by Titanas
Border Waste Wi$ e Partnership
City of San Diego
City of Tijuana
Cal-EPA, Integrated Waste Management Board
U.S. EPA
Science Applications International Corporation
Autonomous University of Baja California
San Diego State University
Products, Processes and Wastes
The macroelectronics industry covers 1) the assembly of microelectronic components, such as printed circuit boards, into larger electronic products like computers and consumer electronics and 2) the fabrication of housings for these products.
Electronics manufacturing includes a wide array of processes specific to the products produced. The primary steps of the manufacturing process are: receiving raw materials, processing materials, manufacturing the product, and storing, packaging and shipping finished products.
Manufacturing products generally follows these four steps: 1) Materials and preassembled subparts are placed in boxes or totes for access by production staff. 2) Prefabricated printed circuit boards (PC boards) undergo surface mounting and/or manual/automatic insertion processes which are then followed by wave soldering and water jet washing. Finished PC boards are connected to testing devices to ensure they function properly. 3) Other components are assembled with the PC boards and the product is placed in its housing. 4) Products are tested and rejects are separated. Most electronics manufacturers have a very low reject rate (1 to 2%).
Solid wastes generated from these processes include component wire trimmings (or “pins”) which can either be loose or adhered to a paper backing, circuit board trim materials, plastic component reels, plastic integrated circuit packing tubes, scrap electrical components and circuit boards, rejected parts, cleanup rags, general office waste, white and colored paper, packing materials (includes polystyrene, cardboard, paperboard, wood pallets, and plastic bags, anti-static bags, bubble-wrap, shrink wrap, open cell foam), scrap labels, and label backing paper.
Plants that have cafeterias or food service/break areas also generate food
wastes, glass and plastic containers and other wastes typically associated with serving food. Food wastes are a large percentage total waste by weight at plants that have cafeterias. For example, Sony’s plant generates a very large amount of food wastes because the company serves 5,000 meals a day.
Examples of solid wastes generated by products manufactured (percentage, 1996)
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by Jcarlosbulas
Waste Reduction Techniques
You have opportunities to improve waste reduction throughout your plant. While some techniques may be company-specific, many apply to all electronic manufacturers. Evaluate these techniques in terms of payback, annual savings and impact on your operations to select the ones to implement. More ideas on steps to improve your program are provided at the end of this guide.
Waste reduction includes waste prevention, material reuse, recycling, composting practices, and buying products with recycled content.
Product Design and Manufacturing
Use “air molding” to make plastic components (e.g., housing), reducing plastic use by as much as 40%.
Employ integral molding process and snap-in designs to eliminate the need for welding and gluing.
Enhance product “recyclability” by minimizing the number of plastic resins used and by avoiding compound materials.
Make housings and other parts (e.g., television chassis frames) out of 100% recycled plastic.
Although these design changes may be costly, they often cut overall production costs per unit by as much as 50% due to fewer materials and faster assembly. Moreover, consumers respond well to green products.
Use automatic insertion processes to minimize reject rates.
Order printed circuit boards, pins and other components to as exact specifications as possible to reduce cutoffs.
Use “in process” quality assurance and controls (e.g., electronic monitoring) to help maintain quality.
Xentek De Taiyo, a manufacturer of power sources, redesigned the specifications for metal fabrication which significantly reduced cutoffs and improved materials efficiency.
Materials Reuse & Recycling
Dismantle inoperable products and reuse subparts in the manufacturing process.
Reuse wire and shrink-wrap spools onsite or return them to the vendor.
Launder and reuse shop towels and rags. Kodak’s Tijuana plant saves $ 20,000/year by contracting with an industrial laundry.
Recycle materials from production processes, such as circuit board pieces, steel and copper pins (from trimming lead wires used in PC board insertion), polystyrene, PVC packaging tubes for integrated circuits, scrap equipment, and solder. Many border manufacturers, such as, Honeywell and Sony, have implemented cost-effective methods to segregate these materials in production lines.
Make recycling convenient. Provide bins in all areas where materials are generated. Bins are available from many different vendors or can be fabricated onsite using empty drums, crates, or boxes. The bins should be colorful, easy to use (i.e., no heavy lids or tools required to open), and clearly marked to indicate the appropriate materials to be disposed in each.
Schedule regular collections. Recyclable materials must be collected and transferred before the collection bins get full. By doing so, sufficient space will always be available for properly segregating and storing the materials.
Establish contracts with local recycling companies for regular removal of recyclables. In some instances, it may be more profitable for a facility to haul its own materials to a recycler than to pay for the pickup service.
