... Solid Waste and Emergency Response (5302W) Policy, Economics & Innovation (1807T) EPA100-R-03-005 October 2003 www.epa.gov/ innovation/lean.htm Lean Manufacturing and the Environment: Research on Advanced Manufacturing Systems and the Environment and Recommendations for Leveraging Better Environmental Performance ACKNOWLEDGMENTS This report was prepared for the U.S. Environmental Protection Agency's Office of Solid Waste and Emergency Response (OSWER) and Office of Policy, Economics, and Innovation (OPEI). Ross & Associates Environmental Consulting, Ltd. prepared this report for U.S. EPA under contract to Industrial Economics, Inc. (U.S. EPA Contract # 68-D9-9018). DISCLAIMER The observations articulated in this report and its appendices represent Ross & Associates’ interpretation of the research, case study information, and interviews with lean experts and do not necessarily represent the opinions of the organizations or lean experts interviewed or researched as part of this effort. U.S. Environmental Protection Agency (EPA) representatives have reviewed and approved this report, but this does not necessarily constitute EPA endorsement of the observations or recommendations presented in this report. Lean Manufacturing and the Environment: Research on Advanced Manufacturing Systems and the Environment and Recommendations for Leveraging Better Environmental Performance Table of Contents Executive Summary . . . . . . . . . . . . . . . . . . . . . . . ....
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...uk Lean production at Portakabin Introduction Portakabin is an international company. It produces some of the most advanced building systems available. The company is part of the £700 million turnover Shepherd Group. The Shepherd Group is one of the largest family-owned companies in the European building industry and employs 3,500 people. It focuses on three main areas: • manufacturing • construction • property. The name Portakabin is a registered trade mark. This instantly recognisable sign means that no other company can use the Portakabin name on its products. Donald Shepherd, the founder of Portakabin, came up with the idea of stand-alone re-locatable buildings in the 1960s. Since that day, only buildings produced by Portakabin can be called Portakabin buildings. Portakabin uses modular buildings. This means they are made up of one or more modules that are constructed in a factory environment. These are then linked together to form multi-purpose buildings. Typical examples of Portakabin buildings include: CURRICULUM TOPICS • Lean production • Kaizen • Just-in-time • Quality management GLOSSARY Turnover: the total value of all sales made in a given period of time, sometimes referred to as sales revenue. Trade mark: text, logos and symbols relating to a company and its products. Hospitals Offices Portakabin Nurseries Schools Portakabin buildings can be erected almost anywhere in the world. Portakabin is able to deliver the same high quality buildings...
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...uk Lean production at Portakabin Introduction Portakabin is an international company. It produces some of the most advanced building systems available. The company is part of the £700 million turnover Shepherd Group. The Shepherd Group is one of the largest family-owned companies in the European building industry and employs 3,500 people. It focuses on three main areas: • manufacturing • construction • property. The name Portakabin is a registered trade mark. This instantly recognisable sign means that no other company can use the Portakabin name on its products. Donald Shepherd, the founder of Portakabin, came up with the idea of stand-alone re-locatable buildings in the 1960s. Since that day, only buildings produced by Portakabin can be called Portakabin buildings. Portakabin uses modular buildings. This means they are made up of one or more modules that are constructed in a factory environment. These are then linked together to form multi-purpose buildings. Typical examples of Portakabin buildings include: CURRICULUM TOPICS • Lean production • Kaizen • Just-in-time • Quality management GLOSSARY Turnover: the total value of all sales made in a given period of time, sometimes referred to as sales revenue. Trade mark: text, logos and symbols relating to a company and its products. Hospitals Offices Portakabin Nurseries Schools Portakabin buildings can be erected almost anywhere in the world. Portakabin is able to deliver the same high quality buildings...
