Clean & Lean Manufacturing Program

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Clean Lean Manufacturing Program

• Raymond McEvoy
• Manufacturing Excellence
• National Lean Seminar
• 20 Oct 2005

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Are Green Lean Opposites?
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Systems View
Inputs Raw matrls Consummables People Energy Buil
ding
Enterprise
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Background

• 3 companies, component manufacture, engineering
  and medical device industries
• Carten Controls
• Frentech Engineering
• Lake Region
• Range from 50 to 700 employees
• Multi-national indigenous
• All had commenced implementation of Lean
  Principles

Grant aided under EPAs Cleaner Greener
Production Programme
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Approach

• Further lean training
• Use modified VSM
• Overlay energy material inputs and outputs
  effluents onto Value Stream Map
• Energy Effluent pro-rata with what?

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Extract Combined VSM Energy/Effluent Data
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Examples of improvements

• Right-sizing process to throughput
• Reduced EP rinsing, rightsize to qty of valves,
  60 reduction in water usage
• Reduce cleanroom energy inputs, 50 redn in
  electricity
• Design modifications
• Minor change to valve design to make heat mark
  removable by hand-buffing, 50 redn in EP usage
• Challenge design of chamfers, 34 redn in swarf
• Change design from welding to riveting,
  eliminates airborne dust, extraction and some
  safety issues

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Examples contd

• Other
• Grinding Coolant, separate supply when dressing
  wheel
• Administrative engineering processes
• Lean lines require less routers, 80 redn in
  paper
• Eliminated steps in quotation purchasing
  process
• (Logicchange information or simply copy it?)

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Advantages of the VSM Tool

• More useful in the bigger companies because the
  process is harder to see in its totality
• Supports whole-system thinking rather than
  sub-optimisation
• What gets measured, gets done
• Promotes why-why-why analysis

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Conclusions So Far

• Yes Lean Clean Green
• Must look at entire system, rather than
  suboptimise
• Use process maps, inputs outputs drivers to
  expose waste

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Further Information

• www.cleanerproduction.ie
• Website describing the overall program, as well
  as case studies from the last 3 years in Irish
  international industry
• www.epa.ie
• Irish Environmental Protection Agency
• www.manufacturing-excellence.ie
• Consultancy Training services in Lean Six
  Sigma
• Detailed results of this program will be
  published in early 2006 on www.cleanerproduction.i
  e