Periodically review market values to ensure you are getting the best value for recyclables. Verify that you are receiving the best prices for high-value materials and minimizing costs on others.
Ask workstation operators to control materials segregation. Try to allocate recycling revenues by cost center in order to provide incentives for production managers. Also provide incentives, such as bonuses, for production workers.
Use on-line waste exchanges, such as the Chicago Board of Trade’s system and the State of California’s CalMax/CalMex exchange to sell or find a use for materials. Go to Border Waste Wi$ e on-line to access these exchanges.
Crydom, a Tijuana facility that makes solid state relays and transistors, dismantles inoperable products and sends reusable parts (e.g., housings) back to the production line.
Philips Consumer Electronics has developed an innovative materials reuse program in Ciudad Juárez, Chihuahua. Philips donates wooden and metal pallets, the wood from the crates, cardboard from packaging and Styrofoam to needy families for use in home building. Workers from Philips donate their time and aid in the building of these structures.
Panasonic’s plant in Tijuana, which manufacturers various products, including car stereo speakers, enjoyed an annual savings of $ 107,000 in recycling revenues and reduced disposal costs during 1995.
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by MissMalaprop
Packaging Reduction
Reduce product packaging. Review all packaging specifications for redundancy and develop a policy that recommends or requires review of potential solid waste impacts of packaging requirements.
Use reusable packaging. Determine the cost-benefit of replacing single-use corrugated boxes in certain shipping operations with durable distribution packaging that can be reused hundreds of times. Several large manufacturers have established closed-loop distribution systems to reduce packaging, labor and waste disposal costs.
Reuse materials and packaging. Reuse pallets and other packaging materials, internally or donate these materials for reuse by others.
The decisions you make on packaging size and type, as well as shipping specifications, impact waste generation at wholesalers, retailers and consumers. Your customers also want to reduce waste disposal costs. Consider this when making packaging decisions.
Honeywell, which manufacturers gas control valves units at its Tijuana facility, ships parts and products to and from other Honeywell facilities in the U.S. in reusable plastic totes.
Corporation Asahi, which repairs and refurbishes telephone answering machines, secures products on pallets with reusable plastic straps and metal clips, thus reducing new plastic strapping and shrink-wrap purchases and cutting these wastes by 40%.
Purchasing
Modify supplier/vendor contracts by adding “affirmative procurement,” “packaging reduction,” “recycled content,” and “design for recycling” requirements.
Develop a facility-specific affirmative procurement program to increase purchasing of recycled-content products, such as cardboard and white paper. Buying recycled products (”closing the loop”) is the best way to expand markets for recycled materials and to reduce their costs.
Purchase less or non-toxic materials, such as non-lead solder and flux.
Order supplies by voice-mail or electronic-mail, and order in bulk and concentrated form to reduce excess packaging (e.g. janitorial supplies and cleaning materials).
Office Paper Use
Implement two-sided photocopying with copiers that have this capability.
Reuse one-sided copies by using the clean side for note pads, distribution lists, and fax cover sheets.
Maximize the use of electronic messages. Review and maintain documents on computer disks rather than printing out multiple hard copies.
Eliminate unnecessary forms. Redesign them to fit on a half sheet.
Reuse envelopes or use two-way envelopes.
Lambda, a Tijuana plant that manufacturers capacitors and other electronic components, has a recycled products purchasing program for paper and cardboard.
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by MissMalaprop
Enhance Your Waste Reduction Program
Develop a written waste reduction policy statement from facility management to employees (e.g., encourage waste reduction to reduce facility costs and impacts on environment).
Establish a waste reduction technical team composed of management and staff.
Identify specific goals and objectives. For example, implement a paper recycling program by December 1997, require the use of reusable plates, cups and utensils in the cafeteria when the next cafeteria contract is up for renewal, and implement affirmative procurement activities throughout the facility by November 1997.
Select waste reduction projects that meet your objectives. For example, purchase bins and post signs to implement a paper recycling program.
Budget and schedule implementation of selected waste reduction projects.
Provide incentives to employees based on returns from recycling, reduced disposal, and material procurement costs. Effective incentives can be in the form of cash bonuses, or funding for company sponsored events, parties or sports teams.
Solicit employees’ opinions about current operations and potential waste reduction opportunities. Employees’ input will help management identify specific waste reduction opportunities they may have overlooked, and will give employees a sense of accomplishment in helping to develop waste reduction activities and procedures.
