Cleaner Production Assessment

Cleaner Production Assessment
Project financed through LIFE+ Programme
"CLEANER PRODUCTION" ASSESSMENT TECHNICAL, ECONOMIC, ENVIRONMENTAL AND FINANCIAL ASSESSMENT OF GENERATED OPTIONS
Team: Lucian Constantin Aurelia Ballo Andrei Vasile Maria Teodorescu Mihai Stefanescu
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CONTENT 1 The Cleaner Production concept (CP) ...................................................................................... 3 2 Cleaner production assessment .................................................................................................... 6 2.1 Preparation ............................................................................................................................ 6 2.2 The analysis of process phases .............................................................................................. 9 2.3 Generating CP opportunities ............................................................................................... 16 2.4 Selection of CP opportunities .............................................................................................. 19 2.5 Implementing CP solutions ................................................................................................. 29 2.6 Supporting CP solutions ...................................................................................................... 32
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1 The Cleaner Production concept (CP)

Cleaner production is an integrated preventive environmental strategy applied during production process and service cycle1.
Figure 1 The concept of Cleaner Production
Cleaner Production
Products - Reducing wastes through a good design - Using wastes for new products link with industrial symbiosis
Processes - Preserving raw material, energy and water - Reducing emission sources - Evaluating technological options - Reducing costs and risks
Services - Efficient environmental management
IMPACT - Environmental performance - Increasing competitiveness
UNIDO Cleaner and Sustainable Production Unit http://www.unido.org/index.php?id=o4460

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Cleaner production applies to PRODUCTION PROCESS by conserving raw material and energy, eliminating toxic materials, reducing the quantity / toxicity / hazard of emissions and wastes at the point of their generation.
Cleaner production applied to PRODUCTS refers to reducing the negative impact, all along the entire products life cycle, from production to final elimination. Cleaner production applied to SERVICES refers to incorporating environmental issuess in designing and offering of services. The concept of Cleaner Production applies to industrial units, production departments, technological installations, production process etc. Application of Cleaner production assessment follows three logical steps: 1. Source inventory: Where are wastes and emissions generated? 2. Evaluation of causes: Why are wastes and emissions generated? 3. Generation of options: How is possible to eliminate these causes? By applying CP, a bridge between industrial production and environmental objectives is created. CP is more than a technical solution. It represents a worldwide application at all levels of decision making from industry, where the objective is to adopt clean technologies and the BAT in the field2. The high costs of end-of-pipe pollution controls system are progressively replaced with a strategy to reduce / prevent pollution and reuse of wastes on manufacturing flow.
Organisation For Economic Co-Operation And Development(OECD)(Hrsg.): Technologies For Cleaner Production And Products- Towards Technological Transformation For Sustainable Development. Paris: OECD, 1995
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Implementation of cleaner production assessment within an industrial unit, production department or technological installation brings benefits with respects to environmental protection, human health and economical aspects.
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2 Cleaner production assessment

Cleaner production assessment consists in the following stages3: START ANALYSIS Stage 1 Preparation Stage 2 Analysis of process stages Stage 3 Generation of CP opportunities IMPROVEMENT Stage 4 - Selection of CP opportunities Stage 5 Implementing CP solutions INTEGRATION Stage 6 Supporting CP solutions
2.1 Preparation
In CP analysis, decision makers are involved in setting up the CP focus. In order to perform CP assessment, the support and participation of top management is crucial. The CP assessment team must be implemented in production departments, and the application of technology must be systematic.
UNIDO NCPC Programme http://www.unido.org/index.php?id=o4460/

