Impact of work activities on the environment

Transcription

1 Unit 35: Managing the environmental impact of work activities in manufacturing engineering Impact of work activities on the environment Across the globe, manufacturing industries have been identified as one of the main factors contributing to environmental damage. There is a relationship between the environment and almost all of the activities within the manufacturing industry, from product definition, to product design, material type, production process, shipment, product use and recycling. There can be a risk of damage to air, water and soil with consequences ranging from noise pollution, acid rain, oil spills, risks to human health or endangerment of other species, and contamination from radioactive materials. We need to identify the environmental risks associated with our manufacturing activities, and evaluate and manage these risks by developing appropriate solutions. Links Unit 1: Ensure compliance with legal, regulatory, ethical and social requirements. HNC in Manufacturing Engineering: Unit 6 Health, safety and risk assessment in engineering, learning outcome 3, assessment criterion 3.1 This topic guide will cover: environmental impacts and risks of work activities assessing the impact of work activities and resources on the environment minimising the environmental impact of work activities and resources identification of hazardous materials and products procedures for the handling and disposal of hazardous substances organisational methods for dealing with recyclable products specialist advice on managing the environmental impact of work activities. 1

2 Before you start Based on your current knowledge, answer the following questions. What is the environmental impact of your job? How is this impact assessed and how could it be minimised? Do you deal with any hazardous materials and substances in your current job role? What are these materials and how are they identified? Explain your organisation s procedures for handling hazardous materials. Explain your organisation s procedures with regard to recyclable products. How do you obtain specialist advice when managing the environmental impact of work activities? Key terms Recycling the process of separating any type of waste which is reusable and converting this waste into new products. Design for the Environment (DfE) a methodology developed to ensure that the environmental impact of products is considered during the early design stage of the product, so a product is designed, produced, operated and disposed of with minimal impact on the environment. 1 Impacting the environment There are several reasons why manufacturing companies should be concerned about the impact of their production on the environment. Environmental problems are not easy and quick to fix, therefore prevention of any damage to the environment is the best approach. The consequences of harm to the environment can be very severe. The environment also belongs to future generations. In some cases environmental impacts are against the law and legislation. There can be very serious financial consequences for pollution, alongside damage to a company s reputation (a good example is the claim brought forward for the oil spillage in the Gulf of Mexico in 2010). Because of the above, along with tighter standards relating to the environment, rapidly growing public interest and growing product liability, the impact of work activities on the environment must be looked at in detail. When considering this impact it is extremely important that the complete life cycle of the product is explored not just the manufacturing and production stage. For example, the manufacture of a new car might have some impact on the environment in terms of its use of raw materials which can be minimised by using recyclable materials but the car itself will have a greater impact on the environment during its lifetime because of the fuel it will consume and the pollution it will create. Towards the end of a car s life cycle, when the car is no longer roadworthy and needs to be scrapped, the use of recycling can help to reduce its environmental impact. Design for environment Design for Environment (DfE) was introduced in the 1990s and it has been adopted by some manufacturing companies, including Airbus and Dell. The concept has been developed based on the understanding that it is much easier and less expensive to consider the environmental impact of a product during its design stage because, at this point, things can be changed or altered easily. The main objective of DfE is to ensure that a product is designed, and its manufacturing process is selected, in such a way to minimise its negative environmental impact. 2

3 2 Assessing the impact of work activities and resources on the environment Key term Sustainable types of materials that are potentially available for a much longer period of time compared to other materials, based on their resources and recyclability. Having anticipated the impact of work activities on the environment, the next step is to assess this impact. The process of predicting and evaluating the impact of different engineering activities and projects on the environment is sometimes referred to as the Environmental Impact Assessment (EIA). As previously mentioned, the assessment should consider the impact of the life cycle of the product at local as well as at wider levels. The local impact can relate to air pollution, water pollution, noise and smell, and wider range impacts include issues such as the destruction of the ozone layer and global warming. For example, if you look at the life cycle of products made from plastic materials, you can see that they are mainly produced by petrochemical companies using fossil fuels that are not sustainable, and therefore have an impact on the environment. Figure : Plastic seats in a stadium may have been produced using nonsustainable fossil fuels. Production normally involves a heating-up process that consumes considerable energy and leads to various emissions into water, air and soil, thus creating another impact on the environment. Sulfur oxides, dust and chlorofluorocarbons are examples of these emissions during the production stage. If not recycled properly or disposed of correctly, plastics can seriously harm the environment after their use. Manufacturers of plastic materials should therefore be aware of the life cycle impact of their products and act responsibly to conserve the environment. Consider the batteries we use to power portable devices. Inside these batteries, heavy metals such as lead react with certain chemicals to produce power. These heavy metals, when processed as the raw material for batteries, can significantly contaminate the environment. There are also potential health risks to employees and the environment during the manufacturing phase, as these materials are 3

