1 etiv - emas technical implementation and verification 1 case study: implementation of emas in the...

1ETIV - EMAS Technical Implementation and Verification 1

Case study:

Implementation of EMAS in the Ceramic industry

Eng. Marisa Almeida - CTCV

CTCV - CoimbraFevereiro.2005

Case study

“Implementation of EMAS in the Ceramic industry”


Issues:

1. Structure of the ceramic study-case• Ceramic process• Development of an EMS according to EMAS II• Enviromental improvement - photos• Main difficulties - photos

2. Training material3. ETIV Main difficulties

Case study



Description of ceramic location

Case study



Analyses of case-study:

1. Study case structure: • Part 1 –

• Description of the company: • Maronagrés – ceramic tiles company – certified by

ISO9001:2000• Sanindusa 2 – Sanitaryware company;

• Brief summary of the case study;• Driving forces and Benefits of EMAS

Case study




1. Study case structure: • Part 2 – Case studies: PDCA MODEL: Plan-

Do-Check-ActIntegrated system - process approachIntegrated system - process approachPLANPLAN Collection of data on the organisation (design information,

environmental information, raw material/production information, economic and other);

Environmental Review Diagnostic; Environmental policy (A.2); Significant environmental aspects (A.3.1); Legal and other requirements (A.3.2); Objectives and targets (A.3.3); Environmental management program (A.3.4);

Case study



Analyses of case-study:1. Study case structure:

• Part 2 – Case studies:Implementation and operation (Do): Definition of structure and responsibility and provide resources (see A.4.1); Training, awareness and competence (see A.4.2);; Establish internal and external communication (see A.4.3); Create and maintain EMS documents (see A.4.4); Documentation control (see A.4.5); Establish and maintain operational control (see A.4.6); Emergency preparedness and response (see A.4.7).Checking and corrective action (Check): Monitoring and measurement (see A.5.1); Non-conformance and corrective and preventive actions (see 4.5.2); Manage Records (see 4.5.3); Conduct periodic EMS audits (see A.5.4).Management Review (Act): conduct Management review (see A.6); identify areas for improvement; environmental declaration;

Case study




1. Study case structure: • Part 2 – Case studies:

ISSUES TO BE ADDRESSED BY ORGANISATIONS IMPLEMENTING EMAS

Legal compliance Performance External communication and relations Employee involvement

Part 3 – Evaluation and conclusions Fundamental difficulties found; Experience collected by the company during EMAS implementation; Environmental improvements achieved (results, benefits); Photos of the environmental achievements of the Company; Conclusions

Case study




2. Ceramic process descriptionCeramic Material Production

Processed material

Body preparation

Moulds Preparation

Forming/shaping (moulding

or pressing)

Drying

Glaze Preparation

Glazing - glaze application

Firing

Product finishing

Sorting, Packaging and

storage

auxiliar phases

Case study



2. Maronagrés ceramic process

Drying

Firing

Storage

Sorting andPackaking

Inputs

Outputs

Electricity Energy

Water

Liquid Effluent

Fugitive Emissions

Gaseous Emissions

Solid Waste

Packing Materials Moulds Colouring Deflocculant Raw Materials Glazes and Paints

Body Preparationand atomization

Granulation

Pressing

Control of thequality

Decoration

Thermal Energy

Case study



2. Sanindusa 2 ceramic process

Casting Slip

Raw MaterialGlaze

Preparation

Componentsand

accessories

PackingMaterial

Glazepreparation

Forming

Drying

Pre-drying

Finishing(1ª phase)

Finishing(2ª phase)

Verificationand Finishing

(3ª phase)

Glazing

Firing(tunnel kiln)

Storage

Sorting

Packaking

Assembly of mechanisms andcomponents

SW

WW

SW

WW

SW

SW

WW

GE

GE

SW

SW

SW

W

W

W

W

M

GE

SW

WW

M

FE

FE

FE

FE

DE

E

M

E

SW

WW

FE

E

W

E

SW

WW

FE

GE

W

M

E

Inputs

Outputs

Energy - natural gas,compressed air and GPL

Water

Material

Waste Water

Fugitive Emissions

Gaseous Emissions

Solid Waste


Implementation of EMS - EMAS

Environmental Review Diagnostic data on the organization (location, production information,

raw materials and energy input); environmental information:

Local conditions: geological, soil, atmospheric Consumption data: raw material, water, energy Emission data: emissions to air, emission to water,

emission to land – wastes, noise; List of legislation and other requirement applicable to

the ceramic industry; Planned activities (summary)

Case study



Analyses of case-study:A.2 Environmental policy

Maronagrés quality and environmental policy states commitments to: Continual improvement of product, process and services with a

minimal adverse environmental impact; environmental legal requirements and other environmental

requirements to which the organization subscribes; prevent pollution; efficient use of resources, avoid and minimized

