SEPTEMBER SEMESTER 2013
SMOM5103 – MANAGEMENT SYSTEM

ASSIGNMENT
OBJECTIVE:
The assignment is to test student understanding of the concept of Environment Management System (ISO 14001:2004) and how to apply it at their company.
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

INTRODUCTION: NSK Bearings (Malaysia) Sdn. Bhd. is a subsidiary of NSK Ltd. Group of companies headquartered in Tokyo, Japan and has served the needs of Malaysia industry for 20 years.

NSK Malaysia supply major to Automotive OEM customers, distributors and heavy industries. At present, we have sixties over employees with three branches operating in Prai, Ipoh, and Johor Bahru. We also have two manufacturing plants in Selangor and one in Perak. At the moment, NSK Bearings is in the midst of achieving the Certification of ISO 14001. Our company decided to get the accreditation due to the recommendations from our customers, especially Toyota.

In NSK Bearings, our premise is divided into three main areas: office, distribution warehouse and production. For this assignment purpose, I will focus on the Environmental Management System activities at the production area.

Our production line consist of one assembly line for two products. We assembled the steering column system for Toyota and Perodua.
[pic]
Example of common steering system of a car.
Task 1
How to plan and establish an Environment Management system at your own organization

The top management of your company have decided to pursue with the certification of MS ISO14001:2004, Environment management system and have appointed you as the
Management Representative/Project Champion for the company. Using the resources within your company, you have to make sure the project to be completed within 12 month.

a) Identify Environmental Aspect (from your company activity or product) that may affect the environment around your workplace/organization.
e.g. Discharge of used oil from maintenance workshop to drain without proper oil-trap which will pollute the soil and in-land water. [20 marks]

Answer:
a)
Before identifying the environmental aspect and impact (EA&I), we need to know the elements that need to be considered. Below are the elements :

|No. |Aspects |Examples |
|1. |Air Pollution (AP) |Gaseous release to the atmosphere, Odour, Dust, etc |
|2. |Water Pollution (WP) |Discharge to Drain |
|3. |Noise Pollution (NP) |Noise of Machinery |
|4. |Land Pollution (LP) |Contamination of Soil & Ground Water |
| | |Disposition of Scheduled Wastes |
| | |Chemical Spillage |
|5. |Resource Depletion (RD) |Use of natural resources |
|6. |Others |Any other that affect ecosystem |

When identifying the environmental aspects and impacts the following situations shall be taken into consideration: • Normal (N) operating conditions • Abnormal (A) operating conditions (i.e. during machine start-up, shut down, maintenance and equipment failure etc.) • Emergency (E) situations (i.e. during fire, spills etc.)

Basically our production involves assembly and repacking processes. Myself as the Environment Management Representative had made the identification of the environmental aspect that may affect the environment around NSK Bearings.

For production area, I’ve divided the area into eight small areas. The areas are: 1. Office. 2. Assembly line. 3. Repacking. 4. QA Inspection. 5. Rework. 6. Loading and unloading. 7. Chemical storage. 8. Schedule Waste.

Plant layout of the Production Area

After identifying the environmental aspects of all activities, products and services, which can have potential and actual impacts to the environment at the eight small areas, below are the identified environmental aspect:

1.Office area.
|Activities / Processes |Environmental Aspect |Actual/Potential Pollution |
|Input: Printer, Photocopier, toner, ink |Changing of Printer Cartridge |Dispose of Ink Cartridge |
|cartridge, paper, etc.. | | |
| | | |
|Output: printed paper, toner powder and | | |
|used ink cartridge, etc.. | | |
| |Inkjet Printing |Paper wastage due to unnecessary printing |
| |Toner Refill of Photocopier Machine |Accidently spillage of toner powder to tile |
| | |floor and create rag with toner powder |
| |Electricity Usage |Air cond. is on while nobody is in a room |

2.Assembly line.
|Activities / Processes |Environmental Aspect |Actual/Potential Pollution |
|To assemble Steering Column |Use brush to apply grease at parts |Dispose any brush with grease |
| | | |
|Input: Uni Paint/Marker, Thinner, Grease, | | |
|Plastic Bag, Cloth, brush, Hydraulic Oil, | | |
|Wrapping Plastic, etc.. | | |
| | | |
|Output: contaminated cloth with | | |
|Grease/Thinner/Paint/Hydraulic Oil/Detergent | | |
| |Use cloth to clean the greasy hand/ |Dispose any cloth with grease |
| |machine/ measurement table | |
| |Use Uni Paint/Marker at part |Dispose any cloth with paint |
| |inspection during assembly process | |
| |Use thinner to clean the table with |Emission of VOC (Vapour) for Thinner |
| |cloth | |
| |Use Cloth to clean the area of spilled|Dispose any contaminated clothes after |
| | |used |
| |Apply detergent during 5s' activities |Discharge the sewage to drain |

