
Q1.
What is a Waste Minimisation Circle (WMC) ?
Q2.
What is the objective of the Waste Minimisation Circle project ?
Q3.
How is the objective planned to be achieved?
Q4.
What are the features of a Waste Minimisation Circle ?
Q5.
How do you compare Quality Circles with WMC's ?
Q6.
What is the structure of the WMC project ?
Q7.
What is the role of the WMC project participants ?
Q8.
Who can be a WMC facilitator ?
Q9.
Who can establish Waste Minimisation Circles ?
Q10.
Who will fund the establishment and running of WMC's ?
Q11.
What will be the funding pattern for facilitators ?
Q12.
What will the facilitators gain out of this project ?
Q13.
Why Waste Minimisation (WM) - Need & Benefits ?
Q14.
Why WMC ?
Q15.
Pre-requisites for adopting WM ?
Q16.
What methodology one needs to adopt for implementing WM ?
Q17.
Why one needs to follow a structured Methodology ?
Q18.
What are the techniques for WM ?
Q19.
What barriers are generally encountered in implementing WM
techniques ?
Q20.
What measures one can adopt for overcoming the barriers ?
Q21.
Examples of WM potential in select Industrial sectors.
Q22.
Potential Industrial sectors that one can consider for formation
of WMC's.
Q23. Is
the concept tried any where so far ?
Q24.
If yes where and in which sectors ?
Q25.
What are the results achieved so far ?
Q26.
What are the major options implemented in each sector ?
Q27.
Where can one find related sources of information on WM ?
Q28.
How WMC's function?
Q29.
What will WMC member units gain by Participating in establishing
and running a circle?
Q30.
What interest NPC have in helping establish WMC's
Q31.
What interest MoEF have in funding WMC's
33.
How WMC's function ?
34.
What will WMC member units gain by Participating in WMC project ?
35.
What interest NPC has in executing the WMC project ?
36.
What interest MoEF has in sponsoring WMC project ?
37.
Why NPC is chosen as the nodal agency for implementing WMC
Project?
38. DO'S
AND DONTS FOR WMC MEMBERS
1.
What is a Waste Minimisation Circle (WMC) ?
Waste
Minimisation Circle is conceptualized on the lines of Quality
Circles (QC's) with the difference that in QC's the group is from
within the Industry where as WMC's are intended to be among the
industries. A Waste Minimisation Circle thus can be defined as
"A small group of entrepreneurs in the small scale sector
whose units manufacture similar products and employ the same
processes meeting periodically and regularly in the premises of each
member unit one after another, to analyse the operation of the host
unit to identity sources of waste generation and implement WM
options leading to an increase in individual profitability and
reduction in pollution load from the units."
2.
What is the objective of the Waste Minimisation Circle (WMC) project
?
To realize benefits of Waste Minimisation Concept
and achieve conservation of resources and environmental improvement
by way of adoption of group efforts at industrial cluster level.
3.
How is the objective planned to be achieved?
1 By
building capacity on 'Waste Minimisation Assessment' applications
through training of WMC Facilitators
2 By creating
awareness and disseminating information on Waste Minimisation to
Small and Medium Enterprises
3 By providing a structured
methodology for systematic application of Waste Minimisation
concept.
4 By creating a platform for discussions and for
sharing experiences, views, knowledge and innovations in
implementation of WM Techniques
5 By enabling dissemination
of information through WMC News letter
4.
How do you compare Quality Circles (QC's) with WMC's ?
| QUALITY
CIRCLES |
WASTE
MINIMISATION CIRCLES |
Developing
innovative IDEAS and applying to the industrial processes for
improving quality and ensuring better ergonomics in the work
environment |
Developing
innovative IDEAS towards identifying Waste Minimisation Options
and implementing WM Solutions for achieving economic and
environmental benefits through collective efforts |
Scenario
: - Within a given industry and applied on Shop floor level
- Employees who carry out tasks / operations in a section of the
industry in same familiar surroundings
- Ideas are
generated by brainstorming, each employee contributing his
knowledge, experience and creativity to evolve solutions
-
Commitment of the employees |
Scenario
: - Among group of Small and Medium Scale units ( 5-6 Nos )
at Cluster of industries level involving units with similar
processes and products - Entrepreneurs / WM Teams focussing
on varying versions of similar enterprises (i.e. member units)
-
Ideas are generated by participants observing unique features in
member units and developing innovative ideas by brainstorming /
cross fertilisation of experiences gained
- Commitment
of the Member Units |
5.