(and valorization) the waste, gaseous emissions and noise control; continual improvement through the implementation of the best

available technologies (BAT) adequate to its environmental impacts; employees qualification and motivation; documented, implemented, maintained and communicated , reviewed

the policy, objectives and other information regarding the Management System (Q&E) to all employees and other interested parties;

involve interested parties like suppliers, clients and local community in the Management System (quality and environment)

Case study



A.2 Environmental policy:* Integrated with quality

and heath and safety;* focus on continual

improvement of product, process and services with a minimal adverse environmental

* environmental legal requirements and other

* best available technologies (BAT)



3. Significant Environmental aspects and impacts procedure

Environmental aspects

Wastewater

Energy

Water Production Gaseous emission (drying, firing)

Raw materials f or ceramic body of Emission to air: dust

Packaging materials Ceramic Noise

Auxiliary materials Materials Solid Wastes

Frit, Pigment and materials f or glazes Waste Heat

Wastes

Traffic and Transport

Ceramic Products

Case study



Analyses of case-study:Summary of enviromental aspects under normal conditions

Env. Aspects

Production phase raw material water energy gaseous emissions watewater waste noise heat

Body Preparation

Forming (Pressing)Forming

(moulding)

Drying

Glaze Preparation

Glazing

Firing

Finishing

Sorting

Packaging

INPUT OUTPUT

Case study



Environmental aspects:• Raw Material Usage: ceramic products are

manufactured mainly from natural raw materials (clays, sands, feldspars, limestone etc)

• Energy consumption: high – big consummer• Emissions to Air: represent the main environmental

concern of the industry: fluorine and heavy metals and VOC and combustion gases

• Emissions to Water: are mainly insoluble particulate matter derived from material processing – so can be separated by settling/filtration (often for re-use).

• Waste: slurry from wastewater treatment, scrap, dangerous waste – few: waste oil, etc...

Case study



Analyses of case-study:A.3.1 Significant Environmental aspects and

impacts procedureConditions: normal, abnormal (shut-down, start-up

and maintenance) and emergency• past, on-going and planned activities,• Criteria: significant environmental impacts according to

requirement in Annex VI(6) of EMAS II: Size (scale), severity and frequecy of the env. aspects Fragillity of enviroment Importance of stakeholders Legal issues: Enviromental legislation or other requeriments

Case study



Environmental aspects procedure:

A.3.1 MaronagrésProcedure

Documentary Analysis

Identification ofEnvironmental Aspects

Criteria areRemained Valid

Classification ofEnvironmental Aspects

Significant Analysis

Approval

Redefinition ofCriteria

Purchases

Customers

yes

no

Classification are Remained

Valid

yes

no

Case study




A.3.1 Maronagrés Env. aspects

Reduction of NaturalResources

Consumption of Water

Environmental Aspects Environmental Impacts

Atmospheric PollutionProduction of

Gaseous Emissions(from chimneys)

Atmospheric PollutionProduction of Fugitive

Emissions(dusts and/or steams)

Hydric PollutionProduction of Liquids

Effluent(industrials)

Hydric PollutionProduction of Liquids

Effluent(domestic)

Noise PollutionNoise Production forthe Exterior

Contamination of SoilsProduction of SolidWaste


Consumption ofElectric Energy


Consumption ofNatural Gas


Consumption of RawMaterials and Auxiliary

Reduction ofResources

Consumption of otherMaterials / Resources

Environmental Aspects Environmental Impacts

Case study



A.3.1 Maronagrés Env. aspects :

Classification of environment aspectsThe significant environment degree (S) is made by:

S = F (fragility) * P (probability) * G (G=gravity = severity*scale) * C (control) * I (Importance of stakeholders) If S < 405, the impact is classified as significant or if there are legal issues applicable.

Criteria: SCALE SEVERITY GRAVITY CONTROL PROBABILITY /FREQUENCY

FRAGILITY OF ENVIRONMENT

Stakeholder*

1 Intolerable Catastrophic Very critic Uncontrollable Very likely Extreme risk to

ecosystem

Several complaints

with NC

2 High Severe Critic Exist but with deficiencies

Likely High risk to ecosystem

Several complaints with no NC

3 Normal Moderate Moderate Exist but with

some deficiencies

Occasional Moderate risk One

complaints with NC

4 Low Mild Marginal Exist Remote Low risk to ecosystem

One complaints with no NC

5 Very low not reportable

Harmless None Exist and are

excellent Unlikely

No risk to ecosystem

No complaints

Case study




A.3.1 Sanindusa 2 Procedure

Approval

Identification of aspectsenvironmental associates tothe activities, products and

services

Identification of environmentalimpacts

Creation of criteria forevaluation of environmental

aspects

Classification of theenvironmental aspects

Manners of actuation for thesignificant environmental

aspects

Register of the results of theraising and classification in

identified folder

Divulgation of the significantenvironmental aspects

No

Yes

ApprovalNo

Yes

Case study



Environmental aspects procedure:Direct environmental aspects include:

emissions to air (from chimneys);sreleases to water (domestic and industrial);production and treatment of wastes;use of natural resources and raw materials (including water, natural resources, electric energy and fuel);local issues (noise, odor, dust, visual appearance, etc.);transport issues (both for goods and services and employees);risks of environmental accidents and impacts arising (or likely), as consequences of incidents, accidents and pot. emergency situations;

Indirect environmental aspects include:product related issues (design, development, packaging, transportation, use and waste recovery/disposal);the environmental performance and practices of contractors, subcontractors and suppliers.

