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

Solutions

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

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

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…

• 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