The Green Factory : Creating Lean and Sustainable Manufacturing

This book 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 uses a kaizen approach to help readers improve mass and energy flows in manufacturing environments that already possess a deployment level in applying lean. It tells the story of how GKN, a major British multinational corporation with operations in more than 30 countries, developed and implemented a lean and green business model in two of its automotive facilities in Brazil. It covers the corporate issues of balancing profit with environmental concern and the behavioral issues of engaging the workforce to identify and reduce environmental waste. -- Read more... Abstract: This book 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 uses a kaizen approach to help readers improve mass and energy flows in manufacturing environments that already possess a deployment level in applying lean. It tells the story of how GKN, a major British multinational corporation with operations in more than 30 countries, developed and implemented a lean and green business model in two of its automotive facilities in Brazil. It covers the corporate issues of balancing profit with environmental concern and the behavioral issues of engaging the workforce to identify and reduce environmental waste This book proposes a new model, the Lean and Green Business Model (L&GBM), where the environmental aspect of sustainability is integrated with Lean thinking in order 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 Green Creating Lean and Sustainable Manufacturing tells the story of how GKN, a major British multinational corporation with operations in more than 30 countries, developed and implemented a Lean and Green Business Model in two of its automotive facilities in Brazil. It provides practical insight into how GKN was able to develop and deploy Lean and Green in a manner that resulted in environmental and cost benefits in the automotive facilities that operated in Brazils high-inflation environment. Detailing proven concepts and sustainable models derived from the first-hand experiences, the book supplies information against the backdrop of GKNs automotive manufacturing environment. The authors take an inside-out approach, describing the real issues Environmental Health & Safety professionals face when implementing sustainable manufacturing policies. The book covers the corporate issues of balancing profit with environmental concern and the behavioral issues of engaging the workforce to identify and reduce environmental waste. All the concepts and models presented in the book have come about through the authors real life experiences in live kaizen events as well as their extensive academic research in the subject area. Content: Foreword by John Bicheno Foreword by Robert W. "Doc" Hall Prologue: A New Way of Thinking Introduction to the Lean and Green Business Model Concept behind the Model Inputs from Operations Management Power of Lean Production Four Dimensions of a Lean Enterprise Sustainable Development and "Green" Thinking Connecting the Concepts: Operations, Lean, Green, and Sustainability How Lean and Green Thinking Can Be Combined into One Conceptual Business Model Analysis of Lean and Green through Operations Lenses Analysis of Lean and Green Taking a Sustainability Perspective Analysis of Green Taking a Lean Perspective Analysis of Lean Taking a Green Perspective Understanding the Connections Lean and Green Business Model and Operational Implementation L&GBM Purpose of the L&GBM Principles of the L&GBM Ways of Working of the L&GBM L&GBM Is Different from Pure Lean and Green Thinking Consolidating the L&GBM Understanding the L&GBM Kaizens L&GBM for a Cell Pilot Testing: L&GBM for a Cell Rollout the L&GBM for a Cell L&GBM for Sister Cells Applying the L&GBM to Sister Cells L&GBM for a Value Stream Applying the L&GBM to a Value Stream Reverse Testing: Applying the L&GBM to a Cell in Different Manufacturing Environments L&GBM Ways to Save Mass and Energy Lean and Green Business Model Strategic Implementation Key Lessons from Implementation Positioning the L&GBM Confirming L&GBM Key Characteristics: Identifying Preconditions for Success 20 Questions and 20 Answers for the L&GBM Conclusions Andrea's Real-Life Story behind the Research and the Book The Beginning Year One Year Two Year Three: The End Glossary of Terms References Index This book 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 uses a kaizen approach to help readers improve mass and energy flows in manufacturing environments that already possess a deployment level in applying lean. It tells the story of how GKN, a major British multinational corporation with operations in more than 30 countries, developed and implemented a lean and green business model in two of its automotive facilities in Brazil. It covers the corporate issues of balancing profit with environmental concern and the behavioral issues of engaging the workforce to identify and reduce environmental waste. -- Edited summary from book Front Cover 1 Contents 7 Foreword by John Bicheno 9 Foreword by Robert W. “Doc” Hall 11 Prologue: A New Way of Thinking 13 Chapter 1: Introduction to the Lean and Green Business Model 23 Chapter 2: Lean and Green Business Model and Operational Implementation 55 Chapter 3: Lean and Green Business Model Strategic Implementation 131 Chapter 4: Conclusions 155 Chapter 5: Andrea’s Real-Life Story behind the Research and the Book 163 Glossary of Terms 173 References 175 Authors 181 Back Cover 183