from cp to ems introducing an environmental management system based on cleaner production stenum...
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From CP to EMS
Introducing an Environmental
Management System based on Cleaner
Production
STENUM GmbHwww.stenum.at
Slides 11 – From CP to EMS
Cleaner Production – Principles
CP considers Technologies Employees Raw materials Processes Emissions Partners Products
Slides 11 – From CP to EMS
PRODUCTSPrimary and secondary
Material emissions
Solid waste, gases, wastewater
SYSTEM UNDER CONSIDERATIO
N
MATERIALRaw material, process material, other material, water
ENERGY CARRIERSFuels, e.g.gas, oil, coal
ENERGYMass-free, e.g. electricity or district heating
Energetic emissions
Waste heat, noise
Cleaner Production – Principles
Slides 11 – From CP to EMS
ISO 14001:2004 – Continuous improvement
Continuous improvement
Environmental policy
Planning Environmental aspects Legal requirements Objectives, targets and
programme(s)
Implementation and operation Resources, roles, responsibilities and authorities Competence, training and awareness Communication Documentation Control of documents Operational control Emergency preparedness and response
Checking Monitoring and measurement Evaluation of compliance Nonconformity, corrective and
preventive action Control of records Internal audit
Management review
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Method: Plan-Do-Check-Act
PLAN: Objectives and processes are defined in accordance with the environmental policy.
DO: Processes are implemented. CHECK: Processes are monitored and
measured against the environmental policy, targets, objectives, legal requirements and requirements from stakeholders. The results are reported.
ACT: Measures to continually improve the performance of the EMS are implemented.
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What is an EMS?An EMS controls all activities of the organization
with environmental impact through responsibilities, tasks and procedures.
Environmental policy: Where do we want to go?
Check environmental impacts: Where are we?
Environmental programme and targets: Where
are we going? Environmental management system: How are we
getting there? Environmental audit: Are we on the right track?
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Benefits of an EMS for a company
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ISO 14001:2004
Requirements of an EMS:Compliance with all relevant legal
regulationsIdentification, documentation and
regular monitoring of objectives and programmes for the continuous improvement of the environmental aspects
Provision of relevant environmental information to the general public
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Elements of an EMS
Environmental policy Initial review Environmental programme Internal audit Certification audit
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Objectives of ISO 14001:2004
Based on this international standard a company shall establish a procedure
which describes and analyses the environmental impacts resulting from its activities in a comprehensive way and take effective action to improve
and control them.
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Structure of ISO 14001:2004
ISO 14001:2004 consists of 4 chapters and the appendixes A and B.
Chapter 1: Scope Chapter 2: Normative references Chapter 3: Terms Chapter 4: Requirements for an EMS
Appendix A: Instruction for application Appendix B: Comparison of ISO
14001:2004 and the quality management system standard ISO 9001:2000
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Initial environmental review
Analysis of environmental aspects and impacts
Objectives: Collection of all relevant data (material and energy
flows by volume, costs and risk) Evaluation of aspects according to their specific
environmental importance Definition of company-specific problems in the scope
of the environmental policy Setting priorities for possible improvement
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Initial environmental review Assessment of environmental impacts
Evaluation tool Analysis of specific aspects Development of opportunities for improvement
Potential environmental impacts: Location of impact: atmosphere, water, soil,
resources, etc. Environmental impact: ground ozone, hazardous
gases, smoke, radioactivity, hazardous substances, waste, soil contamination, energies, raw materials, noise, vibrations, etc.
Influence of: CO², N²O, freons, energy consumption, industrial usage, sealing of land, etc.
