Process Optimization of Advertising Articles Using an

Integrated Strategy of Production and Environmental

Care

Hernan Espejo Vinan1, Blanca Topon Visarrea1, Lloyd Herberth Morris Molina 2
and Ana Lucía Rodriguez Machado 3,
1
SISAu Research Group, Facultad de Ingeniería y Tecnologías de la Información y la
Comunicación, Universidad Tecnológica Indoamérica, Ambato, Ecuador
hernanespejo@uti.edu.ec; blancatopon@uti.edu.ec
2
Entre Ciencia e Ingeniería, Facultad de ciencias básicas e ingeniería, Universidad Católica
de Pereira, Colombia.
lloyd.morris@ucp.edu.co
3
Facultad de industrias agropecuarias y ciencias ambientales
Carrera de Alimentos, Universidad Politécnica Estatal del Carchi, Ecuador.
ana.rodriguez@upec.edu.ec

Abstract. Global pollution has brought together several countries over time in
order to reduce global warming by about 1.5°C, as the productive sector is one
of the main causes, It is suggested to use the model proposed by UNEP and
UNIDO for Cleaner Production (C+P), aiming at reducing raw material con-
sumption and waste reduction; analysis on production processes is started to
obtain data on the use and waste generation, using descriptive statistics and Pa-
reto analysis in the 2019 processes, the main causes are identified through the
6Ms of Ishikawa, so it is concluded that 2 raw materials are responsible for
more than 88% of waste, thereafter, it is identified that the highest percentage of
waste is below the central limit through the use of C+P and statistical process
control, which is expected to reduce waste and environmental impact by 18%
and increase productivity by 22%.

Keywords: Cleaner production · Environmental Impact · Productivity · Statis-

tic process control

1 Introduction
Japan is regarded as the leader country in Cleaner Production (C+P), adopting in its
companies, under the slogan "Produce with better quality, taking full advantage of
their inputs and making good use of Resources". To apply this concept, companies
developed training, following the procedures, standards, and analysis with statistic
quality control, where operators and members of the company detect or prevent failu-
res that may be involved in the quality of products. In North American and European
countries, the perspective of cleaner production is oriented towards technological
replacement, while in Japan the performance is first increased by means of an impro-
vement of processes and once confirmed as a positive technology influence, the chan-
ge is made [1].

Fig. 1. Program Outcomes on C+P

The results of the Resource Efficient Cleaner Production (RECP) programme are
shown in Figure 1. [2], under UNEP. The Ecuadorian Center for Resource Efficiency
and Cleaner Production (CEER), is a corporation created in 2013 by the United Na-
tions Industrial Development Organization-UNIDO and the support of the Ministry of
Industries and Productivity of Ecuador, these organizations have supported projects
for the environment care in Ecuador, which make it possible to apply the theme of
cleaner production, considering the general obligations that all State institutions and
natural or legal persons must have in order to promote new patterns of production and
consumption of goods and services with environmental and social responsibility, to
ensure good living and minimize the ecological footprint. [3]. Figure 2 shows the
outcomes obtained by the CEER in 2019. [4]

Fig. 2. CEER Figures and Results for 2019

To apply the C+P [5] methodology, on the advertising industry, it begins with the
waste identification generated from each process by monitoring the raw materials,
identifies the processes of greater waste generation and their causes, alternatives are
generated to reduce these ones, focused on the source, the technical, economic, and
environmental feasibility is analyzed, the actions are implemented, and there must be
follow-up and control of the plan at the end.
2 Development

2.1 Analysis of advertising processes

The advertising industry is divided into three main production areas, design, printing
and cutting, concentrating the largest amount of waste generated because of its activi-
ties in the second area.

Table 1. Advertising company resources 2019.

Raw material Products Waste

Process
(Kg) (Kg) (Kg)
Canvas print 7765 4698.14 3066.98
Vinyl printing 6198 3282.30 2915.50
Banners 6936 4622.11 2313.39
Price tags 711 396.21 315.21
Die cutter 476 203.43 272.75
Business cards 524 387.91 136.37
Discount labels 625 491.75 133.45
Desing and Fit 122 46.65 75.32
Triptychs 263 198.62 64.74
Laser cut 119 57.77 61.51
Sublimated 120 67.49 52.50
Flyers 135 105.66 29.06
Total 23995 14558 9437

Table 1 shows the raw material, products and resources used in each of the proces-
ses in 2019, concluding that 60.7% are finished products and 39.3% are waste, which
constitute waste of resources and environmental pollution.
To optimize the processes using the cleaner production model, we will be guided in
the one proposed by UNIDO [5], which is shown in Figure 3.

