1. Developing a Workforce for the Green Economy Advancing Manufacturing Summit VIII: The Economic and Environmental Benefits of Sustainable Manufacturing Wednesday March 25, 2009 Purdue University – West Lafayette, Indiana Copyright 2009 Purdue Research Foundation

2. Agenda Background on development of Green Workforce Certificate program Program structure  Generalist  Specialist  Champion level certificate from SME Current and Future Activities Copyright 2009 Purdue Research Foundation

3. Background Developed as part of Purdue TAP participation in the NorthCentral Indiana WIRED program Workforce Innovation in Regional Development (WIRED) is a workforce training program initiated by US Department of Labor (DOL) in 2006 Other TAP programs: Industrial Energy Efficiency Practitioner, Nano-structured coatings, Healthy Workforce, and Business Innovation Copyright 2009 Purdue Research Foundation

4. Genesis of an Idea Worker skills hierarchy  Awareness through Implementation TAP MEP Lean Practitioner program  Embedding Lean Manufacturing through Kaizen Industrial Energy Efficiency Practitioner worker certificate program (IEEP)  Train workers to identify & quantify opportunities; implement and verify solutions  Leveraged US DOE ITP programs  Started August 2007, Wrapping up June 2009  Currently available statewide Copyright 2009 Purdue Research Foundation

5. Best Practices: Energy Efficiency Industrial Energy Efficiency Practitioner worker certificate program  Train workers to identify & quantify opportunities; implement and verify solutions  Leveraged US DOE ITP trainers & curriculum  Started August 2007, Wrapping up June 2009  Currently available statewide  Certificate from Purdue TAP  Embed practices in facility teams Copyright 2009 Purdue Research Foundation

6. IEEP Results 111 workers trained 22 companies engaged After only 9 months: 8 companies reported savings of $1.26 million and; Average energy intensity reduction of 8.5% Copyright 2009 Purdue Research Foundation

7. Green Program Development Started January 2008 Developed Body of Knowledge Developed overview materials Delivered pilots to gauge interest in subject  Interest in general information for everyone  And specialized information for champions Signed Agreement with SME Copyright 2009 Purdue Research Foundation

8. Green Initiative Program Structure Green Worker Generalist Training (Green 101)  Audience: General Workforce  Duration: 1 days  Approach: Training with Hands-on Simulation Waste Stream Mapping (WSM)  Audience: General Workforce, Green Project Teams  Duration: 2 days (Day 1 - Current State / Day 2 – Future State)  Approach: Training with Hands-on WSM Development Green Worker Specialist Certificate Series  Audience: Plant Engineers, Environmental Managers, Green Team Participants, etc.  Time: 1 day per module (6 modules)  Approach: Training with Hands-on Simulation or On-site Activity Green Worker Champion Certificate Preparation  Time: 3 days  Approach: Training only for Certificate Exam with Accreditation  through Society of Manufacturing Engineers (SME) Copyright 2009 Purdue Research Foundation

9. Green 101 - Course Agenda What is “Green”? Sustainability and Global Conditions Solid Waste Generation / Material Use Energy Management Hazard Waste Generation / Green Chemistry Climate / Air Emissions Wastewater Discharge / Water Use Environmental Management Implementation Action Plan Copyright 2009 Purdue Research Foundation

10. Green 101 Outcomes Convey key concepts Provide true “take- home” lessons Make the connection with the business case for sustainability Foundation for further engagement Generalist Certificate Copyright 2009 Purdue Research Foundation

11. G101: Waste Hierarchy – 4Rs Most desirable Least desirable Waste Hierarchy Copyright 2009 Purdue Research Foundation

12. G101: Business & Environmental Benefits Business Benefits: Produces more efficient operations and reduces costs. Enhances public image - saving energy and natural resources by reducing waste. Increasing employee morale - incorporating environmentally sound practices. Mitigates risk for employee health and safety. Environmental Benefits: Slows the depletion of natural resources. Reduces pollution. Conserves valuable landfill space. Reduces risk of noncompliance to regulatory obligations. Copyright 2009 Purdue Research Foundation

13. G101: The Green Approach Minimize the potential negative environmental impacts of your business and use all of your resources as efficiently as possible. Waste minimization means "systematically reducing waste at source".  Prevention and/or reduction of waste generated;  Efficient use of raw materials and packaging;  Efficient use of fuel, electricity and water;  Improving the quality of waste generated to facilitate recycling and/or reduce hazard;  Encouraging the 4Rs thought process throughout the business. Copyright 2009 Purdue Research Foundation

