Presented by Douglas R. Hague Jordan Clous Backs John L. Iley, Ph.D. Pittsburg State University

1. 72nd International Technology and Engineering Educators Association Conference“Green Technology: STEM Solutions for the 21st Century Citizen”Charlotte, North CarolinaLean and Green Manufacturing in Wood Technology11:00-11:50 AMMarch 20, 2010 Presented by Douglas R. Hague Jordan Clous Backs John L. Iley, Ph.D. Pittsburg State University

2. Presentation Description & Presenters • Description: “Lean and Green Manufacturing in Wood Technology” addresses lean and green manufacturing practices in the wood industry. It features latest innovations in engineered wood materials, hardware, and processes; and educational activities. • Presenters: • Douglas “Doug” R. Hague, Assistant Professor, Wood Technology, PSU • Jordan “Clous” Backs, Instructor, Wood Technology, PSU • Dr. John L. Iley, Professor, Technology Education, PSU

3. Agenda—Today’s Presentation • Lean Manufacturing • Definition, origin, goals, implementing lean • Green Manufacturing • Definition and principles • Lean and Green Comparison • Lean and Green in the Wood Industry • Considerations • Design, Material Selection, Production, and Conservation • Case Studies—Industry and PSU • Lean and Green-Implications for Educators • Suggestions, Activities, and Resources www.buker.com/images/Leanchart.gif

4. Lean Manufacturing • Definition: Lean Manufacturing refers to manufacturing practices aimed at maximizing value and minimizing waste in the manufacturing process. It considers expending resources for anything other than creation of value to the customer to be wasteful More value for less money www.buker.com/images/Leanchart.gif

5. Origin and Key Figures of “Lean” • Ben Franklin (1733) – Poor Richard’s Almanac • Eli Whitney (1850’s) – interchangeable parts • Frederick Taylor – Principles of Scientific Management (1911) • Frank Gilbreth – process charts; motion study • Henry Ford – mass assembly manufacturing system (1915) • Kiichirio Toyota (1936) – Kaizen improvement teams • W. Edwards Deming (WWII) – SPC; TQM • Taiichi Ohno – Toyota Production System-TPS (1980) • John Krafcik coined term “Lean Manufacturing” in 1988

6. History Timeline for Lean ManufacturingGraphic from: Strategos www.strategosinc.com/images/lean_timeline.jpg

7. Goals of Lean Manufacturing • Continuously improve quality • Eliminate waste-doesn’t provide value • Waiting • Transport • Extra Processing • Overproduction • Inventory • Motion • Defects • Reduce time-start to finish • Reduce total costs www.sixthsigma.com/weblog/LeanManufacturingPa..

8. Going Lean in Manufacturing • Create simple manufacturing system • Decrease cycle times • Keep less inventory • Increase productivity and efficiency • Increase equipment utilization • Recognize “room for improvement” • Continuously improve • measure improvement chohmann.free.fr/lean.gif

9. Green (or Sustainable) Manufacturing Department of Commerce Definition: “Sustainable (Green) [sic] Manufacturing is defined as the creation of manufactured products that use processes that are non-polluting, conserve energy and natural resources, and are economically sound and safe for employees, communities, and consumers.” From: Sustainable Manufacturing – National Council for Advanced Manufacturing (http://www.nacfam.org/ ) - Definition http://nacfam02.dev.web.sba.com/PolicyInitiatives/SustainableManufacturing/tabid/64/Default.aspx

10. Objectives for Green (Sustainable) Design in Mfg • Increase efficiency in the use of materials, energy and other resources • Minimize damage or pollution from the chosen material • Reduceto a minimum any long-term harm caused by use of the product • Ensure that the planned life of the product is most appropriate in environmental terms and that the product functions efficiently for its full life • Take full account of the effects of the end disposal of the product • Ensure that the packaging and instructions encourage efficient and environmentally friendly use • Minimize nuisances such as noise or smell • Analyze and minimize potential safety hazards Adapted from: Principles of Green Design - http://www.slideshare.net/mschongkong/topic-3-principles-of-green-design

11. Comparison of Lean to Green or Sustainable Manufacturing

12. Wood Industry Promotes Lean & Green Certifications promote commitment • LEED • Leadership in Energy & Environmental Design • U.S. Green Building Council (USGBC) • ESP • Environmental Stewardship Program • Kitchen Cabinet Manufacturers Assn (KCMA) • FSC • Forest Stewardship Council • SFI • Sustainable Forest Initiative

13. Wood Industry Responds to Lean & Green Certifications & policies promote commitment • EPP • Environmentally Preferable Purchase • Government stimulates “buy green” • Green Seal - 1989 • Science-based environmental certification standards • GEI • GREENGUARD Environmental Institute • ANSI standards developer-indoor air quality • SCS • Scientific Certification Systems • Certification of sustainability & environmental claims

