- Email: [email protected]
ISO 14000 Quality Systems
Chapter 35
ISO 14000 Quality Systems Chapter Outline 35.1 Introduction 487 35.2 Evolution of the ISO Standards on Environmental Issues 488 35.3 Global Environmental Issues 489 35.4 Magna Carta on Environment 489 35.5 International Initiatives on Environmental Issues 490 35.6 Evolution of ISO 14000 Series 491 35.6.1 Formation of TC207 491 35.6.2 What is ISO 14001? 492 35.7 Water Footprint 493 35.8 The Benefits of ISO 14000 493 35.9 Engineer’s Role in Environment Protection 494
35.10 Principles of Green Design 35.11 Basic Approaches for Resolving Environmental Problems 35.11.1 Cost Oblivious Approach 35.11.2 Cost-Benefit Approach 35.12 Guidelines for Social Responsibility 35.13 5 Rs of Wastage Utilization 35.14 Conclusion Further Reading
494
495 495 495 496 496 497 498
35.1 INTRODUCTION Total quality management had evolved almost at the same time as the interest in environmental issues began to emerge and as such, it has built in similar issues as those relevant to the environment. A new concept of TQEM (total quality environmental management) has been initiated which clearly reflects the interdependency of quality and environmental problems. The industrial revolution and the consequent development of new chemical processes and other manufacturing processes involving chemicals have resulted in a lot of pollution of the environment. This pollution was considered as a necessary evil in a country’s economic development and was not taken seriously until the middle of the 20th century. Multiplication of this problem resulting in issues such as the depletion of the ozone layer has created a high level of awareness, as well as a movement among all concerned. This movement sought to control the introduction of toxic and unwanted substances into the atmosphere, and to ensure a healthy environment for people. This pollution has not only affected the quality of life, it has also affected the quality of production of industrial goods, specifically in process industries. Total Quality Management: Key Concepts and Case Studies. http://dx.doi.org/10.1016/B978-0-12-811035-5.00035-0 Copyright © 2017 BSP Books Pvt. Ltd. Published by Elsevier Inc. All rights reserved.
487
488 Total Quality Management: Key Concepts and Case Studies
In view of this, ISO formed the Strategic Advisory Group on Environment (SAGE). The purpose of formation of this group was a worldwide emphasis on management of environmental issues as a part of quality management systems.
35.2 EVOLUTION OF THE ISO STANDARDS ON ENVIRONMENTAL ISSUES Let us first give an overview of the evolution of the ISO standards on environmental issues by starting with some of the definitions of the terms related to environment management. Environment is the surroundings in which an organization operates, including the air, water, land, natural resources, flora, fauna, humans, and their interrelationships. In this context, surroundings extend from within the organization to the global systems. Environmental management system is the overall management system that includes organizational structure, planning activities, responsibilities, practices, procedures, processes and resources for developing, implementing, achieving, reviewing, and maintaining the environmental policy. Environmental management system audit is a systematic and documented verification process of objectively obtaining and evaluating evidence to determine whether an organization's environment management systems (EMS) conforms to the EMS audit criteria set by the organization or to the international standards and for communicating the result of this process to the management. Environmental policy is a statement from the organization of its intentions and principles in relation to its overall environmental performance, which provides a framework for action and for setting its environmental objectives and targets. Sustainable development: The medieval concept of industrial development was that if development had to take place, a little of environment had to be sacrificed. If the use of chemicals was necessary for a better process, discharging the effluents of these chemicals into the open was inevitable, so the concept, rather the misconception, said. During the mid-20th century, global consciousness of the need to sustain the environment, despite the development, was created. In simple terms, sustainable development is the development process without any destructive activity, thus integrating development with environment. It is the process of meeting the basic needs of the present generation without affecting the life and scope of the future generations. Environmental engineering: Environmental engineering is the application of engineering principles during all stages of setting up manufacturing units with a view of sustaining, or not adversely affecting the quality of the environment. All efforts for enhancing the public health and welfare must be taken. This includes green design, green manufacture, and development of environment-friendly processes and systems for disposal of solid, liquid, and gaseous wastes.
ISO 14000 Quality Systems Chapter | 35 489
Green design: Green design involves systematic consideration of environmental objectives and factors during all stages of developing products, processes, and services. This also includes planning for recyclability, biodegradability, and eco-friendly disposal of the products after their life cycle. This is also known as design for environment (DOE). Environmentally conscious manufacture: Environmentally conscious manufacture (ECM) is to reduce the harmful effects of manufacturing processes and methods, by reducing the hazardous wastes, emissions, and energy consumption. The principal issue is the elimination or reduction of the occupational hazards. One such step now adapted is the elimination of use of lead as an additive in petroleum refining or in paint manufacture. Another example is the mandatory phasing out of asbestos sheet manufacture. While the principles of green design as explained later involved the design stage, the ECM involves the manufacturing stage.