What is the structure of the WMC project ?
INCOMPLTE
6.
What is the role of the WMC project participants ?
The
World Bank |
·
Funding of the Project |
MoEF |
·
Project Sponsoring and Providing Guidelines |
Project
Monitoring Committee |
·
Project Monitoring / Evaluation and providing guidance. |
NPC |
·
Project Implementation as Nodal Agency |
WMC
Facilitators |
·
Establishment and Running of WMC's. |
WMC
Member Units |
·
Voluntary participation and cooperation in applying WM concept
and generation and implementation of WM Options - Beneficiaries
of the project |
7.
Who can be a WMC Facilitator ?
Institutions (E.g:
Sectoral / Research institutions / Scientific bodies), Public /
Private Environmental / Management Consultancy Organisations,
Industrial Associations etc., who can offer initiative and a high
degree of result oriented efforts to the project and who fulfil the
criteria mentioned below can become a WMC Facilitator organisation.
Criteria
for Organisations wishing to become WMC Facilitators :
| S
No |
Criteria |
Weightage (Percentage) |
| 1. |
Type of
Organisation (Research /Academic / Consultancy) |
10 |
| 2. |
Management's
Commitment |
15 |
| 3. |
Experience
in Environmental Issues |
15 |
| 4. |
Linkages
with Industry and Industrial Associations |
15 |
| 5. |
Available
Manpower and their Qualification |
10 |
| 6. |
Area of
Expertise |
10 |
| 7. |
Available
infrastructure |
15 |
Criteria for
Individuals wishing to become WMC Facilitators :
| S
No |
Criteria |
Weightage (Percentage) |
| 1. |
Industrial
Experience |
15 |
| 2. |
Experience
in Environment related field |
15 |
| 3. |
Nature of
job (Consultancy / Academic) |
10 |
| 4. |
Available
infrastructure |
15 |
| 5. |
Leadership
and Managerial capability |
10 |
| 6. |
Communication
Skills |
10 |
| 7. |
Level of
Commitment |
10 |
8.
Who can be members of a Waste Minimisation Circle ? -
Small and Medium Scale Enterprises - Industries falling under
Environmentally critical industrial sector - Industries willing
to share information and participate actively in group efforts
towards evolving innovative ideas and solutions to effect Waste
Minimisation in participating member units within their WMC -
Industries keen on achieving economic and environmental benefits
11.
What will the WMC Facilitators gain out of this project ? REMUNERATION
: Budget for Establishing and successfully facilitating one WMC
: - Professional Charges = Rs 1,15,000=00 - Variable
Expenses* = Rs 57,500=00 - Total per WMC = Rs. 1,72,500=00
(*Variable
Expenses : Organising Workshops / Meetings, Travel, Documentation
etc.). INTANGIBLE BENEFITS: ·
Receiving Training on WM Assessment Methodology / Techniques ·
Introduction to a large variety of case studies ·
Developing professional Linkages with National and International
Agencies · Strengthening relations with Industries /
Industry Associations · Gaining insights on existing
industrial processes and applications of best practices ·
Experience in Environmental Auditing and Benchmarking ·
Opening up new market opportunities in consultancy services.
12.
Why Waste Minimisation (WM) - Need & Benefits ? Need To -
Conserve Resources (Energy / Water / Raw Materials etc.) -
Control Pollution (Controlling contamination of Land / Water
Resources / Ambient Air etc.) - Improve Occupational Health and
Safety -Match Export Market Requirements
Benefits -
Improving productivity and increasing profits - Improving
Quality of Products - Towards Compliance with emission norms /
regulatory requirements - Reducing Costs on Effluent Treatment /
Pollution Control - Improving Work Environment / Better
Ergonomics - Enhancing Public Image of the Enterprise -
Makes Good Business Sense
13
Why WMC approach ? The WMC approach in
promoting Waste Minimisation in SMEs is appropriate and sound
because of the factors listed below.