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Figure 2 Stage 1 of CP
Interest for CP
Stage 1 - Preparation 1. Setting up working team 2. Listing process phases 3. Selection of focal objective
Interim result Selection of CP focus Stage 2 Analysis of process phases
Setting up working team The working team must address to the following needs: To be capable to identify opportunities, develop solutions and implement them; The team dimension must be in accordance to how big the organization is; Different interests must be represented. Listing the process stages A description of unit and processes is necessary. Technological schemes are presented. This stage consists in presenting all processes, including production processes, manipulation, material transport, utilities, etc. The identification of all inlets and outlets of materials, energy, wastes and emissions is important. The measures already implemented are described. Focus selection After establishing process phases it is necessary to consider aspects used in the selection of CP focus:
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economical considerations funding losses with waste fluxes environmental considerations volume and composition of waste fluxes technical considerations expected potential for improvement.
Table 1 Example of selection key points for a pulp and paper factory
Process of production 1. Preparing raw material 2. Preparing pulp 3. Washing pulp 4. Pulp whitening 5. Preparing stock 6. Paper machine 7. Recovery chemicals 8. Utilities
Economical priority
Environmental priority
Technical potential medium
Other considerations (CSR)
high
high high
medium low working environment
low
high
medium
Elaboration of CP assessment plan The targets, objectives and indicators are established. Also, the activities,
responsibilities and the working program are established. The unitary operations and the material fluxes are linked and the inputs and outputs are correlated.
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2.2 The analysis of process phases

Figure 3 Stage 2 of CP assessment
Stage 1 - Preparation
Intermediary result: CP focus Audit
Stage 2 Analysis of process phases 1. Preparation of flux diagram 2. Balance materials and energy 3. Allocation of costs to waste flows 4. Cause analyses
Intermediary result: Listing of sources and causes of wastes
Stage 3 - Generation of CP opportunities
Technological flow scheme The phases of production process are described, by specifying inputs and outputs. One example is presented in the following figure.
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Raw pulp from theCleaner boiler Production Assessment
Blower basin
Press
Concentrated lye
Dillution basin
Vacuum filtration washing
Diluted lye Recirculated water from paper mashine Vacuum filtration washing
Washed pulp from the whitening section
Figure 4 Example of technological flow sheet

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Balance sheet of materials and energy The material and energy balances are developed based on the conservation law for mass and energy: Material input + = Material generated + Material consumed Material output
General information: Documents referring to environmental politics of the company Standard procedures Organizational diagrams Information regarding materials / products: Composition of products Data regarding raw materials and materials entering the process Product sheets Inventory of raw materials and products Registering of operators Procedures of operations Production schedules Information regarding the process: Technological flow schemes of the production processes Manuals and descriptions of production processes Descriptions of installations Drawings of installations / equipment Scheme of pipe network Data referring to environment: Records of emissions Analysis of wastes Environmental audit reports
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Financial data: Costs for treatment, elimination, and storage of wastes / wastewater / emissions Costs for products, raw materials, materials, utilities Costs of operation and maintenance Financial reports
Figure 5 Material and energy flow sheet
Raw material Gas emissions Materii prime Mat. aux.+op. Catalyzers Water/air Energy
Production process
Wastewater Liquid wastes Solid wastes
recycling By-products Products The balance sheet is based on inputs and outputs of records. One example of balance sheet to be used for development of balance is presented in the following table:
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Table 2 Example of balance sheet for material balance
Inputs Waste paper Fibers Filling Water Re-circulated water 10 t/day Filtrate
Outputs
Losses
8 500 kg/day Fibers 900 kg/day Filling 600 kg/day Water 400 t/day Pulp Fibers Filling Water TOTAL Inputs
350 kg/day 450 kg/day 200 t/day
8 075 kg/day 400 kg/day 190 t/day TOTAL Outputs 8 425 kg/ day 850 kg/ day 390 t/ day Not identified 75 kg/ day (1 %) 50 kg/ day (6 %) 10,6 t/ day (3 %)
Fibers Filling Water
8 500 kg/day Fibers 900 kg/day Filling 400,6 kg/day Water
For the development of material and energy balances, calculus sheets are used, like in the following example:
Table 3 Example of calculus sheet for the balance sheet of energy
INPUTS, kWh Steam Air Product TOTAL INPUTS
2062 786 291 3139
OUTPUTS, kWh Steam Air Product TOTAL OUTPUTS
LOSSES , kWh 484 2027 456 2967
172 (5,5 %)
Once the balance for materials and energy is made, it is necessary to verify: if the measurement units are correct if the material balance is accurate, which means the balance will be increased for materials that are more expensive and toxic by repeating the checking, inconsistencies are identified
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Attaching the monetary flows to the material flows At the elaborated fluxes, there are costs related to wastes and evacuations. These costs are: Internal: Losses of raw material and byproducts Costs of operation for treatment Costs for collection and manipulation of wastes External: Taxes for evacuations Penalties, costs for regulations
Table 4 Example of allocating costs for concentrated lye (pulp and paper)
NAME Residual pulp Chemicals Fiber losses Heat losses Wastewater COD content
CALCULUS Costs for chemical procurement Costs intermediary fibers Costs energy (from caloric value) Price water Costs for treatment and evacuation
SOURCE internal internal internal internal external
This step is an important input step for the management of costs related to environment (Environmental Management Accounting). Monetary flows are used for environmental cost allocation to cost centers or products. The following methods can be used: cost calculations based on activities (activity based costing ABC) cost flows accounting Identifying sources and causes of pollution Identifying sources of pollution implies the analysis of unitary operations and establishing causes generating their occurrence. The following criteria should be considered: impact of product characteristics
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impact of chosen raw material impact of technical factors project of process/ equipment, assembling, equipment/pipes, monitoring equipment etc. impact of operation practices scheduling production, operation procedures, maintenance program, personnel training, etc. impact of waste manipulation. One example of working sheet used for identification of sources and causes of pollution is presented in the following table:
Table 5 Identification of sources and causes of pollution
(e.g. phase of chemical treatment of metallic parts)

