Manufacturing Excellence Clean & Lean Manufacturing Program Raymond McEvoy Manufacturing Excellence National Lean Seminar 20 Oct 2005

Manufacturing Excellence Are Green & Lean Opposites? Lean & Profit Maximise profit by using minimum resources Green Preserve & conserve natural resources Green Lean & Profit Lean & Green Solution s

Manufacturing Excellence Systems View Enterprise Inputs: Raw matrls Consummables People Energy Building Outputs Value = Product or Service Heat Waste materials

Manufacturing Excellence 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 EPA’s Cleaner Greener Production Programme

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

Manufacturing Excellence Extract: Combined VSM & Energy/Effluent Data

Manufacturing Excellence 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% red’n in electricity Design modifications –Minor change to valve design to make heat mark removable by hand-buffing, 50% red’n in EP usage –Challenge design of chamfers, 34% red’n in swarf –Change design from welding to riveting, eliminates airborne dust, extraction and some safety issues

Manufacturing Excellence Examples contd… Other –Grinding Coolant, separate supply when dressing wheel Administrative & engineering processes: –Lean lines require less routers, 80% red’n in paper –Eliminated steps in quotation & purchasing process (Logic=change information or simply copy it?)

Manufacturing Excellence 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

Manufacturing Excellence Conclusions So Far… Yes; Lean = Clean & Green Must look at entire system, rather than suboptimise Use process maps, inputs & outputs & drivers to expose waste

Manufacturing Excellence Further Information… –Website describing the overall program, as well as case studies from the last 3 years in Irish & international industry –Irish Environmental Protection Agency –Consultancy & Training services in Lean & Six Sigma Detailed results of this program will be published in early 2006 on