Implementing Sustainability Into Your Existing Lean and Six Sigma Program June 2014 Brion Hurley

1. Implementing Sustainability Into Your Existing Lean and Six Sigma Program June 2014Brion Hurley

2. Techmotiv Example Processes should be optimized across the entire life cycle, in order to achieve the best Lean and Six Sigma (LSS) and environmental benefits http://asq.org/quality-progress/2010/03/lean/leaning-toward-green.html?WT.dcsvid=OTA2NDMxNDY0MgS2&WT.mc_id=EM118436

3. Rockwell Collins Insert pictures into these angled boxes. Height should be 3.44 inches. • A global company operating from more than 60 locationsin 27 countries • 19,000 employees on our team • Provides navigation, communications and display products and systems for military and commercial customers

4. Agenda • Sustainability and Business • ES&H and Facilities • Why Lean Six Sigma is not enough • Rockwell Collins Examples • Modified Tools • Resources • Actions

5. What is sustainability? • Meeting the needs of the present without compromising the ability of future generations to meet their own needs • Triple Bottom Line Sustainability

6. Triple Bottom Line • Profit – price listed on the item or the shelf, very clear • People – nutritional value, calories/fat, cruelty-free, Fair Trade • Planet– Local sources (low food miles), most only use words (organic, GMO-free, no additives/coloring) PROFIT PEOPLE PLANET Carbon Reduction Labelcourtesy of Carbon Trust

7. Financial reasons for sustainability • 7 areas of financial benefit for companies • “No environment, no consumers in society, no business” From Bob Willard http://www.sustainabilityadvantage.com

8. Lean ElectronicsSMat Rockwell Collins • Started in 1998 • Heavy on Lean tools initially • Incorporated Six Sigma tools in 2007 • Umbrella over all improvement programs Lean ElectronicsSM Total Quality Management (TQM) Theory of Constraints (TOC) Lean Six Sigma Change Management • Use existing improvement program, not something new

9. 7 Forms of Waste

10. What is the problem? “Green” identifies waste outside the processes FuelElectricityLighting ElectricityChemicals Lighting Heating/Cooling LightingElectricity Warehouse Machinery Test and Inspect Shipping Prep Assembly Packaging Lean Six Sigma identifies waste within the processes Lighting Electricity LightingTrash Chemicals LightingTrashHeating/Cooling

11. Why can’t LSS address environmental issues? • Improvement opportunities may be found outside of normal working hours and areas • “Cost of doing business,” not viewed as opportunity • Small impact at process level • Costs and impacts can be blanketed across many areas, hard to isolate data to biggest users • Environmental and human health risks are often not explicitly considered in business decisions • Side benefits of efforts not anticipated or factored in • Take-back, talent acquisition, employee engagement

12. Six Sigma Project (Facilities)

13. Lean Event Format (ES&H) • Four primary “Go and See” sessions (can vary by facility) • Off shift • Start-up • Working time (w/breaks) • Shut down/Transfer • Break into appropriate groups and review defined area • Need mix of process and technical experts, fresh set of eyes, and different levels of organization

14. ES&H and Facilities ES&H • “Bottoms Up” with People • Turn off equipment • Recycling and composting • Hazardous waste processes • Water conservation • Air leak prevention Facilities • “Top Down” with Infrastructure • Renewable Energy • Efficiency Upgrades • Green Cafeteria • Electric Charging Station • LEED buildings • Showers for bikers • Approach sustainability from both directions

15. Event Checklist • Useful when ES&H or Facilities personnel cannot attend event

16. Event Checklist (cont’d) http://gsn.nist.gov/tech/tools.html?id=lean_clean

17. Modified Tools • SIPOC • Add Earth as a customer • QDIP boards • Add “E” for environment • DMAIC  DMAGIC • G is for “Green” impacts • VSM • Add water, energy and chemicals to data box • Show usage on timeline • OEE • Add Energy Consumption to calculation

18. Examples

19. Books

20. Websites • US Environmental Protection Agency (EPA) • Lean, Energy and Climate Toolkit, Lean and Environment Toolkit, The Environmental Professional’s Guide to Lean & Six Sigma, Lean and Chemicals Toolkit, Lean and Water Toolkit, Lean Manufacturing and the Environment (with Case Studies), Design for the Environment (DfE) • Green Supplier Network • Zero Waste Network – Case Studies • Purdue/SME Green Manufacturing Workshops • GM Landfill Free 9-Step Process • Lean and Green Kaizen Model (Cardiff University) • Lean Ecology: Kaizen Workshop for EH&S Professionals • Lean Six Sigma for the Environment Blog

21. Integrating Sustainability into Lean and Six Sigma Strategy • Focus improvement efforts specifically on social and environmental metrics • Relate environmental and social issues to core business needs and priorities (money, risk, reputation, etc) • All process improvements naturally reduce impact on the environment, now start capturing the benefits! • Share this presentation with Facilities, ES&H and LSS personnel Tools • Add Earth as a customer on your SIPOC • Add environmental usage and costs to data boxes on VSM • Add environmental impacts to 7 forms of waste definitions • Integrate environmental checklists into event templates

22. Brion Hurley Rockwell Collins Principal Lean Consultant 319-263-1011 bmhurley@rockwellcollins.com For more information, visit www.rockwellcollins.com “No environment, no consumers in society, no business” – Bob Willard #IIEAnnual