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ISO 9002/14001 Integration at KMU: Strategies and Benefits

Learn about ISO 9002/14001 integration at KMU, understand the differences, similarities, and integration options. Discover the advantages and disadvantages of separate, partial, and fully integrated systems at KMU. Gain insights into the environmental and quality management structures at KMU.

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ISO 9002/14001 Integration at KMU: Strategies and Benefits

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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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