72nd international technology and engineering educators association conference “green technology:...
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72nd International Technology and 72nd International Technology and Engineering Educators Association ConferenceEngineering Educators Association Conference
““Green Technology: STEM Solutions for the 21Green Technology: STEM Solutions for the 21stst Century Citizen Century Citizen”” Charlotte, North CarolinaCharlotte, North Carolina
Lean and Green Manufacturing in Lean and Green Manufacturing in
Wood TechnologyWood Technology
11:00-11:50 AM11:00-11:50 AM
March 20, 2010March 20, 2010 Presented
by
Douglas R. HagueJordan Clous BacksJohn L. Iley, Ph.D.
Pittsburg State University
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Presentation Description & PresentersPresentation Description & Presenters
Description:Description:““Lean and Green Manufacturing in Wood Technology”Lean and Green Manufacturing in Wood Technology”
addresses lean and green manufacturing practices addresses lean and green manufacturing practices in the wood industry. It features latest innovations in the wood industry. It features latest innovations
in engineered wood materials, hardware, and in engineered wood materials, hardware, and processes; and educational activities. processes; and educational activities.
Presenters: Presenters:
• Douglas “Doug” R. Hague, Douglas “Doug” R. Hague, Assistant Professor, Wood Technology, PSUAssistant Professor, Wood Technology, PSU
• Jordan “Clous” Backs, Jordan “Clous” Backs, Instructor, Wood Technology, PSUInstructor, Wood Technology, PSU
• Dr. John L. Iley, Dr. John L. Iley, Professor, Technology Education, PSUProfessor, Technology Education, PSU
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Agenda—Today’s PresentationAgenda—Today’s Presentation
Lean ManufacturingLean Manufacturing• Definition, origin, goals, implementing leanDefinition, origin, goals, implementing lean
Green ManufacturingGreen Manufacturing• Definition and principlesDefinition and principles
Lean and Green ComparisonLean and Green Comparison Lean and Green in the Wood IndustryLean and Green in the Wood Industry
• ConsiderationsConsiderations• Design, Material Selection, Production, and ConservationDesign, Material Selection, Production, and Conservation• Case Studies—Industry and PSUCase Studies—Industry and PSU
Lean and Green-Implications for EducatorsLean and Green-Implications for Educators• Suggestions, Activities, and ResourcesSuggestions, Activities, and Resources
www.buker.com/images/Leanchart.gif
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Lean ManufacturingLean Manufacturing
Definition:Definition:
Lean ManufacturingLean Manufacturing refers to refers to manufacturing practices aimed atmanufacturing practices aimed at
maximizing value and minimizingmaximizing value and minimizing waste in the manufacturing process.waste in the manufacturing process.
It considers expending resources for anything It considers expending resources for anything other than creation of value to the customer to other than creation of value to the customer to be wastefulbe wasteful
More value for less moneyMore value for less money
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Origin and Key Figures of “Lean”Origin and Key Figures of “Lean” Ben Franklin (1733) – Ben Franklin (1733) – Poor Richard’s AlmanacPoor Richard’s Almanac Eli Whitney (1850’s)Eli Whitney (1850’s) – interchangeable parts – interchangeable parts Frederick TaylorFrederick Taylor – – Principles of Scientific Principles of Scientific
ManagementManagement (1911) (1911) Frank Gilbreth Frank Gilbreth – process charts; motion study– process charts; motion study Henry FordHenry Ford – mass assembly manufacturing – mass assembly manufacturing
system (1915)system (1915) Kiichirio ToyotaKiichirio Toyota (1936) – Kaizen improvement (1936) – Kaizen improvement
teamsteams W. Edwards Deming (WWII)W. Edwards Deming (WWII) – SPC; TQM – SPC; TQM Taiichi OhnoTaiichi Ohno – Toyota Production System-TPS – Toyota Production System-TPS
(1980)(1980) John KrafcikJohn Krafcik coined term “Lean Manufacturing” in coined term “Lean Manufacturing” in
19881988
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History Timeline for Lean ManufacturingHistory Timeline for Lean ManufacturingGraphic from: Strategos www.strategosinc.com/images/lean_timeline.jpgGraphic from: Strategos www.strategosinc.com/images/lean_timeline.jpg
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Goals of Lean ManufacturingGoals of Lean Manufacturing Continuously improve qualityContinuously improve quality
Eliminate waste-doesn’t provide valueEliminate waste-doesn’t provide value • WaitingWaiting
• TransportTransport
• Extra ProcessingExtra Processing
• OverproductionOverproduction
• InventoryInventory
• MotionMotion
• DefectsDefects
Reduce time-start to finishReduce time-start to finish
Reduce total costsReduce total costs
www.sixthsigma.com/weblog/LeanManufacturingPa..