35.3 GLOBAL ENVIRONMENTAL ISSUES l l l l l l l l l l l l
Global warming (or green house effect) Acid rain Ozone layer depletion Transboundary movement of hazardous wastes Ocean contamination Decrease in diversity of wild life Deforestation Desertification Pollution of rivers, lakes, and ponds Water-related diseases among humans as well as animals Increasing respiratory illnesses Unmanageable solid and hazardous waste generation
35.4 MAGNA CARTA ON ENVIRONMENT At the United Nations Conference on Human Environment held in Stockholm on Jun. 5, 1972, the famous Declaration called the Magna Carta on Environment as given in the following section was made. l
l
Man has the fundamental right to freedom, equality, and adequate conditions of life in an environment of quality that permits a life of dignity and well-being. Man bears a solemn responsibility to protect and improve the environment for the present and future generations.
The U.N. General Assembly adapted the above resolution in Dec. 1972 and declared Jun. 5th as World Environment Day, which is celebrated all over the world year after year, including by the Institution of Engineers (India).
490 Total Quality Management: Key Concepts and Case Studies
35.5 INTERNATIONAL INITIATIVES ON ENVIRONMENTAL ISSUES The other global initiatives are: l l
l l l
l
l l l l
l
l
l
l
l
l
Charter on Economic Rights and Duties of States in 1974 United Nations Habitat Conference on Human Settlement held in Vancouver in 1976 United Nations Desertification Conference in Nairobi in 1977 Inter-Governmental Environmental Education Conference in Georgia in 1977 United Nations World Water Conference for “Clean drinking Water and Sanitation for All” in Nov. 1980 World Conference on Environment Development held in 1984 where the expression “Sustainable Development of Environment” was conceived. An Earth Summit for 1992 in Rio de Janeiro was planned Montreal Protocol in 1987 Clean Air Act amendments of USA in 1990 Copenhagen Amendments in Jun. 1992 United Nations Conference on Environment Development (UNCED) Earth Summit on Environment was held in Rio De Janeiro in 1992, the most strategic international effort for the preservation of the environment, where the Rio Declaration on Environment and Development was signed by all participating countries Kyoto protocol in 1997 required the industrial nations to reduce emission of carbon dioxide and other green house gases (GHG) by an average of 5.3% below the 1990 level by 2012, and this has come into force as late as Feb. 20, 2005. All the participating countries ratified this except the United States, which was blamed for its big brotherly attitude by all other nations, including European Union. In 1976, the Constitution of India was amended to reflect environmental priorities, motivated in part by the potential threat of natural resource depletion to economic growth. Earth summit 2002—Rio + 10 (+10 signifying the 10th year after the 1992 Rio Declaration) was held in Johannesburg, from Aug. 26 to Sep. 4, 2002. United Nations Conference on Sustainable Development, also known as “Rio 2012” was held in Rio de Janeiro from Jun. 13 to 22, 2012 as a 20-year follow-up of the 1992 Rio Declaration. Bonn Climate Change Conference was held in Bonn, Germany, Oct. 19–23, 2015 as a precurser to the Paris Climate Change Conference. 2015 United Nations Climate Change Conference, COP 21 or CMP 11 was held in Paris, France, from Nov. 30 to Dec. 12, 2015. Some of the positive impacts of the international initiatives are:
l
Categorizing the ozone depleting substances such as chlorofluorocarbons (CFCs) and halogens according to their ODP (ozone depletion potential) and gradual reduction of the production of these items.
ISO 14000 Quality Systems Chapter | 35 491
l
l
l l
Reduction of the use of high ODP materials in automobile and refrigeration industries. Removal of air conditioners, foam insulation materials, and CFC’s from cars before crushing them. Use of warning labels on the products containing High ODP materials. Banning of nonessential products using ozone depleting substances.
35.6 EVOLUTION OF ISO 14000 SERIES ISO was established in 1947 l
l l l l
To facilitate international trade by developing international standards in resonance to individual country standards. Has 115 members representing 95% of the world's industrial production. Has 200 technical committees. Staffed by 3000 experts. Has so far developed over 8500 standards.
In 1992, BSI published the world's first environmental management systems standard, BS 7750. This provided the basic foundation for the development in 1996 of ISO 14000 series which refers to a series of standards related to environmental management to help organizations minimize the negative impact of their operations, processes, etc., on the environment. It stresses that the industries comply with applicable laws, regulations, and other environmentally- oriented requirements, and also to continually improve on the above. This series is similar to ISO 9000 quality management, which pertains to the process of how a product is produced, rather than to the product itself.
35.6.1 Formation of TC207 The TC207 was formed after the 1972 Earth Summit in Rio de Janeiro, which appointed seven subcommittees to work on different aspects of EMS as follows: l
l l l
l l l
SC1 stationed in the United Kingdom, concentrating on EMS (environment management systems) SC2 stationed in the Netherlands, concentrating on EMS Audit SC3 stationed in Australia, concentrating on environmental labeling SC4 stationed in the United States, concentrating on environmental performance and evaluation SC5 stationed in France, concentrating on life cycle analysis SC6 stationed in Norway, concentrating on terms and definitions SC7 stationed in Germany, concentrating on environmental aspects of product standards The following standards were drafted
l
ISO 14001—environmental management system. Specification with guidance for use. This serves as the basis for certification.
