by Noah Scalin
ABOUT THIS GUIDE
This guide is designed to help managers of electronics manufacturing plants increase solid waste reduction and recycling. Smart organizations know that waste reduction is simply good business because it directly improves your bottom line by cutting materials and waste disposal costs. Waste reduction also helps you achieve:
Efficiency improvements in manufacturing (e.g., snap-in units),
Healthier workplace,
Cost-effective compliance with regulations,
ISO 14000 standards,
Cleaner local environment, and
Enhanced company image
Whether your company already has a waste reduction program or wants to start one, this guide’s practical techniques and examples will benefit you.
Electronics is the largest and one of the most competitive industries along the U.S.-Mexico border. Constant changes in technologies reduce product life cycles and increase customer expectations. Many companies, both large and small, have embraced waste reduction as part of their total quality management and continuous improvement programs.
Although this guide is intended to help electronic product manufacturers, many of the waste reduction strategies and techniques apply to all manufacturers.
Improving your bottom line through waste reduction
Recycling revenues from selected plants in Tijuana, Mexico
(1995 dollars)
Border Waste Wi$ e
This guide is part of the Border Waste Wi$ e Project, a solid waste reduction and recycling effort in the border region. The project is funded through the U.S. Environmental Protection Agency’s (EPA) Environmental Technology Initiative, with substantial in-kind contributions by each project partner.
Border Waste Wi$ e focuses on providing technical assistance and training to U.S.,Maquiladora and Mexican National companies in the Tijuana, Baja California and the San Diego, California border region in order to help them take advantage of the economic and environmental benefits of solid waste reduction. Participation in this program is completely voluntary and nonregulatory.
Fact sheets, recyclers listings, industry case studies and other information that complement this guide are available from Border Waste Wi$ e’s Internet site (http://www.borderwastewise.org). Appendix A is a list of project partner contacts.
Review this guide and compare it to your program. If your company is not taking full advantage of the suggestions presented here, start implementing some simple changes. We guarantee that you will find opportunities to improve your company’s bottom line, image and local environment.
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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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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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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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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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