Case study




1 2 3 4

Size (scale) Low Moderate High Very High Severity Harmless Marginal Severe Catastrophic

Fragility of environment

No risk to ecosystem or confined zone

Low risk to ecosystem Moderate risk

Extreme risk to ecosystem

Control Exist and are efficient

Exist but they con be improved

Exist but with deficiencies

Don’t exist

Duration (N) Sporadic Discontinuous Continuous (8 < hour/d<16

Probability Unlikely Not often Occurs several times

Occurs always

Legal issues Does not exist (N) Exist (Y) Interested parties No complaint (N) Complaint (Y)

Case study



Maronagrés significant env. aspects:

A.3.2 Env. aspects % of Significant AspectsMARK

5%

OF

3%

SUB

5% MAN

4%LAB

2% POL e PEC

11%

AUX

2%

PW

3%

ETAR

6%

TRAN

2%

SOT

4%

SP and CQ

5%

FIR

7%

DEC

4%

PRE and DRY

13%

BO and AT

12%

DC

4%FA

9%

Index of Environmental Performance of the Section

0

1

2

3

4

5

6

7

8

9

10

BO andAT

PRE andDRY

DEC FIR SP andCQ

SOT POL ePEC

LAB MAN SUB AUX ETAR PW TRAN FA OF DC MARK

En

viro

nm

enta

l Per

form

ance

Case study



Sanindusa 2 significant env. aspects: A .3.2

Environmental aspects Environmental impact Environmental aspects Environmental impact

Consumption of natural resources and other

Reduction of natural resources Indirect impact*

Consumption of water

Reduction of resources hydric Saving of resources hydric (recirculation)

Incidents, environmental accidents and potential emergency situations

Atmospheric pollution Contamination of Soils PI - Pollution of the soils, of the water and of the air

Use of natural resources, raw materials and other

Consumption of energy and fossil fuels

Reduction of resources Indirect impacts*

Emissions to air (punctual sources)

Atmospheric pollution

Mobil sources


Production of wastes

PI- Pollution of the soils, of the water and of the air Valorization interns

Transport issues (raw materials and other) Fugitive

emissions Atmospheric pollution Contamination of Soils

Environmental noise

Noise pollution

Domestic

PI - Pollution of the water and/or soil

Subjects of local impact

Diffuse emissions Atmospheric pollution

Discharge of liquid effluent

Industrial Contamination of Soils

Case study




Productive Process

Pastereception Forming

Finishing(2ª phase) Drying

Verificationfinishing

(3ª phase)Packaging

Assembly ofmechanisms

WFP

Finishing(1ª phase) Pré-Drying

GlazepreparationLaboratory

1

2

4 5 6 7

8

10

14GlazingFiringSorting

3

91112

13

15

MaintenanceETA

ETAR

WFP - Warehouse offinished product

Phase of the productive process

Environmental aspects Description of environmental aspects

Environmental impact Way of acting Legal requirements Environmental objectives

1, 2, 3, 4, 6, 8, 9, 10, 11, 13, 14, 15 Maintenance e ETA/ ETAR

Use of natural resources

Raw materials and subsidiaries

Reduction of natural resources

To define requirements for the purchase of materials To send questionnaires to know the environmental acting of the suppliers

-- Control of suppliers

1, 2, 3, 5, 4, 6, 10 Maintenance e ETA/ ETAR

Use of water Water of the process Technological water Recovered water

Reduction of hídric resources

To define good practice for the management of the resource (GAI –operation work instruction) The collaborators' sensitization to minimize the consumptions of water (training and posters)

DL n.º 46/94 of 22/02

Reduce the quantity of water used per unit of production in [number %]

3, 5, 7, 11, 15 Use of energy and fossil fuels s

Electric energy GPL Diesel oil

Reduction of resources

To define good practices for the management of the resource (GAI secção) The collaborators' sensitization to minimize the consumptions of energy (training) Energy management plan

DL n. º 58/1982 of 26/02, Port n. º 359/1982 of 7/04

Use of natural gas as fuel Decrease the specific energy consumption in [number %]

Case study




3, 7, 11 Emissions to air (from chimneys)

Emission of the punctual sources


All to monitor the chimneys sources (twice a year) To effect every six months analyzes of the combustion parameters To alter the constructive aspect of the chimneys (to remove hat of the boiler and to increase the remaining chimneys for 12,5 m)

DL n. º 78/04 of 3/04 Port n. º 286/93 of 12/03

Reduce emissions of CO and SOx in the firing equipment (driers and kilns and boilers) in [number %]

