EMS Implementation and Operation ISO 14001 Requirements
Dec 30, 2015
EMS Implementation and Operation
ISO 14001 Requirements
4.4 Implementation and Operation
4.4.1 Structure and responsibility
4.4.2 Training, awareness, competence
4.4.3 Communication
4.4.4 EMS documentation
4.4.5 Document control
4.4.6 Operational control
4.4.7 Emergency preparedness/response
4.4.1 Structure and Responsibility
• Roles, responsibility and authorities defined, documented and communicated
• Management provide essential resources
• Appoint management representative– Ensure EMS requirements are established,
implemented and maintained– Report to top management on EMS
performance
4.4.2 Training, Awareness, Competence
• Identify training needs
• Personnel performing work which can cause significant impacts:– require appropriate training– competent based on appropriate
education, training and/or experience
(cont’d)
4.4.2 Training, Awareness, Competence
• Procedures for employee awareness of – importance of conformance – significant impacts of work activities and
benefits of improved performance– roles and responsibilities in achieving
conformance– potential consequences of departure from
operating procedures
(cont’d)
4.4.3 Communication
• Procedures for:– internal communication– receiving, documenting and
responding to external interested parties
• External communication processes on significant aspects must be recorded
4.4.4 EMS Documentation
• Information to:– describe core elements of the EMS– provide direction to related documentation
• Can be paper or electronic
Document Organization Scheme
Proof that system works
Records
1.EMS
Manual
3. Work instructionsBOM’s, specs, drawings,
visual standards
4. External Documents
6. Completed Forms & Other Records
Policy
Implementationof policy
“How to” for procedures
ControlledDocuments
5. Blank Forms
2. Procedures, programs, permits
4.4.5 Document Control
• Procedures for controlling documents to ensure that:– they can be located– they are periodically reviewed, revised, and
approved– current versions available at essential locations– obsolete documents are promptly removed– any obsolete documents retained for legal and/or
knowledge preservation are suitably identified
(cont’d)
4.4.5 Document Control
• Legible
• Dates of revision and readily identifiable
• Maintained in an orderly manner
• Retained for a specified period
• Creation and modification procedures
(cont’d)
4.4.6 Operational Control
• Identify operations and activities associated with significant aspects
• Plan activities, including maintenance• Ensure activities are carried out under specified
conditions:– Documented procedures where absence could lead
to deviations– Stipulate operating criteria– Procedures related to significant aspects of goods
and services purchased from suppliers
4.4.7 Emergency Preparedness and Response
• Procedures to:
– identify potential for and respond to accidents and emergencies
– prevent and mitigate environmental impacts.
• Review and revise
• Periodically test
EMS Mentoring
Eaton Corporation, Supercharger Division
EMS Implementation and Operation
ISO 14001 - Continuous Improvement Cycle
EMS Responsibility Matrix
?ACTIVITY DEPT/POSITION? PLANT
MGR
EHS QUAL. HR ENG. MFG.
ENG.
MFG. PURCH. ACCT. MAINT. IT
4.2 ENVIRONMENTAL POLICY
Define policy – DRAFT R R P P P P P P P P
Ensure policy is appropriate and includes requiredelements.
R P P P P P P P P P
Ensure policy is available to Public P P R
4.3 PLANNING
Determine and document facility’s environmentalaspects
P R P P R R P
Determine and document legal and otherrequirements applicable to the Env. Aspects
P R
Set objectives and targets R P P P P P P P P P
Environmental management program to meetobjectives and targets. (identify and establishprojects to minimize or eliminate impact of significantenv. aspects.)
P R R R R
4.4 IMPLEMENTATION
Structure and responsibility – appoint mgt. Rep. Whoshall have defined resp. and authority for ensuringthe EMS is established and implemented; reports onprogress and performance of EMS to top mgt.
R P
Training – Determine individuals in roles that impactor influence significant env. aspects.
P R P P
Training – Define and document roles andresponsibilities in achieving EMS goals and targets atall levels of org. P R
Training – Develop training P R P P P
Training
• Steering Team
• Internal Auditors
• Awareness Level
• Job Specific Training
• Utilized existing system to track and document
Communications
• Postings
• Training (refresher and new employee)
• Progress Reports (goals and targets)
• Incident Reports• Surveys, suggestion program, committee
participation, e-mail, open door policy.
