ISO 9002 14001 Integration at KMU WHO

ISO 9002 / 14001 Integration at KMU WHO? WHAT? WHERE? HOW? KMU, Chris Kappert, ISO 9002 / 14001 Integration

Konica Manufacturing USA, Inc. (KMU) K Product: Color Photographic Paper K Located in Whitsett, NC (East of Greensboro on I 85/40) KMU, Chris Kappert, ISO 9002 / 14001 Integration

K. M. U. General Statistics § KMU manufactures color photographic paper and photographic emulsions § First Coating: June 13, 1989 § ~ 350 employees § Continuous operation (12 hr shifts) § 300, 000 ft² in manufacturing facility § Subsidiary of Konica Corporation (Japan) KMU, Chris Kappert, ISO 9002 / 14001 Integration

KMU’s Quality System Status § ISO 9002/1987 certified - July 1994 § ISO 9002/1994 certified - July 1995 § Documentation (prior to EMS implementation) only items “affecting” quality l l Level 1 (Quality Manual) - 1 Level 2 (System) documents - 41 Level 3 (Instruction) documents - 2200 Level 4 (Forms) documents - 1000 KMU, Chris Kappert, ISO 9002 / 14001 Integration

KMU Quality System Documentation Structure QMS Manual Level 1 QMS Systems Level 2 QMS Procedures / Forms Level 3 (2200 +) Level 4 (1000 +) Records KMU, Chris Kappert, ISO 9002 / 14001 Integration

KMU’s Environmental Status § § § Title V Air Permit (Mostly VOCs) Large Quantity Hazardous Waste Generator Wastewater discharge to local POTW Stormwater Permit Silver Recovery (Wastewater Pretreatment) Involved with TSCA, FIFRA, ATF, EPCRA (Tier II & TRI). KMU, Chris Kappert, ISO 9002 / 14001 Integration

KMU’s Q&E Structure (prior to EMS Implementation) § Quality Systems Manager (Chris Kappert) l l Report to QA Senior Manager (ISO Rep) Supervise Document Control Assistant who controls flow and distribution of documents § Environmental Engineer (Sean Bir) l l Report to Engineering Senior Manager Environmental Reporting and Performance Improvement KMU, Chris Kappert, ISO 9002 / 14001 Integration

ISO 14001 vs ISO 9001 INTEGRATION DECISION § Know the differences / similarities in the standards § Know advantages / disadvantages of the integration options § Know your system & your company KMU, Chris Kappert, ISO 9002 / 14001 Integration

ISO 14001 vs ISO 9001 DIFFERENCES KMU, Chris Kappert, ISO 9002 / 14001 Integration

ISO 14001 vs ISO 9001 DIFFERENCES § EMS vs QMS § TC 207 vs TC 176 § 6 elements vs 20 elements (1994 version) § “Established” vs “Documented” Procedures § Possible future integration or alignment KMU, Chris Kappert, ISO 9002 / 14001 Integration

ISO 14001 vs ISO 9001 DIFFERENCES § Environmental Aspects and Impacts (4. 3. 1) § Legal and Other Requirements (4. 3. 2) § Environmental Programmes (4. 3. 4) § Communication (4. 4. 3) § Emergency Preparedness and Response (4. 4. 7) KMU, Chris Kappert, ISO 9002 / 14001 Integration

ISO 14001 vs ISO 9001 SIMILARITIES § § § Policy Targets & Objectives Roles & Responsibilities Training Supplier Control / Purchasing Document Control KMU, Chris Kappert, ISO 9002 / 14001 Integration

ISO 14001 vs ISO 9001 SIMILARITIES § § § Operational Control Calibration Corrective and Preventive Action Records Auditing Management Review KMU, Chris Kappert, ISO 9002 / 14001 Integration

ISO 14001 vs ISO 9001 INTEGRATION OPTIONS § Separate Systems § Partially Integrated Systems § Fully Integrated Systems KMU, Chris Kappert, ISO 9002 / 14001 Integration

Separate Systems KMU, Chris Kappert, ISO 9002 / 14001 Integration

Advantages of Separate Systems § Easy to audit (external) § One-to-one documentation generation § Can be handled by independent groups § Thorough coverage of requirements KMU, Chris Kappert, ISO 9002 / 14001 Integration

Disadvantages of Separate Systems § § § § REDUNDANCY! Results in large system of documentation No plant-wide alignment Requires extra staffing Internal audits harder “Re-inventing the wheel” Start over if ISO 14001 / 9001 merge KMU, Chris Kappert, ISO 9002 / 14001 Integration

Partially Integrated Systems KMU, Chris Kappert, ISO 9002 / 14001 Integration

Advantages of Partially Integrated Systems § Relatively easy audits (external & internal) § Builds on existing systems § Can be managed by groups working closely together or combined § Reduced costs § Consistency § Employee buy-in KMU, Chris Kappert, ISO 9002 / 14001 Integration

Disadvantages of Partially Integrated Systems § Alignment of ISO 9001 / 14001 elements § ISO 9001 systems may not adequately cover 14001 requirements § Unclear responsibilities between QMS and EMS management representatives § Complex procedures (level 2’s) KMU, Chris Kappert, ISO 9002 / 14001 Integration

