Challenges in Tracking Waste Reduction Performance Improvement in Manufacturing Plants

Subodh Chaudhari, Alexandra Botts, Sachin Nimbalkar, Cory Tatarzyn, Tina Burry, Thomas Wenning
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Abstract

The recently released Circularity Gap Report 2023 by the Circle Economy Foundation states that the circularity score for the global economy is declining. The US Environmental Protection Agency (EPA) tracked municipal solid waste from 1960 to 2018 and found that 50% of the waste was destined for landfills. EPA estimates that US industry is responsible for 2.7 Gt of solid nonhazardous waste annually in the US mostly linear economy model. The circular economy framework aims to decouple economic value generation from the extraction of virgin materials from nature. The linear model of material extraction and disposal at the end of life is highly unsustainable. Manufacturing companies are adopting ambitious waste reduction targets to achieve sustainability. Through the Better Plants program, US DOE has established the Waste Reduction Network, which offers technical assistance to partners to achieve their ambitious waste reduction goals. Basic requirements of establishing a target include identifying a baseline, quantifying waste performance, and measuring progress over time. One problem faced by industry is unstandardized metrics for quantifying waste performance that may not be well suited to demonstrate progress. This paper studies traditional methods used to measure waste performance and highlights advantages, disadvantages, and limitations of each method. It also examines the suitability of applying the methods in different manufacturing circumstances. Finally, the paper presents a case study of a large manufacturer that faced inconsistencies in its tracked measurement metric. A solution was proposed and implemented to alter the methodology to enable more accurate waste performance tracking against a baseline.

跟踪制造工厂减少废物绩效改进的挑战
循环经济财团最近发表的《2023年循环差距报告》指出,全球经济的循环性得分正在下降。美国环境保护署(EPA)对1960年至2018年的城市固体废物进行了追踪,发现50%的废物被送往垃圾填埋场。美国环保署估计,美国工业每年产生27亿吨固体无害废物,在美国大部分是线性经济模式。循环经济框架旨在将经济价值的产生与从自然中提取原始材料分离开来。在生命结束时,物质提取和处置的线性模型是高度不可持续的。制造公司正在制定雄心勃勃的减少废物目标,以实现可持续发展。通过“更好的工厂”项目,美国能源部建立了减少废物网络,向合作伙伴提供技术援助,以实现其雄心勃勃的减少废物目标。建立目标的基本要求包括确定基线、量化浪费绩效和衡量随时间推移的进展。工业面临的一个问题是量化废物表现的标准不统一,可能不太适合展示进展。本文研究了用于衡量废物绩效的传统方法,并突出了每种方法的优点,缺点和局限性。它还检查了在不同的生产环境中应用这些方法的适用性。最后,本文给出了一个大型制造商在其跟踪测量度量中面临不一致的案例研究。提出并实施了一项解决方案,以改变方法,以便根据基线更准确地跟踪废物表现。
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