EMS MODEL

By

Abyss
Management

1
Introduction to the following topics:

EHS
EHSAwareness
Awareness
Live
Liveexamples
examples
Incremental
Incremental Changes
Changesand
andHuman.
Human.
Difference
Difference between
betweenQMS
QMSand
andEHS
EHS
Business
Businessand
andEnvironmental
Environmentalconcerns
concerns
Common
CommonEngine
Enginefor
forQMS
QMSand
andEHS
EHS

2
Introduction to the following topics:

Aspects
Aspectsand
andImpacts
Impacts
IER
IERTools:
Tools:
Mass
MassBalance
BalanceDiagram
Diagram
Energy
Energybalance
balanceDiagram
Diagram
Water
Water Balance
BalanceDiagram
Diagram
Accident
Accident and
andIncidents
Incidents
Surveys
Surveysand
andOnsite
OnsiteObservations
Observations
Site
SiteLayout
Layout
Process
ProcessFlow
Flow diagram
diagram
MSDS
MSDSand
and PPE
PPE 3
EHS BUSINESS
MODEL

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Introduction to the following topics:

Business
BusinessRisk
Riskanalysis:
analysis:
Aspect
Aspect and
andImpact
Impact analysis
analysis
Severity
Severity
Occurrence
Occurrence
Detection
Detection
Spread
Spread
Duration
Duration
Significant
Significant Aspect
Aspect

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Introduction to the following topics:

Business
BusinessModel:
Model:
Changes
ChangesininEMS-14001:2004
EMS-14001:2004
Policy
PolicyFormulation
Formulation
Objective
Objectiveand
andtargets
targets
Policy
Policydeployment
deployment
Management
Management programs
programs(Project
(Project Management)
Management)
Control
Control(OCP)
(OCP) and
andEPR
EPR
Business
BusinessModel
ModelLinkages
Linkagesand
andPDCA
PDCA
Business
BusinessResults
Results
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Introduction to the following topics:

Auditing
AuditingBest
Best Practice:
Practice:
Automotive
AutomotiveProcess
Processapproach
approach
Trail
TrailBased
Basedauditing
auditing
Questioning
QuestioningTechniques
Techniques
Objective
ObjectiveEvidence
EvidenceCollection
Collectionand
andreporting
reporting
Tactics
Tacticsof
ofAuditors
Auditors
Role
RolePlaying
Playing
Reporting
ReportingAudit
Audit results.
results.
Best
Best Strategies
Strategies
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 How awareness Spread?
– We are Taking everything from the Environment,
Consuming resources.
Garbage
and
– What we are giving back to Environment???. Waste!!!!

– How long we can continue with this??? We have to

take from the
same
– Our realization is reactive not proactive. Environment

– If we are getting aware, It’s because we are at Risk

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 Live Examples
– Bhopal Gas Case (Business loss, Human life affected)

– Soft Drink not safe for drinking (sales Drop, Advertising

investments, health issues)

– DDT mix in drinking water.

– Fishes started dying (Court case) due to industrial waste

going to water. (living of fisherman got affected)

– Some Disease found in fishes transferred to human.

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Live Examples
– FORD Supply stoppage in Pune due to shift Bus dropped
in the Valley

– Rupees 63 cr. damage due to flood in chandigarh in one of

Panacea Biotech pharmaceutical company.

– Punj Loyd Co Sr. Executive arrested due to chidren died in

a trench digged for pipeline

– Construction sites accidents reported in news

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Why we are reactive not proactive
– We have not stopped damaging the Environment after
knowing the facts.
– WHY???
– A test is done on Frog in the laboratory: Frog
– If you put a frog in the boiling water in a beaker, What
Jumped
out of the
will happen??? water and
survived

– If you put a frog in the water at room temperature and

start heating it slowly to 100degree, What willFrog Died
and even
happen??? didn’t
attempt to
– Due to delta level incremental changes, it’s a Slow
come out.
poisoning 11
Is human the most important element ?
– NO!!!
– In ecology system every species has it’s own
importance.
– There is no terms like independent or dependent rather
it is Interdependence.

– Scientist have come out with facts that we depend on

Sun and Sun also depend on us and Hence the
interdependency.

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 Is human the most important element ?
– Man is not the Center but a center for creating problem.
– What went wrong due to him???
– The other creatures are instinctive, Man has a high
potential to think.
– A Bird goes daily for arranging food for their Kids.
Human will think to keep an inventory of one month in
this case the disturbance to ecological system.

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Difference Between QMS and EHS
– Not by clause……

QMS EHS
– Same management System only the Focus element is
different : Quality and Environment
– Starting Point of EHS is different

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What Should be the Starting point for EHS?

Customer
requirements

QMS Product Drawing,

Specs, Cost, Delivery etc.

Where to get
EHS EHS specs???

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What Should be the Starting point for EHS?

EHS Stakeholders

Requirements
Stakeholders
Expectations

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Do you really know your Stakeholders???

