Riordan Manufacturing EMS Recommendations by Team B Consultants, Inc.
Sheri Sparks, Jeff Jewell, Kevin Rachel, and William Lewis
Management 360
July 9, 2013
Vicki Bauer

Riordan Manufacturing EMS Recommendations by Team B Consultants, Inc.
There are several obstacles for manufacturers attempting to employ changes in their processes for more sustainable practices. One problem that manufacturers will run into is the lack of direction. Knowing that change is needed is the easy part of reaching sustainability. Knowing what changes to make is a much more complicated challenge. The idea of sustainability is discussed often, yet broad scope ideas are traded without specific details and applications. Team B Consultants Inc. (TBCI), is the leading consulting firm hired to perform current business practice audits, which they analyze to gain an understanding of the functionality of specific processes, how to implement changes, and which will be most effective.
Air Emission Controls Upon review of the Riordan Manufacturing (Riordan) facilities in the United States and China, TBCI has determined the organization has multiple sustainable options for air emission reductions. These reductions will result in improved working conditions for employees, better air quality for the surrounding region, and keep the organization ahead of government standards for emission related issues. The first step in the reduction of emissions is to gather baseline data. After establishing a baseline manufacturers need to establish methods for ongoing air quality measurements. “In the last few years, the increased complexity in regulations in developed countries has been even more accelerated, challenging the chemical process industries (CPI) and their suppliers of air-monitoring equipment to reach new heights. It has been determined that fine particles are more damaging to human health than larger ones. New regulations in the US require states to reduce the quantity of fine particles in ambient air.” (“MONITORING AIR EMISSIONS,” 2009, p. 16) A concern from manufacturers is related to expense. A process to convert these emissions to an energy source would require capital investment but would also lower energy costs for the facility. The return on investment of such a project makes it the most appealing option. This would also integrate into the sustainability plan in place for the organization. A second option for Riordan to consider is the use of air scrubbers to reduce emissions. Air scrubber technology is well advanced, but do not reduce emissions. The process eliminates the largest particles from current emissions and is widely used in coal-fired facilities. Implementation of this technology has a marginal benefit for Riordan A third option seen by TBCI is easily administered and requires comparatively minimal investment by the organization. A comprehensive, well enforced, program to reduce the emissions from company owned vehicles is an engaging first step to obtain sustainability. The program would involve conversion of company vehicles to alternative fuels such as electricity or natural gas. Cars, vans, trucks, forklifts, and tractors should be converted. Enforcement of mandatory no idling rules for all vehicles visiting the manufacturing facilities could enhance the program further. Energy Sustainability The equipment used in the plastic manufacturing business requires a large amount of energy. As part of TBCI’s suggested Environmental Management System (EMS) for Riordan, one objective will be to reduce energy consumption. TBCI completed an energy audit of all four Riordan plants and identified several energy reducing opportunities. We have identified three options for energy conservation with varying levels of investment: * Improve lighting * Increase the efficiency of equipment * Upgrade to more efficient equipment
Upgrading the outdated lighting system in Riordan facilities is the most inexpensive method of saving energy. Newer lighting systems bring savings through reduced energy consumption while providing safer working conditions for employee. Although changing the lighting can bring some savings, this is just a small step toward sustainability.
Increasing the efficiency of the equipment, by upgrading components and eliminating the equipment’s inefficiencies is another option for energy savings. Substantial savings can be realized by changing the fixed speed motors on the injection molding equipment, to variable speed motors that use less energy during less demanding cycles. Fixing the leaks in the equipment’s hydraulic system as well as performing other routine maintenance will keep the equipment efficient and running as intended. Whereas these changes can increase efficiencies, they are simply bandages that will need to be changed.
