Mach 2020 - 20-24 April

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"The Green Factory" How to create Lean and sustainable manufacturing.


"The Green Factory" How to create Lean and sustainable manufacturing.

21 Apr 2020
Main Seminar Theatre 6-871

This session tells the story of how a major British multinational corporation with operations in more than 30 countries, developed and implemented a Lean and Green Business Model (L&GBM) in two of its automotive facilities in Brazil. It is based on the book, “The Green Factory”. It provides practical insight into how the company developed and deployed Lean and Green in a manner that resulted in environmental and cost benefits in the automotive facilities that operated in Brazil’s high-inflation environment. It shares the learning journey and lessons of the project, applying theoretical models to live fast moving automotive and aerospace 1st tier manufacturing. The session will also explore the concept of reverse testing, where the project tested the theories that had worked in Brazil and several other global sites.

Detailing proven concepts and sustainable models derived from the practical first-hand experiences, the book supplies information against the backdrop of two automotive manufacturing facilities. The session takes an inside-out approach, describing the real issues Environmental Health & Safety professionals face when implementing sustainable manufacturing policies.

This session proposes a new model, the Lean and Green Business Model (L&GBM), where the environmental aspect of sustainability is integrated with Lean thinking to create a way of thinking that contributes to and balances the three sustainability dimensions of people, profit, and planet. The model presented uses a kaizen approach that will help readers improve mass and energy flows in manufacturing environments that already possess a deployment level in applying Lean.

The obvious mass wastes can be easily identified through visual quantitative inspection. However, finding, identifying and measuring other green wastes like gases, air (pressured), chemicals and liquids is more difficult. Through the inclusive kaizen approach detailed in the book, a way of getting to see and capture these wastes is explained.

It will tackle the 3 key questions for manufacturing.

  • How do you progress lean improvement beyond the classic 7 lean wastes?
  • How can you leverage the inclusive approach of lean to include environmental thinking?
  • How can environmental deployment be enhanced rather than just compliance or top-down directives?

This session will show how to successfully combines 2 manufacturing methods -  Lean and Green. It identifies the Lean deployment level required to successfully be able to “add on” environmental implementation through kaizen and continuous improvement. Conversely, it demonstrates how environmental thinking can be combined successfully as an add-on to established lean implementation. It sets out the lean and green business model, which combines both methodologies.

The session will update the book by describing a recent example of a Lean and Green journey of a multinational company applying the model across 10 sites.


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