3.Repacking area.
|Activities / Processes |Environmental Aspect |Actual/Potential Pollution |
|Finished Goods packed for delivery to |Use stretch film to wrap the finished |Dispose any unneeded stretch film and core |
|customer |goods |after repacking process. |
| | | |
|Input: Stretch film, wood pallet . | | |
| | | |
|Output: Excess unused stretch film, core | | |
|of stretch film | | |
| |Use wooden pallet |Dispose damaged wooden pallet |

4.QA Inspection area.
|Activities / Processes |Environmental Aspect |Actual/Potential Pollution |
|Part Inspection/Testing/ Calibration |Inspection of Parts |Not properly QC & cause to the parts |
| | |rejection. |
|Input: Measuring & Inspection Equipment, | | |
|Rag, Parts, Wooden Pallet, Carton, Paper,| | |
|Record. | | |
| | | |
|Output: Paper, White Form, Rag. | | |
| |Throw the packing materials of incoming |Create general waste |
| |parts | |
| |Cleaning of hand or testing tools with |Disposal of greasy rags/cloth/papers |
| |greasy rag/cloth/papers | |
| |Printing of QA/QC related |Extensive use of other stationery (envelope, |
| |documents/records |inspection sheet, letter head, etc) |
| |Testing equipment malfunction |Dispose of testing equipment that is spoilt |
| |Electricity Usage |Air cond. is on while no inspection process |
| | |conducted |

5.Rework area.
|Activities / Processes |Environmental Aspect |Actual/Potential Pollution |
|To perform rework on the Parts. |Throw away NG/rejected child parts |Return the rejected Parts to supplier |
| | | |
|Input: Measuring & Inspection Equipment, | | |
|Rag, Parts, Wooden Pallet, Carton, paper,| | |
|Solvent, Thinner, Spray, Antirust Oil | | |
| | | |
|Output: Oily Rag, Solvent Rag, Stretch | | |
|Film, Carton Box. | | |
| |Use hand jet to carry parts |Leaking of hydraulic oil |
| |Use solvent and thinner to clean/ rework |Dispose any cloth with solvent/thinner to |
| |parts |general waste bin |
| |Use solvent and thinner to clean/ rework |The odor affects the users' health. |
| |parts | |

6.Loading / unloading area.
|Activities / Processes |Environmental Aspect |Actual/Potential Pollution |
|To prepare load/ unload the finished |Use forklift for loading/ unloading |Release exhaust gas, smoke during forklift is|
|goods/ raw material. | |in use |
| | | |
|Input: Forklift, Hand jet, Manpower, | | |
|Diesel | | |
| | | |
|Output: Exhaust gas, smoke, excess | | |
| |Use hand jet to carry parts |Leaking of hydraulic oil of poor maintenance |
| | |schedule |
| |Refill the diesel |Spilled excessive amount of diesel during |
| | |refill process |

7.Chemical area.
|Activities / Processes |Environmental Aspect |Actual/Potential Pollution |
|To store the chemicals, grease. |Loading/Unloading of Chemical |Accidental spillage/drop of chemical to the |
| | |floor |
|Input : Thinner, Hydraulic oil, Grease | | |
|etc. | | |
| | | |
|Output: oil, oily parts, VOC gases | | |
| |Improper handling of Chemical |Cause its dropping to the floor, and cause |
| | |the floor oily. |
| |Storing of Chemicals (Thinner, Grease, |No use of Warning label for Chemical/Oils |
| |etc) |that will lead to wrong usage/misuse. |
| |Spillage of Chemical |Cause the chemical drains out improperly. |
| |Handling of Oils/Chemical at Container |Chemicals Spillage while imbalance of |
| | |position |

8.Schedule Waste area.
|Activities / Processes |Environmental Aspect |Actual/Potential Pollution |
|Input : Schedule Waste from Production |Loading/Unloading of Scheduled Waste : |Accidental drop of Scheduled Waste to the |
|Output : Stored Schedule Waste by its | |floor |
|Categories | | |
| |Separation of Schedule Waste |Mixing of Scheduled Waste by types |
| |Storage of Schedule Waste |Not comply to all the labeling requirements &|
| | |its Schedule Waste Code to avoid wrong |
| | |delivery |
| |Disposal of Industrial Effluent: |All schedule waste to be kept at > 180 days |
| | |or > 20 matrix tone. |

b. Perform Environment Aspect and Impact Analysis.

