Lean and GreenOverview

Lean and GreenOverview

Concept to integrate Traditional Lean in Green way

Content Layout• Why lean & green• Introduction• History• About lean & green• Tools & techniques• Environment VSM• Energy VSM• Current state of Case study• Areas of application• Benefits

• Why lean & green• Introduction• History• About lean & green• Tools & techniques• Environment VSM• Energy VSM• Current state of Case study• Areas of application• Benefits

Why Lean & green• We are consuming natural resources day by day, causing their

stocks to cease in earth’s crust.• Green & lean manufacturing is a step to use processes that are

non-polluting, conserve energy with least scrap generation.• Operation management is attempting to use the tools and

concepts of lean operations to add green metrics to themeasures of excellence companies use in business processes.

• We are consuming natural resources day by day, causing theirstocks to cease in earth’s crust.

• Green & lean manufacturing is a step to use processes that arenon-polluting, conserve energy with least scrap generation.

• Operation management is attempting to use the tools andconcepts of lean operations to add green metrics to themeasures of excellence companies use in business processes.

Lean in Greenway

− Inclusion of environment and itseffects for the future in all areas oflean manufacturing

Introduction

Lean &Profit

Maximiseprofit by

usingminimumresources

Green

Preserve&conservenaturalresources

Green Lean &Green

Solutions

Lean manufacturing has been used toimprove operational performance

Operations management is concerned withconverting materials and labor into goodsand services as efficiently as possible tooptimize the profit of an organization

Lean &Profit

Maximiseprofit by

usingminimumresources

Green

Preserve&conservenaturalresources Lean &

profit

History

Reducing environmental impacts and resource consumptionin manufacturing processes is one of the important issues ingreen manufacturing.

About Lean & green• Lean and greenmanufacturing conceptis one of the best recenttrends in operationmanagement.• The two strategies(lean and green) can beintegrated and offeredsimultaneously in theoperation managementto reduce both wasteand pollution.• This will certainlyincrease productivityand profit of theorganization also

• Lean and greenmanufacturing conceptis one of the best recenttrends in operationmanagement.• The two strategies(lean and green) can beintegrated and offeredsimultaneously in theoperation managementto reduce both wasteand pollution.• This will certainlyincrease productivityand profit of theorganization also

Tools & Techniques

EnergyVSM & EN

VSM

EnergyVSM & EN

VSM

Environment VSM• Environmental Value Stream Mapping, has all thecharacteristics of its parent, VSM (Value Stream Mapping)and additional Kaizen elements.

• In the E-VSM, the environmental issues and the usage ofmaterial or energy have been added to the established VSMtool.

• In E-VSM the data for raw material or water usage will beadded to the VSM.

• Environmental Value Stream Mapping, has all thecharacteristics of its parent, VSM (Value Stream Mapping)and additional Kaizen elements.

• In the E-VSM, the environmental issues and the usage ofmaterial or energy have been added to the established VSMtool.

• In E-VSM the data for raw material or water usage will beadded to the VSM.

Energy VSM(En-VSM)• En-VSM as a tool which has the information and dataabout energy usage of each process item as well as itsregular lean data in the value stream mapping.

• Energy VSM contains the information of the process andthe energy usage of each element of the process to thedeveloper of the process

• En-VSM as a tool which has the information and dataabout energy usage of each process item as well as itsregular lean data in the value stream mapping.

• Energy VSM contains the information of the process andthe energy usage of each element of the process to thedeveloper of the process

Current State Mapping of En-VSMRaw waterSourcePump No.1

201K galInto Effluenttank per day

Pollution control RegulationsLocal

Boiler feed.Uses 33K gal& rejects all.

293K gal

Washrooms,pantry,Cooling

Sewage

Plant ProcessInitial StateInitial Usage (Gal/day) = 300K gal Per Day

Product Need Per Day = 34K gal Per Day

44Kgal 50Kgal40Kgal179Kgal 44Kgal

H2O:12Kgalreject

Multigradefilter

H2O:44Kgalreject

Softener RO1 RO2

Sterilizeruses andrejects12K gal

Still

H2O:40Kgalreject

25Kgaloverflows&25Kgal isreject281Kgal293Kgal 94Kgal

12Kgal 10Kgal

58KL

H2O:10Kgalreject

Boiler feed.Uses 33K gal& rejects all.

139Kgal45Kgal

34Kgal

Case study• Murray Ohio Manufacturing Company produces lawnmowers and bicycles

• Wanted to develop ways of reducing scrap metal.

• Used a chlorinated oil with an additive of graphite tocreate heightened lubricity.

•Looked at two different chemicals Dry Coating ProductColdkote

• Murray Ohio Manufacturing Company produces lawnmowers and bicycles

• Wanted to develop ways of reducing scrap metal.

• Used a chlorinated oil with an additive of graphite tocreate heightened lubricity.

•Looked at two different chemicals Dry Coating ProductColdkote

Case study• The benefits of Coldkote

− Scrap metal went from 9% to 1/10 of 1%.− Tool life increased 30-50%.

• Dry Coating Product− Required machinery needed 400ft in length.− Teflon coating that the product left made the sheets more slippery.− Cost of machinery was high.

• Coldkote Green Manufacturing− The removal of Coldkote was used with a warm alkaline bath.− Coldkote becomes a solid compound once its applied thereforereducing the amount of spilling and dripping.− Non-oil lubricant reduces toxicity of company’s waste stream.

• The benefits of Coldkote− Scrap metal went from 9% to 1/10 of 1%.− Tool life increased 30-50%.

• Dry Coating Product− Required machinery needed 400ft in length.− Teflon coating that the product left made the sheets more slippery.− Cost of machinery was high.

• Coldkote Green Manufacturing− The removal of Coldkote was used with a warm alkaline bath.− Coldkote becomes a solid compound once its applied thereforereducing the amount of spilling and dripping.− Non-oil lubricant reduces toxicity of company’s waste stream.

Areas of application• Manufacturing• Energy efficiency• Non manufacturing

− Health care & other services− Administrative− Government

• Supply chain• Design of products & processes

• Manufacturing• Energy efficiency• Non manufacturing

− Health care & other services− Administrative− Government

• Supply chain• Design of products & processes

Benefits• Reduce Energy-Related Costs

− Energy and water costs are a prime concern for manufacturers. Focusing onimprovements can reduce these expenses.

• Environmental Benefits− The goal of green & lean manufacturing is to reduce wastage nearly to

zero, helping ecology and reduce pollution.

• Boost Workforce Morale and Innovations− Sustainability improvements are a collaborative effort.

• New Customers and Increase Sales− Green and sustainable practices can make the company more marketable.

• Reduce Energy-Related Costs− Energy and water costs are a prime concern for manufacturers. Focusing on

improvements can reduce these expenses.

• Environmental Benefits− The goal of green & lean manufacturing is to reduce wastage nearly to

zero, helping ecology and reduce pollution.

• Boost Workforce Morale and Innovations− Sustainability improvements are a collaborative effort.

• New Customers and Increase Sales− Green and sustainable practices can make the company more marketable.