4 classified as hazardous. There is the potential for further environmental harm if these batteries are not disposed of according to legal guidelines. Manufacturers of batteries should therefore assess the environmental impact of their products during their life cycle and take measures to minimise their impact. Some of the areas to consider when assessing the environmental impact of work activities are outlined below. Energy conservation, ways to reduce the energy used during production and the risk of global warming electricity is mainly used as the energy source for manufacturing activities, and the production of electricity is associated with burning huge amounts of coal, which leads to the release of carbon dioxide. This creates a blanket of gas around the earth, leading to the greenhouse effect or global warming. When applicable, products should be designed that use less energy during their manufacturing and usage (for example, a car with higher fuel efficiency, a low energy consumption lamp or an electrical appliance that uses less energy to operate). The impact of the raw material used where possible, environmentally friendly, recyclable and fewer materials in general should be used to save resources. For example: a design engineer can look at the solid parts produced by casting to see if they can be made hollow to save materials a material engineer can look into replacing the non-recyclable plastics with ones that are easy to recycle where possible a manufacturing engineer can investigate the possibility of using manufacturing processes that use less material (such as rapid prototyping methods) compared to the traditional metal cutting processes. Use materials and parts that are easy to recycle or reuse at the end of their life cycle. For example, paper carrier bags are much easier to recycle compared to plastic bags. 3 Minimising the environmental impact of work activities and resources Once the environmental impact of a product or manufacturing activity is known, it is important to try to reduce any negative impact as much as possible. For example, if the amount of energy used during production is of concern, think about using more sustainable sources of energy, such as solar energy; if dust emission into the air is having a major impact, consider using industrial filters to reduce it. Always remember that it is better to minimise the environmental impact during the design phase, and therefore the use of DfE is strongly recommended. If DfE is not implemented, look at each individual source of impact and try to reduce it. The method used, and the process and activities that could be employed to reduce the impact of work activities on the environment and resources, depend very much on the nature of the product and the manufacturing organisation. However, some guidelines are presented here. 4

5 Reducing energy consumption This can bring financial savings to the company and has an impact on global warming. Reducing energy consumption is achieved by various activities, such as: the use of cogeneration systems and by-products; for example, the heat generated during the production of electricity in a power plant can be used to heat the buildings during the winter time reducing the energy consumption of a factory outside working hours and during holidays using machinery and equipment with low energy consumption adjusting the operational conditions of the factory (working hours and temperature). Daylight saving is a clear example of changing the working hours to use daylight, hence reducing energy use and environmental impact. As an estimate, reducing the temperature in an office by 1 degree Celsius can lead to savings of up to 8 per cent in energy consumption. Reducing waste All companies should have a waste management system that is well communicated and understood by the staff, and enforced in the organisation. The top priority and the best-case scenario is for an organisation to not produce any waste, and the least preferred option is waste disposal. There are other options that fall between these two extremes, including: reducing the produced waste reusing the waste as much as possible reprocessing or treating the waste, so it can be used in another application. For example, sometimes tyres can be rethreaded and used again. If a tyre cannot be rethreaded for safety reasons, it can be crushed and processed for use in road surfaces. Another example is the surplus food in a canteen which can be used to feed people or animals, or be reprocessed and used as compost. Reducing water use and re-treating water Pollution of water and excessive water usage can have an impact on the environment as a result of some manufacturing activities. The supply of fresh water is limited and we all have a duty to conserve water as much as possible. The UK Environment Agency has published some simple guidelines that can help companies to conserve water and reduce their water bills by half. Making sure the water taps are turned off when not in use, less frequent washing of windows and cars, and insulation of pipes from frost are examples of these guidelines. Take it further Go to and look into other ways that water could be saved. Water should be saved as much as possible during industrial and non-industrial use within an organisation, and water treatment facilities should be installed where possible to reuse water. 5