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Going Lean in ManufacturingGoing Lean in Manufacturing
Create simple manufacturing systemCreate simple manufacturing system
• Decrease cycle timesDecrease cycle times
• Keep less inventoryKeep less inventory
• Increase productivity and efficiencyIncrease productivity and efficiency
• Increase equipment utilizationIncrease equipment utilization
Recognize “room for improvement”Recognize “room for improvement”
Continuously improveContinuously improve
• measure improvementmeasure improvement
chohmann.free.fr/lean.gif
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Green (or Sustainable) ManufacturingGreen (or Sustainable) Manufacturing
Department of Commerce Definition:Department of Commerce Definition:
““Sustainable (Green) [sic] ManufacturingSustainable (Green) [sic] Manufacturing is defined as the creation of manufactured is defined as the creation of manufactured products that use processes that are non-polluting, products that use processes that are non-polluting, conserve energy and natural resources, and are conserve energy and natural resources, and are economically sound and safe for employees, economically sound and safe for employees, communities, and consumers.”communities, and consumers.”
From: Sustainable Manufacturing – National Council for Advanced ManufacturingFrom: Sustainable Manufacturing – National Council for Advanced Manufacturing (http://www.nacfam.org/ ) - Definition (http://www.nacfam.org/ ) - Definition http://nacfam02.dev.web.sba.com/PolicyInitiatives/SustainableManufacturing/tabid/http://nacfam02.dev.web.sba.com/PolicyInitiatives/SustainableManufacturing/tabid/
64/Default.aspx64/Default.aspx
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Objectives for Green (Sustainable) Design in MfgObjectives for Green (Sustainable) Design in Mfg Increase efficiencyIncrease efficiency in the use of materials, energy in the use of materials, energy
and other resources and other resources Minimize damage or pollutionMinimize damage or pollution from the chosen from the chosen
material material ReduceReduce to a minimum to a minimum any long-term harmany long-term harm caused caused
by use of the product by use of the product Ensure that the planned life of the Ensure that the planned life of the product product is most is most
appropriate in environmental terms and that the appropriate in environmental terms and that the product product functions efficiently for its full lifefunctions efficiently for its full life
Take full account of the Take full account of the effects of the end disposaleffects of the end disposal of the product of the product
Ensure that the Ensure that the packaging and instructions encouragepackaging and instructions encourage efficient efficient and and environmentally friendly useenvironmentally friendly use
Minimize nuisancesMinimize nuisances such as noise or smell such as noise or smell Analyze and minimize potential safety hazardsAnalyze and minimize potential safety hazards
Adapted from: Principles of Green Design - Adapted from: Principles of Green Design - http://www.slideshare.net/mschongkong/topic-3-principles-of-http://www.slideshare.net/mschongkong/topic-3-principles-of-green-design green-design
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Comparison of Lean to Green or Sustainable Comparison of Lean to Green or Sustainable ManufacturingManufacturing
Lean Lean ManufacturingManufacturing
Green Green ManufacturingManufacturing
Eliminate WasteEliminate Waste Conserve energy and Conserve energy and natural resourcesnatural resources
Reduce time-start to Reduce time-start to finishfinish
Increase efficiency in Increase efficiency in time and resourcestime and resources
Reduce total costsReduce total costs Reduce pollution & Reduce pollution & damage to environmentdamage to environment
Continuously improve Continuously improve qualityquality
Product function properly Product function properly throughout its lifethroughout its life
Minimize safety hazardsMinimize safety hazards
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Wood Industry Promotes Lean & Green Wood Industry Promotes Lean & Green
Certifications promote commitmentCertifications promote commitment• LEED LEED
Leadership in Energy & Environmental Leadership in Energy & Environmental DesignDesign
U.S. Green Building Council (USGBC) U.S. Green Building Council (USGBC)
• ESPESP Environmental Stewardship Program Environmental Stewardship Program Kitchen Cabinet Manufacturers Assn (KCMA)Kitchen Cabinet Manufacturers Assn (KCMA)
• FSCFSC Forest Stewardship CouncilForest Stewardship Council
• SFISFI Sustainable Forest InitiativeSustainable Forest Initiative
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Wood Industry Responds to Lean & Green Wood Industry Responds to Lean & Green
Certifications & policies promote commitmentCertifications & policies promote commitment• EPP EPP
Environmentally Preferable PurchaseEnvironmentally Preferable Purchase Government stimulates “buy green” Government stimulates “buy green”
• Green SealGreen Seal - 1989 - 1989 Science-based environmental certification Science-based environmental certification
standards standards
• GEIGEI GREENGUARDGREENGUARD Environmental Institute Environmental Institute ANSI standards developer-indoor air qualityANSI standards developer-indoor air quality
• SCSSCS Scientific Certification SystemsScientific Certification Systems Certification of sustainability & environmental Certification of sustainability & environmental
claimsclaims
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Keys to Implementing Lean and GreenKeys to Implementing Lean and Green
PhilosophyPhilosophy Facility Considerations Facility Considerations Product DesignProduct Design Material SelectionMaterial Selection Production TechniquesProduction Techniques FinishingFinishing Hardware SelectionHardware Selection Minimize and Eliminate WasteMinimize and Eliminate Waste
• Reduce-Reuse-RecycleReduce-Reuse-Recycle
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Lean & Green: Philosophy and CommitmentLean & Green: Philosophy and Commitment
Example: Dimensional InnovationsExample: Dimensional Innovations
We utilize digital fabrication to eliminate waste and increase yield We utilize digital fabrication to eliminate waste and increase yield of materials. of materials.