Government Public
Customers

Company

Suppliers

Employees Investors

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 WHY IEHSR Study required?

– The Study is known as IEHSR.

– Initial Environment Heath and Safety review Study.
– What IEHSR does for US.
– Help in identifying the issues with respect to stake
holders.

– E.g., Govt. bodies for legal requirements, Customer for

specific requirements (ELV), Employees concerns,
Accidents , Incidents technology issues, Suppliers
linkages etc...
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What is the Scope of IER

– Is it applicable throughout the organization or some

area it doesn’t cover?
– Please list down one by one where it can be applied….

– It’s applicable to all.

– How it is affects functions like finance, administration,

gate, security, canteen, supplier etc.

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What is the Scope of IER

Human Board of CEO Public Corporate

Resources Directors Relations EH & S

MIS Finance
Quality Plant
Assurance EHS
EH & S

R&D Purchasing

Engineering Real Estate

Quality Strategic Govt.

Manufacturing Assurance Legal Relations
Planning
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What is the Scope of IER

– Does it only covers Environmental concerns or business

concern too?
– It also covers business concerns.

– Customer Specific requirements related to product.

– Cost savings in the Study affecting business.
– Legal requirements which requires compliance.
– Long term and short term implications etc.

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 Do we also need a business model for EHS

– It’s not implemented to meet the clauses requirements

rather requires a business model for effective
implementation.
– It is linked with business results
– so, no separate system for TS, EHS etc. rather one good
management system to liked with performance.
– Cost savings in the Study affecting business.
– Legal requirements which requires compliance.
– Long term and short term implications etc.

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 Do we also need a business model for EHS

– WHAT DO YOU WANT??

Management Only
system Certificate

Business
Management
system Performance
Certificate
as byproduct
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Do we also need a business model for EHS

– What do we understand by IER study. Will it only try to

identify factors that affects the following:
– Air
– Water Resource
Depletion
– Land
Energy losses
– Flora etc.
– Fauna
– Accident
– Incidents
– Heath issues due to product design and process design
– Anything else????? 24
Where Will EHS Lead To ?
Waste Reduction,
reducing production
loss hrs, reducing
material consumption,
Machine uptime,
Higher efficiency

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Similarity Between QMS and EHS
– Not by clause……

QMS EHS
– There is a common platform of engine that drives the
management system
– PDCA based (TS, EHS, OHSAS etc…)

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Similarity Between QMS and EHS

Elements of ISO 14001 According to Deming Cycle

PLAN

ACT/
IMPROVE DO

CHECK/
CORRECT

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 IEHSR Basic Ingredients

– Why are we going for IEHSR

– To address issues related to EHS and related business
concerns
– What are those issues:
– Contamination of Air, land, water, Energy loss,
Resource depletion, Accident, Incident, health, Damage
etc.
– The above is called Consequences Impact.
– Are Impact Negative or Positive too.

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IER Basic Ingredients

Environmental impact - any change to the environment,

whether adverse or beneficial, wholly or partly resulting
from an organization's activities, products or services

For example, impacts might include contamination of air

or water, depletion of a natural resource or harm to human
health.

– Positive Impacts: Plantation, Reuse of oil, Changing

technology having lesser waste etc.

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IER Basic Ingredients

Environmental impact - Effect.

– Why this Impact Happens????

– Are there any reasons behind those Impacts.
– We can terms those reasons as potential Causes
– Is there any relationship between Cause and effect.

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IER Basic Ingredients

Environmental Aspects - An aspect is a cause of one or

more impacts (actual or potential)

Aspect = cause

Impact = effect
Environmental aspect - An element of an organization's
activities, products or services that can interact with the
environment
For example, it could involve a discharge, an emission, or
consumption or reuse of a material.

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IER Basic Ingredients

Y = f (X)
YY (Impact)
(Impact) X
X11…..X
…..XNN(Aspect)
(Aspect)
•• Dependent
Dependent •• Independent
Independent
•• Output
Output •• Input
Input Variable
Variable
•• Effect
Effect •• Cause
Cause
•• Symptom
Symptom •• Problem
Problem
Monitor
Monitor Control
Control

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 OHSAS 18001 Definitions
Hazard

source or situation with potential for harm in
terms of human injury or ill health, damage to
property, damage to the workplace environment
or a combination thereof
Hazard Identification

process of recognizing a hazard exists and
defining its characteristics

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 OHSAS 18001 Definitions

Risk
– combination of the likelihood and
consequence of a specified hazardous event
occurring

Risk Assessment
– overall process of estimating the magnitude of
risk and deciding whether or not the risk is
tolerable
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IER Basic Ingredients

• IS Aspect and Impact is one to one relationship?

• An aspect can have multiple Impacts:

• Example???

