Document 5LEaxjKQoka4R0gwy3d04EmZe
FILE NAME Caterpillar CAT DATE 1990 Sept 13
DOC CAT044
DOCUMENT DESCRIPTION Unpublished Internal Report - Asbestos
Elimination
September 13 1990
ASBESTOS ELIMINATION
SCOPE
Eliminate containing items from the worldwide Parts Distribution network no later than August 25 1994 and prevent a backflow of containing items into the network containing items shall be targeted for elimination in two phases
1
hand part numbers with less than a two 2 year time
supply shall be targeted for elimination by August 25
1992 to avoid relabeling except where EPA relief may be
granted
2
All other material shall be eliminated by the 1st Quarter
of 1994 except where EPA relief may be granted
OBJECTIVES
The following objectives will be used to develop PDIS System specifications for the elimination of asbestos parts from the Parts Distribution network The following abbreviations are used in the list of objectives
A
~
F
-
containing
Asbestos
Receive A material only from all sources
o
All U.S. facilities shall have the capability or resources
to inspect receipts for asbestos and identify the material
as C or F
All facilities shall store A and A items in separate
locations
As much as possible all / material shall be exhausted
from inventory rather than scrapped
All production withdrawals from Parts Distribution
facilities shall be F material only As of April 1
1990 this objective went into effect under manual
controls
CAT- 09801
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ASBESTOS ELIMINATION
-2-
September 13 1990
o
The flow of A material through the Parts Distribution
network shall be in one direction only Effective date
December 1. 1990
A.
No allocation reallocation or returns of /
material to Morton from other Parts Distribution
facilities shall be permitted
Departments B.
No returns.by Depots back to U.S.
be permitted
shall
All Dealer returns shall be inspected and properly
identified as A or A Disposition of the material
shall be made based on cost of the material and the
facility's inventory status
All material shall be identified as part number by
facility as to asbestos status
Appropriate status reports shall be provided to the U. S.
Covernment as required by law
GENERAL DESCRIPTION
The following narrative attempts to describe the functional
components of the asbestos elimination project The necessity and urgency of this project are the result of Governmental Regulations
requiring the elimination of containing material from products in the U.S. by August 25 1994. These requirements impact
the worldwide Parts Distribution network in that the one key aspect
of the elimination project will be to prevent the backflow of
containing items into any facility which has previously
exhausted containing material from its inventory
The elimination process will be controlled by part by facility
The underlying principle to eliminating containing A
items from the Parts Distribution networiks to become asbestos free
A at MPDC and push the / material downward in the P.D.
network After Morton is A on a given part number Parts
Departments then Depots in turn will eliminate their A inventory
An asbestos EPA indicator will be established on the P.D. Master
file for each facility This indicator will indicate the current
inventory status of
asbestos candidate
a part number as being A A inventory will attempt
not A or not an
to be eliminated by
exhausting stock scrapping of inventory will be done only as a
measure of last resort The succeeding topics will describe asbestos elimination efforts by major functional groups
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ASBESTOS ELIMINATION
3
September 13 1990
RECEIVING INSPECTION
The P.D. Master to indicate the
planning indicator 2 field is presently being used
receiving status of an asbestos part from source of
supply An immediate objective
A material at Morton from all
of the project is to receive sources as soon as possible
only
All
U.S. facilities must develop adequate inspection procedures for
inspecting receipts to identify material as A or A Alternate
sources of are unable
supply will need to be developed for any or unwilling to provide F material
suppliers
who
STORING LOCATING
Another critical component of this project is the ability to maintain separate locations by part number for material known to be -
A and material which is know to be / or has the potential of
containing mixed stock Receiving systems will need to have the ability to route A receipts to a known A location until an A receipt generates a new A location at which time all subsequent receipts will be rerouted to the A location or set up additional multiple F locations Locations must be properly identified with C or / labels accordingly
ORDERFILLING
As long as the facility asbestos status indicator reflects the presence of / material at the facility all orderfilling will be done out of identified A locations Once an C location becomes
empty a kill transaction should be generated to remove that location from the location file If all C locations have been
eliminated the facility EPA indicator must be reset to reflect an
A status for the part number All outbound material must also be
properly identified with / or A stickers Also have been defined for the project which prohibit A being used to fill production withdrawal orders
requirements material from
RETURNS ALLOCATIONS REALLOCATIONS
ad oe
pro
ail pro pro 4
ail pro a
a)
he
oe vt
Lo
i /
As mentioned previously one of the most critical requirements of the elimination project will be to prevent the backflow of / items
in the P.D. network At Morton all Dealer returns of asbestos part numbers will be inspected for the presence of asbestos identified
and dispositioned accordingly No Department or Depot returns will be accepted Likewise P.D. Departments will accept A material from Morton only No Depot returns of asbestos parts will be
permitted to the U.S. Departments Once the U.S. Department facilities have exhausted / stock their appropriate inventory status indicators will be reset accordingly P.D. Depots will be the last link in the chain prior to Dealers for exhausting C
material Throughout the network no allocation or reallocation of