We maintain strict standards for proper disposal of batteries, We maintain strict standards for proper disposal of batteries, paint solids and other hazardous materials.paint solids and other hazardous materials.
A high percentage of our post-production product is recycled and A high percentage of our post-production product is recycled and
donated to local art school programs including, the Kansas City donated to local art school programs including, the Kansas City Art Institute and the University of Kansas.Art Institute and the University of Kansas.
We utilize a solvent recycling machine that reduces our solvent We utilize a solvent recycling machine that reduces our solvent
waste by 95 percent. This system reduces 220 gallons of solvent waste by 95 percent. This system reduces 220 gallons of solvent waste per year. waste per year.
Dimensional Innovations interior architectural designer is a LEED Dimensional Innovations interior architectural designer is a LEED AP and has completed several recent exhibits in facilities seeking AP and has completed several recent exhibits in facilities seeking LEED certification. LEED certification.
We are currently exploring supplemental options for recycling We are currently exploring supplemental options for recycling Sintra and EPS foam.Sintra and EPS foam.
From: Dimensional Innovations – Environmental Stewardship - From: Dimensional Innovations – Environmental Stewardship - http://www.dimin.com/?page=about_environment http://www.dimin.com/?page=about_environment
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Lean & Green: Facility ConsiderationsLean & Green: Facility Considerations LocationLocation Environmentally-friendly construction; Environmentally-friendly construction;
renovation; resource conservationrenovation; resource conservation Energy EfficiencyEnergy Efficiency
• Less fossil fuel – alternate energyLess fossil fuel – alternate energy• Energy efficient motors, etc.Energy efficient motors, etc.• Less transportationLess transportation
Efficient flow of materials and productEfficient flow of materials and product Clean environment – indoor air qualityClean environment – indoor air quality
• Dust collection, air filtration & dust extraction; Dust collection, air filtration & dust extraction; incorporate eco-gatesincorporate eco-gates
• EPA adherence - finishingEPA adherence - finishing Space efficiency – less to heat, coolSpace efficiency – less to heat, cool
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Lean & Green: Product DesignLean & Green: Product Design Incorporate green design principlesIncorporate green design principles
• Efficiency in use of materials, energy, resourcesEfficiency in use of materials, energy, resources
• Minimize damage or pollutionMinimize damage or pollution
• Reduce long-term harm of productReduce long-term harm of product
• Planned life of product—full life efficientlyPlanned life of product—full life efficiently
• Effects of end disposal – biodegradable, recyclableEffects of end disposal – biodegradable, recyclable
Specify materialsSpecify materials with environmental certifications—LEED, with environmental certifications—LEED, EPS, SFI, FSC, etc.EPS, SFI, FSC, etc.
