ABC Manufacturing ISO14001 Manager/Supervisor’s Training

ByJames Charles, PESenior Consultant

EHS Management Strategies, LLCwww.ISO14001-Training.com

James.Charles@iso14001-training.com

Why are we here?

• Get ready for ABC’s ISO14001 Registration Audit

• Provide managers/supervisors an overview of: ISO14001 Standard ABC’s Environmental Management System (EMS)

• Define the Manager/Supervisor’s responsibility for the EMS and during the audit

Annual ReviewBoss: We’d like to develop your leadership skills so we are putting you in charge of the ISO 14001 Project

Why get ISO14001 Certified?

• Our customers told us to!! JCI Others – GM, Ford, DiamlerChrysler, other

• Minimize ABC’s impact on the environment• Improve ABC’s Environmental Performance• Reduce operational costs• Reduce risk of MDEQ/EPA enforcement

Why Do We Need EMS? Increased Environmental Regulations

0

50,000

100,000

150,000

200,000

Year

Manhours

1970 Clean Air Act (CAA)1972 Clean Water Act (CWA)

1977 CAA & CWA

1978 Toxic Sub Control Act (TSCA)

1980 Resource Conservation & Recovery Act (RCRA)1982 Superfund

1984 RCRA1985 TSCA

1987 CWA1987 Community Right to Know Act

1990 Pollution Prevention Act1990 CAA

1997 CWA1997 RCRA

Periodic Monitoring & CAMChem Use InventoryISO 14000Comm Right to KnowCAA

Manager/Supervisor’s Responsibility

• Know your EMS Policy Significant Aspects (especially in your area) Procedures/Work Instructions

• Communicate to employees• Training• Keep records• Encourage employee involvement

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Everyone Impacts the Environment

• General trash• Spent aerosol cans• Welding fumes• Waste paint & solvents• Automotive exhaust• Paint spray emissions• Car wash water

• Compressed air use• Electricity• Natural gas• Wastewater discharge• Storm water runoff• Storage tanks• Contaminated land

What is EHS Performance?

Metric Measurement Goal

Injuries/Illness Injuries Decrease

Near Miss Reports Report Increase

Hazardous Waste Pounds Decrease

Recycling Pounds Increase

Solid Waste to LF Tons Decrease

Electrical Usage Kilowatts Decrease

Management Systems Magic

• 1st – Write down everything you do• 2nd – Keep track of everything you do• 3rd – Spend time checking up on your self• Lastly – sit around and talk about what your doing

EMS Pixie Dust

Improved EHS Performance

Certified Management Systems

Registration to international standard by 3rd party registrar.

• Quality – ISO 9000, QS9000, TS16949• Environmental – ISO14001:2004• Health & Safety – OHSAS18001

Continuous ImprovementP

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Time

Continual Improvement

Assurance (quality/environment/health and

safety)

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Value of Third Party Certification

• Yes, it costs money!!• Independent review of your processes• Keep system active through surveillance

audit process• Demonstration to external stakeholders

– Customers, Bankers, Insurance Companies, Regulatory agencies, Employees

• Good Public Relations– Michigan Clean Corporate Citizens

ISO 14000

• Overview of ISO 14000 Series Standards• Major Groups of Standard• ISO 14001 & 14004 - EMS• ISO 14010 to 14015 - Environmental Auditing• ISO 14031 - Environmental Performance Evaluation (EPE)• ISO 14021 - 25 - Environmental Labeling• ISO 14040 - 43 - Life Cycle Assessment (LCA)• ISO 14050 - Terms and Definitions• ISO 14060 - Environmental Aspects in Product Standards

Origin of ISO 14001

• Origin of ISO 14001 Environmental Management System (EMS)

• ISO is a Geneva-based organization of over 100 countries

• ISO International Organization of Standards• ISO 9000 (Quality Management Systems) was the

first "Management Systems" standard and set the template for ISO 14000

• 1996 - Final International Standard - ISO 14001 and 14004

ISO 14001:2004

• Original ISO 14001:1996• Finalized November 15, 2004• 18 Month Transition Period• No new requirements – just provides

clarifications • Audits after March 25, 2005 under new

standard

Similarities between ISO 9001 and ISO 14001

ISO 9000 (TS 16949) ISO 14001 Quality Policy Environmental Policy

Organization Structure and Responsibility

Management Representative Management Representative Requirement under Structure and Responsibility