6 Prevention of air pollution Air pollution can have different sources. In most cases there is a direct relationship between the energy used and air pollution. In 2013 it was estimated that about 63 per cent of electricity generated in power plants involved the use of coal and gas. Plans are underway to reduce this to about 50 per cent by However, not all air pollution comes from the fuel consumed and the gases that are released into the air; for example, dust can be a source of air pollution and therefore reduction of dust and prevention of dust entering the air are considered effective methods of reducing the impact of work activities. Managing chemical substances The chemical substances used in some manufacturing facilities can have a detrimental effect on the environment. It is extremely important that the use of these chemicals is limited and restricted as far as possible, and that alternative materials are sought. The use of these chemicals should be managed effectively, and health and safety, as well as environmental policies and guidelines, should be closely followed. Table shows examples of hazardous materials in manufacturing and summarises the control measures. Table : Hazardous materials used in manufacturing and control measures when working with them. (Source: Working with substances hazardous to health: a brief guide to COSHH, published by HSE.) Substance, process Control equipment Way of working Managing Cleaning with solvent on rag Use a rag holder. Provide a small bin with a lid for used rags. Avoid skin contact. Reduce solvent vapour from used rags. Check controls are used. Safe disposal. Dust and sparks from abrasive wheel Put an enclosure around the wheel and extract the air to a safe place. Check the airflow indicator. Make sure the extraction works. Maintain controls. Test controls as required by law. Fume from cutting demolition scrap Ventilated welding helmet, gloves. Washing facilities. Work outdoors upwind of the fume wherever possible. Allow the fume to clear before removing helmet. Check if there is any lead paint on the scrap being cut. Carry out health checks. Cutting-fluid mist from a lathe Swarf Put an enclosure around the lathe and extract the air to a safe place. Protective gloves. Use skin-care products. Make sure the extraction works. Allow time for the mist to clear from the enclosure before opening it. Train workers. Check and maintain fluid quality. Test controls as required by law. Carry out health checks. Dust from disc cutter on stone worktop Use an enclosure to extract air to a safe place. High-efficiency vacuum cleaner. Cut and polish worktops inside an enclosure. Vacuum up dust. Test and maintain controls. Carry out health checks. When it comes to more dangerous substances, daily inspection of the handling facilities is recommended. Examples of dangerous goods are explosives, flammable liquids and solids, toxic substances and radioactive materials. 6

7 Procurement If possible, a system should be put in place to give priority to suppliers who are more conscious of the environment. This is especially possible for larger manufacturing companies who enjoy considerable buying power. Some companies have set very high standards and require their suppliers to have an environmental management system such as ISO in place. Portfolio activity ( ) Consider your work environment and responsibilities and explain the possible impact of your work activities on the environment. Take into account air, water, and noise pollution, and hazardous materials. Having identified the impact of your work activities and areas of responsibility on the environment, explain how these impacts can be assessed and minimised. 4 Hazardous materials and products Key terms CHIP Chemicals (Hazard Information and Packaging for Supply) Regulations, most recently updated in CHIP is being replaced by the CLP Regulation, which will come into force on 1 June CLP Classification, Labelling and Packaging of Substances and Mixtures Regulation. Each year, thousands of people have their health affected by exposure to hazardous substances. Lung diseases due to dusty working conditions, skin irritation and occupational asthma are examples of the consequences of workers being subjected to hazardous materials. By law, all employers should clearly mark all dangerous substances. The current legislation relating to the packaging and labelling of hazardous materials is CHIP. CHIP will be replaced by the European CLP Regulation in By following CHIP procedures and guidelines, people handling hazardous materials, as well as the environment, are protected to a great degree. According to CHIP, all suppliers are required to inform their customers about the hazards of chemicals. These chemicals must be clearly labelled, identified and safely packaged. The signs shown in Figure are used by CHIP to identify hazardous materials. Figure : CHIP hazard symbols. 7

8 From 1 June 2015, the CLP Regulation states that a new, similar, set of hazard symbols need to be used, as shown in Figure Figure : Hazard symbols under the CLP Regulation. Portfolio activity (2.4) 1 What types of hazardous materials are used in your organisation? Why are these materials classified as hazardous? 2 How do you recognise and distinguish between these materials? 5 Procedures for handling and disposal of hazardous substances Organisations have a duty of care to make sure that any hazardous material or waste they are dealing with or produce does not cause harm to humans or the environment. This duty of care is in place until these materials are given to another authorised business. Therefore it is important for any organisation dealing with these materials to have a relevant policy and procedures in place. The first important step is to recognise which materials are considered as hazardous. Some common examples of hazardous substances and products are car oils, some fridges and pesticides. These materials should be stored safely and recycled when possible. When transporting these materials (whether sending or receiving), a consignment note should be provided and sometimes a licence is needed for transportation. An organisation should have a record of the hazardous material, which includes information such as: type quantity location any treatment which has been carried out. Depending on the type of material, a procedure should also be in place for storage. Some common safety measures relating to storage are outlined below. 8