·
Adoption, acceptance and implementation of WM Options (WMOs) can be
ensured when WMOs are identified by entrepreneurs · To
cover the length and breadth of the country relying on consultants
located at different places is a logical approach · WMC can
generate a spirit of co-operation among its members even beyond WM ·
Members of WMCs after achieving success could generate the desired
multiplier effect · The WMC approach focusing on self help
catalysed by the facilitator is a movement independent of regulatory
pressures
15
Pre-requisites for adopting WM ? - Willingness
- Commitment - Open mind - Team Work -
Structured Methodology
16.
What are the techniques for WM ? Ø
Source Reduction ¨ Good housekeeping ¨
Technology-change ¨ Raw-material quality control ¨
Better process control ¨ Equipment modification etc.
Ø
Waste Utilization - Recycling - Recovery -
Reuse.
DIAGRAM
17.
What barriers are generally encountered in implementing WM
Techniques ? What measures one can adopt for overcoming the barriers
?
| SPECIFIC
BARRIER |
MEASURES
TO OVERCOME |
| POLICY
BARRIERS |
Reservation
policy and protectionism for SME's resulting in adaptation of
unproductive industrial processes
Taxation
Policy which have limited the initiative for growth / expansion
of capacities in SME's
Regime of Prescriptive
Technologies for decades and consequent non-introduction of
timely corrective measures resulting in propagation of obsolete
technology (Khandsari) |
Opening
up of the Economy and Encouraging Competitive Forces
Introduction
to Advanced Technologies and Best Practices
A regime of
uniform Taxation Policy which encourages investment for
expansion / modernisation of SMEs
Non prescriptive
technologies that allow SME's scope for identifying and
selecting technologies best suited for their manufacturing
processes |
| ECONOMIC
BARRIERS |
Inappropriate
Resource accounting resulting in excess consumption of Water /
Electricity causing wastage and losses
Feeling that WM
costs money, additional resources in terms of Raw material &
Energy, investment in new machinery etc.
Low returns on
investment from implementing WM measures.
Realising
profitable margins and acceptable return on investments for
decades by SMEs while focusing on maximising production despite
low productivity and poor quality of goods while catering to
large domestic demand for manufactured goods
Notion of
steady / increasing demand for the manufactured goods in the
country with a steady rate of increasing population |
In
evaluating Economic viability of industrial Enterprises
inclusion of full and true cost of following issues must be
undertaken :
- Resources consumed - Pollution
caused - Waste generated - Potential future liabilities
introduced etc.
SME's
should undertake value addition measures through innovations and
enhancing product quality (by applying concepts like Quality
Circles / Kaizen / 5S etc.) for matching higher consumer
expectations and realising higher profitability
Improving
competitiveness through improving productivity in a shrinking
market |
| TECHNICAL
BARRIERS |
¨
Limited access to technical information. ¨ Limited
availability of trained manpower ¨ Limited
availability of technical experts. ¨ Lack of adequate
external infrastructural facilities ¨ Limited in-house
maintenance facilities ¨ Lack of documentatio -
systematic records ¨ Limitations posed by existing
technology. |
Improving
access to technical information through SISI's, Industry
associations, Cleaner Production Clearing Houses, Waste
Minimisation related Literature / Newsletters / Websites etc.
Improving Operator / Supervisor Training
Establishments and introducing Wast Minimisation concepts in the
curriculum. Encouraging Entrepreneurs to provide periodic
training / retraining to employees for higher efficiencies in
their units.
Building Capacity through training
technical personnel (in different parts of the country) in
respect of applications of Waste Minimisation Concept example
developing WMC Facilitators
Development of suitable
infrastructure facilities in industrial estates / zones.
Encouraging
entrepreneurs to equip themselves or in partnership with
suitable maintenance / monitoring / testing facilities
Create
facilities (finance / consultancy etc.) for technology
upgradation / revamping and re-engineering of enterprises |
| REGULATORY
BARRIERS |
Emphasis
on End-of-Pipe Treatment for deducing environmental compliance |
Emphasis
on Waste Minimisation efforts to be undertaken by industry as
part of Regulatory approach |
| ATTITUDINAL
/ CULTURAL BARRIERS |
Resistance
to change and friction among elements with in a company may
introduce barriers like - Lack of managerial commitment -
Poor internal communication - Restrictive employment
practices - Lack of effective supervision.