C parts will be allowed which violates the backflow restriction
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ASBESTOS ELIMINATION
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September 13 1990
TARGET DATES GOVERNMENT REPORTING
Two significant target dates have been identified as an integral part of the elimination project They are
1
1st Quarter 1994 - All other A items shall be
eliminated this is a cushion to assure compliance with Federal Regulations requiring all A inventories be
scrapped no later than February 25
relief
may
be granted
1995
except where EPA
Finally certain reports will be required to be provided to the
Federal Government The responsibility for generating the necessary reports will be determined during system requirements planning
POIS ESTIMATES
Information Services has addressed the elimination of asbestos and
is providing the following estimates for the work involved based on the project scope and objectives
SYSTEM CHANGE ESTIMATES
PDLMS
Add the asbestos EPA indicator to the DB2 database
Establish separate locations for A material at Morton
York and Denver
0
Pass transaction to update PDD master EPA indicator to A
when applicable
0
Add EPA indicator to Morton Multiloc file for TICS tag
processing
ESTIMATED EFFORT - - - - 170 Staff Days
Receiving System Morton
0
Identify asbestos type parts at receiving time
fe)
RTS will pass information to PDLMS which will determine
the location
Pass EPA indicator to TCAM Tag Print
ESTIMATED EFFORT > - - - 7 Staff Days
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ASBESTOS ELIMINATION
5
September 13 1990
ne id
SYSTEM CHANGE ESTIMATES G^ NT^
Receiving System York & Denver
Identify asbestos type parts at receiving time
Use prelocation subroutine to determine A location
0
York and Denver transit tags need / identification
0
A secondary receipts must be identified via the Summary
Run through SOP and Invoicing to prevent A material from
being mixed at York and Denver
(a)
A production receipts must be identified via the Summary
Run to prevent A material from being mixed at York and
Denver
ESTIMATED EFFORT - - - - 36 Staff Days
Locating System York & Denver
2
Identify A locations on York and Denver SAS Overflow
file
Populate Overflow file with locations containing asbestos
Modify relocations subroutine to determine asbestos
disposition based on information passed from calling
program
cs)
Produce Summary Run transactiotno set asbestos indicator
to /
ESTIMATED EFFORT - - - - 100 Staff Days
Retrieval System
)
Identify and employ FIFO logic for all asbestos parts
Pass transactions to update PDD Master when A material
is depleted to indicate /
ESTIMATED EFFORT - - - - 50 Staff Days
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ASBESTOS ELIMINATION
6
SYSTEM
CHANGE ESTIMATES CONT'D
September 13 1990
Summary Run
Add an EPA indicator to the PDD Master for each parts
facility to track the status of each asbestos part which
is stocked
-
0 Not an asbestos candidate
1 F Only
:
2 Both A & A Parts
-
3 / No Receipt on F
Pass EPA indicator along with each Denver tag as a result of a receipt for processing in System and Denver Receiving System
Department
the SOP
ESTIMATED EFFORT - - - - 25 Staff Days
TICS
Print / or
facilities
/
The
on all asbestos parts for nonrevenue EPA indicator would be used in
conjunction with the location to identify when going from containing to free EPA indicator
to be added to TICS TLOCFILE
the part is would have
Pass EPA indicator from Multiloc TICS TLOCFILE TLOCFILE must be the indicator
and Overflow files to expanded to accommodate
ESTIMATED EFFORT - - - - - 25 Staff Days
Quality Control
9
Add asbestos sampling routines to existing QC and Met Lab
sampling program
ESTIMATED EFFORT - - - - 25 Staff Days
Order Entry
o
Use the PDD Master planning indicator 2 EPA indicator
once it is established to prevent production facilities
from ordering asbestos parts
ESTIMATED EFFORT - - -7 Staff Days
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ASBESTOS ELIMINATION
7
September 13 1990
SYSTEM CHANGE ESTIMATES CONT
D
TCAM Tag Print
0
Print A on nonrevenue type 1 allocations when
applicable Will require some reformatting of the tag to
accommodate the size of the message
ESTIMATED EFFORT - - - - 20 Staff Days
New CICS Application
fe}
Develop a screen to allow Departments and Depots to easily
update the PDD Master EPA indicator when a part becomes
asbestos tape and disk master files
ESTIMATED EFFORT - - - -
5 Staff Days
New Reporting System
0
Develop a reporting system utilizing user programming
SA5 to provide a status update on a periodic basis for
the U.S. Government
ESTIMATED EFFORT - - " - 10 Staff Days
Project Administration
Administrative effort to manage the overall project
ESTIMATED EFFORT - - - - 30 Staff Days
Unknowns
0
A 20 factor was added to cover unknown changes
ESTIMATED EFFORT - - - - 95 Staff Days
Months 30 Months 30
TOTAL ESTIMATED EFFORT - -
70/605 STAFF DAYS
70/605
against
a checwkork work
PROJECTED TARGET DATE - - - - FEBRUARY 1 1991
091390
Months
30 staff
3 mos
Nov
IS
plan
_ 10 people
-
Jan91
-
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015
CONTA - CIONNTAIINNINGG PRODUCTION WITHDRAWALS
All containing part numbers blocked effective
September 1 1990 per administrative agreement
DEALER RETURNS
Inventory Control Willard Jackson is currently reviewing
all returns on containing parts and is
determining
this action
their disposition at approves a degree of
our returns
scrap
facility
This policy allows some asbestos parts
Morton where our hand is deemed low
exhaust within the EPA requirements
to be received at and we expect to
All asbestos Dealer returns should be blocked December 1 1991 This date is in union with program changes to
store asbestos receipts separate from containing
SECONDARY RECEIPTS
When do we block the backflow of asbestos parts December 1 1991
SURPLUS RETURNS CIC FACILITY
Surplus asbestos part numbers should be left at their
respective backflow
facilities to be exhausted Effective date December 1
thus preventing 1991
SUBSIDIARIES RETURNS NON FACILITY
When do we block the backflow of asbestos parts December 1 1991
091390
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015