Process phase Source of Frequency pollution Cause of pollution Effects
- leaks of the ammonia feeding pipes - defects of dosing
- losses of ammonia - improper dosing of treatment gasses
THERMAL During Incinerators TREATMENT functioning
- inefficient ventilation system
-diffuse emissions of gasses in the - deterioration of isolation working system of incinerator atmosphere which can lead to high energy losses - emissions of - low burning efficiency high quantities of burnt gasses - old automation systems
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2.3 Generating CP opportunities

Stage 2 Analysis process phases
Intermediary result: Listing sources and causes of wastes
Stage 3 Generation opportunities for CP
1. Development of CP opportunities 2. Selection of CP opportunities Intermediary result: Listing opportunities for CP Stage 4 - Selection of CP solutions
Once the causes and sources of pollution are known, a brainstorming within the team is performed: Ideas are developed in and out of the team, the participation of all employers in the stage of generation of opportunities for CP is welcomed Options can be generated based on the data base, manuals, reports etc. All the preventive practices are verified, for example: good housekeeping changing raw materials changing technologies modifying the equipment improving process control modifying products local reconditioning and reusing generation of useful by-products
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Development of opportunities for CP Opportunities generated for CP are broken down into 4 categories: A for options of good housekeeping, not requiring financial investments B for measures with small investment (which could be implemented within the internal budget of the company) having a short depreciation period (usually up to 6 months) C for measures with needs large investments and long amortization, which will require more complex feasibility study, D - for measures obviously not feasible at the moment when CP assessment is performed Based on the generated opportunity, this will fall in a certain category, for example options generated within a section of thermal treatment for metallic parts.
Table 6 Development of opportunities based on causes of pollution
(e.g. phase of thermal treatment for metallic parts)

No. opportunities Category A A B C B D
Phase
Factor influencing generation of pollution
CP opportunity identified
improper functioning of incinerators, for long times, between batches, with generation of diffuse emissions of pollutants improper function of incinerators with high energy consumption Thermal treatment
ORGANIZATION PROCESS selection of commands, so that optimal technological flow is organized ORGANIZATION PROCESS starting of incinerator only when a number of benchmarks is collected to allow continuous functioning and decrease of improper functioning Monitoring Equipment buying equipment for determining emissions of pollutants buying modern automation equipment replacing isolation system of incinerators and revising pipes isolation of every incinerator and ventilation of approx. 10 changes / h.
using inadequate flow meters to regulate treatment gas flow
3 4
deterioration of isolation trimming 5 absorption of pollutants through and evacuation through a system of ventilation with natural circulation
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Selection of feasible opportunities Generated options will be selected based on the following criteria: implementing of evidently feasible options unfeasible options will be excluded options to be analyzed based on opportunity / feasibility. A preliminary evaluation of the remained options is made. The potential of implementing is verified. An analysis of economical opportunities/technical feasibilities is made. It is necessary to involve competent experts and technicians in preliminary assessment. It is recommended to use, as much as possible, quantitative measures.
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2.4 Selection of CP opportunities

