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Manufacturing Excellence
Clean & Lean Manufacturing Program
Raymond McEvoy
Manufacturing Excellence
National Lean Seminar
20 Oct 2005
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Manufacturing Excellence
Are Green & Lean Opposites?
Lean &
Profit
Maximise profit by
using minimum resources
Green
Preserve & conserve natural resources
Green
Lean &
Profit
Lean & Green
Solutions
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Manufacturing Excellence
Systems View
Enterprise
Inputs:
Raw matrls
Consummables
People
Energy
Building
Outputs
Value = Product or Service
Heat
Waste materials
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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
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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?
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Manufacturing Excellence
Extract: Combined VSM & Energy/Effluent Data
Anneal wire ends in oven
Grind tapered wire ends
Cut wires to length
-Elec 24/7, -2 Ovens
-Annealed ends?? -Heat 24/7
-Grinding wheels, -Elec qty wires, -Coolant
-Conforming tapers, -Contaminated coolant set-ups, qty wires
-Aircon 24/7
Conforming length
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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
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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?)
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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
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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
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Manufacturing Excellence
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.ie