2, 3, 4, 6, 8, 9, 11 ETA/ ETAR

Liquid effluent Discharge of liquid effluent

Water Pollution (after treatment in ETAR)

To define rules for the operation of ETAR and for emergency situations

DL n.º 236/98 of 1/08; DL n.º 46/94 of 22/02

Minimize potential for spills

1, 2, 3, 4, 6, 8, 9, 11, 12, 13, 14, 15 Maintenance and ETA/ ETAR

Wastes

Waste production – industrial waste, green ware, fired ware waste, paper and card, refractory, Oils, polluted material, electric material

Potential impact - pollution of the soil, air and waters (due to the treatment of the waste) Valorization interns (green ware waste)

To define good practices for the management of the wastes (GAI secção) The collaborators' sensitization to minimize the production of wastes and to do her separation (training)

DL n. º 239/97 of 9/09; Port n.º 792/98 of 2/09; Port n.º 209/04 of 3/03; Port n.º 335/97 of 16/05

Decrease of the waste produce per unit of production Increase waste management

1, 2, 4, 5, 6, 8, 9, 14, 15 Maintenance

Subjects of local impact

Diffuse emissions Contamination of the ambient air (work place) Atmospheric pollution

DL n.º 78/04 of 3/04

--

Emissions of movable sources

Atmospheric pollution DL n.º 132/04 of 3/06 Transport of raw material and other subsidiaries, wastes and products

Transport subjects

Noise production Noise pollution

To define good practices conduction and operation of automobiles for the subcontractors (Poster)

DL n.º 292/2000 of 14/11

Control of the periodic vehicles inspections

Case study



Legal requirements:

Analyses of case-study4.3.2 Legal requirements• Software system: mydox (developed by

CTCV) – compilation of Portuguese and European legislation with an automatic up-date in 15 days;

• Sites: www.dre.pt, www.ipq.pt and www.diramb.gov.pt, www.eudor.com

• permits, licenses or other forms of authorization;

• register of applicable environmental legal requirements.

Case study



Objectives:

Analyses of case-studyA.3.3/4 Objectives, targets and programme(s)

Examples: Environmental management program Objectives and targets

Issues Objective Targets Activities Responsable Dealine Indicator

Raw materials consumption

reduction of dangereous waste on glaze materials

substitute completed the XPTO pigment used on the composition

substitute totaly one of the pigment used in glaze preparation XPTO J une 2004

number of dangerous materials used

Water consumption reduction of water

Reduction of 10% the water consumption compared with 2002

re-use 50% the water from the wastewater treatment to paviment cleaning XPTO Set-04 m3 water/t production

reduction of waste disposal to land-field

Promote de segregation of waste and recycling all green scrapp in "forming" phase to "body preparation" phase XPTO J an-04 t waste/ t production

training the operators XPTO nº hours

Noise reduction of enviromental noise level

to meet 55 dB(A) on day and 45 dB(A) at night all factory

encapsulation of the ventilator of the kiln XPTO Fev-04 noise level - dB(A)

Waste Reduce 5% the waste disposal in land-field compared with 2002

Case study



Maronagrés Objectives, targets and programme(s):

Aspect Objective Target Indicator Actions/activities Personal responsible

Resources Deadline Follow up Other information

Several

Improve employee training

Employee training in environmental fields

([number] hours/employee)

during the year 2004;

Nº hour/employee

a) training on environmental fields b) on job training the operational control c) emergency training

DQA (director of quality and environment) and human resources

DQA December 2004

Ever 3 months

Several Create an audits team from collaborators from Maronagrés;

Create at least one audits team from

collaborators from Maronagrés until the 4º

trimester

Nº audit teams a) external training on quality and environmental fields

Director of human

resources and DQA

External entity

December 2004

Ever 3 months

Subcontractors Improve the evaluation of suppliers (quality and environment);

At least 2 visits to suppliers during the

year 2005;

Number of visits a) perform at least 2 visits to suppliers on matters related with environmental fields b) Send environmental questionnaire

Environmental department

(ED)

ED December 2004

Semestrial

Several Improve the treatment of nonconformities

Informatics treatment of all nonconformities

after the year 2004

a) acquire a software

DQA Software from CTCV

December 2004

Ever 3 months

Wastewater Rehabilitation of the wastewater treatment facility

Rehabilitation of the wastewater treatment facility during 2004

Visual and efficiency treatment

a) civil labor improvement in tanks; b) civil labor in involving area; c) improve the tank efficiency

Maintenance responsible

Civil engineering

December 2004

Semestrial

Waste

Improve Waste management

Selective collection of all packing waste (plastic, wood, metal, paper, etc) during 2004

Nº of improvements

a) acquire individual containers; b) employee training in selective collections of waste; c) Final destination – licensed company

Maintenance responsible and DQA

Containers December 2004

Monthly

Emergency aspects

Minimize the potential for spills

Training in the emergency situations during the 2º semester. Prepare the work instructions

Number of incidents or accidents

Receiving and handling procedures in the work place Containers to avoid spill Training in hazardous chemical handling

