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Sustainable Manufacturing: Comparing Lean, Six Sigma, and Total Quality Manufacturing
 

Sustainable Manufacturing: Comparing Lean, Six Sigma, and Total Quality Manufacturing

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http://www.sustainabilityconsulting.com/extra-resources/sustainable-manufacturing-comparing-lean-six-sigma-and-total.html With growing environmental and social concerns, many organizations are ...

http://www.sustainabilityconsulting.com/extra-resources/sustainable-manufacturing-comparing-lean-six-sigma-and-total.html With growing environmental and social concerns, many organizations are feeling the pressure to reevaluate their business practices in accordance with sustainability standards. Retailers, costumers, and stakeholders expect manufacturers to develop production methods which will have minimal environmental impacts.

How are manufacturing facilities making these mass shifts in business? Through both independent initiatives and in conjunction with management systems that have already been created.

For those with manufacturing facilities, this one is for you!

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    Sustainable Manufacturing: Comparing Lean, Six Sigma, and Total Quality Manufacturing Sustainable Manufacturing: Comparing Lean, Six Sigma, and Total Quality Manufacturing Presentation Transcript

    • SUSTAINABLE MANUFACTURING:Comparing Lean, Six Sigma, and TotalQuality ManufacturingSSC White Paper
    • Sustainable ManufacturingWith growing environmental and social concerns,many organizations are feeling the pressure toreevaluate their business practices in accordance withsustainability standards. Retailers, costumers, andstakeholders expect manufacturers to developproduction methods which will have minimalenvironmental impacts.How are manufacturing facilities making these massshifts in business? Through both independentinitiatives and in conjunction with managementsystems that have already been created.For those with manufacturing facilities, this one is foryou! www.sustainabilityconsulting.com Copyright © 2012, Strategic Sustainability Consulting. All rights reserved.
    • Sustainable ManufacturingThis presentation provides a summary of the white paper SustainableManufacturing: Comparing Lean, Six Sigma, and Total QualityManufacturing, which provides information on Lean Manufacturing, SixSigma, and Total Quality Management and it takes a closer look atenvironmental and social decision making as part of a manufacturingorganization’s sustainable strategy. www.sustainabilityconsulting.com Copyright © 2012, Strategic Sustainability Consulting. All rights reserved.
    • Sustainable ManufacturingThe white paper provides information on: How sustainability can improve manufacturing operations. Lean, Six Sigma and TQM comparisons. The philosophy, history, pros and cons, and some practical examples of sustainable manufacturing.Download this complimentary white paper tolearn more! www.sustainabilityconsulting.com Copyright © 2012, Strategic Sustainability Consulting. All rights reserved.
    • Sustainable Manufacturing at a Glance
    • At A Glance Industry Week reports that a 300% increase in climate change regulations occurred between 2002 and 2007. Meaning that in order to stay in business, drastic changes are having to be made. www.sustainabilityconsulting.com Copyright © 2012, Strategic Sustainability Consulting. All rights reserved.
    • At A Glance Manufacturers are turning to systems such as Lean Manufacturing, Six Sigma, and Total Quality Management (TQM) to reevaluate their businesses. However, these systems are only successful when aligned with sustainability principles. www.sustainabilityconsulting.com Copyright © 2012, Strategic Sustainability Consulting. All rights reserved.
    • At A GlanceSustainability according to the United Nations “Meeting the needs of the present without compromising the ability of future generations to meet their own needs” (UN, 1987, Para. 2). www.sustainabilityconsulting.com Copyright © 2012, Strategic Sustainability Consulting. All rights reserved.
    • At A GlanceKey ideas behindsustainable manufacturing: Standing out from your competitors.  Reporting annual greenhouse gas emissions to the Carbon Disclosure Project.  Following G3 guidelines  Creating sustainability reports and assessments Planning for the future through risk management programs. www.sustainabilityconsulting.com Copyright © 2012, Strategic Sustainability Consulting. All rights reserved.