14. Keys to Implementing Lean and Green • Philosophy • Facility Considerations • Product Design • Material Selection • Production Techniques • Finishing • Hardware Selection • Minimize and Eliminate Waste • Reduce-Reuse-Recycle

15. Lean & Green: Philosophy and Commitment Example: Dimensional Innovations • We utilize digital fabrication to eliminate waste and increase yield of materials. • We maintain strict standards for proper disposal of batteries, paint solids and other hazardous materials. • A high percentage of our post-production product is recycled and donated to local art school programs including, the Kansas City Art Institute and the University of Kansas. • We utilize a solvent recycling machine that reduces our solvent waste by 95 percent. This system reduces 220 gallons of solvent waste per year. • Dimensional Innovations interior architectural designer is a LEED AP and has completed several recent exhibits in facilities seeking LEED certification. • We are currently exploring supplemental options for recycling Sintra and EPS foam. • From: Dimensional Innovations – Environmental Stewardship - http://www.dimin.com/?page=about_environment

16. Lean & Green: Facility Considerations • Location • Environmentally-friendly construction; renovation; resource conservation • Energy Efficiency • Less fossil fuel – alternate energy • Energy efficient motors, etc. • Less transportation • Efficient flow of materials and product • Clean environment – indoor air quality • Dust collection, air filtration & dust extraction; incorporate eco-gates • EPA adherence - finishing • Space efficiency – less to heat, cool

17. Lean & Green: Product Design • Incorporate green design principles • Efficiency in use of materials, energy, resources • Minimize damage or pollution • Reduce long-term harm of product • Planned life of product—full life efficiently • Effects of end disposal – biodegradable, recyclable • Specify materials with environmental certifications—LEED, EPS, SFI, FSC, etc. • More panel construction with veneers and laminate • Use CADD-CAM software and optimization features • Simulate production • Minimize material waste, and production time and cost – consider standard stock material and machine capacity • Weight reduction and modular – reduced shipping costs Reduce, Reuse, Recycle

18. Lean and Green: Material Selection • Cabinet box materials • Composite panels (95% of tree [lumber 63%] • Panels with low formaldehyde certifications (e.g., Composite panel association (CPA) EPP specification CPA 2-06 = formaldehyde levels less than 0.18 per million parts of air • Core material with EPP specification for being manufactured with 100% recycled and/or recovered fiber • Use high percentage of hardwoods with SFI and/or FSC certification • Medite II – wood fibers combined w/ formaldehde free synthetic resin; no commercially viable tree (scrag wood) fiber used • Dur-A-Tek Hardwood Composite - ultra low VOC = wood’s • Wheat board composites – low VOCs (volatile organic compounds); alternative to MDF and particle board

19. Lean and Green: Material Selection (cont-) • Doors, drawers, cabinet component materials • Bamboo – a grass; highly renewable and recyclable • Wood veneers - applied to doors and drawer front base materials—MDF or wheat board • SFI or FSC Certified Wood – little environmental pressure • Lyptus Wood(Lyptus) – Weyerhauser product from eucalyptus; excellent quality, beauty and environmental attributes; excellent choice when selecting exotic hardwood specie • Reconstituted veneers – veneer replicates wood species under environmental pressure; ; engineered and harvested from African hardwood trees and Italian plantation grown poplar trees. • Recycled and reclaimed wood - http://www.greenbuildingsherpa.com/categories/recycled-wood-and-reclaimed-wood-products.html

20. Lean and Green: Material Selection (cont-) • Laminates and veneer adhesives • Use low VOC glues • Water-borne PVA (polyvinyl acetate) adhesive is preferred over contact cement--no VOC’s • Edgebanding • Edgebanding – substitute ABS edge banding for PVC; no chlorine in material and its processing • Finishing • - see slide #22

21. Lean and Green: Production Techniques • Consider material and product flow • Optimization & optimization software • Panel optimization – maximum cutting patterns & yield • Panel utilization – visual scanning systems; reduce scrap • Solid wood yield – high speed material handling & yield • Optimizing rip saws and cut-off saws • CNC for optimizing panel construction • Optimizing features • Simulations can prevent waste • Nested parts • Decrease production times and cycles • Flexible assembly tables; z-lifts – more efficient time and motion • Control dust and waste by-products • Down-draft sanding tables

22. Lean and Green: Finishing • Material selection • Natural finishes – e.g., Tung oil • Low or ultra low VOC finishes • Waterborne finishes and sealants (e.g., • Vermont Natural Coatings – non toxic finish; durable water-based finish from cheese “whey” • Sherwin-Williams Kem Aqua Waterborne Finishing System • Finishing equipment and process • Flat panel coating with recovery systems reduce waste requiring disposal (e.g., Cefla) • Transfer efficiency; flexibility and productivity

