Lean and green; how environmental performance can be enhanced by - - PowerPoint PPT Presentation

Lean and green; how environmental performance can be enhanced by lean production systems and vice versa Target group

• Lean production training
• Lean production

coordinators

• Learning objectives
• Introduction
• Description
• How the 7+1 wastes connects to

Content

• Environmental organisation

1

Henrik Kloo, Volvo Technology 2011-02-03

• How the 7+1 wastes connects to

environmental aspect

• Is lean always green? Areas of

conflict

• Other parts of a production system

that supports environmental improvements

• Examples
• References

1. Learning objectives 2. Introduction 3. Description 4. Examples Appendix

A. References

• Realise that most environmental issues

are due to non value added aspects of production

• See how environmental performance

At the completion of this training the trainee will be able to…

Learning objectives

• See how environmental performance

can be enhanced by a consistent lean thinking

• See opportunities for cost savings

1. Learning objectives 2. Introduction 3. Description 4. Examples Appendix

A. References

• Looking in perspective most environmental problems occur when a material,

that may be valuable occurs at the wrong place, e.g. as a contaminant in air

• r water or as a waste
• Clean production and lean production have the same objective: Minimising

waste and maximise resource efficiency and productivity

• 3. Introduction

How can lean production be beneficial for environment?

• The target is to produce the right

product without rest products product without rest products

• So by a consistent work with “muda”

resource efficiency will be maximised and only the necessary resources will be utilised

1. Learning objectives 2. Introduction 3. Description

1. How the 7+1 wastes connects to environmental aspects 2. Is lean always green? Areas of conflict 3. Other parts of a production system that supports environmental improvements environmental improvements

4. Examples 5. Appendix

A. References

Inventory Overproduction Transport Defects and

The Seven + One Wastes

Inventory Overproduction Transport Rework Unnecessary Processes Movements Wait + Not used employee creativity

Inventory

Transactions not processed, design data which is not organized or not fully utilized

• Warning signs

– Extra space for receiving material – Last-in-first-out (LIFO) instead of First-in-first-out (FIFO) mentality – Constant or large amount of rework when a problem is discovered – Increased resources allocated for administrative processes

• Environmental
• Environmental

– Excess storage space need heating, light etc. – Long lead times may make e.g. rust protection necessary, increases use of chemicals – Packaging material may be needed for storage reasons – All rework consume resources, increase scrapping

Overproduction

• Warning signs

– Extra equipment, space, personal – Tendency to hide problems – Big blocks of work – Unclear project plans

Environmental

– All unnecessary work consumes materials – Long prep or ramp up time cost energy use at non production – Obsolete material consumed resources – Excess use of chemicals and other materials when processes are not optimised

Transport

Extra steps in the process, distance travelled, data hand-offs

Warning signs

– Extra personnel – Different office locations (for same work) – Empty desks – Unreliable copiers, etc.

Environmental

– All transportation consumes energy and creates emissions – Large spaces and moving out and in between buildings– excess energy consumption, especially open ports etc. – Transportation of hazardous materials creates risks and need extra precautions – More packaging materials to protect details and risk for damage creates waste

Defects and rework

Rework, mistakes, quality errors, incorrect data entry, miscommunication

Warning signs

– Extra personnel to review, rework and repair – Complex processes – Dubious quality – Missed deadlines – Reduced profit margins – Reduced profit margins

Environmental

• Defect material becomes waste
• Spills and emissions due to bad equipment
• More production – more resources used
• Bad quality = bad products = producing more future waste (more frequent

replacement needed) – more production

• Space for repair area consumes energy etc.

Unnecessary processes

Multiple sign-offs, inspection, rework, redesign, poorly run team meetings

Warning signs

– Do more activities than is necessary – Improvements unknown to customer – Endless refinement of elegance and details – Extra paper or electronic copies – Information overload – Work that could be combined with another process

Environmental Unnecessary processes consumes unnecessary resources

Movement

Extra steps, travel from office to office desk to desk, unnecessary analysis or testing

Warning signs – Search after tools or forms – Go to several people or extra effort to get info – Too long distance between info and access Environmental – All aspects of transportation – Often a problem at waste sorting: too few bins or placed too far away creates extra movements, or bad sorting result. Apply lean thinking to create efficient system

Waiting

Processing periodically not as the work comes in (i. e. stand by losses

Warning signs – People waiting for equipment, tools, information – Inadequate interest for short delays – Unplanned delays or postponement of work Environmental – Equipment and space consumes energy also at stand by – Risk for component damage or spoiled materials

