developing a workforce for the green economy advancing manufacturing summit viii: the economic and...

Developing a Workforce for the Green Economy

Advancing Manufacturing Summit VIII:The Economic and Environmental Benefits of

Sustainable Manufacturing

Wednesday March 25, 2009Purdue University – West Lafayette, Indiana

Copyright 2009 Purdue Research Foundation

Agenda

Background on development of Green Workforce Certificate program

Program structure Generalist Specialist Champion level certificate from SME

Current and Future Activities


Background

Developed as part of Purdue TAP participation in the NorthCentral Indiana WIRED program

Workforce Innovation in Regional Development (WIRED) is a workforce training program initiated by US Department of Labor (DOL) in 2006

Other TAP programs: Industrial Energy Efficiency Practitioner, Nano-structured coatings, Healthy Workforce, and Business Innovation


Genesis of an Idea

Worker skills hierarchy Awareness through Implementation

TAP MEP Lean Practitioner program Embedding Lean Manufacturing through Kaizen

Industrial Energy Efficiency Practitioner worker certificate program (IEEP) Train workers to identify & quantify opportunities; implement and

verify solutions Leveraged US DOE ITP programs Started August 2007, Wrapping up June 2009 Currently available statewide


Best Practices: Energy Efficiency

Industrial Energy Efficiency Practitioner worker certificate program Train workers to identify & quantify opportunities;

implement and verify solutions Leveraged US DOE ITP trainers & curriculum Started August 2007, Wrapping up June 2009 Currently available statewide Certificate from Purdue TAP Embed practices in facility teams


IEEP Results

111 workers trained 22 companies

engaged

After only 9 months: 8 companies

reported savings of $1.26 million and;

Average energy intensity reduction of 8.5%


Green Program Development

Started January 2008 Developed Body of Knowledge Developed overview materials Delivered pilots to gauge interest in subject

Interest in general information for everyone And specialized information for champions

Signed Agreement with SME


Green Initiative Program Structure Green Worker Generalist Training (Green 101)

Audience: General Workforce Duration: 1 days Approach: Training with Hands-on Simulation

Waste Stream Mapping (WSM) Audience: General Workforce, Green Project Teams Duration: 2 days (Day 1 - Current State / Day 2 – Future State) Approach: Training with Hands-on WSM Development

Green Worker Specialist Certificate Series Audience: Plant Engineers, Environmental Managers, Green Team Participants,

etc. Time: 1 day per module (6 modules) Approach: Training with Hands-on Simulation or On-site Activity

Green Worker Champion Certificate Preparation Time: 3 days Approach: Training only for Certificate Exam with Accreditation through Society of Manufacturing Engineers (SME)


Green 101 - Course Agenda

What is “Green”? Sustainability and Global Conditions Solid Waste Generation / Material Use Energy Management Hazard Waste Generation / Green Chemistry Climate / Air Emissions Wastewater Discharge / Water Use Environmental Management Implementation Action Plan


Green 101 Outcomes

Convey key concepts Provide true “take-

home” lessons Make the connection

with the business case for sustainability

Foundation for further engagement

Generalist Certificate


G101: Waste Hierarchy – 4Rs

Most desirable

Least desirableWaste Hierarchy

Refuse

Reduce

Reuse

Recycling

Recovery (Energy)

Disposal


G101: Business & Environmental Benefits

Business Benefits: Produces more efficient operations and reduces costs. Enhances public image - saving energy and natural resources by

reducing waste. Increasing employee morale - incorporating environmentally sound

practices. Mitigates risk for employee health and safety.

Environmental Benefits: Slows the depletion of natural resources. Reduces pollution. Conserves valuable landfill space. Reduces risk of noncompliance to regulatory obligations.


G101: The Green Approach

Minimize the potential negative environmental impacts of your business and use all of your resources as efficiently as possible.

Waste minimization means "systematically reducing waste at source". Prevention and/or reduction of waste generated; Efficient use of raw materials and packaging; Efficient use of fuel, electricity and water; Improving the quality of waste generated to facilitate recycling

and/or reduce hazard; Encouraging the 4Rs thought process throughout the business.