Integrate waste reduction into your overall environmental and total quality management (TQM) programs (e.g. ISO 9000 and ISO 14000)
Plamex, an audio headset manufacturer in Tijuana, is expanding its employee training program to enhance waste reduction awareness and to improve production line segregation of recyclable materials. In 1996, Plamex reduced wastes by 30%.
Kodak, which refurbishes reproduction machines at its Tijuana plant for reuse by its customers, reduced its solid waste disposal costs from $ 150,000 to $ 54,000 between 1994 and 1995. Kodak provides bonuses to employees from recycling revenues.
Many Border companies, including Panasonic, are actively incorporating solid waste reduction and recycled products procurement as part of their ISO 14010 certification process. Waste reduction and other preventive measures are the factors weighed most heavily in an ISO 14010 audit score.
Giuntini, Ron, and Tom Andel. “Track the Comings and Goings, & Costs of Returnables.” Transportation and Distribution. v35, n7 (July 1994) 55.
Ottman, Jacquelyn A. “Four Strategies for Success in the Green Packaging Era.” American Marketplace. v15, n23 (November 17, 1994).
Saphire, David, “Delivering the Goods, Benefits of Reusable Shipping Containers.” Inform, Inc., 1994.
The Fabricated Metal Products Industry. Guides to Pollution Prevention, EPA/625/7-90/006, U.S. EPA Office of Research and Development, Washington DC, July 1990.
Pollution Prevention in the Electronics Industry. U.S. EPA/SEDESOL Pollution Prevention Workshop (English and Spanish), May 1996.
Profile of the Electronics and Computer Industry. EPA Office of Compliance Sector Notebook Project, EPA/310-R-95-002, September 1995.
Profile of the Fabricated Metal Products Industry. EPA Office of Compliance Sector Notebook Project, EPA/310-R-95-007, September 1995.
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by Auntie P
Mrs. Yvonne Williams
Deputy Director
Environmental Services Department
City of San Diego
9601 Ridgehaven Court
San Diego, CA 92123-1636
Phone (858) 492-5076, Fax (858) 492-5021
Email: ycw@sandiego.gov
Arq. Jose Luis León Romero
Director
Public Works and Services Department
Ayuntamiento de Tijuana
Palacio de Gobierno Municipal
1er nivel Ave. Independencia y Paseo Tijuana
Tijuana, B.C. 22320 México
Phone (52-66) 973-71-41/42/43
US/Mexico Border Team
U.S. Environmental Protection Agency, Region IX
75 Hawthorne Street, H-W-3
San Francisco, CA 94105-3901
Phone (415) 744-2096, Fax (415) 744-1044
California Environmental Protection Agency
Integrated Waste Management Board
8800 Cal Center Drive
Sacramento, CA 95826
Phone (916) 255-2427, Fax (916) 255-2644
Science Applications International Corporation (SAIC)
20 California Street, Suite 400
San Francisco, CA 94111
Phone (415) 399-0140, Fax (415) 399-0299,
Facultad Internacional de Economía*
Universidad Autónoma de Baja California
Calzada Tecnológico S/N, Mesa De Otay
Tijuana, B.C. 22390 México
Phone (52-66) 82-08-32, Fax (52-66) 82-08-32
Dr. Paul Ganster
Director
Institute for Regional Studies of the Californias
San Diego State University
5500 Campanile Drive
San Diego, CA 92182-4403
Phone (619) 594-5423, Fax (619) 594-5474
E-mail: pganster@mail.sdsu.edu
Use this worksheet to identify and record the different waste-generating activities and equipment in your facility, the types of waste produced, and any current waste reduction efforts. In addition, identify all materials that could be targeted by your waste reduction program and brainstorm ways to reduce, recycle, or compost these materials.
The information needed to complete this worksheet can be obtained by conducting a walk-through of targeted functional areas of your entire facility. The walk-through entails carefully observing waste-generating activities and equipment, examining the contents of waste containers, and interviewing supervisors and employees.
Be sure to pay close attention to areas and operations that tend to generate the largest amounts of waste, such as shipping and receiving departments, copying areas, cafeterias, assembly lines, and offices. Remember to include a review of the grounds maintenance operations. While conducting the walk-through, watch closely for activities and equipment that generate waste unnecessarily, as well as waste reduction efforts that are already in place.
Before the walk-through begins, contact department managers to inform them of the visit and the possibility of short interviews with department staff. (More involved interviews should be scheduled separately.) You may also want to interview custodial workers and operations staff.
If possible, schedule the walk-through just before trash pickups to allow a sufficient amount of waste to accumulate. Avoid scheduling it on or around holidays, company parties, or other special events that would produce wastes not representative of a normal workday.