More panel constructionMore panel construction with veneers and laminate with veneers and laminate
Use CADD-CAMUse CADD-CAM software and optimization features software and optimization features
Simulate productionSimulate production
Minimize material wasteMinimize material waste, and production time and cost – , and production time and cost – consider standard stock material and machine capacityconsider standard stock material and machine capacity
Weight reduction and modularWeight reduction and modular – reduced shipping costs – reduced shipping costs
Reduce, Reuse, RecycleReduce, Reuse, Recycle
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Lean and Green: Material SelectionLean and Green: Material Selection
Cabinet box materialsCabinet box materials• Composite panelsComposite panels (95% of tree [lumber 63%] (95% of tree [lumber 63%]
• Panels with low formaldehyde certificationsPanels with low formaldehyde certifications (e.g., (e.g., Composite panel association (CPA) EPP specification CPA 2-06 Composite panel association (CPA) EPP specification CPA 2-06 = formaldehyde levels less than 0.18 per million parts of air= formaldehyde levels less than 0.18 per million parts of air
• Core material with EPP specificationCore material with EPP specification for being for being manufactured with 100% recycled and/or recovered fibermanufactured with 100% recycled and/or recovered fiber
• Use high percentage of Use high percentage of hardwoods with SFI and/or FSC hardwoods with SFI and/or FSC certificationcertification
• Medite IIMedite II – wood fibers combined w/ formaldehde free – wood fibers combined w/ formaldehde free synthetic resin; no commercially viable tree (scrag wood) synthetic resin; no commercially viable tree (scrag wood) fiber usedfiber used
• Dur-A-Tek Hardwood CompositeDur-A-Tek Hardwood Composite - ultra low VOC = wood’s - ultra low VOC = wood’s
• Wheat board compositesWheat board composites – low VOCs (volatile organic – low VOCs (volatile organic compounds); alternative to MDF and particle boardcompounds); alternative to MDF and particle board
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Lean and Green: Material Selection (cont-)Lean and Green: Material Selection (cont-) Doors, drawers, cabinet component materialsDoors, drawers, cabinet component materials
• BambooBamboo – a grass; highly renewable and recyclable – a grass; highly renewable and recyclable
• Wood veneersWood veneers - applied to doors and drawer front base materials— - applied to doors and drawer front base materials—MDF or wheat boardMDF or wheat board
• SFI or FSC Certified WoodSFI or FSC Certified Wood – little environmental pressure – little environmental pressure
• Lyptus WoodLyptus Wood (Lyptus)(Lyptus) – Weyerhauser product from eucalyptus; – Weyerhauser product from eucalyptus; excellent quality, beauty and environmental attributes; excellent excellent quality, beauty and environmental attributes; excellent choice when selecting exotic hardwood speciechoice when selecting exotic hardwood specie
• Reconstituted veneersReconstituted veneers – veneer replicates wood species under – veneer replicates wood species under environmental pressure; ; engineered and harvested from African environmental pressure; ; engineered and harvested from African hardwood trees and Italian plantation grown poplar trees.hardwood trees and Italian plantation grown poplar trees.
• Recycled and reclaimed woodRecycled and reclaimed wood - - http://www.greenbuildingsherpa.com/categories/recycled-wood-and-reclaimed-http://www.greenbuildingsherpa.com/categories/recycled-wood-and-reclaimed-wood-products.html wood-products.html
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Lean and Green: Material Selection (cont-)Lean and Green: Material Selection (cont-)
Laminates and veneer adhesivesLaminates and veneer adhesives• Use low VOC gluesUse low VOC glues
• WWater-borne PVAater-borne PVA (polyvinyl acetate) (polyvinyl acetate) adhesive is preferred over contact adhesive is preferred over contact cement--no VOC’scement--no VOC’s
EdgebandingEdgebanding• EdgebandingEdgebanding – substitute ABS edge banding for PVC; no – substitute ABS edge banding for PVC; no
chlorine in material and its processingchlorine in material and its processing
FinishingFinishing • - see slide #22- see slide #22
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Lean and Green: Production TechniquesLean and Green: Production Techniques Consider Consider material and product flowmaterial and product flow Optimization & optimization softwareOptimization & optimization software
• Panel optimization Panel optimization – maximum cutting patterns & yield– maximum cutting patterns & yield• Panel utilizationPanel utilization – visual scanning systems; reduce – visual scanning systems; reduce
scrapscrap• Solid wood yieldSolid wood yield – high speed material handling & yield – high speed material handling & yield