492 Total Quality Management: Key Concepts and Case Studies
l
l
l l
l
l l l
l l l l
l l l l l
l
ISO 14004—environmental management system—general guidelines on principles, systems, and supporting techniques. ISO 14006—environmental management systems—guidelines for incorporating eco design ISO 14010—guidelines for environmental auditing, general principles. ISO14011—guidelines for environmental auditing, audit procedures, auditing of environmental systems ISO14012—guidelines for environmental auditing—qualification criteria for environmental auditors. ISO 14014—initial review. ISO 14015—site assessment guidelines. ISO 14020, ISO 14021, ISO 14022, ISO 14023, and ISO 14024—basically for environmental labeling. ISO 14030—discusses post-production environmental assessment. ISO 14031—environmental performance evaluation. ISO 14040, ISO 14041, ISO 14042, ISO 14043—for life cycle assessment. ISO 14046—sets guidelines and requirements for water footprint assessments of products, processes, and organizations. Includes only air and soil emissions that impact water quality in the assessment. ISO 14050—terms and definitions. ISO 14060—product standards. ISO 14062—discusses making improvements to environmental impact goals. ISO 14063—environmental communication—Guidelines and examples. ISO 14064—measuring, quantifying, and reducing greenhouse gas emissions. ISO19011—single audit protocol for both 14000 and 9000 series standards together.
35.6.2 What is ISO 14001? ISO 14001is a generic management system standard relevant to improving and managing resources more effectively and applicable to any organization from: l l l
l l
single-site to large multi-national companies high-risk companies to low-risk service organizations manufacturing, process, and the service industries, including local governments all industry sectors, including public and private sectors original equipment manufacturers and their suppliers
All standards are periodically reviewed by ISO to ensure they still meet market requirements. It is interesting to note that ISO 14001 encourages a company to continually improve its environmental performance by Deming’s P-D-C-A methodology described in more detail in the first chapter.
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35.7 WATER FOOTPRINT A water footprint is a concept introduced by UNESCO in 2002 to indicate the amount of fresh water needed by individuals, groups, or companies in order to make goods or provide services used by the community. This term was introduced in line with that of carbon footprint which indicates the total units of greenhouse gas emissions caused by an organization, event, product, or person. This in turn, originated from the ecological footprint concept of the 1990s that created worldwide awareness of the ecological impact of the industrialization. The Water Footprint Network is a Dutch-based International Learning Community which serves as a platform for connecting communities interested in sustainability, equitability, and efficiency in water usage.
35.8 THE BENEFITS OF ISO 14000 The benefits of ISO 14000 specifically of ISO 14001 include: l l l l
Reduced cost of waste management Savings in consumption of energy and materials Lower distribution costs Improved corporate image among regulators, customers, and the public
The Kaizen Consulting Group on their website http://www.kcg.com.sg/ benefits-iso14000.html, indicate the following benefits that can be achieved by complying with ISO 14000 standards. 1. Operational benefits l Efficiency, discipline, and operational integration with ISO 9000 l Greater employee involvement in business operations with a more motivated workforce l Easier to obtain operational permits and authorizations l Assists in developing and transferring technology within the company l Helps reduce pollution l Fewer operating costs l Savings from safer workplace conditions l Reduction of costs associated with emissions, discharges, waste handling, transport, and disposal l Improvements in the product as a result of process changes l Safer products 2. Environmental benefits l Minimizes hazardous and nonhazardous waste l Conserves natural resources—electricity, gas, space and water with resultant cost savings l Prevents pollution and reduces wastage
494 Total Quality Management: Key Concepts and Case Studies
3. Marketing benefits l Demonstrates to customers that the firm has met environmental expectations l Meets potential national and international government purchasing requirements l Delivers profits from marketing “green” products l Provides a competitive marketing tool l Improves international competitiveness 4. Financial benefits l Improves the organization’s relationship with insurance companies l Elimination of costs associated with conformance to conflicting national standards l Process cost savings by reduction of material and energy input l Satisfying investor/shareholder criteria l Helps reduce liability and risk l Improved access to capital
35.9 ENGINEER’S ROLE IN ENVIRONMENT PROTECTION Having discussed the roles played by the international communities, let us now view the role that should be played by the engineer in protecting the environment. 1. As an experimenter involved in environmental issues, the engineer must be aware of his role in environmental protection. 2. He should have full knowledge and confidence in their projects and should be meticulously careful to foresee the environmental effects of the project activities. 3. He should have sincere concerns about the environment during the project planning and execution stage and ask the following questions: l How does the industry effect the environment? l How far can such ill effects, if any, be controlled? l Is political or physical regularization needed? l Whether reasonable protective measures are available for immediate implementation? l Whether the engineer as an individual can ensure a safe and clean environment? 4. He should preplan all the activities and processes and the control systems without frequent re-planning or redesigns. 5. He should plan for safe exits. 6. He must budget the funds required for these control systems including, the safe exits, etc.
35.10 PRINCIPLES OF GREEN DESIGN The following are some of the principles that should be considered while designing any engineering product.
ISO 14000 Quality Systems Chapter | 35 495
l l l
l l l l l
Consider the physical and chemical structure of the material before selection. Avoid use of toxic substances. Evaluate manufacturing processes with reference to environmental impact. Design for longer life. Design for ease of assembly and disassembly. Incorporate source reduction. Design for inter changeability and recyclability. Avoid use of throw-away-after-use materials such as ultra-thin plastic bags.
