Key Lessons Learned from Visits to Companies – EMFACT

Terri Goldberg, NEWMOA & Rick Reibstein, MA OTA

Contacts with Companies/Groups MA OTA technical assistance staff Devens redevelopment eco-efficiency

group (variety of companies represented) Toxics Use Reduction Planners

Association (individual companies and consultants to companies represented)

Allegro Microsystems, Inc. Wyman Gordon Westfield Electroplating Co

Scope of Conversations

Existing EMFACT systems & capacity?

Motivation for creating systems? Uses of system – reports & value? Track energy use? Track materials/energy costs? Advice on EMFACT

EMFACT Users Continuum Clear there is a continuum of EMFACT capabilities among the businesses and groups we talked to –

No tracking/reporting – particularly true for many very small companies

Some tracking/reporting – related to compliance

Extensive tracking – few companies Not much reporting/analysis/presentation even

among those tracking materials/energy/waste

Existing Systems Devens & TURPA meetings – several

participants in each meeting indicated that their company or clients do have some kind of EMFACT-like systems, but most do not

Visited three companies to see their existing system – one of these companies was recently acquired & no longer is able to track materials use

Motivations for Existing Systems

2 Companies with EMFACT-like systems reported that they established their materials tracking systems because of compliance needs – air permits, TRI reporting, TURA compliance

Home grown systems – databases & spreadsheets

Use of Materials Tracking The EHS staff use their materials tracking system

to keep monthly or periodic tabs on the flow of materials in the facility & to report accurately on toxics use and releases for TRI & TURA

Also has value for some if doing an EMS & P2 Plan

Not used much for ongoing P2 analysis/decisions or cost analysis/decisions

Rapidly growing interest in energy evaluation & reduction; little routine energy tracking - not comprehensive

Not enough time to do reports/analysis except that which is required

Elements of Systems Linked with purchasing Use MSDS data to calculate/track

individual chemical use Track by CAS # Quantity of each chemical/product Sum quantities & track over time Link with purchasing can track

some costs

Elements of Systems

Waste/release estimates – separate but linked system

Process flow diagrams By knowing what is coming in &

what is going out in products/waste/releases gives some idea of what happens to materials in the process

Key Messages on EMFACT Others have tried to develop

similar generic systems for commercial sale with no real success

Need to address where users are currently and start from there

Need to provide guidance and training as much as software – balance emphasis

Key Messages on EMFACT

Critical elements for materials tracking – need way to access MSDS electronically

Need way to link to a wide array of purchasing systems

Modularize the system – enable linkages to be made among elements, but enable users to pick aspects they want to implement

Track scrap per unit of product or production line - demonstrate generation of scrap waste

Key Messages on EMFACT Use standard spread sheet &

database software that people already have – i.e., Excel & Access

Enable users to map process, but focus on materials use– treat the process as a black box

Create useful boiler-plate reports (i.e., using Access)

Key Messages on EMFACT

Provide guidance to existing commercially available software that has includes of EMFACT-like functionality

Create an online MSDS system so can be accessed electronically or let people know where they can get MSDS’ electronically

Key Functions Easy way to develop/maintain process

flow diagrams Materials flow function – linking

purchasing – MSDS – CAS – quantities for individual chemicals; Costs???

Waste-release tracking system Boiler plate reports using visuals (i.e.,

pie charts & graphs) & data presentations

EMFACT Vision that is Emerging All components modular & optional  Excel spreadsheet to track materials/water/energy – able

to connect to purchasing system Work with an MSDS system – a community web-based

downloadable framework Link to hazardous waste, other release outputs, &

production & work areas so that user can normalize & produce reports

Create ready-made queries in database like Access that can help user build reports & prompt with the right questions; prompts can be in guidance or other formats  

Add module that prompts users to add in relevant costs Link to Process Flow Diagram/s  After all of this – compare impacts & costs of alternatives

– NPV & Payback  

Key Questions for Advisory Group What are the key reports that the

EMFACT system should be designed to generate?

What are the key visual and numerical outputs?

What do you think about this idea of creating an online source for MSDS? Is that critical?