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GREEN SUPPLIERS NETWORK

GREEN SUPPLIERS NETWORK. An Innovative Industry-Government Collaboration. Responding to Industry’s Needs. OEM. Tier 1 Suppliers. Challenges: Outsourcing causes environmental impacts to move down supply chain

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GREEN SUPPLIERS NETWORK

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  1. GREEN SUPPLIERS NETWORK An Innovative Industry-Government Collaboration

  2. Responding to Industry’s Needs OEM Tier 1 Suppliers Challenges: Outsourcing causes environmental impacts to move down supply chain Manufacturers can be held publicly responsible for suppliers’ environmental performance Small and medium-sized manufacturers are pressured to reduce costs and improve environmental performance with little resources Tier 2 Suppliers Tier N Suppliers Response: The Green Suppliers Network provides lean and environmental technical assistance to lower tier suppliers

  3. Green Suppliers Network in a Nutshell • Green Suppliers provides Lean & Clean technical assistance to small and mid-sized manufacturers that improves competitiveness through environmental and economic benefits • A Lean & Clean approach expands the traditional Lean definition of waste from eliminating non-value added time, labor, and money to include environmental wastes (e.g. energy, emissions) • A collaborative venture among industry, the National Institute of Standards and Technology Manufacturing Extension Partnership (NIST MEP) Program, the States and the U.S. EPA • This voluntary initiative aligns original equipment manufacturer (OEM), supplier and government interests

  4. What is Lean and Clean? Lean reduces: • Defects • Overproduction • Waiting • Non-utilized People • Transportation • Inventory • Motion • Extra processing Clean strives for: • Nature-friendly Substitutes • Optimized Material Efficiency • Waste Elimination • Air/Water Emission Reductions • Solid/ Haz Waste Reduction • Toxic Material Reduction • Efficient Packaging

  5. What Makes Green Suppliers’ Unique? • OEMs drive supplier participation • Only engaging interested sectors and OEMs • Suppliers’ environmental performance is the OEM’s problem • Brings suppliers cost savings • Encourages OEMs to re-visit specifications that hinder improvement • Collects aggregate data through NIST MEP database • Marries NIST MEP system with state environmental resources • Bolsters and expands State and Regional programs

  6. Green Suppliers Network Results Potential savings for 30 Green Suppliers Network Reviews:

  7. Innovation through Collaboration The Green Suppliers Network brings together: • Government & Industry • US EPA, OPPTS • US Department of Commerce’s National Institute of Standards and Technology’s Manufacturing Extension Partnership (MEP) • State Economic and Environmental Resources • State environmental program • NIST Manufacturing Extension Partnership • Lean Manufacturing & P2 • Supply chains • Original Equipment Manufacturers • Suppliers

  8. Green Suppliers’ Industry Champions • Aerospace • Boeing, Lockheed-Martin, Northrop Grumman, Pratt & Whitney, Raytheon, Rockwell Collins, United Technologies Corporation • Automotive (Suppliers’ Partnership for the Environment) • DaimlerChrysler, General Motors and 30 suppliers • Healthcare/Pharmaceutical • Abbott Labs, Baxter Healthcare, Bristol-Myers Squibb, Eli Lilly, GlaxoSmithKline, Johnson & Johnson, Pfizer, Roche and Wyeth • Office Furniture • Haworth, Herman Miller, HNI/AllSteel, Kimball, Light Corp, Steelcase • Any facility can benefit from the Green Suppliers Network

  9. State Perspective Marcia Horan Michigan Department of Environmental Quality

  10. It’s All About Community “All politics are local.” Eugene “Tip” O’Neal, Former Speaker of the U.S. House of Representatives • Focus on inter-relationships at the community level • State programs complement EPA objectives • Creates the potential to leverage a successful model to enhance economic development, manufacturing support and environmental performance • Provides the supplier with follow-up support activity in waste reduction/energy efficiency implementation and realized cost savings.

  11. Clean Corporate Citizen Mentoring RETAP Internship Program GSN Product Stewardship Synergistic Connections Green Suppliers Network connects to other EPA programs and to state programs Design for the Environment Performance Track

  12. Retired Engineer Technical Assistance Program (RETAP) RETAP Internship Program Small Business P2 Loan Program RETAP P2 Technical Demonstration Grant Michigan Business Pollution Prevention Partnership (MBP3) Clean Corporate Citizen (C3) Environmental Management Systems (EMS) State Program Support Michigan Examples

  13. Real World Connections • Five Green Suppliers assessments performed • Three included RETAP engineers • Three RETAP Interns placed Summer 2003 – 2005 • Two OEM and one Supplier awarded Clean Corporate Citizen (C3) status in 2004 • October, 2005- 12 additional suppliers engaged in the Green Suppliers learning process. • December, 2005- 2 Green Suppliers assessments scheduled for 2006

  14. New Direction with Business - Sustainability Along the Supply Chain as Standard Operating Procedure Transparency

  15. Green Suppliers Network Catalyzes Action • Metal Works, Inc.- Supplier working on EMS, joins the Michigan Business Pollution Prevention Program (MBP3) and is setting a goal of gaining C3 status by the end of 2005 • Environmental Coatings Inc. - Supplier agrees to an Investment Grade Audit with RETAP participation and the Delta Institute.