Stage 3 Generation of CP opportunities
Intermediary result: Listing CP opportunities
Stage 4 Selecting CP opportunities

1. 2. 3. 4. 5. Technical feasibility Financial viability Environmental aspects CSR issues Selection of solutions for implementation
Intermediary results: Listing CP solutions
Stage 5 implementing CP solutions
Following the selection of opportunities, a list of technical checking is made, in which the following criteria are important: Availability and insurance of equipment Requirements for utilities, monitoring and control of process and space Maintenance requirements Technical necessary capacities (operators, technicians, etc.)
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Evaluation of technical feasibility

Table 7 Example of evaluation sheet of technical feasibility
IDENTIFIED CP OPPORTUNITIES OPPORTUNITIES TYPE A TECHNICAL FEASIBILITY selection of commands so as to Selection of commands launched in fabrication so as to allow grouping of allow optimal the parts to be treated, during periods of continuous functioning of the organization of the incinerator, it can be made only in limits permitted by the terms of delivery of technological flow commands. Availability and security of equipment starting of the The incinerators for nitruration and carbonitruration have a design incinerator only when capacity, more than it is necessary for thermal treatment. Therefore, it is a number of necessary to limit their functioning a number of days of continuous functioning, benchmarks are avoiding unnecessary times of functioning. collected to allow Requirements for utilities, monitoring and process control continuous functioning The proposed measures will be materialized on: and shortening of the - reduction of utilities for endo gas and ammonia improper functioning - reduction of electrical energy consumption Requirements for maintenance By reducing the unnecessary functioning of incinerators, the period between technical revisions will increase. Necessary technical capacities The measure does not require personnel qualification, only careful monitoring of production scheduling OPPORTUNITIES TYPE B TECHNICAL FEASIBILITY replacing isolation system of incinerators By replacing isolation systems and revision of piping the losses of gasses in and revision of piping the incinerator are avoided. Requests for utilities, monitoring and process and space control Measures proposed will be materialized in reducing utilities: ammonia and endo gas reducing electrical energy consumption with approx. 5% reducing the degree of environmental pollution (on a surface of approx. 12 m around the incinerator). OPPORTUNITIES TYPE C
Technical feasibility
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buying automatization equipment/devices TECHNICAL FEASIBILITY Rquirements for utilities, monitoring and control process, space The proposed measures will be materialized in the reduction of ammonia and endo gas and unnecessary consumption of electricy because the incinerators will be fed with the quantity of gas according to the project, with no excess. Increasing quality of thermal treatment due to the possibilities of continuous monitoring of necessary gas correlated with reaching optimal parameters of the process regarding the gas distribution and temperature in incinerator. The feeding flow of gases will descrease: Maintenance requirements Optimization of consumption leads to reduction of functioning time of incinerators and the increase of periods between maintenance. Technical cpacities The measurement requires qualified personnel, but excludes the efficiency of process management from under the influence of human subjectivity
TECHNICAL FEASIBILITY buying performant AMC equipment for determination of When buying equipment , the control of pollutant imissions at pollutant imissions workplace and emissions in atmosphere can be made. Gas analyzer
Following the market analysis, the obtained data are collected, and a technical, comparative analysis is made, followed by the development of an sheet to establish the differences before and after implementation.
Table 8 Example of calculus sheet for evaluating technical feasibility
RATE OF CONSUMPTION INPUTS: Raw material Manpower Energy Water OUTPUTS: Products Solid wastes Wastewater Gases Market analysis
BEFORE IMPLEMENTATION
AFTER IMPLEMENTATION
After evaluating technical feasibility, a market analysis is made regarding type B and C opportunities. For this it is necessary to know if the product to be bought in order to implement the opportunity exists on the market. Technical specifications are made, in which all the characteristics necessary to satisfy the requests are presented, in order to
