Kaizen is a process of making lots of small, ongoing changes that contribute to more significant overall improvements. From the Japanese meaning ‘change for better’, Kaizen utilises a combination of problem solving, waste identification and standardised working practices to refine and improve existing systems.

There are five principles that kaizen follows, including:

1 Know your customer
2 Let it flow
3 Go to Gemba
4 Empower people, and
5 Be transparent

In the spirit of the fifth principle, we’re sharing our experience of introducing Kaizen to an environmental testing lab.

In December 2022, the operations management team prepared a Kaizen roadmap to run from January 2023 to May 2025. The roadmap was designed to take us through every operational process in the lab and identify waste that could be eliminated at each stage.

The primary aim of the roadmap was to work on our turnaround time performance.

We kicked-off our first Kaizen Event in January 2023 which focussed on Sample Reception, Preparation and Aliquoting processes. It was a great learning experience for everyone at Chemtech and helped us to get to grips with the Kaizen process.

Following the week-long event, we continued refining the process for another two months during which time we eliminated lots of transportation (we have a 30,000 sq. ft facility) and waiting waste. The outcome was that samples were now passed to the laboratory for downstream processing 1-2 days earlier than the previous system.

Taking the valuable knowledge gained during first event (and more importantly learning what not to do again), we moved onto our Inorganics Department, holding a Kaizen Event in each area.

We started with combustion methodology (e.g., TOC – Total Organic Carbon and LOI – Loss on Ignition), then progressed to Colorimetric (e.g., Cyanide, Phenols, Hexavalent Chromium), Wet Chemistry (e.g., pH, EC, Sulphides) and Metals extractions.

Each Kaizen Event has two weeks of time dedicated to it, as well as a period of pre-work during which each step of the process is mapped out, and time studies are performed on each action.

Week One is all about planning, taking our existing processes and repeatedly asking ourselves Why? Why do we do the tests in this order? Why do we use X piece of kit vs. Y? Why do we load X number of samples onto an instrument instead of Y? Why do we store consumables in that specific location?

By following what can often be a challenging process and working within the remits of our UKAS accreditation requirements, we are able to redefine our understanding of the work we do and create new optimised processes with a focus on turnaround time and waste elimination.

We then move into Week Two of the event, which we can only compare to the kind of activity you see on Extreme Makeover Home Edition (or Lab Edition may be more appropriate in this case).

We clear out the existing area and then rebuild from scratch, following a Kaizen 5S methodology:

• Sort
• Set up
• Shine
• Standardise
• Sustain

During every event we managed to rebuild the process within two days while trying to manage workload and minimise delays. The outcome, however, is that results in the areas in which we have held Kaizen events, are available 1-2 days earlier to the reporting team.

As we near the close of 2023, we have begun to turn our attention to the Organics Department.

We’ve committed to significant capital investment already, but our roadmap is set to take us through to May 2025 and includes:

• Organics Extraction
• Volatiles
• Organics Instrumentation
• Metals Instrumentation

However, we have already put more projects into our Kaizen Parking Lot, including:

• a review of our reporting processes post-LIMS implementation
• introduction of streamlined stock management systems
• a revisit to Sample Reception, Preparation and Aliquoting

Our on-time delivery continues to improve (when we don’t have instruments down; see an post from 25 October regarding improvements in this area) and we’ll be focusing on delivering a consistently reliable service moving into 2024.

So, what exactly have we been up to?

2023 has seen a successful UKAS audit against ISO17025 and MCERTS, with a strong focus on continual improvement, culminating in a number of extensions to our capabilities and schedule of accreditation.

