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34.5 Potential Technologies and Strategies
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Several low-cost strategies are available to reduce or eliminate solid waste generation. Once the waste audit has been conducted and annual generation amounts and compositions have been determined, the hierarchy of solid waste reduction can be applied to reduce, reuse, and recycle components of the waste stream. Several very common waste minimization applications in the sector, in order of preference, include
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Waste elimination Several process changes or packaging can be implemented to
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eliminate waste. This range from reducing packaging materials, scrap and defect rates, paperless faxes, and setting copier defaults to print on both sides of the paper. Waste reuse Several relatively simple options exist to reuse materials that have been traditionally disposed of at land lls. Two very common examples are pallets
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and component bindings for in-house transportation. Many organizations that currently utilize wood pallets have been very successful in implementing use of returnable plastic pallets. In terms of in-house bindings, many companies use rubber bands to secure subcomponents for transfer. Upon inspection and evaluation, many of these companies dispose of this as general waste. A simple process of collecting and reusing rubber bands saved one organization $3500 per year. Part washers may be required to clean various caps and plugs that could be reused. Recycle If waste elimination or reduction options are not available, recycling of scrap, paper, plastic, and metal waste should be implemented, in most cases working with an outsourced supplier. Energy recovery Finally, if recycling options are not available, energy recovery may be utilized to convert the waste into electricity at specialized sites. Internet searches will generate several organizations in local areas.
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34.6 Implementation and Approach
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To implement the proposed approaches listed earlier, several approaches are recommended. In unionized environments, buy-in and support from the local union is critical. This will ensure that employees support and understand the program. This will signi cantly increase the success rate of the program. An employee suggestion box and rewards program can also generate great ideas. Many companies have taken an approach where the originator of a process change is entitled to a percentage of the costs savings usually in the magnitude of 1 to 5 percent over the rst year. Second, many manufacturing organizations, speci cally the automotive industry, have been successful in tracking waste generation by work unit or production unit. This may create healthy competition between employees and build teamwork. In addition, awards can be given to top performing units on a quarterly or annual basis. Supply-chain modi cations and the greening of suppliers may also generate excellent waste minimization results. This may be necessary when considering returnable containers and the reuse of certain items. In line with this, is the concept of zero land ll facilities. A zero land ll facility applies the aggressive philosophy of implementing waste minimization working toward the goal of zero land ll. This is accomplished through numerous organization-wide methods, including the focused use of composting and energy recovery.
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34.7 Case Study
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In 2002 The University of Toledo waste minimization team conducted a solid waste audit for an automobile-stamping plant in Northwest Ohio. The objectives of this project were to gain an overall understanding of the plant, identify all major solid waste streams, and then to suggest some areas for reducing, reusing, and recycling materials in the waste stream. At the time of the audit the facility had a small recycling program. The plant collected several materials including mixed of ce paper, cardboard, aluminum
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INDUSTRIAL AND COMMERCIAL MACHINERY INCLUDING AUTOMOTIVE MANUFACTURING
cans, metal-stamping scrap, plastic-stamping scrap, and oily wastewater. The facility was 790,000 ft2 and operated 7 days per week. The annual waste hauling costs were $25,080, which included special wastes. The waste materials currently recycled at the plant are shown in Table 34.2. The table also displays the total annual weight (in terms of pounds) of the currently
TABLE 34.2 TOTAL ANNUAL WASTE STREAM FOR AUTOMOTIVE CASE STUDY YEAR 2000 (TONS) YEAR 2001 (TONS) AVERAGE (TONS/YEAR) AVERAGE (LB/YEAR)
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