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John Cotton Textile Ltd produces high quality decoration textiles, has 80?employees and an annual turnover of roughly EUR 14 million. The provided materials include the company?s environmental policy, its organizational chart, a description of the fully integrated manufacturing process and an input/output table. To improve customer service, the company is producing ever smaller batch sizes in different patterns.The three different problem descriptions for the groups focus on waste, energy and water consumption.The general tasks for each group are:Set up an environmental controlling system and analyse the environmental policy of the company. Check whether the policy can serve as a framework for the definition of specific targets. Analyse the data provided in the input/output table, identify indicators for the respective area and define planned values for the indicators in view of the environmental targets. Draft a deviation analysis, derive hypotheses about the origin of the deviations and define measures in order to achieve the planned values. Finally write a report for the management and the employees of the company.The specific problems for the individual groups include: A threshold value applies to the content of spinning oils and fire proofing chemicals in wastewater. Calculate the actual indicators from the input/output tables and the performance compared to the threshold values. In future, a certain proportion of the wastewater should be recycled.For solid waste the following problems have arisen: So far the textile waste has been recycled. The recycling company, however, no longer accepts it because the contamination with spinning oil is too high. Additionally, the total volume of waste generated by the company is steadily increasing due to higher production turnout. The energy group is faced with the problem that the consumption of gas and electric energy increased significantly over the last years. How can the energy consumption be reduced?In the end, the groups prepare and hold a 15 minutes presentation on a flipchart analysing the questions. Working material: Case study: Environmental controlling: John Cotton Textile LtdCompany description:The company John Cotton Textile Ltd produces high quality decoration textiles, has 80 employees and an annual turnover of EUR 14 million. Their main markets are Austria and Germany, approximately 20% of the production is exported to other EU countries, 10% is sold worldwide.The environmental policy of the company:?We shall:Consider environmental protection to be equally in the economic and social interests of the company;Assume responsibility for the protection of our environment;Save resources;Reuse waste products in material cycles if possible;Encourage the sense of responsibility of all our employees in all fields; andAim at reaching an open dialogue with our customers, the authorities and the public. Management of John Cotton Textile LtdOrganizational chart of the companyThe production processThe purchased yarn is already dyed. First it is impregnated with spinning oil and then weaved on fast running looms in air-conditioned rooms. The spinning oil is washed out after weaving because it would affect the subsequent treatment.Next the material is dried and coated with a special flame retardant by cylinders. After another drying process, a quality control is carried out and then the textiles are cut, wound up on spools and packaged for dispatch. Flow chart: Your task: You were appointed the environmental manager of John Cotton Textile Ltd.Group 1Set up an environmental controlling system for the company John Cotton Textile Ltd. Concentrate on water supply and wastewater.You have the following problems: You are allowed to emit a maximum of 300 mg/l of spinning oil into the water. According to the regulations, no flame retardant must be discharged into the sewer after cleaning because it contains heavy metal. Furthermore, you have to reuse the cooling water in the process. Carry out the following tasks:Analyse the environmental policy and set specific targets for your area;Analyse the provided data;Find indicators for your area;Define planned values for indicators in view of your environmental targets;Carry out a deviation analysis;Propose measures to achieve your planned values;Draft reports for the management and the employees of your company.Group 2Set up an environmental controlling system for the company John Cotton Textile Ltd. Concentrate on waste and logistics.You have the following problems: The company which has recycled the textile waste of your weaving mill so far does not accept it anymore, because of the high pollution with spinning oils. Consider your quality problem and analyse the material use. Carry out the following tasks:Analyse the environmental policy and set specific targets for your area;Analyse the provided data;Find indicators for your area;Define planned values for indicators in view of your environmental targets; Carry out a deviation analysis;Propose measures to achieve your planned values;Draft reports for the management and the employees of your company.Group 3Set up an environmental controlling system for the company John Cotton Textile Ltd. Concentrate on energy supply and exhaust heat.You have the following problems: