Workshop B. ISO 14001:2015 Case Study of a Successful Transition. Tuesday, March 27, :45 a.m. to 11 a.m.

Transcription

1 Workshop B ISO 14001:2015 Case Study of a Successful Transition Tuesday, March 27, :45 a.m. to 11 a.m.

2 Biographical Information Cory Justice, HS&E Specialist, MUBEA North America 8200 Dixie Highway, Florence, Kentucky USA x7062 Mobile: Cory Justice is a Health, Safety, and Environmental Specialist with Mubea North America in Florence, Kentucky. Cory holds a Bachelor of Science in Occupational Safety and Health and a minor in Fire & Safety Engineering Technology from Eastern Kentucky University. Cory is responsible for managing and implementing Environmental, Health, & Safety compliance for 3 Business Units. Prior to joining Mubea North America, Cory worked as a Safety Specialist and Coordinator implementing various safety programs and conducting Environmental, Health, and Safety trainings. Gregory A. Hemker, Principal, EHS Technology Group LLC, 2912 Springboro Road West, Suite 101, Dayton, Ohio Fax: ghemker@ehstech.com Mr. Hemker is one of the founders of EHS Technology Group, LLC located in Moriane, Ohio. He has over 44 years of experience in environmental engineering and management. Mr. Hemker obtained a Master s Degree in Environmental Engineering from the University of Cincinnati and is a Certified Hazardous Materials Manager (CHMM). His principle fields of expertise are air pollution, hazardous waste, and hazardous chemical management. He has conducted numerous environmental management training seminars throughout the U.S. and China. In recent years Mr. Hemker has focused on consulting with manufacturing industries to solve problems associated with air pollution, water pollution, hazardous waste, oil and chemical spill prevention, chemical safety, and industrial hygiene. He has also led the development and implementation of Energy Management Systems at manufacturing facilities in Ohio and Kentucky. Mr. Hemker is a RAB/Exemplar Global trained lead auditor and has been developing and implementing ISO 14001, 9001, and OHSAS management systems since the adoption of the Standards. Eric D. Harper, CSP, CHMM, Manager Process Safety, EHS Technology Group, LLC 2912 Springboro Road West, Suite 101, Dayton, Ohio (937) eharper@ehstech.com Eric is the Manager of Process Safety for EHS Technology Group LLC located in Miamisburg, Ohio. Eric has over 21 years of experience in the field of environmental health and safety. Prior to joining EHS Technology, Eric was responsible for managing the environmental health and safety program for two manufacturing facilities in the automotive industry. In this capacity, Eric was responsible for managing the regulatory compliance, worker s compensation, and various risk management activities for his company. During his time in private industry, he developed and implemented numerous safety programs and injury reduction initiatives. In addition, he developed and conducted various safety training classes on a wide range of safety topics such as confined space, lockout/tagout. Since joining EHS Technology, Eric has been focused on providing safety, health, and environmental consulting services to clients in a wide variety of industries. Specifically, Eric has focused on helping clients with struggling safety and environmental programs achieve improved metrics while providing safer workplaces to their employees. Eric is a graduate of Ohio University with a B.S. in Industrial Hygiene. Eric has been a Certified Safety Professional (CSP) since 2001 and has been a Certified Hazardous Materials Manager (CHMM) since Eric is a member of the American Society of Safety Engineers.

3 ISO 14001: Case Study Mubea Successful Transition By Greg Hemker, CHMM EHS Technology Eric Harper, CSP, CHMM EHS Technology Cory Justice, HS&E Specialist Mubea 27 th MEC Sustainability and EH&S Symposium

4 Program Outline Overview of changes Side by side comparison of 2004 vs Engaging Top Management Context Driving Risks & Opportunities Process Approach risks & audits Continual Improvement Monitoring & Measurement

5 ISO 14001:2015 Changes ISO 14001:2015 New Standards employ a common approach sometimes referred to as the common format (e.g. ISO 9001:2015) Need to recertify to the new standard within 3 years (deadline is September 2018) Need to adjust or even re tool your management system to meet all the new requirements.