Unused or underutilized creativity

Warning signs – Few improvement suggestions – Lack of will to implement X – Lack of passion and enthusiasm – Poor morale – Lack of team activities – Lack of employee involvement – Doing MY job mentality – Doing MY job mentality

Environmental

• All employees can participate in improvements
• Collect ideas to facilitate waste handling
• All employees can be used to report leakages (typically water,

process chemicals and pressurised air)

• Often easy to create engagement for environment, this can be

used to support other improvements

Summary: Clean production and Lean production combined in a

production system have the same objective: Minimising waste and maximise productivity

Less scrap Fewer defects Less spoilage Reduced environmental waste Fewer defects Less overproduction Simpler products Right-sized equipment Reduced use of raw materials Less storage Less inventory space needed Reduced materials, land and energy consumed Less overproduction Less lighting/heating/cooling Less unneeded space Less oversized equipment Less energy use Less over-processing More efficient transport and movement Lower emissions

1. Learning objectives 2. Introduction 3. Description

1. How the 7+1 wastes connects to environmental aspects 2. Is lean always green? Areas of conflict 3. Other parts of a production system that supports environmental improvements environmental improvements

4. Examples 5. Appendix

A. References

Areas of conflict (?)

Just in time may create more in bound and out bound transports due to smaller deliveries

• Apply lean thinking also on transports; empty or half empty trucks are also a

“waste” Treatment equipment for good cleaning often more expensive than more simple treatment

• Limits often set by authorities sooner or later. Proactive work will facilitate

cost efficient solutions; utilize possibilities to recycling to less demanding

• Limits often set by authorities sooner or later. Proactive work will facilitate

cost efficient solutions; utilize possibilities to recycling to less demanding processes Resource efficient equipment and measurement equipment may have investment cost that does not pay back in the short term

• Apply life cycle cost thinking.
• Find “windows of opportunity” e.g. at new investments and major changes,

when obsolete equipment etc. will be changed anyway

1. Learning objectives 2. Introduction 3. Description

1. How the 7+1 wastes connects to environmental aspects 2. Is lean always green? Areas of conflict 3. Other parts of a production system that supports environmental improvements environmental improvements

4. Examples 5. Appendix

A. References

Other parts of a production system that supports environmental improvements

Continuous improvement – Applicable to all improvement work. Value stream mapping - a tool also for identifying environmental aspects. Built in quality – Bad quality creates environmental impact through excess use

• f materials and processes

Just in time – same thinking applicable for reducing: waste, energy use at stand by and heated indoor area TWW- Leadership: Management commitment Safety: Chemicals, spill, air quality etc. Team work – Applicable to environmental improvements, Visualisation – shows clearly improvement areas and results. Process stability: 5s – demonstrates good practice, reduced spill and waste, Maintenance – prevent spills and improve utilisation of materials, Standardised work – set good environmental standard

• f materials and processes

by and heated indoor area

1. Learning objectives 2. Introduction 3. Description 4. Examples

• 1. Working with energy optimisation
• 2. Working with waste minimisation
• 3. Spill prevention
• 4. Water saving and recycling

Appendix

A. References

Energy saving and optimisation hints

Review energy usage and eliminate all non value adding uses To measure is to know: Energy monitoring break down and visualisation. Set relevant KPI´s Stand by losses: Identify and shut down at non production Heating of buildings: Optimise work area, close ports and optimise ventilation Light: Illuminate the right places, where you need the light, Use low energy light bulbs, Utilise daylight Energy demand on equipment in all new investments Reduce working temperatures when applicable, e.g. dry ovens, cleaning, hardening Pressurised air: low energy efficiency, replace with electrical equipment and eliminate all leakages. Downsize, especially at non production Heat recovery on machines and Routines

Energy thieves

Pressurised air – Gates

Open gate 5 min/h

Ventilation

• Ex. 1m3/s without heat exchange =3600 €/y

Light

One Conference room = 150 €/y Gent: modern light technology reduced cost by 50%

Pressurised air – one 5 mm hole =2610 €/y Electric Equipment – One PC = 100 €/y AC

3x5m = 1525 €/y

On line monitoring on energy usage broken down on process level, Volvo Penta, Vara Result: Payback < 6 months through identified improvement

Focus on energy in new paintshop, Volvo Trucks Cab Plant, Umeå

• Reduce air intake volumes
• Recirculation and caskade

function for process air

• High efficient heat recovery for

ventilation and process ventilation

• Energy recovery system for

fumes from termic oxidation (air fumes from termic oxidation (air treatment)

Results from focus TC-project! Project start Production start Propane 12600 MWh 7600 MWh Distr heating 24600 MWh 8200 MWh Electricity 13300 MWh 13700 MWh