• Acid falling on the land will contaminate land, Fumes

will contaminate air and It May cause Human injury
or irritation to skin. There is also a resource depletion.
(Cost impact to business , If expensive chemical)

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IER Basic Ingredients

• What is importance to us the impact or Aspect (In

terms of control)
• IS cause important or effect (for designing a good
system)
• There is no point in running around the effect because
cause is your karma and Impact is effect that will
continue.
• Examples????
• You go to doctor for pain in your stomach. It cures by
attacking the cause.
• Story1: Servant taking care of plants like kids but no
results coming.
• Story2:You give beggar Some money, IS it a real help?
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IER Basic Ingredients

• We Have so many Aspects in my company?

• YES!!!!
• What to do?
• Is it not the same situation?
• I have so many problems in my Co!!!
• I have many Customer Complaint!!!
• I have high Rejections.

• What you normally do to attack them?

• Answer is PRIORTIZE

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IER Basic Ingredients

• WHAT IS THE WAY TO PRIORTIZE

• This is the application of IER study.
• We want to know What is Important for US.
• This we call as SIGNIFICANT ASPECTS which will
Have Significant ASPECTS.
• Attack the vital Few.
Significant aspects have significant impact on the
environment
ISO 14001 requires the organization to manage
the aspect that gives rise to the impact, not the
impact itself.

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IER Basic Ingredients

Identifying significant environmental aspects is usually

done in three steps:
1) identify the activities, products and services of the
organization (i.e the scope of the EHS)
2) identify all aspects and impacts associated with these
activities, products and services
3) decide which ones are significant

• Before Priortizing we should know what to

priortize.
• So complete step1 and 2 Activity first.

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IER Basic Ingredients

TIPS for Study:

Aspects to be covered by the EHS:

• those aspects that the organization can control

• or over which it can be expected to have an
influence
• Include consideration of indirect effects such as:
supplier controlled effects
customer related effects

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IER Basic Ingredients

TIPS for Study:

Impacts that must be considered include:

• Actual or potential impacts

• Past, present or future impacts
• Normal, abnormal or emergency operating
conditions

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TIPS for Study:

Do we always do activities as defined???

Examples:
• Pump not working using manual pumping to fill
the oil in the drum.
• Coolant flow in the Injection moulding machine
from outside motors as inner motor is not
working.
• Noise at the start and during running is different
• The above we call Abnormal situation.
• Now can we define Normal and emergency
Situation?
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TIPS for Study:

• Can we really do the extensive and

comprehensive Study???
• Just by saying it will not be done.
• Let’s Equip ourselves with the requisite
tools.
• Every tool is unique and will help you
identify the Aspect and Impacts!!!!

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IEHSR Tools

IER Tools:
Mass Balance Diagram
Energy balance Diagram
Water Balance Diagram
Accident and Incidents
Surveys and Onsite Observations
Site Layout
Process Flow diagram
MSDS and PPE

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IEHSR Tools

Mass Balance Diagram

• This is very important tool to address resource
depletion issues (Business + Env concerns)
• It works on Input-Output Model.
• But before we apply this model, we should
know what is important to us.
• Identify key resources in the company
(Material Resources)
• It also covers consumables, Chemicals ,
packaging material etc.

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IEHSR Tools

Mass Balance Diagram

• This is Ok BUT I HAVE 1000 Items.
• Where to attack.
• Prioritize using ABC analysis.
• What is “A” class item. IS it expensive item???
• NO!!
• The above categorization is based on
Consumption Value.
• Where your 75% Consumption value is
contained covering only 15- 20% of total item
is normally taken in A class. YOU CAN
DEFINE YOUR CRITERIA 46
IEHSR Tools

Mass Balance Diagram

• Identify the ItEHS and apply the Input Output
Model. WASTE (Volatile,
fumes)

INPUT OUTPUT

WASTE
(solid,Liquid)

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 IEHSR Tools

Mass Balance Diagram

• ABC for Resource Saving Potential
S.no. Item Code unit Name VAL ENV. RSP Mon. Cons Rate % Cum. ABC HML
1 6201-G101210 Kgs. POLYMETHYL PELLETS 876-G-101 Y Y SELECT 11523 120.72 4.045 4.045 A H
2 1201-G001230 Kgs. POLYMETHYL PELLETS 876-G-001 Y Y SELECT 8275 107.36 2.583 6.628 A H
3 1221-0000250 Kgs. POLYCARBONATE BLACK (143R/701) Y Y SELECT 4178 194.37 2.361 8.989 A H
11 1221-0000270 Kgs. POLYCARBONATE GREY (143/70350) Y Y SELECT 2473 260.61 1.874 25.290 A H
12 6201-G001230 Kgs. POLYMETHYL PELLETS 876-G-001 Y Y SELECT 6194 102.81 1.852 27.142 A H
14 6201-G253220 Kgs. POLYMETHYL PELLETS 876-G-253 Y Y SELECT 4671 120.38 1.635 30.486 A H
16 6414-1075000 Nos. PENGUIN CEMENT 1075 Y Y SELECT 177 2682.14 1.378 33.454 A H
24 5941-M627723 Nos. HOTMELT CLEAR Y Y SELECT 965 356.87 1.001 42.302 A H
25 1201-G101210 Kgs. POLYMETHYL PELLETS 876-G-101 Y Y SELECT 2635 121.61 0.932 43.233 A H
28 5941-M626527 Nos. HOTMELT GREY Y Y SELECT 456 602.04 0.799 45.808 A H
31 1221-0000230 Kgs. POLYCARBONATE CLEAR (143R/111) Y Y SELECT 1192 205.53 0.713 48.002 A H
44 1271-1185250 Kgs. SEBS ELASTOMER TE-1185 BK Y Y SELECT 817 227.58 0.541 55.946 A H

