Lean and green; how environmental performance can be enhanced by - PowerPoint PPT Presentation

Lean and green; how environmental performance can be enhanced by lean production systems and vice versa Target group Content • Learning objectives • Lean production training • Introduction Lean production • • Description coordinators - How the 7+1 wastes connects to - How the 7+1 wastes connects to Environmental organisation • environmental aspect - Is lean always green? Areas of conflict - Other parts of a production system that supports environmental improvements • Examples References • Henrik Kloo, Volvo Technology 2011-02-03 1

1. Learning objectives 2. Introduction 3. Description 4. Examples Appendix A. References

Learning objectives At the completion of this training the trainee will be able to… Realise that most environmental issues • are due to non value added aspects of production • • See how environmental performance See how environmental performance can be enhanced by a consistent lean thinking See opportunities for cost savings •

1. Learning objectives 2. Introduction 3. Description 4. Examples Appendix A. References

3. Introduction How can lean production be beneficial for environment? • Looking in perspective most environmental problems occur when a material, that may be valuable occurs at the wrong place, e.g. as a contaminant in air or water or as a waste • Clean production and lean production have the same objective: Minimising waste and maximise resource efficiency and productivity • The target is to produce the right product without rest products product without rest products • So by a consistent work with “muda” resource efficiency will be maximised and only the necessary resources will be utilised

1. Learning objectives 2. Introduction 3. Description 1. How the 7+1 wastes connects to environmental aspects 2. Is lean always green? Areas of conflict 3. Other parts of a production system that supports environmental improvements environmental improvements 4. Examples 5. Appendix A. References

The Seven + One Wastes Defects and Inventory Inventory Overproduction Overproduction Transport Transport Rework + Not used employee creativity Unnecessary Movements Wait Processes

Inventory Transactions not processed, design data which is not organized or not fully utilized Warning signs • – Extra space for receiving material – Last-in-first-out (LIFO) instead of First-in-first-out (FIFO) mentality – Constant or large amount of rework when a problem is discovered – Increased resources allocated for administrative processes Environmental Environmental • • – Excess storage space need heating, light etc. – Long lead times may make e.g. rust protection necessary, increases use of chemicals – Packaging material may be needed for storage reasons – All rework consume resources, increase scrapping

Overproduction Warning signs • – Extra equipment, space, personal – Tendency to hide problems – Big blocks of work – Unclear project plans Environmental – All unnecessary work consumes materials – Long prep or ramp up time cost energy use at non production – Obsolete material consumed resources – Excess use of chemicals and other materials when processes are not optimised

Transport Extra steps in the process, distance travelled, data hand-offs Warning signs – Extra personnel – Different office locations (for same work) – Empty desks – Unreliable copiers, etc . Environmental – All transportation consumes energy and creates emissions – Large spaces and moving out and in between buildings– excess energy consumption, especially open ports etc. – Transportation of hazardous materials creates risks and need extra precautions – More packaging materials to protect details and risk for damage creates waste

Defects and rework Rework, mistakes, quality errors, incorrect data entry, miscommunication Warning signs – Extra personnel to review, rework and repair – Complex processes – Dubious quality – Missed deadlines – – Reduced profit margins Reduced profit margins Environmental - Defect material becomes waste - Spills and emissions due to bad equipment - More production – more resources used - Bad quality = bad products = producing more future waste (more frequent replacement needed) – more production - Space for repair area consumes energy etc .

Unnecessary processes Multiple sign-offs, inspection, rework, redesign, poorly run team meetings Warning signs – Do more activities than is necessary – Improvements unknown to customer – Endless refinement of elegance and details – Extra paper or electronic copies – Information overload – Work that could be combined with another process Environmental Unnecessary processes consumes unnecessary resources

Movement Extra steps, travel from office to office desk to desk, unnecessary analysis or testing Warning signs – Search after tools or forms – Go to several people or extra effort to get info – Too long distance between info and access Environmental – All aspects of transportation – Often a problem at waste sorting: too few bins or placed too far away creates extra movements, or bad sorting result. Apply lean thinking to create efficient system

Waiting Processing periodically not as the work comes in (i. e. stand by losses Warning signs – People waiting for equipment, tools, information – Inadequate interest for short delays – Unplanned delays or postponement of work Environmental – Equipment and space consumes energy also at stand by – Risk for component damage or spoiled materials

Unused or underutilized creativity Warning signs – Few improvement suggestions – Lack of will to implement X – Lack of passion and enthusiasm – Poor morale – Lack of team activities – Lack of employee involvement – Doing MY job mentality – Doing MY job mentality Environmental - All employees can participate in improvements - Collect ideas to facilitate waste handling - All employees can be used to report leakages (typically water, process chemicals and pressurised air) - Often easy to create engagement for environment, this can be used to support other improvements

Summary: Clean production and Lean production combined in a production system have the same objective: Minimising waste and maximise productivity Less scrap Reduced environmental waste Fewer defects Less spoilage Fewer defects Reduced use of raw materials Less overproduction Simpler products Right-sized equipment Reduced materials, land and Less storage energy consumed Less inventory space needed Less overproduction Less lighting/heating/cooling Less energy use Less unneeded space Less oversized equipment Less over-processing Lower emissions More efficient transport and movement

1. Learning objectives 2. Introduction 3. Description 1. How the 7+1 wastes connects to environmental aspects 2. Is lean always green? Areas of conflict 3. Other parts of a production system that supports environmental improvements environmental improvements 4. Examples 5. Appendix A. References

Areas of conflict (?) Just in time may create more in bound and out bound transports due to smaller deliveries - Apply lean thinking also on transports; empty or half empty trucks are also a “waste” Treatment equipment for good cleaning often more expensive than more simple treatment - - Limits often set by authorities sooner or later. Proactive work will facilitate Limits often set by authorities sooner or later. Proactive work will facilitate cost efficient solutions; utilize possibilities to recycling to less demanding cost efficient solutions; utilize possibilities to recycling to less demanding processes Resource efficient equipment and measurement equipment may have investment cost that does not pay back in the short term - Apply life cycle cost thinking. - Find “windows of opportunity” e.g. at new investments and major changes, when obsolete equipment etc. will be changed anyway

1. Learning objectives 2. Introduction 3. Description 1. How the 7+1 wastes connects to environmental aspects 2. Is lean always green? Areas of conflict 3. Other parts of a production system that supports environmental improvements environmental improvements 4. Examples 5. Appendix A. References

Other parts of a production system that supports environmental improvements Continuous improvement – Applicable to all improvement work. Value stream mapping - a tool also for identifying environmental aspects. Just in time – same thinking Built in quality – Bad quality applicable for reducing: creates environmental waste, energy use at stand impact through excess use by and heated indoor area by and heated indoor area of materials and processes of materials and processes Process stability : Team work – Applicable to environmental 5s – demonstrates good improvements, practice, reduced spill and waste, Visualisation – shows clearly improvement areas and Maintenance – prevent spills results. and improve utilisation of materials, TWW- Leadership: Management commitment Standardised work – set good Safety : Chemicals, spill, air quality etc. environmental standard

1. Learning objectives 2. Introduction 3. Description 4. Examples 1. Working with energy optimisation 2. Working with waste minimisation 3. Spill prevention 4. Water saving and recycling Appendix A. References