Concerns
about changes to product quality and customer acceptance
|
-Education
and training programmes with managerial improvements. -Encourage
employees at all levels to provide valuable information about
operational problems and insights into possible solutions Introducing
incentive schemes
Company should take steps to identify
customer needs. Increase quality control in manufacture |
| Mental
Blocks: |
Fear
of disturbing tradition Fear of criticism Fear of making
mistakes ( being considered a guinea pig)
Fear of
making solitary effort (Not me first syndrome) Fear of
losing trade secrets Fear of being exposed for inadequacies
in existing processes etc.
|
Showing
modern units to break traditional mind set, helping conduct
trials with assistance from suppliers, training to enhance risk
taking ability. |
Myths Good
only for multinationals Needs highly qualified personnel. Requires
latest technology Total automation a must Requires high
capital investment It's a one time activity Has limited
potential
Idea Killers Let's
think about it later We have already tried it This is
not the right time You don't understand the problem Talk
to John - This is not my field It sounds nice in theory but
will not work in practice We are too small /big for it. Has
it been tried elsewhere. It doesn't fit into our planning
Over
all production cost increases - Raw material costs -
Production rate decreases - New equipment is required |
|
Company and employees need
to be alert to information from - Government bodies - trade
associations - Professional institutions -Consultants
Literature
Idea
Killers 1) Workers ·
Nothing is Possible · Inadequate facilities · Lack
of knowledge · Boss is always right/does not listen ·
Outdated technology · Why should I do it/what do I gain ·
Fear of job insecurity
2) Management barriers
·
Lack of finances and investment · Resistance to change ·
Adverse effects on quality · Space constraints/lack of
infrastructure · Availability of cheap labor ·
Lack of adequate information
3) Consultants
Barriers
· Resistance to change ·
Convince about the viability of P2 · Not me first syndrome ·
Lack of funds · Lack of authentic data
4)
Environmentalist NGO Barriers
· Lack of
Awareness of people/Society · Lack of support from industry ·
Lack of support from government/opposition ·
Non-availability of funds · Apprehension of Job loss ·
Loss of income for people dependent on waste · Lack of
technical knowledge, technical support
18.
Examples of WM potential in select Industrial sectors. DYE
AND DYE INTERMEDIATE:
| AREA. |
UNIT |
POTENTIAL
OF CLEANER PRODUCTION |
|
|
Quantity
|
Value
(Rs) |
| Yield
improvement |
% |
10-25 |
15000-40000 |
| By-product
recovery |
Kg/T |
125-200
|
8000-20000 |
| Steam
conservation |
Kg/T
|
200-500
|
200-500 |
| Energy
conservation |
KWH/T
|
100-300
|
250-750 |
| Water
conservation |
m3/T |
20-50 |
20-50 |
|
TOTAL |
|
|
23470-61300 |
ELECTROPLATING
| AREA |
POTENTIAL
OF CLEANER PRODUCTION Quantity Value (Rs/month) |
| Pretreatment |
| Chemicals |
200-1000
Kg/month |
500-2500 |
| Rinse
water |
30-300
m3/month |
30-300 |
| Electroplating |
| Chemicals
Kg/month |
20-200
|
2000-20000 |
| Rinse
water |
60-500
m3/month |
60-500 |
| Post-treatment |
| Chemicals
|
10-40
Kg/month |
300-1200 |
| Wastewater
treatment |
| Chemicals
|
1000-5000
Kg/month |
8000-25000 |
| Energy
|
1000-5000
KWH/month |
2000-10000 |
|
|
|
| TOTAL
|
|
12890-59000
|
PULP
& PAPER
| Area
|
Unit |
General
performance/ consumption range |
WM
potential |
|
|
|
Quantity |
Value
(Rs/T) |
| Fibre
|
%
Yield |
40-44
|
40-100 |
250-600 |
| Caustic
|
Kg/t
|
60-120 |
10-15 |
100-150
|
| Additives
|
Kg/t
|
11-15 |
1-2 |
5-10
|
| Steam
|
Kg/t
|
405-605
|
0.5-1.5
|
125-400
|
| Electrical
|
Kg/t
|
850-980
|
60-120
|
150-300
|
| Overall
saving capacity |
Kg/t
|
5-20
|
75-300
|
75-300
|
| Water
consumption |
M3/t |
180-280
|
60-120
|
25-50
|
|
|
|
Total
|
730-1800
|
TANNERY
| AREA |
POTENTIAL |
| UNHAIRING
AND LIMING |
| Recycling
lime sulphide liquor |
·
20-50% sulphide reduction · 60% lime reduction |
| CHROME
TANNING |
| Recycling
chrome tannage |
10-20%
chrome savig |
| Chrome
precipitation & recovery |
98% chrome
recovery |
| FINISHING |
| Direct
contact applications |
20-30%
reduction in chemical consumption |
| Non-solvent
finishing |
100%
solvent reduction |
| Yield
improvement |
2-5% |
HOSIERY
PROCESSING UNITS
| ITEM |
UNIT |
POTENTIAL
FOR CLEANER PRODUCTIONt |
|
|
QUANTITY
|
VALUE (In
Rupees) |
| Production
|
% increase
|
20-30
|
350-500 |
| Chemical &
Dye stuffs |
Kg/T |
10.40%
|
1000-4000
|
| Water
|
m3/T
|
50-100
|
25-50 |
| Fuel/Coal
|
Kg/T
|
200-800 |
400-1600 |
| Energy
|
KWH/T
|
30-60
|
100-200 |
|
|
Potential
range : 2000-5000 Rs/Ton |
20.