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IEHSR Tools

Mass Balance Diagram

Ideal consumption: 442 Kgs.
Input : 560
kgs. Ikg = Rs 2000.
List out all
Waste Rejection: 2 the aspects
and Impacts
: 116 kgs.
Unit Gurgaon Date :16/09/02
kgs.
Department: ASSY Group : CG
Activity, Product Environmental
S.no Environmental Aspects
or Service impacts
N/A/E
1 Adhesive -Generation of solid adhesive waste A Land
application for N Resource Depl.
sealing -Cooling loss in the chilling unit A Energy conservation

* operational control : Temperature indicator with alarming control

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IER Tools

Energy Balance Diagram

What is your energy Bill???
• It is What % of your sales?
• Are we really running our operations efficiently?
• We need to find the Energy Waste!!!
• HOW?????
• This is similar to Mass Balance Diagram.
• The difference is that input is energy.

50
IER Tools

Energy Balance Diagram

What Should we actually consume.
• This can be known through ideal consumption of
Operation.
• Study the active Load (Not with Connected
Load)
• See machine manufacture Specs. Motor
wattage, Heaters Wattage and Convert it into
Electrical Units.
• Use Industrial Standard in some cases.
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IER Tools

Energy Balance Diagram

What Should we actually consume.
• Will Estimate and actual be same???
• NO!!!!
• This is the energy gap we have to Work Out using
Energy balance Diagram.
• Divide your Company into energy Zones based on
consumption pattern or Experience.
• Calculate separately for each Zone Ideal
Consumption. (Theoretical calculation)
• Put Energy meters at each sections.
52
IER Tools

Energy Balance Diagram

What Should we actually consume.
• Analyze the Gaps using Input/Output Model for
each section.
• Identify the Energy loss issue(Not solution at this
time)
• There gaps comes due to Following:
• Excess breakdowns.
• More adjustments
• High setup time.
• Idle running of machine
• Reprocessing and reworks. 53
• Heat Losses.
IER Tools

Energy Balance Diagram

• This need to be followed by energy audits in the
Company.
• Who Should do the Energy Audits?
• What you should look into energy audits:
• Input from EBD.
• More adjustments
• High setup time.
• Idle running of machine
• Reprocessing and reworks.
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IER Tools

Energy Balance Diagram

• What you should look into energy audits:
• Heat Losses form Oven, Chambers, leakages.
• Poor Heat Insulation.
• Type of heating (Electrical/ Gas)
• Wear Out parts/ Poor maintenance Issues.
• Machine Breakdowns.
• Trials done on machines.
• Abnormal activities carried out.
• Lights and switches when not in use.
• External Agency findings.
• Power factor 55
IER Tools

Energy Balance Diagram

Zone-I
Zone-III

Zone-V

Zone-II

Zone-IV

RED : MAJOR ENERGY LOSSES

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IER Tools

Energy Balance Diagram

S.NO ASPECTS N/A/E IMPACT

TOOL ROOM
- Spray gun air leakage A ENERGY LOSS

- Heat loss in atmosphere N ENERGY LOSS

- Location of air curtain and lighting A ENERGY LOSS

List out all
- Poor Maintenance of Baking oven. E FIRE HAZARD
the aspects
MOULDING
- Heat loss in theOven N
and Impacts
ENERGY LOSS

- Cooling water leakage A ENERGY LOSS

- Re-circulation of cooling w ater N ENERGY CONSERVATION

through cooling tow er

MAINTENANCE

- Leakage of water from radiator A ENERGY LOSS

- Leakage of air from pipes/conn- A ENERGY LOSS

- ctors/equipments

ASSEMBLY

- Chilling chamber cooling loss A Energy Loss

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IER Tools

Water Balance Diagram

• This is similar to Mass Balance Diagram.
• The difference is that input is Water.
• This can be known through ideal consumption of
Water.
• Draw a Water balance Diagram using Layout of
the factory.
• Showing with colors (Hot water, Chilledwater,
Fresh water, Waste water)
• Mark the Loops and circulation.
• Mark the Storage tanks and Motors for Lifting the
Water. 58
IER Tools

