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Implementing Sustainability Into Your Existing Lean and Six Sigma Program June 2014 Brion Hurley. Techmotiv Example. Processes should be optimized across the entire life cycle, in order to achieve the best Lean and Six Sigma (LSS) and environmental benefits.

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Presentation Transcript
techmotiv example
Techmotiv Example

Processes should be optimized across the entire life cycle, in order to achieve the best Lean and Six Sigma (LSS) and environmental benefits

http://asq.org/quality-progress/2010/03/lean/leaning-toward-green.html?WT.dcsvid=OTA2NDMxNDY0MgS2&WT.mc_id=EM118436

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Rockwell Collins

Insert pictures into these angled boxes. Height should be 3.44 inches.

  • A global company operating from more than 60 locationsin 27 countries
  • 19,000 employees on our team
  • Provides navigation, communications and display products and systems for military and commercial customers
agenda
Agenda
  • Sustainability and Business
  • ES&H and Facilities
  • Why Lean Six Sigma is not enough
  • Rockwell Collins Examples
  • Modified Tools
  • Resources
  • Actions
what is sustainability
What is sustainability?
  • Meeting the needs of the present without compromising the ability of future generations to meet their own needs
  • Triple Bottom Line

Sustainability

triple bottom line
Triple Bottom Line
  • Profit – price listed on the item or the shelf, very clear
  • People – nutritional value, calories/fat, cruelty-free, Fair Trade
  • Planet– Local sources (low food miles), most only use words (organic, GMO-free, no additives/coloring)

PROFIT

PEOPLE

PLANET

Carbon Reduction Labelcourtesy of Carbon Trust

financial reasons for sustainability
Financial reasons for sustainability
  • 7 areas of financial benefit for companies
  • “No environment, no consumers in society, no business”

From Bob Willard http://www.sustainabilityadvantage.com

lean electronics sm at rockwell collins
Lean ElectronicsSMat Rockwell Collins
  • Started in 1998
  • Heavy on Lean tools initially
  • Incorporated Six Sigma tools in 2007
  • Umbrella over all improvement programs

Lean ElectronicsSM

Total Quality Management (TQM)

Theory of Constraints (TOC)

Lean

Six Sigma

Change Management

  • Use existing improvement program, not something new
what is the problem
What is the problem?

“Green” identifies waste outside the processes

FuelElectricityLighting

ElectricityChemicals

Lighting

Heating/Cooling

LightingElectricity

Warehouse

Machinery

Test and Inspect

Shipping

Prep

Assembly

Packaging

Lean Six Sigma identifies waste within the processes

Lighting

Electricity

LightingTrash

Chemicals

LightingTrashHeating/Cooling

why can t lss address environmental issues
Why can’t LSS address environmental issues?
  • Improvement opportunities may be found outside of normal working hours and areas
  • “Cost of doing business,” not viewed as opportunity
    • Small impact at process level
  • Costs and impacts can be blanketed across many areas, hard to isolate data to biggest users
    • Environmental and human health risks are often not explicitly considered in business decisions
    • Side benefits of efforts not anticipated or factored in
      • Take-back, talent acquisition, employee engagement
lean event format es h
Lean Event Format (ES&H)
  • Four primary “Go and See” sessions (can vary by facility)
    • Off shift
    • Start-up
    • Working time (w/breaks)
    • Shut down/Transfer
  • Break into appropriate groups and review defined area
    • Need mix of process and technical experts, fresh set of eyes, and different levels of organization
es h and facilities
ES&H and Facilities

ES&H

  • “Bottoms Up” with People
    • Turn off equipment
    • Recycling and composting
    • Hazardous waste processes
    • Water conservation
    • Air leak prevention

Facilities

  • “Top Down” with Infrastructure
    • Renewable Energy
    • Efficiency Upgrades
    • Green Cafeteria
    • Electric Charging Station
    • LEED buildings
    • Showers for bikers
  • Approach sustainability from both directions
event checklist
Event Checklist
  • Useful when ES&H or Facilities personnel cannot attend event
event checklist cont d
Event Checklist (cont’d)

http://gsn.nist.gov/tech/tools.html?id=lean_clean

modified tools
Modified Tools
  • SIPOC
    • Add Earth as a customer
  • QDIP boards
    • Add “E” for environment
  • DMAIC  DMAGIC
    • G is for “Green” impacts
  • VSM
    • Add water, energy and chemicals to data box
    • Show usage on timeline
  • OEE
    • Add Energy Consumption to calculation
websites
Websites
  • US Environmental Protection Agency (EPA)
    • Lean, Energy and Climate Toolkit, Lean and Environment Toolkit, The Environmental Professional’s Guide to Lean & Six Sigma, Lean and Chemicals Toolkit, Lean and Water Toolkit, Lean Manufacturing and the Environment (with Case Studies), Design for the Environment (DfE)
  • Green Supplier Network
  • Zero Waste Network – Case Studies
  • Purdue/SME Green Manufacturing Workshops
  • GM Landfill Free 9-Step Process
  • Lean and Green Kaizen Model (Cardiff University)
  • Lean Ecology: Kaizen Workshop for EH&S Professionals
  • Lean Six Sigma for the Environment Blog
integrating sustainability into lean and six sigma
Integrating Sustainability into Lean and Six Sigma

Strategy

  • Focus improvement efforts specifically on social and environmental metrics
  • Relate environmental and social issues to core business needs and priorities (money, risk, reputation, etc)
  • All process improvements naturally reduce impact on the environment, now start capturing the benefits!
  • Share this presentation with Facilities, ES&H and LSS personnel

Tools

  • Add Earth as a customer on your SIPOC
  • Add environmental usage and costs to data boxes on VSM
  • Add environmental impacts to 7 forms of waste definitions
  • Integrate environmental checklists into event templates
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Brion Hurley

Rockwell Collins

Principal Lean Consultant

319-263-1011

bmhurley@rockwellcollins.com

For more information, visit www.rockwellcollins.com

“No environment, no consumers in society, no business” – Bob Willard #IIEAnnual