During the walk-through, ask questions about variations in daily waste generation. For example, periodic deliveries may result in more discards on the delivery day. In addition, ask about any recent or upcoming changes within the department, such as new equipment or procedures, that could alter the types or amounts of waste generated.
Larger companies may want to record information gathered on the walk-through by department, copying this worksheet as needed.
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by redeemdesigns
Many companies have demonstrated that by reducing and recycling materials that would otherwise become trash, they can reap substantial savings, sometimes millions of dollars per year. Border Waste Wi$ e was developed to assist businesses in taking cost-effective actions to reduce solid waste.
Why Reduce Solid Waste?
Waste reduction activities offer distinct benefits, both for the environment and your bottom line.
Waste Prevention
Waste prevention can save your company money through lower purchasing and disposal costs. It can also save your customers money by reducing what they throw out. Avoiding the generation of waste reduces the burden on disposal facilities, conserves natural resources, and often reduces pollution.
Recycling Collection
Collecting recyclables can help keep large amounts of material out of your company’s dumpster. It can reduce your waste disposal bill and generate revenues from the sale of some materials. Recycling offers some of the same environmental benefits as waste prevention: extending the life of landfills, conserving natural resources, and reducing pollution.
Buying or Manufacturing Recycled Products
Recycled products are of high quality and can be competitively priced compared to virgin products. Buying and manufacturing goods with recycled content helps ensure that recycling will continue to advance and will eventually help lower the cost of recycled products.
Why Participate in Border Waste Wi$ e?
In addition to the benefits of waste reduction outlined above, participation in Border WasteWi$ e offers several advantages.
- Border WasteWi$ e offers technical assistance via this website, “how to” publications, lessons from other companies, and training materials. Project partners also offer free, confidential waste reduction assessments to a limited number of companies.
- Successful waste reduction efforts will be highlighted in Border WasteWi$ e partner documents.
- Border WasteWi$ e provides an opportunity for your firm to be viewed by peers and customers as a leader in environmental initiatives.
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by Noah Scalin
Many companies have successful waste reduction programs. Border Waste Wi$ e wants to share the success of these companies and show how they can even accomplish more with our assistance.
Hasbro Manufacturing Services, Juguetrenes, S.A. DE C.V., Plant 1, located in the maquiladora sector of the city of Tijuana, Mexico has initiated a number of successful waste reduction activities. The plant operates with 1,900 employees for the molding, assembly, packaging, and shipping of plastic toy parts and toys. Examples of Hasbro’s accomplishments include the following:
- A large program is in place at Juguetrenes to bale and recycle cardboard and linerboard packaging materials.
- Jugutrenes regrinds waste plastics onsite to sell to recyclers. The injection molding department has invested resources in classifying, regrinding, and selling plastic wastes, and as a result, they have saved $ 230,000 per year.
- Juguetrenes has been operating a pallet rebuilding area to reduce the number of wood pallets used at the facility and reduce the quantity of waste pallets to be disposed of as a solid waste. All repairable pallets are rebuilt and reused by the facility.
- Expired fluorescent light tubes from the plant are recycled through a San Diego facility. As a result, $ 300 to $ 400 per year is generated in recycling revenue.
- Border Waste Wi$ e conducted a solid waste reduction assessment at the Juguetrenes facility in April of 1996. As a result of this assessment, the Border Wate Wi$ e team made several recommendations for how Juguetrenes can improve their operations to reduce wastes and save money. Juguetrenes plans to explore these options for establishing waste reduction goals in 1997.
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by lydiashiningbrightly
Philips Consumer Electronics Company’s Mexican group, Productos de Consumo Electrónicos Philips (PCEP) has developed a program in Ciudad Juárez Chihuahua which uses non-hazardous waste materials from its facilities in a beneficial way for the community. Not only does this program reduce waste from the facilities, it provides housing for those who might not otherwise have it.
- PCEP manufactures televisions and other consumer electronic products. Many of the components for these products are sent to PCEP packed in wooden crates, shrink-wrapped to wooden or metal pallets and/or packaged in styrofoam. Rather than dispose of these materials in a landfill, PCEP looked into the community to see if these materials could be used to benefit the community. The answer was yes, and the PCEP building program was begun.