Water Balance Diagram

• How to find the GAP
USING WATER
• Do we know our Sources??? TANKERS TO
MEET THE
SOURCES USES REQUIREMENTS
Surface Water Municipal
Ground Water Industrial
Rain Water (Collected in Agriculture
Ponds/Lakes) Recreational
Sea Water Groundwater recharge
Recycled Water

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IER Tools

Water Balance Diagram

• How to find the GAP
• Established theoretical total & area wise water
demand.
• Established Present Actual total & area wise water
consumption .
• Put water meters at inlet point to major water
consumption areas.
• Record bore-well running time.
• Work on within workshop water recycling.
* Use Industrial Standard for general Consumption
Pattern
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IER Tools

Water Balance Diagram

Water Consumption standards
* Per Capita Consumption (Average), As per IS Code
♦ Drinking : 5Lts/Capita/day
♦ Kitchen : 5Lts/Capita/day
♦ Bathing : 55Lts/Capita/day
♦ Cloth Washing : 20Lts/Capita/day
♦ Washing & Cleaning
of houses : 10Lts/Capita/day
♦ Flushing of toilet : 30Lts/Capita/day
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 IER Tools

Water Balance Diagram Benefits

Lower raw water Reduced handling of
consumption effluents.
Smaller capacity effluent Pollution control
treatment plants. No regulatory problEHS
Lower project cost and Energy Saving
operating costs
Improved efficiency
Recovery of valuable
products.

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IER Tools

Water Balance Diagram Benefits Don’t Forget to

List Aspects
and Impacts
Some Examples:
• Watering plants using Fire water Hose (More
Water Consumption and energy losses)
• Using unnecessary motors to lift water for
storage. (Energy Issues). Eliminating tank and
motors after studying the Water balance
Diagram. Don’t
Forget to
• Higher evaporation rate of water. Draw the
diagram
• Water Leakage and wastage.

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IEHSR Tools

ACCIDENTS AND INCIDENT LIST

• Are they Same???
• What is the difference between them?
• IS DEATH A DESIRED EVENT OR UNDESIRED?
• Is Only Human Injuries or fatal cases are covered
under accidents?
• NO!!!
• If we get out vehicle hit resulting to vehicle
damage but no injury to you. Still you call it an
Accident and same way we have to treat in
industry which includes property loss and work
Environment loss. 64
IEHSR Tools

ACCIDENTS AND INCIDENT LIST

Accident: undesired event giving rise to death, ill

health, injury, damage or other loss

Incident: event that gave rise to an accident or had

the potential to lead to an accident.
Note: An incident where no ill health, injury,
damage, or other loss occurs is also referred to
as a “near-miss”. The term “incident” includes
“near-misses”
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IEHSR Tools

ACCIDENTS AND INCIDENT LIST

Do we need to record incidents also???

But Why?

What Can We conclude Henrich model

Accident: Effect

Incident: Cause

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IER Tools

1 Major injury

10 Minor injury

30 Property damages

600 Near Accidents

HEINRICH’s MODEL 67
IER Tools

ACCIDENTS AND INCIDENT LIST

• Analyze all previous accidents.

• Start listing all Incidents
• The Challenge is not ZERO ACCIDENTS
• BUT!!!!
• ZERO INCIDENTS (NEAR MISS)
• Take all the reasons and activity into aspect list
• Mark that impact as Occupational Hazard.

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 IER Tools

ACCIDENTS AND INCIDENT LIST

S.TREATMENT

SAFETY HAZARD /
FIRE OCCURRENCE IN THE BASE COAT / PAINTING AREA DUE TO SHORT CIRCUIT OF OVER AIR POLLUTION / THREE TIMES
ACCIDENT A.
HEAD TUBE-LIGHT AND FLOOR SWEEPING MACHINE RESOURCE TILL DATE
DEPLETION
INHALATION OF THE CHEMICAL FUMES WHILE WORKING IN THE PAINT BOOTH OR BASE COAT
SAFETY HAZARD / FREQUENT /
INCIDENT B. AREA DUE TO IMPROPER AIR CIRCULATION OR AIR SUCTION / WATER RECIRCULATION
AIR POLLUTION CONTINUOUS
MECHANISM.

OVER HEATING OF THE BASE COATING AREA DUE TO IMPROPER AIR CIRCULATION CAUSING
INCIDENT C. SAFETY HAZARD CONTINUOUS
UNWORKABLE ATMOSPHERE.