Production manager and

environmental department

Containers and training

November 2004

Monthly

Case study



Sanindusa 2- Objectives, targets and programme(s):Aspect Objective Target Indicator Actions/activities Personal

responsible Resources Deadline Follow up

SME

Improve employee training

Employee training in environmental fields 10 hours/employee during

the year 2004;

Nº hour/employee a) training on EMS and environmental aspects b) on job training the operational control c) emergency training

Environment department and human resources

Training December 2004 and 1º

semester 2005

Ever 3 months

Waste

Improve Waste management

Selective collection of all packing waste (plastic, wood, paper) during 2004

Nº of improvements

a) acquire individual containers; b) employee training in selective collections of waste; c) Final destination – licensed company

Environmental department (ED) and production

manager

Containers training

1º semester 2005

Monthly

Water

Improve Water management

Reduce the quantity of water used per unit of production in [number %]

m3 of Water/ton To define good practice for the management of the resource (work instruction) The collaborators' sensitization to minimize the consumptions of water (training and posters)

Maintenance responsible and

production manager

Training Civil

engineering

December 2005

Monthly

Waste

Decrease the waste production

Reduce the quantity of waste per unit of

production in [number %]

ton of Waste/ton To define good practices for the management of the wastes (work instruction) The collaborators' training to minimize the production of wastes and their separation.

Technical and production managers

Containers; training

December 2005

Ever 3 months

Energy Use of natural gas

Use of natural gas in the production during 2004

-- a) stop with the GPL use b) used an UAG that produces natural gas

Production manager

Civil engineering

May 2004 Monthly

Gaseous emissions Reduce emissions of CO and SOx in

the firing equipment

Reduce emissions of CO and NOx in the firing equipment (driers and

kilns and boilers) in 10 %

Kg CO and Nox per year

a) use of natural gas b) monitor the chimneys c) control the burning of the kiln, boilers, etc

Production manager

Technical December 2005

semester

Emergency aspects

Minimize the potential for spills

Training in the emergency situations during the 2º semester. Prepare the work instructions

Number of incidents or accidents

Receiving and handling procedures in the work place Containers to avoid spill Training in chemical handling.

Production manager and

environmental department

Containers and training

June 2005 Monthly

Case study



A.4.1 Structure and responsability -

Maronagrés: integrated in Quality

The top management was appointed one of the top management directors as a Management Representative for the coordination of the Quality and Environmental Management System (QEMS)

The functions of the Director of Quality and Environment are, among others:

to keep inform the Management Representative about the performance, current status and progress of the QEMS;

to communicate with external entities related to the QEMS;

to collected information to allow management to carry out the management review process.

Case study




The resource needed to implement and maintain the EMS, have considered:

human resources (see organizational structure);

infrastructure technology and Technical resources;

financial resources

Case study




A.4.1 Structure and responsability - Sanindusa 2 : integrated with Quality, health and safety

The top management was appointed one of the top management administrators as a Management Representative for the coordination of the Quality, Environmental and safety and heath Management System (QESHMS).

The Environment responsible as the ultimately responsible for the environmental system

Case study



A.4.2 Training, awareness and competence - Training, awareness and competence -

Maronagrés: integrated in Quality

Sanindusa 2 : integrated with Quality, health and safety

Identify TrainingNeeds

Execution of the

Training Plan

Training Plan

Evaluation of theEffectiveness of the

Training

Training RegistersCertified

Case study



A.4.3 Communication

Communication process

Communication

TopManagement

Community Out

Employees

Community in(interested parties)

Case study



Analyses of case-study :A.4.3 Communication

Maronagrés: integrated in Quality, Plan, Measuring, etc ...Sanindusa 2: procedure - integrated with Quality, health and safety

Internal communication: • Internal communication – placards (see examples in annex

?);• Minutes of meetings;• Training register;• Internal inquires (satisfaction)• electronic mail, · Intranet;• Information brochures (see examples in annex ?).External communication medium types: Letter; Fax; Telephone Email; Internet; Visit to the ceramic industries

