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ISO 9002 / 14001 Integration at KMU

ISO 9002 / 14001 Integration at KMU. WHO? WHAT? WHERE? HOW?. Konica Manufacturing USA, Inc. (KMU). Product: Color Photographic Paper Located in Whitsett, NC (East of Greensboro on I85/40). K.M.U. General Statistics. KMU manufactures color photographic paper and photographic emulsions

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ISO 9002 / 14001 Integration at KMU

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  1. ISO 9002 / 14001Integration at KMU WHO? WHAT? WHERE? HOW? KMU, Chris Kappert, ISO 9002 / 14001 Integration

  2. Konica Manufacturing USA, Inc.(KMU) Product: Color Photographic Paper Located in Whitsett, NC (East of Greensboro on I85/40)

  3. K.M.U. General Statistics • KMU manufactures color photographic paper and photographic emulsions • First Coating: June 13, 1989 • ~ 350 employees • Continuous operation (12 hr shifts) • 300,000 ft² in manufacturing facility • Subsidiary of Konica Corporation (Japan) KMU, Chris Kappert, ISO 9002 / 14001 Integration

  4. KMU’s Quality System Status • ISO 9002/1987 certified - July 1994 • ISO 9002/1994 certified - July 1995 • Documentation (prior to EMS implementation)only items “affecting” quality • Level 1 (Quality Manual) - 1 • Level 2 (System) documents - 41 • Level 3 (Instruction) documents - 2200 • Level 4 (Forms) documents - 1000 KMU, Chris Kappert, ISO 9002 / 14001 Integration

  5. KMU Quality SystemDocumentation Structure Level 1 Level 2 Level 3 (2200 +) Level 4 (1000 +) QMS Manual QMS Systems QMS Procedures / Forms Records KMU, Chris Kappert, ISO 9002 / 14001 Integration

  6. KMU’s Environmental Status • Title V Air Permit (Mostly VOCs) • Large Quantity Hazardous Waste Generator • Wastewater discharge to local POTW • Stormwater Permit • Silver Recovery (Wastewater Pretreatment) • Involved with TSCA, FIFRA, ATF, EPCRA (Tier II & TRI). KMU, Chris Kappert, ISO 9002 / 14001 Integration

  7. KMU’s Q&E Structure(prior to EMS Implementation) • Quality Systems Manager (Chris Kappert) • Report to QA Senior Manager (ISO Rep) • Supervise Document Control Assistant who controls flow and distribution of documents • Environmental Engineer (Sean Bir) • Report to Engineering Senior Manager • Environmental Reporting and Performance Improvement KMU, Chris Kappert, ISO 9002 / 14001 Integration

  8. ISO 14001 vs ISO 9001INTEGRATION DECISION • Know the differences / similarities in the standards • Know advantages / disadvantages of the integration options • Know your system & your company KMU, Chris Kappert, ISO 9002 / 14001 Integration

  9. ISO 14001 vs ISO 9001DIFFERENCES KMU, Chris Kappert, ISO 9002 / 14001 Integration

  10. ISO 14001 vs ISO 9001DIFFERENCES • EMS vs QMS • TC207 vs TC176 • 6 elements vs 20 elements (1994 version) • “Established” vs “Documented” Procedures • Possible future integration or alignment KMU, Chris Kappert, ISO 9002 / 14001 Integration

  11. ISO 14001 vs ISO 9001DIFFERENCES • Environmental Aspects and Impacts (4.3.1) • Legal and Other Requirements (4.3.2) • Environmental Programmes (4.3.4) • Communication (4.4.3) • Emergency Preparedness and Response (4.4.7) KMU, Chris Kappert, ISO 9002 / 14001 Integration

  12. ISO 14001 vs ISO 9001SIMILARITIES • Policy • Targets & Objectives • Roles & Responsibilities • Training • Supplier Control / Purchasing • Document Control KMU, Chris Kappert, ISO 9002 / 14001 Integration

  13. ISO 14001 vs ISO 9001SIMILARITIES • Operational Control • Calibration • Corrective and Preventive Action • Records • Auditing • Management Review KMU, Chris Kappert, ISO 9002 / 14001 Integration

  14. ISO 14001 vs ISO 9001INTEGRATION OPTIONS • Separate Systems • Partially Integrated Systems • Fully Integrated Systems KMU, Chris Kappert, ISO 9002 / 14001 Integration

  15. Separate Systems KMU, Chris Kappert, ISO 9002 / 14001 Integration

  16. Advantages of Separate Systems • Easy to audit (external) • One-to-one documentation generation • Can be handled by independent groups • Thorough coverage of requirements KMU, Chris Kappert, ISO 9002 / 14001 Integration

  17. Disadvantages of Separate Systems • REDUNDANCY! REDUNDANCY! • Results in large system of documentation • No plant-wide alignment • Requires extra staffing • Internal audits harder • “Re-inventing the wheel” • Start over if ISO 14001 / 9001 merge KMU, Chris Kappert, ISO 9002 / 14001 Integration

  18. Partially Integrated Systems KMU, Chris Kappert, ISO 9002 / 14001 Integration

  19. Advantages ofPartially Integrated Systems • Relatively easy audits (external & internal) • Builds on existing systems • Can be managed by groups working closely together or combined • Reduced costs • Consistency • Employee buy-in KMU, Chris Kappert, ISO 9002 / 14001 Integration

  20. Disadvantages ofPartially Integrated Systems • Alignment of ISO 9001 / 14001 elements • ISO 9001 systems may not adequately cover 14001 requirements • Unclear responsibilities between QMS and EMS management representatives • Complex procedures (level 2’s) KMU, Chris Kappert, ISO 9002 / 14001 Integration