    • At A GlanceKey ideas behindsustainable manufacturing: Finding where the production process is wasting resources and energy. Learn more by downloading Sustainable Manufacturing: Comparing Lean, Six Sigma, and Total Quality Manufacturing www.sustainabilityconsulting.com Copyright © 2012, Strategic Sustainability Consulting. All rights reserved.
    • Key Issues to Address
    • Key IssuesSustainable Manufacturingrequires a holistic approach tothe manufacturing process thatmonitors inputs and outputs inorder to reduce the amounts ofmaterials and energy beingconsumed, improve health andsafety, and reduce the life-cycleimpact of products. www.sustainabilityconsulting.com Copyright © 2012, Strategic Sustainability Consulting. All rights reserved.
    • Key Issues Consider the following when assessing your product life-cycle:  Use low impact materials and as few raw materials as necessary.  Address the amount of water consumed and the quality of water wasted.  Implement programs such as water recycling or filter backwash contamination reduction.  Check out more ideas on water usage here! www.sustainabilityconsulting.com Copyright © 2012, Strategic Sustainability Consulting. All rights reserved.
    • Key Issues  Lower energy use by making production more efficient or by improving equipment.  In turn this will also reduce waste and production cost  Improve social sustainability by ensuring that employees:  Earn a livable wage  Are of legal age to work  Work a reasonable amount of hoursLearn more by downloadingSustainable Manufacturing:  Work in a safe environmentComparing Lean, Six Sigma, andTotal Quality Manufacturing www.sustainabilityconsulting.com Copyright © 2012, Strategic Sustainability Consulting. All rights reserved.
    • System One: Lean Manufacturing
    • Lean ManufacturingLean Manufacturing is concerned with “the elimination ofmany types of waste while delivering quality products ontime and at least cost” (US EPA, 2005, P. 1). Waste isdefined as any non-value adding elements in theproduction process whose removal will reduce operatingcosts and improve consumer product quality. www.sustainabilityconsulting.com Copyright © 2012, Strategic Sustainability Consulting. All rights reserved.
    • The Seven Deadly Wastes Recognized by Lean ManufacturingOverproduction The production of goods that do not have an immediate demand creating risk in storing and preserving goods.Inventory The space and resources necessary to store excess raw materials or overproduction to ensure that weather, animals, or the production process does not damage items.Defects Products that are produced below consumer standards, wasting materials, energy, inventory space, and transportation energy and space.Transport The excessive movement of a product that is in the production process or between storage facilities, wasting fuel, storage, and human energy.Motion Any excessive human energy mainly due to poor organization.Over-processing The processes during production that consume more materials and energy than necessary for the final product.Waiting The delays or idle time in the production processes that increase storage spoilage risk and energy resource consumption. www.sustainabilityconsulting.com Copyright © 2012, Strategic Sustainability Consulting. All rights reserved.
    • Lean ManufacturingLean Manufacturing is a value drivenapproach that relies on a system ofcontinual improvements through theapplication of: Understanding Customer Value Value Stream Analysis Flow Pull Perfection www.sustainabilityconsulting.com Copyright © 2012, Strategic Sustainability Consulting. All rights reserved.
    • Lean Manufacturing Lean Manufacturing relies on a collaborative atmosphere between all sectors of the manufacturing process to identify waste and develop solutions. The methods below are often carried out to find these solutions. Value Stream Kaizen 5-S Mapping• A visual and collaborative • A quick process • Order in the workplace is kept exercise • Employees map and measure through:• Employees identify each step in current processes • Sorting the production process • Then institute solutions and • Setting in order• Then insert them into a testing • Shining “production tree” • Improvements must be seen • Standardizing• Thus seeing clearly at which over only a few days • Sustaining step waste may occur www.sustainabilityconsulting.com Copyright © 2012, Strategic Sustainability Consulting. All rights reserved.