9 Store hazardous materials in waterproof containers with proper labels and warning signs, and separate them from non-hazardous materials. In most cases, different hazardous materials should not be stored in the same place. A register of hazardous materials should be kept. Regular inspection and risk assessment should be carried out. Care should also be exercised when handling hazardous materials and a written procedure should be in place. Common safety rules for the handling of hazardous materials are outlined below. Hazardous substances should be handled by trained personnel using the required personal protective equipment (PPE). Containers must be easy to identify and appropriately labelled. Read and follow any instructions by suppliers and producers. Do not eat or drink while working with hazardous materials. Portfolio activity (2.5) Produce a report, or other types of evidence, to show that you are fully aware of your organisation s policies and guidelines for the handling and disposal of hazardous materials and products, and that you follow them closely. Consider the following points when writing your report. Is any training supplied as part of these procedures? Have you done this training? What PPE is used when handling and disposing of hazardous materials? How are the records of hazardous materials kept in your organisation? What types of information are included in these records? What are the procedures for storage, recycling and disposal of hazardous materials in your organisation? 6 Organisational methods for dealing with recyclable products Recycling is an environmentally friendly method of reducing waste by converting what would otherwise be waste into new materials. Recycling is often a costeffective way of reducing waste with a fast return on initial investment. It has a great impact on the conservation of natural resources. Recycling is now a large part of waste management systems and it is important for manufacturing organisations to have a method of dealing with recyclable products and waste. Apart from the moral responsibility to save the environment, there are also UK laws that require some businesses to recycle a portion of what they produce. Examples of these businesses are manufacturers of packaging products, batteries, electrical and electronic components, and vehicles. Some general guidelines and suggestions for a recycling policy in a manufacturing organisation are outlined below. Encourage every part of the business to produce less waste. Make sure all employees feel that they are part of a waste reduction and recycling system. Give priority to suppliers who remove and take away packaging at delivery. Provide training for the recycling of various products. Develop a comprehensive waste management system. 9

10 Develop a wide range of recycling programmes across the organisation. Buy products and materials that are easy to recycle. Portfolio activity (2.6) Provide a report (or any other type of acceptable evidence) to show you are aware of your organisation s methods and policies for dealing with recyclable products, and that you are able to evaluate them. Here are some points to help you with your evaluation. What are your company s methods for dealing with recyclable products? When were these methods introduced? Has there been an impact on the amount of recycling as a result of introducing these methods? How would you change, modify or add to these methods to increase their effectiveness? Are there any barriers to implementation of these methods? How can these barriers be overcome? Key term Carbon footprint a term that describes what quantity of carbon compounds such as carbon dioxide have been released into the atmosphere as a result of an activity. 7 Specialist advice There are different situations when an organisation might seek more specialist advice on environment-related issues. Common examples are when an organisation wants to employ an environmental management system such as ISO 14001, or when advice is needed to comply with certain legislation. There might be cases where the environmental impact of an activity cannot be assessed easily and specialist skills are needed. The following sources can provide advice. The UK Environment Agency s website provides up-to-date information about regulations and guidelines for managing environment-related issues in industry. It provides information on environmental permits, hazardous materials and energy-efficiency schemes. It also has sector-specific information and covers a wide range of industrial sectors such as agriculture, oil and gas, construction and the nuclear industry, where very technical information is found. You can find the website at: environment-agency. Some local councils also offer expert advice on environmental issues such as energy saving, reduction of carbon footprint, environmental management systems, compliance with legislation and environmental permits. The UK government website has very useful information on environmental issues relating to businesses and organisations: waste-environment. It explains the responsibilities and duties of businesses with regard to their products and their impact on the environment. You can also find information about sourcing a local hazardous waste disposal service, a registered waste carrier and an energy assessor. There are private companies which provide expert advice and solutions to organisations in relation to the environmental impact of their work. Some universities and research organisations have specific departments working on a variety of topics and projects in environmental sciences that would be able to provide advice. 10

11 Take it further Look into the sources listed above and see if there are any local companies that could provide you with advice on specific environmental concerns for your company. For example, this could relate to the handling of a specific chemical or the disposal of a dangerous material. Portfolio activity (2.7) 1 Explain the various sources of specialist advice available to your organisation on managing the environmental impact of your work activity. 2 Give examples of where these sources have been used and evaluate their effectiveness. Checklist At the end of this topic guide you should be familiar with: methods to assess and minimise the environmental impact of various manufacturing activities the handling and disposal of hazardous materials and products the promotion of recycling in a manufacturing organisation sources of specialist advice on environmental issues. Further reading and resources Dornfeld, D., Green Manufacturing: Fundamentals and Applications (Springer, 2012) ISBN The story behind Apple s environmental footprint: Acknowledgements The publisher would like to thank the following for their kind permission to reproduce their photographs: Pearson Education Ltd: HL Studios (7). Shutterstock.com: HARELUYA (3). Veer / Corbis: Dmitry Kalinovsky (1) All other images Pearson Education We are grateful to the following for permission to reproduce copyright material: Health and Safety Executive for data from the Table of Examples of control measures, Crown copyright; and Environment Agency for the inclusion of the website link Environment Agency. Every effort has been made to trace the copyright holders and we apologise in advance for any unintentional omissions. We would be pleased to insert the appropriate acknowledgement in any subsequent edition of this publication. 11