  16. Green Suppliers Aggregate Potential Environmental Data for Office Furniture Suppliers in Michigan-5 Technical Reviews (NIST-10-12-05)

  17. Green Suppliers Aggregate Potential Dollars Savings Data for Office Furniture Suppliers in Michigan- 5 Technical Reviews (NIST-10-12-05)

  18. The Rewards • Creates a comfort zone • Connections are supported • Opportunities develop • Business growth and innovation occurs • New directions of state support are created

  19. The Review Bill Stough

  20. MANUFACTURING WASTE LINKS TO LEAN AND ENVIRONMENTAL IMPACTS

  21. What is the Manufacturing Extension Partnership? • The NIST Manufacturing Extension Partnership (MEP) program help’s America’s small manufacturers improve their productivity, economic competitiveness and technological capability. • Created or retained 50,315 jobs • Increased $1.483 billion in sales • Retained sales of $2.638 billion • Realized $686 million in cost savings • Invested $912 million in modernization, including plant and equipment, information systems, and workforce training • Served 18,422 clients in FY 2003 *Survey results of clients served from October 2002 through September 2003

  22. Green Suppliers Network Review Process Step 1 – Green Suppliers Network review team (NIST MEP and State environmental experts) engage supplier to complete Transformation Planner Step 2 –The team works with supplier to determine which process and areas to focus on Step 3 –The team works with supplier to create value stream map and process map while training them at the same time Step 4 – The team uses these maps to find improvement opportunities Step 5 – NIST MEP completes final report including a cost benefit analysis of all identified opportunities Step 6 – The team conducts follow-up with supplier to assist in implementation

  23. Understanding the Current StateBenchmarking Exercise Activities Questionnaire Data Comparison Results Discussion Identify Opportunities Estimate financial Benefit & Generate Final Report Implementation Responsibility Supplier NIST MEP Center NIST MEP Center, State TAP NIST MEP Center, State TAP NIST MEP Center, State TAP NIST MEP Center, State TAP

  24. Understanding the Current StateValue Stream Mapping A Value Stream is the set of activities (both value added and non value added) required to bring a specific product or service from raw material through to the customer. Value Stream Operation A Operation B Operation C Raw Material Final Product

  25. Weekly delivery schedule Production Control Market Forecast Annual Production Plan D Customer A Customer B Supplier 1 Supplier 2 D WK WK Daily schedule Weekly schedule I Daily schedule Daily schedule 30 days Shipping Receiving I Assembly & Inspection Welding Painting Milling I I I 5 days 2 people 3 people 3 people 2 people C/T = 2 min C/O = 2 hr Uptime = 74% C/T = 4 min C/O = 3 hr Uptime = 61% C/T = 2 min C/O = 30 min Uptime = 93% C/T = 7 min C/O = 4 hr Uptime = 48% 5 days 10 days 15 days 8 days 30 days 2 min 4 min 7 min 2 min Total Lead Time = 68 days Value Added Time = 15 min Understanding the Current StateValue Stream Mapping

  26. Production Control Market Forecast Annual Production Plan Customer A Customer B Weekly delivery schedule Supplier 1 Supplier 2 D Daily schedule Weekly schedule I Daily schedule D Daily schedule WK WK 30 days Shipping EHS EHS EHS Receiving I Assembly & Inspection Welding Painting Milling I I I 5 days 2 people 3 people 3 people 2 people C/T = 2 min C/O = 2 hr Uptime = 74% Haz. Waste = 5 lbs C/T = 4 min C/O = 3 hr Uptime = 61% Haz. Waste = 20 lbs C/T = 2 min C/O = 30 min Uptime = 93% C/T = 7 min C/O = 4 hr Uptime = 48% Haz. Waste = 60 lbs 5 days 10 days 15 days 8 days 30 days 2 min 4 min 7 min 2 min Total Lead Time = 68 days Value Added Time = 15 min VSM with Environmental Metrics & EHS Icons