Moulding process

a) Mould changeover - Generation of waste cloth in form N Land contamination Non significant

of cotton hand gloves and dhoti

- Spillage on floor N Land contamination Significant

Working environment Non significant

- Mishandling of tools and dies A Occupational safety Significant

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IER Tools

SURVEYS
• SURVEYS
• Why Don’t we go to people and ask them?
• They work day in day out in the environment?
• Tool used is questionnaire
• Designing a questionnaire is very important.
• Specific to what you want to ask.
• Focus should be on:
• Effect and influence if Environmental Impact.
• Any aspect they came across.
• Saving potential.
• Existing controls and Improvement.
• Accidents and Incidents
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IER Tools
Are people
SURVEYS Aware of
• TIPS EHS before
asking Q
• Don’t ask General question like What troubles
you most?
• Don’t make it a grievance collecting
mechanism.
• Don’t do sampling bases (100%) may be done
phase wise.
• Sequencing of Questions very important.
• Don’t ask database question like how many,
How much.
• Make it more objective then subjective.
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 IER Tools
Have you
collected
Employee Survey data which
7) What type of environmental pollution LAND POLLUTION AIR POLLUTION WATER POLLUTION can be
have you observed the most? analyzed
NOISE POLLUTION ANY OTHER __________________

8) How often have you observed abnormal A Spillage on floor ALWAYS NORMALLY SELDOM NEVER
environment situation in your area ? B Generation of waste water ALWAYS NORMALLY SELDOM NEVER
C Generation of odour ALWAYS NORMALLY SELDOM NEVER
D Generation of waste cloth ALWAYS NORMALLY SELDOM NEVER
E Generation of empty containers ALWAYS NORMALLY SELDOM NEVER
Are we having paint ALWAYS NORMALLY SELDOM NEVER
asking F Generation of dust ALWAYS NORMALLY SELDOM NEVER
Quality G Unsafe working condition ALWAYS NORMALLY SELDOM NEVER
Questions H Any other please specify

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IER Tools

ON SITE OBSERVATIONS

• Enough doing calculation and studying

Documents. Let’s go to the site
• Make teams to visit different areas.
• Don’t do sampling bases
• USE 3G
• Become Gambha(Go to Site) Person.
• Observe using your senses (eyes, Smell,
Listen, Touch etc.)
• Use Auditing basic principles.
• Use auditing techniques and skills.
• Use mainly by observation
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IER Tools

ON SITE OBSERVATIONS
S.no Activity, Product or Service Environmental Aspects N/A/E Environmental impacts

1 Spray Painting - Noise generation from air blower N Noise pollution

and vacuum motor Work environment
- Generation of odour N Work environment
- Generation of paint dust N Work environment/Air
Water pollution
- Generation of plastic scrap N Land contamination
Resource depletion
- Spray gun air leakage A Resource depletion
- Cleaning spray gun during - Excess thinner consumption N Resource depletion
change of shift
- Generation of paint sludge N Land contamination
- Generation of waste in form of N Land contamination
hand gloves , cloth & polythene Resource depletion
- Generation of empty containers N Land contamination
having paint
- Spillage on floor N Land contamination
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IER Tools

SITE LAYOUT

• Study the Site layout of the Company for the

Following:
• Layout of electrical wire.
• Layout of water pipelines.
• Layout LAN Wires etc.
• To know the possibility of mixing of pipes.
• To know the Overhead or Underground
issues.
• To understand the situation with respect to
aging of pipes and wires.
• Club with actual site observation
75
IER Tools

MSDS/ PPE

• Any Chemical used in the company or

hazardous material be followed by MSDS.
• Study the Material safety Data sheet and
identify issues like:
• Storage
• Handling
• Usage
• Disposal etc.
• PPE used in the company will give you an
idea of aspects and Impacts. Why I am
Wearing Goggle, Helmets, Gloves etc.
76
IER Tools

PFD

• Process Flow Diagram is an important tool

used in your process.
• Please use the PFD as used in FMEA.
• Identify what are the Inputs used at each
stage.
• What are the output at each stages.
• Linked with Potential aspects and Impact.

77
 IER
Life Tools
Cycle
Inputs
Inventory

Cradle-to-gate Raw materials acquisition Outputs

system
boundary
Manufacturing, processing Water effluents
and formulation
Airborne emissions
Energy
Distribution and transportation Solid wastes

Raw Other releases

materials Re-use and maintenance

Recycle
Cradle-to-grave
Products
system
boundary Waste management

78
Introduction to the following topics:

Business
BusinessRisk
Riskanalysis:
analysis:
Aspect
Aspect and
andImpact
Impact analysis
analysis
Severity
Severity
Occurrence
Occurrence
Detection
Detection
Spread
Spread
Duration
Duration
Significant
Significant Aspect
Aspect

79
Business Risk analysis

• After applying all IER tools, What do you

get???
• List of aspect and impacts.
• Is everything is important to business?
• NO!!!. We need to prioritize.
• BUT HOW???
• Prioritizing Based on Risk level.
• How to identify risk levels.
• We have to categorize Risk in two categories.
• What are those????