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...Contents Executive Summary 2 Introduction 3 Implementation of TQM & LEAN into MPA objective 4 TQM application to MPA reliability 4 Lean approach vs MPA competitiveness 7 Benefits & Limitations 8 Environmental Issues 8 Sustainable Environment 9 Carbon Emissions 10 Implementation of LEAN in the Environmental Issues 11 Conclusion 12 References 12 Executive Summary: The port of Singapore comprises a number of facilities and terminals that handle a wide range of cargo transported in different forms. In addition, the government has established The Maritime and Port Authority of Singapore (MPA) as a body that is responsible for the overall development and growth of the port of Singapore, overseeing most if not all the activities that are carried out as far the port logistics are concerned. However, the purpose of this paper has been divided into two tasks, one of which involves a critical evaluation of the application of Lean and TQM (Total Quality Management) in logistics and supply chain networks to achieve MPA objectives such as quality of service, competitiveness, reliability and efficiency. In addition the benefits and limitations from a practical perspective for MPA is evaluated. The second task of the paper aims to critically evaluate the key environmental sustainability issues in Cargo maritime logistics for MPA and an analysis of how implementing lean practices by MPA can reduce the environmental impact of an inward and outward maritime...
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...White Paper Lean Manufacturing Lean Manufacturing Table of Contents Executive Summary.......................................................................................................................................................................................2 Introduction .......................................................................................................................................................................................................4 Lean Manufacturing—So What? .................................................................................................................................................4 Objectives .................................................................................................................................................................................................6 The Manufacturing Challenge .................................................................................................................................................................7 Globalization and Competitive Pressure ................................................................................................................................7 Mass Production to Mass Customization ...............................................................................................................................7 Shortening Product Life Cycles........................................................................
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...engine for growth of the economy. Ever changing globalized environment has been posing challenges of competitiveness and survival to all the constituents of the economy. Manufacturers industry have always faced heightened challenges such as rising customer’s demand for better and improved products, erratic demand, and competition in markets. There is no disbelief that the manufacturers are always embracing changes and improvements in their key activities or processes to cope with the ever growing challenges. To be more efficient is the only way to stay and earn profit in a global market. Industries are giving lot of attention to Lean manufacturing. Several industries are struggling to be world class. Principal adoption of lean manufacturing is still found to be complex. Lean Manufacturing is a set of techniques, which have developed gradually over a long period and are based on various minor to major breakthroughs that help in reducing cost and hence increase productivity. Lean is a philosophy of manufacturing that incorporates a collection of principles, tools and techniques into the business processes to optimize time, productivity, HR, and assets, while improving the quality level of products and services to their customers. LEAN MANUFACTURING Lean manufacturing is defined as to produce same and more than the mass production using less effort, lesser space, without any new inventory, better quality and lesser defects. Lean manufacturing improves operating performance by focusing...
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...EXECUTIVE SUMMARY This research paper acknowledges different quality management tools. It is about the evolution of different quality tools and defining the best practice Strategic model in IT organization in relation to achieving quality within their business processes and integrating business processes to achieve strategic goals. Previous research and study indicates the various quality system tools in order to achieve quality management objectives in the competitive business environment. This research paper investigates and finds out the evolution of different quality system tools and significance of various quality tools and then designing best practice strategic model for future in Information Technology organization. The importance of this proposed research is that currently IT companies are experiencing increased global competition and parameters like complexities of the product, different markets, customer focus, high quality of product, decision making and integration among various business units in the global environment and the environment in which the firm operates are the issues of concern. Traditional quality tool in IT systems are not capable of coping with these demands and still stay competitive. Changes are needed in order to achieve sustainable results and maintaining fitness and overcome the problems of traditional tools. Today industrial companies need stable position socially and economically...
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...Lean Management In Automobile Industry Lean Management In Automobile Industry Arvinder Singh, Bargavi Poloju, Inderpreet Kaur, Inderjeet Kaur, Jaskaran Singh Gill Eastern Institute of Technology September 10, 2015 Abstract Lean and six sigma are widely known business improvement processes for industries /organisations these days for achieving drastic results, which are majorly cost cutting, quality maintenance and time management by specializing in processes to boost performance. Nowadays, There are some industries that are even integrating lean and six sigma into a more cohesive strategy i.e., lean sigma in order to establish even more powerful and effective process which focuses at eliminating wasteful activities and retaining most of the strengths of each activity. Lean Sigma aims to combine waste eliminating strategies of Lean Thinking with variability reducing techniques of six sigma to promote growth and increase revenue from the bottom line of organisations(M. Kumara). Lean management is outlined as a consistent and a methodical approach to determining and eliminating waste through continuous improvement, flowing the merchandise at the pull of the client in pursuit of perfection. The idea of lean management was developed for maximizing the resource utilization through reduction of waste, and eventually lean was developed in response to the unsteady and ever-competitive business organisations. For organisations to face major challenges and competition can be...