OptimizingOptimizing rip saws and cut-off rip saws and cut-off sawssaws CNC CNC for optimizing panel constructionfor optimizing panel construction
• Optimizing featuresOptimizing features• Simulations can prevent waste Simulations can prevent waste • Nested partsNested parts• Decrease production times and cyclesDecrease production times and cycles
Flexible assembly tablesFlexible assembly tables; z-lifts – more efficient ; z-lifts – more efficient time and motiontime and motion
Control dustControl dust and waste by-products and waste by-products• Down-draft sanding tablesDown-draft sanding tables
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Lean and Green: FinishingLean and Green: Finishing Material selectionMaterial selection
• Natural finishes – e.g., Tung oilNatural finishes – e.g., Tung oil• Low or ultra low VOC finishesLow or ultra low VOC finishes• Waterborne finishes and sealants (e.g., Waterborne finishes and sealants (e.g.,
Vermont Natural Coatings – non toxic finish; Vermont Natural Coatings – non toxic finish; durable water-based finish from cheese durable water-based finish from cheese “whey”“whey”
Sherwin-Williams Kem Aqua Waterborne Sherwin-Williams Kem Aqua Waterborne Finishing SystemFinishing System
Finishing equipment and processFinishing equipment and process• Flat panel coating with recovery systems Flat panel coating with recovery systems
reduce waste requiring disposal (e.g., reduce waste requiring disposal (e.g., Cefla)Cefla)
• Transfer efficiency; flexibility and Transfer efficiency; flexibility and
productivityproductivity
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Finishing Integration and Green MfgFinishing Integration and Green Mfgfrom M&M Solutions, WMS, September 2009from M&M Solutions, WMS, September 2009
http://m-mwoodsolutions.com/knowledge/M+M-WMS_October_2009.pdfhttp://m-mwoodsolutions.com/knowledge/M+M-WMS_October_2009.pdf
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Lean and Green: Hardware SelectionLean and Green: Hardware Selection Specialty designed hardwareSpecialty designed hardware components for components for
lighter panel materials and composites (e.g., lighter panel materials and composites (e.g., Hafele)Hafele)
Green door and cabinet hardwareGreen door and cabinet hardware• Recycled glassRecycled glass
• Varia eco-resin -40% post-industrial reclaimed materialVaria eco-resin -40% post-industrial reclaimed material
• Cork InlayCork Inlay
• Fused glass –layers of glass fired in a kilnFused glass –layers of glass fired in a kiln
• Recycled aluminumRecycled aluminum
• Stainless steelStainless steel
Recycled hardwareRecycled hardware
Recommended Resource:Recommended Resource: Rustica Hardware Rustica Hardware -http://www.rusticahardware.com/GREEN-HARDWARE-sp--http://www.rusticahardware.com/GREEN-HARDWARE-sp-1.html 1.html
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Lean and Green: Minimize & Eliminate WasteLean and Green: Minimize & Eliminate Waste
Waste utilizationWaste utilization• Biomass furnaceBiomass furnace burns sawdust and wood burns sawdust and wood
wastewaste Briquetting wood wasteBriquetting wood waste can provide a fuel can provide a fuel
sourcesource Dust collection systemDust collection system captures dust to silo captures dust to silo
• Packing materialPacking material
VOC AbatementVOC Abatement• VOC emissions used as fuelVOC emissions used as fuel
Reduce, Recycle, ReuseReduce, Recycle, Reuse
Resource: Stiles Machinery—Green Manufacturing - Resource: Stiles Machinery—Green Manufacturing - http://www.stilesmachinery.com/Equipment/Showroom/green-mfg.aspxhttp://www.stilesmachinery.com/Equipment/Showroom/green-mfg.aspx
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Case Study #1 – Case Study #1 – Mark Richey Woodworking and DesignMark Richey Woodworking and Design
PhilosophyPhilosophy• Environmentally-responsible company since founding in 1980Environmentally-responsible company since founding in 1980
Facility ConsiderationsFacility Considerations• Cut energy usageCut energy usage• Renovate existing structuresRenovate existing structures• Combine natural and energy-efficient lightingCombine natural and energy-efficient lighting• Insulate, seal building envelopeInsulate, seal building envelope• Operate wind turbine to generate electricityOperate wind turbine to generate electricity
Product DesignProduct Design• Design products for material savingsDesign products for material savings• Design to make products that lastDesign to make products that last
Material SelectionMaterial Selection• Specify wood from sustainable sources – FSC certifiedSpecify wood from sustainable sources – FSC certified• Use veneered product with particleboard or MDF cores – recycled coresUse veneered product with particleboard or MDF cores – recycled cores
Production TechniquesProduction Techniques• Use advanced equipment to cut and machines materials efficientlyUse advanced equipment to cut and machines materials efficiently
FinishingFinishing Hardware SelectionHardware Selection Minimize and Eliminate Waste - Reduce-Reuse-RecycleMinimize and Eliminate Waste - Reduce-Reuse-Recycle