23. Finishing Integration and Green Mfgfrom M&M Solutions, WMS, September 2009http://m-mwoodsolutions.com/knowledge/M+M-WMS_October_2009.pdf

24. Lean and Green: Hardware Selection • Specialty designed hardware components for lighter panel materials and composites (e.g., Hafele) • Green door and cabinet hardware • Recycled glass • Varia eco-resin -40% post-industrial reclaimed material • Cork Inlay • Fused glass –layers of glass fired in a kiln • Recycled aluminum • Stainless steel • Recycled hardware Recommended Resource: Rustica Hardware -http://www.rusticahardware.com/GREEN-HARDWARE-sp-1.html

25. Lean and Green: Minimize & Eliminate Waste • Waste utilization • Biomass furnace burns sawdust and wood waste • Briquetting wood waste can provide a fuel source • Dust collection system captures dust to silo • Packing material • VOC Abatement • VOC emissions used as fuel • Reduce, Recycle, Reuse • Resource: Stiles Machinery—Green Manufacturing - http://www.stilesmachinery.com/Equipment/Showroom/green-mfg.aspx

26. Case Study #1 – Mark Richey Woodworking and Design • Philosophy • Environmentally-responsible company since founding in 1980 • Facility Considerations • Cut energy usage • Renovate existing structures • Combine natural and energy-efficient lighting • Insulate, seal building envelope • Operate wind turbine to generate electricity • Product Design • Design products for material savings • Design to make products that last • Material Selection • Specify wood from sustainable sources – FSC certified • Use veneered product with particleboard or MDF cores – recycled cores • Production Techniques • Use advanced equipment to cut and machines materials efficiently • Finishing • Hardware Selection • Minimize and Eliminate Waste - Reduce-Reuse-Recycle • Burn wood waste in biomass furnace to heat plant • Use post-industrial or recycled product for packing materials From: “Taking the Lead in Green Manufacturing” by George Lausch http://www.fdmonline.com/richeyinterview.aspx

27. Case Studies: Four Additional Wood Industries • Case Green Cabinetry Environmentally Friendly or Green Cabinet Options http://www.casegreen.com/process/GreenCabinetOptions.html • Pacific Crest Industries Amero Cabinet Collection Builds responsibly as steward of environment http://amerocabinetcollection.com/environment.html • Industrial Woodworking Corporation IWC leads the way to a sustainable future http://www.industrialwoodworking.com/HTML/environment/index.htm • Fimbel Architectural Door Specialties Well documented policies concerning “green” http://www.fimbelads.com/green_manufacturing.html

28. Pittsburg State University Wood Technology: Addressing Lean and Green • Facility Considerations • Product Design • Material Selection • Production Techniques • Hardware Selection • Finishing • Minimize and Eliminate Waste

29. PSU: Lean & Green Lab Considerations • Production Equipment • Optimizing Rip Saw • CNC Router • Horizontal Beam saw • Shop Layout • Production and Material Flow • Assembly Tables • Dust Collection • Dust collection system and downdraft tables • Finishing Lab

30. PSU: Lean & Green: Product Design • Design to use standard stock sizes • Design for production and efficiency • CAD/CAM and CNC • Machine capacity and capability • Use optimization software and/or features – get most out of material • Design to minimize waste of material, energy, and time • Keep end-use and end-user in mind

31. PSU: Lean & Green Material Selection • Composite Materials • MDF • TruPan • Extensive Use of Veneers • Solid Lumber – Saw Mill • Local species – readily available • Logs provided by tree removal services

32. PSU: Lean & Green Production Techniques • CNC • optimization • nested production • Vacuum Bag • Veneer to substrate (MDF) • Tiger Stop • Save time • Minimize waste caused by operator error

33. PSU: Lean & Green Finishing • Flash Tunnel • Reduces Dry Time • Recycle Waste • Spray Guns • High transfer rate spray guns • Low VOC Finishes • Water Borne Finishes • Make students aware • Experiment with finishes

34. PSU: Lean & Green Hardware Selection • Hardware for Composite Material • Specialty hardware is needed for use in some composite materials that are used.

