l5: gp techniques / 1 asian productivity organization, tokyo organization of the gp techniques
TRANSCRIPT
L5: GP TECHNIQUES / 1Asian Productivity Organization, Tokyo
Organization of the GP Techniques
L5: GP TECHNIQUES / 2Asian Productivity Organization, Tokyo
• Operating procedures and process specifications• Scheduling Operations• Equipment operation procedures• Maintenance procedures• Material and product handling and storage • Safety considerations for staff• Comparison with resource and energy consumption norms
CHECK !
Improved Operating Procedures
L5: GP TECHNIQUES / 3Asian Productivity Organization, Tokyo
Glycerin losses inprocess were high
High COD wastewater
Improvement in Operating Procedure of Glycerin
Increase in productivity by 32 per cent.Daily glycerin yield increased by 5 per cent i.e., an additional6 kilograms.Reduced chemical oxygen demand (COD) of wastewater.
Example of Improved Operating Procedures
L5: GP TECHNIQUES / 4Asian Productivity Organization, Tokyo
Advantages of Waste Segregation
• Ease in end-of-pipe treatment of a non-compatiblepollutant stream• Increased possibility of recycling / reusing a wastestream
Electroplating wastewater
Chromium rinse waterNickel
Rinsewater
Degreasingwastewater Possible
chromium recovery
Possible Nickel recovery
Waste Stream Segregation
L5: GP TECHNIQUES / 5Asian Productivity Organization, Tokyo
Good Housekeeping
L5: GP TECHNIQUES / 6Asian Productivity Organization, Tokyo
• Seiri - Organization
• Seiton - Neatness
• Seiso - Cleaning
• Seiketsu - Standardization
• Shitsuke - Discipline
Stratification ManagementTreating the causesStratification ManagementTreating the causes
Functional LayoutFunctional Layout
Inspection SitesAchieving zero grime, zerodirt
Inspection SitesAchieving zero grime, zerodirt
Visual managementColour managementVisual managementColour management
Changing behavioral patternsChanging behavioral patterns
The 5S Technique
L5: GP TECHNIQUES / 7Asian Productivity Organization, Tokyo
7 Wastes
L5: GP TECHNIQUES / 8Asian Productivity Organization, Tokyo
Preventive and Productive Maintenance
The Preventive Maintenance comprises of the following active items:• Cleaning• Lubrication • Inspection of protective coating• Replacement of parts & overhauls
Design of a Cost Effective Maintenance System:
These are the following steps in designing a cost-effective maintenance system:
Classification and identification of equipmentCollection of informationSelection of maintenance policiesPreparation of preventive maintenance programPreparation of corrective maintenance guidelinesOrganizing for maintenance
L5: GP TECHNIQUES / 9Asian Productivity Organization, Tokyo
Product
Waste
Raw materials
Separation EquipmentSeparation EquipmentHeat Recovery
Heat Recovery
By ProductMaterialbalance
Cause and Effect AnalysisCost-benefit analysis
Brainstorming
Process 2Process 2Process 1Process 1
Recovery
Recycle, Reuse and Recovery
L5: GP TECHNIQUES / 10Asian Productivity Organization, Tokyo
When Product specifications changereactor is washed with alcoholRaw
materials
BatchReactorBatch
Reactor
EnergyPhenol Formaldehyde
Washing of Batch
Reactor
Washing of Batch
Reactor
Alcohol
Phenol Form aldehyde resin50% Alcohol and water to waste
treatment
On-site Distillation
kettle
On-site Distillation
kettle
Phenol Formaldehyde resin waste to reuse or disposal
100% alcoholrecycled towashing process
Manufacturing Process
Washing of Batch
Reactor
Washing of Batch
Reactor
On- Site Recovery and Recycle
Phenol Form aldehyde resin50% Alcohol and water to
waste treatment to recycling
On-site Recovery and Recycle
L5: GP TECHNIQUES / 11Asian Productivity Organization, Tokyo
Raw materials
Residual Waste tonearby facility foroff - site recycling
Off-sitewaste
processor
Off-sitewaste
processor
Metal Finishing Industry
Metal Finishing Industry
Heat Recovery
Heat Recovery
Metal bearingWaste Heat
Energy
Recover metalsfrom wastes
Residualwaste totreatment
Recycle back tooriginal industry orsell to another buyer
Off-site Recovery and Recycling
L5: GP TECHNIQUES / 12Asian Productivity Organization, Tokyo
Energy Conversion
Boiler efficiency,Quality of Fuel used,
Maintenance
EnergyTransfer
Insulation of Steam piping,Jackets for hot fluid pipes to
prevent losses
EnergyUtilization
Equipment efficiency, Maintenance,
Energy Recovery
Waste heat exchangers,
Energy Conservation
L5: GP TECHNIQUES / 13Asian Productivity Organization, Tokyo
Better and safer Product
Raw materials
By-Product
Use of improved catalystfor enhancing the productyield
Process 2Process 2Process 1Process 1
Separation EquipmentSeparation EquipmentHeat Recovery
Heat Recovery
Waste Treatment
Plant
Waste Treatment
Plant
Substitute toxic materialwith non- toxic- improved health and safety
Non-toxic waste residues,safe for disposal
Non-toxic wastes,easy to treat
Input Material Changes
L5: GP TECHNIQUES / 14Asian Productivity Organization, Tokyo
Industry sector: Paint manufacture
Size: SME
Push Factor: Pressure from the Western European market, stricter legislation,community pressure, worker health and safety.