G101: Activity ExampleImplementation Action Plan

Team up with 1 or 2 others.

Identify at least 1 idea from the concepts we’ve discussed that you can implement right away.

Use the Environmental Waste Reduction Plan form in the Appendix to document this idea.

Complete the data requested as best as you can – make an educated guess if you don’t have exact information and complete in more detail later.


Waste Stream Mapping (WSM)

Mapping tool for Energy & Green projects IEEP worker cert. program NIST/US EPA Green Supplier Network (GSN)

program Green Workforce program

Evaluate multiple environmental waste streams

Integrates root cause analysis & problem solving tools


Waste Stream Mapping Course AgendaResource & Waste Management

Environmental Waste Streams

Seeing the Waste

What / How to Improve

Considering Alternatives

Implementation Action Plan

Course Evaluation


Waste Stream Mapping Approach

Understand how things currently operate. Identify areas where there is waste. Quantify waste and determine source(s).

Design a Green flow by applying the 4Rs to the resources/waste.

Determine the Waste Stream(s) to be improved.

Make the changes - this is the goal of mapping!

Screen the improvement options and develop a detailed implementation plan to support improvement objectives (what, who, when).

Waste Stream Scope

Current Waste FlowEntire Process/

Detailed Operations

Implementation Plan

Implementation of Improved Plan

Identify Improvement Areas

Sta

nd

ard

ize

for

late

r im

pro

vem

ent


WSM: Current State

ProcessInputs

Raw MaterialsEnergyWaterChemicals

Outputs

ProductsUseful By-products

Wastes

Air Emissions Off-spec ProductsEffluents By-productsSolid Waste Hazardous MaterialsHeat Losses Energy Inefficiencies


WSM: Getting to the Future State

Reuse

Refuse

Red

uce

Rec

ycle

Apply the 4Rs to each Waste Stream.


WSM: Getting to the Future State

What would be needed for an environmentally-preferred future state with:

Zero environmental and production wastes?

Products and processes that pose no risks to human health or the environment?

No need for environmental permits?


Specialist & Champion Modules Specialist – (six 1-day modules)

Material Use & Solid Waste Management “Dumpster Dive”

Environmental Business Management Energy Management Supply Water & Waste Water Climate Change & Air Emissions Green Chemistry & Chemical Wastes

Champion SME outcome based assessment/exam


Material Use/Solid Waste1-day Course Outline

Solid Waste Streams

Managing Solid Waste

Waste Sort (Dumpster Dive)

4Rs – Refuse, Reduce, Reuse, Recycle

Considering the Entire Lifecycle

Putting Waste Minimization in Practice

Sustaining the Improvements

Course Evaluation


Sorting by Material Category

Paper MetalGlass

Plastic

Other

X? Mixed Materials


Moving UP the Waste Hierarchy

Recycle

Reuse

Reduce

Refuse

Goal is to move as many items from the waste stream to the next level or higher.

Must consider costs and feasibility to justify the change.


Environmental Business Mgmt. 1-day Course Outline

Sustainable Consumption and Production

Green Business Components

Standard, Regulations, Permitting

Justifying a Green Investment

Environmental Footprint

Drive for Innovation

Course Evaluation


Environmental Management Success

Cross-functional cooperation for environmental improvements.

Environmental compliance and auditing programs.

Cooperation with suppliers for environmental objectives.

Cooperation with customer for eco-design, clean production and green packaging.


Environmental Metrics

Energy Used Air Emissions Materials Use Hazardous Waste Generation Chemical Use Solid Waste Generation Water Use Wastewater Discharges


Energy Management 1-day Course Outline

Non-Renewable Energy Sources

Renewable Energy Sources

Major Energy Systems

4Rs – Refuse, Reduce, Reuse, Recycle/Recover

Energy Audits

Measuring & Managing Energy Use

Course Evaluation


Primary Energy Sources

Traditional Sources

(Non-Renewable) Coal Petroleum Natural Gas Uranium

Alternative Technology

(Renewable) Wind Energy Solar Power Biomass Geothermal Hydropower


Renewable Energy - Biomass


Supply Water/Wastewater 1-day Course Outline

Water Cycle

Supply Water Resources & Conservation

Water Pollution Prevention, Reduction & Treatment (4Rs)

Water Sampling

Measuring & Managing Supply Water Use/Wastewater

Course Evaluation


Freshwater is a Finite Resource


Non-Point Source Water Pollution

Leading cause of water pollution in the U.S. today.

