elec2017 2.4 n. trivedi - the green factory creating lean and sustainable manufacturing

TheGreenFactory

NeilTrivediThePerfectProcessCompany

neil.trivedi@theperfectprocess.co.ukwww.theperfectprocess.co.uk

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CareerandClients

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Agenda

• Background• WhyLeanandGreen?• TheApproach• TheResults• Reversetesting• LeanandGreeninaction– Gembawalk• Summary

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BackgroundtoLeanandGreen

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JourneytoTheGreenFactory

• JoinedGKNin2006• DevelopedglobaltrainingforBusinessProcessImprovement

• MetAndreaandtrainedherin2008

• 2009receivedthephonecall….

• Andreas’sPhDfollowed• TheGreenFactory- aftermanyfalsestarts

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JourneytoTheGreenFactory

Pilot1Cell

Machining

Pilot2CellAssy

Pilot2SiteVSM

Pilot2EVSM

Reversetesting

Andrea’sPhD

TheGreenFactory

Leantraining

Env.problemsolving

SisterCellrollout

GlobalDeployment

AcademicResearch

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Theresearchproposedanewframework,amodelthatisabletotranslatetheenvironmentallanguageandtheintentionofthe

environmentalsustainablepracticestothemanufacturingworld.

GreenDimension

LeanThinking

Lean+GreenBusinessModel

IntheL&GBM,thegreendimension,theenvironmentalaspectofsustainability,isaddedtothepureleanthinkingconceptinordertocreate

anewwayofthinking.

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WhyLeanandGreen?

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WhydoyouneedtodoLeanandgreen?

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L&GBMisdifferentfrompuregreenthinking

Introducesintoleananewdimension- theenvironmentalcost Lean&

GreenBusinessModel

Unlocksenvironmentalorganizationalblockages

Focusonothersourcesofsavingsreducingcosts

MeasuretheEWaste

Customerandvalue

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Topdown

BottomUp

Topdownandbottomup

The5principlesofLeanandGreen

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TheApproach

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Aswithanychangeprojectstakeholdermanagementiskey

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AnexampleofaLeanandGreenBusinessmodelcurrentstatemap

HOB BalanceWash VibrateCellTurn

ChipsFiltersTowelsSpenttoolingOilCoolant

ChipsToolingTowelsPigmatsOil

ChipsUsedclaySpenttools

wastesStonesTowelsCoolantSuspensionfluid

PartsDrillbitsClayAirWaterDegreaser

PartsTowelsAirElectricitySolventWater/soapWateruse

PartsToolingTowelsPigmatAirElectricityDegreaserOilCoolant

CastingToolingRagsAirElectricityCoolantDegreaserTransmissionfluidCoolantMachinecoolant

ChipsTowelsFiltersPlasticCard/plasticSpenttoolingOilCoolantTransmissionfluidAiremissionsMistextraction

PartsBroachbarsTowelsGlovesAirElectricityDegreaserCoolantHydraulicfluidCoolant

Broach

Inputs

Outputs06/11/2017 Copyright2017©ThePerfectProcessCompany

Go-Seeshopfloorreviewrevealsdirectwasteandhiddenproductdegradation

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TheResults

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E-Flowmappingwasusedasadiagnosticforenvironmentalwaste

TornearexternoM558- Torno

21,33ton/mês

21,9MW/mês

TornearexternoM558- Torno

19,6ton/mês

21,9MW/mês

TornearinternoM0366- Torno

9,84ton/mês

11,23MW/mês

FresarpistaM747- Fresa

4,24ton/mês

9,55MW/mês

RolarsplineM0072- Fresa

24,71MW/mês

TemperarM0103- Têmpera

0,3ton/mês

24,0MW/mês 4,6m³/mês 104L/mês

3,7m³/mês

InspeçãoFinal

Marcar Magnateste LavarM0682- Lavadora

1,12MW/mês 4,6m³/mês 8L/mês

0,6m³/mês

RevenirM0626- Forno

33MW/mês

Retificarø defaceM1847- Retífica

0,36ton/mês

26,4MW/mês

QualificarpistasM1852- Fresa

31,45MW/mês

AbrirrasgoM1585- Torno

27,52MW/mês

LavarM0710- Lavadoura

1,12MW/mês 1,9m³/mês 25L/mês

1,5m³/mês

MagnetizareVerificarTrincaM1691- MagnaFlux

24,71MW/mês 0,6m³/mês 49L/mês

0,5m³/mês

OlearM0720- Oleadeira

1,12MW/mês 380L/mês

255– FinalMONTAGEM

0,02ton/mês

1,12MW/mês

0,0L/mês

PROCESSMAPPINGCELLA– MONOBLOC

Energy

Water

ChemicalProducts

HazourdsWaste

MetallicWaste

Effluent

In OutLEGEND

ELIMINATED ELIMINATED

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Identificationandeliminationofwastesoil:oilscollectedarereturnedtothesystemL&GWasteOilReduction:24.522L/year

ReductionofmetallicwastesbyredesigningofpartsL&GMetallicWasteReduction:33,29ton/year

After Before

TimersystemsinthemachinestoavoidunnecessaryenergyuseL&GEnergyConsumptionReduction:254,42Mwh/year

TheL&GBMforacellrolloutapplicationwasconsideredsuccessful(1)Confirmedthe5stepsproposed- Theroll-outinvolvedatotalof15% ofthetotalworkforceand12% ofthetotalnumberofcells.