35.11 BASIC APPROACHES FOR RESOLVING ENVIRONMENTAL PROBLEMS 35.11.1 Cost Oblivious Approach All efforts are to be made to make the environment as clean as possible, whatever may be the cost to do so. No level of environmental degradation is accepted. This approach is somewhat similar to that of rights and duty ethics. Though ideal, this approach has two obvious problems. l l
It is difficult to define exactly what is as clean as possible and In the highly competitive world of Indian industry, where every rupee counts, industries try to use the above indeterminate parameter as a loophole, and only try to do minimal expenditure to provide short run measures, enough to create an impression with the public that they are protecting the environment, which may not be true in the long run.
35.11.2 Cost-Benefit Approach The problems are analyzed in terms of the benefits derived by reducing the pollution problems. The costs and the benefits are weighed to determine the optimum combination. Here the target is not to achieve a completely clean environment, but an economically viable environment protection. This can be compared to the Utilitarian theory of professional ethics which says that acts are morally right if they produce the most good to the most people, giving equal consideration to everyone that is affected.
35.11.3 Difficulties of Cost-Benefit Approach This approach too suffers from four major difficulties. l
l
It is difficult to assess the true cost of human life or loss of a species, or environmental protection. It is difficult to assess accurately the costs and benefits, and much guess work or safety factors have to go into the calculations.
496 Total Quality Management: Key Concepts and Case Studies
l
l
This approach does not necessarily specify who should bear the cost and who should get the benefit. The cost-benefit analysis does not take morality and ethics into account. The decision is simply based on mathematical simulations and calculations, and there is no room for a discussion whether what is done is right or wrong.
A combination of the above with a sincere application of professional and personal ethics: l
l
l
Unlike professional decisions like bridge designs, projects involving environment affects the engineer personally, even as a member of the public. Hence the need to apply his decision-making with reference to his personal ethics. Whatever the approach may be, it is essential that the engineer applies both his professional and personal ethics, at the same time meticulously the following laws and regulations of the state. From the perspective of human health, the engineer’s responsibility to protect is clear, which must be balanced between the consideration of the wellbeing of his employer, the public, and the community.
35.12 GUIDELINES FOR SOCIAL RESPONSIBILITY On November 1, 2010, ISO launched an International Standard providing guidelines for social responsibility (SR) named ISO 26000, or simply ISO SR. As per the ISO website, its goal is to contribute to global sustainable development, by encouraging business and other organizations to practice SR to improve their impacts on their workers, their natural environments, and their communities. It is a voluntary guidance standard. There is no certification process for this, but organizations are allowed to state that they have used ISO 26000 as a guide to integrate SR into our values and practices.
35.13 5 RS OF WASTAGE UTILIZATION Environmentalists all over the world profess 4 Rs in ensuring the reduction of solid waste pollution. These are Reduce, Re-use, Recycle, and Replace (or Remanufacture). This author would like to add another R, viz, Recover. These 5 Rs are illustrated in Fig. 35.1 and supported by the subsequent case study. An interesting incident of the 1970s can be cited to illustrate the 5th R (Recover): “A medium-scale industry reported the loss of a small batch of work-inprogress components which were last seen at the inspector’s table. After a couple of days, they were located in the scrap yard, perhaps being swept off by the sweepers. Since then the company started the practice of a weekly scrap yard visit by a supervisor for identifying any such recoverable, non-scrap item. We can call this as a pre-cursor to the Gemba walk practiced today.”
ISO 14000 Quality Systems Chapter | 35 497
R
1
Symbol
Design your product or process to reduce waste generation at all stages. Value Analysis and DFSS are best illustrations.
Reduce
2
Reuse
3
Recycle
4
Replace
5
Recover
Explanation
Reuse equipment parts and fixtures. Also reuse packaging materials (boxes/bags), where possible. Install tramp oil removers that enable reuse of coolant fluids. Sort scrap metal, wood and plastic from industrial waste according to what can be recycled and what that cannot be. Choose environmentally friendly and biodegradable alternatives where possible. Use durable items instead of disposable items like use of cloth/jute bags in place of thin plastic bags. During the above sorting identify if any good component or other item is found to be wrongly scrapped and recover it after due testing.
FIG. 35.1 5 Rs of wastage utilization.
35.14 CONCLUSION Having understood the scenario of the environment issues and the evolution of the environment management systems, and the efforts of ISO and other organizations in instilling the SR of the engineers for environmental protection, it is hoped that the engineer perceives any process, or the industrial project from the environment perspective and applies his mind in achieving his objective of the project with minimal environmental degradation.
On the Lighter Side A person who likes sweets very much but is very calorie conscious would apply sugar-taste analysis to match the taste he enjoys to the sugar intake. This is akin to the cost-benefit analysis we discussed in para 35.11.
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FURTHER READING [1] [2] [3] [4] [5] [6] [7] [8]
http://en.wikipedia.org/wiki/Carbon_footprint. http://www.iso.org/iso/home/standards/management-standards/iso14000.html. http://www.qualitydigest.com/oct/iso14000.html. Kiran DR. Professional ethics and human values. 2nd ed. New Delhi: McGraw Hill, Higher Education; 2013. Kiran DR. Maintenance engineering and management—precepts and practices. BS Publications; 2014. Kiran DR. Environmental engineering and principles of green design environmental. In: Seminar at Velammal Engineering College; 2004. Kiran DR. Evolution of ISO 14000. In: Proceedings of 11th NIQR National Convention; 2005. Kiran DR. Energy audit. In: Chief Guest address at ENFUSE Seminar at Sairam Engineering College; 2005.
