The MTES/MDE ISO 14000 Program

The MTES/MDE ISO 14000 Program

Paul Gietka, Manager

Environmental Engineering ProgramUniversity of Maryland

MD Manufacturing Assistance Program

_______________________________________________________________________________________________________A program of the Maryland Technology Enterprise Institute in the A. James Clark School of Engineering, and a NIST MEP Affiliate.

www.mtes.org

The Agenda

• What is MTES/UMMAP?

• Environmental Management Systems

• The ISO 14000 Standard

• The MTES/MDE ISO 14000 Program

• Other MTES/MDE Collaborations


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A. James Clark School of Engineering

MTECH Partnerships MTECH Ventures

UMMAP/UNIVERSITY INFRASTRUCTURE

UMMMAPMIPSBREP

Hinman CEOsVenture Accelerator

TAP

3

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• Manufacturing outreach program within the University of Maryland College Park

• Maryland’s MEP (Manufacturing Extension Partnership) Center

MTES/UMMAP

Maryland Technology Extension Serviceis now

UM Manufacturing Assistance Program

5

UMMAP SERVICES

Lean Training and Implementation Assistance

Environmental / Sustainability

Plant Process Layout – Facility Expansion or Company Relocation

Other Engineering Consulting (e.g. Failure Analysis, Equipment Sourcing, Material/Machinery Issues)

A program of the Maryland Technology Enterprise Institute in the A. James Clark School of Engineering, and a NIST MEP Affiliate.

What is an EMS?

An EMS is a systematic approach to ensuring that environmental activities are well managed in any organization. Because an EMS focuses on management practices, it can operate at facilities of widely varying size, complexity, and missions, whether they be offices, laboratories, ships, facilities, programs, or agencies. An EMS can provide managers with a predictable structure for managing, assessing, and continuously improving the effectiveness and efficiency of the management of their environmental activities. An EMS approach builds in periodic review by top management and emphasizes continuous improvement instead of crisis management. - (US EPA)


What is an EMS?

Environmental management systems are “that part of the overall management system which includes organizational structure, planning activities, responsibilities, practices, procedures, processes and resources for developing, implementing, achieving, reviewing and maintaining the environmental policy.“ – (ISO 14001, Environmental Management System Standard)


What is an EMS?

An environmental management system is a series of related procedures that are developed by an organization that identify the environmental issues that are affected by their operations, establish a plan to address these issues, monitor their effectiveness, and periodically review their status with top management. – (PMG, 2005)


The ISO 14000 Standard

• The EMS standard developed by the International Organization for Standardization (ISO) in Geneva Switzerland

• Initially issued as an International standard in 1996• Second edition issued in 2004• Requires an organization to define an environmental

policy and establish 16 management procedures that support the policy.

• A formalized process that requires third party audits on a periodic and continuing basis


Core Elements of an EMS

ISO 14001 - Structure

ISO 14001:2004

Section 1Scope

Section 2Normative References

Section 3Terms &

Definitions

Section 4EMS Requirements

Section 4 – EMS Requirements


Element – Policy

Top management commits to environmental improvement and establishes an environmental policy that:

• Commits to continual improvement & pollution prevention

• Commits to comply with legal and other requirements related to environmental aspects

• Establishes a framework for setting and reviewing environmental objectives and targets

• Is available to the public


Element – Planning

Conduct a review of operations to:• Identify legal requirements• Identify environmental aspects & impacts• Establish objectives and set targets• Devise a plan to meet those targets


Element – Implementation

• Establish responsibilities• Develop operating and control procedures• Provide training


Element – Evaluation

• Monitor operations to determine if targets are being met

• Take corrective action if needed


Element - Review

• Annual/periodic review of progress with top management

• Modify the EMS to optimize its effectiveness per top management direction

• This creates the continuous improvement loop


Why Implement an EMS?

• Customer requirement• Corporate requirement • Federal mandate• State mandate• Avoid citations and fines• Improve your image• Possibly save money

The MTES/MDE Program

• History

• Methodology

• Participants

• Results


www.mtes.org

The MTES/MDE Program

• A Collaborative Effort– MD Dept. of the Environment (MDE)

• Laura Armstrong, Pollution Prevention Coordinator

– MD Technology Extension Service (i.e.UMMAP)• Curt Bluefeld, Facilitator• Paul Gietka, Manager


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Funding History

• US EPA PPIS grants as the funding source

• Match from MDE to leverage the funding

• MOU between MDE & MTES

• First grant awarded October 2001

• Current funding through 2011


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Methodology

• ISO 14000 based EMS implementations using group workshops & individual on site assistance

• A company joins by submitting a commitment letter signed by the CEO

• They commit to providing sufficient people & resources to complete the program

• Registration is not required


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Methodology

• Groups of 3-5 companies over a 6 month period– Four 1 day group meetings w/ homework– 1st meeting at MDE. Other’s hosted by

participants.– Individual technical assistance meetings at

each company as needed.