Training Training, Awareness and Competence

Document and Data Control Document Control

Quality System Procedures, Contract Review, Design Control, Purchasing, Process Control, Handling, Storage,

Packaging, Preservation and Delivery, Servicing

Operational Control

Inspection and Testing, Control of Inspection, Measuring and Test

Equipment

Monitoring and Measurement

Corrective and Preventive Action Non-Conformance and Corrective and Preventive Action

Control of Quality Records Records

Internal Quality Audits Environmental Management System Audits

Management Review Management Review

CERTIFICATION TRENDSCERTIFICATION TRENDS

ISO 14001:2004 ELEMENTS

4.1 GENERAL REQUIREMENTS

4.2 ENVIRONMENTAL POLICY

4.3 PLANNING

4.4 IMPLEMENTATION AND OPERATION

4.5 CHECKING AND CORRECTIVE ACTION

4.6 MANAGEMENT REVIEW

Environmental Management System Requirements

4.1 GENERAL REQUIREMENTS4.2 ENVIRONMENTAL POLICY4.3 PLANNING

4.3.1Environmental Aspects4.3.2 Legal and Other

Requirements4.3.3 Objectives, Targets, and

Environmental Management Programs

4.4 IMPLEMENTATION AND OPERATION

4.4.1 Structure and Responsibility4.4.2 Training, Awareness and

Competence 4.4.3 Communications4.4.4 EMS Documentation

4.4.5 Document Control4.4.6 Operational Control4.4.7 Emergency Preparedness4.5 CHECKING AND CORRECTIVE

ACTION

4.5.1 Monitoring and Measurement4.5.2 Evaluation of Compliance4.5.3 Nonconformance, Corrective and

Preventive Action4.5.3 Records4.5.4 EMS Audit4.6 MANAGEMENT REVIEW

a) Establish a Policy Appropriate to Activities/Products/Services

b) Commit to Continual Improvement and Prevention of Pollution

c) Commit to Legislative and Other Requirements

d) Set Framework for Objectives and Targets

e) Documented, implemented, and maintained

f) Communicate to All Stakeholders

g) Available to the public

4.2 Environmental Policy

ABC’s Environmental PolicyIt is the policy of ABC, Inc. a manufacturing company which produces mechanism type

assemblies for the automotive, furniture, and other industries to be a responsible corporate citizen in protecting the environment. In support of this policy, ABC is committed to:

· Meeting and, where possible, exceeding applicable environmental regulatory, legal and other requirements.

· Striving for continual improvement in environmental performance.· Minimizing the creation of waste, pollution and adverse impacts on the

environment.· Managing processes, materials and people to reduce environmental impacts

associated with ABC Manufacturing activities.This Environmental Policy Statement applies to ABC manufacturing activities, whether

directly or indirectly involved with the manufacture of automotive components. It is communicated to all persons working for or on behalf of ABC and is available to the public.

As an integral part of this Environmental Policy Statement, ABC pledges to implement and operate an ISO 14001 environmental management system that identifies and addresses the significant environmental aspects of plant operations.

Goals are set by the ISO 14001 team and reviewed annually by the undersigned management.

Policy Commitments

• Prevention of Pollution

• Improve Continuously

• Comply with Legal Requirements

Remember “PIC”

Prevention of Pollution

Pollution Prevention = Controlling Significant Aspects

Exterior HousekeepingPreventing Spills

So yes, conserving electricity and recycling paper is “Pollution Prevention”

4.3.1 Environmental Aspects/Impacts

4.3.2 Legislated and Other Requirements.

4.3.3 Objectives, Targets, and Environmental Management Programs (combine 4.3.3 & 4.3.4)

4.3 Planning (“PLAN”)

Activity / Aspect / Impact

An Environmental Aspect refers to an element of our activities, products or services which can have a beneficial or adverse impact on the environment (i.e., it is the cause of an impact such as an emission).