Potential Industrial sectors that one can consider for formation of
WMC's.
21. Is the WMC
concept tried any where so far, if yes, where and in which sectors ?
Yes!
The
concept is tried in two phases. Phase-I is tried as an experimental
phase with 15 WMC's established in sectors in towns and cities
Having
achieved success in the first phase the second phase was initiated
with plan to establish 100 WMC's. Till now 45 No. of Waste
Minimisation Circles are established covering 180+ number of
industries in 29 cities and towns covering 23 industrial sectors.
The sectors and places where WMC's are established are given below:
| 1. |
Khandsari
- Bijnore, |
13. |
Pulp
& Paper - Muzaffarnagar, Chandigarh, Modi Nagar, Rajahmundry |
| 2. |
Refractories
- Muzaffarnagar |
14. |
Dye
and Dye Intermediates - Ahmedabad |
| 3. |
Foundry
and metal forging industries - Belgaum , Delhi |
15. |
Electroplating
- Ludhiana, Cuttack, |
| 4. |
Hotels
- Mumbai , Shimla, Bhopal |
16. |
Distillery
- Akluj |
| 5. |
Textiles
processing and printing ( Cotton, synthetics etc) - Ludhiana,
Tripur, Surat, Faridabad |
17 |
Dairy
- Calcutta |
| 6. |
Paints
- Vadodara |
18. |
Resins
- Vadodara |
| 7. |
Bulk
Drug - |
19. |
Marble
& Slurry - Udaipur |
| 8. |
Rice
Mills (Raw rice & Parboiled Rice) - Nizamabad |
20. |
Steel
Rolling Mills - Ahmedabad |
| 9. |
Pesticide
Formulation - Ahemdabad |
21. |
Printed
Circuit Board - Ahmedabad |
| 10. |
Lead
Acid Battery Manufacturing - Bangalore |
22. |
Edible
Oil - Virudhunagar, Chitradurga |
| 11. |
Ply
Board manufacturing - Dehradun |
23. |
Engineering
sector - Bhilai |
| 12. |
Utensils
manufacturing |
|
|
|
(Aluminium,
Brass and Stainless Steel) etc.- Jagadhri |
|
|
|
|
|
|
23.
What are the results achieved so far ?Together
the 45 WMC's generated 300+ Waste Minimisation Options(WMOs) out of
which 120+ options were implemented achieving an aggregate savings
of Rs.100 Lakhs/annum
Phase-I : In the
15 established WMC's in Phase no. of WM options and realising Rs
economic benefits and reducing pollution load by %.
Phase-II
26.
What are the issues/dilemmas faced by WMC Facilitators in
establishing a circle - Certificate of identity
as facilitator - Introductory letter as trained facilitators -
Members expect full technical solutions - Members expect support
in terms of clearance from Govt. agencies - Suspicion about
misuse of data - Non co-operation of members even after forming
WMC
27.
What are the barriers encountered by WMC facilitators in running a
Circle?
