elec2017 2.4 n. trivedi - the green factory creating lean and sustainable manufacturing
TRANSCRIPT
TheGreenFactory
NeilTrivediThePerfectProcessCompany
06/11/2017 Copyright2017©ThePerfectProcessCompany
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
W:Bookpage:http://www.theperfectprocess.co.uk/the-green-
factory-creating-lean-and-sustainable-manufacturing/
06/11/2017 Copyright2017©ThePerfectProcessCompany
ThePerfectProcessCompanyNeilTrivedi
• AhighlyexperiencedStrategyandTransformationConsultantandqualifiedLeanexpert,withbroadexperienceacrossglobalplatformswithintheAutomotive,Aerospace,Food,FMCG,Transportation,Biomedical,andPublicSectors.Helpingorganisationsimprovetheirperformancebycollaborativelytacklingcomplexbusinessproblemsanddesigningandimplementingsolutionsthatdemonstratetangiblebenefitstothebusiness.
• NeilpreviouslyworkedforGKNastheGlobalBusinessProcessExcellenceDirector,wherehedeployedLeanacrossalllevelsintomanufacturingandbusinessprocesses.Priortothis,heworkedatMarsandRoyalMailinavarietyofoperationalmanagementrolesdeployingleanacrossEuropeinsupplychain,production,projectmanagementandquality.
• HewaseducatedatLeedsUniversity,ImperialCollegeLondonandCardiffUniversity.HeholdsaBSc(Hons),anMBAandanMScLeanOperations(Distinction)
06/11/2017 Copyright2017©ThePerfectProcessCompany