Lean: Process based on the fundamental goal of eliminating waste and maximizing flow.

Lean Objectives and goals Define value from customer perspectives Reduce waste/improve quality Utilize employee potential Standardize work Balance workflow and processes Continuous improvement

8 sequential steps used to implement Lean concepts

Commit to Lean Choose the Value Stream Value Stream= is the collection of steps that is needed to produce what the customer want Learn about Lean Map the current state Map out everything that you are doing now. Identify Lean Metrics Identify the time it takes to complete all processes

Map the future state

Map the minimal collection of steps that is needed to produce what the customer want

Create Kaizen plans (kai means take part and zen means make good
Small daily improvements made improved by everyone Implement kaizen plans

What is Lean Manufacturing?

A systematic approach to the identification and elimination..of? all forms of waste from the value stream.

TPS Definitions of Waste

1. Overproduction 2. Waiting, including time in queue 3. Transportation (between workstations, or between supplier and customer) 4. Non-value-adding activities / Over Processing 5. Inventory 6. Waste motion 7. Cost of poor quality: scrap, rework, and inspection

Benefits of Lean Manufacturing

(1) Lower production cost higher profits and wages
Cost avoidance flows directly to the bottom line.

(2) Supports ISO 14001 and "green" manufacturing

Reduction of material waste and associated disposal costs higher profits

(3) Shorter cycle times: make-to-order vs. maketo-stock

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Control Surface Approach

Material Inputs Material Outputs

Process
Energy Inputs Energy Outputs Control Surface

The material and energy balance is standard practice for chemical process design. Outputs must equal inputs. Material outputs, for example, include everything that is thrown away, as well as the product.
7

So..
Most of lean manufacturing is common sense!

We can conclude that,

Business activities can contain enormous quantities of built-in waste (muda, friction). The greatest obstacle to the waste's removal is usually failure to recognize it. Lean manufacturing includes techniques for recognition and removal of the waste. This delivers an overwhelming competitive advantage. This we will read as GREEN OPERATIONS.
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5S-CANDO
5S-CANDO, a systematic approach to cleaning and organizing the workplace, suppresses friction. Seiri = Clearing up
"When in doubt, throw it out."

Seitori = Organizing (Arranging)

"A place for everything and everything in its place."

Seiso = Cleaning (Neatness) Shitsuke = Discipline Seiketsu = Standardization (Ongoing improvement, holding the gains)
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5S Performance Excellence Model

For which this one? Customer Expectations

Systematic-Systematic Organization
Improved Quality Improved Safety Reduced costs Consistent Deliveries

Standardizing Control

Improved Product/ Service Options

Self-DisciplineControl Sorting Visual Placement Scrubbing clean

Tool Kit Comparison

Major Tools CPI (6s) Kaizen Lean Description Process capability assessment Design of experiments Process control based on statistics and data analysis Risk assessment tool Correlate effect one variable has on another Map process steps to communicate and identify opportunities 4 4 Determination Column chart ranking items highest to lowest 4 Cause / Effect Diagram Elimination waste 4 Emphasis on visual techniques to manage process 4 Error proofing techniques 4 Material storage technique used to control process Determine pace or beat of a process Evaluate tasks done during a process Single minute exchange of dies - Quick machine set up Integrate maintenance strategy with process Reduce inventory & cycle time thru process layout and pull production techniques Cp/Cpk 4 DOE 4 SPC 4 FMEA 4 Regression 4 Process Map 4 4 5 whys /2 hows 4 methods for root cause discovery Pareto 4 4 Fishbone 4 5S 4 Visual Mgmt 4 Poka-Yoke Spagetti Chart 4 Kanban Takt Time 4 Std Work 4 SMED 4 TPM Cellular Flow

4 4 4 4 4 4 4 4 4 4 4 4 4

Expand Process Improvement Program to Utilize Kaizen Tool Kit

Spaghetti
WASHINGTON Gen. Stanley A. McChrystal, the leader of American and NATO forces in Afghanistan, was shown a PowerPoint slide in Kabul last summer that was meant to portray the complexity of American military strategy, but looked more like a bowl of spaghetti.