  21. Fully Integrated Systems KMU, Chris Kappert, ISO 9002 / 14001 Integration

  22. Advantages ofFully Integrated Systems • Easy to audit (internal) • Consistent plant-wide philosophy, planning, and information management • No redundancies • Reduced costs • System already established if ISO 14001 / 9001 merge KMU, Chris Kappert, ISO 9002 / 14001 Integration

  23. Disadvantages ofFully Integrated Systems • Complex documents (level 1 and 2’s) • Difficult to audit (external) • Unclear responsibility between QMS and EMS management representatives • Difficult to implement after 9001 has already been established KMU, Chris Kappert, ISO 9002 / 14001 Integration

  24. ISO 14001 vs ISO 9001INTEGRATION DECISION • Know your current system • Does it lend itself to integration? • What is the function of the various documents in your current system? • ??? • Know your company • Could we do it like that? KMU, Chris Kappert, ISO 9002 / 14001 Integration

  25. Which is right for you ? KMU, Chris Kappert, ISO 9002 / 14001 Integration

  26. KMU’s Implementation ofPartially Integrated System • ISO 9002 system established • ISO 14001 EMS Manual written(references made to existing system documentation and unknown new documents) • Existing systems modified • No new level 2’s added • Many environmental specific level 3’sadded KMU, Chris Kappert, ISO 9002 / 14001 Integration

  27. KMU’sPartially Integrated System KMU, Chris Kappert, ISO 9002 / 14001 Integration

  28. KMU’s Implementation & Integration Team • Team Leaders • Quality Systems Manager • Environmental Engineer • Core Team • Representatives from each major functional area; 10 experienced people • Employees Involved • 100%!! KMU, Chris Kappert, ISO 9002 / 14001 Integration

  29. ISO 14000 CostsKMU Person-Hours KMU, Chris Kappert, ISO 9002 / 14001 Integration

  30. KMU’s ISO 14001 Timeline • Spring 1997 • Key Personnel Receive ISO 14001 Training. • Drafted Environmental Policy • Summer 1997 • Decide to Develop Integrated Management System Incorporating Quality and Environmental Commitments. KMU, Chris Kappert, ISO 9002 / 14001 Integration

  31. KMU’s ISO 14001 Timeline • Fall 1997 • Join NC ISO 14001 Pilot Program • Complete Environmental Manual (& Policy) • Created the Konica Environmental Group with members from all KMU departments. • Identify Environmental Aspects and Impacts. KMU, Chris Kappert, ISO 9002 / 14001 Integration

  32. KMU’s ISO 14001 Timeline • Winter 1997/1998 • Developed Environmental Targets and Objectives for 1998. • Completed Initial Environmental Training of all KMU Personnel. • Registrar Performed ISO 14001 Preassessment of KMU’s Management System. KMU, Chris Kappert, ISO 9002 / 14001 Integration

  33. KMU’s ISO 14001 Timeline • April 1998 • Completed Implementation of EMS. • June 15-19, 1998 • Passed KMU ISO 14001 and 9002 Certification Audit. TOTAL ELAPSED TIME: 14 months (8 months dedicated) KMU, Chris Kappert, ISO 9002 / 14001 Integration

  34. 14001 Registration!!!!!!! KMU, Chris Kappert, ISO 9002 / 14001 Integration

  35. KMU’s Documentation System(after EMS Implementation) • Documentation - items “affecting” quality or environmental performance • Quality Manual - 1 • Environmental Manual - 1 • Level 2 (System) documents - 41(none created; 40% modified for EMS) • Level 3 (Instruction) documents - 2320(~120 created + 5% modified for EMS) • Level 4 (Forms) documents - 1050 (~5% created new or just added to control system) KMU, Chris Kappert, ISO 9002 / 14001 Integration

  36. KMU Management SystemDocumentation Structure EMS & QMS Manuals Level 1 Level 1 Level 2 Level 3 (2320 +) Level 4 (1050 +) Systems Documents Procedures / Forms Records KMU, Chris Kappert, ISO 9002 / 14001 Integration

  37. KMU’s Q&E ISO Structure(after EMS Implementation) • Environmental Engineer / Systems Manager (Dorothy Vannoy) • Report to Engineering Senior Manager (ISO rep) • Responsible for all (ISO) Management Systems • Environmental Reporting and Performance Improvement • Document Control Assistant still controls flow of document revisions and distribution KMU, Chris Kappert, ISO 9002 / 14001 Integration

  38. Benefits Realized….. … from EMS IMPLEMENTATION • Increased Employee Awareness & Involvement • Better Knowledge Preservation & Transfer • Increased Efficiency & Reduced Costs • Improved Environmental Performance • Enhanced Public Image • Enhanced Image with Regulators KMU, Chris Kappert, ISO 9002 / 14001 Integration

  39. Benefits Realized….. … from EMS (partial) INTEGRATION • Reduced head count • Simplified introduction into daily operations • Minimal increase in documentation KMU, Chris Kappert, ISO 9002 / 14001 Integration

  40. INTEGRATION REFERENCES • Book: Stepping Up to ISO 14000 - Integrating Environmental Quality with ISO 9000 and TQM Subhash C. Puri, $39.00 www.ppress.com • ASQ Course: Integrating ISO 14001 into QS-9000 Certified Systems - $835June 20-21, 2000, Greensboro, NC • NC DENR - FREE! • Your Auditor - $? KMU, Chris Kappert, ISO 9002 / 14001 Integration

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