Measures: replacing solvent-based paints in its product range with solvent-free,water-soluble or aqueous dispersion paints; reusing paint wastes generated duringapplication through use of air filters.
Productivity benefits: Improved working conditions; increased sales; improvedmarket position; improved community image; superior product quality.
Economic benefits: Investment of HUF 50-60 million and 10 to 30% higher costs foreco-friendly product development. Turnover increased from HUF 830 million in 1994to HUF 1,300 million in 1995 and exports from HUF 16 million to HUF 80 million.
Environmental benefits: Waste recovery and reuse, regulatory compliance andimproved worker health and safety.
Input Material ChangesDunalakk Paint Producing and Servicing Ltd.,
Hungary
L5: GP TECHNIQUES / 15Asian Productivity Organization, Tokyo
Product withslightly changedspecifications
Raw materials
Change from wet tomore effi cient dryprocess
Process 2Process 2Process 1Process 1
Heat Recovery
Heat Recovery
Waste Treatment
Plant
Waste Treatment
Plant
Substantial reductionof wastewater
Reduced load ontreatment plant dueto dry process
Process / Equipment Changes
L5: GP TECHNIQUES / 16Asian Productivity Organization, Tokyo
Industry: Textile printing and finishing
Size: Medium Scale
Push Factor: Inferior product quality and health and safety concerns for the workers.
Measures: Modification of the acid ageing process during dyeing using azoic dyes. Control charting used to identify and implement minimization of usage of toxic substances like acetic acid during dyeing. Productivity Benefits: Product quality improved extensively; Improved worker health and safety.
Economic Benefits: Reduction of acetic acid procurement costs by over $33,280 annually. Total savings in chemical costs approx . $78,520 while wastewater treatment costs have been saved by $200,000.
Environmental Benefits: Effluent quality improved. Reduction in air emissions
Example of Process/ Equipment ChangesPrint Works, Massachusetts, USA
L5: GP TECHNIQUES / 17Asian Productivity Organization, Tokyo
Manufacturing Processes
Manufacturing Processes
Waste Treatment Plant
Waste Treatment Plant
Raw Materials
Products
Waste
On-site Waste Recovery and Recycling
By-Products
Waste DisposalWaste
Disposal
Residues
Off-site Waste RecyclingGP Technique Intervention
Pollution Control
L5: GP TECHNIQUES / 18Asian Productivity Organization, Tokyo
• Industrial Boiler emissions• Acid Bath Fumes• Chemical Odours
• Gravitational settlers• Cyclonic collectors• Bag filters • Wet scrubbers• Electrostatic precipitators• Adsorption towers• Adsorption columns
Techniques for Air Emission Control
Particulates Gaseous pollutants
Air Emission Control
L5: GP TECHNIQUES / 19Asian Productivity Organization, Tokyo
DomesticEffluent
DomesticEffluent
ProcessEffluentProcessEffluent
Effluent fromUtilities (e.g.cooling etc.)
Effluent fromUtilities (e.g.cooling etc.)
Equalization / NeutralizationEqualization / Neutralization
ClariflocculationClariflocculation
Biological treatmentaerobic / anaerobicBiological treatmentaerobic / anaerobic
Tertiary treatmentTertiary treatment
Selective segregation forrecovery / detoxification Heat Recovery
Thickener /Filtration
Thickener /Filtration
DisposalDisposal
Returneffluent
For recycling
Degritting /screening andequalization
Optional
Optional
Wsatewater Management
L5: GP TECHNIQUES / 20Asian Productivity Organization, Tokyo
Industry sector: Food Processing ( dessicated coconut production)
Size: Medium scale
Push Factor: Serious environmental non- compliance due to very high levels ofBiological and Chemical Oxygen Demand (BOD and COD).
Measures: Utilization of 80,000 liters of wasted coconut water through a recoveryprocess to produce a commercial drink; improvement of operational practices.
Productivity benefits: Profitability due to new by-product; Increase in production ofdessicated coconut.
Economic benefits: Annual savings of US $ 370,000 due to increased production;treatment cost savings of US $ 3700 per year.
Environmental benefits: Regulatory compliance possible due to reduction ineffluent BOD by 50%.