Case study



Documentation – Process aproach

PC01Identification of theCustomers Needs

PC02Sales

PC

03

Pro

duct

ion

Production of Normal ProductNOR

Polishing ProductionPOL

Production of Cut Special PiecesPEC

Production of Pressed Special PiecesPEP

PC04Storage and Product Delivery

PC05Development of New Products

PS

-D01

Man

age

men

t R

evie

w

PS

-D02

Bu

sine

ss P

lan

PS

-R01

Qua

lity

and

Env

iron

me

ntS

yste

m M

ana

gem

ent

PS

-R02

Hum

an

Res

our

ces

Man

age

men

t

PS

-R03

Pu

rch

asin

g M

ana

gem

ent

PS

-R04

Mai

nten

ance

Man

age

men

t

PS

-R05

Mea

suri

ng a

nd

Mon

itorin

gD

evic

es M

anag

emen

t

PS

-R06

En

viro

nmen

tal A

spec

tsM

anag

em

ent

PS

-R07

Hea

th a

nd S

afet

yM

anag

em

ent

PS

-R08

Fin

anc

ial M

ana

gem

ent

PS

-M01

Com

pla

ints

Ma

nage

me

nt

PS

-M02

Au

dit M

anag

em

ent

PS

-M03

Non

conf

orm

ing

and

Cor

rect

ive

Act

ion

sM

anag

em

ent

PS

-M04

Imp

rove

me

nt a

ndP

reve

ntiv

e A

ctio

ns

Man

age

men

t

PS

-M05

Cus

tom

er S

atis

fact

ion

Mon

itori

ng

Top Management Resources Management Control and Improvement

Support Process

Co

mm

un

ity

=E

nv

iro

nm

en

tal

Le

gis

lati

on

=

Cu

sto

mer

s=

Re

qu

ire

men

ts=

Cu

sto

mer

s=

Sat

isfa

cti

on

=

Co

mm

un

ity

=E

nv

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nm

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tal

Imp

act=

Key Process

(1)

(1) No Quality and EnvironmentSystem Management

(2) (1) (3)

(2) Only Quality and EnvironmentSystem Management

(3) Only activity 01 is Quality andEnvironment System Management

Case study



DocumentationA.4.4. Documentation – integrated with Quality and health and safety:

1. Manual2. Funcional procedures3. Operative procedures –work instructions4. Records

Funcional procedures:Identifying and classification of Environmental Aspects;Legal and other environmental requirements;Competence, training and awareness - QCommunication - QEmergency preparedness and responseMonitoring and measurementNonconformity, corrective and preventive actions - QInternal audit – Q – adictional requeriments - programmeManagement Review - Q

Descriçãodasactividadesrelativasa cadaprocessonecessáriasàmanutençãodo SG Q&A e implementaçãodos ObjectivosdaEmpresa

1ºNível

2ºNível

3ºNível

4ºNívelDescriçãodetalhadadasactividadese documentosde registo

DescriçãodaEmpresae do SG Q&Ade acordocom a PolíticaQ&Ae com a NP EN ISO 9001:2000

Documentaçãoquedefine osparâmetrose/ouvaloresde trabalhonecessáriosàmanutençãodo SG Q&A e implementaçãoDos ObjectivosdaEmpresa

IT MOP FR CAT TAB EXTIT MOP FR CAT TAB EXT

PL ESPPL ESP

PRCPRC

MANMANDescriçãodasactividadesrelativasa cadaprocessonecessáriasàmanutençãodo SG Q&A e implementaçãodos ObjectivosdaEmpresa

1ºNível

2ºNível

3ºNível


DescriçãodaEmpresae do SG Q&Ade acordocom a PolíticaQ&Ae com a NP EN ISO 9001:2000 e EMAS



PL ESPPL ESP

PRCPRC

MANMAN


PL ESPPL ESP

PRCPRC


1ºNível

2ºNível

3ºNível





PL ESPPL ESP

PRCPRC


1ºNível

2ºNível

3ºNível





PL ESPPL ESP

PRCPRC


1ºNível

2ºNível

3ºNível





PL ESPPL ESP

PRCPRC


1ºNível

2ºNível

3ºNível





PL ESPPL ESP

PRCPRC

MANMAN


PL ESPPL ESP

PRCPRC

MANMAN

Case study



Documentation (2):

A.4.5 Document controlthe control document procedure

(GSP001) includes the documentation structure including the titles, code numbers, dates, version, revisions, revision history or authority, approval, pages and total pages.

The control is made to documentation from internal and external sources.

Example of an informatics' program for documentation management – ISI 9000

Case study



A.4.6. Operational control A.4.6. Operational control – procedures and work instructions:

Maronagrés:

integrated with previous quality work instructions (including purschasing) through the process activities;

Specific procedures: Waste management; waterwater Treatment facility; Gaseous emissions treatment facility - fluorine;

Subcontracting; Chemical substances

Case study



A.4.6 Operational control:Sanindusa 2: two level approach : overall and specific

procedure for operational control – GAP004 Specific procedures:

GAP007 – Gestão de resíduos GAP008 – Gestão de efluentes gasosos (in annex) GAP009 – Gestão de efluentes líquidos GAE001 – Requisitos ambientais para compras – environmental requirements in purchasing GAI001 – Preenchimento das Guias de acompanhamento de resíduos; GAI002 – controlo operacional da secção de preparação de vidro; GAI003 – controlo operacional da secção de olaria; GAI004 – controlo operacional da secção de secagem; GAI005 – controlo operacional da secção de vidragem; GAI006 – controlo operacional da secção de fornos; GAI007 – controlo operacional dos resíduos de caco cozido; GAI008 – Controlo Operacional da Manutenção – operational control in maintenance GAI009 - Controlo Operacional da ETA e ETAR – operational control in ETA (water treatment facility) and ETAR (wasterwater facility); GAI010 – controlo operacional do laboratório GAI011 – controlo operacional do armazém; GAI012 – controlo operacional avaliação de questionários; GAI013 – controlo operacional de serviços administrativos; GAI014 – Controlo das operações de trasfega – operational control on handling and transport ;

