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WASTE FLOW MAPPING HANDBOOK Printed by AJ E-Print AB WASTE FLOW MAPPING HANDBOOK Printed by AJ E-print AB ISBN: 978-91-7485-339-1 © Copyright: This book may be used and reproduced without charge if it is unchanged, copied in full, and this copyright note remains unchanged. Full rights and ownership of the material is claimed collectively by the authors and their organizations: Martin Kurdve Sasha Shahbazi Marcus Wendin Cecilia Bengtsson Magnus Wiktorsson Pernilla Amprazis Layout: Anna Sandberg and Moa Önell The picture at the front is copyrighted by Mälardalen University The editing of the book has been funded by XPRES and by Mistra foundation through the project Material efficiency management in manufacturing (MEMIMAN) in the program closing the loop. This handbook can be referenced to as: Kurdve, M., Shahbazi, S., Wendin, M., Bengtsson, C., Wiktorsson, M. & Amprazis, P. (2017). Waste Flow Mapping: Handbook (eng). ISBN 978-91-7485-339-1, Mälardalen University, Eskilstuna, Sweden. Summary INDUSTRIAL WASTE MANAGEMENT involves several the waste management and the production management actors and personnel from different organizations; this to- since this is crucial for the rest of the waste management gether with the fact that material waste management may process. be of less operational importance than producing the main product, means that even effective and environmentally AS A CONSEQUENCE, the Waste Flow Mapping (WFM) aware companies usually have improvement opportuni- method is useful for waste management researchers and ties in waste management. A major challenge is to develop different actors operating or managing waste handling ac- methods that support participation, visualization, and in- tivities, e.g. waste managers, environmental coordinators, tegration of operational environmental management. purchasers of waste services, line managers, improvement experts and waste management service suppliers. The THIS HANDBOOK presents methods for use in manu- WFM’s framework relies on existing and well proven tools facturing industries who wants to minimize waste and and methods to analyse the current state and find impro- improve waste management system. The methods were vement potentials with regards to material losses and inef- developed during the Mistra funded project MEMIMAN ficiencies in the handling of materials and waste. within the “Closing the Loop” program during 2012 to 2015. The experience from using the WFM method shows bene- fits like: THE MAIN METHOD “Waste Flow Mapping” or “WFM”, is an analysis method joining several common tools. Some of • Systematic problem solving. these tools are then further described separately as ways • Performance can be analysed by easy traceable KPI:s. to work with continous material management improve- • Supports team efforts, communication and ment in the industry. engagement. • Possible to standardise. THE MAIN PURPOSE of the WFM method is to provide • Supports requirements in ISO14001 such as a framework for identifying and analyzing potentials involvement of everyone and pro-activeness. for waste management and material efficiency in manu- facturing industry, including residual material values of metals, combustible and inert waste, process fluids and other hazardous waste. Waste Flow Mapping combines lean and green principles and tools e.g. Value Stream Map- ping (VSM), Eco-mapping and a Waste composition analy- sis to imply the business improvement potentials. WFM analyses the unwanted material output in order to find efficiency losses upstream, increase the value regained from residuals and ultimately reduce unnecessary input. WFM focuses on analysis of the material waste manage- ment supply chain and especially on the interface between The Waste Flow Mapping Handbook 3 Content Introduction 5 We need to utilise resources better 6 WFM context and characteristics 8 Why Waste Flow Mapping? 10 How to perform the WFM in 8 steps 11 The Waste Flow Mapping framework 12 WFM limitation and specifics 18 A. Waste hierarchy 20 B. Material sorting analysis 21 C. Eco-mapping 22 D. Material handling analysis 23 E. Environmental value stream mapping 24 F. Green performance map 25 Selected bibliography 26 4 The Waste Flow Mapping Handbook Introduction PROFESSIONAL WORK WITH MATERIAL EFFICIENCY TO ACHIEVE material efficiency it is important to reduce and waste management involves people with different the amount of spill and unnecessary use of raw material. point of view, particularly regarding natural resource Still when material ends up as waste, the efficiency is im- consumption and recycling. However the waste hierarchy, proved by climbing higher on the five step waste hierar- is accepted broadly as a prioritization tool to handle waste. chy. The higher the level in the hierarchy, the higher is the value