The pollutants include:

Excess fertilizers, herbicides, insecticides, and animal wastes from agricultural lands and residential areas.

Oil, grease, and toxic chemicals from urban runoff and energy production.

Forestry activities including tree and vegetation removal and road construction.


Climate/Air Emissions 1-day Course Outline

Air Contaminants

Industrial Hygiene

Air Pollution Prevention, Reduction & Treatment (4Rs)

Noise Pollution

Air Sampling

Measuring & Managing Emissions

Course Evaluation


Gas Phase Contaminants Gas Vapor

Aerosol Contaminants Dust Fume Mist Smog Smoke

Air Contaminants


Air Quality IndexAir Quality Index

Levels of Health ConcernNumerical

ValueMeaning

Good 0 – 50 Air quality is considered satisfactory, and air pollution poses little or no risk.

Moderate 51 – 100 Air quality is acceptable; however, for some pollutants there may be a moderate health concern for a very small number of people who are unusually sensitive to air pollution.

Unhealthy for Sensitive Groups 101 – 150

Members of sensitive groups may experience health effects. The general public is not likely to be affected.

Unhealthy 151 – 200 Everyone may begin to experience health effects; members of sensitive groups may experience more serious health effects.

Very Unhealthy 201 – 300 Health alert: everyone may experience more serious health effects.

Hazardous > 300 Health warnings of emergency conditions. The entire population is more likely to be affected.


Green Chemistry/Chemical Waste 1-day Course Outline

Principles of Green Chemistry

Auxiliary Substances

Process Reengineering

4Rs – Refuse, Reduce, Reuse, Recycle/Recover

Environmental Hazard Prevention/Reduction

Measuring & Managing Chemical Use/Waste

Course Evaluation


Green Chemistry Philosophy

Design products and processes that reduce or eliminate use and generation of hazardous substances.

Design processes to maximize the amount of raw material that ends up in the product;

Use safe, environment-benign substances whenever possible;

Design energy-efficient processes;

Utilize the best form of waste disposal -- do not create waste in the first place!


Re-engineering Processes

Switch from batch reactions to continuous processing, e.g., replace baths with showers.

Continuous processing is safer and typically gives a higher purity product.

Prepare chemicals on demand rather than storing.


Partnership with SME

National accreditation Independent verification of body of knowledge Outcome based assessment

Joint promotion Administration of exam Foundation for future work


Certificate vs. Certification

Certificate: Assessment independent of course participation Not designed to evaluate accomplishments Educator not sole provider of required body of

knowledge Certification:

Requires a field of practitioners sufficient to sustain credentialing program

Exam disconnected from curriculum and administered by third party


Timeline

Generalist – available today WSM – available today Specialist

Training on-going within NCI WIRED region All modules to be completed by 8/1/09

Champion SME to complete work 12/2009 First exams before February 2010


Purdue TAP Sustainability Portfolio

Industrial Energy Efficiency Practitioner worker certificate program

Green Workforce Generalist Specialist Champion

Waste Stream Mapping Energy & environmental surveys,

assessments, and kaizen eventsCopyright 2009 Purdue Research

Foundation

Contribution From:

Dr. Rodney G. Handy Associate Professor,

Purdue University Ph.D. Environmental

Engineering Certified Industrial

Hygienist Dr. Loring Nies

Associate Professor, Purdue University

Ph.D. Environmental Engineering

Dr. Michael Whitt Engineering Chair,

Miami Dade College Ph.D. Biomedical

Engineering


Future Events

WIRED program G101 - Kokomo

March 31st Solid Waste - Kokomo

April 2nd

Statewide Program G101 - Evansville

May 5th (tentative) G101 – Indianapolis

May 19th (tentative)

Thank You!Ethan Rogers

[email protected]

(317) 275-6817


mailto:[email protected]

developing a workforce for the green economy advancing manufacturing summit viii: the economic and...

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