Waste Minimization: Yachts of Opportunity

Marquis Yachts, LLC Founded in 1954 in Pulaski, WI Founded in 1954 in Pulaski, WI Past up to 1400 employees at Pulaski, WI Past up to 1400 employees at Pulaski, WI 15 – 43 - >700, – 43 - >700,000 Vertically Integrated (wood, metal, fiberglass, coatings) Vertically Integrated (wood, metal, fiberglass, coatings) 13 Buildings of Operations 13 Buildings of Operations

Opportunity 146 hoist lifts rated up to 40 tons 56 industrial vehicles with continuous education Respiratory fit testing for 350 employees Elevated surfaces of heights over 30 feet Needle-sharp fiberglass and razor blades Eye contaminates from sand blasting, grinding, sanding, spraying, polishing, drilling and cutting. OSHA VPP guidelines

What does ‘WASTE’ mean to you?

Seven Types of Wastes Overproduction Unnecessary Inventory TransportProcess Rejected Product Waiting Unnecessary Motion

Process Wastes Chemicals Chemicals Energy Energy Temperature Temperature Water Water Industrial Waste Disposal Industrial Waste Disposal

Chemical Management Types of chemicals utilized Types of chemicals utilized –Wood, metal, fiberglass coatings –Resin Emission sources Emission sources By-product development By-product development Alternative Process Options Alternative Process Options Alternative Chemicals Alternative Chemicals

Alternative Chemicals Cross Linking vs. Carriers Cross Linking vs. Carriers Acids vs. Bases Acids vs. Bases Heavy Metal Elimination Heavy Metal Elimination Solvent vs. Water-based Solvent vs. Water-based

Energy Management Natural and Propane Gas Natural and Propane Gas Fossil Fuels Fossil Fuels Electricity Electricity –Air compressor leaks –Computers left on

Temperature Management Heating Ovens Heating Ovens Air Conditioning Air Conditioning Natural Sources of Heat Natural Sources of Heat –Air compressors –Computers –Water –Boilers

Water Management Sinks, Toilets, Bubblers Sinks, Toilets, Bubblers Rain Rain Condensation Condensation

Industrial Wastes Hazardous Hazardous Non-hazardous Non-hazardous By-products By-products Metal Metal Paper, cardboard, plastics, etc. Paper, cardboard, plastics, etc. Electronics Electronics

Alternative Process Options Closed Molding Closed Molding UV Light Ovens UV Light Ovens Re-circulating Exhausts Re-circulating Exhausts Monitoring Sensors Monitoring Sensors Application Process Application Process Light Sensors, fluorescent Light Sensors, fluorescent Wind Turbine Generators Wind Turbine Generators

Waste Reductions EPA Clean Air Excellence Award in 2002 EPA Clean Air Excellence Award in 2002 Green Tier Induction Ceremony in 2006 Green Tier Induction Ceremony in 2006 Air Emission Reduction (> 40%) Air Emission Reduction (> 40%) Small Quantity Generator (>60%) Small Quantity Generator (>60%) Process Waste Water Reductions (> 80%) Process Waste Water Reductions (> 80%) Real Time Air Emission Tracking (>50%) Real Time Air Emission Tracking (>50%) Labor Reductions (16%) Labor Reductions (16%) Cost Savings over $4,000,000 Cost Savings over $4,000,000

Management Tools EMS Lean Manufacturing Six Sigma

What are the basic elements of an EMS? POLICY Adoption of an environmental policy that includes a commitment to compliance with environmental requirements, pollution prevention, and continual improvement in environmental performance. POLICY Adoption of an environmental policy that includes a commitment to compliance with environmental requirements, pollution prevention, and continual improvement in environmental performance. FOOTPRINT An analysis of the environmental aspects and impacts of an entity’s activities. FOOTPRINT An analysis of the environmental aspects and impacts of an entity’s activities. COMPLIANCE Plans and procedures to achieve compliance with environmental requirements and to maintain that com­pliance. COMPLIANCE Plans and procedures to achieve compliance with environmental requirements and to maintain that com­pliance. REQUIREMENTS Identification of all environmental requirements applicable to the entity. REQUIREMENTS Identification of all environmental requirements applicable to the entity. ACTION PLANS A process for setting environmental objectives and developing appropriate action plans to meet the objec­tives. ACTION PLANS A process for setting environmental objectives and developing appropriate action plans to meet the objec­tives. CONTROL Establishment of a structure for operational con­trol and responsibility for environmental performance. CONTROL Establishment of a structure for operational con­trol and responsibility for environmental performance. TRAINING An employee training program to develop aware­ness of and competence to manage environmental issues. TRAINING An employee training program to develop aware­ness of and competence to manage environmental issues.

RESPONSE A plan for taking actions to prevent environmental problems and for taking emergency response and correc­tive actions when environmental problems occur. COMMUNICATIONA communication plan for collaboration with employees, the public, and the department on the design of projects and activities to achieve continuous improve­ment in environmental performance. RECORDS Procedures for control of documents and for keeping records related to environmental performance. AUDITSEnvironmental management system audits. Housekeeping IMPROVEMENT A plan for continually improving environmental performance and provision for senior management review of the plan.

Improvement Methodologies Lean Manufacturing Six Sigma (DMAIC) –Define the problem (D) –Measure the extent of the problem (M) –Analyze the sources of variation (A) –Improve the process (I) –Control the process for sustained improvements (C)

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