Answer:
b)
I've already highlighted the elements and situations that need to be considered when identifying the Environment Aspects. After we have identified the environment aspects, we need to set the criteria in deciding whether the environment impact is significant or not significant. For NSK Bearings, If the identified environmental impacts fall under the followings, they shall be considered as “significant” any of the below: • If the individual rating for that impact under the “Legal Requirement Impact ” is equal to “3” or more. • If the individual rating for that impact under the “Business Concern Impact ” is equal to “3”. • If the sum of the rating for “Environmental Impact “ and “Probability of Occurrence” is equal to 11 points or more

Before we proceed to the evaluation, we need to set the criteria for evaluating the environmental impacts. The criteria are:
1. Environmental Legal Requirements (LR)
2. Pollution Impacts (air, water, land, waste and noise) (PI)
3. Resource Depletion (RD)
4. Business Concerns (BC)

Each criterion has their own weightage based on the suitable description that will be used in calculating the rating of the environmental impacts. Please refer the table below:

|Environmental Legal Requirements (LR)|Pollution Impacts (air, water, |Resource Depletion (RD) |Business Concerns (BC) |
| |land, waste and noise) (PI) | | |
|Practice(s) that are Not complying |Evidence of discharging, emitting, |Evidence of wastage in the usage |Issues that may caused |
|with the currently Environmental Laws|and/ releasing large amount of the|of resources such as electricity | |
|and/ Legislative requirements |following pollutants that cause |and/ water, raw materials and/ |- Loss of customer |
| |significant or immediate |by-products, etc. |- Social liability |
|Practice(s) that had once violating |environment impact to the targets :| |- Severe customer |
|the applicable environmental laws and|- Polluted effluents |No evidence of practicing |complaints |
|legislative requirements |- Noxious gases or fume |recycling of appropriate materials|- Complaints from |
| |- Toxic and/ hazardous | |external interested parties. |
|No monitoring to demonstrate |wastes | | |
|compliance |- High environmental noise level | | |
| |that is above or equal to 65dB(A) | | |
|No effective control in place | | | |
|5 |3 |3 |3 |
|Practice(s) that is currently comply |Evidence of discharging, emitting, |Evidence of opportunity to further|Issues that may determined |
|with the existing Environmental Laws |and/ releasing reasonable amount|saving the usage of electricity |customer preferences |
|and Legislative requirements. |of the following pollutants that |and/ water, raw materials (direct | |
| |cause moderate / indirect |& indirect) |Issues that may caused |
|Practice(s) that are affected by the |environmental impacts: | |complaints from internal |
|new legislative requirements which |- Polluted effluents |Evidence of opportunity for |interested parties |
|expected to be enforced. |- Noxious gases or fume |improvement in energy and/ | |
| |- Toxic and/ hazardous |resource depletion | |
| |wastes | | |
| |- Environmental noise | | |
| |level that is between | | |
| |60~ 65dB(A) | | |
|3 |2 |2 |2 |
|Practice(s) that does not create |Evidence of discharging, emitting, |No evidence of wastage of of |No concerns from customers, |
|concerns on Environmental Laws and |and/ releasing negligible amount|resources, such as water and/ |external and internal |
|Legislative requirements |of the following pollutants that |electricity |interested parties. |
| |however not causing any | | |
| |direct/indirect significant |No evidence of wastage of raw | |
| |environmental impacts: |materials (direct and indirect) | |
| |- Polluted effluents | | |
| |- Noxious gases or |Evidence of recycling of materials| |
| |fume |used. | |
| |- Toxic and/ hazardous | | |
| |wastes |Criteria is not applicable. | |
| |- Noise level that is | | |
| |between 55 ~ | | |
| |60dB(A) | | |
|1 |1 |1 |1 |

Another item that we need to set is the criteria for evaluating the rating of Probability of Occurrence. The criteria and rating are:

|Probability of |Occur on daily basis |Occur on periodical basis |Occur once in six month or |No happen at all |
|Occurrence | | |longer | |
|Rating |4 |3 |2 |1 |

After we already identified the Environmental Aspects, set all the criterions for evaluating the Environmental Impact, we will transfer the activities, aspects and impacts into the Environmental Aspects And Impacts Evaluation Table as below:

[pic]
Below are the explanations on how to do the EA&I Analysis by using the table: 1. We need to evaluate the Operating Conditions whether it is Normal (N), Abnormal (A) or Emergency (E). 2. We will decide which environment element will be getting the impacts : AP, WP, NP, LP, RD or others. 3. We will put the rating of the environmental impacts based on the rating criterions that we already set for column LR, PI, RD and BC. 4. We need to set the rating of Probability of Occurrence. 5. At the Total column, it will sum up the rating of the environmental impacts. 6. Then we need to decide whether it is significant or not, based on the Total value. 7. For the Reference column, we will state the related Work Instruction for the EA&I.