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buy the product. Suppliers are requested, offers are made and finally a comparative analysis of offers is made, in order for selecting the best one. Technical analysis During technical analysis different criteria are considered, so that after selection of an offer, this will answer the requests. Once the offer is selected, an evaluation of financial viability is made. Evaluating financial viability The basic idea in establishing the necessary budget is by comparing different alternatives of investment. Evaluation of investment is used for determining economical costs. Economical variables are used for determining cost economy. Economical variables used for evaluating static financial analysis are: initial costs of investment operational costs interest internal rate of return period of recovery In dynamic financial analyses, future fluxes of money inputs and outputs are updated based on the moment of investment based on the internal rate of update. The opportunity costs of capital are considered by their update with the rate of interest on the finalcial market. The sum of all money fluxes are used for determining the net value of the project, which is compared with the value of the old equipment and the rate of interest on the financial market. A planned investment must be more profitable than the gain by interest due to bank deposit. Initial cost of investment Based on the classification of equipment (equipment for treatment of wastes or integrated technology) there are included initial costs and anual amortisement. Costs of anual operations
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Anual evaluation of total costs is vital as starting point in accountability of environmental costs. This ensures that once the general image is made, in the future only parts of this are considered related to a cost center or specific equipment. This assures that together with the general image generated, in the future there will be considered only parts of it related to a cost center or specific equipment. The measures for preventing pollution helps in reducing treatment and elimination costs of emissions and reducing efficient use of provided material. Often, when investment is evaluated, material and treatment costs are not completely calculated, which leads to distorted investement decisions. Costs with future liabilities There are two general forms of investment for future liabilities: liabilities for accidents personnel and remediations, field constructions and penalties and taxes for breaking environmental laws.
Potential economies Less tangible benefits resulted from investment in pollution prevention such as increasing income due to better product quality, image of company or product, reducing costs related to personnel illness, maintenance or productivity are difficult to foresee or cuantify. The following economical potential must be considered4: reduction of treatment and limination costs for wastes ans emissions. This includes internal and external treatment, equipment and materials for operation, personnel for waste manipulation, costs for storage, taxes for discharge, transport, inssurance and provisions, production autorizations, reporting to auhorities, etc. economies from inssurance, provisions and costs for remediation. Decrease of wastes and emissions. The new processes requiring operation materials less dangerous offer a good argument for reduction of risks of breaking, losses, leakages,
Schaltegger,S.; Bennett, M.; Burritt, R. & Jasch, C.: Environmental Management Accounting as a Support for Cleaner Production, in: Schaltegger,S.; Bennett, M.; Burritt, R. & Jasch, C. (Eds): Environmental Management Accounting for Cleaner Production. Dordrecht: Springer, 2008, 3-26
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soil contamination, remediation or other costs related to reconstruction and remediation costs of personnel and materials related to maintenance will be affected by product design or implementation of clean technologies economies of energy and water requiring clean technologies with less material consumption use utilities more efficiently economies for raw material, auxiliaries and wrappers. Alternatives to reduce waste in general include less material usage economies due to a better quality of product. Product design can improve quality and reduce costs for quality, related to rejects and to reprocessing gainings of new secondary products. If wastes are replaced by secondary products, cost of product design could be the source of generation of new gainings reduced risk of accidents and absenteeism by elimination of dangerous substances together with increasing personnel motivation improving relation with authorities, reduction of time for obtaining authorizations and for other official procedures future economies due to anticipation of results Additionally, other positive effects could result from environmental management. These also called "soft" factors could be: increasing efficiency in bussiness, client satisfaction, differentiation towards competitors incresing image better relationships with competitors, costs of conformation with smaller reglementation better credibility towards banks, reduced inssurance rates, good rating for brokers and investment agents better relations with interested parts and local communities increasing motivation and personnel satisfaction, reducing absenteeism and disease Financial indicators used in evaluating financial viability are: Payback period
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Risk indicator; Fast rule for small projects.
Net present value (NPV) n = time of depreciation (years) i = annual rate of interest (%) I = total investment For viable projects >>0
= n
E x tra C a s h , n e t (1 + i) j
-I
j= 1
Internal rate of return r = internal rate of return >> rate of interest