• External communications (inquiries, compliance reports, and regulatory inspections)
Documents and Document Control
• Used existing system for QS 9000.• Keep EMS documents separate from QS
documents within the system, but all documents are controlled in the same manner.
• Develop a matrix of important documents and retention times.
Operational Controls
Significant Aspect Objective/Target Environmental Program Operational Control
Energy Use 5% reduction/SC= 58 KW/SC
EMP-1, Replace equipment withhigher efficient models.
Lighting Control Schedule
Maintaining proper fluidconcentrationPer Method SheetMachine coolant change outand disposal per CMS#214086Waste Water Treatment
Preventative Maintenance(filter changes, machinecleaning)
Cutting FluidManagement
10% reduction/SC
= 0.9 lbs/SC
EMP-2,a. Switch machines to
biologically stable coolant.b. Improve WWT efficiency by
improving oil split and filtercleansing.
Purchasing –New EquipmentChemical approval
Solid Wastes 20% reduction/SC= 1.3 lbs/SC
EMP-3a. Form Recycle Team toimplement paper, cardboard,plastics and pallet recycling.
Waste segregation anddisposal
Questions?
Eaton Corporation, Supercharger Division
EMS Implementation and Operation
EMS Mentoring Workshop Day 2
Day 1 Review and Day 2 Overview
EMS Implementation and Operation Elements Cont.
EMS Checking and Corrective Action Elements
EMS Management Review Elements
EMS SWOT Analysis/Planning Group Exercise
EMS Mentoring
Yamaha Motors Manufacturing Corporation of America
EMS Implementation and Operation
ISO and 8-step Process
Align ISO program with current processes
Step 1: Problem Statement
“YMMC generates and ships hazardous waste off-site for disposal.”
ISO and 8-step Process
Project selection – ISO objective
ISO 14001 Objective
“Reduce amount of hazardous waste shipped off-site.”
ISO and 8-step Process
Step 2: Current Level Attributes –
Loss Tracking MEK Usage Tracking
Step 2: Current Level Attributes –
Loss Tracking Hazardous Waste Disposal Tracking
ISO and 8-step Process
Step 3: Setting Baseline and Target Hazardous Waste Disposal
MEK/Paint Hazardous Waste Shipments
4235
3135
2530
19801815
2255
2860 2915
1980
3520
2585
0
500
1000
1500
2000
2500
3000
3500
4000
4500
Apr
-00
May
-00
Jun-
00
Jul-0
0
Aug
-00
Sep
-00
Oct
-00
Nov
-00
Dec
-00
Jan-
01
Feb
-01
Mar
-01
Gal
lon
s o
f H
azar
do
us
Was
te
MEK/Paint Generated (gallons)
Average 2,900 gallons/month
ISO and 8-step Process
Step 3: Setting Baseline and Target
Monthly Hazardous Waste Disposal
0
500
1,000
1,500
2,000
2,500
3,000
3,500
Current Goal
ISO and 8-step Process
50% Reduction
($84,000/yr or 17,000 gal/yr)
Improvement Approach
Methodology:
• Data Analysis
• Chemical Analysis
• Case Studies - Pollution Prevention
• Brainstorming
• Site Visit to US Can - observe onsite distillation
ISO and 8-step Process
Step 4: Root Cause Analysis
Other2%
Waste MEK and Paint85%
Waste MEK and Styrene
3%
Waste IPA10%
YMMC Hazardous Waste Generation
ISO and 8-step Process
Brainstorming Results:
1. Non-hazardous Line Cleaner - Pilot
2. Off-site distillation - Quotes
3. Purchase Distillation Equipment - Quotes
4. Mobile on-site distillation - Pilot
ISO and 8-step Process
Step 5: Countermeasure
Distillation Process
ISO and 8-step Process
Step 5: Countermeasure
ISO and 8-step Process
Step 6: Implementation of Critical Path
ISO and 8-step Process
Step 7: Confirmation of Effects and Results
Lab Analysis Results of Distilled MEK:• Outside Lab• PPG Lab Analysis
Conducted Onsite Pilot Distillation with First Source:
ISO and 8-step Process
Monthly Hazardous Waste Disposal
0
500
1,000
1,500
2,000
2,500
3,000
3,500
BaselineCurrent
Step 7: Confirmation of Effects and Results
ISO and 8-step Process
73% Reduction($126,000/yr or 25,500 gal/yr)
Intangible Results:
• Reduction in Risk and Liability
• Improved YMMC’s Environmental Image
ISO and 8-step Process
Step 8: Prevention of Reoccurrence
Created ISO Operation Standard:
