EMS Implementation and Operation

1. EMS Implementation and Operation ISO 14001 Requirements

2. 4.4 Implementation and Operation 4.4.1 Structure and responsibility 4.4.2 Training, awareness, competence 4.4.3 Communication 4.4.4 EMS documentation 4.4.5 Document control 4.4.6 Operational control 4.4.7 Emergency preparedness/response

3. 4.4.1 Structure and Responsibility • Roles, responsibility and authorities defined, documented and communicated • Management provide essential resources • Appoint management representative • Ensure EMS requirements are established, implemented and maintained • Report to top management on EMS performance

4. 4.4.2 Training, Awareness, Competence • Identify training needs • Personnel performing work which can cause significant impacts: • require appropriate training • competent based on appropriate education, training and/or experience (cont’d)

5. 4.4.2 Training, Awareness, Competence • Procedures for employee awareness of • importance of conformance • significant impacts of work activities and benefits of improved performance • roles and responsibilities in achieving conformance • potential consequences of departure from operating procedures (cont’d)

6. 4.4.3 Communication • Procedures for: • internal communication • receiving, documenting and responding to external interested parties • External communication processes on significant aspects must be recorded

7. 4.4.4 EMS Documentation • Information to: • describe core elements of the EMS • provide direction to related documentation • Can be paper or electronic

8. Document Organization Scheme 1.EMS Manual Policy 2. Procedures, programs, permits ControlledDocuments Implementation of policy 3. Work instructions BOM’s, specs, drawings, visual standards “How to” for procedures 4. External Documents 5. Blank Forms Proof that system works 6. Completed Forms & Other Records Records

9. 4.4.5 Document Control • Procedures for controlling documents to ensure that: • they can be located • they are periodically reviewed, revised, and approved • current versions available at essential locations • obsolete documents are promptly removed • any obsolete documents retained for legal and/or knowledge preservation are suitably identified (cont’d)

10. 4.4.5 Document Control (cont’d) • Legible • Dates of revision and readily identifiable • Maintained in an orderly manner • Retained for a specified period • Creation and modification procedures

11. 4.4.6 Operational Control • Identify operations and activities associated with significant aspects • Plan activities, including maintenance • Ensure activities are carried out under specified conditions: • Documented procedures where absence could lead to deviations • Stipulate operating criteria • Procedures related to significant aspects of goods and services purchased from suppliers

12. 4.4.7 Emergency Preparedness and Response • Procedures to: • identify potential for and respond to accidents and emergencies • prevent and mitigate environmental impacts. • Review and revise • Periodically test

13. EMS Implementation and Operation EMS Mentoring Eaton Corporation, Supercharger Division

14. ISO 14001 - Continuous Improvement Cycle Management Review Checking & Corrective Action Commitment & Policy Implementation & Operation Planning

15. EMS Responsibility Matrix

16. Training • Steering Team • Internal Auditors • Awareness Level • Job Specific Training • Utilized existing system to track and document

17. Communications • Postings • Training(refresher and new employee) • Progress Reports (goals and targets) • Incident Reports • Surveys, suggestion program, committee participation, e-mail, open door policy. • External communications(inquiries, compliance reports, and regulatory inspections)

18. Documents and Document Control • Used existing system for QS 9000. • Keep EMS documents separate from QS documents within the system, but all documents are controlled in the same manner. • Develop a matrix of important documents and retention times.

19. Operational Controls

20. EMS Implementation and Operation Questions? Eaton Corporation, Supercharger Division

21. EMS Mentoring Workshop Day 2 Day 1 Review and Day 2 Overview EMS Implementation and Operation Elements Cont. EMS Checking and Corrective Action Elements EMS Management Review Elements EMS SWOT Analysis/Planning Group Exercise

22. EMS Implementation and Operation EMS Mentoring Yamaha Motors Manufacturing Corporation of America

23. ISO and 8-step Process Align ISO program with current processes Step 1: Problem Statement “YMMC generates and ships hazardous waste off-site for disposal.”

24. ISO and 8-step Process Project selection – ISO objective ISO 14001 Objective “Reduce amount of hazardous waste shipped off-site.”

