iStalkr

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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by SATOBOY SOCIAL VANDALISM NETWORK ACTIVISM GUERRILL

Businesses and institutions are in a powerful position to reduce packaging wastes and save money. Businesses can influence supplier contract terms toward environmentally preferable packaging practices, and other “green” contract related issues. Most businesses can significantly reduce the amount of packaging on their products, demonstrating concern about the environment to customers. In some cases, federal and state laws (e.g., California’s Rigid Plastic Container Packaging Law), impose new environmental requirements and taxes on many packaged products.¹

Manufacturers may receive parts and materials from many different vendors worldwide. Waste reduction opportunities for manufacturing facilities include reducing the packaging used for items received from suppliers and items shipped to warehouses and retailers. The amount of packaging used to protect parts and materials from damage during shipment and storage is sometimes excessive.

Packaging reduction can have a significant impact on a facility’s waste generation. Typically, the majority of solid waste generated by a manufacturing business is related to packaging. Reduced packaging leads to cost savings for purchased parts, product shipment, and waste disposal. Also, the use of recycled content materials “closes the loop” on recycling, and helps to maintain viable markets for recyclable materials in the future.

Recommendations:

Develop standard contract language with suppliers to address the following issues:

• Minimize the amount of packaging used for transporting materials to/from facilities.

• Require the use of recycled-content packaging.

• Require the use of reusable boxes and pallets.

Small businesses could get help from trade associations who may be able to provide assistance by approaching suppliers about these issues on behalf of a large number of facilities.

Common examples of excessive packaging which should be addressed include:

• Plastic bags, cardboard separators, and foam padding or styrofoam peanuts used for packing non-cosmetic parts. Non-cosmetic parts can frequently be shipped in bulk (without individual packaging) because slight scratching would not impact quality.

• Padded bags with tied plastic wrap or plastic/wire closures. The closures often use more material than is necessary. No tie-wrap may be required if the container is designed correctly.

• Redundant packaging. A good example is boxes shipped inside other boxes.

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by bubbo.etsy.com

Manufacturers can request certain types of packaging from suppliers. They also can consider waste reduction when repackaging items for sale to customers. Manufacturers should review all packaging specifications for redundancy and develop a policy that reviews potential solid waste impacts of new packaging requirements. The following ideas may help get you started.

• Reduce multiple layers of packaging whenever product integrity will not be threatened. For instance, wrapping smaller boxes on a pallet or in reusable trays or totes (without a larger box as a container) can reduce packaging waste and save money.
• Include packaging questions in market research surveys in order to evaluate consumer preferences regarding packaging. More and more consumers are choosing products packaged in minimal amounts of materials.
• Investigate the use of fiberboard trays and stretch wrap. Large wholesalers commonly ship materials to warehouse clubs (i.e., Sam’s, BJs, Pace, Price Club) using specialized packages of only stretch wrapped fiberboard trays rather than cardboard boxes, reducing corrugated cardboard waste by over 25 percent. This approach could possibly be used by smaller manufacturers and retailers.
• Coordinate packaging reduction efforts with suppliers and customers. Potential cost savings may be achievable from reduced purchasing requirements, lower labor and disposal costs for the supplier, the manufacturer, the retailer, and the customer. Work with suppliers and customers to brainstorm packaging reduction ideas and promote “green packaging.
• Buy packaging and other products made with recycled-content materials. Contract language for suppliers of parts and packaging materials should be modified to specify recycled content levels. See the fact sheet on “Developing a Facility-Specific Affirmative Procurement Project” for information on vendors that sell products with recycled content.
• Encourage suppliers to design for recycling. The design of a product or packaging system should take into account the “recyclability” of the item after its useful life is completed. For example, if multiple plastic parts are used in a product design, the plastic would be easier to recycle if it was all made from the same type material. Mixtures of different type plastics create problems for segregating properly.
• Another design to avoid, for example, is packaging that uses cardboard bonded to styrofoam (or urethane foam). This is because it creates a segregation problem for recyclers making it less likely to be recycled. Contracts should direct suppliers to use more recyclable designs and materials.

