KMU, Chris Kappert, ISO 9002 / 14001 Integration ISO 9002 / 14001 Integration at KMU WHO? WHAT? WHERE? HOW?

KMU, Chris Kappert, ISO 9002 / 14001 Integration

ISO 9002 / 14001Integration at KMU

WHO? WHAT? WHERE? HOW?

Konica Manufacturing USA, Inc.(KMU)

Product: Color Photographic Paper Located in Whitsett, NC (East of Greensboro on I85/40)


K.M.U. General Statistics

KMU manufactures color photographic paper and photographic emulsions

First Coating: June 13, 1989~ 350 employeesContinuous operation (12 hr shifts)300,000 ft² in manufacturing facilitySubsidiary of Konica Corporation (Japan)


KMU’s Quality System StatusISO 9002/1987 certified - July 1994

ISO 9002/1994 certified - July 1995

Documentation (prior to EMS implementation)

only items “affecting” quality

Level 1 (Quality Manual) - 1 Level 2 (System) documents - 41 Level 3 (Instruction) documents - 2200 Level 4 (Forms) documents - 1000


KMU Quality SystemDocumentation Structure

Level 1

Level 2

Level 3(2200 +)

Level 4 (1000 +)

QMS Manual

QMS Systems

QMS Procedures / Forms

Records


KMU’s Environmental Status

Title V Air Permit (Mostly VOCs)Large Quantity Hazardous Waste GeneratorWastewater discharge to local POTWStormwater Permit Silver Recovery (Wastewater Pretreatment)Involved with TSCA, FIFRA, ATF,

EPCRA (Tier II & TRI).


KMU’s Q&E Structure(prior to EMS Implementation)

Quality Systems Manager (Chris Kappert) Report to QA Senior Manager (ISO Rep) Supervise Document Control Assistant who

controls flow and distribution of documents

Environmental Engineer (Sean Bir) Report to Engineering Senior Manager Environmental Reporting and Performance

Improvement


ISO 14001 vs ISO 9001INTEGRATION DECISION

Know the differences / similarities in the standards

Know advantages / disadvantages of the integration options

Know your system & your company


ISO 14001 vs ISO 9001DIFFERENCES



EMS vs QMS

TC207 vs TC176

6 elements vs 20 elements (1994 version)

“Established” vs “Documented” Procedures

Possible future integration or alignment



Environmental Aspects and Impacts (4.3.1)

Legal and Other Requirements (4.3.2)

Environmental Programmes (4.3.4)

Communication (4.4.3)

Emergency Preparedness and Response (4.4.7)


ISO 14001 vs ISO 9001SIMILARITIES

PolicyTargets & ObjectivesRoles & ResponsibilitiesTrainingSupplier Control / PurchasingDocument Control


ISO 14001 vs ISO 9001SIMILARITIES

Operational ControlCalibrationCorrective and Preventive ActionRecordsAuditingManagement Review


ISO 14001 vs ISO 9001INTEGRATION OPTIONS

Separate Systems

Partially Integrated Systems

Fully Integrated Systems


Separate Systems

QMS Manual

QMS Level 2's(approx. one for each

of the 20 elements)

QMS Level 3's(as needed)

EMS Manual

EMS Level 2's(approx. one for each

of the 6 elements)

EMS Level 3's(as needed)


Advantages of Separate Systems

Easy to audit (external)

One-to-one documentation generation

Can be handled by independent groups

Thorough coverage of requirements


Disadvantages of Separate Systems

REDUNDANCY! REDUNDANCY!Results in large system of documentationNo plant-wide alignmentRequires extra staffingInternal audits harder“Re-inventing the wheel”Start over if ISO 14001 / 9001 merge


Partially Integrated Systems

QMS Manual EMS Manual

Level 2's(approx 1 for each

9001 element+ ? for 14001)

Level 3's(as needed)


Advantages ofPartially Integrated Systems

Relatively easy audits (external & internal)Builds on existing systemsCan be managed by groups working closely

together or combinedReduced costsConsistencyEmployee buy-in


Disadvantages ofPartially Integrated Systems

Alignment of ISO 9001 / 14001 elementsISO 9001 systems may not adequately

cover 14001 requirementsUnclear responsibilities between QMS and

EMS management representativesComplex procedures (level 2’s)


Fully Integrated SystemsManagement

SystemsManual




Advantages ofFully Integrated Systems

Easy to audit (internal)Consistent plant-wide philosophy, planning,

and information managementNo redundanciesReduced costsSystem already established if ISO 14001 /

9001 merge


Disadvantages ofFully Integrated Systems

Complex documents (level 1 and 2’s)Difficult to audit (external)Unclear responsibility between QMS and

EMS management representativesDifficult to implement after 9001 has

already been established


ISO 14001 vs ISO 9001INTEGRATION DECISION

Know your current system Does it lend itself to integration?

