Fabtech 2014 sustainable lean

FABTECH ATLANTA 2014

Lean Sustainable Practices

For Manufacturers

William Shema

Paper-Less, LLC.


Lean Sustainable Practices For

Manufacturers

Definition – Environmental Waste.

Why Important (past, present, future)?

Lean Structure.

Environmental Management.

Business Objective.

Solutions.

Conclusion.


Lean Sustainable Practices for

Manufacturers - Definition

Environmental waste is an unnecessary use of

resources or a substance released to the air, water, or

land that could harm human health or the environment.

This would include materials consumed in excess of

what is needed to meet customer demand, pollutants

and material wastes released into the environment, and

hazardous substances that affect human health or the

environment.



Manufacturers – Importance

(Past)

Los

Angeles

USA



Manufacturers – Importance

(Present)

China



Manufacturers – Importance (Future)



Manufacturers – Lean Structure

Principles:

• Zero tolerance for waste

• Optimization of resources

• Customer focus

• Teamwork and Communication

• Continuous Improvement




Tools:

• 5S – Issues become

Visible

• Standard work

• Total Productive

Maintenance

• Process Improvement

Workshops

• Kanban (Pull/Flow)

• Mistake Proofing (Poke-

Yoke)

• Visual Management

• Value Stream Mapping




Wastes:

• Over Production

• Waiting

• Inventory

• Over Processing

• Defects

• Transportation

• Motion




Goals:

• Improved Safety

• Improved Productivity

• Improved Quality

• Lower Costs

• Improved Customer Satisfaction

• Improved Delivery



Manufacturers – Environmental

Management

Goals found in Lean Manufacturing:

• Reduction in Energy Use (heating, cooling, and

lighting).

• Reduction in Raw Material Usage.

• Reduction in Emissions.

• Reduction in Disposal.

• Reduction in Water Use.



Manufacturers – Environmental

Management

Goals Not Found in Lean Manufacturing:

• Toxicity of Substances

• Resources used in Extraction of Materials used in

Manufacturing.

• Life Cycle Assessment (Cradle to Grave) - LCA



Manufacturers – Business Objectives




Cuts in Greenhouse-Gas Emissions by

2030:

USA average = 30%

Washington = 71.9%

Georgia = 44.4%

New York = 44.1%

Texas = 39.1 %

Wisconsin = 34.2%

Pennsylvania = 31.7%

Michigan = 31.5%

Ohio = 27.7%

Alabama = 26.7%

California = 23.1%

Indiana = 20.4%




Companies With Environmental Management

Systems:

Ford Motor Company

Sherwin Williams

Coca-Cola Company

SC Johnson Co.

Sprint

The McGraw Hill

Altria



Manufacturers – Solution

Roof Top Sky

lighting:

Less energy required

for lighting and

heating (during the

winter months).




Natural Lighting:

Similar to Sky

Lighting, the use of

natural lighting of

both office and shop

areas.




Reflective Roofing

Material:

Reduces the energy

required to cool down

industrial buildings.




LED Lighting:

Reduces the

energy use to light

industrial buildings.




Life Cycle

Assessments:

Consider a product’s

complete lifecycle

and begin to

increase the amount

of reusable material

from a discarded

item.




MES System:

Use of software in

order reduce the

amount of disposable

material used for a

customer order.




Nesting Software:

Increases the

utilization of sheeted

raw materials. Less

scrap material per

sheet size.




Alternatives to Toxic

Materials:

Consider removing toxic

materials that are used in

the processing of the final

product.



Manufacturers - Conclusion

Your company can enhance its Lean performance by

ensuring that environmental wastes are additionally

identified during Lean activities. This can be started by

including environmental waste in the Lean training

effort. Incorporating environmental metrics, such as

energy usage, in your Lean goals will aid in ensuring

that sustainable manufacturing practices are used.


Thank

You

Fabtech 2014 sustainable lean

Technology

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