Chapter IV
IMPLEMENT
CLEANER PRODUCTION
WHAT IS CLEANER PRODUCTION ???
A new and innovative view of the products
and processes that make them
Achieved by applying continuous
strategies to minimize waste.
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CONSTRUCT THE DATA MONITORING SYSTEM
1. Purpose
Set up a monitoring and measuring system for the data
of factories. That is important for the opportunity
construction process of cleaner production.
Baseline data includes:
- Consumption of raw materials
- Water and electricity consumption
- Determine the discharge and toxicity of waste
streams
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CONSTRUCT THE DATA MONITORING SYSTEM
2. Collect the data
Assigning the CP group and related departments to collect
production data in each department:
- Storage Dept. : material quantity and quality
- Manufactory: norms of raw materials / finished products,
semi-finished products.
- Electromechanical parts: quantity of electricity, water
consumption / day
- Finance and Accounting Dept.: Cost data, including the cost
of wastewater
- Dept. of Quality Control: product quality monitoring
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- Technical dept.: Energy consumption and pollutant load
CONSTRUCT THE DATA MONITORING SYSTEM
3. Frequency of data collection
Daily:
- Quantity of raw materials / finished products
- Water consumption / finished products
- Electricity or oil consumption / finished products
- The amount of solid waste collected in the day
- Number of workers in production day
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CONSTRUCT THE DATA MONITORING SYSTEM
3. Frequency of data collection
Monthly:
- FO/DO fuel consumption amount
- The amount of solvent loss
- The amount of waste solid or recycled
Quarterly :
- Discharge loading
- Content / concentration of wastes in waste
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streams (BOD, COD, SS ...)
CONSTRUCT THE DATA MONITORING SYSTEM
4. Data analysis
Data analysis find out the causes and give solutions
- It should brainstorm team to answer for the dramatically
change the data collected.
- Ask more questions: why?
- Recheck previous norms
- Compared with previous data to determine improvement
norms.
- Use these collected data to assess savings when applying
CP
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CONSTRUCT THE DATA MONITORING SYSTEM
5. Report
Leader of the CP team reports to the leadership
-> experience, adjustment, troubleshooting.
A brief report highlights the savings amount
Form of report at weekly or monthly meeting.
Notify all group members, workers in the
factory through newsletters, bulletin boards
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CONSTRUCT THE DATA MONITORING SYSTEM
STATUS OF PRODUCTION MANAGEMENT
There is only one main electricial meter to monitor the
electricity for the whole plant.
There is no water meter to monitor the water using.
Do not know the amount of consumed electricity and
water separately for each factory / area or product.
The water meter is mounted but the operation is not
effective.
No monitoring data .
Good housekeeping has not done well. 9
CONSTRUCT THE DATA MONITORING SYSTEM
STATUS OF PRODUCTION MANAGEMENT
Do not know the norm in the industry
There is a high energy consumption but it is not known
how.
There is a water loss but not known
Only take care about the quality of production but lack
of effective management of energy use.
Awareness of workers about saving, using electricity
and water is still poor.
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HOW TO CARRY OUT THE CP?
Determine the assessment focus
Determine the target
Planning
Establishment of CP team
Training and sharing information
Building a data monitoring system
Implementation evaluation.
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HOW TO CARRY OUT THE CP?
Determine the assessment focus
Based on
Demand for production development
Operational strategy of the company.
There are many economic, environmental and
technical opportunities.
The rate of consumption/loss is high
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HOW TO CARRY OUT THE CP?
Determine the assessment focus
FISHERY FACTORY
Water consumption waste water ( BOD, SS,
grease..)
Electricity.
Solid water
Fatty matter
Boiler
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HOW TO CARRY OUT THE CP?
Determine the assessment focus
INSTANT NOODLES FACTORY
Water consumption waste water ( BOD, SS,
grease..)
Electricity
Heating
Noodles Loss
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HOW TO CARRY OUT THE CP?
Determine the assessment focus
SOLE PRODUCTION FACTORY
Water consumption waste water ( BOD, SS, ..)