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Procedure for the assessment of environmental impacts
Site inspection Material and energy
analysis Gap analysis Risk assessment Legal compliance
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Assessment: Site inspection
Identifying environmental aspects and impacts of all technical equipment, processes and prior activities
Analysing the equipment and comparing to best available technology (efficiency, losses)
Analysing the possible risks arising from use of the equipment
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Assessment: Material and energy analysis
Identification of material and energy losses due to inefficiencies
Identification of toxic or environmentally hazardous substances
Balance scheme
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Assessment: Gap analysis and risk analysis
Gap analysis: Evaluation of responsibilities, existing procedures and documents related to environmental aspects
Risk analysis: Determined by relevance and probability
Example:
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Assessment: Legal compliance Determine which legal and other requirements
apply to the company’s situation Adapt procedures accordingly Define the environmental aspects concerned
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Evaluation of the initial environmental review
Prioritization of the evaluated environmental problems
Priorities set by evaluation criteriaIn practice often determined by economic
parameters High losses occur but only low investment is
necessary Responsibilities are not defined Limits are exceeded Clear non-compliance with ISO 14001:2004
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Environmental Policy – Environmental Objectives
Where are we going?
Steps to draft and issue an environmental policy1. Analysing environmental policy requirements2. Environmental policy proposal3. Identifying and evaluating aspects4. Include significant aspects in the policy5. Discussion with the heads of department
whether the policy can be used as a basis for the definition of environmental objectives
6. Issuing the environmental policy
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Environmental targets and environmental programme
Definition of targets to ensure that the objectives are met
Environmental targets must be defined to
Provide all necessary resources
Define responsibilities at all relevant levels
Ensure a continuous process of improvement
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Documentation
The EMS manual describes how the company’s EMS operates
The EMS manual should include:
Environmental policy Organizational structure Statement of objectives and
targets and the environmental improvement programme
Responsibilities and authorities of employees involved in the EMS
Documented procedures for all processes and activities with significant potential environmental impact
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Documentation of selected elements Operational control and record keeping Management of the EMS Emergency planning Internal audits
Selecting auditors Frequency Audit process Nonconformities
Information on the management system
Basic information Deeper understanding Training records
Contractor awareness
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Template for an EMS manual according to ISO 14001:2004
The EMS manual documents: Environmental policy Environmental objectives Planning process Responsibilities and
procedures for environmental protection
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Structure of an EMS
I. Table of ContentsII. General Requirements1 Environmental Policy2 Planning3 Implementation and
procedures4 Control5 Management review
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General requirements Introduction of the company Authorities – responsibilities
(environmental organization chart) Revision status and date of last revision Information for the user, contents of the
environmental manual and structure of an element
List of environmentally relevant documents
Terms and abbreviations
TOOLKIT
The environmentally relevant documents (energy and material flows, hazardous materials, waste management concept) have been defined in the respective volumes of the UNIDO CP Toolkit.
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1 Environmental policy Part of the company’s overall policy Objectives:
Definition of an environmental policy Authorization and communication within the
company Contents:
Lines of action Compliance with relevant environmental legislation Commitment to continuous improvement of
environmental aspects Reduction of environmental aspects using best
available technology
TOOLKITEnvironmental policy defined during the cleaner production programme (Volume 2).
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… building a vision
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2 Planning – Environmental aspects
Objective: Development of a procedure for auditing,
controlling and evaluating the relevant environmental aspects
Implementation: Identifying the environmental aspects of
activities, products and services Considering aspects which are connected to
products and services Introducing criteria and an identification process
for environmental aspects Documenting and filing relevant environmental
aspects
TOOLKIT
An input-output analysis carried out and documented in the Top 20 worksheets;
Worksheets for waste and emissions completed; Toxic raw materials identified; Material flow analysis and energy analysis completed.
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Relevant processes and plants
Which environmentally relevant plants are in operation?What are their regular emissions?(Flowchart, emissions)
Which unscheduled processes are relevant? (FMEA, Ishikawa)
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Example: Process map of a machine manufacturing company
Core processes:Customer consulting
Development and designPrototypingProductionSamplingServicing
Recruitment, training
CU
STO
MER
Support processes:Sales
Accounting and administrationMaintenance
Management processes:Planning
ControllingInvestment
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Evaluation of environmental effects Standard
process operation
Emergency
Red Use of toxic materialsNon-complianceHigh loss of material and energy in relation to sector-specific benchmarks. Or: No information available
Several accidents per yearConsiderable effects possibleNo precautionsOr:No information available on risks and effects
Yellow Efficiency could be improvedMaterials could be substituted
A few accidents, Precautionary measures could be improved
Green No toxic materials Full compliance, Small losses
No accidents, no risk, effective precautionary measures
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2 Planning – Legal and other requirements
Objective: Establishment of a procedure for identifying,
evaluating and updating legal requirements and requirements from stakeholders
Implementation: Identification of all legal requirements Compliance with laws and regulations Identification of a person responsible for
environmental laws
TOOLKIT No direct reference.