ISO 14000 Quality Systems Chapter Outline 35.1 Introduction 487 35.2 Evolution of the ISO Standards on Environmental Issues 488 35.3 Global Environmental Issues 489 35.4 Magna Carta on Environment 489 35.5 International Initiatives on Environmental Issues 490 35.6 Evolution of ISO 14000 Series 491 35.6.1 Formation of TC207 491 35.6.2 What is ISO 14001? 492 35.7 Water Footprint 493 35.8 The Benefits of ISO 14000 493 35.9 Engineer’s Role in Environment Protection 494
35.10 Principles of Green Design 35.11 Basic Approaches for Resolving Environmental Problems 35.11.1 Cost Oblivious Approach 35.11.2 Cost-Benefit Approach 35.12 Guidelines for Social Responsibility 35.13 5 Rs of Wastage Utilization 35.14 Conclusion Further Reading
494
495 495 495 496 496 497 498
35.1 INTRODUCTION Total quality management had evolved almost at the same time as the interest in environmental issues began to emerge and as such, it has built in similar issues as those relevant to the environment. A new concept of TQEM (total quality environmental management) has been initiated which clearly reflects the interdependency of quality and environmental problems. The industrial revolution and the consequent development of new chemical processes and other manufacturing processes involving chemicals have resulted in a lot of pollution of the environment. This pollution was considered as a necessary evil in a country’s economic development and was not taken seriously until the middle of the 20th century. Multiplication of this problem resulting in issues such as the depletion of the ozone layer has created a high level of awareness, as well as a movement among all concerned. This movement sought to control the introduction of toxic and unwanted substances into the atmosphere, and to ensure a healthy environment for people. This pollution has not only affected the quality of life, it has also affected the quality of production of industrial goods, specifically in process industries. Total Quality Management: Key Concepts and Case Studies. http://dx.doi.org/10.1016/B978-0-12-811035-5.00035-0 Copyright © 2017 BSP Books Pvt. Ltd. Published by Elsevier Inc. All rights reserved.
487
488 Total Quality Management: Key Concepts and Case Studies
In view of this, ISO formed the Strategic Advisory Group on Environment (SAGE). The purpose of formation of this group was a worldwide emphasis on management of environmental issues as a part of quality management systems.
35.2 EVOLUTION OF THE ISO STANDARDS ON ENVIRONMENTAL ISSUES Let us first give an overview of the evolution of the ISO standards on environmental issues by starting with some of the definitions of the terms related to environment management. Environment is the surroundings in which an organization operates, including the air, water, land, natural resources, flora, fauna, humans, and their interrelationships. In this context, surroundings extend from within the organization to the global systems. Environmental management system is the overall management system that includes organizational structure, planning activities, responsibilities, practices, procedures, processes and resources for developing, implementing, achieving, reviewing, and maintaining the environmental policy. Environmental management system audit is a systematic and documented verification process of objectively obtaining and evaluating evidence to determine whether an organization's environment management systems (EMS) conforms to the EMS audit criteria set by the organization or to the international standards and for communicating the result of this process to the management. Environmental policy is a statement from the organization of its intentions and principles in relation to its overall environmental performance, which provides a framework for action and for setting its environmental objectives and targets. Sustainable development: The medieval concept of industrial development was that if development had to take place, a little of environment had to be sacrificed. If the use of chemicals was necessary for a better process, discharging the effluents of these chemicals into the open was inevitable, so the concept, rather the misconception, said. During the mid-20th century, global consciousness of the need to sustain the environment, despite the development, was created. In simple terms, sustainable development is the development process without any destructive activity, thus integrating development with environment. It is the process of meeting the basic needs of the present generation without affecting the life and scope of the future generations. Environmental engineering: Environmental engineering is the application of engineering principles during all stages of setting up manufacturing units with a view of sustaining, or not adversely affecting the quality of the environment. All efforts for enhancing the public health and welfare must be taken. This includes green design, green manufacture, and development of environment-friendly processes and systems for disposal of solid, liquid, and gaseous wastes.
ISO 14000 Quality Systems Chapter | 35 489
Green design: Green design involves systematic consideration of environmental objectives and factors during all stages of developing products, processes, and services. This also includes planning for recyclability, biodegradability, and eco-friendly disposal of the products after their life cycle. This is also known as design for environment (DOE). Environmentally conscious manufacture: Environmentally conscious manufacture (ECM) is to reduce the harmful effects of manufacturing processes and methods, by reducing the hazardous wastes, emissions, and energy consumption. The principal issue is the elimination or reduction of the occupational hazards. One such step now adapted is the elimination of use of lead as an additive in petroleum refining or in paint manufacture. Another example is the mandatory phasing out of asbestos sheet manufacture. While the principles of green design as explained later involved the design stage, the ECM involves the manufacturing stage.