Example of Wastewater ManagementPeter Paul Philippines Corporation, Philippines
L5: GP TECHNIQUES / 21Asian Productivity Organization, Tokyo
Product
Raw materials
Industrial ProcessesIndustrial Processes
Energy
ETP
AEC
Industrial Solid WasteIndustrial Solid Waste
ETP Sludge
APCSludge
Process Residuals / Still bottoms / sludge
Hazardous and non-hazardous
Non-process Solid Waste e.g. packaging
Process Liquid Waste
ProcessGaseousEmission
ETP Effluent Treatment PlantAPC Air Emission Control
Sources of Solid Waste Generation
Solid Waste Management
L5: GP TECHNIQUES / 22Asian Productivity Organization, Tokyo
Design for Environment
CONVENTIONAL PRODUCT DESIGN
DESIGN FOR ENVIRONMENT
Reduction in production cost
Achieve higher performance
Lower production costs through efficient resource
utilization
Improve product performance
Reduce environmental
impact
L5: GP TECHNIQUES / 23Asian Productivity Organization, Tokyo
New Concept DevelopmentDematerializationShared use of the productIntegration of functionsFunctional optimization of product components
Selection of Low impact MaterialsNon-hazardous materialsNon-exhaustible materialsLow energy content materialsRecycled materialsRecyclable materials
ReductionReduction in weightReduction in transport volume
Optimization of Production TechniquesAlternative production techniquesFewer production techniquesLow/clean energy consumptionLow generation of wasteFew/clean production consummables
Efficient DistributionSystemLess/clean packingEfficient transport modeEfficient logistics
Reduction of the EnvironmentalImpact in the User stageLow energy consumptionClean energy sourceFew consummables needed duringuseClean consumables during useNo energy / auxiliary materialwastage
- +
Optimize Initial LifetimeReliability and durabilityEasy maintenance and repairModular product structureClassic designUser taking care of product
Optimize End-of-Life systemReuse of productRemanufacturing / refurbishingRecycling of materialsClean incineration
Design for Environment Strategies
Design for Environment (DFE)
L5: GP TECHNIQUES / 24Asian Productivity Organization, Tokyo
Design for Environment - Illustration from SONY
Cabinet for a new line of speakers is made out of recycled tetrapak cartons; Better sound quality.
Reduced the number of materials used; Plastic parts marked with the symbol of plastic to assist recyclers in identifying the parts; Water based lacquers for finishing; Snap and slide connections to facilitateeasy disassembly; Only a small part of the TV cannot be recycled.
“take back” label part of every SONY monitor sold in Germany.
Take Back
DfE for TV sets
DfE for monitors
DfE for loudspeakercabinets
L5: GP TECHNIQUES / 25Asian Productivity Organization, Tokyo
Life-Cycle Assessment
Goal definition and ScopeGoal definition and Scope
Inventory analysisProcess flow chart; data collection; system boundary defined and data processing
Inventory analysisProcess flow chart; data collection; system boundary defined and data processing
Impact AssessmentClassification and characterization of effects of resource use; valuation
Impact AssessmentClassification and characterization of effects of resource use; valuation
Improvement AssessmentReporting; evaluation of the need and opportunities to reduce impact
Improvement AssessmentReporting; evaluation of the need and opportunities to reduce impact
L5: GP TECHNIQUES / 26Asian Productivity Organization, Tokyo
Life-Cycle Assessment - Illustration from Japan
Renewable reducedresources Base Materials UTILIZATION
Durable, repairableand necessary products
MANUFACTURINGusing clean technology
MINIMAL WASTE
Cycle1: Waste prevention, long life products
Cycle 2: Waste reduction, recycling of useful material
Establishment of the Life Cycle Assessment Society of Japan in 1995 with the support of the Keidanren and the Ministry of International Trade and Industry. Almost all industries have assisted in its activities.
The basic premise is that product design should take LCA and environmental advantage into account and life cycle engineering approach should be adopted to maintain sustainable development.
L5: GP TECHNIQUES / 27Asian Productivity Organization, Tokyo
Green Purchasing
GREENPURCHASING
Consideration of product cycle
Green Purchasing is at two levels
Procurement of safereco-friendly materials, technologyetc.by the producers
Consumers seeking ecofriendlyproducts
Three basic principles of Green Purchasing
Management policies and practices regardingGreen Purchasing
Availability of eco-related information to evaluate productsmanufacturers and distributors
L5: GP TECHNIQUES / 28Asian Productivity Organization, Tokyo
GP Techniques, Cost and Level of Effort
Costand
Levelof
Effort
Process and Equipment Change
GP Techniques
GP Techniques, Cost and Level of Efforts
Design for Environment
Input Material Changes
Resource Conservation
Recycle, Reuse and Recovery
Improved Operating Procedures
Housekeeping (5S) and 7 Wastes
Pollution Control