Waste Management

 Introduction
 Reason for obsolete/scrap
 Identification of Scrap
 Disposal of Scrap
 3M
 Case Study on Waste Management
Wastes are unwanted or unusable materials. Waste is any substance
which is discarded after primary use, or is worthless, defective and
of no use.

What are Industrial Wastes?

Industrial waste refers to the solid, liquid and gaseous emissions,

residual and unwanted wastes from an industrial operation.

Example:
 Refineries: oil, grease, suspended solids, phenols, sulphides and
ammonia nitrogen
 Chemical : acids, bases, suspended solids
 Pulp and paper: dioxins and furans produced from the chlorine
used in the bleaching process
 Hazardous wastes
 Hazardous wastes, which may be in solid, liquid or gaseous form,
may cause danger to health or environment, either alone or when
in contact with other wastes.
 About 10 to 15 percent of wastes produced by industries are
hazardous and are increasing at the rate of 2 to 5 percent per year.
 Hazardous industrial wastes in India can be categorized broadly into
two categories.
Hazardous wastes generated from various industries in India
Hazardous industrial wastes imported into India from Western
Countries for re-processing and recycling.
 Hazardous waste in particular includes products that are explosive,
flammable, irritant, harmful, toxic, corrosive, infectious, or toxic to
reproduction.
Chemical waste.
 It is a type of waste product that constitutes of different chemicals
plus their residues.
 Most chemical wastes are generated from factories, plants, as well
as processing centers.

Industrial solid waste.

 This type of waste refers to discarded cardboard boxes, packaging

materials and other related stuff.

 It is greatly recommended that industrial solid waste should be

directed to a recycling center and can be made into another usable

product.
Toxic waste.
 This is definitely one of the most dangerous industrial wastes as it
can cause deaths or even birth defects to any living organism.
 Toxic waste is a byproduct of various materials which may be
generated from hospitals, factories and automotive garages.
Non-Hazardous Wastes
 Non-hazardous or ordinary industrial waste is generated by
industrial or commercial activities, but is similar to household waste
by its nature and composition.
 It is not toxic, presents no hazard and thus requires no special
treatment.
 In particular, it includes ordinary waste produced by companies,
shopkeepers and trades people (paper, cardboard, wood, textiles,
packaging, etc.).
 Due to its non-hazardous nature, this waste is often sorted and
treated in the same facilities as household waste.
Waste management comprises of a collective activity of segregation,
collection, transportation, recycling and disposal of waste.

However the newer concepts of ‘Waste management’ talk about

‘Reduce, Reuse and Recycle and Recover (4 R’s) of waste’ over and
above waste disposal
According to Union Minister of State for Environment, Forests and
Climate Change,
 62 million tonnes of waste is generated annually in the country

 5.6 million tonnes is plastic waste

 0.17 million tonnes is biomedical waste

 Hazardous waste generation is 7.90 million tonnes per annum

 15 lakh tonnes is e-waste.

 Only about 75-80 per cent of the municipal waste gets collected
and only 22-28 per cent of this waste is processed and treated.

Waste management in India falls under the purview of the Union

Ministry of Environment, Forests and Climate Change (MoEF&CC).
 Affects our health
 Affects our socio-economic conditions
 Affects our coastal and marine environment
 Affects our climate
 Rising global temperatures are expected to raise sea levels and
change precipitation and other local climate conditions.
 Changing regional climates could alter forests, crop yields, and
water supplies.
 This could also affect human health, animals, and many types of
ecosystems.
 Deserts might expand into existing rangelands, and features of
some of our national parks might be permanently altered.
 Changes in product design
 Faulty purchase practices
 Faulty planning and forecasting
 Rationalization
 Cannibalization
 Other causes
 Changes in product design
This may lead to some items getting invalid so far as the final product
is concerned. Hence, the entire stock of such items as surplus
obsolete.

 Rationalization
Sometimes raw materials are renationalized so as to minimize variety
and simplify procurement. The rationalization process renders some
items as surplus or obsolete.
 Faulty planning and forecasting
The marketing department may have projected a sales forecast which
might be on the higher side. Any material planning has to be based on
sales forecasts and this could result in surplus items. Wrong indenting by
the user departments also leads to accumulation.

 Cannibalization
When a machine breakdown occurs, sometimes it is rectified using parts
of an identical machine which is not functioning due to various reasons.
This process of ‘cannibalization’ is not uncommon in many project-based
industries. When continued unchecked, this results in obsolete and scrap
items.
 Faulty purchase practices
Sub-optimizing decisions like buying in bulk to take care of discounts and
transportation economy without taking into account factors such as,
shelf life, storage space requirements and technological changes once
again lead to the accumulation of surplus and obsolete stocks.

