Ecolibrium in the Transformation of Mitsubishi Electric, Livingston, Scotland, UK
(Relevant Experience – Sustainable Business Mission + Strategy ► Leadership)
From air-con “start-up”, with significant environmental issues to address (1995), to a world leading “green jobs” exemplar delivering heat pump solutions for a decarbonised net-zero world (2022) – as cited and broadcast on BBC News in Sept 2021 (see links below).
Introduction
In 1995, Ecolibrium (Environmental Science & Management) Ltd. had already identified the global trend towards businesses becoming more accountable for their environmental impacts and sustainability performance. Not only was legislation pushing industry in that direction (eg. The Environmental Protection Act 1990), but the most forward-thinking organisations were starting to realise that there was added value in going beyond mere legal compliance, to being able to demonstrate year-on-year improvement and sector leadership.
Project Objective
Mitsubishi Electric was one such global business that was promoting itself as one to lead the way on sustainability best practice. However, with a myriad of environmental impacts, due to the wide range of on-site processes and associated legal obligations, their Livingston operation was some way off meeting that aspiration.
Of course, when we first started working with Mitsubishi we had no idea that we would still be working with them on sustainability issues almost 2 decades later. “The project” rolled on and on, so the project objectives rolled forward as both partners strived to identify and deliver leading-edge practice. Close collaboration with our client and “hands on” consultancy (we don’t just write reports, we like to get our hands dirty!) ultimately led to this success.
Establishing the Performance Baseline + Priority Action
At Livingston, One of Ecolibrium’s first tasks was to lead a team to undertake what was called a “Preparatory Review” in BS 7750 (the precursor Standard to now well-recognised ISO 14001). We evaluated the full range of environmental impacts associated with all the manufacturing and assembly processes, and assessed the implications of systematic environmental management approaches and solutions for continually improving performance. We essentially established the baseline and priorities for action.
Systematic Approaches
The process of ISO 9000 Quality Management System (QMS) implementation had already started at the site, so we set out to work with Mitsubishi personnel already engaged in implementing this standard (as they have similar governance models and underlying principles). In the spirit of resource efficiency and systems thinking, other core skills at Ecolibrium, integration of common elements was practiced from the very first days of working at Mitsubishi.
The on-site processes themselves involved significant manufacturing of AC unit components, so it was not just a straightforward assembly plant. For example, steel panels were pressed / formed, treated, powder coated and cured at the site, copper pipework was formed and brazed, and elements were combined to form heat exchangers. So, there were significant atmospheric emissions in addition to trade effluents discharged and waste streams generated (hazardous and non).
The transformation required much more than just ensuring many bits of technology functioned efficiently, and that the most cost-effective technical solutions were implemented. There was an equally large element of best practice training and behaviour change involved too in order to meet policies and standard requirements.
As Ecolibrium’s Project Lead, Derek Panton, was one of the first trained and registered Environmental Auditors in Scotland, so Ecolibrium was also one of the first specialist firms to offer ISO 14001 Environmental Management System Standard (1996) services too, given the Plan-Do-Check-Act nature of this Standard (ie. auditing skills a key part).
The Initial Action
Initial work from 1996 – 1998 to meet the tight ISO 14001 certification deadline set in Japan, mainly involved quantifying the environmental impacts, from energy consumption to waste generation, implementing reduction / efficiency processes, and engaging with the workforce to transform embedded practices which gave rise to significant aspects and impacts. Very briefly, a selection of tasks / projects included:
- Evaluation / ranking of Environmental Aspects, using state-of-the-art science-based risk assessment skills + techniques to ensure focus on priorities (looking back over reports, it is quite interesting to note that out of all effects / impacts, we had already started to highlight “global warming potential”, although not necessarily as the absolute top priority it has become).