-"Not Me First" syndrome -Fear
of Competition -Fear of losing monopoly -Fear of misuse of
information -Fear of being exposed -Sceptical about benefits
of WMC
33.
How WMC's function ?
Planning for
Establishing WMC by WMC Facilitators and exploring potential for WM
and preparing Industrial / Cluster profile
Organising
Awareness Workshop and Training Programme for interested SMEs and
Establishing WMCs and forming WM Teams
| Technical Support / follow
up visits by NPC |
Conducting WMC Meetings,
Assessing Industrial Processes, Analysing Waste Streams, Cause
Analysis, Evolving WM Options, Analysing Options, Implementing
WM Solutions, Impact evaluation etc. |
Progress Assessment by NPC
(Nodal Agency) |
|
Identifying Multiplier
Effect, preparing Case Study, Submitting Final Report,
Conducting Final Workshop Sustaining WMC |
|
34.
What will WMC member units gain by Participating in WMC project ?
-Improved productivity and
increased profits - Improved Quality of Products -
Conservation of valuable Resources (Energy / Water / Raw Materials
etc.) - Progress towards achieving / complying with Emission
Norms for Pollution Control - Reduced Cost of Effluent Treatment
/ Pollution Control - Improved Occupational Health and Safety
standards - Match Export Market Requirements - Improved
Documentation / Record keeping / Accounting system - Developing
Benchmarks for comparison with industry leaders - Improved Work
Environment / Ergonomics - Enhanced Public Image of the
Enterprise
35.
What interest NPC has in executing the WMC project ?
36.
What interest MoEF has in sponsoring WMC project ?
Role
of NPC as implementing agency NPC is an appropriate
choice to implement WMC Project (because of factors mentioned below) ¨
NPC promotes productivity and WM is a subset of increasing
productivity ¨ NPC has a strong technical knowledge base
and expertise in various areas such as Pollution Prevention and
Control, Energy Conservation, Production process etc. ¨
Technical manpower available in the central and regional offices of
NPC ¨ Linkages NPC has with NCPC and through it with State
Cleaner Production Centres ¨ Trust existing between
Industry (SMEs) and NPC
38.
DO'S AND DONTS FOR WMC MEMBERS DO'S Free
and informal atmosphere should be maintained WMC members should
have harmony and respect for each other Experimentations/ trials
should be encouraged Credit should be given liberally WM
Methodology should be followed Be the principal listener Proper
documentation of activities should be done
DON'T'S Direct
financial assistance not to be expected Ready made technical
solutions should not be looked for Don't allow snubbing Don't
impose ideas on groups Don't demotivate be pointing mistakes
| The World
Bank |
· Funding
of the Project |
| MoEF |
· Project
Sponsoring and Providing Guidelines |
| Project
Monitoring Committee |
· Project
Monitoring / Evaluation and providing guidance. |
| NPC |
· Project
Implementation |
| NPC |
·
Identification of cluster of industries |
| NPC |
·
Identification of opinion leaders/resource persons |
| NPC |
·
Identification of sector specific technical experts |
| NPC/WMC
Facilitator |
·
Organising awareness workshop |
| WMC
Facilitator/WMC Member units |
·
Establishment and Running of WMCs Formation of circle from
interested units |
| WMC
Facilitators |
·
Organising training workshop |
| WMC
Facilitators |
·
Facilitating circle meetings |
| WMC Member
Units |
·
Participating in circle meetings & discussions, implementing
WM options |
|
Degradation of
Land / Water / Air The adoption of WM is needed to: 1.
Conserve chemical and auxiliary chemicals 2. Conserve water 3.
Conserve energy 4. Control pollution - - a considerable
portion of chemicals used appear in wastewater which if discharged
without treatment can cause grave damage to the environment. WM
helps to reduce treatment cost and some times eliminating the need
of treatment.
- Water conservation leads to reduced volume
of wastewater and reduced space and capital requirements for ETP.
5.
Enhance workers awareness regarding occupational health and safety.
6. Match Export market requirements: - Some of the
developed countries are restricting imports for reasons of using
toxic materials as input in producing the goods. The trend is
expected to rise with growing awareness. 7. Help build
industry's image in public : - Public awareness about issues of
environmental protection are growing and the risk of rejecting a
product on environmental grounds is increasing day by day. -
Affected communities due to pollution are increasingly taking the
role of watchdog.
|
|