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

<p>PREFACE xi</p>
<p>ACKNOWLEDGMENTS xv</p>
<p>1 MANUFACTURING 1</p>
<p>Introduction 1</p>
<p>Manufacturing Sequence 2</p>
<p>Product Life Cycles There s More Than One 3</p>
<p>Life Cycle Analysis 4</p>
<p>Potential for Waste and Value Added in Manufacturing 9</p>
<p>Vertically versus Horizontally Integrated Manufacturing 11</p>
<p>Waste and Its Unexpected Sources 13</p>
<p>The First Source of Waste 14</p>
<p>The Second Source of Waste 17</p>
<p>The Third Source of Waste 19</p>
<p>A New Product First Phase for Waste Reduction 20</p>
<p>Existing Products Second Phase for Waste Reduction 22</p>
<p>Regeneration 24</p>
<p>Life Cycle of the Manufacturing Facility 25&nbsp;</p>
<p>Creating a Classifi cation System for a Compliant and Profitable Manufacturing System 27</p>
<p>Summary 29</p>
<p>Selected Bibliography 31</p>
<p>2 BUILDING A DECISION–MAKING MODEL 33</p>
<p>Introduction 33</p>
<p>Industrial Production and Manufacturing 34</p>
<p>Classifying Manufacturing Industries 38</p>
<p>Major Product Groups from NAICS 40</p>
<p>Material Stocks 51</p>
<p>Major Material Families 52</p>
<p>Basic Process Classifi cations 53</p>
<p>Forming Processes 55</p>
<p>Separating Processes 56</p>
<p>Joining Processes 57</p>
<p>Conditioning Processes 58</p>
<p>Finishing Processes 59</p>
<p>Design Template for Classifying Manufacturing Processes 60</p>
<p>It All Began in Sally s Garden 60</p>
<p>The Analysis 62</p>
<p>Next Steps 67</p>
<p>Selected Bibliography 68</p>
<p>3 ENVIRONMENTAL REGULATIONS, STANDARDS, AND PROFITABILITY 69</p>
<p>Introduction 69</p>
<p>Organizing to Comply The Management Foundation 71</p>
<p>Formalizing the Management Approach The ISO Standards 73</p>
<p>ISO 14000 Series of Standards 74</p>
<p>Overview of Major Environmental Regulations 75</p>
<p>Clean Air Act Overview 77</p>
<p>Clean Water Act Overview 79</p>
<p>Solid and Hazardous Waste Management Overview 81</p>
<p>Summary Compliance Can Mean Profits 82</p>
<p>Selected Bibliography 84</p>
<p>4 CASE STUDIES 85</p>
<p>Introduction 85</p>
<p>Case Study 1 88</p>
<p>Introduction 88</p>
<p>Waste Minimization Programs 91</p>
<p>Reuse and Recycling Activities in the Office 92</p>
<p>Reduction and Reuse of Packaging 92</p>
<p>Comment 93</p>
<p>Case Study 2 93</p>
<p>Introduction 93</p>
<p>The Study and Methods Used 94</p>
<p>Conclusion 97</p>
<p>Comment 97</p>
<p>Case Study 3 98</p>
<p>Introduction 98</p>
<p>Description of the Manufacturing Operation 98</p>
<p>Manufacturing Operations and Sequence 99</p>
<p>Steps Taken to Lessen the Environmental Impact of the Manufacturing Facility 102</p>
<p>Material Waste Reduction 102</p>
<p>Resource Reduction 103</p>
<p>Methods the Company Uses to Identify and Make Improvements 104</p>
<p>Summary 105</p>
<p>Comment 106</p>
<p>Case Study 4 106</p>
<p>Introduction 107</p>
<p>Manufacturing Operations and Sequence 109</p>
<p>Steps Taken to Lessen the Environmental Impact of the Facility 111</p>
<p>Methods Used to Make Improvements 112</p>
<p>Examples of Waste Reduction 114</p>
<p>Comment 115</p>
<p>Case Study 5 115</p>
<p>Introduction 115</p>
<p>Singapore Packaging Agreement 117</p>
<p>The Three Rs Approach to Solid Waste Minimization 118</p>
<p>Comment 120</p>
<p>Conclusion 120</p>
<p>Selected Bibliography 121</p>
<p>5 AN OVERVIEW OF TOOLS USED TO IMPROVE MANUFACTURING OPERATIONS 123</p>
<p>Introduction 123</p>
<p>Waste Reduction: The Profi table and Compliant Process Chart A Collaborative Tool for Both Groups and All Functions 128</p>
<p>Training and Development 129</p>
<p>Operator Self–Control 129</p>
<p>Culture Change 130</p>
<p>Manufacturing Engineering and Operations 131</p>
<p>Lean Manufacturing 132</p>
<p>Kaizen 135</p>
<p>Pareto Principle 136</p>
<p>Process Control 136</p>
<p>Certifi ed Management Systems 137</p>
<p>Design of Experiments 137</p>
<p>Poka–Yoke 138</p>
<p>Finding the Root Cause of a Problem 139</p>
<p>Fishbone or Ishikawa Diagram 139</p>
<p>Situational Awareness 140</p>
<p>Product Design 142</p>
<p>Design for Assembly 142</p>
<p>Human Resources 143</p>
<p>The Life Cycle 143</p>
<p>A Just–in–Time Workforce 144</p>
<p>Summary 147</p>
<p>Selected Bibliography 148</p>
<p>6 THE FACILITY 149</p>
<p>Introduction 149</p>
<p>Making a Building That Can Be Regenerated 152</p>
<p>Plant Location 152</p>
<p>Sustainable Design 154</p>
<p>A Sustainable Building 157</p>
<p>Construction Sequence 159</p>
<p>Life Cycle and Life Cycle Cost Analysis 160</p>
<p>Cost Analysis Software 163</p>
<p>The eQUEST&reg; Program 164</p>
<p>The eVALUator Program 164</p>
<p>Building for Environmental and Economic Sustainability 166</p>
<p>Energy Star 167</p>
<p>Energy Management Program 169</p>
<p>Steps to Establish an Energy Management Program 170</p>
<p>International Standards for an Energy Management System 173</p>
<p>Leadership in Energy and Environmental Design 174&nbsp;</p>
<p>Summary 177</p>
<p>Selected Bibliography 178</p>
<p>7 APPLYING THE PROFITABLE AND COMPLIANT PROCESS CHART 181</p>
<p>Introduction 181</p>
<p>PCPC Worksheets 182</p>
<p>Using the Data Collection Worksheets 189</p>
<p>Step 1: Material Selection 189</p>
<p>Step 2: Process Identifi cation 190</p>
<p>Step 3: Outsourcing Manufacturing Processes 195</p>
<p>Summary 195</p>
<p>Industrial Applications of the PCPC 197</p>
<p>Application 1: Avionic Systems, Incorporated 198</p>
<p>Comment 198</p>
<p>Application 2: American Automotive Corporation 200</p>
<p>Comment 200</p>
<p>Application 3: NAVAC Logistics Center 202</p>
<p>Comment 202</p>
<p>Application 4: Custom Machine Builders 204</p>
<p>Comment 207</p>
<p>Observations 209</p>
<p>Constructing the Virtual PCPC 209</p>
<p>Conclusion 211</p>
<p>Selected Bibliography 212</p>
<p>GLOSSARY 213</p>
<p>INDEX 223</p>