Improving Profitability Through Green Manufacturing

Manufacturers can be green and highly profitable at the same timeProfits do not have to be sacrificed to environmental responsibility, or vice versa. Following this book's tested and proven approach, readers discover how to create and operate manufacturing facilities that are highly profitable while meeting or exceeding the environmental standards of their local community, state, and federal governments. The authors' approach is broad in scope, setting forth the roles and responsibilities of organizational functions such as marketing, product design, manufacturing technology, management, and human resources.The book begins with an overview explaining why profitability and green manufacturing must be viewed as a single objective.Next, the book becomes a "how to" guide to creating and maintaining an environmentally compliant and profitable manufacturing operation, with chapters covering:* Manufacturing, waste, and regeneration* Building a decision-making model* Environmental regulation, standards, and profitability* Case studies* Tools used to improve manufacturing operations* The facility* Applying the profitable and compliant process chartThe final chapter is dedicated to a step-by-step approach in the application and use of the profitable and compliant process chart, a core working tool discussed in the book. In this chapter, several actual manufacturing applications, along with their worksheets, are presented to illustrate how this approach can minimize resources and waste. Armed with this comprehensive systems approach, readers will no longer view profitability and green manufacturing as two opposing goals. Instead, they'll have the tools and knowledge needed to create and maintain a manufacturing operation that is both profitable and green.

PREFACE xiACKNOWLEDGMENTS xv1 MANUFACTURING 1Introduction 1Manufacturing Sequence 2Product Life Cycles--There's More Than One 3Life Cycle Analysis 4Potential for Waste and Value Added in Manufacturing 9Vertically versus Horizontally Integrated Manufacturing 11Waste and Its Unexpected Sources 13The First Source of Waste 14The Second Source of Waste 17The Third Source of Waste 19A New Product--First Phase for Waste Reduction 20Existing Products--Second Phase for Waste Reduction 22Regeneration 24Life Cycle of the Manufacturing Facility 25Creating a Classifi cation System for a Compliant and Profitable Manufacturing System 27Summary 29Selected Bibliography 312 BUILDING A DECISION-MAKING MODEL 33Introduction 33Industrial Production and Manufacturing 34Classifying Manufacturing Industries 38Major Product Groups from NAICS 40Material Stocks 51Major Material Families 52Basic Process Classifi cations 53Forming Processes 55Separating Processes 56Joining Processes 57Conditioning Processes 58Finishing Processes 59Design Template for Classifying Manufacturing Processes 60It All Began in Sally's Garden 60The Analysis 62Next Steps 67Selected Bibliography 683 ENVIRONMENTAL REGULATIONS, STANDARDS, AND PROFITABILITY 69Introduction 69Organizing to Comply--The Management Foundation 71Formalizing the Management Approach--The ISO Standards 73ISO 14000 Series of Standards 74Overview of Major Environmental Regulations 75Clean Air Act Overview 77Clean Water Act Overview 79Solid and Hazardous Waste Management Overview 81Summary--Compliance Can Mean Profits 82Selected Bibliography 844 CASE STUDIES 85Introduction 85Case Study 1 88Introduction 88Waste Minimization Programs 91Reuse and Recycling Activities in the Office 92Reduction and Reuse of Packaging 92Comment 93Case Study 2 93Introduction 93The Study and Methods Used 94Conclusion 97Comment 97Case Study 3 98Introduction 98Description of the Manufacturing Operation 98Manufacturing Operations and Sequence 99Steps Taken to Lessen the Environmental Impact of the Manufacturing Facility 102Material Waste Reduction 102Resource Reduction 103Methods the Company Uses to Identify and Make Improvements 104Summary 105Comment 106Case Study 4 106Introduction 107Manufacturing Operations and Sequence 109Steps Taken to Lessen the Environmental Impact of the Facility 111Methods Used to Make Improvements 112Examples of Waste Reduction 114Comment 115Case Study 5 115Introduction 115Singapore Packaging Agreement 117The "Three Rs" Approach to Solid Waste Minimization 118Comment 120Conclusion 120Selected Bibliography 1215 AN OVERVIEW OF TOOLS USED TO IMPROVE MANUFACTURING OPERATIONS 123Introduction 123Waste Reduction: The Profi table and Compliant Process Chart--A Collaborative Tool for Both Groups and All Functions 128Training and Development 129Operator Self-Control 129Culture Change 130Manufacturing Engineering and Operations 131Lean Manufacturing 132Kaizen 135Pareto Principle 136Process Control 136Certifi ed Management Systems 137Design of Experiments 137Poka-Yoke 138Finding the Root Cause of a Problem 139Fishbone or Ishikawa Diagram 139Situational Awareness 140Product Design 142Design for Assembly 142Human Resources 143The Life Cycle 143A Just-in-Time Workforce 144Summary 147Selected Bibliography 1486 THE FACILITY 149Introduction 149Making a Building That Can Be Regenerated 152Plant Location 152Sustainable Design 154A Sustainable Building 157Construction Sequence 159Life Cycle and Life Cycle Cost Analysis 160Cost Analysis Software 163The eQUEST(r) Program 164The eVALUator Program 164Building for Environmental and Economic Sustainability 166Energy Star 167Energy Management Program 169Steps to Establish an Energy Management Program 170International Standards for an Energy Management System 173Leadership in Energy and Environmental Design 174Summary 177Selected Bibliography 1787 APPLYING THE PROFITABLE AND COMPLIANT PROCESS CHART 181Introduction 181PCPC Worksheets 182Using the Data Collection Worksheets 189Step 1: Material Selection 189Step 2: Process Identifi cation 190Step 3: Outsourcing Manufacturing Processes 195Summary 195Industrial Applications of the PCPC 197Application 1: Avionic Systems, Incorporated 198Comment 198Application 2: American Automotive Corporation 200Comment 200Application 3: NAVAC Logistics Center 202Comment 202Application 4: Custom Machine Builders 204Comment 207Observations 209Constructing the Virtual PCPC 209Conclusion 211Selected Bibliography 212GLOSSARY 213INDEX 223