Cleaner Production : A tool for Green Competitiveness in the Turkish Industry

1. Cleaner Production: A tool for Green Competitiveness in the Turkish Industry The Ingenuity Factory Ltd. Middle East Technical University Department of Environmental Engineering Workshop Series 31 March-2 April 2008 Ankara, Turkey

2. The Ingenuity Factory Ltd. Training In Waste Reduction Using A Mock Industrial Process Activity developed by the Minnesota Technical Assistance Program and the Waste Reduction Institute for Training and Application Research Target audience: anyone interested in an introduction to the concept of CP!!!! • Goal: to give students experience in recognising waste reduction opportunities. • recognition of options that might reduce waste generation • difficulties encountered in the implementation phase. • natural human resistance to change • pressures of day-to-day operation of a business • difficulties inherent in selecting and justifying process modifications.

3. The Ingenuity Factory Ltd. Training In Waste Reduction Using A Mock Industrial Process A work table A sheet of paper to place the production plant (1 m2 approx.) Markers and sticky labels Plasticine extrusion machines (with the necessary accessories: knife, etc.) 2 pots of yellow plasticine 2 pots of blue plasticine 2 pots of any other plasticine colour. Scales

4. The Ingenuity Factory Ltd. Training In Waste Reduction Using A Mock Industrial Process General Manager: the person who has overall responsibility of the company. He is in charge of relations with the customer. As potential customers must be wooed, the customer is always right and customer satisfaction is essential. He is not aware of the production process and confines himself to passing on the orders to the production manager Financial Manager: analyses the production results in accordance with the cost of raw material and personnel. The rest are indirect costs (although he will find that the waste management can represent a large part of the cost if it is not controlled separately). He prepares the annual financial results for approval. The accounts always balance perfectly Production Manager: is in charge of supervising the production process. He informs the operators of the quantity and type of material to be manufactured, gives the order to the warehouse manager for the necessary raw materials to be prepared and he is very strict with the safety measures required for this type of installation and in accordance with the raw material handled. He centralises the operators’ complaints and is in charge of organizing the New Year party.

5. NO The Ingenuity Factory Ltd. Training In Waste Reduction Using A Mock Industrial Process Warehouse Manager: is in charge of the stocks of raw materials and waste, and informs the production manager periodically. He receives orders from the production Manager to prepare the materials required for the production lots and collection of waste generated. He does not understand very well why there is currently such a fuss with waste, as it was very easy to put it in drums and stack them out in the court. Operators: load and operate the machines to manufacture extruded products according to orders received from the production manager. They are responsible for cleaning the equipment. They have no specific training. They are happy with their jobs. They buy the sports paper on Mondays and fill out the lottery on Thursdays. Engineer responsible for quality and environment: his job is based on checking that the finished product meets the specifications requested by the customer. He collects master courses. He already had a Metrology and a Quality master degree and now he has done a course on Environment in order to assume the tasks associated with same as the pressure has increased, because the company does not have a specific department for these tasks. Next year, he would like to do a master course on Health and Safety. He believes he must be very strict in the implementation of what he has learnt.

6. The Ingenuity Factory Ltd. Training In Waste Reduction Using A Mock Industrial Process Environmental Compliance Inspector Representative of TAESSA.

7. The Ingenuity Factory Ltd. Training In Waste Reduction Using A Mock Industrial Process The Ingenuity FactoryLtd. specializes in the production of parts of different shapes and sizes for the automobile industry, through the extrusion of plastic material. 14 months ago, the company lost a major contract with their largest customer. Since then, the company is going through a difficult situation that will become untenable unless they obtain an important contract very soon. Presently, the company is competing for a large contract from one of the manufacturers of middle range automobiles with the largest market share, the firm TAESSA,that is developing its new model and planning a production line applying Just-in-time techniques.

8. The Ingenuity Factory Ltd. Training In Waste Reduction Using A Mock Industrial Process • TAESSA will base its selection for a supplier of extruded plastic parts on the following criteria: • Availability/capacity to start production immediately • Capacity to deliver the new products within the expected limits • Capacity to respond to urgent orders • Implementation of ISO 9000 and 14000, and EMAS standards in particular cases, paying special attention to the following points: • Product quality • Production level outside specifications • Meeting environmental laws • Generation of special waste.

9. The Ingenuity Factory Ltd. Training In Waste Reduction Using A Mock Industrial Process New product specifications imply using three types of raw materials: Type I Type II Type III : Innocuous toxic and/or hazardous. Type III materials result in the highest operating costs as the handling and transport of these highly toxic materials require special care. Any mixture of these materials will produce materials that must be considered as toxic and/or hazardous.

10. The Ingenuity Factory Ltd. Training In Waste Reduction Using A Mock Industrial Process Get started...

11. The Ingenuity Factory Ltd. Training In Waste Reduction Using A Mock Industrial Process Prepare the production plant... The sheet of paper will represent the facilities on which the spaces for the various activities of the company must be distributed. Lines made with the marker will represent a physical separation between the spaces...a sensible planning and distribution is very important to ensure the correct operation of the industrial activity. The plant must include space for the inflow and outflow of materials, the extrusion machine, warehouses for raw materials, products and waste, control laboratory, offices and any other space the company should require.

12. The Ingenuity Factory Ltd. Training In Waste Reduction Using A Mock Industrial Process Production begins when the orders are received Everyone has a specific task. Once the material is introduced in the extrusion machine, it is processed into products or waste. Direct reuse or recycling of material is not considered. Finished products must go through a quality control to determine if they meet the specifications required. Products that do not meet the quality control requirements set by the company or the buyer, will be considered as waste. Waste must be classified according to the operation in which they were generated and will need to be quantified.

13. The Ingenuity Factory Ltd. Training In Waste Reduction Using A Mock Industrial Process The production Manager will convey the information to the financial manager, who will calculate the financial balance of the production

14. The Ingenuity Factory Ltd. Training In Waste Reduction Using A Mock Industrial Process Once the production is completed... each work group will get together to discuss the evolution of the company, modifications that were made on the spot or that should be taken into account for future production batches. Some of suggestions to be discussed regarding improvement possibilities: Analyze if there is a difference between the amount of waste generated, according to the colour of the parts and defective material Determine which operations or reasons generated waste. A cause-effect diagram can be applied here with methods, materials, machinery, labour Propose measures (financial and environmental) that should be adopted to improve the company’s results.

15. University of Girona Maria Martin Maria J. Martin Facultat de Ciències. Campus Montilivi s/n E17071- Girona (Spain) Telf: +34 972 418 161 E-mail: maria.martin@udg.edu