CO2
Boiler
Solvent vapor
Hazardous waste.
hazardous solid 15
Determine the target
No. Iterms 4/2018 Target % decrease
1 Water using 90 m3/ ton 60 33.33%
products
2 Electricity 1.67 Kwh/ ton 1.4 16.17%
products
3 Waster water COD = 1700 COD = 1100
BOD = 1000 BOD = 700
4 Fatty matter ? ?
recovery
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Planning
PROGRESS OF CONDUCTION (To 4/2018 - 11/2018)
No. Content Name 4 5 6 7 8 9 10 11 Note
1 CP training A
2 Carry out a quick survey B
3 Set up the meter system to control the data C
4 Operating instructions and monitoring the
meter system
5 Energy Audit and propose energy solutions
6 Identify causes and propose cleaner
production options
7 Screening and selection of solutions
8 Monitoring the implementation
9 Planning for major solutions
10 Evaluate the implementation of the solution
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Building a data monitoring system
Define what to need control: water
Establishing the status drawing: water supply and
drainage network
Select the place to install the water monitoring meter.
Set up meter monitoring diagram.
Set up a separate control sheet for each meter and
transferred to the management
Establish a general monitoring system for the overall
scale factory and transfer to the engineering management
department.
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SET UP WATER DIAGRAM AND LOCATE THE
METERS FOR FISHERY FACTORY
Sample
production
Pasteurization Lab Water WH1 WH 2
Dept.
dept. softener 150 120
tons tons
Elec. plant Wash
cans
4 1
Toilet 3 6
2 5 WH
Warehouse
Product Engine
room
Water
treatment
plant Office
Boiler Engine Defrost 19
room
WATER BALANCE
materials
Supply water 1000 kg
13.5 – 16 m3 Waste water
15 – 18 m3
Ice manufactory
1.2 – 2 tons Solid waste
Chemistry 600 kg
No data Product
320 kg
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WATER BALANCE
1 slaughter
manufactory 2 Phile
3 Pre-processing
4 Factory 1 (Molding)
Waste
water
T Clean water 5 Factory 2 (Molding)
treatment
treatment
plant
6 Freezing
a tree
Sub-dept b Canteen
c Office 21
WATER BALANCE
Month Quantity (ton) Water (m3) Norm (m3/ton)
1 70 14824 211.8
2 85 16352 192.4
3 120 17844 148.7
4 60 17533 292.2
5 120 19430 161.9
6 110 18748 170.4
7 120 17810 148.4
8 120 18202 151.7
9 130 18202 140.0
10 130 21030 161.8
11 160 21190 132.4
12 130 17957 138.1 22
SET UP THE SCHEDULE TO CONTROL WATER USING
THE SCHEDULE TO CONTROL WATER USING
Meter code: 1
Objective: measure A area
Time : at the begin of the shift, each day
Responsible: Electromechanical department
Person: Nguyễn Văn Chung
Montyh: 8/2018
No. Day Indicator Note
1 1/8/2008
2 2/8/2008
3 3/8/2008
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SET UP THE SCHEDULE TO CONTROL WATER USING
THE SCHEDULE TO CONTROL WATER USING AT
FACTORIES
- PROCESSING DEPT. 1-
Code Dept Quantity water Theory Practical Note
(ton) (m3) norm norm
1 Toilet
2 Processing
3 Defrost
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SET UP THE SCHEDULE TO CONTROL WATER USING
THE SCHEDULE TO CONTROL WATER USING
WHOLE COMPANY
- MONTH : /2018 -
Area Code of Quantity Norm Ratio Note
meter (m3) %
Processing 1
dept.1 2
3
Processing 4
dept. 2 5
Office 6
Total T
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ENERGY AUDIT
Collection of data: consumption departments, energy bill
Set up the distribution diagram of electricity, heat.
Installation of electricity meters for equipment.
Set up power consumption monitor board.
Measurement of electrical and steam parameters
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ENERGY AUDIT
Carry out to evaluate on each device:
Technical and operational status.