  27. Production Control Market Forecast Annual Production Plan Customer A Customer B Weekly delivery schedule Supplier 1 Supplier 2 D Daily schedule Weekly schedule I Daily schedule Daily schedule D WK WK 30 days Shipping EHS EHS EHS Receiving I Assembly & Inspection Welding Painting Milling I I I 5 days 2 people 3 people 3 people 2 people C/T = 2 min C/O = 2 hr Uptime = 74% C/T = 4 min C/O = 3 hr Uptime = 61% C/T = 2 min C/O = 30 min Uptime = 93% C/T = 7 min C/O = 4 hr Uptime = 48% 5 days 10 days 15 days 8 days 30 days 2 min 4 min 7 min 2 min 20 lbs 120 lbs 15 lbs 40 lbs 80 lbs 5 lbs 20 lbs 5 lbs Total Lead Time = 68 days Value Added Time = 15 min Total Materials Used = 195 lbs Materials Needed = 110 lbs VSM with Materials Line and EHS Icons

  28. Production Control Market Forecast Annual Production Plan Daily schedule Customer A Customer B Supplier 1 Supplier 2 Daily schedule D I Shipping EHS EHS EHS Assembly & Inspection Milling Welding Painting 2 people 2 people 3 people 3 people C/T = 2 min C/O = 2 hr Uptime = 74% C/T = 4 min C/O = 3 hr Uptime = 61% C/T = 7 min C/O = 4 hr Uptime = 48% C/T = 2 min C/O = 30 min Uptime = 93% 8 days 10 days 5 days 15 days 2 min 7 min 2 min 4 min <90 lbs 15 lbs 20 lbs <25 lbs 5 lb 20 lbs 80 lbs 5 lbs Lead Time = 68 days Value Added Time = 15 min Total Materials Used < 150 lbs Materials Needed = 110 lbs Future State VSM with Materials Line and EHS Icons

  29. Lubricants Water Energy Process Final Product Raw Material Atmospheric Emissions Contaminated Water Used Oil Understanding the Current StateProcess Mapping • A schematic depiction of a process • Used to enhance resource utilization • Used to identify, eliminate/reduce wastes

  30. Next Steps: Implement Changes Green Suppliers’ Implementation support • $1,000 credit toward implementation assistance if suppliers work with MEP center on an environmental project within 3 months of review MEP • Create implementation recommendation report • Share results and cost-benefit analysis with supplier • Conduct follow-up survey within 6 months to assess impacts State • Direct supplier to state resources and programs

  31. Review Specifics • Cost $7,000 Cost of review $2,500 U.S. EPA program discount* $4,500 Total cost to supplier for Green Suppliers review • Supplier benefits often exceed 3:1 ROI • Reviews offered first come, first served • Reviews focus on single process • On-site reviews take 2-3 days • Reports generated in 4-6 weeks • Technical assistance providers disclosed before review *Suppliers Must Qualify Under SBA Definitions

  32. Real World Examples Metalworks, Inc.,(a metal fabricator for furniture industry) Green Suppliers Assessment recommended: 1. Used 21,828,138 gallons of water per year; recommended a 25 percent reduction; reduced water consumption to 8,500,000 gallons per year, a 60 percent reduction, saved $30,000. 2. Used $700,000/year on electricity and natural gas; recommended a 10 percent conservation goal; achieved over 12 percent, saved $85,000. 3. Develop an Environmental Management System team that integrates the Lean Team

  33. Review Results: H&L Advantage Plastic Injection molding and assembly for furniture and automotive industries: • Reduce Energy Use by 10 percent by joining the EnergyStar program, focus on improving air compressor efficiency. • Reduce chemical use for cooling water system; reduce Water Use by 15 percent by • “…The Lean and Green principles have become our way of doing business for everything we do at H&L, and it’s now in our DNA. I would encourage anyone who has an opportunity to become involved in the Green Supplier’s Network to take that opportunity. It is extremely valuable.” –Steve Beurkens, Sales Marketing Manager, H&L Advantage

  34. Waste Types

  35. The End Result is, Any Type of Waste has Multiple Negative Impacts to Your Profit Margin

  36. The Challenges • Motivating engagement • Speaking the same language • Building trusting relationships • Maintaining a consistent message • Maximizing resources • Large scale adoption and diffusion system • Getting participants to implement recommendations

  37. Contact Information For more information about the Green Suppliers Network visit www.greensuppliers.gov or contact: Tom Murray – Pollution Prevention Division, US EPA (murray.tom-hq@epa.gov or 202-564-8829) Marcia Horan – Environmental Science and Services Division, Michigan Department of Environmental Quality (horanm@michigan.gov or 517-373-9122) Bill Stough – The Right Place, Inc. (srg@iserv.net or 616-301-1059)

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