Subcontracting;

Case study



A.4.7 - Emergency4.4.7 Emergency preparedness and

responseIdentified emergency situation

include:Untreated wastewater discharges;Chemical substances discharges including (products for wastewater treatment, solvents, glazes);Fuel or Oil discharges; * Natural gas release; Particulates emissions (diffuse emissions);Firing; * Explosion;natural disasters (e.g. flooding, earthquakes)

Identify PotencialEmergency Situations

OK

Yes

No

Establish EmergencyPlans and Procedures

Communication andTraining the Emergency

Plan / Procedure

Evaluation of theEffectiveness of theEmergency Training

Periodic TestingEmergency Response

Procedures

Case study



A.4.7 EmergencyThe emergency preparedness and response Plan include:

general description of ceramic industry; location of the ceramic industry including a schematic map

of the facility, evacuation routes, location of environmental emergency equipment, and assembly points;

Identification of potentials environmental accidents and emergencies;

list of hazardous substances and quantities; emergency organization and responsibilitie; action procedure: written procedures to mitigation and

response actions to be taken to solve different types of emergency situations or accidents.

alarms; internal and external communication (e.g. neighborhood); distribution: list to whom the plan is distributed and the

responsible for distribution; annex.

Case study



A.5.1 Monitoring and measuring

The environmental key characteristics are:

Waste management; Gaseous emissions; Water consumption; Wastewater discharges (industrial and

domestic); Noise; Energy.

Case study



A.5.1 Monitoring and measuring

Example of monitoring plan in Maronagrés

Frequency SamplingMeasurable

VariableOperator

pHExternal Sampling

Supplier of the

treatment products

Clean Water Tank

Re

gu

lato

ry R

eq

uir

em

en

t -

Lic

en

se o

f U

se

of

the

Hyd

ric

Pu

blic

Do

ma

in

TSS

Control

6-9

Fill the nonconformity

report preventing at

minimum industrial

director and wastewater

plant responsible

Date of delivery of the

external reports

Copy of external reports,

validated by quality and

environmental director

External reports,

validated by environmental

responsible

Item. Control Name

Work Instruction

Record

Chemical Oxygen Demand (COD)

Total Suspended Solids (TSS)

Semestrial Communic

ation

<150 mg/l

Preconized methods in the legal

requirements

Once a month

Actions Under Non Conformity

External Communication

pH

COD External entity with the waste

water treatment

plant operator

Specification

Fill the nonconformity

report preventing at

minimum industrial

director and wastewater

plant responsible

Define by quality and environmental director in view of

the risk of the situation

Quality and environmental

director send to official entity

(CCDR)

<60 mg/l

Case study



A. 5.1 Monitoring and measuring

Example of monitoring plan in Sanindusa 2

VMR/VMA

VLE Unid. Freq. Doc. Ent.

Water Consumption (captation of the puncture)

Volume PunctureNot Applicable (n.a.)

Daily, Except end Weekend

Reading in the water-meter

GAR xxx Sanindusa LaboratoryDLn.º 46/94 de 22/02

2900 n.a. m3/month n.a n.a n.a

Dissolved or Emulsified Hydrocarbons

SMEWW5520F µg/l n.a n.a n.a

Oils and Fats SMEWW5520C mg/l n.a n.a n.aIron SMEWW3120B

ConductivityAfter Osmosis

Daily, Except end Weekend

Sanindusa µg/l n.a n.a n.a

Domestic Liquid Effluent

VolumeWater-meter

Municipal ETAR (sanitation)

MonthlyReading in the water-meter

GAR003 Sanindusa GA CMC (Inova) n.a.. m3 -- -- --

pH Quarterly Electrometry n.a.. 6-9Scale of

Sörensen

Total Suspended Solids (TSS)

Quarterly

Following Filtration by Drying and gravimetry

n.a.. 60 mg/l

Chemical Oxygen Demand (COD)

Quarterly n.a.. 150 mg/l

Auxiliary Parameters

Biannual n.a n.a. several

Flow Biannual n.a n.a. Nm3/h

Particulates Biannual n.a 300 mg/Nm3

CO Biannual n.a 1000 mg/Nm3

NOx Biannual n.a 1500 mg/Nm4Total Organic Compounds (TOC)

Biannual n.a 50 mg/Nm5

Fluoride Biannual n.a 50 mg/Nm6

Heavy Metals (Pb, Cd)

Biannual n.a Pb<5; Cd<0,2

mg/Nm7

CONoxCO2

SemestrialInstrumental method

GAR023 e GAR032

Sanindusa GA n.a10001500

--mg/Nm8 -- -- --

INR - Institute of wastes ; DGE - General Direction of Energy EPA - American Norms ISO - International Norms

Instrumental methods/ EPA/ NP/ ISO/EN

External EntityPuncture Quarterly

MONITORING PLANMonitoring of Environmental Parameters

Responsib

le Specifications / Conditions Discharge

Sam

pling P

lace

Reje

cti

on P

lace

Fre

quency

Contr

ol D

ocum

ent

Meth

odolo

gy/

N

orm

/ IT

CCDRC

CCDRCGA

Bulletin of External EssayGAR022 Liquid Effluent

External ReportGAR019

External Entity GA

Semester

Bulletin of

analysis (ext)

Until 60 Days After

the Measurem

ents

Bulletin of

analysis (ext)

Laboratory --

License of Use of the

Hydric Public

Domain Legal

Requir

em

ents

Envir

onm

enta

l A

spects

Technological Water

Not Applicable (n.a.)

