Sustainable Manufacturing Practices Through the Use of Lean Techniques Lean Manufacturing techniques and tools can also be applied to green initiatives. When applied correctly, Lean principles can help individuals see the big picture and long range impact that a green initiative is having on both the environment, workers, and a company’s operation by helping apply appropriate costs to the longer term return on investment.

1. FABTECH ATLANTA 2014
Lean Sustainable Practices
For Manufacturers
William Shema
Paper-Less, LLC.

2. FABTECH ATLANTA 2014
Lean Sustainable Practices For
Manufacturers
 Definition – Environmental Waste.
 Why Important (past, present, future)?
 Lean Structure.
 Environmental Management.
 Business Objective.
 Solutions.
 Conclusion.

3. FABTECH ATLANTA 2014
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.

4. FABTECH ATLANTA 2014
Lean Sustainable Practices for
Manufacturers – Importance
(Past)
Los
Angeles
USA

5. FABTECH ATLANTA 2014
Lean Sustainable Practices for
Manufacturers – Importance
(Present)
China

6. FABTECH ATLANTA 2014
Lean Sustainable Practices for
Manufacturers – Importance (Future)

7. FABTECH ATLANTA 2014
Lean Sustainable Practices for
Manufacturers – Importance (Future)

8. FABTECH ATLANTA 2014
Lean Sustainable Practices for
Manufacturers – Lean Structure
Principles:
• Zero tolerance for waste
• Optimization of resources
• Customer focus
• Teamwork and Communication
• Continuous Improvement

9. FABTECH ATLANTA 2014
Lean Sustainable Practices for
Manufacturers – Lean Structure
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

10. FABTECH ATLANTA 2014
Lean Sustainable Practices for
Manufacturers – Lean Structure
Wastes:
• Over Production
• Waiting
• Inventory
• Over Processing
• Defects
• Transportation
• Motion

11. FABTECH ATLANTA 2014
Lean Sustainable Practices for
Manufacturers – Lean Structure
Goals:
• Improved Safety
• Improved Productivity
• Improved Quality
• Lower Costs
• Improved Customer Satisfaction
• Improved Delivery

12. FABTECH ATLANTA 2014
Lean Sustainable Practices for
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.

13. FABTECH ATLANTA 2014
Lean Sustainable Practices for
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

14. FABTECH ATLANTA 2014
Lean Sustainable Practices for
Manufacturers – Business Objectives

15. FABTECH ATLANTA 2014
Lean Sustainable Practices for
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%

16. FABTECH ATLANTA 2014
Lean Sustainable Practices for
Manufacturers – Business Objectives
Companies With Environmental Management
Systems:
Ford Motor Company
Sherwin Williams
Coca-Cola Company
SC Johnson Co.
Sprint
The McGraw Hill
Altria

17. FABTECH ATLANTA 2014
Lean Sustainable Practices for
Manufacturers – Solution
Roof Top Sky
lighting:
Less energy required
for lighting and
heating (during the
winter months).

18. FABTECH ATLANTA 2014
Lean Sustainable Practices for
Manufacturers – Solution
Natural Lighting:
Similar to Sky
Lighting, the use of
natural lighting of
both office and shop
areas.

19. FABTECH ATLANTA 2014
Lean Sustainable Practices for
Manufacturers – Solution
Reflective Roofing
Material:
Reduces the energy
required to cool down
industrial buildings.

20. FABTECH ATLANTA 2014
Lean Sustainable Practices for
Manufacturers – Solution
LED Lighting:
Reduces the
energy use to light
industrial buildings.

21. FABTECH ATLANTA 2014
Lean Sustainable Practices for
Manufacturers – Solution
Life Cycle
Assessments:
Consider a product’s
complete lifecycle
and begin to
increase the amount
of reusable material
from a discarded
item.

22. FABTECH ATLANTA 2014
Lean Sustainable Practices for
Manufacturers – Solution
MES System:
Use of software in
order reduce the
amount of disposable
material used for a
customer order.

23. FABTECH ATLANTA 2014
Lean Sustainable Practices for
Manufacturers – Solution
Nesting Software:
Increases the
utilization of sheeted
raw materials. Less
scrap material per
sheet size.

24. FABTECH ATLANTA 2014
Lean Sustainable Practices for
Manufacturers – Solution
Alternatives to Toxic
Materials:
Consider removing toxic
materials that are used in
the processing of the final
product.

25. FABTECH ATLANTA 2014
Lean Sustainable Practices for
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.

26. FABTECH ATLANTA 2014
Thank
You