SPAGHETTI

Spaghetti Chart
Spaghetti Chart is used to detail the actual physical flow and distances involved in a work process. Processes that have not been streamlined frequently are poorly laid out with work/product taking a path through the work area that looks like a mass of cooked spaghetti.

To create a spaghetti chart you:

1. Create a scale map of a work station or work process 2. Draw a line from the initial point of work to the next step 3. Continue until the work/product exits the work area
Examination of this resulting chart will show where improvements are to be made

Spaghetti Chart

Waste Management
Waste Volume contents Activity data collection (solid waste) Waste categories
Overview of methodological issues and challenges in reporting

Waste Volume
1 Waste generation, composition and management data

2 Solid waste disposal l 3 Biological treatment of solid waste 4 Incineration and Open Burning of Waste 5 Wastewater treatment and discharge

1. Activity data for solid waste

Waste generation, composition and management data
encourage collection and use of country-specific data (local conditions vary much; uncertainties for default data large) regional/country-specific default data on amounts, management and waste composition management data: solid waste disposal, incineration, composting and other (recycling) consistent treatment across categories

1. Activity data for solid waste1

Default waste categories: MSW, Sludge, Industrial waste and Other
regional defaults for MSW components (paper, food, wood, plastics, etc.) defaults for carbon contents in the different waste types
degradable organic carbon (SWDS) fossil carbon (incineration, open burning)

2. Solid waste disposal

Significant source of methane Considerable time lag in emissions after disposal - taken into account in the First order decay model (revised from GPG2000; spreadsheet; can be used for all Tiers) default parameters provided (updated values - decay rates by climate zone) default regional acitivity data (guidance how to estimate historical disposal) methane recovery - guidance improved

2. Solid waste disposal

Provide data for HWP estimates
FOD model produces estimates on carbon storage in SWDS only long-term carbon storage estimated also corresponding methane estimates carbon storage taken into account in the AFOLU/HWP section => long-term carbon storage reported as an information item in the Waste sector

2. Solid waste disposal

Start Box 3: Tier 3 Are good quality country-specific activity data on historical and current waste disposal1 available? Are country-specific models or key parameters2 available? Yes Estimate emissions using country-specific methods or IPCC FOD method with countryspecific key parameters and good quality country-specific activity data Box 2: Tier 2 Estimate emissions using the IPCC FOD method with default parameters and good quality countryspecific activity data Yes

No

Collect current waste disposal data and estimate historical data using guidance in Section 3.2.2.

No

Is solid waste disposal on land a key category 3? No

Yes Box 1: Tier 1 Estimate Emissions using the IPCC FOD method with default data to fill in missing country-specific data

1 2 3

Good quality country-specific activity data mean country-specific data on waste disposed in SDWS for 10 years or more. Key parameters mean DOC/Lo, DOCf and half-life time See Volume 1 Chapter 4, "Methodological Choice and Identification of Key Categories" (noting Section 4.1.2 on limited resources), for discussion of key categories and use of decision trees.

3. Biological treatment of solid waste

GHG (CH4, N2O) emissions from biological treatment small (CO2 not taken into account as of biogenic origin) simple methdology - activity data times emission factor (defaults provided for composting and anaerobic digestion) energy use of methane from anaerobic digestion => emissions from combustion to be reported in the Energy sector

4. Incineration and open burning of waste

Waste-to-energy reported in the energy sector CO2 from fossil waste fractions (plastics, waste oils, etc.), N2O and CH4 open burning - new category; important in developing countries

5. Wastewater treatment and discharge

Improved guidance (incl. tier-structure) wastewater and sludge - emissions during treatment estimated together (organic matter in sludge disposed at SWDS, spread in agricultural soils or incinerated subtracted) uncollected wastewater methodology N2O - methodology also for industrial waste water treatment