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NECESSITY IS THE MOTHER OF INVENTION

GP CONCEPT, PRACTICES & METHODOLOGY By: K. D. Bhardwaj Program Officer Asian Productivity Organization. NECESSITY IS THE MOTHER OF INVENTION. Global Environmental Concerns Cost of Environmental damage Public Concern Environmental Management System Occupational Safety & Health

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NECESSITY IS THE MOTHER OF INVENTION

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  1. GP CONCEPT, PRACTICES & METHODOLOGYBy:K. D. BhardwajProgram OfficerAsian Productivity Organization

  2. NECESSITY IS THE MOTHER OF INVENTION Global Environmental Concerns Cost of Environmental damage Public Concern Environmental Management System Occupational Safety & Health Social Accountability GREEN PRODUCTIVITY

  3. Quality • Traditional focus of productivity was ensuring cost effectiveness through cost reduction. • The quality drive and customer satisfaction was the next focus Productivity Cost The next step required integration of "Environment" into these productivity improvement programs. Environment GREEN PRODUCTIVITY

  4. PRODUCTIVITY CONCEPTS & PRINCIPLES •  Technical Concept •  Social Concept •  Economic Concept •  Management Concept • INTEGRATED CONCEPT OF PRODUCTIVTY LEADS TO GREEN PRODUCTVITY

  5. GREEN PRODUCTIVITY Concept: GP Concept:5

  6. Definition: Green Productivity (GP) is a strategy for enhancing productivity and environmental performance for overall socio-economic development. It is the application of appropriate productivity and environmental management tools, techniques, technologies to reduce the environmental impact of organization’s activities, goods and services GREEN PRODUCTIVITY GP Concept:6

  7. ADOPTING GP PRACTICES DOES NOT REQUIRE A NEW SET OF SKILLS TO BE LEARNED, RATHER IT IS APPLICATION OF MANAGEMENT & PRODUCTIVITY TOOLS

  8. IN GP PRACTICES, MAIN OBJECTVE IS TO IDENTIFY WAYS TO PREVENT POLLUTION AT SOURCE AS WELL AS REDUCE THE LEVEL OF RESOURCES INPUT THROUGH RATIONALISATION / OPTIMISATION

  9. RESOURCE EFFICIENCY NOT ONLY LEADS TO PROTECTION OF NATURAL RESOURCES BUT ALSO RESULTS IN IMPROVED PRODUCTIVTY

  10. RECOGNITION OF THIS INTEGRATED APPROACH IS REFLECTED IN THE CONCEPT OF GREEN PRODUCTIVITY CONCEIVED AND DEVELOPED BY APO IN 1994

  11. GREEN PRODUCTIVITY Features: Ensures profitability Enhances Quality of Life Reduces environmental impact GP Concept:7

  12. GREEN PRODUCTIVITY TripleFocus: Environment (Sustainable Development) GREEN PRODUCTIVITY Profitability (Factor Inputs) Quality (Voice of Customer ) GP Concept:8

  13. GREEN PRODUCTIVITY Approach: RAW MATERIAL PRODUCTION PROCESS PRODUCT GASEOUS LIQUID SOLID WASTES TREATMENT &/DISPOSAL CONVENTIONAL PRACTICES PRODUCT RAW MATERIAL PRODUCTION PROCESS BY- PRODUCT RECYCLE/ REUSE GASEOUS LIQUID SOLID REMAINDER LESS WASTES GP PRACTICES TREATMENT &/DISPOSAL GP Concept:10

  14. GREEN PRODUCTIVITY • GuidingPrinciple: •  Ecological Principle •  Accountability •  Polluter Pays •  Precautionary approach •  Productivity Principle • Profitability •  Competitive Advantage •  People Building GP Concept:11

  15. GREEN PRODUCTIVITY • DrivingForces: •  External Forces •  Regulation •  International/ Regional Conventions & Treaties •  Market Forces •  Customers requirements/demands •  Pressure form NGOs, Banks, Shareholders, Insurance agencies •  Internal Forces • Resource conservation/Profitability •  Competitive Advantage •  Internal Efficiency •  Workers safety & health GP Concept:12

  16. UMBRELLA CONCEPT COVERING • Pollution Prevention • Environment Management System • Pollution Control • Occupational Safety & Health • Cleaner Production

  17. Eco- efficiency • Responsible Care • Environment Stewardship • Social Accountability • Corporate Environment Response • Eco-design • And so on…………………………

  18. Green Productivity-Methodology GPMethodology- Framework: GP Methodology Guiding Principles of GP GP Tools GP Techniques GP-Methodology:1

