Objects on which techniques are applied

The objects on which OGT are applied are divided into Input and Output categories.

Input indicates things put into the manufacturing or construction process, and Output, things other than products which are discharged during the manufacturing or construction process.

Input

Energy is the only element classified into Input. Unless energy is controlled on the input side, it can only be understood in terms of utilization of waste heat.
Thus, energy is considered as input. Other raw materials, supplementary materials, and water are included in the Output category because reduction on the amount used is related to reduction on the amount generated.

• Energy
  Energy input should be kept to minimum. Minimization of energy input leads to production efficiency and directly to more profits for the company. Therefore, corporations are involved actively in working on energy saving techniques. It also leads to the reduction of carbon dioxide discharged, thereby contributing to the preservation of the global environment. Lately ways of using waste heat effectively and reusing wastes products as fuel are being implemented.

Output

Output encompasses discharged matters other than manufactured goods. Therefore, the output should be kept to minimum. Output is classified into
categories listed below.

• Solid waste
  Solid waste is defined as waste matters which are solid and result during the manufacturing or construction process, such as defective goods, scraps from the manufactured goods, impurities in raw materials and supplementary materials (like slag generated from the manufacture of iron.) Wrapping materials are classified into a separate category in this survey because they are generated differently and have characteristics that are different from solid wastes.

• Wrapping materials
  Wrapping materials include protective cushioning materials, plastic containers, boxes and bags, strings, tapes, and cans which are used when transporting raw materials and supplementary materials as well as when shipping out the manufactured goods. Styrofoam has been used extensively as the protective cushioning material; however, the difficulty in disposing of it appropriately has been pointed out.
  Wrapping materials account for a high percentage of waste matter. This issue has been a serious concern since ever before, and in recent days reduction of wrapping materials has become a major issue on a global scale.

• Waste liquid (waste water, waste solution, waste oil) and sludge
  In this survey, liquids discharged during the manufacturing or construction process are termed as waste liquid, which include water used for washing and other waste waters, medical fluid and other waste solutions, and waste oils such as lubricants, cutting oil, and organic solvents. Sludge has a high water content, and contains a high level of organic matter and sometimes harmful materials. Thus, sludge has characteristics which are difficult to deal with.

• Exhaust gas and offensive odor
  Exhaust gases are defined as harmful materials generated during burning, heating, and warming done in the manufacturing process; gases including dust; gases resulting from chemical reaction; as well as volatile materials. Offensive odor connote gases and mist including odors which cause discomfort. These materials are often harmful to human health; therefore, every effort must be made to prevent them from occurring.

• Noise and vibration
  Noise and vibration mean uncomfortable sound and vibration generated as machines and equipment are operated on the manufacturing (construction) site and as vehicles pass nearby.

Strategy

Strategies on input energy are as follows:

1. Reduction of the amount of input energy used by implementing appropriate control and energy-saving measures (Control on usage)

2. Reuse of wastes generated in one step of the manufacturing process as fuel in another step of the process; Reuse of waste heat (Reuse)

Strategies on output are as follows:

1. Decrease in the incidence of stagnancy by improving the manufacturing process and equipment; reduction in the amount of raw materials and supplementary materials used in the manufacturing process (Control on generation)

2. Use of any discarded material as raw material to produce another product; reuse of any discarded material back in the manufacturing or construction process (Reuse)

3. Proper management of discharged matters to make sure that pollutants do not flow from the site. (Proper management)

Cases representative of the questionnaire survey results are listed below.

Input

• Energy
  [Control on usage]
  • Streamlining the operation of equipment to reduce the amount of input energy
  • Re-evaluating the operating hours and rotation of the equipment to reduce the total number of operating hours
  • Paying careful attention to the exhaust air to improve cooling and heating efficiency
  [Reuse]
  • Sludge dried by using exhaust gas

Output

• Solid wastes
  [Control on generation]
  • Review of raw material selection
  • Re-evaluation of the design in order to reduce the incidence of stagnancy
  [Reuse]
  • Thorough separation of wastes into groups to reuse some of them as raw materials.
  • Transferring waste generated by one company to another company for reuse as raw material
  • Use as fuel

• Wrapping materials
  [Control on generation]
  • Switch from throw-away containers (corrugated cardboard boxes, plastic bags)to containers and goods-delivery boxes
  • Packing container design which requires minimum amount of protective cushioning materials and tapes
  • Repeated use of protective cushioning materials
  [Reuse]
  • Collection of corrugated cardboard boxes and protective cushioning materials in separate groups
  [Proper management]
  • Reduction of volume and easier classification by material change

• Waste liquids and sludge
  [Control on generation]
  • Decrease in the amount of water used by circulating the washing water Adoption of waste water treatment which reduces the excessive amount of sludge
  • Thorough reuse of liquids which can be reused by circulation
  [Reuse]
  • Reuse of treated water
  • Reuse of sludge as cement aggregate
  • Reuse of waste oils as fuel
  [Proper management]
  • Implementation of checkup system when treated water is discharged

• Exhaust gas and offensive odor
  [Control on generation]
  • Dust collection near the source of generation
  [Reuse]
  • Collection and reuse of raw materials contained in the exhaust gas
  [Proper management]
  • Re-evaluation of ventilation system adopted in the working environment of employees

• Noise and vibration
  [Control on generation]
  • Insulation on the equipment against noise and vibration
  • Thorough maintenance and inspection

Action

Specific actions taken are classified into categories listed below.

[Development of equipment]
Required equipment was developed by the company.
• The equipment which removes iron from the sludge generated from the glass-grinding phase was designed. The iron-removed sludge is reused as raw material for manufacturing glass.

[Introduction of equipment]
The equipment developed by one company was introduced into other companies, as required.
• The equipment which separates scraps of vinyl-chloride covered pipes into vinyl chloride and iron, which were both reused.

[Improvement on equipment]
The existing equipment was revised with unique ideas to meet the requirement.
• Patro-light was connected on the switch for visual monitoring of the channel which is being used, in order to minimize misled operation.

[Improvement on process]
Improvement ideas are implemented such as thorough material management during the manufacturing process.
• Separation of discharged water into concentrated waste fluids and dilute circulated water
• Jet spraying of waste fluids in the incinerator

[Specification revision]
Design and materials were revised.
• Boxes which do not require protective cushioning materials and tapes

[Complete separation & classification]
Materials were completely separated at the phase when generated and allowable materials were returned into the manufacturing process.
• Waste oil was put through a centrifugal separating machine during the manufacturing process to remove foreign matters, and the resultant material was reused as fuel.

[Thorough inspection & management]
Machines and equipment were used properly.
• Machines were maintained and inspected thoroughly to reduce noise and vibration caused by insufficient maintenance.

List of Techniques

Questionnaires are organized according to three basic viewpoints as described above. The content of each technique is summarized on the charts.