6 ISO 14001:2015 Changes Consider purchasing companion guide ISO 14004:2016 Copies of both available at Standards Store

7 New Terminology Appropriate and Applicable are not the same Appropriate = suitable for your situation with some freedom Applicable = If it can be done, it must be done Consider = think about but can exclude Take into account = think about AND incorporate Ensure = responsibility for action can be delegated, but not accountability Compliance Obligations = legal and other requirements (2004) Documented Information = documentation, documents and records (2004) Environmental Objective now includes BOTH objectives AND targets (2004)

8 Comparison of Standards ISO 14001:2015 ISO 14001: Scope 1 Scope 2 Normative references 2 Normative references 3 Terms & Definitions 3 Terms & Definitions 4 Context of the Organization 4.1 Organization and its Context 4.2 Needs & Expectations of Interested Parties 4.3 Scope of the EMS 4.1 General Requirements 4.4 EMS 4.1 General Requirements

9 Comparison of Standards 5 Leadership ISO 14001:2015 ISO 14001: Leadership & Commitment 5.2 Environmental Policy 4.2 Environmental Policy 5.3 Roles, Responsibilities & Authorities Resources, Roles, Responsibilities & Authority

10 Comparison of Standards ISO 14001:2015 ISO 14001: Planning 4.3 Planning 6.1 Actions to address risks & opportunities General Environmental Aspects Environmental Aspects Compliance Obligations Legal & Other Requirements Planning Action 6.2 Objectives & plan to achieve Objectives, Targets & Programs Environmental Objectives Objectives, Targets & Programs Planning Actions for O&Ts Objectives, Targets & Programs

11 Comparison of Standards ISO 14001:2015 ISO 14001: Support 4.4 Implementation & Operation 7.1 Resources Resources, roles, responsibility and authority 7.2 Competence Competence, training & awareness 7.3 Awareness Competence, training & awareness 7.4 Communication Communications General Communications Internal Communication Communications External Communication Communications

12 Comparison of Standards ISO 14001:2015 ISO 14001: Documented Information Documentation General Documentation Creating & Updating Control of Documents Control of records Control of Documented Info Control of Documents Control of Records 8 Operation 4.4 Implementation 8.1 Operational Planning & Control Operational Control 8.2 Emergency preparedness & response Emergency preparedness & response

13 Comparison of Standards ISO 14001:2015 ISO 14001: Performance Evaluation 4.5 Checking 9.1 Monitoring, measurement, Monitoring & measurement analysis and evaluation General Monitoring & measurement Evaluation of Compliance Evaluation of Compliance 9.2 Internal Audit Internal Audit General Internal Audit Internal Audit Program Internal Audit 9.3 Management Review 4.6 Management Review

14 Comparison of Standards 10 Improvement 10.1 General ISO 14001:2015 ISO 14001: Nonconformity & Corrective action 10.3 Continual Improvement Nonconformity, corrective action & preventive action

15 Plan Do Check Act Model (old)

16 Plan Do Check Act Model (new)

17 Verbal language of the Standard shall indicates a requirement should indicates a recommendation may indicates a permission can indicates a possibility or a capability

18 Context The Starting Point Context developed by North American Leadership Team (NALT) through meetings & discussions Five (5) basic questions evaluated & answered What will the Mubea EMS be used to accomplish? What are the external issues that can affect the purpose of the Mubea EMS? What are the internal issues that can affect the purpose of the Mubea EMS? Who are the relevant interested parties for the Mubea EMS? What are the needs & expectations of the identified relevant parties? Context document was essentially meeting minutes signed by members of the NALT

19 EMS Purpose NALT determined that they wanted the EMS to accomplish the following tasks: Compliance with applicable laws & regulations Improve environmental performance through procedural enhancements Achieve organizational environmental objectives Improve environmental communication between BU Standardize environmental procedures within BUs where applicable

20 External Issues The following topics were considered to identify the potential external issues: Political system Economic availability of utilities, transportation, infrastructure, etc. Financial availability to resources Social workforce availability, education, languages, values, etc. Competition similar organizations that may be modelled Supply Chain Management availability, capacity, capability Cultural Market & Public Demand lifecycle of products & wastes Technological Legislative framework

21 Risks & Opportunities Risks Employee turnover could impact environmental performance Shot peen disposal issues if current recycler stops taking material Hazardous waste handling categorical changes & implementation Opportunities Anticipated expansion of corporate Mubea energy focus to Florence campus due to success at German facilities As auto industry continues to reduce carbon footprints, Mubea s technology (ability) to reduce vehicle weights and help lower CO2 emissions may help improve market share

22 Internal Issues The following topics were considered to identify the potential internal issues: Organizational governance & structure Legal compliance Other management systems Organizational structure, style, & culture Organizational vision Resources human, financial, etc.