Safe Handling and Recycling of Chemicals and Solvents Riordan’s four locations are at various stages of recycling and reuse of their plastics. It is suggested that all locations follow sustainability practices set by Riordan. By developing recycling and reuse practices Riordan will realize savings on resources. Part of their immediate EMS would include:
Any off-spec raw materials - Returning off-spec raw materials to the vendors would save costs on disposal. TBCI suggests that Riordan work with their vendors on quality to ensure raw materials are of the quality needed for their products. If the vendor does not respond, other vendors should be procured.
Scrap plastic and off-spec products - Purge materials, such as scraps from the molding process should be looked at to see if they could be re-melted and reused instead of treated as waste. PET plastic bottles are the most often closed loop recycled thermoplastics (Hopewell, Dvorak, Kosior, 2009). Off-spec product should be look at to see if parts can be used in future products or re-melted to make other parts. By reusing or recycling costs could be reduced. Fewer raw materials would be needed. Third-party recyclers are to be used for the plastics that cannot be reused. Riordan’s use of plastics that are readily reusable and recyclable will enhance their sustainability plan. Reused plastics reduce “oil usage, carbon dioxide emissions, and the quantities of waste requiring disposal” (Hopewell, Dvorak, Kosior, 2009, p. 2115).
The molding process needs to have a maintenance schedule that ensures the equipment is in top condition and is calibrated to use as little plastic as possible to make a quality product but minimize scrap and trim. This is both cost-efficient as well as a best sustainability practice.
Used oils - Collected by third party hazardous waste materials handlers for recycling. The practice of reusing of used oils that can be easily reused will save money and use fewer raw materials.
Metal shavings and slag - Collected by metal salvagers and recycled. Metal is easily recycled and reused. While Riordan does not consume and use a large amount of metals in their products their sustainability plan should include the recycling and use of metals as much as possible. A longer term and expensive EMS is the safe handling of solvents used in cleaning. The safe handling of this waste water would have an immediate affect on local groundwater and soil. By recycling these chemicals and solvents, we could reduce costs in disposal and the purchasing of new chemicals and solvents. Pollution of the ground water and soil is a top concern so Riordan needs to find the most socially and ecologically acceptable methods of reclamation. Research into biodegradable solvents needs to be done so waste water disposable and safe handling would no longer be a concern. Riordan needs to continue to be up-to-date with all current permits pertaining to storm water run-off. Riordan needs to meet or exceed all requirements. The multiple options identified by TBCI are all viable options. The implementation of a waste to energy program is the most comprehensive and follows the sustainability plan of the organization. Upgrading to more efficient equipment will be a major investment, but well worth it. Changing to all electric or hybrid machines is the ideal choice for an industry leader like Riordan to make. Changing to electric or hybrid fueled machines can decrease the energy consumption by machines, the largest source of energy use for a plastic manufacturing company, by up to 60%. The investment in new machines can bring increased efficiency, less energy use, less maintenance, reduced noise levels, elimination of hydraulic and cooling fluids, reduction of cleaning solvents, and happier, healthier employees, consumers, and community members. According to TCBI’s findings the California plant seems to have good waste dye safe handling practices in place. Riordan may want to consider eliminating customization of dye to eliminate waste dye water. By continuing to define and implement safe handling and disposal of dye’s Riordan can thrive in their continued success of existing as a sustainable business. TBCI recommends these options as the preferred process for Riordan Manufacturing.

References
Hopewell, J., Dvorak, R., & Kosior, E. (July 27, 2009). Plastics Recycling: Challenges and opportunities. Philosophical Transactions: Biological Sciences, 1526(364), 2115-2126.
Monitoring Air Emissions. (August, 2009). Retrieved from http://search.proquest.com.ezproxy.apollolibrary.com/docview/194409437
National association of manufacturers. (2013). Retrieved from http://www.nam.org/Special/Media-Campaign/EPA - Overregulation/Energy-and-Environmental-Regulations.aspx
Smith, L., & Ball, P. (November 2012). Steps towards sustainable manufacturing through modeling material, energy, and waste flows. International Journal of Production Economics, 140(1), 227-238.