Below is the example of a completed Environmental Aspects And Impacts Evaluation Table : [pic] ** Refer Appendix for the clearer version of the Environmental Aspects And Impacts Evaluation Table.

After we've finished doing the analysis, we found these below aspects that are significant :
|Environmental Aspect |Actual/Potential Pollution |
|Changing of Printer Cartridge |Dispose of Ink Cartridge |
|Toner Refill of Photocopier Machine |Accidently spillage of toner powder to tile floor and|
| |create rag with toner powder |
|Use brush to apply grease at parts |Dispose any brush with grease |
|Use cloth to clean the greasy hand/ machine/ |Dispose any cloth with grease |
|measurement table | |
|Use Uni Paint/Marker at part inspection during |Dispose any cloth with paint |
|assembly process | |
|Cleaning of hand or testing tools with greasy |Disposal of greasy rags/cloth/papers |
|rag/cloth/papers | |
|Use solvent and thinner to clean/ rework parts |Dispose any cloth with solvent/thinner to general |
| |waste bin |
|Use forklift for loading/ unloading |Release exhaust gas, smoke during forklift is in use |
|Storing of Chemicals (Thinner, Grease, etc) |No use of Warning label for Chemical/Oils that will |
| |lead to wrong usage/misuse. |
|Spillage of Chemical |Cause the chemical drains out improperly. |
|Loading/Unloading of Scheduled Waste : |Accidental drop of Scheduled Waste to the floor |
|Separation of Schedule Waste |Mixing of Scheduled Waste by types |
|Storage of Schedule Waste |Not comply to all the labeling requirements & its |
| |Schedule Waste Code to avoid wrong delivery |
|Disposal of Industrial Effluent : |All schedule waste to be kept at > 180 days or > 20 |
| |matrix tone. |

From the table , we can summarize that overall actual / potential pollution can be prevented by Scheduled Waste Management.

c. Provide the action plan in order to prevent the business activities from affecting the environment around your workplace/ organization.

Answer:
c)
In order to prevent the business activities from affecting the environment around NSK Bearings, the management need to set an essential environmental objectives and targets.

The MD & EMR shall be responsible for setting the objectives and targets. The Managing Director shall take lead in setting environmental objectives and targets during the Management Review or at the appropriate interval.

When establishing the environmental objectives and targets, the 7 factors as below shall be considered:

The Environmental Policy - ensure that objectives and targets selected shall be consistent with the Environmental Policy

1. Significant environmental aspects and impacts - Priority shall be given to those significant impacts listed in the Environmental Aspects & Impacts Evaluation Table.

2. Legal and other requirements - To ensure those requirements of the existing and newly amended (if any) legal and other requirements are taken into consideration.

3. Views of interested parties - If interested parties have no concern over a specific significant aspect or impact, the related EMP shall be postponed to the forth-coming evaluation.

4. Achievement of previous environmental objectives and targets - Achievement of previous objectives and targets, if any, shall be taken into consideration to ensure that objectives and targets being set are achievable and challenging.

5. Technological options - If there is no technological option available for the time being, EMP shall be reviewed during the forth-coming year or when technological option is available.

6. Financial Feasibility - If the cost is not feasible to improve a specific significant aspect or impact, the related EMP shall be postponed to the forth-coming evaluation.

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Steering Column

7

Pallet Area

Trash

Door

Warehouse Area

Door

Door

Door

Warehouse Area

Engineering Room

Surau

Document Room

Toilet

Toilet

Serve Room

Discussion

Meeting Room

Door

General office

Reception

TNB

Toilet

Production Office

Assembly Line

QA Insp.

Warehouse storage

Rework Area

S.Waste

Chemical Area

Warehouse storage

Warehouse storage

Repacking

1

Loading Area

Warehouse storage

Warehouse storage

Door

Guard house

2

3

4

5

6

7

8