35. PSU: Lean & Green Minimize and Eliminate Waste • Chipper/ Wood Grinder • Experimented and tested the benefits of a wood grinder • Tiger Stop • Capabilities of optimizing • CNC & Horizontal Beam Saw • Increase of material yield

36. Lean and Green Implications for Educators • Suggestions for Educators • Activities • Resources

37. Lean and Green: Suggestions for Educators Note: Many of the following are not new, but have been used by teachers for years to conserve limited resources and funds—”Lean Teaching” • Organize lab (“shop”) for material & production flow—save time and energy • Purchase materials locally & regionally • Design custom and mass produced products to optimize standard stock material • CAD/ Cam software • Optimizing software and/or features

38. Lean and Green: Suggestions for Educators (cont-) • Material selection • Local, more plentiful solid lumber species • Recycled wood • Composite materials & veneers • Urea-free MDF • Formaldehyde-free plywood • Finishing and laminate projects • Natural finishes – e.g., tung oil • Finishes low in VOCs and HAPs

39. Lean and Green: Suggestions for Educators (cont-) • Hardware Selection • Environmentally-friendly new • Materials – recycled glass and aluminum; cork; fused-glass; eco-resin (e.g., Varia); lead-free pewter and stainless steel • Recycled hardware • Specialty stores • Sample Resources • Rustic Hardware - Hardware -http://www.rusticahardware.com/GREEN-HARDWARE-sp-1.html • Hafele – www.hafele.com ?

40. Lean and Green: Suggestions for Educators (cont-) • Minimize and Eliminate Waste—Reduce, Reuse, Recycle • Recycle or reuse abrasives—abrasive belts, sand paper, etc. • Sawdust • Packing material • Cage bedding-Biology animals • Mulch for acid-loving plants (e.g., blueberries) – Note: Walnut harmful to plants • Specialty Projects – wood flour molded knobs, coasters, etc. • Solid wood waste • Kindling for wood stoves, etc.

41. Lean and Green: Suggestions for Educators (cont-) • Rough Lumber or S2S – surface and edge joint whole board to eliminate having small pieces that can’t be machines safely and become “scrap” • Create “Standard Stock” – instead of lots of odd sized “shorts”, create standard sizes (t” x w”) for small projects • Small ”Filler” Projects – several small projects • Use up leftover material • Students do these during “idle” times • Examples: wood puzzles; cutting boards; key holders; salad fork & spoon re-saw project; etc.

42. Lean and Green: Activities for Educators: Green Design Brief #1: Bird House • Scenario: Local Audubon Society needs a large quantity of “bird houses” built for local wildlife area • Design Brief: Design and mass produce a large number of eco-friendly, solid wood “bird houses,” as efficiently as possible for the lowest cost. This image is from: www.birdingessentials.com/page/birdhouses

43. Lean and Green: Activities for Educators:Green Design Brief #1: Bird House (cont-) • Considerations for evaluating solution: • Material Selection – appropriate for application; standard stock; proper hardware • Design - appropriate size for bird; optimizes use of standard stock material; minimum number of T x W x L • Production – manufacturability—ease of making; material & production flow; minimum number of cuts, fasteners, assemblies; surface preparation; etc. • Finish – none; environmentally friendly; exterior application • Installation – ease of installation • Aesthetics – craftsmanship; appearance

44. Lean and Green: Activities for Educators:Green Design Brief #1: Bird House (cont-) • Comparison of cut lists of two solutions for a given type of house with one-piece roof:

45. Lean and Green: Activities for Educators:Green Design Brief #2: Recycle Bins • Scenario: The school district needs 20 special recycle container bins (10 for cans; 10 for plastic bottles) built. • Design Brief: Design and mass produce a large number of eco-friendly, composite- panel “recycle container bins”, as efficiently as possible for the lowest cost.

46. Lean and Green: Activities for Educators:Green Design Brief #2: Recycle Bins (cont-) • Considerations for evaluating solution: • Material selection – appropriate for application; standard stock; proper hardware • Design - appropriate openings for containers; optimizes use of standard stock material; minimum number of W x L • Production – manufacturability—ease of making; material & production flow; minimum number of cuts, fasteners, assemblies; etc. • Finish –environmentally friendly; appropriate for application • Aesthetics – craftsmanship; appearance

47. Green Activities & Resources for Educators--Activity: Green Manufacturing Terminology • Directions: • Complete the “Green (or Sustainable) Manufacturing Crossword Puzzle.” • Handout: “Glossary of Green Terms Related to Wood Manufacturing” – Compiled by Pittsburg State University Wood Technology ______________________________________ • Presentation Resources on CD: • “Going Green in the Woodworking Industry” • PowerPoint/PowerPoint Handout (48 slides/4-pages f/b) • Glossary of Green Terms Related to Wood Manufacturing • Crossword Puzzle & Answer Key • Outline of Presentation with Website Resources

48. Kansas Technology Center Questions and Answers Thank You for Your Attention to this Presentation: Going Green in the Woodworking Industry Contact Information: Douglas R. Hague Jordan Clous Backs John L. Iley, Ph.D., Chairman Department of Technology and Workforce Learning Pittsburg State University Pittsburg, KS 66762 TWL Phone: 620-235-4371 Emails: drhague@pittstate.edu jcbacks@gus.pittstate.edu jiley@pittstate.edu