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2 Planning – Objectives, targets and programme(s)
Objective: Objectives and targets for each relevant
function and level of the organization
Implementation: Objectives consistent with the environmental
policy to support preventive environmental protection and minimize negative environmental impacts
Specific and measurable objectives and targets – development of indicators
TOOLKITUse of indicators described in Volume 7 and the environmental programme documented in the Cleaner production report (Volume 9).
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Policy – targets – programme
PolicyObjectives
TargetsProgramme
Action (responsibility, date, resources)
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Definition of targets
Targets could be: Best available
practices and technology
Minimization of costs Continuous
improvement
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Targets should be
Specific
Measurable
Achievable
Realistic
Time-related
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3 Implementation and operation – Framework
Objectives: Allocation of the necessary resources (personnel,
know-how, technology and financial means) Definition of responsibilities, tasks and authorities
Implementation: Appointment of an environmental management
representative Documentation of responsibilities and authorities Sufficient resources
TOOLKIT Environmental team set up and environmental manager
appointed (see Volume 2); Responsibilities are partly defined.
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Organization
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3 Implementation and operation – competence, training and awareness
Objectives: Implementation of a procedure to systemically
develop technical competences Identifying training needs, preparing a training
plan and creating awareness
Implementation: Training, information and motivation of
employees Focused training ensures competence of
personnel Reducing the risk of accidents and incidents
TOOLKIT No direct reference.
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3 Implementation and operation – Communication
Objectives: Development of a system which ensures
external and internal information
Implementation: Development of a communication concept
and its implementation Use of different instruments (meetings,
reports, etc.) Communication with relevant stakeholders
(employees, external stakeholders such as suppliers, investors, NGOs, etc.)
TOOLKITSome measures implemented (see Volume 2: Providing information for relevant stakeholders).
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Communication and information
How long does it take to inform our employees about the environmental policy? If each informed employee talks to two uninformed ones per day, on will know!
day employees1 22 43 84 165 326 647 1288 2569 512
10 1024
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Information
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3 Implementation and operation – Documentation
Objectives: Installation of a documentation system including
the elements required by ISO 14001. Implementation:
Elements of an EMS documentation (manual, checklists, forms, process instructions, etc.)
Criteria for the documentation Benefits of proper documentation:
• Easier implementation by communication and training• Easier maintenance and revision• Lower risks• Easier proof and explanation
TOOLKITCleaner production report (Volume 9) documented certain elements of an EMS (environmental policy, environmental manager, environmental team).
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3 Implementation and operation – Control of documents
Objectives: Definition of a procedure which controls the
collection, identification, registration, storage and retrieval of environmental documents
Implementation: Decision on the contents of the documents
and the objectives Explanation of the procedures for drawing up,
checking, dissemination, updating and invalidation
TOOLKIT No corresponding measures.
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3 Implementation and operation – Operational control
Objectives: Exact control of processes with
environmental impacts Identification of necessary measurements
and indicators
Implementation: Description of regulations and definition of
processes with relevant environmental impacts
• Ecological procurement• Storage of materials• Maintenance• Energy management, …
TOOLKIT
A basis for operational control has been developed during the identification of environmentally relevant company areas (Volume 1) and all relevant emissions have been identified and quantified (Volumes 3 and 4).
