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Waste Cause Analysis and CP Techniques
Samantha KumarasenaDeputy DirectorNational Cleaner Production Centre, Sri Lanka
05/03/2023 1Samantha Kumarasena
Option generation
An organized, participative activity!
Brainstorming is a good tool!!
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Cause Analysis (Reasons for Waste)
How Do We Find Waste Causes Ask Questions
What, Why, Where, When, How Never WHO
Make Observations with CP Team Conduct Brainstorming sessions Use suitable Tools such as
Fishbone Diagram
Is the waste caused due to…
Choice & quality input
material
Choice of technology
Technical status of
equipment
Operation & maintenance
Personal skills & motivation
Product specification
Management planning & information
systems
Design & layout of plant &
machinery
Waste Cause Categories
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Choice & Quality of Input Material
• low quality• Impurities• Composition• Size of material• Cleaning requirement• Toxicity / hazardousness
IS THIS THE BEST RAW MATERIAL?
Choice of Production Technology
Obsolete technologies Available technologiesModern technologies Appropriate technology
Obsolete equipment Absence of indicator
instruments Improperly working
controllers
Technical Status of Equipment
Design and Layout of Equipment
Arrangement at the production floor
Placement and arrangement of stores
Material conveying method Long distance distribution Capacity balance Service / utility needs
Product Specification
Dimensions (size) Colors Surface finishPackaging
requirementPerformance
properties
• Inefficient process controls
• Cleanliness / housekeeping
• Correct load / parameters• Frequent down time• Power failures• Improper maintenance /
lack of maintenance planning
Operation & Maintenance
• Lack of production planning
• Wrong information• Inadequate information• Inventory management• Absence of record
keeping culture
Management Planning & Information Systems
• Attitudes• Carelessness• Short cuts• Incomplete work
Personal Skills & Motivation
Cleaner Production techniques Input substitutionGood housekeepingBetter process control Product modification Equipment modification Technology change On-site recovery/reuse Creation of useful by products
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Classification of CP Techniques
CP TECHNIQUES
PRODUCT MODIFICATION
RECYCLING
Onsite recovery and reuse
Creation ofUseful by-products
SOURCE REDUCTION
Process
Change
s
GoodHouse-Keeping
InputMaterialchange
Better process control
Equipment
modification
Technology change
Good housekeeping
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Good Housekeeping
Take appropriate operational actions to prevent:
- leaks- spills
Formulate & enforce to practice appropriate operational instructions
• Tighten valves, check & repair leaking pumps, valves, pipes to reduce/ avoid leaks
• Store chemicals in appropriate places
• Insulate steam pipes and design proper steam distribution system
Spills The spilling of dyes and chemicals at a
washing plant amounted to Rs 37,600/- per month
Drips In a rubber factory the dripping of a
chemical was estimated to be Rs 46,000/- per month
Leaks The steam leaks in a textile industry
was equivalent to 9300 liters of furnace oil (Rs 67,000/-) per month (23% of total cost)
Input substitution
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Input SubstitutionSubstitute input materials where
ever possible with- less toxic materials- renewable materials- materials with longer
lifetime
• Replace organic solvents with water• Replace Formic acid by Hydrochloric
Acid in textile dyeing• Replace chlorine bleaching with O3
bleaching• Use of soft water for preparation of dye
bath: Higher dye exhaustion levels lower dye consumption
Better process control
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Better Process ControlModify:
- operational procedures- equipment instructions
Process record keeping in order to run the processes more efficiently and at lower waste and emission generation rates
Improving process controls – e.g.
• Optimize and control operating parameters in the plant to reduce product reprocessing rate
eg: pH, temperature, time• Optimize the boiler operations
Combustion (CO2> 12%, O2< 2%)Reduce heat losses (surface, flue gas) therefore reduce fuel consumption
• Optimize fabric : liquor ratio for dyeing
Reduce energy, water and chemical consumption
Equipment modification
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Equipment ModificationModify the existing production
equipment and utilities to- run the processes at higher
efficiency- lower waste and emission
generation ratesRepair faulty equipment to reduce
losses and rejectsReplace obsolete equipment or parts
• Multiple countercurrent rinsing• Installation of hood above dryer drums
for faster moisture withdrawal • Replace solvent cleaning with
mechanical cleaning• Use of high pressure jet nozzles for
for screen washing in printing- efficient cleaning and save
water
Technology Change
Change the product & process technology in order to minimize waste and emission generation and optimize the resource efficiency
Technology change
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Product modification
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Product Modification
Modify the product characteristicsin order:
- to minimize the environmental impacts of the product during or after its use (disposal) - to minimize the environmental impacts of its production
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Product Modification
Raw Material Extraction Manufacture Transportation Use End-of-life
On-site recovery/reuse
Water, Packaging, containers !!!!
On site Recovery/Reuse
Reuse/recovery or recycling of the wasted materials in the same process or outside, for same or another application
Recovery, reuse, recycle• Water of last rinse for the first
rinse• Chrome recovery in leather
industry• In plastic injection moulding the
waste is recycled• Condensate recovery in boilers
Production of Useful By-products
Reuse of the wasted materials for manufacturing of another product.
eg:• Waste tyres are used for energy recovery• Use of fabric cuttings for mattress
manufacturing• Coconut water from DC mills
- Juice Preparation- Vinegar production
Creation of useful by products
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Your Questions
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?
Thank you!
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