The Basics of Lean and Clean - ideals.illinois.edu

The Basics of Lean and Clean

Laura Pyzik2007 Great Lakes/Great Plains P2 ConferenceMarch 13, 2007

2

Defining Lean

Lean is:

“A systematic approach to identifying and eliminating waste (non-value added activities) through continuous improvement by flowing the product at the pull of the customer in pursuit of perfection”

—The MEP Lean Network

3

What is Lean Manufacturing?

A business model that emphasizes eliminating “waste” while delivering quality products at the least cost to the manufacturer and customers.

Lean thinking focuses on three objectives: Reduce production resource requirements by

minimizing inventory, equipment, storage and production space, and materials;

Increase manufacturing velocity and flexibility; and

Improve quality and eliminate defects.

4

What is Lean Cont.

Lean can provide an “entry point” for P2

Lean methods create a continual improvement-based, waste elimination culture

Lean tools can be used to address environmental concerns

5

The L&E Initiative

OPEI coordinates a cross-office partnership including OPPT and OSWER.

Work with P2 assistance providers, as well as, business assistance providers, with outreach activities.

Work with specific companies, industrial sectors, Lean experts and EPA programs to: Develop or adapt appropriate tools Find applications for existing tools Address regulatory barriers

6

Lean’s Environmental “Blind Spots”

Lean’s “Deadly Wastes”

1. Overproduction2. Inventory 3. Transportation4. Motion5. Defects6. Over Processing7. Waiting

Where are environmental wastes?

• Excess materials use• Pollution/emissions• Scrap & non-product output• Hazardous wastes

7

The P2 – Lean Connection

Late 1990s: EPA, others began to see similarities between lean and P2

Many lean efforts had environmental benefits: Material savings Less solid waste generated Less energy use

Developed The Lean Manufacturing and Environment report documenting these opportunities.

8

Making the Connection– The Lean and Environment Toolkit

Identify and eliminate environmental waste

Modified Value Stream Mapping

Kaizen Events 6S= 5S plus Safety

9

The Toolkit and the Green Suppliers Network

Green Suppliers Network is a direct application of the Toolkit

Green Suppliers Network team helped in development

Value Stream and Process Mapping sections are foundation of reviews

Integral in collaborations with lean experts at Manufacturing Extension Partnership Centers

10

Value Stream Mapping

Value stream mapping is a mapping method that enables an organization to “see” all the actions involved in producing a product or service

Current State Map: Visual representation of existing operations (information and product flows) Identify the largest sources of waste (non-value

added activity) in the value stream

Future State Map: Drawing of Lean flow (vision) Develop implementation plan for Lean activities

Presenter

Presentation Notes

What EHS opportunities are there with Value Stream Mapping? “Learn to see” environmental waste and material efficiency opportunities in value stream maps (VSMs) Identify new opportunities to improve operational and environmental results Include environmental expertise in Lean events to best achieve the desired future state

11

Map the Process

Makes work visible Visibility improves communication and

understanding Identifies Improvement Opportunities

Eliminate the non-value added steps Reduce wasted resources

Diagnostics Determine the cause of a problem or condition.

Training and communication

12

Current State Value Stream Map

Market Forecast

Total Lead Time = 68 days Value Added Time = 15 min

CustomerA

2 people

C/T = 4 minC/O = 3 hrUptime = 61%

Assembly &Inspection

2 people

Milling


3 people


Painting

I I I 3 people

Shipping

7 min4 min2 min

15 days 8 days10 days 30 days

Production Control

WK

I

5 days

D ID

30 daysWK

Receiving

C/T = 2 minC/O = 30 minUptime = 93%

Welding

5 days

2 min

CustomerBSupplier

1Supplier

2

13

Enhanced Value Stream Mapping

• Use icons to identify processes with EHS opportunities

• Record environmental data for processes in VSMs

• Analyze materials use vs. need in a “materials line” for VSMs

• Expand the application of value stream mapping to natural resource flows

• Find Lean and Clean opportunities in future state VSMs

Presenter

Presentation Notes

These tools can be used alone or in combination with one another. Experiment with using some of these tools, and try more as you go along. Adapt the tools or develop new ones to better meet your organization’s needs and culture.

