Supplier Development Initiative on Resource Conservation & Pollution Prevention Material & Energy Resource Considerations

WASTE OF INVENTORY

Root Causes Symptoms  Poor process planning and setup  Leftover production materials  Lack of knowledge of the process  High disposal costs  Inadequate measurement systems  Unnecessary chemical costs  Incomplete job instructions  High utility costs  Outdated technologies  Excess storage & handling  Weak process control  Need for material & energy conservation practices

Corrective Actions: INV meter or measure material usage where possible INV know the optimum amount of material needed for each process INV monitor, record, and post material usage compared to desired usage for all operations INV update written user or job instructions to include material use specifications INV utilize up-to-date technology to minimize waste and pollution INV utilize energy efficient replacement lighting and equipment INV install thermostats and/or timers on heating systems INV install motion detection switches on lighting systems INV disconnect ballasts in unused light fixtures to reduce energy use INV minimize facility and task lighting to only what is needed INV find ways to reduce water usage INV minimize dragout losses by slowing dragout equipment INV utilize all materials in a container prior to its disposal INV utilize just-in-time systems for indirect or nonproduction materials as well as production materials INV purchase high volume usage materials/chemicals in bulk INV eliminate shelf-life expirations

WASTE OF OVERPRODUCTION

Root Causes Symptoms  Waste of materials from “engineered” scrap  High waste volumes  Overspecification beyond acceptable  Excess packaging and dunnage requirements  Insufficient reuse and recycling  High disposal costs  Specification of virgin material use only  High utility costs  Need for material & energy conservation practices  Need for waste handling & treatment equipment  Weak process control  No recycled-content in packaging & production material

Corrective Actions: OVR utilize only recyclable & returnable packaging materials with recycled content OVR specify minimal packaging needed to protect products OVR optimize space usage in containers & packaging OVR find ways to reduce, reuse/return, recycle, or make all containers & packaging add value to products OVR find ways to reclaim, reuse, or recycle waste materials that can not be prevented OVR specify the use of recycled content materials for products and supplies OVR minimize overspecification which consumes excess raw materials and can generate environmental waste OVR set material dispensers for optimum discharge OVR adjust paint timing equipment to minimize overspray OVR utilize only two-sided copying OVR recirculate and reuse cooling water OVR insulate active steam lines and other heat loss sources OVR utilize waste heat for other heating purposes OVR utilize high energy efficient motors Supplier Development Initiative on Resource Conservation & Pollution Prevention Material & Energy Resource Considerations

WASTE OF CORRECTION

Root Causes Symptoms  Need to consider environmental & health impacts  High toxic emission rates  Incomplete process instructions  Hazardous waste generation  Improper handling procedures  Increased employee exposures  Need for appropriate supplier specifications  Frequent spill cleanups  Insufficient workplace org. & visual controls  Excess material usage  Deficient planned maintenance  High pollution control costs  High utility costs  High disposal costs

Corrective Actions: COR consider environmental & human health impacts of product manufacturing, use & disposal during design stages COR provide suppliers with performance specifications not prescriptive specifications for parts and supplies COR require incoming packaging to be easily disassembled for recycling & plastics labelled with proper SPI codes COR eliminate discharges to the sewer or treatment plant that contain toxic materials COR substitute materials that reduce toxic emissions & hazardous wastes COR post information that increases awareness of the cost & environmental impacts of waste COR purchase only non-toxic materials and products COR utilize non-solvent based coatings and cleaners COR provide instructions for proper material handling to eliminate spills and waste COR eliminate sources of material contamination COR avoid the purchase or generation of out-of-spec materials COR minimize evaporative and heat losses from tanks and equipment COR repair fluid, compressed air, and steam leaks COR keep dock and pedestrial door closed during cold weather COR establish preventive maintenance program to repair fluid leaks, reduce lubricant use, seal windows& doors

WASTE OF MOVEMENT

Root Causes Symptoms  Need to consider environmental impacts  High fuel costs  Inadequate waste management planning  Excess material handling  Poor workplace organization  High disposal costs  Poor material handling practices  Excess repair  Lack of reuse and recycling procedures  Inadequate preventive maintenance

Corrective Actions: MOV establish material separation techniques & management procedures for recyclable materials MOV incorporate waste segregation methods (for recycling) into workplace layouts MOV avoid material damage during handling by fork truck or manually MOV keep conveyors in good working order to avoid materials damage MOV consider fuel consumption and air emission reductions when optimizing product transportation logistics Supplier Development Initiative on Resource Conservation & Pollution Prevention Material & Energy Resource Considerations

WASTE OF PROCESSING

Root Causes Symptoms  Incomplete job instructions  High waste volumes  Weak process control  High disposal costs  Outdated technologies  High utility costs  Need for material & energy conservation practices  High indirect chemical costs  Excess equipment idling time

Corrective Actions: PRC segregate waste streams in-process to avoid manual or mechanical sorting PRO look for opportunities to use waste materials as feedstock for other processes & products, internal & external PRO stagger startups to reduce energy demand PRO shut off equipment not needed, especially during peak electrical demand periods PRO ensure that motors are not oversized for their needs PRO install wipers on dispensing equipment to prevent dripping PRO purchase chemical management services based on production volumes, not chemical volumes PRO adjust boiler systems and/or furnaces to ensure complete combustion PRO preheat boiler feedwater and air used in combustion to conserve energy and fuel PRO turn off chillers when outside air is cold enough for cooling needs PRO provide compressed air only at minimum pressures required for production PRO use less energy intensive methods than compressed air for cooling, parts moving and agitating liquids

WASTE OF WAITING

Root Causes Symptoms  Poor management practices  High utility & fuel costs  High coolant/lubrication usage

Corrective Actions: WAI minimize machine idling time to reduce energy use and extent coolant & lubrication life WAI limit vehicle & fuel-powered equipment idling to conserve fuel and reduce emissions WAI eliminate use of tanks and process lines where coolants & lubricants become stagnant

WASTE OF MOTION

Root Causes Symptoms  Poor workplace organization  High utility costs  Inadequate waste management planning  Excess equipment movement  Poor management practices

Corrective Actions: MOT establish efficient workplace layouts to minimize fork truck movement, energy use, and emissions MOT keep recycling segregation areas for waste materials close to operators MOT turn off fans and motors after-hours to reduce energy use MOT minimize non-value-added equipment movement to reduce cycle time & thus, energy usage