Consumption and potential savings
Suggestions for energy saving.
Continuous monitoring of power consumption for each
device to manage and evaluate power consumption.
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SET UP THE ELECTRICITY SUPPLY DIAGRAM
Total meter
T
NH3 system.
1 2 3
Cold frozen scales Office
storageconveyor ice
Fact. 1 Fact. 2 freezing T1 T2 T3 T4 T5
1000T Waste water
treatment
plant
WH WH WH WH
1 2 3 4
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THE SCHEDULE OF POWER CONTROL
Identifying objects to monitor is a high power consumption
device. Example:
Freezing conveyor
Cold storage
Ice crushers
Boiler ..
How to control
Scheduled controlling (day, week, month)
Link production data to manage consumption norms or
potential savings
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THE SCHEDULE OF POWER CONTROL
(COLD STORAGE 4)
Time Day Quantity Power (kwh) (kwh/[Link])
(tons)
week 1 8-14/5/18 59.00 1,170 19.83
week 2 15-21/5/18 67.00 1,494 22.30
week 3 22-28/5/18 76.00 1,233 16.22
week 4 29/5-4/6/18 76.35 1,536 20.12
week 5 5-11/6/18 78.96 1,464 18.54
week 6 12-18/6/18 78.18 1,638 20.95
week 7 19-25/6/18 78.34 1,311 16.73
week 8 26/6-2/7/18 79.00 1,311 16.59
week 9 3-9/7/18 78.74 1,170 14.86
week 10 10-16/7/18 76.00 1,260 16.58
week 11 17-23/7/18 79.00 1,218 15.42 30
POWER USING CONTROL PROCESSING
Daily, the Electromechanical department is
responsible monitor power consumption data and
provide electrical data consumption for departments
Departments use the deployed data down the place to
self-monitor and evaluate daily electricity
consumption norms
Monthly/weekly, the relevant departments will send
the evaluation sheet for engineering department for
synthesis and evaluate power consumption for the
factory.
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EXPERIENCE THROUGH THE CP IMPLEMENTATION
Decision of success
First of all there is the commitment of the leaders
The role of the leader is to give direction, create the
ensure and support implementation.
The role of key person must be to form a Cleaner
production team
Make the activeness from the enterprises, due to the
real requirements of enterprises
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EXPERIENCE THROUGH THE CP IMPLEMENTATION
Cleaner Production assessment techniques
Training and introducing the program overview to the CP
team before proceeding to the assessment.
During the assessment, combine training and applying
operation
It is necessary to install monitoring meter (electricity,
water ...)
Have to build up a data monitoring system from the
beginning.
The monitoring system as a control tool Cleaner
Production. 33
EXPERIENCE THROUGH THE CP IMPLEMENTATION
Operating the monitoring system is difficult, evaluating
data is more difficult
Need to know the norm of the company and the industry
Depending on the production characteristics, the flexible
use step by step.
Put the monitoring system into daily action of the
operators and management.
Special instructions, detailed and make timely correct.
Bringing the concept of cleaner production into a familiar
thinking, creation
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EXPERIENCE THROUGH THE CP IMPLEMENTATION
Support of consultants
Need experienced expert to lead CP program in
the right order and speed up program continuous
operation.
Complex energy solutions, need advice from
experts to come up with solutions technology.
Experts must monitor and timely evaluate the
data, for authentic comments.
Link to external research departments to convert
ideas to reality. 35
EXPERIENCE THROUGH THE CP IMPLEMENTATION
The supported means from the factory
Timely provision of working facilities: computers
and the other facilities
Equip with suitable tools.
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EXPERIENCE THROUGH THE CP IMPLEMENTATION
Maintaining a good CP program
It is necessary to lead and equip competence the
CP team.
Incorporate data collection and monitoring into
one component of production.
The CP program avoids formalize.
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CONCLUSION
TO SUCCESS
Commitment of Board
Commitment of the leader
The CP Team works effectively.
Training, guidance.
Installation of monitoring system.
Promote collective thinking.
Process Improvement.
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