80
Business Risk analysis

• Business Concerns and Environmental

Concerns.
• What is business Concern in the study?
• Customer specific requirements.
• Legal Requirements.
• LTI
• STI
• RSV
• EC
• Any aspect or Impact , if related to Business
concern should be taken as significant aspect
without any risk calculation
81
Business Risk analysis

• If it doesn’t affects the business in any of the

category then do an environmental concern
study.
• How to do environmental Risk study?
• Severity
• Occurrence
• Detection
• Duration
• Spread
• Scale each category appropriate to your
business and rate them individually.
• Calculate a risk factor and it’s cutoff for
identifying the significant aspect
82
Business Risk analysis

• What is severity???
• How much damaging in terms of impact?
• Fatal to human, Accidents, Pollution etc.
• Bhopal gas….Is it severe!!!
• What Is Occurrence?
• It is frequency of occurrence.
• Leakage happen every months, every days!!!
• What is LPG leakage frequency in your house.

83
Business Risk analysis

• What is Duration?
• How long it continues after it occurred.
• Your LPG gas frequency is twice a year but Is
duration 2hrs or 1 minute???
• What is Detection?
• What is our mechanism to detect.
• Our effectiveness of detection.
• What is Spread?
• How far it goes if it fails…
• Within m/c, Within shop, Within co. or Outside
• Can You give Examples!!!! 84
Business Risk analysis

Evaluation criteria for identification of Environmental concerns

(For a minimum period of six months data)

SCALE SEVERITY SPREAD PROB. DUR.

Human Noise Fumes Land
1 Incident < 40 db Normal Easily wiped WITHIN ONCE IN SIX < 60 sec. in a
with no odor. off without WORK MONTH shift.
physical damage. CELL
injury
2 Minor 40< =x <60 db Bad or fowl Binding with WORK ONCE IN A 1 <= x < 30
injury. odor land. STATION MONTH min. in a shift.
3 Temporary 60< =x <100 Unease due Absorption SHOP ONCE IN A 1 <= x < 4 hrs
disableme db to in the land. FLOOR FORTNIGHT in a shift.
nt suffocation LEVEL

4 Permanent 100< =x <120 Difficult to Chemical COMPANY ONCE IN A 4 <= x < 8 Hrs.
disableme db breath reaction with LEVEL WEEK in a shift.
nt land
5 Loss of life > 120 db Toxic Permanent LOCAL & EVERYDAY 8 hrs. In a
damage to BEYOND shift.
land.
85
 Business Risk analysis

CRITERIA FOR EVALUATION OF ASPECTS

BUSINESS CONCERNS ENVIRONMENTAL CONCERNS

S.NO ASPECTS N/A/E IMPACT RSP EC LC LTI CR SPR SEV PRO DUR SCORE
SIGNIFICANT

TOOL ROOM
- Generation of scrap in form N LAND CONTAMINATION N N N N N 3 1 5 4 60 SIGNIFICANT

of metal chips of MS/Die steel NON SIGNIFICANT

- Spillage of cutting and lubricant N LAND CONTAMINATION N N N N N 1 3 5 4 60 SIGNIFICANT

- EDM oil fumes N AIR POLLUTION N N N N N 2 2 5 5 100 SIGNIFICANT

- Oil Filter disposal N LAND CONTAMINATION N N N N N 5 1 2 5 50 NON SIGNIFICANT

- EDM oil recirculation N RESOURCE CONSERVATION Recycle (reducing negative interaction) 0 NON SIGNIFICANT

- Generation of metal chips N LAND CONTAMINATION N N N N N 3 1 5 4 60 SIGNIFICANT

86
Business Risk analysis

• What is the output of IER study.

• LIST OF SIGNIFICANT ASPECT……
• What can be done with these significant
aspects.
• EITHER I CAN CONTROL OR IMPROVE.
• FOR CONTROL …… OCPs….
• FOR IMPROVE…. O&T
• There are only two options left with this.
• Why I can’t improve everything …...

87
OCP

• How do we control our processes??

• Control Plan, Work Instructions, Visual
Controls Mistake proofing etc.
• Same here but few things to remember!!!
• How do we know that OCP is working or not
working.
• SET Operational Criteria.
• E.g., if criteria is to wear goggles and you find
it is not there so OCP not working.
• What happens when there is a departure from
the OCP??
• We need Reaction plan etc. 88
OCP

• We need Reaction plan….

• If acid falls on the floor..What you will do?
• Put a fencing or board, Call the competent
person to clean the floor etc..
• OCP is based on Impact OR Aspect ???
• Significant Aspects to Have OCPs!!!
• Is it possible that departure from a some OCP
can be dangerous??
• FIRE, ACCIDENTS, LEGAL requirements!!
• In Such Cases reaction plans are refined to
ERP (Emergency Response preparedness)
89
ERP

• Emergency doesn’t come knocking at the

door.
• Only knocking is from Incidents.
• Before emergency ,we can think coolly.
• During Emergency , We can’t think coolly.
• We need to plan in advance. Have we done
enough preparation???
• MOCK Drills!!! Are we taking seriously???
• At the end of drills, are we monitoring Head
counts, Time taken to come out, Success of
drills etc.
90
 OCP
1.0.PURPOSE : To reduce spillage of Hot melt adhesive

