNIQUE
8. Implementation of
selected Options
9. Training, Awareness
building & developing
competence
10. Monitoring &
Evaluation of Results
11. Management Review
12. Incorporate changes
13. Identify/additional
problem areas for
continuous improvement
STEP - IV: IMPLEMENTATION OF GP OPTIONS
TRAINING NEED ANALYSIS
TEAM BRIEFING
RESPONSIBILITY MATRIX
CRITICAL PATH ANALYSIS
GANTT CHART
SPIDERWEB DIAGRAMS
STEP - V: MONITORING & REVIEW
SOLUTION EFFECT ANALYSIS
ECO MAPPING
FAILURE MODE & EFFECT ANALYSIS
CHARTS (CONTROL, TALLY ETC.) / SPIDERWEB DIAGAM
STEP - VI: SUSAINING GP
SOME OF THE TOOLS ARE REPEATED HERE, SINCE THE ACTIVITIES ARE
LOOPED BACK TO THE PREVIOUS STEPS
Green Productivity-Methodology
GP Prerequisite: Commitment & Involvement
of Top Management
Task based involvement of Top Management is critical
Task 1: Team Formation
Task 4: Setting Objectives & Targets
Task 7: Formulation of Implementation Plan
Task 8: Implementation of selected options
Task 11: Management Review
Task 12: Incorporate changes into organizations
system of management
How do we Manage Green
Productivity?
Law of Ecology -
Nothing comes fromnowhere
Everything comes fromSomewhere
Nothing ever goes away
Everything goes somewhere
Raw Materials
Energy
Safer Products
and By-products
Reduced Wastes
& Off-spec products
Efficient
Production
Process
Green Productivity - Doing more with less
Environmental
Protection
Green Productivity
Sustainability is the vision or driving force for Green
Productivity.
Role of Small and Medium Enterprises is an essential factor
to sustainable development in the Asian region.
Reduced
inputs
and less
toxic
materials
Profits
Costs
Reuse
Recycle
ADOPTING GP PRACTICES DOES NOT
REQUIRE
- A NEW SET OF SKILLS
- IT IS APPLICATION OF
* ENVIRONMENTAL
* MANAGEMENT &
* PRODUCTIVITY TOOLS,
TECHNIQUES
GREEN PRODUCTIVITY
GP Tools & Techniques :helps in
Data generation
Interpretation &
Presentation
A Tool is defined as a mean while
Technique is a process to achieve GP.
GP Tools & Techniques
Brainstorming
Material Balance
Cause-effect Analysis (Fishbone Diagram
5 S & 7 Wastes Techniques
Eco-maps
Process Flow diagrams, etc.
TOOLS FOR GP STEPS
Pareto Anal ysis
Material Balance
Flow Chart
FMEA
Check List/Check Sheet
Control Chart
Cost:Benefit Anal ysis
Eco-Mapping
Critical Path Anal ysis
Gantt Chart
Cause-effect Analysis
Benchmarking
Brainstorming
GP TOOLS
GP STEP
I II III IV V VI
Team Formation
Team should be dynamic and involving
Members on relevance and need basis
Can be a core team with sub-teams in large
organizations
Core team to supervise the overall GP program
and sub team to assist core team on specific tasks
Team leader should be dynamic, open minded
and versatile
For a Large Organization For an SME
Sub
Team 1
Sub
Team 2
Sub
Team 3
External
Consultant
External
Consultant
Top
Management
Core
Team
Overlap of the circles indicate the extent of common interaction
Dept. 1
Dept 2 Dept 3
Note: In the case of SMEs Top
Management will have more
participation in the Core Team
Note: In large organizations, finance, administration
section, utilities and stores are also depts.
Core
Team
Top
Management
Team Formation
One way to avoid such occurrences is by having one-to-one meetings and
asking the right questions to the right people so as to ensure that the answers
obtained are valid and reliable
Documented
information (such as in
operating or do-how
manuals)
Actual practices in
operations on the
shopfloor
GP
Team
Production
personnel
Based on norms /
guidelines
No
communication
Different than
One-to-One Meetings to aid
Information Collection
Brainstorming
Idea 1
Supporting
Idea 1
Extension
to Idea 1
Opposing
Idea 1
Idea 2
Idea 3
based on 1
and 2
Supporting
Idea 3
Supporting
Idea 3
Idea 4
Group technique for generating ideas - creative
Eco-maps
N
ETP
Finished
Product Storage
Raw
Material Storage
Manufacturing Process Line
Prod. Capacity 10,000 product items per day
Administrative
Block
Quality Control
and Final Packaging
Proposed Production line of capacity 10,000 product items per day
Utilities
Laboratories
Toilet Block
30m
Stack for
emissions
C
e
n
t
r
a
l

H
i
g
h
w
a
y

0
5
Main
Entrance
100m 100.5m 101m
Municipal
Water
Supply
Entry Exit
0 5
metres
Scale
101.5
m
Plant Layout
Process
Inputs
Outputs
Wastes
Raw materials
Energy
Water
Chemicals
Air emissions
Effluents
Solid waste
Heat losses
Off-spec products
Byproducts
Products,
Useful
byproducts
Material Balance
Make Material & Energy Balance
Data sources:
# on-site measurements
# purchase and sales records
# production records
Assessment of data quality:
# reliability
# accuracy
# representativeness
Brainstorm individual
activities
List activities in order
Draw the Flowchart
Is it
complete
No
Agree
changes
Test the flowchart
Unsatisfactory
Results
Flow Charts
Process Flow Diagram
A Process Flow Diagram should address:
All processes/operations in proper sequence
Inputs and outputs of each process stage
Points of measurements and quality control
Releases or emissions (air, water and solids) to be
clearly shown
Separate PFD may be required for special process
variations (e.g seasonal)
Identification of Problems and
Causes
Processes
Water
Chemicals
Energy
Labor
Costs
Waste Generation
Production
Capacity Utilization
Product Quality
Market Demand
And, Causes could
be so many.... !!!