Fig. 3. C+P development model

2.2 Data collection.
Raw material flow. Printing processes concentrate more than 88% of the amount of
waste, for this reason the identification of their generating activities is focused on the
printing of tests and jobs.
To identify the causes of misuse of resources, root cause analysis and its 6Ms metho-
dology are used as shown in Figure 4.

Fig. 4. Root cause of the printing process.

Results are prioritized by setting 5 criteria to evaluate each cause and are graded on
a three-level scale. [6].

Table 2. Root cause prioritization

Criteria
Causes Direct Direct Feasible Total
Factor Measurable
cause solution solution
METHOD
Empirical procedures 2 3 2 2 3 12
ENVIROMENT
No residue control 3 3 3 3 3 15
MACHINERY
Empirical maintenance 2 2 3 2 2 11
WORKFORCE
Relearning by new processes 3 2 2 2 2 11
RAW MATERIAL
Vertical storage 3 3 3 3 3 15
MEASUREMENTS
Compliance measure record 3 3 3 3 3 15

Table 2 shows the valuation scale from which the highest weighting causes have
been selected.

2.3 Generating options

It is developed based on the root-cause prioritization and the model proposed by
UNIDO for integrated environmental prevention, which suggests starting at level 1,
and if not applied is lowered to level 2 or 3. [5]

2.4 Reduction in source

Based on the generation of options, the best alternatives are chosen that minimize the
amount of waste, costs, and environmental impacts from sourcing to the production
process.

Table 3. Source reduction options.

Improvement
Detected cause C+P Option Potential benefits
Potential
Related to the Empirical proce- Creating process Reduction of waste and costs by mis-
Method dures, lack of sheets takes.
processes
Concerning Waste control is Waste control sheets under a person
the environ- not carried out in charge
ment

Concerning to Empirical mainte- Record of equip- Analyze company failures and dama-
machinery nance ment stops ges to develop a maintenance plan for
cost reduction, downtime, environ-
mental impacts, and work accidents
Associated Relearning by Order data sheet Customer data and specifications to
with workfor- new processes. support if there is a new process,
ce avoiding mistakes.

Concerning Vertical storage Storage failure Better use of warehouse space and
the raw mate- logging handling thereof, avoiding damage
rial
Related to Disposal of lefto- Data sheet of Material specifications for reuse and
measures vers without con- waste generated waste management, sale, recycling, or
sidering measures for reuse final disposal
 Table 3 shows the analysis carried out for each of the problem causes, applying
cleaner production techniques.

3 Results

3.1 Estimating reduction levels

In Figure 5, control graphs [6] are applied, the amount of waste [7] is analyzed, to
identify their behaviour, allowing to estimate an 18% decrease in the use of raw mate-
rial by the reduction of these limits [6]

Fig. 5. Projection to apply the waste reduction estimate.

3.2 Calculation of productivity increase

Considering a reduction in the use of raw materials because of the reduction in control
limits, an improving productivity is estimated, calculated with equations 1 and 2.
Productivity = Finished product / Raw material (1)

Productivity Increase (IP) = (Final Productivity(P+L) / Initial Productivity) - 1 (2)

(2)

IP = (Raw material / (Raw material (P+L) – 1 (3)

IP = (23995 / 19721) – 1 = 1.22 – 1 = 0.22 = 22%

The obtained value shows that a 22% reduction in the raw material consumption and
waste is expected to decrease the environmental impact in equal magnitude.

4 Conclusions and future work

This research is a practical implementation of cleaner production methodologies C+P,
for advertising companies, a reduction of 18% in the consumption of raw materials
and consequent reduction of environmental impacts is achieved in the first run which
will be effective if plans of continuity, monitoring and follow-up on the proposal are
applied, likewise, an increase in productivity of 22% is expected, which gives a posi-
tive projection for its application.
In the future, improvement proposals should continue to be analyzed in the differ-
ent processes and activities of the company, such as machinery maintenance plans,
storage procedures, solid waste management, and more improvement opportunities
with the C+P vision, which contributes to improve productivity and the local and
global environment.

References
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Producción más Limpia. (2013).
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