Your gas and energy consumption has increased because the company is producing smaller batches. What is the share of renewable energy in your company? Carry out the following tasks:Analyse the environmental policy and set specific targets for your area;Analyse the provided data;Find indicators for your area;Define planned values for indicators in view of your environmental targets;Carry out a deviation analysis;Propose measures to achieve your planned values;Draft reports for the management and the employees of your company. Input/output analysisInput20022003Amount kgCosts EURAmount kgCosts EURRaw, process and operating materialYarns2 000 0008 000 0002 300 0008 200 000Spinning oil20 000100 00030 000110 000Flame retardant30 000150 00031 000155 000WaterCooling water30 000 00030 000 000Process water40 000 00040 000 000EnergyElectricity [kWh]4 000 000440 0005 200 000572 000Natural gas [Nm]1 000 000200 0001 500 000300 000Output20022003Amount kgCosts EURAmount kgCosts EURProductsProduct1 500 0001 650 000Textile recycling300 000revenue 20 00000Trade wasteSolid waste200 00060 000650 000120 000From that:Weaving mill300 000Quality control100 000250 000Cutting100 000100 000Wastewater70 000 00028 00070 000 00028 000Contents ofSpinning oil~ 17 000~ 26 000Flame retardant??Additional instructions/background information for trainersWhat does the environmental policy convey: Is it challenging, motivating, specific about the company?s environmental aspects? Does it provide a framework for setting goals for improvement? Actually it is more or less a general template, which could be used for many different sectors. It does not relate to the company?s problems (waste, energy consumption, water consumption). What do you think about general statements such as ?We shall consider environmental protection equally as an economic and social interest of the company?? Do you think the company observes this rule in practice?Formulate a job description of the environmental manager, focus on the actual challenges that he has to face such as reporting, collecting information and data, leading an environmental team. Do not focus on specific details at the beginning. What can we deduce from the input/output table? Look at the absolute figures: production is increasing, material consumption is also increasing but which of the values is growing faster? Should we use specific indicators (material consumption per ton of product, energy consumption per ton of product)? These indicators would show:That the proportion of waste is increasing. Obviously the more we push the machines, the more waste we produce. Could this be related to the age and construction of the machines?We used considerably more spinning oil per ton of raw material than in the previous year. The specific price has decreased. Maybe the quality is not the same any more?Right now we are not recycling any water. 50% of the water consumption is used for cooling the textiles in the drier. This water is clean, but has a higher temperature (approx. 35 ?C). Could this be used for washing the textiles?The specific energy consumption is increasing. Could it be due to the smaller batch sizes?The waste textiles cannot be recycled anymore. They are contaminated with spinning oil. What could be the reasons for that?All the data for this discussion are included in the input/output table. Solution:The following indicators should be identified:All groups:Raw material consumption per ton of product.Group ?Water?:Water consumption per ton of product;Spinning oil per m? of wastewater;Flame retardant per m? of wastewater;Percentage of water recycled.Group ?Energy?Energy consumption (gas and electricity) per ton of product.Group ?Waste?Waste per ton of product;Percentage of waste recycled.The following measures should be proposed:Improve the environmental policy, make it more company-specific, address key environmental issues;Introduce indicators;Improve work planning to ensure continuous operation;Move to higher value products as an increase in production seems very difficult with the existing machines, which cannot be pushed any more;Provide clear working instructions regarding key parameters of the machines;Recycle cooling water from the drier for washing;Buy better spinning oil;Measure the actual content of flame retardant in the wastewater as you do not know how much is discharged into the sewer during cleaning.Exercises 7 ? 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Alle Rechte vorbehalten. The OPX file format is the confidential and proprietary property of Banner Blue. Banner Blue requires prior written consent and advanced royalty payment to use this format. A violation of these rights is against the law and Banner Blue will aggressively pursue prosecution. ??) Copyright 1992 Banner Blue Software Incorporated. Alle Rechte vorbehalten. The OPX file format is the confidential and proprietary prope? \ ? \@@@@`Name`Title` Comment 1` Comment 2`?"r Bl} ?`@!?d?DD?????3?3????????????????????? "" $.,?????"T,## 2B\\STENUM\pq_laser.stenum,winspool,Ne01:??\\STENUM\pq_laser.stenum?0 ? 4dXXA4 ????DINU"07խ? ?  @###### # ` @?%Arial `@aaaaaa aa a ???a aaa???` @&`@aa a`&`Diagrammtitel@aa a`&`@aa a`&`@aa a`&`@aa a`&`@aa a` `$#RS???????T?$V?????????@A??B@PQ$$?S???????@` Management@aaa???``Mr. G. 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