Waste Minimization:Waste Minimization:Yachts of OpportunityYachts of Opportunity

Marquis Yachts, LLCMarquis Yachts, LLC

• Founded in 1954 in Pulaski, WIFounded in 1954 in Pulaski, WI

• Past up to 1400 employees at Past up to 1400 employees at Pulaski, WIPulaski, WI

• 15 – 43 - >700,00015 – 43 - >700,000• Vertically Integrated Vertically Integrated (wood, metal, fiberglass, (wood, metal, fiberglass,

coatings)coatings)

• 13 Buildings of Operations13 Buildings of Operations

OpportunityOpportunity

• 146 hoist lifts rated up to 40 tons

• 56 industrial vehicles with continuous education

• Respiratory fit testing for 350 employees

• Elevated surfaces of heights over 30 feet

• Needle-sharp fiberglass and razor blades

• Eye contaminates from sand blasting, grinding, sanding, spraying, polishing, drilling and cutting.

• OSHA VPP guidelines

What does ‘What does ‘WASTEWASTE’ ’ mean to you?mean to you?

Seven Types of WastesSeven Types of Wastes

OverproductionOverproductionUnnecessary InventoryUnnecessary InventoryTransportTransportProcessProcessRejected ProductRejected ProductWaitingWaitingUnnecessary MotionUnnecessary Motion

Process WastesProcess Wastes

• ChemicalsChemicals

• EnergyEnergy

• TemperatureTemperature

• WaterWater

• Industrial Waste Industrial Waste DisposalDisposal

Chemical ManagementChemical Management

• Types of chemicals utilizedTypes of chemicals utilized– Wood, metal, fiberglass coatingsWood, metal, fiberglass coatings– ResinResin

• Emission sourcesEmission sources

• By-product developmentBy-product development

• Alternative Process OptionsAlternative Process Options

• Alternative ChemicalsAlternative Chemicals

Alternative ChemicalsAlternative Chemicals

• Cross Linking vs. CarriersCross Linking vs. Carriers

• Acids vs. BasesAcids vs. Bases

• Heavy Metal EliminationHeavy Metal Elimination

• Solvent vs. Water-basedSolvent vs. Water-based

Energy ManagementEnergy Management

• Natural and Propane GasNatural and Propane Gas

• Fossil FuelsFossil Fuels

• ElectricityElectricity– Air compressor leaksAir compressor leaks– Computers left onComputers left on

Temperature ManagementTemperature Management

• Heating OvensHeating Ovens

• Air ConditioningAir Conditioning

• Natural Sources of HeatNatural Sources of Heat– Air compressorsAir compressors– ComputersComputers– WaterWater– BoilersBoilers

Water ManagementWater Management

• Sinks, Toilets, BubblersSinks, Toilets, Bubblers

• RainRain

• CondensationCondensation

Industrial WastesIndustrial Wastes

• HazardousHazardous

• Non-hazardousNon-hazardous

• By-productsBy-products

• MetalMetal

• Paper, cardboard, plastics, etc.Paper, cardboard, plastics, etc.

• ElectronicsElectronics

Alternative Process OptionsAlternative Process Options

• Closed MoldingClosed Molding

• UV Light OvensUV Light Ovens

• Re-circulating ExhaustsRe-circulating Exhausts

• Monitoring SensorsMonitoring Sensors

• Application ProcessApplication Process

• Light Sensors, fluorescentLight Sensors, fluorescent

• Wind Turbine GeneratorsWind Turbine Generators

Waste ReductionsWaste Reductions

• EPA Clean Air Excellence Award in 2002EPA Clean Air Excellence Award in 2002• Green Tier Induction Ceremony in 2006Green Tier Induction Ceremony in 2006• Air Emission Reduction (> 40%)Air Emission Reduction (> 40%)• Small Quantity Generator (>60%)Small Quantity Generator (>60%)• Process Waste Water Reductions (> Process Waste Water Reductions (>

80%)80%)• Real Time Air Emission Tracking (>50%)Real Time Air Emission Tracking (>50%)• Labor Reductions (16%)Labor Reductions (16%)• Cost Savings over $4,000,000Cost Savings over $4,000,000

Management ToolsManagement Tools

EMSEMS

Lean ManufacturingLean Manufacturing

Six SigmaSix Sigma

What are the basic elements of an EMS?What are the basic elements of an EMS?• POLICYPOLICY Adoption of an environmental policy that includes a Adoption of an environmental policy that includes a

commitment to compliance with commitment to compliance with environmental environmental requirements, pollution requirements, pollution prevention, and continual prevention, and continual improvement in improvement in environmental performance. environmental performance.

• FFOOTPRINTOOTPRINT An analysis of the environmental aspects and An analysis of the environmental aspects and impacts of an entity’s activities. impacts of an entity’s activities.

• COMPLIANCECOMPLIANCE Plans and procedures to achieve compliance Plans and procedures to achieve compliance with with environmental requirements and to maintain environmental requirements and to maintain that that com pliance. com pliance.

• REQUIREMENTSREQUIREMENTS Identification of all environmental Identification of all environmental requirements requirements applicable to the entity. applicable to the entity.

• ACTION PLANSACTION PLANS A process for setting environmental A process for setting environmental objectives and objectives and developing appropriate action developing appropriate action plans to meet the plans to meet the objec tives. objec tives.

• CONTROLCONTROL Establishment of a structure for operational con trol Establishment of a structure for operational con trol and and responsibility for environmental performance.responsibility for environmental performance.

• TRAININGTRAINING An employee training program to develop aware ness An employee training program to develop aware ness of and of and competence to manage environmental issues. competence to manage environmental issues.

RESPONSERESPONSE A plan for taking actions to prevent environmental A plan for taking actions to prevent environmental problems and problems and for taking emergency response and correc tive for taking emergency response and correc tive actions when actions when environmental problems occur. environmental problems occur.

COMMUNICATIONCOMMUNICATION A communication plan for collaboration with A communication plan for collaboration with employees, the public, and the employees, the public, and the

department on the department on the design of projects and design of projects and activities to achieve continuous activities to achieve continuous improve ment in improve ment in environmental performance. environmental performance.

RECORDSRECORDS Procedures for control of documents and for keeping Procedures for control of documents and for keeping records records related to environmental performance. related to environmental performance.

AUDITSAUDITS Environmental management system audits. Environmental management system audits. HousekeepingHousekeeping

IMPROVEMENTIMPROVEMENT A plan for continually improving environmental A plan for continually improving environmental performance and provision for senior performance and provision for senior

management management review of the plan.review of the plan.

Improvement MethodologiesImprovement Methodologies

Lean ManufacturingLean ManufacturingSix Sigma (DMAIC)Six Sigma (DMAIC)– Define the problem (D)Define the problem (D)– Measure the extent of the problem (M)Measure the extent of the problem (M)– Analyze the sources of variation (A)Analyze the sources of variation (A)– Improve the process (I)Improve the process (I)– Control the process for sustained Control the process for sustained

improvements (C)improvements (C)

Thank You for Your Time!Thank You for Your Time!

Any Questions?Any Questions?