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Methodology

• Final audit by MTES using industry mentors

• Annual Awards Ceremony


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EMS Program

Progress (thru 2010):

• 51 companies in 15 groups have completed the program

• All have implemented an EMS in their plants • 27 have successfully registered to the ISO 14001

standard. (Registration is not required)


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EMS Program

Results (thru 2010):

• 17,501,255 lbs of waste reduced

• Cost savings of $1,369,440


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EMS Program

EMS Participants (thru 2010):AAI Corp. Collins and AikmanLocke Insulators Procter & GambleATK Elkton Filtronic Comtek Modular Components National, Inc. LafargeBookham Technology Quantum Photonics (TAP) Nurad Technologies FKI Logistex Chemspec, Inc. Rhodia, Inc.Perdue Heidtman Steel Cytec Engineered Materials Smiths DetectionPerkinElmer K&L Microwave St. Lawrence Cement Unilever Best Foods


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EMS ProgramEMS Participants (thru 2010):Shire Pharmaceuticals Airpax-FrederickCoca Cola-Silver Spring Coca Cola-BaltimoreFreedom Electronics Recycling General Dynamics RSStandard Register Lorch MicrowaveColonial Metals L3BAI Washington MetroTA Thales Communications CDM E End USA EU Services Kopflex Plasticoid Phoenix MecanoWm Burnett E-Structors Human Genome Sciences Unilever HPCDuvinage Franklin Square Hospital


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EMS Program

Current EMS Participants (started April 2010):

Plymouth Tube - Salisbury

Erachem Comilog – Baltimore


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EMS ProgramQuotes:

"Our corporate parent is headquartered in the U.K. where there is a major focus on environmental management and green manufacturing. When the opportunity was presented by MDE to receive assistance in developing and implementing our environmental management system, we enthusiastically agreed to participate. We understand the difficulty and costs associated with ISO and EMS implementation, compliance and certification as well as finding a consulting service with proven experience and success. We have a very high opinion of the University of Maryland, its technical competence and experience related to ISO and business and quality excellence, having participated in the University of Maryland Programs ISO Consortium and U.S. Senate and Maryland Quality Program.”

John McNulla, President, Nurad Technologies (saved $110,000)

“We really enjoyed the program. We particularly liked its interactive nature (i.e., working closely with other organizations), the free exchange of information, and the invaluable technical assistance.”

Dan Rettig, PerkinElmer Fluid Sciences (saved $90,000)


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Other MDE/MTES Programs for Manufacturers

• P2 Site Assessments

• P2 Internships

*P2 = Pollution Prevention


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P2 Site Assessments

• An on site evaluation of the facility to identify cost-saving & waste reducing P2 opportunities

• Typically two engineers over ½ to 1 day

• Report highlights existing P2 practices, then provides recommendations (with cost savings, if available)


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P2 Site Assessments

Progress:

• To date, 72 assessments completed

• Printers, Vehicle Repair shops/Dealerships, Aerospace, Metal Fabricators, Chemical, Pharmaceutical, Brewery


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P2 Site Assessments

Results (2009):

• Identified $162,000 in potential savings

• Participants claimed increased investment of $52,000

• “What a great service. I highly recommend it to others.” Carol Green, owner, Groundfloor Xposure (saved $5,500)


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P2 Internship• Undergraduate/graduate engineering students

hired to perform in-depth engineering evaluations of potential P2 projects

• Work part time in Spring Semester – Learning about P2, the industry and available resources

• Work full time Summer – At company - collecting data, evaluating alternatives, engineering design, cost benefit analyses

• Finalized in a report to company with recommendations and costs_______________________________________________________________________________________________________


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P2 Internship

Progress:

• 14 projects at 9 companies with 5 interns

• Participating companies – Airpax, Alcore, Automated Coatings, General Die Finishing, Rhodia, Stone Industrial, Victor Graphics, Kopflex, EU Services


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P2 Internship

Two Interns this summer:

• Fritolay

• Thales Communications


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P2 Internship

Results:

• Identified over $350,000 in potential savings

• Reduced water use by 180,000 gallons per month

• Reduced phosphorus discharge by 50 %

• Reduced ammonia emissions by 40%


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P2 Internship

Quotes:“We feel the benefits gained were invaluable.” Woody Cannon, EH& S

manager, Airpax (saved 150,000 gallons of water/month & reduced pretreatment costs)

“The whole program is outstanding. Everyone (intern and advisors) did a great job and was very accessible. I would do it all over again.” Paul Wajbel, owner. General Die Finishing (saved $45,000)

“The P2 Intern Project was a beneficial endeavor on all of our parts.” John Easto, Stone Industrial. (Identified savings of $90,000 annually)

“In manufacturing, there’s always the potential for problems and for opportunities. This service help us identify those opportunities.” David Gishel, VP, Victor Graphics. (Saved $32,000 year)


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Case Study – P2 Program

Company: Garrett Container Systems

• Manufacturer of custom designed aluminum containers for military and commercial applications.


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Sample of recommendations: • The current paint filters are disposable. The dried filters

are sent to the landfill for disposal. The company should investigate the feasibility of using reusable paint filters.

• The waste paint and solvent used for cleaning is stored in a 55 gallon drum and shipped to an incinerator as a waste fuel – good P2 practice. But the lacquer thinner to clean the paint spray guns could be recycled using a solvent distillation unit, and re-used.

• Many drill bits of various sizes are used throughout the operation, and are discarded when dull. Re-sharpening them in house should be considered. _______________________________________________________________________________________________________


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Results:

• To date, Company has implemented 2 recommendations

• Savings estimated at $8,000


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Case Study – P2 Internship

Company: Alcore, Inc

• Manufacturer of aluminum honeycomb core products for the aerospace industry


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Recommendation:

• Install an ion exchange system on the waste water discharge from the anodizing process to maintain aluminum concentration in the bath and reduce phosphorous and water discharged to sewer.


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Results:

• Cost: $58,000

• Savings: $37,000/year


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Case Study - EMS Program

Company: Perkin Elmer Fluid Sciences

• Manufacturer of high tech seals and related components


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Case Study - EMS Program

Results:

• Company implemented an EMS and successfully registered to ISO 14001 standard

• Savings: $90,000/year (NIST survey)


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Questions/Comments?


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Documents

The MTES/MDE ISO 14000 Program