 Other causes
Many items are held as insurable spares for many years without any
consumption. Faulty store-keeping methods, without adequate
preservation, lead to spoilage. Inferior materials handling, improper
codification and poor manufacturing methods also result in obsolete,
surplus and scrap items. Poor maintenance of machine tools may result
in excessive tools wear and greater process scrap.
 Identification of Scrap

 What is scrap
a small piece or amount of something, especially one that is left over
after the greater part has been used.

https://www.youtube.com/watch?v=2x0eVIGyrDM

Types of Scrap

Ferrous Non-ferrous
metals metals
 Non-ferrous metals
Non-ferrous metals are typically more valuable than ferrous, making it
important to know the difference. Once you’ve used the magnet test to
separate your ferrous and non-ferrous metals.

 Ferrous metals
Most ferrous metals are magnetic which makes them very useful for
motor and electrical applications. The use of ferrous metals in your
refrigerator door.
 Non-ferrous metals

Aluminum
Easy to identify as we see it regularly in soda pop cans. This metal is very
light, non-ferrous and does not rust.
Brass or bronze
Is typically seen in musical instruments, decorative pieces, pipe valves and
manifolds. It is a yellowish color and is generally about 50% the value of
copper
Copper
Is seen often in cookware, electronics and wiring. Pure copper is pink, but
tarnished copper is usually brown or red
Stainless Steel
Non-magnetic iron alloy which contains 4% nickel, 7% manganese and 17%
chromium.
Lead
Is extremely heavy and is very toxic. It has a density that is 150%
more than iron and is soft enough that you can make carvings in it
with a pocket knife. Lead is used in x-ray machines and for making
bullets.
 Ferrous metals
Carbon Steel
They are primarily made up of iron, with over 90% of their chemical
composition being that element. Common applications of carbon steels
include structures, furniture, and automotive components.
Cast Iron
This gives it a high amount of strength. Although high in strength, it is
quite brittle. The lack of other alloying elements outside of iron and
carbon. Common applications of cast iron include cookware, small
components subject to wear such as gears, rods, and pins, and mining
equipment.
Alloy Steel
Specially formulated to serve specific purposes. While composed
primarily of iron, differing amounts of copper, vanadium, tungsten,
manganese, and other elements can be used to tailor an alloy steel to
have higher toughness, ductility, tensile strength, hardness, and other
properties. Common applications of alloy steels include tools, dies, and
machining equipment.
 Scrap
A small piece or amount of something, especially one that is left
over after the greater part has been used.

 Scrap Management
Manufacturers do not intend to produce or develop scrap, but
depending on the industry the scrap is produced. But depending
on the nature of the scrap it may be reused or recycled or can be
sold to get some revenue and this process is called is called as
Scrap Management.
There are mainly Four types of scrap namely

Electronic or
Ferrous Scrap
Metal Scrap

Pharmaceutical Biological
Waste or Scrap Waste or Scrap
 Reuse.

 Return to Supplier.

 Sale to another company.

 Sale to Dealer.
 What is 3M?
3M is the Japanese method of waste identification, elimination
and processing starting with the letter ‘M’

1. MUDA– Waste

2. MURA- Imbalance or inconsistency.

3. MURI– Stress/Strain or over burden.

 TRANSPORTATION
 INVENTORY
 MOTION
 WAITING
 OVER PRODUCTION
 OVER PROCESSING
 DEFECTS
MURA (IMBALANCE)

Reasons of MURA
 Improper work distribution
 Variation in cycle times
 Unorganized work

Impact of MURA
 Variation in quality
 Unbalanced capacities

 Using equipment unreasonably or wastefully

 Reasons for Muri
 Repeat tiring action
 Wasteful walk
 Unorganized work place

Impacts of Muri
 Strain due to poor design
 Increased work load due to lack of workers
 Running machines beyond its designed capacity

https://www.youtube.com/watch?v=e3D__vikjiY
 Brand Image

 Sustainability

 Competitor

 Government

 Greta & PETA

 Carlsberg

 Coca-Cola

 Burger King

 ITC – WOW

 Adidas/Nike

 Zara / H&M
 Use to make energy as solar energy, wind energy in the production
process instead of using the electricity for the production.
 Formulate policies and strategies towards prioritizing waste
reduction and minimization rather than mere disposal.
 Remediation strategy needs to focus on the ‘polluter pays
principle’ with the polluter being asked to pay penalty as well as
costs of cleaning up the pollution.
 Industries causing pollution repeatedly should be blacklisted
 Where polluters are not traceable, a dedicated fund needs to be
created by State Pollution Control Board/Pollution Control
Committee (SPCB/PCC) for remediation.
 Waste Exchange Banks/Collection Centres should be developed to
provide information on wastes as on the types of waste and the
methods to manage