Lean Ambiental Toolkits

Lean Ambiental Toolkits

(Parte 1 de 9)

The Lean and Environment Toolkit


◆ Improve Environmental Results

◆ Identify and Eliminate Waste ◆ Reduce Business Costs and Risk

Toolkit Format and Icons The toolkit uses icons in the page margins to help you fi nd and follow important information in each chapter.

Key Point Identifi es an important point to remember

Key Term Defi nes an important term or concept

New Tool Presents a technique or resource that helps capture, communicate, or apply new knowledge

How-to Steps Describes sequenced actions to implement a tool

Chapters also include one or more “To Consider” text boxes that contain questions to help you explore how the information relates to your organization.

Lean and Environment Toolkit

Chapter 1 Introduction: Getting Started with Lean & Environment1
Chapter 2 Identifying Environmental Wastes1
Chapter 3 Value Stream Mapping21
Chapter 4 Kaizen Events35
Chapter 5 6S (5S+Safety)49
Chapter 6 Conclusion and Implementation Strategies61

Table of Contents

Appendix A Lean Methods67
Appendix B Basic Environmental Measures for Lean Enterprises74
Appendix C Lean Event EHS Checklist7
Appendix D Pollution Prevention Resources79

Appendices Appendix E 6S Safety Audit Checklist .............................................................................................. 81

Lean and Environment Toolkit


This Lean and Environment Toolkit assembles practical experience collected by the U.S. Environmental Protection Agency (EPA) from a group of partner companies and organizations that have experience with coordinating Lean implementation and environmental management. The toolkit builds on work conducted and research sponsored by EPA’s Lean Manufacturing and Environment Initiative (see http://www.epa.gov/lean).

The EPA’s intent in developing this toolkit is to enable Lean practitioners to improve both their business performance and their environmental performance by identifying and eliminating environmental wastes at their organizations. The toolkit offers practical strategies and tools for integrating environmental considerations into Lean initiatives in ways that support Lean’s focus on the elimination of waste and non-value added activity.

This is the second iteration of the Toolkit. EPA welcomes your comments and refl ections on this document, as well as other ideas you have for Lean and environment strategies, tools, and resources which can be incorporated in future versions of the toolkit. Please contact EPA to share your experiences with Lean and the environment and/or to discuss partnership opportunities by using the form found at http://www.epa.gov/lean/auxfi les/contact.htm.

Lean and Environment Toolkit


The U.S. Environmental Protection Agency is very grateful for the invaluable assistance of its partners in developing this toolkit. EPA’s partners shared their experiences, tools, and techniques for integrating Lean and environmental management, and worked collaboratively with EPA to develop, test, and refi ne the content of this toolkit.

EPA’s Lean and Environment partners include: Baxter International, Chicago Manufacturing Center, CONNSTEP, HNI Corporation, Robins Air Force Base, Rockwell Collins, and the U.S. Army Materiel Command. Participating Offi ces at EPA include: the National Center for Environmental Innovation; the Offi ce of Pollution Prevention and Toxics; and the Offi ce of Solid Waste.

In addition to these organizational partners, this toolkit has benefi ted from the collective expertise and ideas of many individuals. In particular, EPA would like to thank the following individuals for their thoughtful contributions:

Pat Bartholomew of Baxter International Kate V. Bates of Earth Tech, Inc., working with Robins Air Force Base Dave Bury of Robins Air Force Base Jenni Cawein of Baxter International Angie Coyle of Delphi Corporation Rob Currie of Baxter International

James Ellor of Elzly Technology Corporation, working with the U.S. Army Materiel Command

Mike Fisher of Baxter International Vicki Fisher of Rockwell Collins Antonia Giardina of the U.S. Army Materiel Command Scott Lesnet of HNI Corporation Alistair Stewart of the Chicago Manufacturing Center Karen Wan of the Chicago Manufacturing Center Megan Wertz of The George Washington University Judy Wlodarczyk of CONNSTEP, Inc.

