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Lean Services and Office Kaizen
Center for Advanced Manufacturing and Lean Systems 1
From Lean to Green and
FAIM2011, June 26FAIM2011, June 26--29, 201129, 2011
F Frank Chen Ph D
From Lean to Green and Sustainable Manufacturing
F. Frank Chen, Ph.D.Lutcher Brown Distinguished Chair in Manufacturing &
Director, Center for Advanced Manufacturing & Lean Systems
University of Texas at San [email protected]
© Copyright 2011 – Center for Advanced Manufacturing & Lean Systems
Sustainable Production Definition
“The creation of goods and services using processes and systems that areprocesses and systems that are non-polluting;
conserve energy and natural resources;
economically viable;
safe and healthy for workers, communities, yand consumers; and
socially and creatively rewarding for all working people.”
(Lowell Center for Sustainable Production,1998)2
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© Copyright 2011 – Center for Advanced Manufacturing & Lean Systems
Sustainability
According to the Brundtland Commission of the United Nations (1987):“sustainable development is development that
meets the needs of the present without compromising the ability of future generations to meet their own needs”
This involves the three pillars of environmental, economic, and social sustainability
-- Wikipedia: http://en.wikipedia.org/wiki/Sustainability
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© Copyright 2011 – Center for Advanced Manufacturing & Lean Systems
Green Manufacturing Green manufacturing attempts to establish a solid
foundation for all three pillars to achieve a sustainable business operationsustainable business operation
En
viron
men
Eco
no
mic
So
cial
Sustainability
Primary focus of most businesses
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Green Manufacturing
ntal
c
For complete sustainability, all three must be given attentions
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© Copyright 2011 – Center for Advanced Manufacturing & Lean Systems
Waste Management Hierarchy
high
Green Impact
l
Traditional 3Rs
To have the largest energy and environmental impact Eliminate the processes you can, reduce what you cannot eliminate
One very effective means of reducing processes is Lean5
low
© Copyright 2011 – Center for Advanced Manufacturing & Lean Systems
Principles of Lean Let customers identify Value
Companies provide what customers really want A product/service is not just an object, but a whole p oduct/se ce s ot just a object, but a o e
experience Identify the Value Stream
Value Stream: Sequence of all activities and resources required to bring a product/service to customers
Make the value stream Flow Create smooth and uninterrupted flow for
d t /
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products/processes Pull from downstream
Operations are performed when needed, not before Always pursue Perfection
Continuous improvement is a way of life (Womack & Jones, 1996)
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© Copyright 2011 – Center for Advanced Manufacturing & Lean Systems
Merging Lean and Green
A Lean and Green Enterprise is one that kseeks
Operational excellence,
Energy efficiency, and
Environmental sustainabilityLean and
Green
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Operational Excellence
Energy Efficiency
Environmental Sustainability
Green Enterprise
© Copyright 2011 – Center for Advanced Manufacturing & Lean Systems
The Seven WastesWaste: Anything that adds cost or time without adding value
InventoryInventory TransportTransport
W itiW itiMotionMotion
WastesWastes
InventoryInventory
UnderUnder--Utilization of Utilization of Human TalentHuman Talent
OverOver--ProcessingProcessing
88thth
WaitingWaiting
OverOver--ProductionProductionDefectsDefects
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© Copyright 2011 – Center for Advanced Manufacturing & Lean Systems
9th Waste Added for GreenEnvironmental Waste - “any use of resources or a
substance released into the air, water, or land that could harm human health or the environment”could harm human health or the environment -- Lean and Environment Toolkit (EPA)
Green Examples: “Energy, water, or raw materials consumed in excess
of what is needed to meet customer needs”
“Pollutants and material wastes released into the
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Pollutants and material wastes released into the environment”
“Hazardous substances that adversely affect human health or the environment during their use in production or their presence in products”
© Copyright 2011 – Center for Advanced Manufacturing & Lean Systems
Lean Wastes – ExampleIncoming Queue
Outgoing Queue
Milling Process
Lean WastesWaiting, WIP
Energy WastesElectricity, Heat
Environmental WastesScrap, Fumes
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© Copyright 2011 – Center for Advanced Manufacturing & Lean Systems
Waste Elimination
Waste is all around, we don’t usually
Where are the wastes?
