Cleaner Production Audit

1. Cleaner Production Audit

2. CP audit • Knowing where you are and what you have got is the essence of good management and yet it is surprising how many organizations are not aware of their environmental positioning. • Audio = to listen

3. Purpose of a CP audit • Identify “low hanging fruits” to generate immediate savings and to motivate the project team • Set priorities for the project

4. Context of a cleaner production audit • First company visit: Convince the company to participate in a project with the NCPC. • Start of the cleaner production project:Collect initial data for project planning, identify options to motivate the team. • EMS initial review:Obtain an overview of environmental impacts and the organization. • Within a cost reduction audit:Obtain an overview of the reduction potential. • Within continuous improvement:Determine benchmarks and ask for an expert opinion.

5. How to conduct a CP audit? • Scope: • Technical (data, technology, special observations) • Legal compliance • Organization • Preparation: • Team, participants • Date • Materials to prepare (company brochure, layout, flowcharts, etc.) • Checklist

6. The tasks of an audit Planning ? Training Learning Identifyingoptions

7. Before the company visit • Plan the first visit to the company • Team • Timing • Questions • Draw up a form for the documentation of the first visit • Company information and data • Flowchart • Data • Observations

8. Three steps • Step 1 – PREPARE • Define responsibilities • Define the scope • Collect documents • Develop a schedule • Prepare checklists and inform staff • Step 2 – CARRY OUT • Audit • Evaluate findings • Organize a wrap-up meeting • Step 3 – FOLLOW-UP • Follow up on corrective action • Report to the management • Document and report

9. Key qualifications of auditors • Diplomacy • Ability to listen and good communication skills • Attention to detail • Flexibility in adapting to a company’s culture • Authority, acceptance and support within the organization • Access to expert knowledge on relevant laws, regulations, codes and organizational standards • Access to staff or advisors who are able to convert legal and other obligations into daily organizational procedures • Access to all levels of the organization • Access to senior decision makers

10. Schedule for a quick scan • Meeting with the director (company policy, products, plans) • General technical introduction(introduction to site, responsibilities, layout, flowchart) • Site visit (in operation) • Take notes (preliminary data, flowcharts, pictures: ASK FIRST!) • Feedback session

11. Audit checklist

12. Question techniques • Open questions • Closed questions • “Mirror” questions

13. MATERIAL • Raw material Process material Other material OBSERVEDSYSTEM PRODUCTS Primary and coupled MATERIAL EMISSIONS • ENERGY CARRIERS • Fuels, e.g. gas, oil, coal Solid waste Gases Wastewater • ENERGY • Mass free, e.g. electricity or district heating • ENERGY EMISSIONS • Waste heat Noise

14. Data sources Accounting Receipts Records on waste Stock Process data disposal Verbal information Measurements Office Process A Process B Process ... Energy balance Materials Energy Products Waste, emissions

15. Audit • Report completed within three weeks and submitted to the EMS coordinator • Subsequent audits shall in particular address previous non-conformities and ensure that the corrective action taken prevents their recurrence • The audit procedure should be reviewed annually

16. Where auditors look ... Auditors will carefully check • Stacks • Waste pipes • Storage locations for chemicals • Non-labelled containers • Contents of containers to find items that do not belong there • Items that are not supposed to be thrown away • Leaking valves, tanks and pipes, broken trays • Storage of chemicals in their respective designated locations

17. What auditors ask ... • Who empties the containers? • Where does the waste go? • How are hazardous chemicals disposed of? • How is their use monitored? • What would you do if a container with a chemical was spilled onto the floor?

18. Audit interviews Audit interviews are to check whether: • Rules and procedures are observed • Operational controls are in place • Employees understand their role in the EMS • Significant impacts are addressed • Important documents are accessible

19. Audit outcomes • Report to management • Identification and implementation of corrective action • Recording of audit results

20. Quick scan: Where to look – 1 (General information) • Talk to staff (about training, experience, health and safety, problems, ideas, approximate data) • Measuring equipment • Storage (cleanliness, waste, losses) • Logistics (handling losses, space, problems) • Accounting (structure of accounts, figures) • Cleaning (product recovery, time, chemicals, dosage)

21. Where to look – 2 (Plant and process) • Plants and machinery (follow the process flow): • Type • Design • Age • Maintenance • Control • General impression • Consumption of energy and water • Waste generation per plant, type and quantity

22. Where to look – 3(Options and low hanging fruits) • Heating system(piping, leaks, insulation, boiler, quantities of fuel, type, price) • Cooling system(insulation, compressor, etc.) • Compressed-air system(leaks, compressor, etc.) • Water preparation and distribution(dosage of chemicals, leaks, quantities, costs)

23. The audit iceberg

24. Tips for auditees • Understand the scope of the audit. • Review and familiarise yourself with procedures and work instructions in your area. • Familiarize yourself with the audit plan and find out at what point you may be involved. • Be prepared for questions about your job as well as about the procedures and work instructions that you use. • Ensure that you know the location of documents relevant to the audit.

25. Listen, listen, listen! • Listen to a question completely before answering it. • Answer ONLY the question you are asked. • Do not offer any additional information that you THINK the auditor might find interesting. • Do not avoid questions, answer directly.

26. Get help if you need it! • Find the most competent person available for a certain area of expertise. • Do not guess responses, try to find the person who can provide the answer. • Ask supervisors or team leaders for assistance.

27. Correct non-conformities • If possible, correct minor non-conformities before the final meeting of the audit • Thus you demonstrate your intention to comply with the requirements

28. It’s about time ... • You have worked with your processes. The audit is the time for you to show how much you have done and how well you have done it. • Enjoy the opportunity to demonstrate your professionalism. • You have done everything you could do and now you’re READY!

29. Analysis of the sources of waste