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Development of a set of indicators
Targets: Reduction of material losses Substitution (e.g. processes,
materials) Cost reduction Structuring of relevant data
(databases, organization charts etc.),
Presentation, analysis and monitoring of data
Decision making (choose relevant data to achieve targets)
Mass balances and costs
Targets
Set of indicators
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3 Implementation and maintenance – Emergency preparedness and
response Objectives:
Identification of potential accidents and emergencies and implementation of preventive measures
Implementation: Definition of emergency procedures for all activities
and areas Individual procedures for the use of hazardous
materials Establishing a standard procedure to prevent risks
and minimize danger Documentation of behaviour during accidents and
emergency situations
TOOLKITA list of hazardous materials has been compiled and environmental risks have been considered during the identification of priority areas (Volume 6).
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4 Checking – Monitoring and measurement
Objectives: Introduction of a procedure to measure and monitor
environmentally relevant aspects Documentation of corresponding objectives and
targets
Implementation: Permits, specific threshold values for concentrations
and loads of pollutants, applicable procedures and standards for measurement and monitoring
Measurement of process parameters Recording of measurements List of inspection equipment including parameters
(emission parameters, equipment to be used, frequency of measurements, etc.)
TOOLKITThe results of environmentally relevant measurements partly documented in the Cleaner production report (Volume 9).
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4 Checking – Evaluation of compliance
Objectives: Implementation of a procedure to evaluate
compliance with all relevant laws, regulations and legal obligations
Documentation of compliance audits
Implementation: Definition of the responsibility for implementation Regular compliance audit Monitoring compliance with the identified legal
requirements
TOOLKITNo corresponding measures during the cleaner production programme.
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4 Checking – Nonconformity, corrective and preventive action
Objectives: Implementation of a procedure for identifying
corrective measures and eliminating measures which result in nonconformity
Implementation of corrective and preventive measures
Implementation of a procedure to document gaps and corrective measures including updates
Implementation: Documentation of procedures in case of deviation
from the targets and the environmental programme
TOOLKIT
Some basic activities have been implemented in the UNIDO IPA report (Volume 7 – Worksheets 7-1 and 7-2 for the definition of indicators for an environmental management system).
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4 Checking – Control of records Objectives:
All documents used inside the company• Must be clearly identified• Are checked and revised• Must only be used in their valid version
Expired documents have to be immediately withdrawn and clearly marked as such
Implementation: Identification, filing, protection, retrieval,
retention and disposal of relevant records (documentation of trainings, records from process control, etc.)
TOOLKIT
Documentation of the environmental programme Input/output data in the IPA report Data describing waste and emissions Results of the environmental impact assessment and
environmental measures
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4 Checking – Internal audit
Objectives: Development of a procedure and programme for
internal audits and systematic preparation and documentation of the certification audit
Implementation: The regular and objective evaluation of
performance of the company, the management and the processes is systematically documented
Qualified internal auditors or external auditor
TOOLKITNo corresponding measures during the cleaner production programme.
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The tasks of an auditor
TrainingPlanning
Learning
Option identification
?
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5 Management review
Objectives: Regular management review of the system and
documentation of a procedure to ensure continuous improvement
Implementation: Regular monitoring and evaluation ensures
improvement of the environmental performance Definition of responsibilities Report including observations, conclusions and
recommendations and a list of necessary measures Various documents (results from internal audits,
reports, analyses and minutes, results of external audits, etc.)
TOOLKITNo corresponding measures during the cleaner production programme.
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Case Study: Znovin Znojmo Winery with 80 employees 100 m crowns of annual turnover 30,000 hl of production in 1997 High quality wines
Objective: Production of organically grown wine
Wine production:• Wine harvest,
Transport to cellar• Pressing• Fermentation• Filtering, treatment• Filling, packing• Delivering
Wastewater
Organic waste
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Case Study: Znovin Znojmo
Environmental programme: Environmental policy Manual Definition of procedures:
Legal compliance Materials, products and
emissions Plants Training Correction, audit, review
Training of employees Optimization of water
system
Introduction of the EMS (1995)
Review
Workshops
Collection of regulations and documents
Completion, documentation of procedures
Documentation
Coordination, training
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Case Study: Znovin Znojmo
EMS:Procedure, organization, documentation
Leg
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Mate
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Documentation:
Slides 11 – From CP to EMS
Case Study: Znovin Znojmo
Result: BOD emissions reduced by 18 t
per year!
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