Lean & Environment Toolkit: Content & Acknowledgments

• Table of Contents
  • Boxes
  • Figures
  • Tables
• Acknowledgements

Table of Contents

• Preface
• Chapter 1: Introduction: Getting Started with Lean & Environment
  • Purpose of this Toolkit
  • Why Use this Toolkit
  • Conclusion
• Chapter 2: Identifying Environmental Waste
  • Introduction to Identifying Environmental Wastes
  • How to "Learn to See" Environmental Waste in Your Organization
  • Conclusion
• Chapter 3: Value Stream Mapping
  • Introduction to Value Stream Mapping
  • How to Incorporate Environmental Considerations into Value Stream Mapping
  • Conclusion
• Chapter 4: Kaizen Events
  • Introduction to Kaizen Events
  • How to Establish a Lean and Environment Change Management System
  • How to Identify and Find Solutions for Lean and Environment Opportunities in Kaizen Events
  • Conclusion
• Chapter 5: 6S (5S + Safety)
  • Introduction to 6S
  • How to Identify EHS Issues During "Sort"
  • How to Incorporate EHS into 6S Inspections
  • Plant-Wide 6S Inspection Checklists and Audit Questions
  • Shine Checklists for Specific Work Areas
  • Conclusion
• Chapter 6: Conclusion and Implementation Strategy
  • Summary Key Point in the Toolkit
  • Toolkit Implementation Strategy
  • The Lean and Environment Journey
• Appendix A: Lean Methods
• Appendix B: Basic Environmental Measures for Lean Enterprises
• Appendix C: Lean Event EHS Checklist
• Appendix D: Pollution Prevention Resources
• Appendix E: 6S Safety Audit Checklist

Boxes

• Benefits of Coordinating Lean & Environment (Box 1)
• Business Case for Integrating Lean & Environment (Box 2)
• Case Study: Lockheed Martin Corporation (Box 3)
• Case Study: Apollo Hardwoods (Box 4)
• Case Study: Rejuvenation (Box 5)
• Types of Environmental Metrics (Box 6)
• Case Study: General Motors (Box 7)
• 10 Common Manufacturing Processes With Environmental Opportunities (Box 8)
• Case Study: Baxter International Healthcare Corporation (Box 9)
• Common Operational Changes That Trigger EHS Involvement (Box 10)
• Case Study: Goodrich Corporation (Box 11)
• Key Questions for Identifying Lean-Environment Opportunities (Box 12)
• Case Study: Robins Air Force Base (Box 13)
• 6S Implementation Tips (Box 14)
• Asking Why Five Times (Box 15)
• 6S Inspection and Audit Questions for Eliminating Environmental Waste and Risk (Box 16)
• Case Study: 3M Corporation (Box 17)
• Case Study: Canyon Creek (Box 18)

Figures

• Improved Lean & Environmental Performance (Figure 1)
• Sample EHS Icon (Figure 2)
• Current State VSM with Environmental Data (Figure 3)
• Example Materials Line Showing Materials Use Versus Need (Figure 4)
• Current State VSM with Materials Line (Figure 5)
• Current State Water Use VSM (Figure 6)
• Future State VSM with EHS Icons and Materials Line (Figure 7)
• Sample EHS Checklist (Figure 8)
• Drilling Down with Hierarchical Process Mapping (Figure 9)
• Process Step Description and Accounting Sheet Template (Figure 10)
• Process Step Description and Accounting Sheet Sample (Figure 11)
• The Six Pillars of 6S (Figure 12)
• Example Yellow Tag (Figure 13)

Tables

• Environmental Impacts of the Deadly Wastes (Table 1)

Acknowledgments

The U.S. Environmental Protection Agency is very grateful for the invaluable assistance of its partners in developing this toolkit. EPA’s partners shared their experiences, tools, and techniques for integrating Lean and environmental management, and worked collaboratively with EPA to develop, test, and refine the content of this toolkit.

EPA’s Lean and Environment partners include: Baxter International, Chicago Manufacturing Center, CONNSTEP, HNI Corporation, Robins Air Force Base, Rockwell Collins, and the U.S. Army Materiel Command. Participating Offices at EPA include: the National Center for Environmental Innovation; the Office of Pollution Prevention and Toxics; and the Office of Solid Waste.

In addition to these organizational partners, this toolkit has benefited from the collective expertise and ideas of many individuals. In particular, EPA would like to thank the following individuals for their thoughtful contributions:

• Pat Bartholomew of Baxter International
• Kate V. Bates of Earth Tech, Inc., working with Robins Air Force Base
• Dave Bury of Robins Air Force Base
• Jenni Cawein of Baxter International
• Angie Coyle of Delphi Corporation
• Rob Currie of Baxter International
• James Ellor of Elzly Technology Corporation, working with the U.S. Army Materiel Command
• Mike Fisher of Baxter International
• Vicki Fisher of Rockwell Collins
• Antonia Giardina of the U.S. Army Materiel Command
• Scott Lesnet of HNI Corporation
• Alistair Stewart of the Chicago Manufacturing Center
• Karen Wan of the Chicago Manufacturing Center
• Megan Wertz of The George Washington University
• Judy Wlodarczyk of CONNSTEP, Inc.

This toolkit was prepared for EPA with the assistance of Ross & Associates Environmental Consulting, Ltd. Ross & Associates worked under contract to Industrial Economics, Inc. (EPA Contract # EP-W-04-23).