Optimised work area suggestion, (Thesis work ref 4) Current state and suggestion after lean review

1. Learning objectives 2. Introduction 3. Description 4. Examples

• 1. Working with energy optimisation
• 2. Working with waste minimisation
• 3. Spill prevention
• 4. Water saving and recycling

Appendix

A. References

Working with waste minimisation, hints

• All waste in Non Value Adding!
• Prevent waste generation:

Reduce packaging material, use recyclable boxes etc. Standardised packaging materials and methods Review material handling routines Select process chemicals to reduce hazardous waste

• Efficient processes, reduce spill
• Efficient and standardised waste recycling, reduces cost
• Think lean, efficiency in set up of waste sorting, to avoid mixing of waste
• Quality improvements to reduce scrapping etc.
• Recycling and recovery of chemicals, e.g. closed loop rinse systems (see

water saving actions)

2 proposals for lean waste, (Thesis ref 4)

V-EMB 500 V-EMB 750

Suggestion: Move the plastic waste bin to the cart reduces movement by operator Suggestion: Replace the paper boxes with plastic container

Waste standard

Production

• f material

Internal logistics

Purchase cost Resource material usage Handling, transport costs Energy usage, waste production

Assembly

Handling and sorting costs Waste production

Waste

Handling and transport costs Energy for transports Re-use, recycling or incineration

A standard of single-use packaging A standard of single-use packaging material types can reduce costs and lower environmental impact of the production system.

1. Learning objectives 2. Introduction 3. Description 4. Examples

• 1. Working with energy optimisation
• 2. Working with waste minimisation
• 3. Spill prevention
• 4. Water saving and recycling

Appendix

A. References

Spill prevention hints

Remediation of small spill may be very costly Make a risk analysis Handling of fluids: Recommendation: under roof and within containment Always ask: what happens if…? Safety advisor for transport of dangerous goods Quick and easy incident reporting without creating embarrassment and “scrape goats” stops leakage to cause bigger damage, good for preventive work

1. Learning objectives 2. Introduction 3. Description 4. Examples

• 1. Working with energy optimisation
• 2. Working with waste minimisation
• 3. Spill prevention
• 4. Water saving and recycling

Appendix

A. References

Water saving and recycling hints:

• Follow up of usage to detect non productive users
• Optimise amount used
• Right water specification;
• High salt content may give quality problems.

Recycled water may be an option

• Cleaning of contaminated water often a high cost
• Rinsing: multi step systems saves water
• Rinsing: multi step systems saves water
• Rinse water is often contaminated by process chemicals (e.g. Phosphating

50% of chemicals lost in rinsing)

• Waste water disposal or recycling? Often easier and less demanding

treatment if recycled to less demanding processes

• Take care of process fluids!

Follow up measurements and replenishing in stead of disposal save chemicals, water and cost for treatment. Examples cutting fluids, rinse baths, washing fluids, surface treatment

• Hot baths costs energy

Good examples water 2. New River Valley, USA

Water recycling to less demanding processes – no water to external treatment plant saved cost

Extra Equipment needed to reach water quality demand. Replaces external quality demand. Replaces external treatment. Treatment result now controlled by own demands, not regulatory agencies or ecosystems

Good examples 2: water saving

Multi step rinsing: ex rinsing ratio 1000:1: single step: 1000 l/h, 2 step 32 l/h, 3 step 10 l/h Centralised system for cutting fluids Centralised system for cutting fluids in Skövde: Facilitates fluid maintenance. Prolonged lifetime from months to steady state. Annual savings ca 5 mSEK

1. Learning objectives 2. Introduction 3. Description 4. Examples 5. Appendix

A. References

References

1. This training material is based on a lean and green training material from Opex office (operational excellence) at AB Volvo by Henrik Kloo, Volvo Technology 2010. 2. Environmental requirements for production sites and other operating units: Violin, AB Volvo, core value, environmental care, steering documents and Other environmental steering documents on Volvo intranet (Violin) 3. Water saving actions report: Volvo report, ER-59995 (2006) 4. Evaluation of the environmental impacts from implementing lean in production processes of manufacturing industry, Master of Science Thesis, XIAOJIN QIU and XIAOXIA CHEN, Chalmers 2009 5. The lean and environmental toolkit, US Environmental protection agency, EPA100-K-06-003, 2007

Källor/Kontaktuppgifter

Företag

• AB Volvo

Mer att läsa

• Se referenslistan

39

Kontaktpersoner i Lean & Green Production Navigator-projektet

Henrik Kloo, Volvo Technology 2011-02-03