CHAPTER # 2

1. CHAPTER # 2 Improved Manufacturing Operations

2. The Manufacturing Process • Objective: • to transform an idea into a saleable product • Steps • Design • Product Development • Quality Control • General Management • Production

3. Design • Product Planning • long term process to identify the product areas of interest • Product Development • concept further explored in relation to possibilities of the company • Product Design • creates a design on the basis of market-related, functional technical, manufacturing and aesthetics requirements

4. Sequential Engineering • Marketing identifies the need for new products, price ranges and their expected performance from customers or potential customers • Design and Engineering work independently and develop the technical requirements and final design details • Manufacturing, testing, quality control and service groups see the design in an almost complete stage • As the manufacturing process is sequential in progression, it is commonly called sequential engineering

5. Sequential Engineering Process

6. Concurrent Engineering Provides a systematic and integrated approach to introduction and design of products so as to ensure that decisions made in the design stage result in a minimum overall cost during its life-cycle

7. Concurrent Engineering Process

8. P2 Potential in theDesign Process

9. Strategies for Minimizing Pollution • Avoid adsorptive separations where adsorbent beds cannot be readily regenerated • Provide separate reactors for recycle streams, to permit optimization of reactions • Consider low-temperature distillation columns when dealing with thermally labile process streams • Consider continuous processing when batch cleaning wastes are likely to be significant (e.g., with highly viscous, water-insoluble, or adherent materials)

10. Process ChangesImproved Reactor Design • Improve the degree of agitation • better mass transfer efficiency • use more efficient mixers and baffling systems • Insulate the reactors • improves temperature control within the reactor • Use high efficiency heat exchangers • Switch to continuous flow mode • Simplify cleaning of the reactor

11. Other Process Changes • Increasing the number of stages in extraction processes that use water • Changing from wet cooling towers to air coolers • Attaching triggers to hoses to prevent unattended running

12. Process ChangesImproved Reactor Control • Improving reactor environment controls can have a substantial impact • Control system efficiency improved by • Measurement accuracy, stability and repeatability • Sensor locations, controller response action • Process dynamics • Final control element (valves, dampers, relays, etc.) characteristics and location • Overall system reliability

13. Process ChangesImproved Separation Processes • Do mechanical separations first if more than one phase exists in the feed. • Avoid over-design and use designs that operate efficiently over a range of conditions. Favor simple processes. • Favor processes transferring the minor rather than the major component between phases.

14. Product Changes • Make changes in the product itself or in the chemicals used to make the product • Replace solvent-based paints with water-base paints • Substitute parts which can be reused

15. Storage • Establish a Spill Prevention, Control and Countermeasures (SPCC) plan • Use properly designed storage tanks and vessels, and only for the intended purpose • Install overflow alarms on all storage tanks • Install secondary containment areas • Document all spillage • Space containers to facilitate inspection • Stack containers properly to minimize tipping, breaking, or puncturing

16. Storage (contd.) • Raise containers off the floor to minimize corrosion from “sweating” concrete • Separate different hazardous substances to minimize cross-contamination and to separate incompatible materials • Use a just-in-time order system for process chemicals • Order reagent chemicals in exact amounts • Establish an inventory control program to trace chemicals from cradle to grave • Rotate chemical stock

17. Storage (contd.) • Validate shelf-life of chemical expiration dates, eliminate shelf-life requirements for stable materials, and test effectiveness of outdated materials • Label all materials and containers with material identification, health hazards, and first aid recommendations • Switch to less hazardous raw materials • Switch to materials packaging and storage containers that are less susceptible to corrosion or leakage

18. Storage (contd.) • Use large containers where possible to minimize the tank surface-to-volume ratio, thereby reducing the area that has to be cleaned • Use rinsable/reusable containers • Empty drums and containers thoroughly before cleaning or disposing

19. Management • For P2 programs to be successful, management has to be fully committed to concepts of Pollution Prevention • Well conceived and functional preventive maintenance program • Proper employee training • Good Record keeping

20. Housekeeping • Close or cover solvent containers when not in use • Isolate liquid wastes from solid wastes • Turn off equipment and lights when not in use • Eliminate leaks, drips and other fugitive emissions • Control and clean up all spills and leaks as they occur • Develop a preventive maintenance schedule and enforce its use • Schedule production runs to minimize cleaning frequency

21. Housekeeping (contd.) • Improve lubrication of equipment • Keep machinery running at optimum efficiency • Dry sweep floors when ever possible • Do not allow materials to mix in common floor drains • Insist on proper labeling of all containers • Educate all employees as to the need for proper housekeeping practices • Include housekeeping reviews in all process inspections

22. Training • Key to the success of any P2 program • Should be ongoing, with frequent review updates • Should provide the necessary information to achieve P2 goals • Variety of training techniques should be used • Operators should play a major role in training

23. Record Keeping • Helps in both the development and implementation of a sound pollution prevention program • Document process procedures, control parameters, chemical specifications, chemical usage, energy usage, waste generation, and spill frequencies • Inventory control, for both process chemicals and waste materials, will reduce the volumes and thus reduce costs and potential losses to the environment from leaks or spills, or the need to dispose of contaminated, off-specification or out-of-date reagents