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How is the product to be produced Make or buy decision Process selection Equipment selection Process time determination
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The desired outputs of the design phase are
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Processes Equipment Raw materials required Formal documents Route sheet Assembly chart Operation process chart Precedence diagram
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Table 1.2 gives an example of a route sheet. Figures 1.4, 1.5 and 1.6 give examples of the assembly chart, operation process chart, and precedence diagram respectively.
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DEFINITION OF SOLID WASTE ANALYSIS AND MINIMIZATION
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TABLE 1.2 DATA
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ROUTING SHEET DATA REQUIREMENT PRODUCTION EXAMPLE
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Component name and number Operation description and number Equipment description Unit times Raw material requirement
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Plunger housing Shape, drill, and cut off Automatic screw machining Setup time: 5 h operation time and 0.005 h per component 1 in diameter 12 ft of aluminum bar per 80 components
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Body Plunger housing
Spring
Plunger
O-ring 3251 Seat ring SA-1 A-1
O-ring Plunger retainer
Lock nut
Pipe plug
I-1 Packaging materials
Assembly chart.
THE SYSTEMS APPROACH FOR WASTE MINIMIZATION
OPERATION PROCESS CHART Company A.R.C., Inc. Prepared by J. A.
Product
Air Flow Regulator
Date
Plunger retainer 4150 0105
Shape, drill tap inside thread, hook outside thread, inspect
Seat ring 3250 0102
Shape, drill, cut off, inspect
Plunger 3252 0103
Mill, shape, cut off, inspect
Plunger housing 3254
Plunger housing 0101 Cut to length Grind to length
2200 Shape, 0104 drill, length cut off Machine 0204 slot and thread 0304 Drill (8) holes
0301 Deburr Drill (4) holes, 0401 tap, ream, countersink 0501 Drill, tap, roll ream, countersink
Deburr and 0404 blowout inspect
0601 Drill, tap Spring 3253 O-ring 3251 O-ring, 3255 3656 SA1 Locknut 4250 Pipe plug 1050 Remove burrs on inside and inspect 0701 inner and outer surfaces A1
I1 Packaging A4
Operation process chart.
The schedule design phase examines the following issues:
How much to produce (lot sizing) When to produce (production scheduling) How long to produce (market forecasts)
The determination of the outputs of a system seems very straightforward at rst examination, as it should be de ned in the goal. In the television example, it is 30,000 televisions per year. This is only a partial answer as there will also be unintended outputs, which includes waste and by-products, that must also be considered. Waste
DEFINITION OF SOLID WASTE ANALYSIS AND MINIMIZATION
Packaging 1050 4250 0401
0501 0101
0201 3250 32 52 32 54
41 50
0103 0204 0104 0304 0105 3251 3253 3255 0404 SA-1
Precedence diagram.
management becomes a new unintended problem created by the system. In the previously discusssed 30,000 unit television set manufactoring example, this includes wire fragments to food waste from employees lunches. In terms of solid waste, managers and decisions makers must take a reactive role to resolve these problems, ranging from recycling to reuse. A better approach is to handle these issues proactively when determining processes and inputs. From a system approach, this book will provide waste analysis and minimization techniques and strategies for all phases of the supply chain.
1.6 Summary
The systems approach in an integral concept to the successful implementation of solid waste minimization and serves as the basis for the solution methodologies. This holistic approach considers the entire supply chain and addresses waste generation
SUMMARY
issues at the earliest phases possible, often preventing the generation of the waste and eliminating waste management issues all together. The solid waste management hierarchy ensures that solution alternatives are applied in the preferred order and serve as guidelines thought the analysis process. In a manner of thinking, the systems approach examines the solid waste problem from a macro level and the hierarchy examines it from a micro level. An understanding and agreement to the meaning of the terms used in solid waste management are essential in communication and problem resolution. These terms, which include source reduction, recycling, pollution prevention, and solid waste analysis and minimization, are often used as synonyms, but as discussed in this chapter can carry different meanings. These terms are not intended to be comprehensive, but provide a general framework to aid in a meaningful discussion of these issues. When promoting solid waste minimization to decision makers, it is critical to relate the bene ts to both the environment and the economics of the company. Creating this win-win situation in a manager s eyes will signi cantly enhance the likelihood that solid waste minimization recommendation will be implemented.
BACKGROUND AND FUNDAMENTALS OF SOLID WASTE ANALYSIS AND MINIMIZATION
2.1 Introduction
Solid waste generation continues to increase in the United States, and as discussed in this chapter, solid waste measurement and reduction tools have not kept pace. Each year, U.S. industrial facilities generate and dispose of 7.6 billion tons of nonhazardous industrial waste (www.epa.gov, retrieved August 12, 2002). This solid waste is measured and monitored by various U.S. government agencies, such as the U.S. Environmental Protection Agency and similar state-level organizations. These agencies also develop methods to reduce the solid waste generation levels by promoting waste reduction and recycling. As mentioned in Chap. 1, a common problem the government agencies face from U.S. corporations is perceived poor economics of solid waste reduction programs. Many corporate leaders believe waste reduction and recycling are not pro table for their company. U.S. corporations feel they are in the business of manufacturing products and providing services, not recycling and waste disposal. This common attitude is problematic and hinders waste reduction efforts across the United States. The paradigm must be shifted from this attitude to one that stresses concern for the environment makes good business sense. Corporate environmental concern makes sense because it can be economically bene cial, positively raises pubic opinion, and assists corporations to comply with environmental regulations. The U.S. Department of Labor estimates over 4.8 million corporations operated in the United States in the year 2001. The fact that such a large number of corporations are operating in the United States, each generating various amounts and compositions of solid waste, stresses the importance of widespread waste reduction. Economical justi cation of waste reduction will increase top corporations managements to improve the environment and minimize the waste each disposes. The evaluation and
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