Cp gp day03 session 11 - implementation of cp solutions - copy

CP ImplementationSamantha KumarasenaDeputy DirectorNational Cleaner Production Centre, Sri Lanka

05/01/2023 Samantha Kumarasena 2

Cleaner Production OptionsLow hanging fruits - No cost options

- Low cost, short termInvestment oriented

- Medium cost, medium term- High cost, long term


When is implementation started?

From Day 1!

No cost options are implementedin no time!


When is implementation started? Medium and high cost options that needs a feasibility evaluation most of the time, are normally implemented after the CP assessment completed


What are the essential details when implementing medium and high cost options?


Essential details Detailed technical specification Detailed construction planComparative evaluation &

selection of supplierUtility supply and infrastructureAlternative arrangements for

meeting production & minimizing down time

Commissioning and training


PlanPlan should includeMachinery & equipment

requirementsAll Material RequirementsUtilities requirementsMan Power RequirementsSpace requirementsContractual requirements

including transport/material handling

Resource and task management Plan


Machinery & EquipmentDetailed SpecificationsPotential SuppliersComparative QuotationsAuxiliary Equipment


Material requirementConstruction materialsDown stream equipment

◦Piping, valves◦Wires, cables and electrical fittings

Operational materials◦Chemicals◦Cleaning materials


UtilitiesDoes the new system require

◦Water◦Compressed air◦Steam◦Chilled water◦Safety equipment


Space and layoutDoes the new system needs

extra space and is it availableWill the installation disturb the

current operationWill it cause extra safety risks to

the movement of employees


Man power and trainingDo we have staff for the extra

work?Are they skilled, competent and

trained?Are they experienced?Continuous training of Human

Recourses is an investment


Resource and task management planScheduling of tasksMaterial requirement planning?Storing of materials?Availability and safekeeping of

hand tools


InitiateHave you established your

baseline data?Have you established your

desired output from the project?Have you developed the

performance monitoring indicators?

Can you identify some indicators?


Activity Oct Nov Dec Jan Feb March

Conducting a big cleaning daySorting out all items & labeling Preparing suitableinfrastructure Placing all items in right orderTraining the employeesProgress evaluationRe-implementing with changes

Implementation plan


Execute CP implementation

Supervise construction and installation:◦control progress of work;◦control equipment & installation specification.

Prepare for start up:◦purchase start up chemicals, spare parts etc.;

◦prepare preventive maintenance schedule;◦train operators, supervisors and technicians.


Measure progress

Track waste generation, materials usage, and cost savings

Take into account variation in production level

Document your results and your cost savings

Celebrate your successes


Monitor & evaluate results Evaluate progress!1. Compare measured benefits with

expected benefits;2. Identify ways to further improve the

benefits of the technical installations;3. Verify installation and operation

according to specifications.

05/01/2023 Samantha Kumarasena19

Technology Types

Appropriate Technology

Good Housekeeping

Innovation Clean Technology

Technological Complexity

Primacy of Environmental Motivation

low

low

high

high

05/01/2023 Samantha Kumarasena20

Good HousekeepingImprovement of operating and

maintenance practices and management

Repair and clean up Eliminate leaks, spills, etc.

Standardise and train Operating practices and skills

Invest in basic process controls Water meters, thermometers, timers, etc

◦ low or no investment, apart from staff time and management focus

innovation clean technology

appropriate technology

good housekeeping

05/01/2023 Samantha Kumarasena

21

Appropriate TechnologyUse the right technology

from cost, productivity, quality and environmental perspectives◦ Eg. Rotary Screen printing

in Textile printing industry◦ Medium to high cost investments with multiple benefits



good housekeeping


22

Clean TechnologyUse advanced

technology primarily for an environmental outcome◦ Eg. Reverse Osmosis

for water recovery ◦ Medium to high cost

investments with primarily environmental (and/or community) benefits



good housekeeping


23

InnovationDevelop and apply new

processes and products that are ‘better and greener’

Limited experience within the NCPC network

Opportunity for greater collaboration with R&TD sector

◦ High cost investments with element of risk and prospect of significant benefits including environmental and resource productivity



good housekeeping

Biomimicry

Green Chemistry

Green Engineering

Factor X

Design forSustainability


Case 1 – Old fabric and towel dyeing FactorySteam supply by old steam boiler unitDyeing with jigger and yarn dyeing

machinePlace is thoroughly disorganizedDemoralized workforceNo waste management facilities and

systemsUn insulated steam pipes, steam and

water leaks


Case 2 – Knitted fabric dyeing facilityOld furnace oil boilerOverflow dyeing machinesHigh liquor ratio Jet machinesManual color machineWorkplace organized; 5S

implementedNo quantification of waterOld dye mixing unitPoor layout - Stores kept far away


Case 3 – Apparel washing plantFurnace oil boilerManually operated washing machinesRenewed and expanded several timesState of the Art waste water treatment

facilitySolid Waste Management systemAll resource supplies are quantifiedWon 5S and Productivity AwardsISO 14001 EMS Certified


Case 4 – Knitted fabric processing millNewly established in a IPZ; layout

optimized Fully automated dyes and

chemicals supply systemProgrammable dyeing machinesMachines in the complete range

of sizesRecognized as the best in the

country

Your Questions


?

Thank you!