• Burn wood waste in biomass furnace to heat plantBurn wood waste in biomass furnace to heat plant• Use post-industrial or recycled product for packing materialsUse post-industrial or recycled product for packing materials
From: “Taking the Lead in Green Manufacturing” by George Lausch From: “Taking the Lead in Green Manufacturing” by George Lausch http://www.fdmonline.com/richeyinterview.aspxhttp://www.fdmonline.com/richeyinterview.aspx
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Case Studies: Four Additional Wood IndustriesCase Studies: Four Additional Wood Industries
Case Green CabinetryCase Green CabinetryEnvironmentally Friendly or Green Cabinet Options Environmentally Friendly or Green Cabinet Options http://www.casegreen.com/process/GreenCabinetOhttp://www.casegreen.com/process/GreenCabinetOptions.htmlptions.html
Pacific Crest IndustriesPacific Crest IndustriesAmero Cabinet CollectionAmero Cabinet Collection
Builds responsibly as steward of environment Builds responsibly as steward of environment http://amerocabinetcollection.com/environment.htmlhttp://amerocabinetcollection.com/environment.html
Industrial Woodworking CorporationIndustrial Woodworking CorporationIWC leads the way to a sustainable futureIWC leads the way to a sustainable futurehttp://www.industrialwoodworking.com/HTML/environment/index.htm http://www.industrialwoodworking.com/HTML/environment/index.htm
Fimbel Architectural Door SpecialtiesFimbel Architectural Door SpecialtiesWell documented policies concerning “green”Well documented policies concerning “green”
http://www.fimbelads.com/green_manufacturing.html http://www.fimbelads.com/green_manufacturing.html
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Pittsburg State University Wood Technology: Pittsburg State University Wood Technology: Addressing Lean and GreenAddressing Lean and Green
Facility ConsiderationsFacility Considerations Product DesignProduct Design Material SelectionMaterial Selection Production TechniquesProduction Techniques Hardware SelectionHardware Selection FinishingFinishing Minimize and Eliminate WasteMinimize and Eliminate Waste
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PSU: Lean & Green Lab ConsiderationsPSU: Lean & Green Lab Considerations
Production Equipment Production Equipment • Optimizing Rip SawOptimizing Rip Saw• CNC RouterCNC Router• Horizontal Beam sawHorizontal Beam saw• Shop LayoutShop Layout• Production and Material Production and Material
FlowFlow Assembly TablesAssembly Tables Dust CollectionDust Collection
• Dust collection system and Dust collection system and downdraft tablesdowndraft tables
Finishing Lab Finishing Lab
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PSU: Lean & Green: Product DesignPSU: Lean & Green: Product Design
Design to use standard stock sizesDesign to use standard stock sizes Design for production and efficiencyDesign for production and efficiency
• CAD/CAM and CNCCAD/CAM and CNC• Machine capacity and capabilityMachine capacity and capability
Use optimization software and/or Use optimization software and/or features – get most out of materialfeatures – get most out of material
Design to minimize waste of material, Design to minimize waste of material, energy, and timeenergy, and time
Keep end-use and end-user in mind Keep end-use and end-user in mind
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PSU: Lean & Green Material SelectionPSU: Lean & Green Material Selection
Composite MaterialsComposite Materials• MDFMDF• TruPanTruPan
Extensive Use of VeneersExtensive Use of Veneers Solid Lumber – Saw MillSolid Lumber – Saw Mill
• Local species – readily availableLocal species – readily available• Logs provided by tree removal servicesLogs provided by tree removal services
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PSU: Lean & Green Production TechniquesPSU: Lean & Green Production Techniques
CNCCNC• optimization optimization • nested productionnested production
Vacuum BagVacuum Bag• Veneer to substrate (MDF)Veneer to substrate (MDF)
Tiger Stop Tiger Stop • Save timeSave time• Minimize waste caused by operator errorMinimize waste caused by operator error
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PSU: Lean & Green FinishingPSU: Lean & Green Finishing
Flash TunnelFlash Tunnel• Reduces Dry TimeReduces Dry Time
Recycle WasteRecycle Waste Spray Guns Spray Guns
• High transfer rate spray gunsHigh transfer rate spray guns Low VOC FinishesLow VOC Finishes Water Borne FinishesWater Borne Finishes
• Make students awareMake students aware• Experiment with finishesExperiment with finishes
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PSU: Lean & Green Hardware SelectionPSU: Lean & Green Hardware Selection
Hardware for Composite MaterialHardware for Composite Material• Specialty hardware is needed for use in Specialty hardware is needed for use in
some composite materials that are some composite materials that are used.used.
