Emissions Forecasting

  • Automatically Tracks and Projects VOC Emissions
  • Minimizes Risk of Exceeding Plant Emissions Limit
  • Eliminates Extensive Clerical Effort Required
  • Simplifies Resolution of Emissions Bottlenecks in Production Schedule
  • Improves Production Schedule Accuracy

This module identifies up to 12 different emission compounds for each item in the system. The emission compounds are basically assigned at the raw material level and then rolled up through each item’s Bill of Material. The Emissions Forecasting module uses the rolled-up emission compound totals as the basis for reporting on the total quantity of each compound emitted each day based on daily production schedules. Daily emission reporting has been designed per Environmental Protection Agency (EPA) requirements.

Emission Compounds

The Emissions Forecasting module can track up to 12 different types of emission compounds. These compounds are all user-defined. Common compounds include Volatile Organic Compounds (VOC’s), non-VOC compounds, lead, water, etc. Each of the valid emission compounds that you wish to track in the system must first be identified with an Emission Code.

Basically, a separate item number should be established for each of the emission codes that are defined. Each of these items is then identified with the appropriate emission code via the Item Master Maintenance screen in the Quality Assurance module. These emission compounds should then be placed within each Bill of Material in which they originate; this may be at the raw material level, or as a by-product from the production of a specific parent item.

The cost roll-up process within the Cost Accounting module includes the optional ability to roll-up emission compounds for each item. Since the emission roll-up process is almost identical to the cost roll-up process, the two procedures have been combined into the same program so as to reduce system overhead and processing requirements. Furthermore, since cost roll-ups are normally performed on a regular basis so as to maintain accurate current planned costs, the emission compounds can be simultaneously rolled up to maintain accurate emission forecasts.

The result of the emission roll-up process is that the total quantity of each emission compound is accumulated for each item number. The total content of each emission compound for a given parent item is an aggregate of the total quantity of that emission compound within each component multiplied by its respective quantity per in the parent item’s single level Bill of Material. These rolled-up quantities are then used as the basis for daily emission reporting.

Emission Groups

Daily emission reporting is accumulated at the Emission Group level. Basically, each work center defined in the system can be assigned to a specific emission group.

Depending on your operation, each work center may be assigned to a unique emission group, or several similar work centers may be grouped together under one emission group.

Since routing operations are tied to work centers, which can now be linked to an emission group, emission reporting looks at the daily production for each operation and then tracks it forward to the work center and then to the emission group to which it is linked.

Daily Emission Reporting

Daily emissions are tracked based on the material used in your production environment and the operations in which that material was used. Since DMACS provides the ability within the Manufacturing Engineering module for linking an item’s Bill of Material components with specific operations in its routing, the system is able to determine the emission group to which each component has been issued, or from which a component was returned. Basically, a component is tied to an operation, which in turn is linked to a work center, which can optionally be assigned to an emission group for daily emission reporting.

The system determines the material used or returned in your production environment by reviewing the Inventory Audit Trail table for all component issues and returns for the day(s) in question. By tracking material consumed/returned back to the operation at which it was used, the system is able to determine the emission group to which the operation is linked. Since clean-up operations generally require the use of certain chemicals or operatives that generate VOC emissions, the daily emission report also calculates separately the total emission quantities that were generated during clean-up.

For each component in question, the system determines the total emission quantity for each emission code based on the production quantity of the component multiplied by the component’s total emission quantity for each of its emission codes. Since emission quantities are normally defined in the Bill of Material in pounds per gram, the daily emission quantities are converted to pounds per gallon for EPA emission reporting.

For each emission group, a daily emission report displays the total quantity emitted for each emission code. The report also accumulates the total quantity emitted by emission code and displays these summary totals at the end of the report.