How to identify them?
Problems Could be with
IDENTIFICATION OF PROBLEM
Cause Effect Analysis using Fishbone Diagram
Tools for Generation and
Evaluation of GP Options
Brainstorming
Checklists
Cost-Benefits analysis
Profitability Analysis
Simple Payback
Internal Rate of Return
[IRR> Cost of Capital]
Net Present Value
[a positive NPV is desired]
Generation of GP Options
GP
Options
Brainstorming
Ishikawa diagram
GP Techniques
GP Tools
GP Techniques, Cost and Level of Effort
Cost
and
Level
of
Effort
Process and Equipment Change
GP Techniques
GP Techniques, Cost and Level of Efforts
Design for Environment
Input Material Changes
Resource Conservation
Recycle, Reuse and Recovery
Improved Operating Procedures
Housekeeping (5S) and 7 Wastes
Pollution Control
The top management plays a critical role in the The top management plays a critical role in the
implementation of certain tasks of the GP methodology implementation of certain tasks of the GP methodology
Task 1
Task 1
Task 4
Task 4
Task 7
Task 7
Task 8
Task 8
Task 11
Task 11
Task 12
Task 12
Top
Management
Top
Management
Commitment and Involvement of Top Management
An important Pre-requisite
Evaluation of Options
Technical Feasibility
Short term/Long term
Cost/Returns
Risk
Quantity
Scale of Implementation
Cumulative Impacts
To Evaluation
Section
Economical
Technically
sound
High returns
SCREEN
SCREEN
High Cost
High Risk
Complicated
Technology
GP Options
Screening of GP Options
Preparation of Implementation Plan
Building GP
Option
Implementation
Plan
Issue
Technical
Feasibility
Economic and
Financial
Feasibility
Non-quantifiable
benefits
Sustaining the
options
Checklist
Any Risk?
Any Shortfalls?
Are these in line
with objectives &
targets
Can the options
be sustained?
Strategies while building
implementation plan
Lab studies, Pilot trials,
external consultants
External sources, Green
Funds, Doing in phase
Staff, worker and
neighborhood
communication
Training and awareness
building, Establishment of
Management System
GP Options
New Equipment
New Material / chemical
Change of Supplier
Modification in existing process
Change in operating practices
Suppliers, Installation space,
Cost (capital, operating),
personpower requirement
Suppliers, Installation space,
Cost (capital, operating),
personpower requirement
Suppliers, Quantity, Cost, effects
on other processes, safety sheets,
transport
Suppliers, Quantity, Cost, effects
on other processes, safety sheets,
transport
New Suppliers, reliability, costs,
effect on market, other clients of
the new supplier
New Suppliers, reliability, costs,
effect on market, other clients of
the new supplier
Installation, fabrication,
commissioning requirements,
costs
Installation, fabrication,
commissioning requirements,
costs
Effects of new practice, changes
due to new practice, time
scheduling
Effects of new practice, changes
due to new practice, time
scheduling
Option Specific Information required
Collection of Option Specific Information
Implementation of Selected Options
Trial and small scale implementation
Regular meetings and trouble shooting sessions
Follow-up and Accountability
Allocate resources and schedule the pilot implementation
Management support needed
Review and refinement of options
Training, Awareness Building and
Developing Competence
Assessing training needs
Selecting suitable programs, methods and material
Preparing a training plan (5W1H))
Implementing training programs
Tracking and recording training programs
Evaluating training effectiveness
Improving training program as needed
ISO 14001 ENVIRONMENT MANAGEMENT SYSTEM
MODEL
GP/ Environmental
Policy
Implementation
and Operation
Planning
Checking and
Corrective
Action
Management
Review
Continual
Improvement
Application of GP
GP has been applied to a number of industries and
institutions in APO member countries cut across industrial
sectors ranging from Chemical, Electroplating, Community,
Tannery, Dyes & Intermediate, Edible Oil, etc.
In addition, GP has also been adopted by service sector
such as community in Vietnam and local bodies in India
GP helps in achieving ISO 14001 by applying GP Tools &
Techniques.
Some of the industries & service sectors such as Edible Oil,
Local Body in India have received ISO 14001 by adopting GP.
Summary
GP methodology
GP Tools & Techniques
Application of GP
Achieving ISO 14001