14

Types of Environmental Metrics

Scrap/Non-Product Output Materials Use Hazardous Materials Use Energy Use Water Use Air Emissions Solid Waste Hazardous Waste Water Pollution/Wastewater

15

Common Processes with EHS Wastes and Opportunities

Metal casting Chemical and heat

treatment of materials

Metal fabrication and machining

Cleaning and surface preparation

Bonding and sealing

Welding Metal finishing and

plating Painting and

coating Waste

management Chemical and

hazardous materials management

Presenter

Presentation Notes

It is essential for EHS staff to participate in planning for and conducting Lean events on these processes because of the potential risks of noncompliance and the potential hazards to workers. Note: Other processes not on this list can also have significant environmental waste elimination opportunities. For example: Shipping and receiving processes can generate large amounts of packaging waste – adding both time and disposal costs Assembly processes can consume significant energy

16

Adding EHS Icons to Value Stream Maps

Market Forecast


CustomerA

2 people



2 people

Milling


3 people


Painting

I I I 3 people

Shipping

7 min4 min2 min


Production Control

WK

I

5 days

D ID

30 daysWK

Receiving


Welding

5 days

2 min

CustomerBSupplier

1Supplier

2

EHS EHS EHS

Presenter

Presentation Notes

Use icons or red dots to identify processes with key environmental, health, and safety (EHS) opportunities on value stream maps Icons can also highlight where EHS staff expertise will likely be needed Look for processes… with high energy, water, and material use with significant solid or hazardous waste generation requiring environmental permits or reporting to environmental agencies with pollution control equipment using toxic chemicals that require personal protective equipment (PPE)

17

Record Environmental Data for Processes in VSMs

C/T = 2 minC/O = 2 hrUptime = 74%Haz. Waste = 5 lbs

2 people

Milling

EHS

Hazardous waste generated per shift

Presenter

Presentation Notes

Add key environmental data to process boxes on value stream maps This may require your company to invest additional time and/or resources to collect environmental data for each process. Examples include using energy meters to estimate typical energy use, or weighing the amounts of scrap and solid wastes generated by each process during a shift. As with other data collection efforts in Lean, this extra investment in data collection will allow you to appropriately target Lean improvement efforts on the highest priority problems, thereby achieving the greatest benefits. KEY C/T = Cycle time C/O = Changeover time (total time spent changing over equipment per shift) Uptime = Percent of time a machine is running (calculated based on cycle time and changeover time)

18

VSM with Environmental Metrics & EHS Icons

Market Forecast


CustomerA

2 people



2 people

Milling


3 people


Painting

I I I 3 people

Shipping

7 min4 min2 min


Production Control

WK

I

5 days

D ID

30 daysWK

Receiving


Welding

5 days

2 min

CustomerBSupplier

1Supplier

2

EHS EHS EHS

19

Analyze Materials Use Versus Need in a “Materials Line”

The “timeline” on value stream maps looks at value-added and non-value-added time in the value stream

4 min2 min

10 days5 daysLead Time = 15 days Value Added Time = 6 min

Add a “materials line” to examine: Amount of raw materials used by each process Amount of materials that end up in the product

and add value from the customer’s perspective

Presenter

Presentation Notes

Raw materials are often a large source of a product’s cost—yet these costs are often “hidden” in value stream maps, which focus on time. The materials line is a powerful way to show how materials are used and wasted in the value stream.

20

Example Materials Line

Materials lines can be developed for any major material source used in processes and products

2 people2 people

Milling

II

Welding

EHS EHS

5 lbs80 lbs

15 lbs120 lbsMaterials Used = 135 lbs Materials Needed = 85 lbsMaterials Wasted = 50 lbsTop line:

Materials Used by Process

Bottom line:Materials Added to Product During the Process

Presenter

Presentation Notes

This example looks at total materials use. You could also look at hazardous materials/chemicals used, or focus on a particular type of raw material (e.g., steel or plastic) that is responsible for a large portion of the product’s cost.