Waste is all around, we don t usually see it because it has become “normal”
We need to train our eyes to be able to see waste
Lean Concepts and Tools can help you toLocate the wastes eliminate them and
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Locate the wastes, eliminate them, and sustain your efforts
© Copyright 2011 – Center for Advanced Manufacturing & Lean Systems
Lean Tool: Visual Workplace
Visual Workplace - Provides visual indicators so that goals and the current status of the workplace can easily be identified
Green Impact:
This can include energy usage goals, which can h l k d t b i fhelp workers and managers to be conscious of energy use and opportunities for energy reduction
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© Copyright 2011 – Center for Advanced Manufacturing & Lean Systems
Lean Tool: TPM
Total Productive Maintenance (TPM) – a systematic care and maintenance program conducted by the operators on their machines/equipment to increase productive time
Green Impact:
E th t i t d hi Ensures that equipment and machinery are operating at peak efficiency, thus reducing energy consumption and decreasing the likelihood of system downtime
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© Copyright 2011 – Center for Advanced Manufacturing & Lean Systems
Lean Tool: Quick Changeover
Quick Changeover – a procedure to reduce the setup and changeover time for a process
Green Impact:
Reduces the time the line is down
It also reduces the energy used to make the changeover and provide light and heat during non-productive time
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© Copyright 2011 – Center for Advanced Manufacturing & Lean Systems
Lean Tool: Error Proofing
Error Proofing – a method to eliminate errors from occurring, prevent errors from being passed on to the next process, or detect errors once they occur
Green Impact:
Att t t id tif ibl Attempts to identify errors as soon as possible or to eliminate them altogether
This saves the energy and material required to fix or replace errors
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© Copyright 2011 – Center for Advanced Manufacturing & Lean Systems
Lean Tool: Right-Sized Equipment
Right-Sized Equipment – a method that ensures that the appropriate machines and equipment are used to complete a process step
Green Impact:
Selecting equipment that has just enough capability and speed to satisfy the flow of a production cell can provide tremendous energy savings over an outdated machine that has much more capacity than is required
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© Copyright 2011 – Center for Advanced Manufacturing & Lean Systems
Lean Tool: Value Stream Mapping
Value Stream Mapping (VSM) – an effective tool th t i d t id h li ti i f ththat is used to provide a holistic view of the process of converting raw materials into finished products
Green Impact: Traditionally VSM has focused on identifying and Traditionally, VSM has focused on identifying and
eliminating manufacturing wastes to reduce the production lead time
Reducing these wastes will often provide someenergy savings and positive environmental impacts
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© Copyright 2011 – Center for Advanced Manufacturing & Lean Systems
Energy and Environment VSM(EE-VSM)
A modified VSM is needed to fully realize the ypotential energy and environmental savings
EE-VSM is introduced to enhance the traditional VSM to incorporate both energy and material usage throughout the complete manufacturing conversion and delivery process
EE-VSM will enable manufacturers to:Reduce the delivery lead time and
Reduce wasteful energy consumption and
Reduce environmental wastes18
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© Copyright 2011 – Center for Advanced Manufacturing & Lean Systems
VSM Icons – Energy Flow
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© Copyright 2011 – Center for Advanced Manufacturing & Lean Systems
Value-Adding Line
Non-Value Added Value Added Non-Value Added Value Added
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© Copyright 2011 – Center for Advanced Manufacturing & Lean Systems
EE-VSM Example
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© Copyright 2011 – Center for Advanced Manufacturing & Lean Systems
Lean Sustainability Metrics
Productivity MetricsTotal Lead Time
Value Added Time / Non-Value Added Time
Throughput
Sustainability MetricsEnergy ConsumptionEnergy Consumption
Water Consumption
Material Usage
CO2 Emissions22
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© Copyright 2011 – Center for Advanced Manufacturing & Lean Systems
Lean Sustainable Production Assessment Tool The tool is introduced to help visualize and
l b th th d ti it danalyze both the productivity and sustainability metrics
It consists of a:Real-time Dashboard
Consists of a meter for each metricConsists of a meter for each metric
Represents the current state of the system
Continuous Improvement Dashboard Used to ensure achieved improvement levels are
maintained and that progress is being made23
© Copyright 2011 – Center for Advanced Manufacturing & Lean Systems
Real-time Dashboard
Meters include a:
Target value
Buffer zone (yellow)
Good zone (green)
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Bad zone (red)
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© Copyright 2011 – Center for Advanced Manufacturing & Lean Systems
Continuous Improvement Dashboard
Total Lead Time
CO2 Emissions
Energy Consumption
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Note: Only a portion of the dashboard is shown.
© Copyright 2011 – Center for Advanced Manufacturing & Lean Systems
Summary Combining Lean and Green is a natural fit It enables the possibility of a truly sustainableIt enables the possibility of a truly sustainable
business One that has Environmental, Economic, and
Social SustainabilityGood for everyone:
the company the company, its shareholders, its customers, society, and the environment!!!
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© Copyright 2011 – Center for Advanced Manufacturing & Lean Systems
UTSA Center for Advanced Manufacturing and Lean Systems “Value-Creation” Process
Lean
Automation
Robotics
Lean
Automation
Robotics
TO
OL
ST
OO
LS
Productivity
Energy &Environment
Quality of Life
Productivity
Energy &Environment
Quality of Life
ME
TR
ICS
ME
TR
ICS
SolutionsSolutions ValueValueSustainable Mfg Sys Lab
SOCIETALNEED
TECHNICALNEED
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© Copyright 2011 – Center for Advanced Manufacturing & Lean Systems
Conclusion
If Lean and Green are performed correctly,
Green = Green
==
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For more info – send inquiries to [email protected]
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© Copyright 2011 – Center for Advanced Manufacturing & Lean Systems
References
EPA. The Lean and Energy Toolkit, U.S. Environmental Protection Agency, Lean Manufacturing and the Environment. Available at:Lean Manufacturing and the Environment. Available at: http://www.epa.gov/innovation/lean/toolkit/LeanEnergyToolkit.pdf, Accessed on 3/18/09.
EPA. The Lean and Environment Toolkit, U.S. Environmental Protection Agency, Lean Manufacturing and the Environment. Available at: http://www.epa.gov/innovation/lean/toolkit/LeanEnviroToolkit.pdf, Accessed on 3/18/09.
Wikipedia. “Sustainability”, Available at: http://en wikipedia org/wiki/Sustainability Accessed on 11/24/09http://en.wikipedia.org/wiki/Sustainability, Accessed on 11/24/09.
Womack, J. P. and Jones, D. T., 1996, Lean Thinking, Simon and Schuster, New York, NY.
Lowell Center for Sustainable Production, 1998, Sustainable Production: A Working Definition, Informal Meeting of the Committee Members.
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