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Manufacturing Excellence

Clean & Lean Manufacturing


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

Are Green & Lean Opposites?


Green

Lean &
Lean &
Green
Green Profit Solution
s

Preserve Maximise
& profit by
conserve using
natural Lean &
minimum
resources resources Profit
Manufacturing Excellence

Systems View
Outputs
Inputs:
Value = Product
Raw matrls
or Service
Consummables
People Enterprise Heat

Energy Waste
materials
Building
Manufacturing Excellence

Background
3 companies, component Grant aided
manufacture, engineering and
under EPAs
medical device industries
Carten Controls
Cleaner Greener
Frentech Engineering Production
Lake Region Programme
Range from 50 to 700 employees
Multi-national & indigenous
All had commenced
implementation of Lean Principles
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
-Aircon 24/7

-Conforming tapers,
-Annealed ends?? -Contaminated coolant
-Heat 24/7 set-ups, qty wires
Conforming
length

Cut wires Anneal Grind


to length wire ends tapered wire
in oven ends

-Grinding wheels,
-Elec 24/7, -Elec qty wires,
-2 Ovens -Coolant
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% 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
Manufacturing Excellence

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
(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