    • Lean Manufacturing Where Lean Manufacturing falls short:  High susceptibility to disruptions due to a sudden change in the production process.  The continual improvement used to streamline efficiency can create an inflexible production system.  Fails to address the environmental value of products.  Also fails to consider the effects that the production process has on workers. Learn more by downloading Sustainable Manufacturing: Comparing Lean, Six Sigma, and Total Quality Manufacturing www.sustainabilityconsulting.com Copyright © 2012, Strategic Sustainability Consulting. All rights reserved.
    • System Two: Six Sigma
    • Six SigmaSix Sigma is a calculated approach which relies onverifiable data to improve the success rate ofproduction processes though defect reduction. Theultimate goal being to reduce these defects in theproduction process to less than 3.4 defectiveproducts per million (Anderson, et. al, 2006). www.sustainabilityconsulting.com Copyright © 2012, Strategic Sustainability Consulting. All rights reserved.
    • Six Sigma Application  Involves only five to ten individuals from both the manufacturing team and a team of highly trained Six Sigma experts.  Takes several months to a year to pinpoint issues, construct solutions, and implement changes. www.sustainabilityconsulting.com Copyright © 2012, Strategic Sustainability Consulting. All rights reserved.
    • Six SigmaStages of the Six Sigma Process Find out more about the five stages in the complete white paper here! Control Improvement Analysis Measurement Definition www.sustainabilityconsulting.com Copyright © 2012, Strategic Sustainability Consulting. All rights reserved.
    • Six SigmaThroughout these stagesof problem solving theteam will often rely on: Descriptive Statistics The 5 Whys Pareto Charts Design of Experiments Failure Mode Effect Analysis Learn more by downloading Sustainable Manufacturing: Comparing Lean, Six Sigma, and Total Quality Manufacturing www.sustainabilityconsulting.com Copyright © 2012, Strategic Sustainability Consulting. All rights reserved.
    • Six SigmaWhile this method of reachingsustainable manufacturing ismore precise than leanmanufacturing, its incredibly longimplementation time is offputting for many manufacturers.Not to mention that the trainingand intense involvement ofemployees can temporarily slowproduction rates, as well as The sustainability of the product cancompromise social sustainability. also be questioned when this method alone is used. www.sustainabilityconsulting.com Copyright © 2012, Strategic Sustainability Consulting. All rights reserved.
    • System Three: Total Quality Management
    • Total Quality ManagementThe goal set out by this method focuses onachieving system-wide quality improvements andcontinually meeting stakeholder demands. Byreducing risk-associated costs, costumersatisfaction is improved and revenue is driven up. www.sustainabilityconsulting.com Copyright © 2012, Strategic Sustainability Consulting. All rights reserved.
    • Total Quality Management Attributes  TQM utilizes a continual improvement approach where the focus of these improvements is flexible.  Flexibility allows for shifting in order to foresee future needs and exceed all future stakeholder demands. www.sustainabilityconsulting.com Copyright © 2012, Strategic Sustainability Consulting. All rights reserved.
    • Total Quality Management Attributes  TQM recognizes specific failures which derive from a stagnant improvement plan such as:  Prevention Costs  Appraisal Costs  Internal Failure Costs  External Failure Costs www.sustainabilityconsulting.com Copyright © 2012, Strategic Sustainability Consulting. All rights reserved.
    • Factors of Applying TQMCommitted Leadership Long-term commitment by management to TQMAdoption and Communication Using mission statements and slogansCloser Customer Relationship Determining customer demands and meeting themCloser Supplier Relationship Working with suppliers who can routinely provide materials that will meet customer demandsBenchmarking Observing the best competitive practicesIncreased Training TQM principles, team skills, and problem solvingOpen Organization Relaxed hierarchy, open communication, and small working groupsEmployee Empowerment Involve employees in planning and decision makingZero-defects Mentality System to catch defects as they occur, rather than through inspectionsFlexible Manufacturing Just-in-time inventory, cellular manufacturing, statistical process control and design of experimentsProcess Improvement Reduce waste and time through whole process analysisMeasurement Goal-oriented approach with statistical methods applied to constant improvements www.sustainabilityconsulting.com Copyright © 2012, Strategic Sustainability Consulting. All rights reserved.