35.3 GLOBAL ENVIRONMENTAL ISSUES l l l l l l l l l l l l
Global warming (or green house effect) Acid rain Ozone layer depletion Transboundary movement of hazardous wastes Ocean contamination Decrease in diversity of wild life Deforestation Desertification Pollution of rivers, lakes, and ponds Water-related diseases among humans as well as animals Increasing respiratory illnesses Unmanageable solid and hazardous waste generation
35.4 MAGNA CARTA ON ENVIRONMENT At the United Nations Conference on Human Environment held in Stockholm on Jun. 5, 1972, the famous Declaration called the Magna Carta on Environment as given in the following section was made. l
l
Man has the fundamental right to freedom, equality, and adequate conditions of life in an environment of quality that permits a life of dignity and well-being. Man bears a solemn responsibility to protect and improve the environment for the present and future generations.
The U.N. General Assembly adapted the above resolution in Dec. 1972 and declared Jun. 5th as World Environment Day, which is celebrated all over the world year after year, including by the Institution of Engineers (India).
490 Total Quality Management: Key Concepts and Case Studies
35.5 INTERNATIONAL INITIATIVES ON ENVIRONMENTAL ISSUES The other global initiatives are: l l
l l l
l
l l l l
l
l
l
l
l
l
Charter on Economic Rights and Duties of States in 1974 United Nations Habitat Conference on Human Settlement held in Vancouver in 1976 United Nations Desertification Conference in Nairobi in 1977 Inter-Governmental Environmental Education Conference in Georgia in 1977 United Nations World Water Conference for “Clean drinking Water and Sanitation for All” in Nov. 1980 World Conference on Environment Development held in 1984 where the expression “Sustainable Development of Environment” was conceived. An Earth Summit for 1992 in Rio de Janeiro was planned Montreal Protocol in 1987 Clean Air Act amendments of USA in 1990 Copenhagen Amendments in Jun. 1992 United Nations Conference on Environment Development (UNCED) Earth Summit on Environment was held in Rio De Janeiro in 1992, the most strategic international effort for the preservation of the environment, where the Rio Declaration on Environment and Development was signed by all participating countries Kyoto protocol in 1997 required the industrial nations to reduce emission of carbon dioxide and other green house gases (GHG) by an average of 5.3% below the 1990 level by 2012, and this has come into force as late as Feb. 20, 2005. All the participating countries ratified this except the United States, which was blamed for its big brotherly attitude by all other nations, including European Union. In 1976, the Constitution of India was amended to reflect environmental priorities, motivated in part by the potential threat of natural resource depletion to economic growth. Earth summit 2002—Rio + 10 (+10 signifying the 10th year after the 1992 Rio Declaration) was held in Johannesburg, from Aug. 26 to Sep. 4, 2002. United Nations Conference on Sustainable Development, also known as “Rio 2012” was held in Rio de Janeiro from Jun. 13 to 22, 2012 as a 20-year follow-up of the 1992 Rio Declaration. Bonn Climate Change Conference was held in Bonn, Germany, Oct. 19–23, 2015 as a precurser to the Paris Climate Change Conference. 2015 United Nations Climate Change Conference, COP 21 or CMP 11 was held in Paris, France, from Nov. 30 to Dec. 12, 2015. Some of the positive impacts of the international initiatives are:
l
Categorizing the ozone depleting substances such as chlorofluorocarbons (CFCs) and halogens according to their ODP (ozone depletion potential) and gradual reduction of the production of these items.
ISO 14000 Quality Systems Chapter | 35 491
l
l
l l
Reduction of the use of high ODP materials in automobile and refrigeration industries. Removal of air conditioners, foam insulation materials, and CFC’s from cars before crushing them. Use of warning labels on the products containing High ODP materials. Banning of nonessential products using ozone depleting substances.
35.6 EVOLUTION OF ISO 14000 SERIES ISO was established in 1947 l
l l l l
To facilitate international trade by developing international standards in resonance to individual country standards. Has 115 members representing 95% of the world's industrial production. Has 200 technical committees. Staffed by 3000 experts. Has so far developed over 8500 standards.
In 1992, BSI published the world's first environmental management systems standard, BS 7750. This provided the basic foundation for the development in 1996 of ISO 14000 series which refers to a series of standards related to environmental management to help organizations minimize the negative impact of their operations, processes, etc., on the environment. It stresses that the industries comply with applicable laws, regulations, and other environmentally- oriented requirements, and also to continually improve on the above. This series is similar to ISO 9000 quality management, which pertains to the process of how a product is produced, rather than to the product itself.
35.6.1 Formation of TC207 The TC207 was formed after the 1972 Earth Summit in Rio de Janeiro, which appointed seven subcommittees to work on different aspects of EMS as follows: l
l l l
l l l
SC1 stationed in the United Kingdom, concentrating on EMS (environment management systems) SC2 stationed in the Netherlands, concentrating on EMS Audit SC3 stationed in Australia, concentrating on environmental labeling SC4 stationed in the United States, concentrating on environmental performance and evaluation SC5 stationed in France, concentrating on life cycle analysis SC6 stationed in Norway, concentrating on terms and definitions SC7 stationed in Germany, concentrating on environmental aspects of product standards The following standards were drafted
l
ISO 14001—environmental management system. Specification with guidance for use. This serves as the basis for certification.