This toolkit was prepared for the U.S. Environmental Protection Agency by Ross & Associates Environmental Consulting, Ltd. in association with Industrial Economics, Inc. (EPA Contract # EP-W-04-23).

Chapter Contents

Purpose of This Toolkit Key Questions Addressed by the Toolkit

Why Use This Toolkit 1. Learn to See Hidden Environmental Waste 2. Enhance the Effectiveness of Lean Implementation 3. Deliver What Customers and Employees Want

How to Use This Toolkit Toolkit Structure and Chapters Toolkit Format and Icons

Conclusion Summary

Your Thoughts

CHAPTER 1 Introduction: Getting Started with Lean & Environment

Chapter 1: Introduction—Getting Started With Lean & Environment

Purpose of This Toolkit

The Lean and Environment Toolkit offers practical strategies and techniques to Lean implementers about how to improve Lean results—waste elimination, quality enhancement, and delivery of value to customers—while achieving environmental performance goals. The toolkit also provides tools to help your organization get better environmental performance from Lean efforts on the shop fl oor.

Benefi ts of Coordinating Lean & Environment

✓ Reduce costs ✓ Improve process fl ow and reduce lead times

✓ Lower regulatory non-compliance risk

✓ Improve environmental quality

✓ Improve employee morale and commitment

The “Lean” methods discussed in this Toolkit are organizational improvement methods pioneered in the Toyota Production System. Lean production and Lean manufacturing refer to a customer-focused business model and collection of methods that focuses on the elimination of waste (non-value added activity) while delivering quality products on time and at a low cost. The toolkit assumes that you are familiar with Lean methods and their implementation. For those who want to learn more about Lean methods discussed in the toolkit, see Appendix A.

Key Questions Addressed by the Toolkit

Lean works well when it focuses on identifying and eliminating non-value added activity. Environmental improvement efforts that have potential to distract Lean efforts from this prime focus will likely not get much traction. By contrast, this toolkit contains strategies and techniques that can seamlessly enable Lean practitioners to easily identify environmental wastes and improvement opportunities alongside the myriad other wastes and improvement opportunities uncovered by Lean. To accomplish this, the toolkit aims to answer the following questions:

What is environmental waste? Environmental waste is an unnecessary or excess use of resources or a substance released to the air, water, or land that could harm human health or the environment. Environmental wastes can occur when companies use resources to provide products or services to customers, and/or when customers use and dispose of products. Chapter 2 defi nes and provides examples of environmental waste.

Chapter 1: Introduction—Getting Started With Lean & Environment

Why should I identify environmental waste in my processes? Environmental wastes do not add value to the customer. Environmental wastes can also directly affect production fl ow, time, quality, and cost—making them ripe targets for Lean initiatives. In many cases, the costs associated with pollution and wasted energy, water, and raw materials can be signifi - cant. This chapter (Chapter 1) discusses the business case for eliminating environmental waste.

How will I know when I see environmental waste? Some environmental wastes are easy to see. Containers of solid and hazardous waste are visual indications of environmental waste. Health and environmental risks posed by certain chemicals or materials can be more diffi cult to see, although they can represent costly non-value added aspects of a process or product. Chapter 2 provides examples of environmental wastes and describes organizational strategies that will make it easier to know when you see them.

Where should I look for environmental wastes? Environmental wastes can be found in almost any process. Processes requiring environmental permits—such as painting, metal fi nishing, and hazardous waste management processes—are often a good place to look for environmental improvement opportunities. If your organization has an environmental management system (EMS), your Environmental, Health and Safety (EHS) personnel may have already identifi ed key environmental impacts associated with each of the organization’s processes. Chapter 3 discusses how value stream mapping (VSM) tools and techniques can be used to help Lean practitioners see environmental wastes in processes. Chapter 4 discusses how to identify and address environmental wastes during kaizen rapid improvement events.

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