(2)Confirmedthe7prerequisites–IncludingthatstabilityiskeyforL&GBM.

(3)IdentifiedSavings- kaizensdevelopedwereinaverage60%implemented,savingaround$420Kwhichrepresenteda5,5%reduction.

RollingoutL&GBMforaCell

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Financialresultsweremuchmoresignificantinthemachiningcell

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2KaizenEvents– 2CellsInvolvedSavings:$147K

10KaizenEvents– 17CellsInvolvedSavings:$450K

Know-howtransferGKNCelayaMexico&GKNNewtonUSA

Book:RollOut&Sisterscells– 2011/2012

Afterthebook:2013/2015

Book:PilotTesting– 2008/2010

23KaizenEvents– 23CellsInvolvedSavings:$250K

L&GBMforaCell- Results

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Weidentified7pre-requisitestosuccesswithLeanandGreen

1. Astableprocess,withdeliveryover90%*2. Amaturedeploymentlevelinusingandapplying

leantools3. EmployeeInvolvement(EI)systemsareinplace4. Asupportivemanagementteam5. Goodlevelofenvironmentalawareness6. Significantuseofnaturalresources7. Structureinplaceforenvironmentaldata

collection.*Industryspecific

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REVERSETESTING

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Aerospace Automotive Powder MetalsNature ofOperations Aluminium machining Steelmachiningand

assemblyHeattreatment

Level ofLean 3/5 3/5 3/5

Processstability 98%…….<90% 90%+ <90%

EmployeeInvolvement 3/5 4/5 3/5

Leadershipsupport 3/5 4/5 3/5

Environmentalawareness

4/5 4/5 4/5

UseofEresources Veryhigh Medium High

Datacollection Medium Medium No

Analysisofthepre-requisitesshowsthatallparameterswerenotinplace

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Hiddenlessonsofthereversetesting

• Topdownsponsorshipdidnotconsidertheenablingfactorsofthemodel

• Vacancyoflocalenvironmentalmanagermeantexpertisewasmissingattheworkshopandforfollowup

• LackofproductionstabilityandOTIFmeantthesitebecamedistractedbyurgentcustomerissues

• Leadership,leandeploymentandadatacollectionstructureallneedtobeinplaceforsuccess

• Reversetestingchangedtheoriginalpre-requisites,addingdatacollectionandenvironmentalawareness(thesewerere-appliedinPOAandweresuccessful)

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SUMMARY

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SoL&GBM…Isagoodpollutionpreventionstrategy

Reducescosts

Requiresalevelof

manufacturingstability

EmbracesaLean-to-Green

approach

Introducesanew

dimensionintoleanthinking

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TheGreenFactory:CreatingLeanandSustainableManufacturing

AndreaPampanelli,NeilTrivedi,PaulineFound

Amazonhttp://www.amazon.com/Green-Factory-Creating-Sustainable-Manufacturing-ebook/dp/B01448FWNI/ref=sr_1_13?ie=UTF8&qid=1441632528&sr=8-13&keywords=the+green+factory

GoogleBookshttps://books.google.com.br/books?id=PIBjCgAAQBAJ&dq=the+green+factory&source=gbs_navlinks_s

Taylor&Francishttp://www.taylorandfrancis.com/books/details/9781498707855/

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Contactdetails

NeilTrivediM:07758953366

E:neil.trivedi@theperfectprocess.co.ukwww.theperfectprocess.co.uk

W:Bookpage:http://www.theperfectprocess.co.uk/the-green-

factory-creating-lean-and-sustainable-manufacturing/

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ThePerfectProcessCompanyNeilTrivedi

• AhighlyexperiencedStrategyandTransformationConsultantandqualifiedLeanexpert,withbroadexperienceacrossglobalplatformswithintheAutomotive,Aerospace,Food,FMCG,Transportation,Biomedical,andPublicSectors.Helpingorganisationsimprovetheirperformancebycollaborativelytacklingcomplexbusinessproblemsanddesigningandimplementingsolutionsthatdemonstratetangiblebenefitstothebusiness.

• NeilpreviouslyworkedforGKNastheGlobalBusinessProcessExcellenceDirector,wherehedeployedLeanacrossalllevelsintomanufacturingandbusinessprocesses.Priortothis,heworkedatMarsandRoyalMailinavarietyofoperationalmanagementrolesdeployingleanacrossEuropeinsupplychain,production,projectmanagementandquality.

• HewaseducatedatLeedsUniversity,ImperialCollegeLondonandCardiffUniversity.HeholdsaBSc(Hons),anMBAandanMScLeanOperations(Distinction)

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