business & environment series: polin - waste reduction at central container corp
TRANSCRIPT
From Cradle to GateManaging Upstream Waste
August 16, 2012
Central Container Corporation
Ed Polin LBC-Sensei
Lean Enterprise Manager
Our Company’s History
Why-When-How-Our Lean-Green Journey
Sustainable Mission Statement
7 Green Wastes
7R’s
Challenges-Solutions-Examples
Today’s Agenda
Who We Are TodayCentral Container Corporation
Housing 130 Full Time Employees and 25 Temporary Employees
Main Facility – 85th Ave.175,000 square feet
Additional -- West Broadway25,000 square feet
Currently Operating at Approximately 70%
Growth - Business ModelHigh Tech & Medical Companies
•Service
•Quality
•Spirit of innovation
•Breadth of experience
•Expertise in multiple mediums
Sustainability Begins Here – 7R’s2011 Design Department Expansion
Promotional Packs
A major portion of solid waste produced by mankind is in the form of packaging
What % packaging?
Throwing away of reusable resources = $$
Why the Need for Sustainable Packaging Solutions?
What is it?
Sustainability
1. There is no one definition for sustainability. No right and no wrong definitions.
2. Like an unregulated industry
3. You are defining yourself and your unique characteristics
Source: United States EPA
It’s called “Sustainability”
“Meeting the needs of the present with out compromising the ability of future generations to meet theirs”
Eliminating Waste & Reducing Costs
According to CFO.com, nearly 9 of 10 corporate executives rank the environment as “the top public issue that could affect shareholder value.”
Who are the shareholders?
“We did not inherit the earth from our parents, we are
borrowing it from our children.”Native American Proverb
Why Should We Do This?(sounds like an expense)
Environment
Central Container is committed to promote and engage in actions which support sound
environmental stewardship.
To advance this attitude within our organization, our employees and families,
our suppliers, and our Customers.
Sustainable Mission Statement
Learning to See Green
What is a Green Value Stream?
Source: Brett Wills “GREEN INTENTIONS” Amazon
7 Green Wastes
Source: Brett Wills
Energy
Water
Materials
Garbage
Transportation
Emissions
Biodiversity
Our HistoryPractice Environmental Biodiversity Future Home of Central Container, 1991
The 7 R’s
1. Remove Packaging:
2. Reduce Packaging:
3. Reuse Packaging:
4. Renewable Packaging:
5. Recyclable Packaging:
6. Revenue:
7. Read:
Eliminate unnecessary packaging, extra boxes or layers
“Right-Size” packages and optimize material strength
Use materials made of highest recycled content without compromising quality
Achieve all above principles at cost parity or cost savings
Get educated on sustainability
Use materials made of renewable resources; select biodegradable or compostable materials
Design for multiple use
Alternatives in PackagingRemove, Replace, Recycle, etc.
Organic based cushioning foams
“Bubble Wrap” and other void fills from 100% recycled materials
Corrugated average recycled content = 62% + with 100% available
Innovative protective packaging systems – suspension packaging.
Medical Device Packaging
Sustainability in PackagingCase Study
The Challenge:
Remove petro based flexible foam and fluted plastic from medical instrument package
Sustainability in Packaging
Solution:
Develop a packaging system made of recycled, recyclable corrugated.
The Challenge: Reduce amount of packaging materials being used… current package uses two carton system for clock used in institutional settings
Sustainability in PackagingCase Study
The Solution:
“Clever Corrugated”…develop a package requiring 33% less corrugated, while maintaining protection.
Sustainability in Packaging
• E ordering control by user, location, and Kanban Item barcodes scanned using hand held device to Green Link
• Auto acknowledgement upon retrieval of datao Ability to go paperlesso Establishes standard worko Easy of use
• No Receiving-Direct delivery to individual cellso Cartons arrive fully assembled
• Reclaim pallets on next day delivery
• Benefits Cost savings o Resources, time, space, and the
environment
Packaging VMI Process Results in Zero Inventory
Standing Timber
• 39% increase since 1952• 10 million acres added (1987-2007)• Planting 1.7 million trees…..a day
Renewable Energy
• Leading producer and user of carbon neutral bio mass energy
• 65% of energy to make paper• Reduced fossil fuels 56% (1972-2006)
and 9.2% (2004-2006)
Paper Industry (Forest Products)
Growth - Awards and Certifications Boston Scientific 2011 Supplier Achievement Award Cost-Q-
OTD 2009 Received 100% on 3rd Party Audit
Medtronic Supplier of the Year Award HID Global Supplier Excellence Award - 5 years running AICC 2009 Innovator of the Year Award Lean/Green GMI (Graphic Measures International, Ltd.) Enterprise Minnesota “Lean and Green Manufacturer” 2010 NIST (National Institute of Standards and Technology Excellence in
Sustainability 2010 TEC Certified Green Facility (Total Energy Concepts, Inc.) 2010 Rosemount Supplier of the Year Award Cost–Q-OTD 2011 ASI Certificate of Excellence in Food Packaging Safety 2012
Growth - Surviving in a Down Economy Ongoing *Annual Lean, Green Savings 2008 to 2011
Organized & Visual Achieve Performance Targets Capture the Benefits
How will these promote culture?Engagement Communication & Development
Ownership Promotion
Solid Cultural Foundation Builders
Energy Savings Power Factor 81 to 99%*TPM Production Hours/Year Increased 560Floor Space (square feet) 22,300Distance (miles) Fork Truck 782Removed Unnecessary Items 1,100Safety Improvements 32Quality Improvements 39Visual Work Instructions 91Recycled Corrugated (Lbs/year) 3,500,000Reduced Pallets/Year 3,088Green E Link P.O.’s 48,200Idea’s Cost Savings $158,936Combined Lunch Break/Year $57,650Time Recording Window/Year $47,785Green Savings/Year $304,134Total Savings/Year $568,505
*Not Dollarized
5S Metric Boards Results/Savings
Shine
3
Standardize
4
Sustain5
Set in Order2
Sort
1
CENTRAL CORPORATE SALES 15 YEAR HISTORY
Compound annual increase in sales 5.16% in last 5 years.
Our FutureReasons for Commitment to the Future and Sustainability
Useful Links & Resources • www.sfiprogram.org
• www.fsc.org
• www.ecolabeling.org
• www.greenseal.org
• www.packaging.marketgate.com
• www.gsn.gov
- Green Supplier Network
• enterpriseminnesota.org
• www.centralcontainer.com
