Kodak Field Trip Summary
How to Save Energy, Water and $$$ with ISO 14001
The field trip started with a nice lunch provided by Kodak and a presentation by George Thomas (to contact him click here), our host and the manager of the Environmental, Health and Safety Management system (EHMS) at Kodak Park. In his presentation he introduced the Kodak corporate EHMS and described how, through the implementation of the management system, ownership of environmental issues had spread throughout the company. This presentation is available online click here. He showed how corporate goals had been put in place and were taken seriously by each of Kodak’s divisions. Of particular interest to us during this field trip, were the energy and water goals in 1997, Kodak Park committed to a 15% reduction in both energy use and water use. Kodak Park was certified to ISO 14001, the international environmental management standard in 1999 and was recently re-certified in December 2002.
The tour of the paper mill was introduced by Russ Williams, the paper mill manager. He impressed us with some serious statistics, for example, roughly half of Kodak’s photographic paper was made at this paper mill and enough paper to make the equivalent of 5 million consumer prints are made per hour! In terms of environmental management, the requirements of ISO 14001 are managed within the mill’s strategic framework consisting of key result areas, measures and programs. Both the energy conservation and water conservation programs were conducted as Six Sigma projects a well known business management tool, which prescribes an approach that applies sophisticated quality tools to projects and problem solving.
The RGBN group was then shown around the paper mill to view how pulp, imported from Canada, is made into huge rolls of photographic paper ready for coating.
Gretchen Gilmore described to us her approach to the energy conservation project which comprised the following steps: collating baseline energy data, mapping the process, gathering data, analyzing data, benchmarking with industry best practices, generating a list of opportunities and implementing projects with a positive business case. This presentation is available online click here. A key finding for electricity savings was a hierarchy of opportunities (potential savings and costs increase downwards through the hierarchy):
- turn it off or reduce usage
- use high efficiency motors
- use high efficiency processes
- design more efficient manufacturing processes
In terms of achievements in energy conservation, production weighted reductions were 5.6% in steam use 8.5% in electricity use. This equated to savings equivalent to over $300,000 from 2001 to 2002. Projects planned for 2003/4 should further decrease electricity and steam use.
Marty Pinto then described his Green Belt project which had a goal of 10% savings in water use. The same Six Sigma approach was used to approach the project and the key findings were as follows:
- tracking data more frequently aids understanding
- look for leaks during plant shutdown periods
- operator practices causing wastage e.g. unattended hoses left on need to increase operator awareness by training and signage.
The achievements of this project significantly surpassed the goal and totaled an 18% reduction in water use, with an equivalent savings of $300,000.
As a final note, it was acknowledged that without the corporate goals, these projects would probably not have been implemented - the cost savings and associated environmental benefits would not have been realized. This illustrates the real benefits -environmental and costs, associated with a well-implemented environmental management system.
If you are interested in finding out more details about the water and energy saving programs, please contact George Thomas who will put you in touch with the right person at Kodak.
Kodak, through George Thomas, has expressed an interest in mentoring smaller companies on environmental management it could be in terms of ISO 14001, energy or water conservation, or any other related subject. If you are interested in taking up this offer, please contact the RGBN.
Many Thanks to Kodak
RGBN in conjunction with the Center for Environmental Information would like to thank Kodak Park and all the Kodak staff involved in making the field trip a success. We very much appreciated the opportunity to visit and are grateful that so much information was shared.