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/ton.week)
(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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