zero waste 11.15.16

Insider Tips on Leading a Zero-waste Initiative

APICS Fox Valley Presentation

November 15, 2016

Joanne Gorski, SCOR-P, CFPIM, CSCP

President, Sustainable Insights

[email protected]


Zero-waste initiatives have been around forever

“There is no such thing as waste” ~ Leonardo Da Vinci

(1452 – 1519)

Lean is now up to 8 wastes

So… are you at zero-waste?


What is waste? Can you name all 8?

1. Waiting2. Motion3. Non-used talent4. Over-processing5. Inventory6. Transportation7. Defects8. Over production

All these wastes are managed throughout the supply chain


Session Overview

• Explain the steps to zero-waste using the continuous improvement framework

• Discuss current strategies and barriers

• Identify three things that you will do when you return to work

• Share insider tips to zero-waste

• Questions and answers

Insider Tips on Leading a Zero-waste InitiativeStep 1: Set a vision and scope

• Why create the business case (vision) for zero-waste• Driving business reasons?

• Customer driven?

• Cost reduction?

• Reduce business risks?

• “So why not zero-waste?

• Define your zero-waste scope• Zero manufacturing waste?

• Pre or post-consumer waste?

• Hazardous waste included?

• Event-related waste?

• Needs to link to your organization’s sustainability plan and business strategy ---- Do you know what they say?

Plan


Step 2: Get management buy-in • Ensure support

• Align and gain needed resources

• Identify and mitigate any issues

• Management buy-in is a critical step!

Plan


Step 2: Get management buy-in

• Kotter’s 8 Steps to Accelerate Change in 20151. CREATE sense of urgency2. BUILD guiding coalition3. FORM strategic vision and initiatives4. ENLIST volunteer army5. ENABLE action by removing barriers6. GENERATE short-term wins7. SUSTAIN acceleration8. INSTITUTE change

Change is difficult…. Be prepared….Do not skip a step

Plan


Step 3: Create your project team • Project champion• Engaged team members• Executive sponsor• Select individuals strategically from needed departments • Consider education, experiences, aptitudes, leadership

• Having an engaged and adaptive project team is essential!

Plan


Step 3: Create your project team

• HS.0160 Waste

• From SCOR

Plan


Step 4: Access current performance

• Conduct waste audit

• Identify “easy” waste to divert

• Identify top sources of landfill (80/20 or ABC analysis)

• Identify barriers and opportunities to achieving higher waste diversion

Plan

Insider Tips on Leading a Zero-waste InitiativePlan




Accenture research shows that leading organizations are now adopting circular economy models—decoupling growth from scarce resources and, thus, gaining a competitive edge (a circular advantage).

Closed-loop system: a system that accounts for the return flow of products for reuse, asset recovery, or recycling in a way that is cost-effective and maximizes returns. APICS Dictionary, 15th edition


Break Out – 5 minutesAnswer the following questions:What are your current struggles?What are your current barriers?


Service example:

• New North Summit 2015

• ISO 20121

• 99.5% waste diversion from landfill

• World-class performance

Plan


New North Summit Waste Diversion Results Over Time


Step 5: Set future goals

What does success look like?What needs to happen to improve waste diversion?

• Sustainable purchasing policy?• Apply the waste hierarchy• Supply chain and operations management applications• Education• Identify salvage markets for process by-products• Returnable/reusable packaging • Change materials to a environmentally friendly

alternative


Step 5: Set future goals Let’s talk about salvage markets and difficult waste

• Scrapindex.com• Sort, bail, compact, be careful of shipping costs• Establish good relations with the scrap dealers and recyclers• Outagamie County offers free business assistance – check your MRF• American Chemistry Council provides content analysis to see if waste

can be recycled• Line item focus on waste hauling/landfill contracts and volumes• Good use of an intern!