What is the function of the various documents in your current system?

???

Know your company Could we do it like that?


Which is right for you

?


KMU’s Implementation ofPartially Integrated System ISO 9002 system established ISO 14001 EMS Manual written

(references made to existing system documentation and unknown new documents)

Existing systems modifiedNo new level 2’s addedMany environmental specific level 3’s

added


KMU’sPartially Integrated System

QMS Manual EMS Manual

Level 2's(approx 1 for each

9002 element)



KMU’s Implementation & Integration TeamTeam Leaders

Quality Systems Manager Environmental Engineer

Core Team Representatives from each major functional area; 10

experienced people

Employees Involved 100%!!


ISO 14000 CostsKMU Person-Hours

ITEM / Person Hours QSE EE DENR* KEG OtherExternal Training 16 40 40 0 0Documentation Framework / Integration 160 40 8 0 0Aspect Determination 20 80 20 50 8Work Instructions 24 60 50 80 80Level I Training 16 40 20 0 360Level II Training 0 32 16 30 180Gap Analysis / Internal Audits 16 40 24 0 12Pre-assessment Planning / Performance 40 32 32 0 24Assessment Planning / Performance 60 40 40 0 80

352 404 250 160 744

1910QSE = KMU Quality Systems Engineer

EE = KMU Environmental Engineer

DENR = NC State Consultant provided at no cost to KMU

KEG = 10 member cross-plant team


KMU’s ISO 14001 Timeline

Spring 1997 Key Personnel Receive ISO 14001 Training. Drafted Environmental Policy

Summer 1997 Decide to Develop Integrated Management

System Incorporating Quality and Environmental Commitments.



Fall 1997 Join NC ISO 14001 Pilot Program Complete Environmental Manual (& Policy) Created the Konica Environmental Group with

members from all KMU departments. Identify Environmental Aspects and Impacts.



Winter 1997/1998 Developed Environmental Targets and

Objectives for 1998. Completed Initial Environmental Training of all

KMU Personnel. Registrar Performed ISO 14001 Preassessment

of KMU’s Management System.


KMU’s ISO 14001 TimelineApril 1998

Completed Implementation of EMS.

June 15-19, 1998 Passed KMU ISO 14001 and 9002 Certification

Audit.

TOTAL ELAPSED TIME:

14 months (8 months dedicated)


14001 Registration!!!!!!!


KMU’s Documentation System(after EMS Implementation)Documentation - items “affecting” quality

or environmental performance Quality Manual - 1 Environmental Manual - 1 Level 2 (System) documents - 41

(none created; 40% modified for EMS) Level 3 (Instruction) documents - 2320

(~120 created + 5% modified for EMS) Level 4 (Forms) documents - 1050

(~5% created new or just added to control system)


KMU Management SystemDocumentation Structure

EMS & QMS Manuals

Systems Documents

Procedures / Forms

Records

Level 1 Level 1

Level 2

Level 3(2320 +)

Level 4 (1050 +)


KMU’s Q&E ISO Structure(after EMS Implementation)

Environmental Engineer / Systems Manager (Dorothy Vannoy) Report to Engineering Senior Manager (ISO rep) Responsible for all (ISO) Management Systems Environmental Reporting and Performance

Improvement Document Control Assistant still controls flow of

document revisions and distribution


Benefits Realized…..… from EMS IMPLEMENTATION

Increased Employee Awareness & Involvement

Better Knowledge Preservation & Transfer

$ Increased Efficiency & Reduced Costs

Improved Environmental Performance

Enhanced Public Image

Enhanced Image with Regulators


Benefits Realized…..… from EMS (partial) INTEGRATION

Reduced head count

Simplified introduction into daily operations

Minimal increase in documentation


INTEGRATION REFERENCES

Book: Stepping Up to ISO 14000 - Integrating Environmental Quality with ISO 9000 and TQMSubhash C. Puri, $39.00

www.ppress.com

ASQ Course: Integrating ISO 14001 into QS-9000 Certified Systems - $835June 20-21, 2000, Greensboro, NC

NC DENR - FREE!Your Auditor - $?