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Clean & Lean Manufacturing Program

Clean & Lean Manufacturing Program. Raymond McEvoy Manufacturing Excellence National Lean Seminar 20 Oct 2005. Green. Lean & Green Solutions. Lean & Profit Maximise profit by using minimum resources. Green Preserve & conserve natural resources. Lean & Profit.

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Clean & Lean Manufacturing Program

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  1. Clean & Lean Manufacturing Program Raymond McEvoy Manufacturing Excellence National Lean Seminar 20 Oct 2005

  2. Green Lean & Green Solutions Lean & Profit Maximise profit by using minimum resources Green Preserve & conserve natural resources Lean & Profit Are Green & Lean Opposites?

  3. Outputs Value = Product or Service Heat Waste materials Systems View Inputs: Raw matrls Consummables People Energy Building Enterprise

  4. Background • 3 companies, component manufacture, engineering and medical device industries • Carten Controls • Frentech Engineering • Lake Region • Range from 50 to 700 employees • Multi-national & indigenous • All had commenced implementation of Lean Principles Grant aided under EPA’s Cleaner Greener Production Programme

  5. Approach • Further lean training • Use modified VSM • Overlay energy & material inputs and outputs & effluents onto Value Stream Map • Energy & Effluent pro-rata with what?

  6. Extract: Combined VSM & Energy/Effluent Data

  7. Examples of improvements • Right-sizing process to throughput: • Reduced EP rinsing, rightsize to qty of valves, 60% reduction in water usage • Reduce cleanroom energy inputs, 50% red’n in electricity • Design modifications • Minor change to valve design to make heat mark removable by hand-buffing, 50% red’n in EP usage • Challenge design of chamfers, 34% red’n in swarf • Change design from welding to riveting, eliminates airborne dust, extraction and some safety issues

  8. Examples contd… • Other • Grinding Coolant, separate supply when dressing wheel • Administrative & engineering processes: • Lean lines require less routers, 80% red’n in paper • Eliminated steps in quotation & purchasing process • (Logic=change information or simply copy it?)

  9. Advantages of the VSM Tool • More useful in the bigger companies because the process is harder to see in its totality • Supports “whole-system thinking” rather than sub-optimisation • What gets measured, gets done • Promotes “why-why-why” analysis

  10. Conclusions So Far… • Yes; Lean = Clean & Green • Must look at entire system, rather than suboptimise • Use process maps, inputs & outputs & drivers to expose waste

  11. Further Information… • www.cleanerproduction.ie • Website describing the overall program, as well as case studies from the last 3 years in Irish & international industry • www.epa.ie • Irish Environmental Protection Agency • www.manufacturing-excellence.ie • Consultancy & Training services in Lean & Six Sigma • Detailed results of this program will be published in early 2006 on www.cleanerproduction.ie

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