14. G101: Activity Example Implementation Action Plan Team up with 1 or 2 others. Identify at least 1 idea from the concepts we’ve discussed that you can implement right away. Use the Environmental Waste Reduction Plan form in the Appendix to document this idea. Complete the data requested as best as you can – make an educated guess if you don’t have exact information and complete in more detail later. Copyright 2009 Purdue Research Foundation

15. Waste Stream Mapping (WSM) Mapping tool for Energy & Green projects  IEEP worker cert. program  NIST/US EPA Green Supplier Network (GSN) program  Green Workforce program Evaluate multiple environmental waste streams Integrates root cause analysis & problem solving tools Copyright 2009 Purdue Research Foundation

16. Waste Stream Mapping Course Agenda Resource & Waste Management Environmental Waste Streams Seeing the Waste What / How to Improve Considering Alternatives Implementation Action Plan Course Evaluation Copyright 2009 Purdue Research Foundation

17. Waste Stream Mapping Approach Understand how things currently operate. Identify areas where there is waste. Quantify waste and determine source(s). Design a Green flow by applying the 4Rs to the resources/waste. Determine the Waste Stream(s) to be improved. Make the changes - this is the goal of mapping! Screen the improvement options and develop a detailed implementation plan to support improvement objectives (what, who, when). Waste Stream Scope Current Waste Flow Entire Process/ Detailed Operations Implementation Plan Implementation of Improved Plan Identify Improvement Areas Standardize for later improvement Copyright 2009 Purdue Research Foundation

18. WSM: Current State Process Inputs Raw Materials Energy Water Chemicals Outputs Products Useful By-products Wastes Air EmissionsOff-spec Products EffluentsBy-products Solid WasteHazardous Materials Heat LossesEnergy Inefficiencies Copyright 2009 Purdue Research Foundation

19. WSM: Getting to the Future State Apply the 4Rs to each Waste Stream. Copyright 2009 Purdue Research Foundation

20. WSM: Getting to the Future State What would be needed for an environmentally- preferred future state with: Zero environmental and production wastes? Products and processes that pose no risks to human health or the environment? No need for environmental permits? Copyright 2009 Purdue Research Foundation

21. Specialist & Champion Modules Specialist – ( six 1-day modules)  Material Use & Solid Waste Management “Dumpster Dive”  Environmental Business Management  Energy Management  Supply Water & Waste Water  Climate Change & Air Emissions  Green Chemistry & Chemical Wastes Champion  SME outcome based assessment/exam Copyright 2009 Purdue Research Foundation

22. Material Use/Solid Waste 1-day Course Outline Solid Waste Streams Managing Solid Waste Waste Sort (Dumpster Dive) 4Rs – Refuse, Reduce, Reuse, Recycle Considering the Entire Lifecycle Putting Waste Minimization in Practice Sustaining the Improvements Course Evaluation Copyright 2009 Purdue Research Foundation

23. Sorting by Material Category Paper Metal Glass Plastic Other X ? Mixed Materials Copyright 2009 Purdue Research Foundation

24. Moving UP the Waste Hierarchy Recycle Reuse ReduceRefuse  Goal is to move as many items from the waste stream to the next level or higher.  Must consider costs and feasibility to justify the change. Copyright 2009 Purdue Research Foundation

25. Environmental Business Mgmt. 1-day Course Outline Sustainable Consumption and Production Green Business Components Standard, Regulations, Permitting Justifying a Green Investment Environmental Footprint Drive for Innovation Course Evaluation Copyright 2009 Purdue Research Foundation

26. Environmental Management Success  Cross-functional cooperation for environmental improvements.  Environmental compliance and auditing programs.  Cooperation with suppliers for environmental objectives.  Cooperation with customer for eco-design, clean production and green packaging. Copyright 2009 Purdue Research Foundation

27. Environmental Metrics Energy Used Air Emissions Materials Use Hazardous Waste Generation Chemical Use Solid Waste Generation Water Use Wastewater Discharges Copyright 2009 Purdue Research Foundation

28. Energy Management 1-day Course Outline Non-Renewable Energy Sources Renewable Energy Sources Major Energy Systems 4Rs – Refuse, Reduce, Reuse, Recycle/Recover Energy Audits Measuring & Managing Energy Use Course Evaluation Copyright 2009 Purdue Research Foundation

29. Primary Energy Sources Traditional Sources (Non-Renewable)  Coal  Petroleum  Natural Gas  Uranium Alternative Technology (Renewable)  Wind Energy  Solar Power  Biomass  Geothermal  Hydropower Copyright 2009 Purdue Research Foundation

