Improving Profitability Through Green Manufacturing Creating a Profitable and Environmentally Compliant Manufacturing Facility

DAVID R. HILLIS, PhD, has more than thirty-five years of experience in academia and private industry. Currently he is an independent consultant who works with manufacturers to maximize productivity and minimize waste. Hillis is coauthor of Manufacturing Processes: Materials, Productivity, and Lean Strategies; Manufacturing Processes: Automation, Materials, and Packaging; and Waste Reduction Strategies for Fiberglass Fabricators.

J. BARRY DuVALL, PhD, has more than forty years of experience in industry and academia. He is currently a full Professor in the Department of Technology Systems at East Carolina University. He has taught courses in many areas including productivity improvement, manufacturing processes and materials, digital communication, and technology management. Dr. DuVall is the author or coauthor of Contemporary Manufacturing Processes; Manufacturing Processes: Materials, Productivity, and Lean Strategies; Manufacturing Processes: Automation, Materials, and Packaging; and Getting the Message: the Technology of Communications.

PREFACE xi

ACKNOWLEDGMENTS xv

1 MANUFACTURING 1

Introduction 1

Manufacturing Sequence 2

Product Life Cycles—There’s More Than One 3

Life Cycle Analysis 4

Potential for Waste and Value Added in Manufacturing 9

Vertically versus Horizontally Integrated Manufacturing 11

Waste and Its Unexpected Sources 13

The First Source of Waste 14

The Second Source of Waste 17

The Third Source of Waste 19

A New Product—First Phase for Waste Reduction 20

Existing Products—Second Phase for Waste Reduction 22

Regeneration 24

Life Cycle of the Manufacturing Facility 25 

Creating a Classifi cation System for a Compliant and Profitable Manufacturing System 27

Summary 29

Selected Bibliography 31

2 BUILDING A DECISION-MAKING MODEL 33

Introduction 33

Industrial Production and Manufacturing 34

Classifying Manufacturing Industries 38

Major Product Groups from NAICS 40

Material Stocks 51

Major Material Families 52

Basic Process Classifi cations 53

Forming Processes 55

Separating Processes 56

Joining Processes 57

Conditioning Processes 58

Finishing Processes 59

Design Template for Classifying Manufacturing Processes 60

It All Began in Sally’s Garden 60

The Analysis 62

Next Steps 67

Selected Bibliography 68

3 ENVIRONMENTAL REGULATIONS, STANDARDS, AND PROFITABILITY 69

Introduction 69

Organizing to Comply—The Management Foundation 71

Formalizing the Management Approach—The ISO Standards 73

ISO 14000 Series of Standards 74

Overview of Major Environmental Regulations 75

Clean Air Act Overview 77

Clean Water Act Overview 79

Solid and Hazardous Waste Management Overview 81

Summary—Compliance Can Mean Profits 82

Selected Bibliography 84

4 CASE STUDIES 85

Introduction 85

Case Study 1 88

Introduction 88

Waste Minimization Programs 91

Reuse and Recycling Activities in the Office 92

Reduction and Reuse of Packaging 92

Comment 93

Case Study 2 93

Introduction 93

The Study and Methods Used 94

Conclusion 97

Comment 97

Case Study 3 98

Introduction 98

Description of the Manufacturing Operation 98

Manufacturing Operations and Sequence 99

Steps Taken to Lessen the Environmental Impact of the Manufacturing Facility 102

Material Waste Reduction 102

Resource Reduction 103

Methods the Company Uses to Identify and Make Improvements 104

Summary 105

Comment 106

Case Study 4 106

Introduction 107

Manufacturing Operations and Sequence 109

Steps Taken to Lessen the Environmental Impact of the Facility 111

Methods Used to Make Improvements 112

Examples of Waste Reduction 114

Comment 115

Case Study 5 115

Introduction 115

Singapore Packaging Agreement 117

The “Three Rs” Approach to Solid Waste Minimization 118

Comment 120

Conclusion 120

Selected Bibliography 121

5 AN OVERVIEW OF TOOLS USED TO IMPROVE MANUFACTURING OPERATIONS 123

Introduction 123

Waste Reduction: The Profi table and Compliant Process Chart—A Collaborative Tool for Both Groups and All Functions 128

Training and Development 129

Operator Self-Control 129

Culture Change 130

Manufacturing Engineering and Operations 131

Lean Manufacturing 132

Kaizen 135

Pareto Principle 136

Process Control 136

Certifi ed Management Systems 137

Design of Experiments 137

Poka-Yoke 138

Finding the Root Cause of a Problem 139

Fishbone or Ishikawa Diagram 139

Situational Awareness 140

Product Design 142

Design for Assembly 142

Human Resources 143

The Life Cycle 143

A Just-in-Time Workforce 144

Summary 147

Selected Bibliography 148

6 THE FACILITY 149

Introduction 149

Making a Building That Can Be Regenerated 152

Plant Location 152

Sustainable Design 154

A Sustainable Building 157

Construction Sequence 159

Life Cycle and Life Cycle Cost Analysis 160

Cost Analysis Software 163

The eQUEST® Program 164

The eVALUator Program 164

Building for Environmental and Economic Sustainability 166

Energy Star 167

Energy Management Program 169

Steps to Establish an Energy Management Program 170

International Standards for an Energy Management System 173

Leadership in Energy and Environmental Design 174 

Summary 177

Selected Bibliography 178

7 APPLYING THE PROFITABLE AND COMPLIANT PROCESS CHART 181

Introduction 181

PCPC Worksheets 182

Using the Data Collection Worksheets 189

Step 1: Material Selection 189

Step 2: Process Identifi cation 190

Step 3: Outsourcing Manufacturing Processes 195

Summary 195

Industrial Applications of the PCPC 197

Application 1: Avionic Systems, Incorporated 198

Comment 198

Application 2: American Automotive Corporation 200

Comment 200

Application 3: NAVAC Logistics Center 202

Comment 202

Application 4: Custom Machine Builders 204

Comment 207

Observations 209

Constructing the Virtual PCPC 209

Conclusion 211

Selected Bibliography 212

GLOSSARY 213

INDEX 223

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