of the output material. Hence, the approach will IN RECENT YEARS, a “green, lean” mindset has been esta- include also moving the Non Productive Output material, blished that improvement of environmental issues should or material waste, to higher stages in the waste hierarchy. be delegated from the environmental organization to the operative personnell. The updates of the environmental BASED ON THIS BACKGROUND, a research project, fun- management system standard ISO14001 are in line with ded by Mistra, has investigated material efficiency mana- this trend. This handbook introduces Waste Flow Map- gement within manufacturing industries. The industrial ping, and a systematic collection of tools and practices that partners include Volvo Group, Stena Recycling, Dynamate/ can be used by operative personnel with support from the Scania and Alfa Laval. The academic partners are Mälar- environmental organization to improve material efficien- dalen University, Lund University, the research institute cy and waste management efficiency. Swerea IVF and the Consultancy company Miljögiraff. The project has delivered both scientific publications and indu- THE FACTS that waste management may be of less ope- strial methods in order to tackle environmental issues in rational importance than producing the main products, manufacturing industries. while at the same time the interface between production management and waste management is crucial for the ef- 6 FACTS ABOUT THE WASTE FLOW MAPPING METHOD fectivity of the waste management process and material ef- • It identifies potentials of improving waste ficiency, poses a major challenge. Another obstacle is that management. the waste management process involves several actors and • It is based on case studies at more than 20 personnel from different organizations. Even effective and manufacturing sites in Sweden. environmentally aware companies often have challenges • Large potentials are found in cost and environment in communicating common goals and targets for material at the sites. efficiency. Substantial opportunities exists in development • Industrial waste management often involves several of methods that supports participation, visualization, and actors and organizations. integration into existing waste management practice. • The method integrates lean thinking and environmental management. • Visualization, ease of use and integration of current practice are the keys. The Waste Flow Mapping Handbook 5 We need to utilise natural resources better MANUFACTURING INDUSTRIES play an important role in IN THE PAST 20 YEARS, industrial waste has become a developing a resource-efficient and low-carbon economy. critical issue and causes concerns with regards to global Globalisation, industrialisation, and economic develop- sustainability and environmental effects. In 2012, the to- ment has led to increased product demand and manu- tal waste generated by households and economic activities facturing activities – we have seen a 35% increase of global in Europe amounted to 2.4 billion tons, 11% (270 million manufacturing activities over 2001-2010 while the global tons) of which was contributed by the manufacturing se- GDP increased by only 26%. The increase lead to larger vo- ctor. The total waste generated by households and econo- lumes of industrial waste and larger depletion of natural mic activities in Sweden in 2012 amounted to 156 million resources. Extraction and processing of virgin material is tons, of which the manufacturing industry contributed 6.2 energy demanding which with combustion of fossil based million tons, or approximately 4%1. Excluding the mining waste material directly affects greenhouse gases and the industry, only 47% of non-hazardous material was recycled climate. in 2012. The amount of waste incineration has increased since 2010, primarily due to increased burning of mixed SUSTAINABLE DEVELOPMENT is one of the most impor- industrial and imported waste2. tant challenges of the future that we all have to work with to protect the future climate changing and environment. SWEDISH MANUFACTURING COMPANIES, with its Most companies’ nowdays embrace visions in line with 550 000 employees account for a significant share of sustainable development. With an ever- growing consump- Swedish exports and GDP – and a significant environ- tion demand and upcoming shortages of resources, materi- mental impact. Several Swedish companies have worked al efficiency is an important part of manufacturing compa- with environmental and sustainability issues for a long nies’ operational strategies. Several companies meet this time, with environmental policies certified by ISO 14001. challenge by radical program of resource efficiency. For However, more efforts are required to broaden commit- example, Toyota has established
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