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...safeguard Singapore strategic maritime objectives. Research for this report includes evaluating the application on Lean and Total Quality Management (TQM) in logistics and supply chain networks to achieve Maritime Port Authority (MPA) objectives such as quality of service, competitiveness, reliability and efficiency. The major findings shows that lean implementation improves processing times achieving more work in less staff time and bringing services up to standard. (Radnor, Walley, Stephens, & Bucci, 2006). It also changes the focus of management from optimizing separate technologies, assets, and vertical departments to optimizing the flow of products and services through entire value streams that flow horizontally across technologies, assets, and departments to customers. Lean helps to eliminate waste along entire value streams, instead of at isolated points, creates processes that need less human effort, less space, less capital, and less time to make products and services at far less costs and with much fewer defects, compared with traditional business systems. Also, it requires keeping far less than half the needed inventory on site, results in many fewer defects and produces a greater and ever growing variety of productions. TQM Management can be a tool to support and create synergy for inducing a more competitive market among companies. Total quality management (TQM) may be considered as a management approach to long term success through continuous improvements...
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...global maritime logistics and the MPA. In this report, the utilisation as well as impacts of Lean and Six Sigma strategies will be analysed. In addition to this, the two strategies will be compared and contrasted. Lean and Six Sigma assist in working efficiently and reducing wastes. In recent times, IT has proven to be a vital tool in assisting organisations and global maritime logistics. This report will examine the relationship between IT and quality (TQM), efficiency (Lean) and collaboration and has shown assist them in their objectives and gain a competitive edge. This report has shown that IT has proven to be effective in helping organisations and global supply networks work and communicate among one another effectively and efficiently. 1.0 INTRODUCTION In this report, its main focus is on determining the most optimal cost reduction strategies in the implementation of green strategies in global maritime logistics such as the Singapore maritime logistics network or Maritime and Port Authority of Singapore (MPA) and for this particular paper, the researcher has chosen two specific cost reduction strategies specifically: Six Sigma and Lean. Container ports the world over are increasing at an alarming rate and ports have to take into account of its efficiency, throughput and green performance. TASK 1 2.0 COST REDUCTION STRATEGIES TO ACHIEVE OBJECTIVES Six Sigma and Lean are the strategies that will be critically examined and analysed to be implemented in the global...
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...Executive Summary: Total quality management and lean provide a means to improve the delivery of services using a disciplined, qualitative and minimalistic approach. They also bring numerous advantages to an organization and the surrounding environment if implemented properly, but it also risks being regarded as another management or profit oriented move. This paper aims to evaluate these business processes, and provide guidelines for the application of total quality management and Lean in the port activities in Singapore, through its maritime port authority. As this is the scope of the paper, an analysis is also carried out to identify the areas that the maritime port authority of Singapore has applied these measures, the impact of these methods as well as recommendation of aspects that can be leaned in order to improve both port activities and sustainability. Secondary data sources is the main methodological method used in this paper, and various pieces of information have been retrieved from these sources to indicate and support claims made in this paper In addition, this paper is targeted towards administrators and scholars responsible for a wide range of public-sector services, including those provided to citizens and those provided to internal customers both in the logistics and supply chain industry such as ports authorities, and as a business process improvement measure. Introduction: The economic development in Asia, and in particularly in the south...