Step 5: Set future goals Chemical Example

Lease your chemicals instead of buying them:Reduces waste because the focus is on creating value, not selling chemicalsReduces overall inventory levels, less storage of inefficient inventory ordering methods for multiple SKU’sReduces risks of shipping, paperwork, handling, expert management of hazardous materials, and safer solutions can be identified through supplierCloser to a Total Cost of Ownership model versus Landed Cost model

Who is using this model?General Motors Lockheed Martin Harley Davidson Seagate Coca-Cola Hotels


Step 5: Set future goals Goodwill NCW Examples


Step 5: Set future goals Menasha Corporation example:

Die boards made up 20% of all landfilled waste

Die boards are hard to recycle due to mix of steels blades, foam and

rubber blocks, and chemically treated wood

OPS manually removes the foam, rubber, and steel materials

from the die boards

The die boards are then chipped up into mulch

and the steel and rubber materials are recycled

Step 6: Create project plan• Organizational plan

• Team charter

• Objectives, targets, measures

• Financials: ROA, Total Cost to Serve, Return of SC Fixed Assets, Return of Working Capital, COGS, Production Costs, etc.

• Solid project management (PMI framework is good)

• Communication strategy


Step 6: Create project plan• Include fun – slogans, pictures, celebrations –

engage people• Akron Marathon• Raffle item – proceeds to charity

Other slogans:• “One more use” – Goodwill NCW• “Zero-waste mindset” - Unilever



Step 7: CollaborateWho can help you overcome your barriers?

CollegesInternshipsNGO’sIndustry groups - like www.apics.orgConsortiumsWaste haulerCouncil for Responsible Sport, Sustainable Event Alliance

Strategically picking the right collaborators is critical!

Step 7: Collaborate

• National Parks and Subaru to reduce landfill waste


Step 7: Collaborate

Kansas City Marathon and Girl Scouts, Boy Scouts


Step 7: Collaborate


Step 7: Collaborate

• Egg Farms

• Distribution Centers

• Retailers


Step 7: Collaborate• Ministry Health Care and Practice Greenhealth

• Surgical blue wrap is comprised of polypropylene (aka #5 plastics)

• They have been recycling this locally since 2012


Break Out – 5 minutes

• Answer the following questions:

• What three things will you do after you return to work?

Insider Tips on Leading a Zero-waste InitiativeDo

Step 8: Implement Plan

• Just do it!

• Plan for the unexpected

• Clear your calendar and observe and direct – someone needs to own the process on-site

• Continue to educate and problem-solve

• Provide checklists to help ensure details are covered

Insider Tips on Leading a Zero-waste InitiativeDo

Step 9: Review results

• How did you do?

• Gather feedback

• What needs changed?

• Celebrate your accomplishments!

Insider Tips on Leading a Zero-waste InitiativeCheck

Step 10: Revise, improve and create best practices

• Keep the momentum going

• Set bigger goals• Product/Service design

• Suppliers

• Internal processes

• Customers

“We have the responsibility to look after our planet. It is our only home.” ~ The Dalai Lama

Insider Tips on Leading a Zero-waste InitiativeAct

Kimberly-Clark shares best practices in scrap material sorting and sales, identifying material reuse and recycling opportunities within operations and supply chain, and developing relationships with outside recyclers.

Oshkosh Corporation has a sustainability council, which has representation of top management for several key functions and includes an outside member from the local university.


Step 10: Revise, improve, and create best practicesCLTD Certification BOK – Reverse Logistics & Sustainability

Major content on this topic


• Master Planner

• Master Scheduler

• Demand Manager

• Forecaster

Plan

• Procurement Mgr

• Procurement Outsourcing Mgr

Source • Production Manager

• Production Scheduler

Make

• Distribution Mgr

• Transportation Mgr

• Warehouse Mgr

Deliver • Reverse Logistics Manager

Return

• Summary tips:• Answer the business question “So why not zero-waste?”

• Management buy-in is critical step

Having an engaged and adaptive project team is essential

Include fun – slogans, pictures, celebrations – engage people

• Strategically pick the right collaborators

If you want to go fast, go alone. If you want to go far, go together.

~ African proverb


• Contact Information:• Joanne Gorski, SCOR-P, CFPIM, CSCP, President, Sustainable Insights LLC

• [email protected]

• 920-636-6721


mailto:[email protected]

zero waste 11.15.16

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