  19. The Vicious Cycle of Bad Quality Green Productivity-Methodology GPMethodology- Introduction: GP-Methodology:2

  20. Green Productivity-Methodology GPMethodology- Introduction: The Conversion Process GP-Methodology:3

  21. Green Productivity-Methodology GPMethodology- Introduction: KAIZEN vs. INNOVATION GP-Methodology:4

  22. Green Productivity-Methodology GPMethodology- Introduction: CONTINUOUS IMPROVEMENT THROUGH PDCA GP-Methodology:5

  23. Green Productivity-Methodology GPMethodology- Components:  Step by step problem solving framework Tools, techniques & methodologies used in conjunction with the framework  Social, economic, environmental & cultural principles and values govern the choice of tools, techniques and technologies and the design of GP process GP-Methodology:6

  24. Green Productivity-Methodology GPMethodology- Components: •  Step by step problem solving framework • Identify the problem • Analyze the problem • Find the root cause • Evolve options to solve the problem • Evaluate the options • Plant to implement options • Monitor & review GP-Methodology:7

  25. Green Productivity-Methodology GPMethodology- Components: • Tools, techniques & methodologies • used in conjunction with the framework • Management • Engineering • Environmental • Economic etc. GP-Methodology:8

  26. Getting Started I Sustaining GP II Planning Planning VI III Generation and Monitoring and Review Generation and Evaluation of GP Options Evaluation V IV Implementation of GP Options Implementation of GP Options Green Productivity-Methodology GPMethodology- 6 STEPS: 6 STEPS GP METHODOLOGY GP-Methodology:9

  27. Green Productivity-Methodology GPMethodology- 6 STEPS & 13 TASKS: STEP I: GETTING STARTED TASK 1 -TEAM FORMATION TASK 2 -WALK THROUGH SURVEY & INFORMATION COLLECTION STEP II: PLANNING TASK 3 -IDENTIFICATION OF PROBLEMS TASK 4 -SETTING OBJECTIVES & TARGETS STEP III: GENERATION, & EVALUATION OF GP OPTIONS TASK 5 -GENERATION OF GP OPTIONS TASK 6 -SCREENING & EVALUATION OF GP OPTIONS TASK 7 - FORMATION OF GP IMPLEMENTATION PLAN STEP IV: IMPLEMENTATION OF GP OPTIONS TASK 8 -IMPLEMENTATION OF SELECTED GP OPTIONS TASK 9 -TRAINING, AWARENESS BUILDING & DEVELOPING COMPETENCE STEP V: MONITORING & REVIEW TASK 10 -MONITORING & EVALUATION OF RESULT TASK 11 -MANAGEMENT REVIEW STEP VI: SUSTAINING GP TASK 12 -INCORPORATE CHANGES INTO ORGANIZATION,S SYSTEM OF MANAGEMNET TASK 13 -IDENTIFYING NEW/ADDITIONAL PROBLEM AREAS FRO CONTINUOUS IMPROVEMNET GP-Methodology:10

  28. Green Productivity-Methodology GPPrerequisite:Commitment & Involvement of Top Management • Task based involvement of Top Management is critical • Task 1: Team Formation • Task 4: Setting Objectives & Targets • Task 7: Formulation of Implementation Plan • Task 8: Implementation of selected options • Task 11: Management Review • Task 12: Incorporate changes into organization’s system of management GP-Methodology:11

  29. Barriers Green Productivity-Methodology Barriers to Commitment of Top Management • Attitudinal barriers • Information related barriers • Technical • Financial barriers GP-Methodology:12

  30. Green Productivity-Methodology Means of Achieving Commitment of Top Management • Awareness programs • Visits to Industries that have successfully implemented GP Barriers GP-Methodology:13

  31. For a Large Organization For an SME Top Management Top Management External Consultant Core Team External Consultant Core Team Sub Team 1 Sub Team 2 Sub Team 4 Dept. 1 Dept 2 Dept 4 Note: In the case of SMEs Top Management will have more participation in the Core Team Note: In large organizations, finance, administration section, utilities and stores are also departments. Green Productivity-Methodology Task-1 :Team Formation Sample GP Team GP-Methodology:14

  32. 6 5 4 3 2 1 Green Productivity-Methodology Task-2 :Walk-though survey & information collection Walk-through survey Lime Storage Hides receiving and Storage material Liming / Deliming Soaking and Unhairing Pollution Control Facility Laboratories, Utilities Pickling / Tanning Product Storage and Inspection Administrative block Finishing GP-Methodology:15

  33. Green Productivity-Methodology Task-2 :Walk-though survey & information collection Techniques for Information Collection Information Collection Review Existing Documents Walk-Through One-to-one meetings Carry out Updates Organized Information easy to access, update and use GP-Methodology:16

  34. Green Productivity-Methodology Task-2 :Walk-though survey & information collection Document Review Organizational Financial Employee information Organizational and Reporting structure Service Production Packaging and disposal Supply chain requirements Technologies, processes, equipment, efficiencies Environmental Waste collection/ conveyance system Waste treatment and disposal operations Environmental Impacts of Operations Materials and Product Resource Material Inventories Supplier Information Fuel type and requirements Material Inventories, MSDSs, consumption patterns, properties GP-Methodology:17

