1. Using EMS Targets to Reduce Chemical Inventory June 3, 2008 Kristin Klossner Clover Leaf Environmental Solutions Albuquerque, NM Sandia is a multiprogram laboratory operated by Sandia Corporation, a Lockheed Martin Company, for the United States Department of Energy’s National Nuclear Security Administration under contract DE-AC04-94AL85000.

3. Home Culture Sandia National Laboratories/New Mexico (SNL/NM) is a national security facility owned by the Department of Energy (DOE)/National Nuclear Security Administration (NNSA) and operated by Sandia Corporation, a Lockheed Martin Company. SNL/NM designs non-nuclear components for nuclear weapons, performs energy research and development projects, and develops projects to address national security Employs approximately 10,000 employees and contractors. The mix ranges from PhD-level scientists and engineers to blue collar technicians. Located on Kirtland Air Force Base in Albuquerque, New Mexico

4. Home Culture Ongoing tension between researchers and support functions Researcher autonomy is valued to preserve creativity Resistance and skepticism to change, authority and centralization Laid back supportive atmosphere can create lack of accountability

5. Home Culture SNL has over 120,000 containers of chemicals with 25,000 of those being unique chemicals

6. Home Culture This is the story of one Division at Sandia (there are nine). Division 2000,Weapons Engineering and Product Realization conducts R&D and production activities mostly in laboratory environments. It employs nearly 1500 employees and contractors Division 2000 had about 22,000 chemical containers before the reduction effort Most lab activities involve small-scale experiments and require small amounts of a variety of chemicals

8. Home Culture The division is divided into six Centers. Each Center has an ES&H Coordinator (heroes).

10. The Heroes

12. Call To Adventure Estimated 40% of the Division’s laboratory waste is unused chemicals (unopened, partially used, expired) Chemical management and disposal can cost 6 times the purchase price of chemicals Example: 1 Gallon Acetone Purchase Cost = $43.15 1 Gallon Acetone Disposal Cost = $128.64 Old chemicals can be a safety hazard due to chemical instability or container deterioration.

14. Supernatural Aid-Management Commitment Steve Rottler, Division Vice President and Wizard

16. Crossing the Threshold Division 2000 EMS TEAM To provide leadership for Center and Division environmental matters and to achieve best-in-class operational performance. 2007 Chemical Reduction Objectives and Targets Objective Target Due DateOwner Status Reduce chemical inventories (target chemicals over 5 years old) by 10% utilizing 6S events and other methodologies. Reduce number of chemicals over five years old. 3/15/2007 SaltzsteinLabs have eliminated 17% of old chemicals.

18. The Abyss Avoiding the Five Deadly Myths “I can’t get the chemical I want when I need it so I need to keep a lot on hand.” “I get a great price break when I buy in bulk.” “There’s no expiration date, therefore the chemical is still good.” This is just a flavor of the week initiative and if I ignore it, it will go away.” “I don’t have (you pick) a) time b) money c) resources d) any possible combination of the first three.

19. The Abyss Avoiding the Five Deadly Myths Make it voluntary Use sensible parameters-visual Make it competitive Establish a baseline Report progress often Be prepared to de-bunk the myths Reward success

21. Meeting with the Goddess

22. Lean Manufacturing Tools 6 S Events Sort Straighten Shine Standardize Safety Sustain

24. Lean Manufacturing Tools Kanban Kanban is a lean manufacturing term for inventory control This method utilized at Sandia uses taped-off and labeled storage areas for each item and cards for re- order It is a simple system to allow the user to easily see when new chemicals need to be ordered and when there is an excess

27. Treasure 23% reduction Eliminated over 5,000 containers of old chemicals

29. Master of Two Worlds Get management commitment if you can True cost of chemicals is a great driver but so is friendly competition Most rational lab owners see the value of a clean, well organized lab with well- controlled chemicals Expect resistance

30. The Moral of the Story No chemical inventory reduction targets in 2008 In 2007: 7739 containers over five years old Now: 7409 Time works against us Need more aggressive prevention measures Another effort in 2009

31. Sources Campbell, Joseph. The Hero with a Thousand Faces. Princeton: Princeton University Press, 1949.The Hero with a Thousand Faces Princeton University Press Jewett, Robert and John Shelton Lawrence (1977) The American Monomyth. New York: Doubleday. Questions Kristin Klossner Clover Leaf Environmental Solutions kklossner@cloversolutions.us 505-844-9204