Following significant investment in both the lab teams and instrumentation, we have added to our routine service offering (all under Kens watchful eye…)

• 2 new GCMS systems to extend capacity for PAH, SVOC, PCB analysis, with a successful application for the extension of our ISO17025 and MCERTS accreditation for PAHs in Soil.
• Setting up and accreditation to ISO17025 and MCERTS of a new ICPOES methodology for the analysis of metals in soil. Previously based on ICPMS, we have set a new robust soils analysis method on a brand-new instrument, cross validated on our existing system to provide a greater capacity for analysis combined with the faster run time available with OES to allow us greater flexibility in our service delivery and a more resilient service.
• To complement the soils analysis, we have a new ICPMS method for the testing of metals in waters (Groundwater, Surface Water, Effluent, Prepared Leachate and Landfill Leachate) which was successfully accredited to ISO17025, and the purchase of a second instrument to add further depth to our ongoing capacity.
• Accreditation of a new Discrete Analyser to improve scope and automation in the testing of anions and nutrients in both soils and waters. Analysis covered include Chromium VI, Ammoniacal Nitrogen, Chloride, Fluoride, Sulphate, Phosphate, Oxides of Nitrogen and Alkalinity. Accreditation has been conferred on a range of testing (see our UKAS schedule of accreditation for full details)

What’s Next?

Doesn’t do to let the grass grow under your feet, so the next set of projects taking us into the New Year include:

• TPHCWG: As well as a recent exercise to re-assess levels of detection in soil, we are also performing a full validation with the intent to obtain accreditation to ISO17025 and MCERTS for our GCxGC method in soil, covering the Aliphatic and Aromatic hydrocarbon bands from C10 to C35. We hope to submit the Extension to Scope (ETS) this year, with accreditation to follow in 2024.
• Re-accreditation of our soils PCB method to MCERTS – following the purchase of some new instrumentation, we’re progressing a submission to re-add MCERTS accreditation to our PCB method in early 2024.
• More automation: in line with our principles of Lean management, continual improvement and efficiency we will this month take delivery of a new robotic titration system which will allow the automation of multiple titrimetric analyses, bring more operational efficiency and capacity.
• More BTEX: another area we’re investing heavily is expanding the instrumental platform for the analysis of BTEX and VPH (C5 – C10 Petroleum Hydrocarbons) with the additional of two new instruments (one in the building and another on its way) so we can complement the growing scope of accreditation in the area of TPH with additional capacity and higher throughput.
• Not content with new methods for routine metals, we’re also putting the new ICPOES to work adding accreditation for Water Soluble Boron and Water and Acid Soluble Sulphates to increase capacity and resilience.

It’s fast-approaching the holiday season and we want to give you all the information you need to make the most of us. Use the following information for a day-by-day breakdown of how Chemtech will be operating for the final few weeks of 2023.

The laboratory will be running a full analytical service up to and including the morning of Friday 22nd December. Please note the last day for dropping samples off at the lab is Thursday 21st December. Please ensure any samples are received at the laboratory before Friday 22nd December or after Tuesday 2nd January as we will be closed during this time and will not be able to receive samples.

 

Monday 11th December	Normal laboratory service (last courier collection for jobs to be reported before Christmas)
Tuesday 12th December	Normal laboratory service (last Chemtech driver collection for jobs to be reported before Christmas)
Wednesday 13th December	Normal laboratory service (last day to drop samples at Chemtech for jobs to be reported before Christmas)
Thursday 14th December	Normal laboratory service
Friday 15th December	Normal laboratory service
Monday 18th December	Normal laboratory service (last day for courier collections)
Tuesday 19th December	Normal laboratory service
Wednesday 20th December	Normal laboratory service (last day for sample submission)
Thursday 21st December	Normal laboratory service (last day to drop samples off)
Friday 22nd December	Normal laboratory service until 13:00
Tuesday 26th December	Bank holiday – laboratory closed
Wednesday 27th December	Bank holiday – laboratory closed
Thursday 28th December	Laboratory closed
Friday 29th December	Laboratory closed
Monday 1st January	Bank holiday – laboratory closed
Tuesday 2nd January	Courier collections and normal laboratory service resume

The waste wood industry has been under Regulatory Position Statement (RPS) 250 since 2021, which applied to hazardous waste wood removed from domestic premises and demolition sites and its route of disposal. On 1 September 2023, RPS 250 was removed, leading to changes in waste wood handling regulations. What does this mean for waste wood operators?

How has RPS 250 shaped the waste wood landscape?