  35. Green Productivity-Methodology Task-3 :Identification of problems & causes Problem could be with the And, causes could be so many.....! How to identify them? • Process • Water • Chemicals • Energy • Labor • Costs • Waste Generation • Production • Capacity Utilization • Product Quality • Market demand GP-Methodology:18

  36. Green Productivity-Methodology Task-3 :Identification of problems & causes Tools & Techniques could be • Process Flow Diagram (PFD) • Layout & Eco-Mapping • Concentration Diagram • Material/Energy Balance • Cost of waste stream • Brainstorming • Benchmarking • Control Charts • Ishikawa Diagram (Fishbone) • Cause-effect Analysis • Critical Path Analysis Tools and Techniques to be used? GP-Methodology:19

  37. Green Productivity-Methodology Task-3 :Identification of problems & causes illustration Detailed Process Flow Diagram Eco-Map to identify focus areas Baseline information on production, environmental performance, etc. Plant level comparison with norms Detailed Unit level Material / Energy Balance Plant level Material / Energy Balance Identification of Problems Unit level Comparison with production norms GP-Methodology:20

  38. Green Productivity-Methodology Task-3 :Identification of problems & causes Identificationof Root Causes Problem 1 ? ? ? Cause 2 Cause 3 Cause 1 Why? How? Common Causes? Common Problems? Cause 1 Problem 1 Problem 3 Problem 2 Problem 1 Problem 2 Problem 3 Problem 4 Problem 5 GP-Methodology:21

  39. Green Productivity-Methodology Task-4 :Setting Objectives & Targets • Objectives & Targets Shall be “SMART” •  Specific •  Measurable/Motivating •  Achievable/Attainable •  Relevant & •  Trackable/Time bound GP-Methodology:22

  40. Green Productivity-Methodology Task- 5 & 6 :Generation, Screening & Evaluation of GP Options Generation of GP Options Review existing GP options Generate new GP options Screening of GP Options Collect Option specific Information Evaluation of GP Options GP-Methodology:23

  41. Green Productivity-Methodology Task- 5 & 6 :Generation, Screening & Evaluation of GP Options Reviewing Exiting GP Options Ways of Generation of GP Options X Generating New GP Options  • Option was not implemented • Option was implemented but did not work at all • Option did not succeed as expected (partial achievement / elimination of concern) • Option succeeded as expected but has not been evaluated and documented Reviewing options already implemented or thought of in the past. GP-Methodology:24

  42. Green Productivity-Methodology Task- 5 & 6 :Generation, Screening & Evaluation of GP Options Generation of new GP Options EquipmentChange GP Techniques Reuse/recycle Material Substitution Process Modification Housekeeping Technological Change Process Optimization End-of-pipe GP Tools Brainstorming Ishikawa diagram GP Options GP-Methodology:25

  43. Green Productivity-Methodology Task- 5 & 6 :Generation, Screening & Evaluation of GP Options Screening of GP Options GP Options SCREEN Reject Further Evaluation • Implement Immediately • House Keeping • Awareness • Economical • Technically • sound • High returns • High Cost • High Risk • Complicated • Technology To Evaluation Section GP-Methodology:26

  44. Green Productivity-Methodology Task- 5 & 6 :Generation, Screening & Evaluation of GP Options Evaluation of GP Options • GP OPTION shall be: • Technically Feasible • Economically Viable • Environmentally Sound • Short term / Long term • Low cost /High Returns • Low Risk/High Gain GP-Methodology:27

  45. Green Productivity-Methodology Task- 7 & 8:Preparation & Implementation of Plan Components of Plan •  Objectives & Targets •  Action as per scheme •  Time Frame •  Responsibility •  Resources required •  Indicator for accomplishment GP-Methodology:28

  46. Green Productivity-Methodology Task- 9:Training, Awareness Building & developing competence • Assessing training needs • Selecting suitable programs, methods and material • Preparing a training plan (5W1H)) • Implementing training programs • Tracking and recording training programs • Evaluating training effectiveness • Improving training program as needed GP-Methodology:29

  47. Green Productivity-Methodology Task- 9:Training, Awareness Building & developing competence Ways of Training & Development • Off-the-Job Training (Seminars & Lectures) • On-the-Job Training • Video presentations and Posters • Operation Manuals and work instructions • Field Visits GP-Methodology:30

  48. Green Productivity-Methodology Task- 10:Monitoring & Evaluation of Result • Parameters affecting the end results • Performance indicators for the end result • Appraise the performance of the option against the targets GP-Methodology:31

  49. Green Productivity-Methodology Task- 11:Management Review • Effectiveness of the GP Options Implemented • Tangible and in-tangible benefits • Financial savings achieved • Difficulties faced (GP Methodology) • Identify areas for future improvement G P GP-Methodology:32

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