ISO and 8-step Process
ISO 14001 Training Needs Matrix
Environmental Training
General ISO (IMS) Awareness
Initial
Emergency Response / Evacuation
Initial
RCRA / Emergency Response
Initial and Annual
Initial and Annual
External Annual
External Annual
Initial and Annual
HAZWOPER 40 hourInitial
CertificationInitial
Certification
HAZWOPER 8 hour Refresher
Annual Annual
Wastewater Treatment Training Credits (external)
6 credits / 2yrs
6 credits / 2yrs
Environmental Training (external)
24 hours/yr minimum
24 hours/yr minimum
Significant Environmental Impact Operation Standard Training
Initial
Training
Communication
Document Creation Schedule
Document Control
• Contingency Plan
• Emergency Evacuation
YMMC Contingency Plan TestSOP-0082
Scheduled Date Test Date Test Type Attendees Comments
4Q2000 12/13/00 Spill Response J im Gentryidentified possible future release risk - PAR #004 (work order) will be issued to Maintenance to repair pavement
12/13/00 Lonnie Booth Good ResponseJerry PuckettBill BohachJodie Jackowiec
2Q2001 8/2/01 Evacuation All Facility8/2/01 create flow chart responsibility
create emergency kit for executivesincorporate into EHS Yamaha Video
Emergency Preparedness & Response
Questions?
Yamaha Motor Manufacturing Corporation of America
EMS Implementation and Operation
EMS/P2 IntegrationP2
EMS Implementation and Operation
Structure and Responsibility
Require representation from all departments and business units on EMS Team
Make process supervisors and department managers responsible for the environmental performance of their units.
Use full-cost accounting to link P2 and resource use efficiency performance to operating budget and employee compensation rules.
Structure and Responsibility
Where feasible, rotate staff between environmental and production responsibilities.
Integrate quality and environmental improvement teams into one single workgroup focused on production efficiency.
Give highest decision-making priority to projects with significant P2/resource conservation benefits.
Include P2 and resource management performance in job descriptions and employee evaluations.
EMS Communication
EMS bulletin boards, company newsletters, company meetings and training
Communicate how and where P2 and resource conservation is integrated within your EMS
External Open houses, press releases, focus groups, annual reports, advertising, community meetings, permit applications, industry mentoring
Internal
Training, Awareness & Competence
Training on the waste/resource management hierarchy and the use of “systems approach” tools within the EMS Basic training - P2 and resource conservation concepts
All Employees
Develop an EMS employee incentive program
Specific training - P2 resources and solutions applicable to employee functions
Create friendly competitions for environmental improvement between departments and shifts
Training, Awareness & Competence
Understanding of P2 measures with potential to reduce or eliminate the aspect . Use the Internet to tap into the local and global network of practical P2 and resource conservation solutions.
Staff performing or managing an activity linked to a significant environmental aspect
Post process maps in work areas w/ environmental aspects
Highlight significant aspects
Use as visual element of standard operating procedure
EMS Operational Controls
Document all P2 and resource conservation suggestions, implemented or not.
Create a standard form
Collate the form as a reference tool for staff
EMS Operational Controls
EMS Operational Controls
Develop a written procedure for:
Using the Waste/Resource Management Hierarchy
Reporting P2 and resource conservation progress to senior
management
Monitoring, recording and posting the full cost of
significant aspects
Ensuring that aspects with written procedures required
because their absence could cause a significant environmental
impact receive the highest P2 priority