23 Risks & Opportunities Opportunities Improve employee environmental training Integrate EMS with quality management system where applicable Standardize environmental procedures across BUs with similar environmental aspects Risks First global Mubea facility to transition to ISO 14001:2015 & status is monitored by corporate Mubea Turnover in EHS department Employee environmental training Environmental communications between BUs

24 Interested Parties Interested parties were identified along with the needs & expectations of each Documented in a table Regulatory agencies Mubea corporate Customers Employees, neighbors, & community Mubea registrar Needs & expectations of each were reviewed & specific compliance obligations were identified Key expectations included: Compliance with applicable laws & regulations Continued management of environmental risks to prevent pollution

25 Risk Management Key upgrade in the new standard is a systematic risk analysis of impacts to the environment Defined in Clause & the theme is the prevention of negative environmental impacts Clause requires consideration of the following: Context issues Environmental aspects Compliance obligations Views of interested parties Documented information must be developed for the risks & opportunities

26 Process Approach Numerous references to managing processes in new standard Each BU treated as separate process due to organizational structure & BU process complexity Process maps created for each BU showing inter relation of all BU sub processes Large core processes broken down into manageable smaller processes Used to identify inputs & outputs (aspects) of each BU process Allows focus on environmentally significant sub processes Helps guide internal audits of BU

27 Connecting Products

28 Risk in Aspect Analysis Used rating scale for consistency & repeatability Rating scale designed to incorporate risk via determination of significance Extent of compliance obligations Frequency of impact associated with aspect Severity of impact associated with aspect Emergency/non routine impact associated with aspect Significant aspects were considered most highest risks for Mubea WW from WWT processes Solvent & adhesive use and disposal from adhesive spray booth Salt and salt water use and disposal from hardening lines Solvent & paint use and disposal from paint booth

29 Addressing Risks & Opportunities Aspects Established O&T to improve WWT processes to ensure permit limits are achieved for Nickel & Zinc Significant Aspect Established O&T to reduce water consumption related to hardening lines Opportunity identified during aspect review Established O&T centered around campus wide energy reduction Opportunity identified as External Issue Established EWI for all significant aspects, provided training, & made available via Green Binders Turnover Developed new environmental training matrix showing 11 different types of trainings required of 9 different categories of employees Revised employee ISO new hire orientation & required temporary agency to complete training for temporaries prior to first day of work Provided Green Binders to each BU to aid in employee training conducted by supervisors Included Green Binder training as annual requirement for each BU Included employee engagement in newly developed environmental audit New 2015 manual created incorporating 2004 procedures Outside resources provided by management to address EHS manpower issue

30 Addressing Risks & Opportunities Environmental Communications Bi weekly NALT meeting used to convey important information Standardized EWI when possible (i.e. Universal Waste) Green binders used as main avenue of ISO communications Key element reviews One page summary of EMS Waste Handling Established documented EWI for waste handling Established waste characterization & waste tracking spreadsheets to provide better understanding & tracking of wastes Profiles updated Appointed and trained Waste Contacts for each BU Included waste handling review on weekly environmental audit

31 Green Binders Designed to be One Stop Shop for employees regarding EMS Found throughout each BU Includes the following: Applicable EWI Environmental policy Responsibilities matrix Key element review Significant aspects Contributions to EMS Current O&T Emergency action plan

32 EWI Quick References Requested by management to ensure key points not overlooked in procedure(s) Key points of work instruction now summarized & highlighted on page 1 Step by step procedure(s) follow

33 Reports & Obligations List Reference document created to summarize required environmental reports & inspections Serves as compliance calendar for EHS department

34 Manual Stand alone ISO 14001:2004 procedures revised & incorporated into one manual Documented information corresponding to standard elements identified One stop shop for the Mubea EMS

35 Management Involvement Bi Weekly NALT Meetings Environmental & Safety Committee Weekly Environmental Audits Management Participation as Internal Auditors

36 Management Review Bi Weekly Meetings with HS&E GM Bi Weekly NALT Meetings Increased Frequency Quarterly Bi Weekly

37 Monitoring & Measurements Compliance Driven Context Data Driven Management O&T Monthly Compliance Quarterly Weekly Environmental Audits Improved Environmental Performance Frequency Improved Tracking

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39 Challenges Moving Forward Document Control Contractor Management MOC Corrective Action Log NALT Management Review Documentation Increased Shotpeen Waste

40 Conclusion Keys for a successful upgrade: Start early Find ways to involve management regularly (> 1/year) Utilize a cross functional team to de centralize the EMS Consider non traditional forms of documentation Communicate with Registrar so there are no surprises in the certificate upgrade process

41 Thank you Questions?