- Development of Legal and Other Requirements Register (including horizon scanning procedure)
- Development of prioritised and quantified objectives and targets, and associated improvement programme, against key Aspects
- Collaborating and drafting of key policy and process documents
- Undertaking gap analyses and auditing of progress
- Undertaking Training Needs Analysis for all personnel, and subsequent running of various sessions and courses; eg.:
- Intros for management personnel
- Detailed training of key personnel on priority legal and sustainability issues at the site (eg. Environmental Project Team leaders, key dept. leaders, etc.)
- Area / process specific training for personnel undertaking critical sustainability-related tasks
- Environmental awareness for groups of employees
- Training of trainers, to raise pace of behaviour changes + implementation of requirements
- Internal EMS Auditor training (4-5 day training, including practical “on the job” auditing of processes and other sites to rapidly build experience)
Building on ISO 14001 Success
With ISO 14001 certification achieved in 1998, Ecolibrium’s scientific and technical skills then came to the fore to build in systems to ensure ongoing compliance with new and future legislation, and continual improvement in sustainability performance. We also had to assist in expanding the system, and rolling out best practices, as the Mitsubishi operation expanded from the 1 main site on Nettlehill Road, to 4 sites in Nettlehill Industrial Estate.
Some key contracts included:
- Development of trade effluent management programme to achieve zero non-compliances with discharge consent conditions and optimise treatment and recycle options; including: extensive sampling and analysis, tracing, root-cause analysis, process SOP development for process optimisation.
- Air Pollution Control (APC) permit application development to address increasing production and associated emissions over control threshold. Work included assessment of Prescribed Substances and Processes, Calculation of HMIP minimum discharge stack height, BATNEEC, development of operations guidance, liaison with SEPA, etc. Delivered successful APC application.
- EU Eco-Management and Audit Scheme (EMAS) – feedback and advising in preparation for verification.
- Integrated Energy + Water Efficiency Assessments – including all sub-processes, energy / water / carbon reduction opportunities, alternatives + combinations, water balance and anomalies, cost + future economic issues, etc.
- Quarterly Legal, Policy and Guidance reviews of new and future developments. Given multitude of legal requirements for operations from ozone-depleting refrigerants, to trade effluent, Special Waste, etc. As environmental regulations increased, this involvement also took in energy performance requirements, Producer Responsibility, REACH, fluorinated greenhouse gases, etc.
The Results and Business Benefits
The Livingston, Scotland operations of Mitsubishi Electric plant went from AC unit start-up site, with an initial priority on getting manufacturing up and running, to a unit now operating as Mitsubishi’s premier European site, not just trusted to produce the heat pumps of the future, but leading on heat pump R+D to address the 17% of UK carbon emissions that space heating contributes. It is certainly not a coincidence that this site, steeped in sustainability management focus from the very start, is now manufacturing some of the world’s finest heat pump systems to address the climate emergency.
Excellent sustainability performance created the foundation for these sites to become a leading “green jobs” hub in Scotland, at the forefront of climate leadership, very much part of the solution!
Back in 1996, we certainly had no inkling this site would be leading a Japanese company’s innovation in a critical technology. But, with hindsight, as we got into the work, seeing identified action and solutions implemented, perhaps we could have foreseen that the incredibly focussed senior management team and remarkable workforce (in their ability to rapidly adapt to change) were going to pull off something outstanding. Ecolibrium is proud to have played a small part in that.
George Clarke, Architect and TV presenter, even showcased the Mitsubishi operation in 2020 as, not just a centre of excellence in heat pump (“Ecodan”) manufacture, but also now in research + development too – a world leader! In Sept 2021 the BBC main UK evening news also carried a feature on “Green Jobs”, broadcasting action from this inspiring operation.
A Final Thought!
We think this is how “consultancy” is supposed to work! We gradually did less and less for Mitsubishi as the workforce became more empowered and enabled to identify and make the improvements necessary themselves. It is definitely not about the one-off engagement, delivery of a heavyweight report and then making your client dependent on the next one-off! But, perhaps that’s why we were fortunate to work with Mitsubishi for 16+ years, and why this site is an exemplar of leading-edge practice into the 2020s?
