THE FINAL TOLLGATE - MoreSteam

1 THEFINALTOLLGATEID efineBODW asteReductionProblemStatement:Currentope rationsproduceBODwastelevelsaveraging386 4mg/L- 1546% :Atleast50%reductioninBODby3/15/10andthe creationofa sustainablesystemcapableofreachinga longtermtargetof95% : Dramaticreductioninsolidwasteenteringflo ordrains Increasedthroughputatvariousplantprocess es Greeninitiativefortheorganization $195,000indirect,hardcostreductionsDefin eBOD,whichstandsforBiologicalOxygenDeman d,is ; ,Kahiki'ssupportfortheenvironmentandclos eto$204,000insurchargesin2009,Kahikichar tereda goodworkingrelationshipwiththecustomer(C ityofColumbus)wasparamountatthisstagein theroadmapandservedasa "BODstartsasfoodwasteenteringfloordrains ".

2 Createdatvariousproductionprocessesinclu dingrawchickenprocessing,fryingprocesses , ,andis sprayedcleanintooneof50+plant SI POCforBODW asteReductionInput-~in entory:T,..n:AIIt'~I ~7 Ibwimla'ltory:~~ . rtaIS~:co~:~-:-!p=,~~~,;I "'<n," "~fr=cnprodud,~_ooI T_J~_Ii,Jl~to~~_~~~J~nutcrUls~~:i~ ,.,mory~::::~~to houJeil:lll :~~'W"'I~"PishW-mnc~ ~i::"S.<li'IY~~~'iv~l~::,:.~,~:::::: :ltcr-,~ ;Khi~ ;chcmic315; " < (lr::,ll1sBeginningin1961,theKahikiSuppe rClubinColumbus,OHhasattractedmillionsof customerstovisit"Oneofthetop100 Restaurantsofthe20thCentury".Althoughclo sedsince2000,KahikiFoodshasgrowntobea ,membershipwarehouseclubs,conveniencesto res, 119, a filterbasketinwhichsomesolidsarefiltered whileremainingsolidsandliquidstraveltoa solid/liquidseparatorwhichthenpumpswhat' slefttoa , ,thismetricwouldbetheteam'sprimarymetric howevertheothermetricsTSS(TotalSuspended May/June2010 OSU/ISE2 :SuccessinMeasurehingedontheexecutionofa BOOQllwIilIlOM6 IJsedon\VelbullDl5lJiI; ~II,~ 11US!))

3 ;:5)II50=='-_lUU1II=-" ~ 11 Sew~ ;,x~II1=::::1::PP!o!!CI:III!XI:IXII:UIOI I""f:: ~"I"I*Manyof thesemetricshadneverbeenrecordedsomuchti mewasspentdevelopingoperationalmethodsof datacollectionSolidwasteFoundatDrainBask etto >ncentrationmorefrequentsamp!"_floomCity Cityof "llourownmeterConsumption-waterconsumpti on llar-'"Gallonsor ,secIbsAmountof wasteSampledrainbasketsenteringdrainsat variousandwei&hsolidsafterplantlocations 2ndshiftSolidWastefoundatSumpSolids),and TKN(TotalKjeldhalNitrogen) majorsystemchange, ,eachrecording4 , , , , demandanalysiswasperformedtounderstandwh at"pulls" ,theneedfora ,waterandsewerconsumption,Ibsofwasteente ringvariousplantdrainbaskets, , , :"0 OSU/ISE3 THEFINALTOLLGATEA nalyzeIBODW asteReduction5 therea GapbetweenCurrentStateandFutureState?

