cp gp day03 session 11 - implementation of cp solutions - copy
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CP ImplementationSamantha KumarasenaDeputy DirectorNational Cleaner Production Centre, Sri Lanka
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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
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When is implementation started?
From Day 1!
No cost options are implementedin no time!
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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
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What are the essential details when implementing medium and high cost options?
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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
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PlanPlan should includeMachinery & equipment
requirementsAll Material RequirementsUtilities requirementsMan Power RequirementsSpace requirementsContractual requirements
including transport/material handling
Resource and task management Plan
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Machinery & EquipmentDetailed SpecificationsPotential SuppliersComparative QuotationsAuxiliary Equipment
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Material requirementConstruction materialsDown stream equipment
◦Piping, valves◦Wires, cables and electrical fittings
Operational materials◦Chemicals◦Cleaning materials
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UtilitiesDoes the new system require
◦Water◦Compressed air◦Steam◦Chilled water◦Safety equipment
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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
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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
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Resource and task management planScheduling of tasksMaterial requirement planning?Storing of materials?Availability and safekeeping of
hand tools
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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?
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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
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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.
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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
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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.
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Technology Types
Appropriate Technology
Good Housekeeping
Innovation Clean Technology
Technological Complexity
Primacy of Environmental Motivation
low
low
high
high
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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
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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
innovation clean technology
appropriate technology
good housekeeping
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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
innovation clean technology
appropriate technology
good housekeeping
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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
innovation clean technology
appropriate technology
good housekeeping
Biomimicry
Green Chemistry
Green Engineering
Factor X
Design forSustainability
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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
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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
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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
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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
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Your Questions
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?
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Thank you!
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