Managing Environmental Aspects

An Integrated FMEA Approach

Why do we Assess Risk?

It’s our job Ensure compliance Protect our assets Balance our concerns Drive improvement

Why Integrate?

Incorporate risk as part of “big picture” Common tools provide for:

– Decreased Training Needs– Increased Skill– Improved Interaction

More Eyes = More Opportunities for Improvement

When we don’t integrate…

Conflicting information in different areas We risk focusing on trees instead of the forest We may initiate projects with conflicting goals We may find ourselves competing for vital

resources

Goals for this Session:

Identify potential environmental impacts using a process approach

Analyze environmental risks in light of multiple business objectives

Define appropriate control measures Formulate strategic improvement projects

Borrowing from the Quality Toolbox

“Go with the flow”- process flow diagrams Find the flaws - FMEA Create a game plan - SOPs, etc. Summarize Controls - Control Plan Reduce Risk - CI Process…Review & Repeat!

Process Flow Diagrams

What do we have? (inputs)

Where/Why? (process) What’s left? (outputs,

waste) How do we control? Who do we train? How can we reduce?

CGL Process Section

Utility Process OutputsInputs

Coil From EntrySectionPF-08

PDI Info

Coil advancesthrough Cleaner

SOP-UT-01

Process Water

Caustic Cleaner

Wastewater toWWTPF-14

Coil advances toFurnace

SOP-PR-01

Gas:Natural Gas, Nitrogen,

Hydrogen

Coil advances toPot WI-PR-01

Coil advancesthrough air knivesand baffle plates

SOP-PR-03

GA?

Coil through EdgeBurners

Coil through GalvRig SOP-PR-05Electricity

Cooling SolutionCtg Wt OK?

Coil throughQuench

Coil through SPM(on if rqd)

SOP-PR-02

Coil through TL(on if rqd)

SOP-PR-04

Coil throughstenciler (on if rqd)

WI-PR-06

Coil through RollCoater (on if rqd)

WI-UT-02

Roll CoaterChemicals

Stenciler Ink

Coil To ExitInspection

PF-10

Rolling Solution

Rags to HazWaste Disposal

50-foot Records

ZincAdd ZincWI-PR-02

Yes

NoAuto

ControlLoop

NOX emissions

Equipment TimeBased Data

(from various)

Pot Sample to LabWI-LB-23Take Sample

Dross

See Control Plan for Monitoringand Measurement Requirements

Line StopOccurs

See Environmental FMEAfor Significant Aspects

Assess the Risk - FMEA

Lay out the process steps Identify hazards and effects for each action Assess the risk = Severity / Probability Summarize Controls Prioritize Actions - the power of FMEA

Karen’s Kwik Lube

Welcome to the Kwik Lube Krew! Your job today will be to:

– Map the Kwik Lube process– Identify potential environmental impacts– Assess their various risks– Draft a game plan for improvement

Let’s Begin…

Process Map - Reminders

All inputs captured (information, materials, tools, equipment)

All steps clear All outputs captured (final product, information, wastes) The cross-functional model

Identifying Hazards/Aspects

Aspects can include any solid, liquid or gas added to, used in, created by, or left over as the result of a process that has the potential to impact the environment

Aspects must include elements that may not be under our direct control, but over which we can be expected to have an influence (e.g., work of contractors, etc.).

Consider plans for process changes and improvements

Identifying Effects/Impacts

Impacts May Include: emissions to air releases to water or land use of raw materials or natural resources use/emission of energy creation of waste Safety would include motion, energy, chemicals,

etc.

Severity

Score Effect Severity – Environmental Impact

10 Catastrophic Irreparable damage to environment or living beings

9 Critical Spill, release, incident resulting in major remedy costs, fines, prison

7 Significant Spill, release, or incident resulting in moderate remedy costs and/or potential fines

5 Marginal Spill, release, or incident resulting in minor remedy costs, no penalties

3 Minor Environmental impact not regulated / no potential to exceed requirements

1 Positive Provides net environmental benefit

Severity - Other Elements

Score Effect Severity – Personnel Severity – Property

10 Catastrophic Multiple Deaths Catastrophic damage to equipment

9 Critical Death Major damage to equipment / Significant delay

7 Significant Major injury, disabling illness

Minor damage to equipment / Significant delay

5 Marginal Lost time injury or illness

Equipment damage unlikely / Minor delay

3 Minor Minor Injury, First Aid, Near Miss

Equipment damage improbable

1 Positive Promotes / improves health

None

Severity - Other Elements

Score Effect Severity – Resource Consumption/Waste Generation

Severity – Public Concerns

10 Catastrophic Destruction of resources or uncontrolled release of hazardous waste resulting in irreparable damage

Regulatory intervention, shut-down of operations

9 Critical Endangerment of resources or uncontrolled release of hazardous waste repairable over a number of years

Permanent public disfavor / disruption to operations

7 Significant Resource consumption exceeds industry standards. Waste streams of excessive quantity and/or hazardous nature.

Public protest / disruption to plant operations

5 Marginal Resource consumption at or below industry standards. Waste reduction / lean efforts have minimized waste streams.

Public disfavor

3 Minor Resource consumption at or below industry standards. Waste streams are recycled or reused.

Public concern (local)

1 Positive Provides resource recovery Improves Public Perception

Probability

Ranking Effect Probability

10 Frequent Occurrence almost certain in exposure interval

9 Probable Quite likely to occur in exposure interval

7 Occasional May occur in exposure interval

5 Remote Not likely to occur in exposure interval

3 Improbable So unlikely it can be assumed occurrence may not be expected

1 Impossible Redundant/fail-safe engineering controls in place

Risk = S x P

ProbabilitySEVERITY

  10 9 7 5 3 110   High9  7   Med5  3   Low1

Controls

Controlling Conditions– Engineering Controls– Pre-treatment Systems– Housekeeping

Controlling Behavior– Controlled Practices (SOPs, Work Instructions)– Training & Communication– Behavior Modification

Control

Ranking Effect Control

10 Almost Impossible

Control is non-existent, non-functioning, or impossible to achieve

9 Slight Control is subject to human error or misuse, no supervision provided. Includes general awareness training.

7 Low Control is subject to human error or misuse; activity is supervised. Includes general awareness training.

5 Medium Engineering controls isolate risk during proper use (e.g., guarding), no verification measures in place.

3 High Engineering controls isolate risk during proper use (e.g., guarding), verification measures in place.

1 Almost Certain Interlocks or other measures prevent the bodily contact with hazard at all time.

RPN

Risk Prioritization Number S x P x C

– Multiplication helps stratify hazards Relative Measure of Risk - relies on:

– Well-defined criteria– Consistent Application

Determining Significance

Define the criteria– Severity– Risk

Avoid “lines in the sand” Continual improvement should drive change

How can we improve?

Focus on THE PROCESS– Modify process to change or eliminate step– Reduce Severity– Reduce Probability– Institute or Improve Control

Use ALL the tools - P2, Lean, 6-sigma, 5-S

Ideas??

Integration

Cross-functional Approach Adding Safety Adding Quality

– Process versus Product Continual Improvement Programs

Questions??

kmreaume@worthingtonindustries.com