492 Total Quality Management: Key Concepts and Case Studies
l
l
l l
l
l l l
l l l l
l l l l l
l
ISO 14004—environmental management system—general guidelines on principles, systems, and supporting techniques. ISO 14006—environmental management systems—guidelines for incorporating eco design ISO 14010—guidelines for environmental auditing, general principles. ISO14011—guidelines for environmental auditing, audit procedures, auditing of environmental systems ISO14012—guidelines for environmental auditing—qualification criteria for environmental auditors. ISO 14014—initial review. ISO 14015—site assessment guidelines. ISO 14020, ISO 14021, ISO 14022, ISO 14023, and ISO 14024—basically for environmental labeling. ISO 14030—discusses post-production environmental assessment. ISO 14031—environmental performance evaluation. ISO 14040, ISO 14041, ISO 14042, ISO 14043—for life cycle assessment. ISO 14046—sets guidelines and requirements for water footprint assessments of products, processes, and organizations. Includes only air and soil emissions that impact water quality in the assessment. ISO 14050—terms and definitions. ISO 14060—product standards. ISO 14062—discusses making improvements to environmental impact goals. ISO 14063—environmental communication—Guidelines and examples. ISO 14064—measuring, quantifying, and reducing greenhouse gas emissions. ISO19011—single audit protocol for both 14000 and 9000 series standards together.
35.6.2 What is ISO 14001? ISO 14001is a generic management system standard relevant to improving and managing resources more effectively and applicable to any organization from: l l l
l l
single-site to large multi-national companies high-risk companies to low-risk service organizations manufacturing, process, and the service industries, including local governments all industry sectors, including public and private sectors original equipment manufacturers and their suppliers
All standards are periodically reviewed by ISO to ensure they still meet market requirements. It is interesting to note that ISO 14001 encourages a company to continually improve its environmental performance by Deming’s P-D-C-A methodology described in more detail in the first chapter.
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35.7 WATER FOOTPRINT A water footprint is a concept introduced by UNESCO in 2002 to indicate the amount of fresh water needed by individuals, groups, or companies in order to make goods or provide services used by the community. This term was introduced in line with that of carbon footprint which indicates the total units of greenhouse gas emissions caused by an organization, event, product, or person. This in turn, originated from the ecological footprint concept of the 1990s that created worldwide awareness of the ecological impact of the industrialization. The Water Footprint Network is a Dutch-based International Learning Community which serves as a platform for connecting communities interested in sustainability, equitability, and efficiency in water usage.
35.8 THE BENEFITS OF ISO 14000 The benefits of ISO 14000 specifically of ISO 14001 include: l l l l
Reduced cost of waste management Savings in consumption of energy and materials Lower distribution costs Improved corporate image among regulators, customers, and the public
The Kaizen Consulting Group on their website http://www.kcg.com.sg/ benefits-iso14000.html, indicate the following benefits that can be achieved by complying with ISO 14000 standards. 1. Operational benefits l Efficiency, discipline, and operational integration with ISO 9000 l Greater employee involvement in business operations with a more motivated workforce l Easier to obtain operational permits and authorizations l Assists in developing and transferring technology within the company l Helps reduce pollution l Fewer operating costs l Savings from safer workplace conditions l Reduction of costs associated with emissions, discharges, waste handling, transport, and disposal l Improvements in the product as a result of process changes l Safer products 2. Environmental benefits l Minimizes hazardous and nonhazardous waste l Conserves natural resources—electricity, gas, space and water with resultant cost savings l Prevents pollution and reduces wastage
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3. Marketing benefits l Demonstrates to customers that the firm has met environmental expectations l Meets potential national and international government purchasing requirements l Delivers profits from marketing “green” products l Provides a competitive marketing tool l Improves international competitiveness 4. Financial benefits l Improves the organization’s relationship with insurance companies l Elimination of costs associated with conformance to conflicting national standards l Process cost savings by reduction of material and energy input l Satisfying investor/shareholder criteria l Helps reduce liability and risk l Improved access to capital
35.9 ENGINEER’S ROLE IN ENVIRONMENT PROTECTION Having discussed the roles played by the international communities, let us now view the role that should be played by the engineer in protecting the environment. 1. As an experimenter involved in environmental issues, the engineer must be aware of his role in environmental protection. 2. He should have full knowledge and confidence in their projects and should be meticulously careful to foresee the environmental effects of the project activities. 3. He should have sincere concerns about the environment during the project planning and execution stage and ask the following questions: l How does the industry effect the environment? l How far can such ill effects, if any, be controlled? l Is political or physical regularization needed? l Whether reasonable protective measures are available for immediate implementation? l Whether the engineer as an individual can ensure a safe and clean environment? 4. He should preplan all the activities and processes and the control systems without frequent re-planning or redesigns. 5. He should plan for safe exits. 6. He must budget the funds required for these control systems including, the safe exits, etc.
35.10 PRINCIPLES OF GREEN DESIGN The following are some of the principles that should be considered while designing any engineering product.
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Consider the physical and chemical structure of the material before selection. Avoid use of toxic substances. Evaluate manufacturing processes with reference to environmental impact. Design for longer life. Design for ease of assembly and disassembly. Incorporate source reduction. Design for inter changeability and recyclability. Avoid use of throw-away-after-use materials such as ultra-thin plastic bags.