NPV =
j=1
Extra Cash, Net (1+r)j
- I=0
Decision criteria: 1. Payback period: < 1-2 years (for projects of small value) < 3-4 years (for projects of medium value) < 5 years (for projects of high value)
2. Net present value >> 0 (after a depreciation period) 3. Internal rate of return >> rate of interest
Evaluation regarding environmental aspects Following collection of opportunities the next step is evaluating environmental aspects through environmental improvements: Reducing quantity of pollutants and generated wastes Reducing toxicity of pollutants Reducing material consumption Reducing use of not recovered material Reducing energy consumption Reducing energy consumption from nonrenewable resources Reducing water consumption
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Reducing noise, dust, smog, smell etc. In the evaluation step of environmental aspects, more factors are taking into consideration: legal pressure pressure from population reducing expenses By implementing selected opportunities, legislative answers and pressure from population, in case there exists one. The measures for implementation lead to reducing pollutants evacuated in the environment, at utilizing some nontoxic products, to the manufacturing of ecological products, some expenses could be reduced. Every selected opportunity is analyzed:
Table 9 Example of evaluation sheet regarding environmental aspects

IDENTIFIED CP OPPRTUNITIES OPPORTUNITIES TYPE A ENVIRONMENTAL FEASIBILITY selection of commands, so that it Reducing overall gas consumption for thermal treatment with 50 % allows optimal leads to the corresponding reduction of pollutants evacuated into organization of atmosphere. technological flow starting the incinerator only when a number of marks is gathered to allow continuous functioning and reduction of excessive functioning OPPORTUNITIES TYPE B
Environmental feasibility
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replacing isolation systems of incinerators and revision of piping system. ENVIRONMENTAL FEASIBILITY Environmental benefit consists in reduction of imissions evacuated in the environment in the ventilation system of thermal treatment chamber.
OPPORTUNITIES TYPE C buying performant equipment/devices of automation. buying AMC devices for determining pollutant imissions GAS ANALYZER ENVIRONMENTAL FEASIBILITY The environmental benefit consists in reducing imissions at the workplace and reduction of emissions evacuated into environment. ENVIRONMENTAL FEASIBILITY Buying this device allows monitoring concentration of noxes at workplace, identification of leaks due to deterioration of incinerators and pipes, allowing repairing and reducing risk for human health. This will allow measurement of pollution into atmosphere induced by the activity in the factory. The environmental benefits are materialized by reduction of penalties, which can reach 2500 USD.
Evaluation of RSC (Social corporate responsibility) issues Corporate social responsibility, as element of sustainable development, completes 3 main elements (economic + environment + social) in one whole where each element is important.
Table 10 Factors less tangible which must be considered in evaluating opportunities Productivity product quality product flexibility product trust personal absenteeism personnel moral Potential obligations costs for closing company taxes for nonconformity costs for remediation legal costs personnel accidents reclamations affecting natural resources Inssurance inssurance for health of workers compensations for workers inssurance for property general obligations environmental obligations unemployment Imaginea companie acces to clients and on the market acces to finance public relations
Future regulations strict imposing actual regulations modification of actual regulations new regulations
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Selection of solutions for implementation In this phase the results of technical, economical, RSC and environmental evaluations of CP opportunities are evaluated. It is necessary to document the results and benefits for every option, in order to obtain funds and monitor implementation. Following technical analyses of selected units, for e.g. type A , it can be concluded the benefit to be registered. For example, for an opportunity type A, mentioned in previous chapters, it was found the following consumption decrease:
Thermal treatment ammonia endo gas electric energy
Before 5700 mc /h 7120 mc /h 5,53 kwh
After 5600 mc /h 5600 mc /h 1,38 kwh
In case of opportunity type C, from the previous example, it was calculated the payback period in case of buying a gas analyzer and it was foud if the investment was profitable. For example, investment (equipment) having a value of 8 000 Euro with annual penalties of 2 500 Euro, is paid back after 3.2 years. PB =
8000 = 3.2 years 2500
Calculus sheets for investment in projects can be used for calculating alternatives and comparing them, for direct estimation of cost economies. An annual evaluation of total costs for environment must be realized, in order to provide data for realizing a database. Once costs for environment for the two alternatives were evaluated for one year, these can be extended over the period of the project. Estimating inputs and outputs for the first 3 years could be sufficient . For the following years estimations are sufficient. Determining total costs per year is a request for calculus options. If these were not evaluated, the potential of saving is not calculated. After determining total annual costs, the calculus can be made for cost centers or specific production processes.
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When comparing investment options it is recommended to evaluate first the old equipment in a proposed scheme and then to calculate costs for new equipment. These also called "soft" factors or less tangible factors must be added if it is necessary.
2.5 Implementing CP solutions