4 Whyaren'tBODlevelsincustomerspec?DWhyare BODlevelstoohigh?DWhyis theretoomuchwasteincitysample?DWhydoesto omuchwasteflowthroughKahikrsWasteRemoval System? wastecreated?ThroughputYieldnot100%ateve ryprocess , "HotSpot"Chart:Thisdepictionshowsa ,feelandperformanceofapotentialfuturesta tewascriticalduringthebeginningportionso fAnalyze,Theteamexaminedbestinclassindus trieswithregardtoBODandalsoexaminedKahik i'sownperformancetoestablisha ,theteamdida gapanalysistounderstandwhatspecificallyn eedstohappentocertaininputsin orderforthesystemtoeventuallyachievethis futurestate,Oncethegapanalysiswasperform ed,it becameapparentthatcertaininputsintothesy stemweremorecriticalthanothersandalsofar therawayfromoptimalthanothers,Theteamdid multiplecauseandeffectmatricesandFMEA' drain"hotspot" (9 drains)

5 Accountfor70%ofthetotalamountofsolidsfou ndinall50+drains,ThistoolLegend 70%of WasteCollectedfrom: 25%a/ WasteCollectedfrom: 5 WorstDrains:37,9,20,21,2~ 3 '~reQs~' , companysimilartoKahikiintermsofvolumeand productsmadewhichservedasa 5 whyanalysiswasperformedusingtheexpertise oftheteam, , , '.?yJJwv'2010 :Inefficientsolid/liquidseparationfromFM EA ledtoa pilottestusinga :Simplebuteffectiveemployeetrainingwasim plementedregardingwastepracticesinrelati ontoBODBestPracticeIdentification:Goingh and-in-handwithtraining, :A "WasteAwarenessProgram" :AddingvisualSOP's, ~==============JI--~-'------~~------~700 0 OIJ/fl'JAwerace60005000~4000'"E 300020001000o 1 DateImproveFromtheenormousbodyofliteratu reavailable, ,customsolutionswerebrainstormedandimple mentedspecifictoKahiki' Tiersof solutionsandteamswerecreatedtotackleimpr ovementspostedtotheactionregister.

6 Tier1 solutionsinvolvedthoseimprovementsthatwe re"JustDoIt's"andinvolvedsimpleandmoreef ficientcleaningmethods,proposedpilottest ingofa moreefficientseparator,employeetraining, theformofcreatinga WasteAwarenessProgramCommittee,errorproo fing,formalSOp' ,tier3 smarter, ,theWAPcommitteeandotherfocusedimproveme ntteamswouldcontinuallydevelop, "best"practicesoneday,canbe"better" , :BOD(3/15/10):1375mg/L:::70%ReductionTSS (3/15/10):790mg/L:::61%ReductionExpected HardCostReduction2010:$178,365 Strongdownwardtrendandsystembecomingcapa bleof :Continuedemployeetrainingis :Sustainabilityhingesonemployeesactivein .

7 Errorproofingin theformofvisualSOP's, , KahikiPerformallceSystem"SQD"AwarenessCO noCII,""lItode 'BOO'(jBOOe' 'l, ,Kahikihadrealizedclosetoa 70%reductioninBODanda 61% $178, ,thiswasjustthetipoftheicebergastheconti nueddevelopmentandcompletionoftier2 and3 solutionsthroughouttheendoftheyeararepro jectedtorealizea 95% ,thesecontinuedresultsdependonsustainabi lityControlhingesonemployeepresencenoton lyinsolutiondevelopment, , ,howeveronepotentialfailuremodeis ,a WAPcommitteewasformedwhichservestoactive lyengageemployeesintheprocessofcreatinga ndenforcingSOp' chancetobea ~-=-'-:;:::",--~~.)

8 :.~~----k ..-l:;'.-m--","-leaderintheplantamongthe irpeersasa spokespersonforefficientandgreenwastehan dlingpractices,Errorproofingwasa ' , theformofhardcostreductionsandalsoasa projectleaderandis a blackbelt candidateatOhioStatestudyingIndustrialan d BradGoolsbycontinueto lead futureimplementationat Kahikifor ScollSink,ProgramDirectorfor LS CertificationsCollegeof Engineering/ISE, , ,helpedcoachthe belt candidatethroughoutthe cycleof the project.