35.11 BASIC APPROACHES FOR RESOLVING ENVIRONMENTAL PROBLEMS 35.11.1 Cost Oblivious Approach All efforts are to be made to make the environment as clean as possible, whatever may be the cost to do so. No level of environmental degradation is accepted. This approach is somewhat similar to that of rights and duty ethics. Though ideal, this approach has two obvious problems. l l
It is difficult to define exactly what is as clean as possible and In the highly competitive world of Indian industry, where every rupee counts, industries try to use the above indeterminate parameter as a loophole, and only try to do minimal expenditure to provide short run measures, enough to create an impression with the public that they are protecting the environment, which may not be true in the long run.
35.11.2 Cost-Benefit Approach The problems are analyzed in terms of the benefits derived by reducing the pollution problems. The costs and the benefits are weighed to determine the optimum combination. Here the target is not to achieve a completely clean environment, but an economically viable environment protection. This can be compared to the Utilitarian theory of professional ethics which says that acts are morally right if they produce the most good to the most people, giving equal consideration to everyone that is affected.
35.11.3 Difficulties of Cost-Benefit Approach This approach too suffers from four major difficulties. l
l
It is difficult to assess the true cost of human life or loss of a species, or environmental protection. It is difficult to assess accurately the costs and benefits, and much guess work or safety factors have to go into the calculations.
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l
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This approach does not necessarily specify who should bear the cost and who should get the benefit. The cost-benefit analysis does not take morality and ethics into account. The decision is simply based on mathematical simulations and calculations, and there is no room for a discussion whether what is done is right or wrong.
A combination of the above with a sincere application of professional and personal ethics: l
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Unlike professional decisions like bridge designs, projects involving environment affects the engineer personally, even as a member of the public. Hence the need to apply his decision-making with reference to his personal ethics. Whatever the approach may be, it is essential that the engineer applies both his professional and personal ethics, at the same time meticulously the following laws and regulations of the state. From the perspective of human health, the engineer’s responsibility to protect is clear, which must be balanced between the consideration of the wellbeing of his employer, the public, and the community.
35.12 GUIDELINES FOR SOCIAL RESPONSIBILITY On November 1, 2010, ISO launched an International Standard providing guidelines for social responsibility (SR) named ISO 26000, or simply ISO SR. As per the ISO website, its goal is to contribute to global sustainable development, by encouraging business and other organizations to practice SR to improve their impacts on their workers, their natural environments, and their communities. It is a voluntary guidance standard. There is no certification process for this, but organizations are allowed to state that they have used ISO 26000 as a guide to integrate SR into our values and practices.
35.13 5 RS OF WASTAGE UTILIZATION Environmentalists all over the world profess 4 Rs in ensuring the reduction of solid waste pollution. These are Reduce, Re-use, Recycle, and Replace (or Remanufacture). This author would like to add another R, viz, Recover. These 5 Rs are illustrated in Fig. 35.1 and supported by the subsequent case study. An interesting incident of the 1970s can be cited to illustrate the 5th R (Recover): “A medium-scale industry reported the loss of a small batch of work-inprogress components which were last seen at the inspector’s table. After a couple of days, they were located in the scrap yard, perhaps being swept off by the sweepers. Since then the company started the practice of a weekly scrap yard visit by a supervisor for identifying any such recoverable, non-scrap item. We can call this as a pre-cursor to the Gemba walk practiced today.”
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R
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Symbol
Design your product or process to reduce waste generation at all stages. Value Analysis and DFSS are best illustrations.
Reduce
2
Reuse
3
Recycle
4
Replace
5
Recover
Explanation
Reuse equipment parts and fixtures. Also reuse packaging materials (boxes/bags), where possible. Install tramp oil removers that enable reuse of coolant fluids. Sort scrap metal, wood and plastic from industrial waste according to what can be recycled and what that cannot be. Choose environmentally friendly and biodegradable alternatives where possible. Use durable items instead of disposable items like use of cloth/jute bags in place of thin plastic bags. During the above sorting identify if any good component or other item is found to be wrongly scrapped and recover it after due testing.
FIG. 35.1 5 Rs of wastage utilization.
35.14 CONCLUSION Having understood the scenario of the environment issues and the evolution of the environment management systems, and the efforts of ISO and other organizations in instilling the SR of the engineers for environmental protection, it is hoped that the engineer perceives any process, or the industrial project from the environment perspective and applies his mind in achieving his objective of the project with minimal environmental degradation.
On the Lighter Side A person who likes sweets very much but is very calorie conscious would apply sugar-taste analysis to match the taste he enjoys to the sugar intake. This is akin to the cost-benefit analysis we discussed in para 35.11.
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FURTHER READING [1] [2] [3] [4] [5] [6] [7] [8]
http://en.wikipedia.org/wiki/Carbon_footprint. http://www.iso.org/iso/home/standards/management-standards/iso14000.html. http://www.qualitydigest.com/oct/iso14000.html. Kiran DR. Professional ethics and human values. 2nd ed. New Delhi: McGraw Hill, Higher Education; 2013. Kiran DR. Maintenance engineering and management—precepts and practices. BS Publications; 2014. Kiran DR. Environmental engineering and principles of green design environmental. In: Seminar at Velammal Engineering College; 2004. Kiran DR. Evolution of ISO 14000. In: Proceedings of 11th NIQR National Convention; 2005. Kiran DR. Energy audit. In: Chief Guest address at ENFUSE Seminar at Sairam Engineering College; 2005.