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PSU: Lean & Green Minimize and Eliminate PSU: Lean & Green Minimize and Eliminate WasteWaste
Chipper/ Wood GrinderChipper/ Wood Grinder• Experimented and tested the benefits of Experimented and tested the benefits of
a wood grindera wood grinder Tiger StopTiger Stop
• Capabilities of optimizingCapabilities of optimizing CNC & Horizontal Beam SawCNC & Horizontal Beam Saw
• Increase of material yieldIncrease of material yield
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Lean and Green Implications for EducatorsLean and Green Implications for Educators
Suggestions for EducatorsSuggestions for Educators ActivitiesActivities ResourcesResources
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Lean and Green: Suggestions for EducatorsLean and Green: Suggestions for Educators
Organize lab (“shop”) for material & Organize lab (“shop”) for material & production flow—save time and energyproduction flow—save time and energy
Purchase materials locally & regionallyPurchase materials locally & regionally Design custom and mass produced Design custom and mass produced
products to optimize standard stock products to optimize standard stock materialmaterial• CAD/ Cam softwareCAD/ Cam software• Optimizing software and/or featuresOptimizing software and/or features
Note: Many of the following are not new, but have been used by teachers for years to conserve limited resources and funds—”Lean Teaching”
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Lean and Green: Suggestions for Educators Lean and Green: Suggestions for Educators (cont-)(cont-)
Material selectionMaterial selection• Local, more plentiful solid lumber speciesLocal, more plentiful solid lumber species• Recycled woodRecycled wood• Composite materials & veneersComposite materials & veneers
Urea-free MDFUrea-free MDF Formaldehyde-free plywood Formaldehyde-free plywood
Finishing and laminate projectsFinishing and laminate projects• Natural finishes – e.g., tung oilNatural finishes – e.g., tung oil• Finishes low in VOCs and HAPsFinishes low in VOCs and HAPs
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Lean and Green: Suggestions for Educators Lean and Green: Suggestions for Educators (cont-)(cont-)
• Hardware SelectionHardware Selection Environmentally-friendly newEnvironmentally-friendly new
• Materials – recycled glass and aluminum; cork; Materials – recycled glass and aluminum; cork; fused-glass; eco-resin (e.g., Varia); lead-free fused-glass; eco-resin (e.g., Varia); lead-free pewter and stainless steelpewter and stainless steel
Recycled hardwareRecycled hardware• Specialty storesSpecialty stores
Sample ResourcesSample Resources• Rustic Hardware - Hardware Rustic Hardware - Hardware
-http://www.rusticahardware.com/GREEN--http://www.rusticahardware.com/GREEN-HARDWARE-sp-1.html HARDWARE-sp-1.html
• Hafele – www.hafele.com ?Hafele – www.hafele.com ?
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Lean and Green: Suggestions for Educators Lean and Green: Suggestions for Educators (cont-)(cont-)
• Minimize and Eliminate Waste—Reduce, Minimize and Eliminate Waste—Reduce, Reuse, RecycleReuse, Recycle
Recycle or reuse abrasives—abrasive belts, sand Recycle or reuse abrasives—abrasive belts, sand paper, etc.paper, etc.
SawdustSawdust• Packing materialPacking material• Cage bedding-Biology animalsCage bedding-Biology animals• Mulch for acid-loving plants (e.g., blueberries) – Note: Mulch for acid-loving plants (e.g., blueberries) – Note:
Walnut harmful to plantsWalnut harmful to plants• Specialty Projects – wood flour molded knobs, coasters, Specialty Projects – wood flour molded knobs, coasters,
etc.etc. Solid wood wasteSolid wood waste
• Kindling for wood stoves, etc.Kindling for wood stoves, etc.
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Lean and Green: Suggestions for Educators Lean and Green: Suggestions for Educators (cont-)(cont-)
Rough Lumber or S2SRough Lumber or S2S – surface and edge – surface and edge joint whole board to eliminate having small joint whole board to eliminate having small pieces that can’t be machines safely and pieces that can’t be machines safely and become “scrap”become “scrap”
Create “Standard Stock”Create “Standard Stock” – instead of lots – instead of lots of odd sized “shorts”, create standard sizes of odd sized “shorts”, create standard sizes (t” x w”) for small projects (t” x w”) for small projects
Small ”Filler” ProjectsSmall ”Filler” Projects – several small – several small projects projects • Use up leftover materialUse up leftover material• Students do these during “idle” timesStudents do these during “idle” times• Examples: wood puzzles; cutting boards; key Examples: wood puzzles; cutting boards; key
holders; salad fork & spoon re-saw project; etc. holders; salad fork & spoon re-saw project; etc.
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Lean and Green: Activities for Educators: Lean and Green: Activities for Educators: Green Design Brief #1: Bird House Green Design Brief #1: Bird House Scenario: Scenario: Local Audubon Society Local Audubon Society
needs a large quantity of “bird needs a large quantity of “bird houses” built for local wildlife houses” built for local wildlife areaarea
Design Brief: Design Brief: Design and mass Design and mass produce a large number of eco-produce a large number of eco-friendly, solid wood “bird friendly, solid wood “bird houses,” as efficiently as houses,” as efficiently as possible for the lowest cost. possible for the lowest cost.