30. Renewable Energy - Biomass Copyright 2009 Purdue Research Foundation

31. Supply Water/Wastewater 1-day Course Outline Water Cycle Supply Water Resources & Conservation Water Pollution Prevention, Reduction & Treatment (4Rs) Water Sampling Measuring & Managing Supply Water Use/Wastewater Course Evaluation Copyright 2009 Purdue Research Foundation

32. Freshwater is a Finite Resource Copyright 2009 Purdue Research Foundation

33. Non-Point Source Water Pollution Leading cause of water pollution in the U.S. today. The pollutants include:  Excess fertilizers, herbicides, insecticides, and animal wastes from agricultural lands and residential areas.  Oil, grease, and toxic chemicals from urban runoff and energy production.  Forestry activities including tree and vegetation removal and road construction. Copyright 2009 Purdue Research Foundation

34. Climate/Air Emissions 1-day Course Outline Air Contaminants Industrial Hygiene Air Pollution Prevention, Reduction & Treatment (4Rs) Noise Pollution Air Sampling Measuring & Managing Emissions Course Evaluation Copyright 2009 Purdue Research Foundation

35. Gas Phase Contaminants  Gas  Vapor Aerosol Contaminants  Dust  Fume  Mist  Smog  Smoke Air Contaminants Copyright 2009 Purdue Research Foundation

36. Air Quality Index Levels of Health Concern Numerical Value Meaning Good0 – 50 Air quality is considered satisfactory, and air pollution poses little or no risk. Moderate51 – 100 Air quality is acceptable; however, for some pollutants there may be a moderate health concern for a very small number of people who are unusually sensitive to air pollution. Unhealthy for Sensitive Groups101 – 150 Members of sensitive groups may experience health effects. The general public is not likely to be affected. Unhealthy151 – 200 Everyone may begin to experience health effects; members of sensitive groups may experience more serious health effects. Very Unhealthy201 – 300 Health alert: everyone may experience more serious health effects. Hazardous> 300 Health warnings of emergency conditions. The entire population is more likely to be affected. Copyright 2009 Purdue Research Foundation

37. Green Chemistry/Chemical Waste 1-day Course Outline Principles of Green Chemistry Auxiliary Substances Process Reengineering 4Rs – Refuse, Reduce, Reuse, Recycle/Recover Environmental Hazard Prevention/Reduction Measuring & Managing Chemical Use/Waste Course Evaluation Copyright 2009 Purdue Research Foundation

38. Green Chemistry Philosophy Design products and processes that reduce or eliminate use and generation of hazardous substances. Design processes to maximize the amount of raw material that ends up in the product; Use safe, environment-benign substances whenever possible; Design energy-efficient processes; Utilize the best form of waste disposal -- do not create waste in the first place! Copyright 2009 Purdue Research Foundation

39. Re-engineering Processes Switch from batch reactions to continuous processing, e.g., replace baths with showers. Continuous processing is safer and typically gives a higher purity product. Prepare chemicals on demand rather than storing. Copyright 2009 Purdue Research Foundation

40. Partnership with SME National accreditation  Independent verification of body of knowledge  Outcome based assessment Joint promotion Administration of exam Foundation for future work Copyright 2009 Purdue Research Foundation

41. Certificate vs. Certification Certificate:  Assessment independent of course participation  Not designed to evaluate accomplishments  Educator not sole provider of required body of knowledge Certification:  Requires a field of practitioners sufficient to sustain credentialing program  Exam disconnected from curriculum and administered by third party Copyright 2009 Purdue Research Foundation

42. Timeline Generalist – available today WSM – available today Specialist  Training on-going within NCI WIRED region  All modules to be completed by 8/1/09 Champion  SME to complete work 12/2009  First exams before February 2010 Copyright 2009 Purdue Research Foundation

43. Purdue TAP Sustainability Portfolio Industrial Energy Efficiency Practitioner worker certificate program Green Workforce  Generalist  Specialist  Champion Waste Stream Mapping Energy & environmental surveys, assessments, and kaizen events Copyright 2009 Purdue Research Foundation

44. Contribution From:  Dr. Rodney G. Handy Associate Professor, Purdue University Ph.D. Environmental Engineering Certified Industrial Hygienist  Dr. Loring Nies Associate Professor, Purdue University Ph.D. Environmental Engineering  Dr. Michael Whitt Engineering Chair, Miami Dade College Ph.D. Biomedical Engineering Copyright 2009 Purdue Research Foundation

45. Future Events WIRED program  G101 - Kokomo March 31 st  Solid Waste - Kokomo April 2 nd Statewide Program  G101 - Evansville May 5 th (tentative)  G101 – Indianapolis May 19 th (tentative) Thank You! Ethan Rogers earogers@purdue.edu (317) 275-6817 Copyright 2009 Purdue Research Foundation