A Significant Impact refers to the change which takes place in the environment as a result of the aspect (i.e., it is the effect of an emission such as the contamination of water).

Significant Environmental Aspect

A significant environmental aspect is an environmental aspect that has or can

have a significant environmental impact…….

These are ABC’s most significant activities that

can impact the environment

Key Question:

What would happen if you lost control of the aspect?

Under normal operating conditions?Under start-up conditions?Under emergency conditions?

Aspects/ Impacts

Determining SignificanceIdentify all

Environmental Aspects & Impacts

Evaluate for its Significance

Significance Criteria

Minor Aspects

Keeping Records

Significant Aspect

Operational Control

(CONTROL ALL)

Objectives & Target Setting

(IMPROVE Some)

ABC’s Significant Aspects

• Electrical Usage• Cardboard Usage• Recycling• Oil Usage• Stormwater Run-off

• Who determined these? We did!!

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Objectives and Targets (Improvement Goals)

• Set Objectives and Targets to Prevent or Minimize the Impacts Quantifiable, Time-bound, Accountable Detailed Plan(s) to Accomplish Objectives & Targets must be

Developed• Incorporate into Plant Business Plan

Gives Environmental the Same Level of Visibility and Attention as Other Issues

Establish Overall "Objectives” for the Reduction or Elimination of Environmental Impacts - Increases Accountability

• Improve Business & Environmental Performance by Meeting Objectives.& Targets

Environmental Management Programs (Action Plans)

• Program For Achieving Objectives & Targets

• Every Objective & Target Must have a EMP• EMP Must Include:

Responsible Party Means to Achieve Objectives & Targets Time-frame

• Update If There Are New or Modified Site Activities

ABCs Environmental Goals

• Reduce Electrical Usage

• Reduce Cardboard Usage (More returnables)

4.4.1 Define Roles, Responsibilities and Authorities4.4.2 Identify Training Needs, Ensure Awareness and Assess

Competence4.4.3 Establish Procedures for Communicating with All

Stakeholders4.4.4 Establish and Maintain Procedures for Document Control4.4.5 Establish Procedures for Document Control4.4.6 Establish Operational Control Procedures4.4.7 Establish Procedures for Emergency Response

4.4 Implementation & Operation (“DO”)

Environmental Management Representative

• Oversees the Day to Day Environmental Operations

• Coordinates Environmental Matters as Appropriate• Champions EMS Implementation • Should Report Directly to Plant Manager

ABC’s EMR• Environmental Management Representative

Lori Smith• EMS Team

Operations Mgrs., Lean Coordinator, Facilities Supervisor, QA Mgr., Eng. Mgr., Facilities Supervisor, Director of Operations

• Responsible for Environmental Compliance Mickey Mouse - Facilities Sup.

• General Environmental Awareness Training Covers EMS Policy, System, Environmental Aspects & General

Env. Awareness All Employees (Required by ISO 14001) Integrate with Routine Meetings (Monthly Safety Talks,

Townhalls, Department Meetings) and Other Awareness Techniques

• Work Station / Operational Control Training Required for All Significant Activities Aware of the Significant Impacts of Their Work Activities and

the Environmental Benefits of Improved Personal Performance Key area for Managers/Supervisors

Training

• Regulatory - Mandated Functional Environmental Training Training You Should Already be Doing - Current Requirement Training Required by Law (RCRA, SPCC, etc.) Specific Employees Required by Their Job Assignment to

Have this Training

• Emergency Plan Training Training You Should Already by Doing - Current Requirement Training Required by Corporate and (possibly) Law All Employees (Some Employees May Require More Detail

Training)

Training

• Internal Auditor Training Develops Skills Needed to Prepare For & Conduct an

Effective EMS Assessment One Time Training Requirement

• Contractor / Supplier Orientation EMS Fundamentals and Facility Environmental Policy Selected Contractors Whose Work Could Affect the

Facility’s Environmental Regulatory Status or Performance (ie., Paint Supplier, Waste Hauler, etc.)