This image is from:
www.birdingessentials.com/page/birdhouses
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Lean and Green: Activities for Educators:Lean and Green: Activities for Educators:Green Design Brief #1: Bird House Green Design Brief #1: Bird House (cont-)(cont-)
Considerations for evaluating solution:Considerations for evaluating solution:• Material SelectionMaterial Selection – appropriate for – appropriate for
application; standard stock; proper hardwareapplication; standard stock; proper hardware• DesignDesign - appropriate size for bird; optimizes - appropriate size for bird; optimizes
use of standard stock material; minimum use of standard stock material; minimum number of T x W x Lnumber of T x W x L
• ProductionProduction – manufacturability—ease of – manufacturability—ease of making; material & production flow; minimum making; material & production flow; minimum number of cuts, fasteners, assemblies; surface number of cuts, fasteners, assemblies; surface preparation; etc.preparation; etc.
• FinishFinish – none; environmentally friendly; – none; environmentally friendly; exterior applicationexterior application
• InstallationInstallation – ease of installation – ease of installation• AestheticsAesthetics – craftsmanship; appearance – craftsmanship; appearance
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Lean and Green: Activities for Educators:Lean and Green: Activities for Educators:Green Design Brief #1: Bird House Green Design Brief #1: Bird House (cont-)(cont-)
Comparison of cut lists of two solutions for a Comparison of cut lists of two solutions for a given type of house with one-piece roofgiven type of house with one-piece roof::
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Lean and Green: Activities for Educators:Lean and Green: Activities for Educators:Green Design Brief #2: Recycle BinsGreen Design Brief #2: Recycle Bins
Scenario: Scenario: The school district The school district needs 20 special recycle container needs 20 special recycle container bins (10 for cans; 10 for plastic bins (10 for cans; 10 for plastic bottles) built.bottles) built.
Design Brief: Design Brief: Design and mass Design and mass produce a large number of eco-produce a large number of eco-friendly, composite- panel “recycle friendly, composite- panel “recycle container bins”, as efficiently as container bins”, as efficiently as possible for the lowest cost. possible for the lowest cost.
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Lean and Green: Activities for Educators:Lean and Green: Activities for Educators:Green Design Brief #2: Recycle Bins Green Design Brief #2: Recycle Bins (cont-)(cont-)
Considerations for evaluating solution:Considerations for evaluating solution:• Material selectionMaterial selection – appropriate for – appropriate for
application; standard stock; proper hardwareapplication; standard stock; proper hardware• DesignDesign - appropriate openings for containers; - appropriate openings for containers;
optimizes use of standard stock material; optimizes use of standard stock material; minimum number of W x Lminimum number of W x L
• ProductionProduction – manufacturability—ease of – manufacturability—ease of making; material & production flow; minimum making; material & production flow; minimum number of cuts, fasteners, assemblies; etc.number of cuts, fasteners, assemblies; etc.
• FinishFinish –environmentally friendly; appropriate –environmentally friendly; appropriate for applicationfor application
• AestheticsAesthetics – craftsmanship; appearance – craftsmanship; appearance
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Green Activities & Resources for Educators--Green Activities & Resources for Educators--Activity: Green Manufacturing TerminologyActivity: Green Manufacturing Terminology
Directions: Directions: • Complete the “Green (or Sustainable) Complete the “Green (or Sustainable)
Manufacturing Crossword Puzzle.”Manufacturing Crossword Puzzle.”• Handout: “Glossary of Green Terms Related to Handout: “Glossary of Green Terms Related to
Wood Manufacturing” – Compiled by Pittsburg State Wood Manufacturing” – Compiled by Pittsburg State University Wood TechnologyUniversity Wood Technology
____________________________________________________________________________
Presentation Resources on CD:Presentation Resources on CD:• ““Going Green in the Woodworking Industry”Going Green in the Woodworking Industry”
PowerPoint/PowerPoint Handout (48 slides/4-pages f/b)PowerPoint/PowerPoint Handout (48 slides/4-pages f/b) Glossary of Green Terms Related to Wood ManufacturingGlossary of Green Terms Related to Wood Manufacturing Crossword Puzzle & Answer KeyCrossword Puzzle & Answer Key Outline of Presentation with Website ResourcesOutline of Presentation with Website Resources
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Questions and AnswersQuestions and Answers
Thank You for Your Attention to this Presentation:
Going Green in the Woodworking Going Green in the Woodworking
IndustryIndustry
Contact Information:Douglas R. HagueJordan Clous BacksJohn L. Iley, Ph.D., Chairman
Department of Technology and Workforce LearningPittsburg State UniversityPittsburg, KS 66762
TWL Phone: 620-235-4371Emails: [email protected]
[email protected] [email protected]
Kansas Technology Center