    • Total Quality Management  Problems with the TQM system:  Implementation is prolonged due to training and cultural changes that may occur within the organization.  Relying solely on stakeholder pressure stifles innovation.  This reliance on the stakeholder can also Learn more by downloading compromise sustainability. Sustainable Manufacturing: Comparing Lean, Six Sigma, and  TQM lacks clear framework. Total Quality Manufacturing www.sustainabilityconsulting.com Copyright © 2012, Strategic Sustainability Consulting. All rights reserved.
    • A Brief System Comparison
    • A Brief System Comparison Lean Six Sigma TQM ManufacturingMaterial Reduces raw material purchasing through Through reducing defects and improving process Reducing operating costs will find options to reduceEfficiency material recycling and efficiency, material use is material use defect reduction minimized Recycles scraps and accepts end-of-life products for recycling into new productsWater Use To avoid over-processing water use is evaluated to Through reducing defects, water is less often in a Water use is evaluated and reduction goals are set to minimize waste wasted production reduce costs When water use is By using Six Sigma Wastewater is recycled minimized, storage assessments, water quality whenever possible to capacity is reduced saving is improved reduce water use space and money. To improve brand management, water contamination is minimized www.sustainabilityconsulting.com Copyright © 2012, Strategic Sustainability Consulting. All rights reserved.
    • Lean Six Sigma TQM ManufacturingEnergy Use To avoid over-processing, energy use is evaluated to Reducing defects reduces energy wasted on failed Energy is analyzed and reduced to cut costs minimize waste production Options to purchase or Energy use is monitored produce renewable energy and improved using are explored to statistical tools to prevent differentiate from spiking during competition manufacturingWaste and Reduces solid waste through material recycling Through reducing defects, solid waste is reduced Waste is reduced for brand managementEmissions and defect recycling Waste is reduced through Emissions are difficult to recycling and in re-use monitor with Kaizen event products changes Emissions are measured and reportedSocial Regulatory compliance can be an issue with Kaizen Material safety is a concern for customer satisfaction to Employee health and fair treatment are majorSustainability even process changes reduce defects priorities due to employee involvement in process Employee safety is Only a fraction of considered as part of the employees are engaged in Community development is deadly waste of motion Six Sigma process a priority for brand management Material safety is a concern to reduce defects and improve quality www.sustainabilityconsulting.com Copyright © 2012, Strategic Sustainability Consulting. All rights reserved.
    • Building a Sustainable Future
    • Building a Sustainable Future Each of the systems that have been discussed are viable options for manufacturing improvement, but only when aligned with sustainability concerns. A manufacturer already using Lean Manufacturing, Six Sigma, or TQM must consider their environmental and social impacts to achieve sustainability. www.sustainabilityconsulting.com Copyright © 2012, Strategic Sustainability Consulting. All rights reserved.
    • Sustainable ManufacturingLearn more by downloading Sustainable Manufacturing: ComparingLean, Six Sigma, and Total Quality Manufacturing, which providesinformation on Lean Manufacturing, Six Sigma, and Total QualityManagement and takes a closer look at environmental and socialdecision making as part of a manufacturing organization’s sustainablestrategy. www.sustainabilityconsulting.com Copyright © 2012, Strategic Sustainability Consulting. All rights reserved.
    • Download the complimentary white paper in it’sentirety by visiting the SSC website today:Sustainable Manufacturing:Comparing Lean, Six Sigma, and Total QualityManufacturingWhat are your thoughts? Join theconversation on twitter @jenniferwoofter!