Key area for Managers/Supervisors

Training

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System Documents

SYSTEMPROCEDURES

OPERATIONALPROCEDURES

WORKPRACTICES

POLICY

ASPECTS

OBJ. & TARGETS

PROGRAMS

ORGANIZATIONALCHART

ROLES &RESPONSIBILITIES

LEGAL REQUIREMENTS

TRAINING MATRIX

MASTER DOCUMENT

LIST

MASTER RECORDS

LIST

4.4.6 Operational Control

• Required for all significant aspects (Activities)• Procedure/Work Instruction Designed to

“Control” the activity• All people involved in the activity need to be

trained and this should be documented

ABC’s Operational Control

Significant Aspect Control

Electrical Usage Procedure/EMP

Cardboard Usage Procedure/EMP

Oil Disposal Procedure

Stormwater Run-Off Procedure, SWPPP, Permit

Recycling Procedure/Signage

4.4.7 Emergency Preparedness

• All managers/supervisors need to know what to do in the event of an emergency Spill, Fire, etc.

• Auditor will ask manager/supervisors and employees how they would respond to an emergency Could be as simple as “I’d notify my manager and leave the

area”• Standard requires that emergency preparedness plans

be review after any incedint• Emergency Preparedness plans need to be tested

annually

4.5.1 Measurement - Maintain and Calibrate Monitoring Equipment

4.5.2 Evaluation of Compliance4.5.3 Nonconformity, corrective (CARs) &

preventative actions (PARs)4.5.4 Control of Environmental Records4.5.5 Establish and Maintain Internal EMS Audits

4.5 Checking an Corrective Action (“CHECK”)

ABC’s Internal EMS Auditors

• Joe• Kathy• Beth• Mike

4.6 Management and Review (“ACT”)

• Establish Procedures for Senior Management Review of EMS

• Contemplate Changes to the System• Contemplate Actions to Effect Changes• Keep the System Relevant to Your Needs• Keep Minutes of Review Meetings

Implementation Process• Step 1 – Implementation Planning• Step 2 - COMMUNICATE• Step 3 – Aspects / Impacts Evaluation• Step 4 – Draft Objectives and Targets, and EMP’s• Step 5 – Write Environmental Policy• Step 6 – Identify Training Needs and Develop Training Plan• Step 7 – Write EMS Procedures and Operational Control• Step 8– Implement Document Control• Step 9 – Internal Audits• Step 10 - Management Review• Step 11– Registration Audit - Celebrate

ABC’s ISO14001 Audit

• Registrar NSF• March 27 – Document• April 15 – Pre-Assessment• May 12-15 – Registrations Audit• 60 days to closeout corrective actions• ISO14001 Certification Awarded

Prior to the Audit

• Review Policy/PIC• Know Significant Aspects (especially in your

area)• Review Environmental Goals• Review Procedures/documentation• Let employees know about audit• Review information with employees• Quiz Employees

During the Audit

• Greet Auditors has they pass through plant• Answer questions directly and completely• Do not hide information• REMEMBER

The auditor has to find things to write up as CARs (they feel it is their job)

The auditor wants to approve ABC for registration

Now what do I do?• Get to know your EMS

Policy – Remember PIC Procedures Significant Aspects Improvement Goals (Environmental)

• Communicate Policy/PIC to all employees• Conduct General Awareness Training• Give employees overview of what to expect for

the Audit

EHS Management Strategies, LLC

• ISO 14001 and OHSAS Certification Support Training and Procedure Writing

• Internal Auditing – ISO14001, TS16949, OHSAS18001

• SPCC and SWPPP Plans / Certification• DOT / RCRA (hazardous waste) Training –

49CFR172 and 40CFR265• Spill Response Training• Compliance Auditing (Legal & other)• Air & Water Permitting / Reporting

Presented by:

James Charles, PE, CPG

Principal Consultant

EHS Management Strategies

(616) 666-5490

www.ISO14001-Training.com

Call us today!!