RPS 250 enabled operators to continue disposing of construction and demolition (C&D) wood waste at waste transfer stations, and/or mix hazardous with non-hazardous waste wood at a processing site, for the past two years. This meant that it could be disposed of under a mirror non-hazardous waste code.

The Environment Agency implemented this on 31 August 2021, giving the waste wood industry two years to understand the quantities and types of hazardous waste wood arising from construction and demolition activity. This also allowed waste wood storage and processing businesses to apply for a permit variation to accept hazardous waste wood if there is a market need.

In response to this, the Wood Recyclers Association (WRA) was proactive in encouraging its members to sample waste wood and submit it for analysis. This aimed to determine how hazardous our waste wood really is in the UK in general and determine the market requirement for alternative disposal options.

The EA identified two wood waste streams as containing potentially hazardous materials: household recycled wood (such as fenceposts and decking) and C&D wood from pre-2007 buildings (including barge boards, fascia board, soffit board, external joinery from wooden windows and conservatories, external doors, roof timbers, tiling battens, cladding battens, timber frames, and timber joists).

To identify hazardous materials in waste wood, the WRA, using WM3 technical guidance, created test suites for both waste streams that target the contaminants of concern.

• WRA01: specific to household recycled wood. Focuses only on moisture content and select heavy metals. Household materials (such as fenceposts and decking) are covered separately by RPS 249, which will remain in place until April 2024.
• WRA02: for C&D wood. Includes the same analysis for moisture content and select heavy metals, as well as polyaromatic hydrocarbons and select organochlorine pesticides.

What’s all the fuss about?

The EA is concerned that, as pre-2007 homes are renovated or demolished, the wood that ends up at waste transfer stations could be treated with creosote, or other varnishes and paints containing heavy metals and pesticides, which are harmful to human health and the environment. Whilst there is now guidance that prohibits dangerous chemicals being used in the manufacture of wood treatment products, the EA has to ensure that wood from pre-2007 buildings is disposed of properly to avoid these products entering our environment. The same applies to household recycled waste wood.

By classifying waste wood, we can identify which items are hazardous in accordance with WM3 guidance and ensure they are dealt with appropriately and safely. This also helps producers, carriers and disposers maintain compliance whilst protecting the environment.

Why was RPS 250 removed and what does this mean for waste operators?

The WRA funded the trial analysis of samples collected by its members. Whilst a significant amount of data was collected for household fence posts and decking (which is still ongoing), the WRA did not receive enough C&D derived wood to determine concentrations of hazardous substances in this waste stream. As a result, the EA withdrew RPS 250 as planned on 1 September 2023.

This means that certain waste wood categories, which would have previously been sent to wood recyclers, will now need to be classified as hazardous waste unless analysed to prove that it is non-hazardous. If it is classified as hazardous, it will need to be disposed of at a suitably permitted facility.

As of 1 September 2023, the WRA02 test suite is now mandatory to ensure the correct disposal route for all potentially hazardous C&D waste wood items. Essentially, all demolition waste wood will now be classified as hazardous unless analysed to prove otherwise—meaning that there’s a lot more testing required for the waste wood sector.

We would encourage all wood waste producers to share data with the WRA, whether you are a member or not. This ensures that sufficient evidence can be collated to accurately determine the presence of hazardous properties in the wood waste stream, so that this new legislation can be reviewed at a later date by the EA.

Our sister lab, Marchwood, is one of only three WRA member laboratories who offer both the WRA01 and WRA02 UKAS accredited test suites. Drop us a line to find out more.

Whether RPS211 is withdrawn or not next month (answers on a postcard please), there’s little doubt that the analysis and detection of coal tar has seen a significant increase in the last few years. In the latest issue of the AGS Magazine, Will Fardon, Technical Director at Chemtech, discusses some of the considerations and pitfalls when selecting appropriate testing for the black stuff. Click below to read the article in full.

AGS is a FREE magazine from the Association of Geotechnical and Geoenvironmental Specialists focusing on geotechnics, engineering geology and geoenvironmental engineering.