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SMITHFIELD PACKING COMPANY BMPsTraining Conference 2013 – Chicago, IL
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Training Conference 2013 – Chicago, IL
SMITHFIELD PACKING COMPANY BMPs
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Smithfield Packing CompanyBMPs
• Sustainability Ideations– Tar Heel
• Critical Control Point Operational Controls– Wastewater Operations
• EMS Training for Plant Managers & Senior Staff
• Weekly Environmental/Sustainability Call• Entering PMs related to Significant Aspects
in SAP
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SUSTAINABILITY
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Company E-mail
Joel Miller Smithfield Packing [email protected]
Keith Bailey Smithfield Packing [email protected]
Ruth Debrito Smithfield Packing [email protected]
Paul Wright Smithfield Packing [email protected]
Wayne Cain Smithfield Packing [email protected]
Kirby Elkins Smithfield Packing [email protected]
Frank Jackson Smithfield Packing [email protected]
Jarred Turner Smithfield Packing [email protected]
Buddy Harris Smithfield Packing [email protected]
Tom Green Smithfield Packing [email protected]
Bethany McLean Smithfield Packing [email protected]
Walter Wardlaw Smithfield Packing [email protected]
Calvin Held Smithfield Packing [email protected]
Lee Casey Smithfield Foods [email protected]
Rocky Beem Smithfield Foods [email protected]
Scott Schoolmeesters US Energy [email protected]
Nick Franco US Energy [email protected]
Neil McAdam World Water Works [email protected]
Bill Reingans Hydro Thermal [email protected]
Wade Turner Reid Engineering [email protected]
Rob Henderson Chem Treat [email protected]
Travis Hitchcock Waste Industries [email protected]
Roy Carawan Water Reuse Specialist [email protected]
Jimmy Smith Four County [email protected]
Sean Fallon McGill Environmental Service [email protected]
Stephanie Richardson Dontech Industries [email protected]
DL Catton Dontech Industries [email protected]
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Plant Overview
• Year Built: 1992• Property Size: 888 acres• Building Size: 1million sq ft• Capacity (5 day wk):
• Fresh Pork – 191,000 hd/wk• Converted Lbs – 11,725,000 lbs/wk• Marination - 250,000 lbs/wk• Lbs Distributed – 33,000,000 lbs/wk
• Headcount: – Hourly = 4,439– Salary = 300
• Union status: 56 % Union• Average Wage Rate (Oct 2012)
– Hourly = $11.85/hr– Loaded = $19.75/hr
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Surface Water Plant
Main Engine Room
Back-up Generators
WW Water Plant
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Relevant Info• Local Fueling Cost ~ $3.80 / gal diesel (non highway grade)• Refrigerated Storage Trailer $1500.00 / month• Utility Cost
– Natural Gas $5.57 / MCF– Electric $0.0756 / KWH– Water $2.02 / 1000gal
• Utility Usage– Natural Gas 759,642 MCF/yr– Electric 155,731,838 KWH/yr– Water 809,712 1000gal/yr
• Spotter Service – Internal
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PLANT TOUR
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TEAMSTeam #1 Team #2 Team #3
Facilitator Miller Bailey Wright
Scribe Green DeBrito Turner J
Members
Henderson Richardson DL Catton
Schoolmeesters Carawan Beem
Franco Held McLean
Casey Jackson Harris
Reingans Cain Wardlaw
Smith McAdam Turner W
Elkins Hitchcock Fallon
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Identified Opportunities
• Plastic Recycling / Recycling Hub – Waste Industries
• Shipping Condensers – Switch to Final Effluent versus Potable Water
• Cryovac Bag Tails-Recyclable
• Heat Exchanger- Boiler Blowdown Water and Boiler Feed Water
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Brainstorming
• Generates large number of ideas• Goal is for participants to create new ideas
off of other ideas• Seems like a “no brainer,” but right
approach can improve idea outputRules for Brainstorming No one interrupts, censors, criticizes, or praises Questions are allowed only to clarify and idea Hitchhiking off other ideas is encouraged Freewheeling, unrelated ideas are okay here
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How to Brainstorm• Write a description of the brainstorming objective
– Leads to more effective session
• One person records the ideas so all can see– Flip chart, white board, or computer/projector will all work
• Each person can offer one idea per turn– Avoiding “shout outs” keeps all participants actively
involved
• People can pass on one turn but come back in later if they think of something– Someone else’s idea may trigger a new idea later on
• When everyone passes on a turn, the session is over• Compile the idea list for future use
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Determining ComplexityConstraint: 0 1 2 3 Total
Technical Difficulty The opportunity is a single problem that is well understood
The opportunity is a made up of a number of problems some of which are well understood
The opportunity is a made up of a number of problems none of which are well understood
The opportunity is made up of problems that we have applied rigorous analysis to but still don’t understand
Resources Needed to Deliver Savings
Internal Internal plus local suppliers/contractors
External within supply chainExternal within supply chain & external suppliers/contractors
Time Needed to Realize Savings
<3 months 3-6 months 6-9 months >9 months
Level of Capital/Expense Required
Expense Only <$100,000 Capital (Richter Approval only)
>$100,000 and <$1,000,000 Capital
>$1,000,000 Capital
**Assess the constraint against the criteria on the right & apply the score in the "Total" column which best describes it. After scoring all 4 constraints, total up the complexity score at the bottom & apply to the O&A column 0. 0
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• Tar Heel Combined Ideation List.xlsx
INPUT/OUTPUT
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Critical Control PointsWastewater Operations
• Critical Control Points (CCP) are areas in a process where something is measured to determine
• Examples of CCPs in a wastewater system are:– Flow– pH– Turbidity– Oxygen Concentration– MLSS– Chemical Feed
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• Grayson\2013 Critical Controls Grayson052413.xlsx
CCP Example – Grayson, KY
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Plant Manager Training• What is EMS• Benefits of EMS• Goals of EMS• Key Components of EMS
– Roles– Environmental Aspects– Training– Communication– Controls– Monitoring & Measuring– Corrective Actions
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Plant Manager Training• Reviewed NOVs• Identified Root Causes
– Mechanical– Program Execution
• Corrective Actions– Equipment Upgrades– Equipment PMs in SAP– Identify Critical Spares– Improve EMS Training– Improve Awareness– Improve Participation– Improve Communication– Weekly Calls with PM
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Weekly Environmental/Sustainability Call
• Held each Tuesday qt 1130– VPs, Plant Managers, ECs
• Agenda– NOVS– Spills/Releases– SMS Events– Regulatory– ISO 14001– “SOP Of the Week”
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PMs in SAP
• Prior top SAP, PMs were in Tab Ware• Included
– Air Pollution Control Equipment for Title V Compliance
– Weekly/Monthly Inspections for SWPPP and SPCC compliance
– WW Equipment
• Quick transition to SAP resulted in these items not being programmed into SAP
• Ongoing effort to migrate these items and more into SAP