21

VSM with Materials Line and EHS Icons

Market Forecast


CustomerA

2 people



2 people

Milling


3 people


Painting

I I I 3 people

Shipping

7 min4 min2 min


Production Control

WK

I

5 days

D ID

30 daysWK

Receiving


Welding

5 days

2 min

CustomerBSupplier

1Supplier

2

EHS EHS EHS

Total Materials Used = 195 lbs Materials Needed = 110 lbs

20 lbs5 lbs80 lbs

40 lbs 20 lbs15 lbs120 lbs

5 lbs

22

Example Future State VSM

2x Week

Market Forecast

Lead Time = 27 days Value Added Time = 15 min

CustomerA

Customer B

2 people



2 people

Milling


3 people

C/T = 7 minC/O = 1.5 hrUptime = 80%

Painting

3 people

Shipping

Production Control

Supplier 1

Supplier 2


Total Materials Used < 150 lbsMaterials Needed = 110 lbs

Welding

<90 lbs5 lb

EHSEHS EHS

DI

7 min4 min2 min6 days 3 days4 days2 days

2 min

20 lbs5 lbs<25 lbs 20 lbs15 lbs

80 lbs

12 days

Presenter

Presentation Notes

This future state VSM includes both Lean and environmental improvements—the “Details” slides have more info. This represents an incremental step to a more Lean and less wasteful future state – further improvements are also possible.

23

Expand the Application of Value Stream Mapping to Natural Resource Flows

You can also use VSMs to look in more detail at the use of energy, water, and/or materials

Energy/water/materials used vs. needed

Environmental waste streams

Information flows to regulatory agencies

Presenter

Presentation Notes

Examples: Energy/materials use vs. need – as in “materials line” Waste streams – air emissions, wastewater, hazardous waste, solid waste Info Flows – reporting air emissions How can natural resource flow VSMs be useful? VSMs for energy, water, or materials are designed to explicitly map resource flows to help illuminate environmental improvement opportunities

24

Raw waterSourcePump No.1

or 2

Plant ProcessInitial StateInitial Usage (Gal/day) = 300K gal Per Day

Product Need Per Day = 34K gal Per Day

44Kgal 50Kgal40Kgal

179Kgal 44Kgal

H2O: 12Kgal reject

Multigrade filter

H2O: 44Kgal reject

Softener RO1 RO2

Sterilizer uses and rejects 12K gal

Still

H2O: 40Kgal reject

25Kgal overflows & 25Kgal is reject

281Kgal293Kgal 94Kgal

201K galInto Effluent tank per day

Pollution control Regulations

12Kgal 10Kgal

58KL

Local

H2O: 10Kgal reject

Boiler feed. Uses 33K gal & rejects all.

293K gal

Wash rooms,pantry,Cooling

Sewage

139Kgal

45Kgal

34Kgal

25

Raw waterSourcePump No.1

or 2

Plant ProcessGoal and Achievement

Usage goal (K gal) = 213K gal / dayAchieved usage = 233K gal / dayProduct Need = 34K gal/ day

44Kgal 0Kgal22Kgal

159Kgal 44Kgal

10K gal reject as backwash time shall be reduced by 5 mins

Multigrade filter

44K gal reject

Softener RO1 RO2

Sterilizer uses and rejects 12K gal

Still

18K gal shall be channelised to wash room out of 40KL gal reject

10K gal overflow is channelised to RO1 Tank and 40K gal goes to wash room

203Kgal213Kgal 94Kgal

121K galInto Effluent tank per day

Pollution control Regulations

10Kgal 0Kgal

18Kgal

Distillation reject

Local

10K gal reject now goes to boiler feed tank

Boiler feed. uses 23Kgal from RO1 & 10Kgal from still and rejects all.

213K galWash rooms, pantry,Cooling tower gets 18Kgal from RO1 reject and 40Kgal from RO2 reject

Sewage

119Kgal

45Kgal

34Kgal

10K gal of overflow40Kgal of reject

Achieved

UnchangedOngoing

Documents

The Basics of Lean and Clean - ideals.illinois.edu