Stage 4 Selection of CP opportunities
Intermediary result: Listing CP solutions

1 2 3
Stage 5 Implementing CP solutions

Preparing implementation Applying CP implementation Monitoring and evaluation of results
Intermediary result:
Successfully CP implemented solutions
Stage 6 Support for CP solutions
Elaboration of implementation plan Preparing for CP implementing measures consists in: Selection of the best offer received in the previous stage Preparing plans for construction (if necessary)
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Assuring a rigorous plan for reducing stoppage time
Implementing CP measures An action plan is elaborated, in which it is designated a responsible, it is established an execution term and indicators to be followed. The action plan represents the program of implementation of all CP measures selected as feasible and feasible by society. Each action is characterized by measurable indicators, quantifying the results of CP action, of which a positive evolution leads to reaching the targets and proposed objectives, although in some situations it is difficult to establish them, due to the lack of measurement, recording etc.
Table 11 Example of sheet for the action plan
No. opportunity 1 2 .. N
Responsible
Final term
Indicator technical environmental
The following will be considered: supervising construction and installation controlling progress of activity verifying specification of equipment and installation.
The followings will be prepared: necessary substances, spare parts, etc. a program of preventive maintenance will be prepared instruction of operators, foremen etc.
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Beside the Action plan the Monitoring program and Future plan, where there are stipulated measurement that must be considered in order to implement CP plans, which must be signed and sealed by the company management. Monitoring and evaluating results The monitoring activity is laborious, needs special efforts from the personnel responsible and a large implication of different compartments besides production, to finalize procedure. The obtained results will be correlated with process performance and will show the level and opportunity to apply the CP established measures. 1. Method of analysis: changes in quantity of wastes changes in resource consumption changes of profit rate 2. Changes of total production 3. Changes of products. Finally, the progress made is evaluated by comparing measured and stipulated benefits. Other ways of improving technical installations are verified. The installations and their operation mode are verified toward specifications.
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2.6 Supporting CP solutions

Stage 5 Implementing CP solutions Intermediary result:

CP solutions successfully implemented
Stage 6 Supporting CP solutions 1. Supporting CP solutions 2. Selecting new targets
Final result: CP activity in progress
Supporting CP solutions involves: 1. Establishing an organizational structure for CP; 2. Involving employers for instruction and benefits; 3. CP politics and strategies on long term; 4. Integrating CP in technical development. Supporting CP involves establishing support mechanisms for CP at strategic and operational levels. This involves the analysis at management level of the implemented CP results through:
Presenting results of gained experience

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Integrating CP approach in company activity, using environmental system management structure and instruments for continuous improvement Reporting dialog with interested parts
Additionally, in order to sustain CP it is developed a monitoring and control system of efficient use of materials and energy. Organizational structure: the key responsibility in implementing CP must be supported by production sector the chiefs and foremen must be responsible for generating wastes the technical and environmental departments will participate to continuous improvement. Involvement of employers in CP: Changing attitude requires effort and continuous education of personnel Clean production benefits in two directions to the internal practice of communication Clean production gives personnel satisfaction Bonuses for the best employers CP in technical development: To realize programs of preventive maintenance To verify new equipment regarding protection of environment To integrate the CP concept in technological research-development. The most important factors determining successful implementation of CP approach and its integration at strategic and operational level of the company are: support and participation at superior management; the evaluation team effectively involved in production departments; application of systematic methodology; obtaining economical and environmental benefits on short term.
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Cleaner Production Assessment

Project financed through LIFE+ Programme