- Infrastructure in the border zone, especially housing and general utility services, has not been able to keep up with economic growth. One of the consequences of this lag is the colonies, essentially shanty towns where people may live in cardboard houses with no running water. PCEP decided to donate the wooden and metal pallets, the wood from the crates, cardboard from packaging and styrofoam, to needy families for use in home building in the colonies. The metal pallets form the framework of the houses, the wood is used for the rest of the construction, and the styrofoam is used for insulation. Workers from PCEP donate their time and aid in the building of these structures.
- In addition to the building program, PCEP has organized a water distribution program. Old plastic containers from water coolers and new, clean plastic drums are filled wtth potable water and taken to the colonies for distribution to the residents, many of whom do not have running water or close access to drinking water. Again, PCEP’s workers volunteer their time in this program.
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by MissMalaprop
Sony’s Video Tec de Mexico (VTM) plant, located in Tijuana, Mexico has made great strides in waste reduction and recycling. This plant, one of Sony’s largest worldwide, employs over 5,000, people in four facilities and assembles TVs, computer monitors and several subassemblies such as PC boards and tuners. Examples of Sony’s accomplishments include:
- Since 1993, average annual increase in tonnage recycled has been over 45% per year (from 2,000 tons in 1993, to 4,300 tons in 1995.)
- Sony VTM’s bottom line result from its recycling program in 1995 was over $ 500,000 in combined revenue and cost avoidance.
- In 1995, Sony VTM recycled cardboard, pallets, plastics, wood, lead ends, foam, dross, cartons, scrap equipment, copper, PC boards, steel, paper, wire, and other materials.
- In November 1995, Sony VTM installed new balers which enabled the company to further reduce remaining wastes by 50%.
- Sony’s engineers reduced the size of a component of one of their TVs, substantially reducing plastic material use, material costs and wastes.
- Sony also reuses items such as wood pallets which are picked up at the VTM plant and refurbished/re-worked.
- Sony VTM was recognized in 1996 for their recycling efforts with a “Grand Prize” award in Sony’s prestigious corporate environmental award program.
- Border WasteWi$ e conducted a solid waste reduction assessment and study at Sony’s VTM II plant. Sony implemented our recommendation of installing hand dryers in its restrooms, immediately reducing large quantities of paper towels, and is considering implementing other recommendations, including those that would dramatically reduce wastes generated by the plant’s cafeterias, which serve several thousand meals daily.
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by practicalowl
Corporation Asahi, which repairs and refurbishes telephone answering machines, has a well established waste reduction program.
- One recent innovation, which Border Waste Wi$ e has shared with other companies, is employing reusable plastic straps to secure products on pallets. Corporation Asahi straps the products to pallets with metal clips, reducing purchases of new strapping and plastic shrink wrap, and cutting these wastes by 40%.
- As a result of Border Waste Wi$ e, Asahi is implementing a food composting program to reduce waste from cafeteria operations and they are considering our recommendations to recycle off-spec and scrap electronic components and parts.
Day Runner De Mexico
Day Runner De Mexico, a manufacturer of business organizer books and other products, has implemented several waste reduction and recycling practices.
- The company uses an inventory control and production supply system that requires the plant manager to approve all purchase orders. This and other steps help ensure that over-ordering and excess materials are minimized.
- Employees and janitors assist in segregating recyclables to prevent them from becoming solid waste. Almost all leather, vinyl and cardboard are recycled.
- The Border Waste Wi$ e assessment and resulting report at Day Runner identified waste reduction opportunities including: a recommendation for the facility to use reusable totes for shipping supplies and finished products between the company’s Pasadena Headquarters and their Tijuana facility. Border Waste Wi$ e also provided waste reduction and pollution prevention opportunities for construction activities that can be implemented when Day Runner begins construction of an additional Tijuana facility in the near future.
EBT (Philips Electronics)
EBT (Philips Electronics), a large manufacturer of electronic components, has an established waste reduction program.
- EBT already recycles most of the wastes they generate.
- The plant has also installed a compactor/baler that helps the company get higher prices for recycled cardboard and reduces its overall solid waste disposal costs because of the reduced volume of wastes requiring disposal. The equipment is provided under a lease agreement by a local recycling company.
- With help from Border Waste Wi$ e, EBT is searching for ways to reuse excess asphalt material resulting from their manufacturing process. Border Waste Wi$ e referred EBT to the City of Tijuana’s Public Works Department, one of our government partners, to discuss the possibility of using the asphalt in road construction and maintenance. Border Waste Wi$ e is also assisting EBT to find other organizations that may be interested in reusing the asphalt by helping the company list this material in CalMex, a bi-lingual materials exchange established for Border Waste Wi$ e by the California Integrated Waste Management Board, another one of our government partners.
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