The implementation and success of many waste reduction opportunities depends on cooperation between suppliers, manufacturers, and retailers. If the retailers do not want to alter packaging, the manufacturer may not have any choice in reducing or altering packaging.

Packaging is meant to reduce damage of goods. Packaging waste reduction efforts must not compromise the package function.

Recycled content packaging may cost more than virgin materials. Increased costs resulting from the use of recycled content materials may not be well received by customers and retailers. All requirements for packaging changes should be carefully researched before implementation.

¹ California’s Rigid Plastic Packaging Container Program requires that most rigid plastic containers with a volume greater than eight ounces: a) be made from recycled materials, b) be reduced in weight by ten percent, c) or meet recycling goals. This law applies to products sold in California. Mexico has just enacted legislation that requires resin coding on certain plastic containers. The European Union has adopted the Directive on Packaging and Packaging Waste, requiring each member state to meet specific five and ten-year goals. Germany, Italy, France, Austria and Hungary have levied material-specific fees on packaing. Other members are rapidly following suit. Japan’s Bill Concerning Promotion of Separation, Collection and Recycling of Container Packaging will require businesses to recycle packaging wastes. Producers of plastic containers and paperboard packaging will be required to ensure the recovery of these materials. (SOURCE: SAIC)

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by Urban Woodswalker

Most businesses generate significant amounts of paper waste each day (See the list below). A significant portion of the paper waste is recyclable material of high enough quality that can be resold to a local recycler. Paper use can be reduced through the implementation of some simple source reduction practices. Many companies are saving thousands of dollars by reducing and recycling office paper, which has a top price in the recycling market. A well organized waste reduction and recycling program is essential in reducing the amount of solid waste generated by an organization.

Recommendations:

Source Reduction

Implement photocopying on both sides of the paper with photocopy machines that have this capability.

Papers with copies on just one side could be used in other ways (e.g. note pads) before they are discarded/recycled.

Maximize the usage of electronic mail. Revise and keep documents on computer disks instead of printing multiple hard copies.

Develop other forms of source reduction by conducting employee informal surveys or establish a suggestion program.

Recycling

Improve the employees recycling conscience. This could include: Holding contests that reward the teams that recollect the most paper, putting up signs reminding personnel to recycle, etc.

Include a discussion about the waste reduction and recycling programs in the orientation of new employees and during other appropriate gatherings/meetings. This will increase the participation of the new employees in the programs. The repetitive reminders that are given to employees during training that take place during the year also help to maintain focus on the goals and procedures of the program.

Make recycling convenient. Provide bins in all areas where the materials are generated. The bins can easily be obtained from many providers or can be made by using empty barrels, boxes, etc. The bins should be colorful and easy to use (i.e., without heavy lids or the need of tools to open them) and clearly marked to indicate the kind of materials that should be placed in each bin.

Schedule regular collections. The recyclable materials should be collected and transferred before the collection bins are full. By doing this, there will always be sufficient space for the correct segregation and storing of materials.

Establish contracts with local recycling companies to collect and transport the recyclable material. In some cases it could be more productive for the company to transport their own materials to a recycler than to pay for it.

Periodically review the market values to make sure you are obtaining the best price for your recyclables and minimizing the costs of others.

The initial investment for the purchase of bins for the collection of recyclables, the development of graphics for the communication of programs, the personnel training, etc. could be expensive. Many companies use a phase approach, that allows the implementation of the prioritized improvements first without incurring all the great capital expenses at the same time.

Information about providers:*

Fiber Recyclers

Recyclable Paper (high grade, mixed, newspaper, magazines, cardboard)
Contact: María Prado
Calle Guadalupe
Victoria No. 13 Fracc. García, Tijuana
ph. (011-52-66) 89-40-94
fx. (011-52-66) 89-41-04

Industrial Dibrán ( high grade, mixed, newspaper, cardboard)
Contact: Ana Picos
Calle Granate #10 B
Fracc. El Rubí, Tijuana
ph. (011-52-66) 84-50-25
fx. (011-52-66) 84-54-13

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