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Lean with green
- 1. Lean and Green Overview Lean and Green Overview Concept to integrate Traditional Lean in Green way
- 2. 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
- 3. 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 the measures of excellence companies use in business processes. • 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 the measures of excellence companies use in business processes.
- 4. Lean in Green way − Inclusion of environment and its effects for the future in all areas of lean manufacturing
- 5. Introduction Lean & Profit Maximise profit by using minimum resources Green Preserve & conserve natural resources Green Lean & Green Solutions Lean manufacturing has been used to improve operational performance Operations management is concerned with converting materials and labor into goods and services as efficiently as possible to optimize the profit of an organization Lean & Profit Maximise profit by using minimum resources Green Preserve & conserve natural resources Lean & profit
- 6. History Reducing environmental impacts and resource consumption in manufacturing processes is one of the important issues in green manufacturing.
- 7. About Lean & green • Lean and green manufacturing concept is one of the best recent trends in operation management. • The two strategies (lean and green) can be integrated and offered simultaneously in the operation management to reduce both waste and pollution. • This will certainly increase productivity and profit of the organization also • Lean and green manufacturing concept is one of the best recent trends in operation management. • The two strategies (lean and green) can be integrated and offered simultaneously in the operation management to reduce both waste and pollution. • This will certainly increase productivity and profit of the organization also
- 8. Tools & Techniques Energy VSM & EN VSM Energy VSM & EN VSM
- 9. Environment VSM • Environmental Value Stream Mapping, has all the characteristics of its parent, VSM (Value Stream Mapping) and additional Kaizen elements. • In the E-VSM, the environmental issues and the usage of material or energy have been added to the established VSM tool. • In E-VSM the data for raw material or water usage will be added to the VSM. • Environmental Value Stream Mapping, has all the characteristics of its parent, VSM (Value Stream Mapping) and additional Kaizen elements. • In the E-VSM, the environmental issues and the usage of material or energy have been added to the established VSM tool. • In E-VSM the data for raw material or water usage will be added to the VSM.
- 10. Energy VSM(En-VSM) • En-VSM as a tool which has the information and data about energy usage of each process item as well as its regular lean data in the value stream mapping. • Energy VSM contains the information of the process and the energy usage of each element of the process to the developer of the process • En-VSM as a tool which has the information and data about energy usage of each process item as well as its regular lean data in the value stream mapping. • Energy VSM contains the information of the process and the energy usage of each element of the process to the developer of the process
- 11. Current State Mapping of En-VSM Raw water Source Pump No.1 201K gal Into Effluent tank per day Pollution control Regulations Local Boiler feed. Uses 33K gal & rejects all. 293K gal Wash rooms,pantry ,Cooling Sewage Plant Process Initial State Initial Usage (Gal/day) = 300K gal Per Day Product Need Per Day = 34K gal Per Day 44Kgal 50Kgal40Kgal 179Kgal 44Kgal H2O: 12Kgal reject Multigrade filter H2O: 44Kgal reject Softener RO1 RO2 Sterilizer uses and rejects 12K gal Still H2O: 40Kgal reject 25Kgal overflows & 25Kgal is reject281Kgal293Kgal 94Kgal 12Kgal 10Kgal 58K L H2O: 10Kgal reject Boiler feed. Uses 33K gal & rejects all. 139Kgal 45Kgal 34Kgal
- 12. Case study • Murray Ohio Manufacturing Company produces lawn mowers and bicycles • Wanted to develop ways of reducing scrap metal. • Used a chlorinated oil with an additive of graphite to create heightened lubricity. •Looked at two different chemicals Dry Coating Product Coldkote • Murray Ohio Manufacturing Company produces lawn mowers and bicycles • Wanted to develop ways of reducing scrap metal. • Used a chlorinated oil with an additive of graphite to create heightened lubricity. •Looked at two different chemicals Dry Coating Product Coldkote
- 13. 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 therefore reducing 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 therefore reducing the amount of spilling and dripping. − Non-oil lubricant reduces toxicity of company’s waste stream.
- 14. 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
- 15. Benefits • 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. • 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.