25. ISO and 8-step Process Step 2: Current Level Attributes – Loss Tracking MEK Usage Tracking

26. ISO and 8-step Process Step 2: Current Level Attributes – Loss Tracking Hazardous Waste Disposal Tracking

27. MEK/Paint Hazardous Waste Shipments MEK/Paint Generated (gallons) 4500 4235 Average 2,900 gallons/month 4000 3520 3500 3135 2915 2860 3000 2585 2530 Gallons of Hazardous Waste 2500 2255 1980 1980 1815 2000 1500 1000 500 0 Jul-00 Apr-00 Jun-00 Oct-00 Jan-01 Aug-00 Sep-00 Dec-00 Feb-01 Mar-01 Nov-00 May-00 ISO and 8-step Process Step 3: Setting Baseline and Target Hazardous Waste Disposal

28. ISO and 8-step Process Step 3: Setting Baseline and Target Monthly Hazardous Waste Disposal 3,500 50% Reduction ($84,000/yr or 17,000 gal/yr) 3,000 2,500 Current Goal 2,000 1,500 1,000 500 0

29. ISO and 8-step Process Improvement Approach • Methodology: • Data Analysis • Chemical Analysis • Case Studies - Pollution Prevention • Brainstorming • Site Visit to US Can - observe onsite distillation

30. ISO and 8-step Process Step 4: Root Cause Analysis YMMC Hazardous Waste Generation

31. ISO and 8-step Process Brainstorming Results: 1. Non-hazardous Line Cleaner - Pilot 2. Off-site distillation - Quotes 3. Purchase Distillation Equipment - Quotes 4. Mobile on-site distillation - Pilot

32. ISO and 8-step Process Step 5: Countermeasure Distillation Process

33. ISO and 8-step Process Step 5: Countermeasure

34. ISO and 8-step Process Step 6: Implementation of Critical Path

35. ISO and 8-step Process Step 7: Confirmation of Effects and Results Conducted Onsite Pilot Distillation with First Source: • Lab Analysis Results of Distilled MEK: • Outside Lab • PPG Lab Analysis

36. ISO and 8-step Process Step 7: Confirmation of Effects and Results 73% Reduction ($126,000/yr or 25,500 gal/yr)

37. ISO and 8-step Process • Intangible Results: • Reduction in Risk and Liability • Improved YMMC’s Environmental Image

38. ISO and 8-step Process Step 8: Prevention of Reoccurrence Created ISO Operation Standard:

39. Training

40. Communication

41. Document Creation Schedule

42. Document Control

43. Emergency Preparedness & Response • Contingency Plan • Emergency Evacuation

44. EMS Implementation and Operation Questions? Yamaha Motor Manufacturing Corporation of America

45. EMS Implementation and Operation EMS/P2 Integration P2

46. Structure and Responsibility Require representation from all departments and business units on EMS Team Make process supervisors and department managers responsible for the environmental performance of their units. Use full-cost accounting to link P2 and resource use efficiency performance to operating budget and employee compensation rules.

47. Structure and Responsibility Include P2 and resource management performance in job descriptions and employee evaluations. Give highest decision-making priority to projects with significant P2/resource conservation benefits. Integrate quality and environmental improvement teams into one single workgroup focused on production efficiency. Where feasible, rotate staff between environmental and production responsibilities.

48. EMS Communication Communicate how and where P2 and resource conservation is integrated within your EMS EMS bulletin boards, company newsletters, company meetings and training Internal Open houses, press releases, focus groups, annual reports, advertising, community meetings, permit applications, industry mentoring External

49. Training, Awareness & Competence All Employees • Training on the waste/resource management hierarchy and the use of “systems approach” tools within the EMS • Basic training - P2 and resource conservation concepts • Specific training - P2 resources and solutions applicable to employee functions • Develop an EMS employee incentive program • Create friendly competitions for environmental improvement between departments and shifts

50. Training, Awareness & Competence Staff performing or managing an activity linked to a significant environmental aspect • Understanding of P2 measures with potential to reduce or eliminate the aspect . • Use the Internet to tap into the local and global network of practical P2 and resource conservation solutions.