Lean & Green

Manufacturing
Overview
 Purpose of study
 What is Lean Manufacturing ?
 Is Lean Manufacturing Green ?
 Approaches toward Lean & Green Manufacturing
 Familiar examples
 Conclusion
 Purpose of study
 To investigate the relationship between
lean and green manufacturing
 What’s Lean Manufacturing ?
 Manufacturing Concept developed as a tool for reducing
and eliminating waste
 Zero waste
 Just In Time (JIT)
 Kaizen (Continuous improvement)
 Waste:
– Defects
– Over-production
– Work-in-process (WIP)
– Non-value added activities
(Womack 1996: Lean Thinking: Banish Waste And Create Wealth in Your Corporation)
 What’s Lean Manufacturing ?
 Combination of three primary areas in manufacturing
industry:
– Buffer Minimization
- Labor Management
– Work Systems:
- trained workforce, controlled process, and continuous
improvement

• Pull System (based on downstream consumption)

– Low cycle time
– Limits inventory buildup & WIP
– Use of Kanban Card (relationship between the
point of consumption and point of procurement)
 What’s Lean Manufacturing ?

Materials Delivery Frequency

# Changeovers

Traditional Defects Supplier Stress

Lean
(Push) Cycle Time
(Pull)
Inventory Cost
 Can Lean be Green ?
 Rothenberg & Maxwell :
~ Strong correlations between good manufacturing practices and
superb environmental performance
~ Tradeoffs between lean production and environmental
performance
~ Highly important to consider multiple measures of
environmental performance
 Can Lean be Green ?
 King & Lenox :

~ Empirical support that “Lean is Green”

~ Adoption of ISO9001 is important step toward

Lean Concept

~ ISO9001 Certified plants:

 less waste
 low inventory levels
 likely to adopt ISO14001
 Approaches toward Lean & Green
 Environmental Technologies (Shrivastava)
– Design for Disassembly:
 Maximum useful life
– Redesign Production Systems for the Environment:
 Minimize waste upstream, efficient production technologies, cleaner technologies

– TQEM:
 Total Quality Environmental Management

– Industrial Ecosystems:
 Inter-organization linkage

– Technological Assessment:
 Monitoring performance
 Familiar examples
 Paint Shop Simulation Model
~ Minimize the setups (changeovers)
~ Reducing waste
~ VOC Emissions
~ Possible Tradeoffs
- Cycle time increase
- Queue increase (WIP)
- Change in reorder policy
 Familiar examples
 3M
~ Created 3P Program (Pollution Prevention Pays)
~ Prevent Pollution at Source
~ Use of water-based coating for tablets as a
substitute for solvent solution coating, results:  $15 K/yr
cost savings in raw materials
 Prevention of 24 tons of air pollution
 Eliminated end of pipe treatment for the air pollution
($180K)
~ Uses Life cycle analysis to minimize total life cycle costs.
 Conclusion
 Lean is Green
 Results may vary depending on specific applications

LEAN GREEN

Reduce Changeovers
Min Cycle Time Min Inventory
Multiple Material Reduce usage of raw
Deliveries materials
Reduce WIP
Product Varieties
Min Defects
Reduce Waste