2.0.SCOPE : Lumax Industries Limited Gurgaon - Assembly shop

3.0.RESPONSIBILITY : Rajeev Gambhir

4.0.SIGNIFICANT ASPECT : Leakage in machine, resource depletion

5.0.OPERATING CRITERIA : wastage of adhesive not to exceed gm

6.0.DESCRIPTION :
Ref ACTIVITIES RESP.
6.1
1 Clean the machine and check parameters temp and pressure operator
2 if found ok start the button of motor and check speed operator
3 check the flow of hot melt adhesive and readjust motor speed as per requirement operator
4 if flow not ok then report maintenance for filter cleaning operator
5 start production operator
6 check the adhesive falling in water bin for re using of adheive operator
7 report to supervisor for any leakage observed in machine operator

6.2.0 CORRECTIVE ACTION : For any spillage , immediately clean the floor with wet cloth

6.3.0 PREVENTIVE ACTION : regular maintenance of hot melt applicator

7.0.RECORDS : 5 s records and breakdown slips

91
ISSUED BY ISSUE NO : DATE: APPROVED BY
O&T

• The second route of significant aspect is

Objective and targets.
• Improve those significant aspects which is
linked with Business results improving
environmental performance in line with policy.
• ALSO see the technical feasibility!!!
• We can’t get the results in one day so we
need to have a road map!!!
• What is the way to achieve our O&T??

92
O&T

• This follows project management .

• We have to run EMP (Environmental
Management Programme)
• Focus in EMP:
• Responsibility
• Dates(Start/End)
• Gantt Chart.
• CPM.
• Resources required
• Performance Criteria.
93
EMP

• Have you practices Project management in

your personal life?
• YES!!!!
• Follow Marriage example for Project
management. If date if 14 Feb we don’t say to
relative that come on 15th FEB Because
• I Failed to arrange caterer!!!
• I failed to arrange accommodation.
• I failed to arrange Venue!!!
• Responsibility clearly defined.
• Champion role clear!!!
94
EMP
A c t i v it y : C o ld m e lt a d h e s iv e d is p e n s in g .

S i g n i f i c a n t A s p e c t : V a r i a ti o n d u e t o m a n u a l a p p li c a ti o n o f s e a lin g a d h e s i v e .

S i g n i f i c a n t I m p a c t : R e s o u r c e d e p l e t io n .

B u s i n e s s C o n c e r n : R e s o u r c e S a v i n g P o t e n ti a l

P r o p o s e d O b j e c t i v e : T o o p ti m i z e t h e c o n s u m p t i o n o f s e a li n g a d h e s i v e
( P e n g u in c e m e n t) .

P r o p o s e d T a r g e t : I n s t a l la ti o n o f r o b o ti c a p p li c a ti o n f o r d i s p e n s i n g o f s e a li n g
a d h e s iv e to r e d u c e th e c o n s u m p tio n fro m 1 7 g r a m s to 1 1 g r a m s b y m a r c h 2 0 0 3 .

R e s o u r c e R e q u ir e m e n t :

F in a n c e : R s .2 ,0 0 ,0 0 0 ( R u p e e s T w o L a c o n ly .)
I n c lu s i v e o f tr a i n i n g o n r o b o ti c t e a c h in g

P a y B a c k : 3 m o n th s

T e c h n o l o g y : O u t s o u r c e d f r o m M / s E C O - T E C H s o l u ti o n s a n d s y s t e m s .

S k i l l s : R o b o t i c d e s i g n a n d d e v e l o p m e n t s k ill .

O t h e r s : N il.

D e fe rr e d T o : N A

95
 Business Model FIT
TOP LEVEL REVIEW COMMITTEE

MR (Available resource to Process owners

Planning

Process Owners CFT

Core Team (IER Study)
Handles Significant Improves Significant
Policy Formulation
Aspects in their area Aspects through EMP
Spread Awareness
Monitors EMP Investigation Purposes

96
Business Model FIT

• EHS Requires Structure and Methodology

METHOD and TOOLS

Planning DO Checking

PROJECT AUDITING
IER TOOLS
MANAGEMENT TOOLS (SNAP AUDITS)
(EMP) (RED TAG)

97
Business Model FIT

Initial Environmental Review M

A
Risk Analysis (Significant Aspects) N
A
G
Policy Formulation
E
M
A E
Objective and Target
U N
D T
Deployed O&T OCP I
T R
EMP I E
N V
G I
E
W 98
PLUG IN

TOOLS COMPARISION

QMS EHS
FMEA RISK ANALYSIS
PFD IER TOOL
CUSTOMER SURVEY IER TOOL
POLICY DELPOYMENT POLICY DELPOYMENT
APQP MP
CONTROL PLAN OCP
CONTINGENY PLAN ERP
AUDITING AUDITING
MR MR
CAPA CAPA WITH INVESTIGATION
99