Fully Integrated Systems KMU, Chris Kappert, ISO 9002 / 14001 Integration

Advantages of Fully Integrated Systems § Easy to audit (internal) § Consistent plant-wide philosophy, planning, and information management § No redundancies § Reduced costs § System already established if ISO 14001 / 9001 merge KMU, Chris Kappert, ISO 9002 / 14001 Integration

Disadvantages of Fully Integrated Systems § Complex documents (level 1 and 2’s) § Difficult to audit (external) § Unclear responsibility between QMS and EMS management representatives § Difficult to implement after 9001 has already been established KMU, Chris Kappert, ISO 9002 / 14001 Integration

ISO 14001 vs ISO 9001 INTEGRATION DECISION § Know your current system l l l Does it lend itself to integration? What is the function of the various documents in your current system? ? § Know your company l Could we do it like that? KMU, Chris Kappert, ISO 9002 / 14001 Integration

Which is right for you ? KMU, Chris Kappert, ISO 9002 / 14001 Integration

KMU’s Implementation of Partially Integrated System § ISO 9002 system established § ISO 14001 EMS Manual written (references made to existing system documentation and unknown new documents) § Existing systems modified § No new level 2’s added § Many environmental specific level 3’s added KMU, Chris Kappert, ISO 9002 / 14001 Integration

KMU’s Partially Integrated System KMU, Chris Kappert, ISO 9002 / 14001 Integration

KMU’s Implementation & Integration Team § Team Leaders l l Quality Systems Manager Environmental Engineer § Core Team l Representatives from each major functional area; 10 experienced people § Employees Involved l 100%!! KMU, Chris Kappert, ISO 9002 / 14001 Integration

ISO 14000 Costs KMU Person-Hours KMU, Chris Kappert, ISO 9002 / 14001 Integration

KMU’s ISO 14001 Timeline § Spring 1997 l l Key Personnel Receive ISO 14001 Training. Drafted Environmental Policy § Summer 1997 l Decide to Develop Integrated Management System Incorporating Quality and Environmental Commitments. KMU, Chris Kappert, ISO 9002 / 14001 Integration

KMU’s ISO 14001 Timeline § Fall 1997 l l Join NC ISO 14001 Pilot Program Complete Environmental Manual (& Policy) Created the Konica Environmental Group with members from all KMU departments. Identify Environmental Aspects and Impacts. KMU, Chris Kappert, ISO 9002 / 14001 Integration

KMU’s ISO 14001 Timeline § Winter 1997/1998 l l l Developed Environmental Targets and Objectives for 1998. Completed Initial Environmental Training of all KMU Personnel. Registrar Performed ISO 14001 Preassessment of KMU’s Management System. KMU, Chris Kappert, ISO 9002 / 14001 Integration

KMU’s ISO 14001 Timeline § April 1998 l Completed Implementation of EMS. § June 15 -19, 1998 l Passed KMU ISO 14001 and 9002 Certification Audit. TOTAL ELAPSED TIME: 14 months (8 months dedicated) KMU, Chris Kappert, ISO 9002 / 14001 Integration

14001 Registration!!!!!!! KMU, Chris Kappert, ISO 9002 / 14001 Integration

KMU’s Documentation System (after EMS Implementation) § Documentation - items “affecting” quality or environmental performance l l l Quality Manual - 1 Environmental Manual - 1 Level 2 (System) documents - 41 (none created; 40% modified for EMS) l Level 3 (Instruction) documents - 2320 (~120 created + 5% modified for EMS) l Level 4 (Forms) documents - 1050 (~5% created new or just added to control system) KMU, Chris Kappert, ISO 9002 / 14001 Integration

KMU Management System Documentation Structure Level 1 EMS & QMS Manuals Level 2 Systems Documents Level 3 (2320 +) Procedures / Forms Level 4 (1050 +) Records KMU, Chris Kappert, ISO 9002 / 14001 Integration

KMU’s Q&E ISO Structure (after EMS Implementation) § Environmental Engineer / Systems Manager (Dorothy Vannoy) l l Report to Engineering Senior Manager (ISO rep) Responsible for all (ISO) Management Systems Environmental Reporting and Performance Improvement Document Control Assistant still controls flow of document revisions and distribution KMU, Chris Kappert, ISO 9002 / 14001 Integration

Benefits Realized…. . … from EMS IMPLEMENTATION J Increased Employee Awareness & Involvement óBetter Knowledge Preservation & Transfer $ Increased Efficiency & Reduced Costs ¶ Improved Environmental Performance $Enhanced Public Image $Enhanced Image with Regulators KMU, Chris Kappert, ISO 9002 / 14001 Integration

Benefits Realized…. . … from EMS (partial) INTEGRATION ¶ Reduced head count ¶ Simplified introduction into daily operations ¶ Minimal increase in documentation KMU, Chris Kappert, ISO 9002 / 14001 Integration

INTEGRATION REFERENCES § Book: Stepping Up to ISO 14000 - Integrating Environmental Quality with ISO 9000 and TQM Subhash C. Puri, $39. 00 www. ppress. com § ASQ Course: Integrating ISO 14001 into QS 9000 Certified Systems - $835 June 20 -21, 2000, Greensboro, NC § NC DENR - FREE! § Your Auditor - $? KMU, Chris Kappert, ISO 9002 / 14001 Integration