Sending of the Results

Industrial Liquid Effluent

Exit of the ETAR

Soil

Executa

nt

External Entity

Gaseous Emissions

DLn.º 78/2004

Port n.º286/93 de 12 de Março

CCDR - Commission of Coordination of Regional

Monit

ori

ng

Para

mete

rs

Bulletin of External Essay

AirGAT003

EN - European Norms

Case study



NONCONFORMANCE AND CORRECTIVE AND PREVENTIVE ACTION

Fonte: CTCV

Examples of nonconformities can include: Gaseous emissions, noise, water, wastewater or energy

reduction targets are not achieved; Operating criteria (e.g. permitted limits) are not met; Results from audits; Records analysis; Legal requirement and other analysis; Complains from interested parties; Records required of progress on objectives and targets

are not being kept; Responsibilities are not assigned as required for an

important function of the EMS, such as emergency response;

Case study



NONCONFORMANCE

Fonte: CTCV

NONCONFORMANCE AND

CORRECTIVE AND PREVENTIVE ACTION

Undesirable

situation

The solutionwas efficient?

yes

no

Detection ofnonconformity

Resolution ofnonconformity

Beginning of thecorrective action

Register of thecorrective actions

Determination ofthe probable

causes

Implementation ofthe proposal

solution

Conclusion of theaction

Register of thefollowing of the

corrective actions

Revision of thecorrective action

Case study



RECORDS

Maronagrés – informatics treatment

Some examples of environmental records include:a) Information on environmental aspects of the

ceramic industry;b) Information on environmental indicator

performance;c) evidence of accomplishment of objectives/targets;d) Information on applicable environmental laws and

regulations;e) permits, licenses or other forms of legal

authorization;f) Monitoring and measuring data;g) Calibration and maintenance activities of the

equipment;h) Training records;i) Decisions regarding external communication;j) Information regarding contractors and suppliers;k) results of operational controls;l) details of nonconformities and corrective and

preventive actions;m) Audit results;n) Results of management reviews.

Fonte: CTCV

Case study



EMS AUDIT

EMS Audit integrated: Quality – Maronagrés Quality and heath safety –

Sanindusa 2

Conducting the audit include several techniques and tools like ISO19011:2003, checklist, observations, documents consulted.The internal EMS audits can be carried out by personnel from the ceramic company, by external auditors (consultant) or by a combination of both

Fonte: CTCV

Nomination ofAuditors

Audits

No

Approval?

Yes

Audit Program

Audit Plan

Audit Report

Actions andEvaluations

Records ofNonconformance

Yes

NoNonconfor-

mance?

Case study



MANAGEMENT REVIEW

Management review integrated: Quality – Maronagrés Quality and heath safety – Sanindusa 2

The review cover the environmental aspects of activities, products and services that are within the scope of the EMS.

The EMS of both ceramic industries should be reviewed at least once a year in order to guarantee suitability, adequacy, and effectiveness of the system. It is also analyse its integration with the overall management system and its relationship to the current and anticipated regulatory legislations

Fonte: CTCV

Case study



Environmental improvements achieved

Results and benefits: reduction of the amounts of energy

consumed – process optimization; Gaseous emissions treatment - fluorine; Adopt of BAT (best available tecniques) Noise reduction; Natural gas - optimization.

Fonte: CTCV

Case study




Results and benefits:

reduction of the amounts of energy consumed – process optimization;

Adopt of BAT (best available tecniques)

Use of natural gas in substitution of propane gas (GPL), provided by LNG Storage tank

Fonte: CTCV

Case study




Fonte: CTCV

selective collection of wastes produced;Waste selective area;Waste valorisation;Rehabilitation of watewater facilitytoner cartridges and ink cartridges container;Chemical substances container;Minization of environmental accidents

Case study



Main Difficulties found in EMAS:

Fonte: CTCV

The Portuguese legal requirement on gaseous emissions: monitoring all chimneys, chimneys high, etc ... The waste final manager – not all legally authorizedThe environmental noise, specially in the case of Maronagrés, has the surrounding human house growth after the Maronagrés facilities installationsChanging old practices …

Case study


1 etiv - emas technical implementation and verification 1 case study: implementation of emas in the...

Documents

study case structure

analyses of case

implementation of ems

case studies

ceramic industry slide

ceramic process slide

environmental requirements

environmental achievements