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...Series Towards An Integration Of The Lean Enterprise System, Total Quality Management, Six Sigma And Related Enterprise Process Improvement Methods Kirkor Bozdogan Center for Technology, Policy and Industrial Development Massachusetts Institute of Technology Cambridge, MA USA 02139 Tel. 617 253-8540 bozdogan mit.edu ESD-WP-2010-05 August 2010 esd.mit.edu/wps ESD Working Paper Series Towards An Integration Of The Lean Enterprise System, Total Quality Management, Six Sigma And Related Enterprise Process Improvement Methods Kirkor Bozdogan Center for Technology, Policy and Industrial Development Massachusetts Institute of Technology Cambridge, MA USA 02139 Tel. 617 253-8540 bozdogan mit.edu ESD-WP-2010-05 August 2010 esd.mit.edu/wps TOWARDS AN INTEGRATION OF THE LEAN ENTERPRISE SYSTEM, TOTAL QUALITY MANAGEMENT, SIX SIGMA AND RELATED + ENTERPRISE PROCESS IMPROVEMENT METHODS Kirkor Bozdogan # Center for Technology, Policy and Industrial Development, Massachusetts Institute of Technology, Cambridge, MA USA 02139 August 5, 2010 Key Words: Lean manufacturing; just-in-time-production (JIT); Toyota Production System (TPS); lean enterprise system; total quality management (TQM); six sigma; lean six sigma; theory of constraints (TOC); agile manufacturing; business process reengineering (BPR); enterprise change and transformation; evidence-based management practices Abstract: The lean enterprise system, total quality management, six sigma, theory of constraints...
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...Autoliv is a world class example of lean manufacturing. This Fortune 500 Company makes automotive safety components such as seat belt, airbags, and steering wheels, and has over 80 plants in more than 32 countries. Revenue in 2007 topped $6.7 billion. Autoliv’s lean manufacturing environment is called the Autoliv Production System (APS), and is based on the world’s largest automobile manufacturers, and embodied in its Toyota Production System (TPS). At the heart of Autoliv is a system that focuses on continuous improvement. Based on the “House of Toyota”, Autoliv Ogden, Utah, air bag plants put the concepts embodied in the house to work every day. The only difference between the Toyota house and the one at Autoliv is that the company has added a third pillar to its house to represent employee involvement while the norm in Japan not always found in the United States Autoliv started its journey back in 1995 at the time the ogden plant was manufacturing capacity with 22work cells company managers acknowledge that back then Autoliv was “broken” and in need of significant and immediate change if it was to survive. This meant that everyone from senior management to employees and suppliers needed to be on board with rebuilding the company. It was not that the company could not fulfill the needs of its automaker customers however with increasing demand for both reliable and cost effective component supplies pressure to change become obvious. Recognizing the value of Toyotas approach...
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...Executive Summary The report covers the Agile development methods, what they are and how they are beneficial and help maintain desired levels of quality by keeping room for change in the system that may be requested by the client. We identify the problems of existing techniques and problems faced by those techniques in the current environment. We also compare dominant techniques such as the Waterfall development model with Agile methods to show how Agile methods are advantageous in the current dynamic business environment. The report also occurs Lean software development, what it is and the common areas that it has with Agile development. How using both the methods can result in even faster delivery of product to the customer and help reduce costs incurred during defect detection and correction, identification of common error categories and giving developers more responsibility increases better quality code and building of knowledge base. Table of Contents Executive Summary......................................................................................................................................1 Introduction...................................................................................................................................................1 Problem Identification...................................................................................................................................1 Agile development Technique............................
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...Research on Lean Project Management Summary This report explains theories and assumptions of current project management methods, and compares it to the Lean Production Delivery System (LPDS) by showing advantages and disadvantages of each method. This report also includes how the LPDS is more efficient than other methods by eliminating wastes and save cost and duration. Introduction: Client needs nowadays are getting more stylish due to the continuous new challenges in the environment, economy, technology and society for the necessity of creating or upgrading new projects. Meeting these requirements involves changing old methods in managing projects into new ones which are more essential to meet the needs of the market. Moreover, new concepts have been considered in addition for the time, cost and quality to guaranty the success of a project. Many new concepts could be presented for production management, but the Lean Production Delivery System (LPDS) is one of the most successful practices concerning the development of project management. For this matter, this report will include an investigation and discussion comparing the advantages and disadvantages of current project management methods and Lean Production Delivery Systems (LPDS). Current project management methods, Advantages and Disadvantages: As described in the text, ―Project Management is the application of knowledge, skills...
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