Haynes Lean Six Sigma Program

Mark Comerford, President and CEO of Haynes International, discusses the company's results and highlights its Lean Six Sigma program which is focused on delivering operational efficiency. Haynes improvement culture extends to the environmental discipline where its has driven energy cost savings. ...

... "We’ve also expanded the use of key metrics across our business focusing on cost reduction initiatives and extending our Lean and Six Sigma programs. During the year, we were also nominated for the 2009 Indiana Governor’s Award for Environmental Excellence, and we were recognized by Indiana Lieutenant Governor Becky Skillman, for environmental stewardship. Furthermore, working with Purdue University and US Department of Energy, we’ve taken on initiatives in our plants, which we estimate will result in savings of approximately $300,000 in annual energy costs. " ...

Via Seeking Alpha: Haynes International Earnings

More on the Haynes and Purdue collaboration ...

Purdue Manufacturing Extension Partnership project with Haynes International: "Haynes implemented a five-person Energy Savings Team to identify and implement energy savings projects ... Haynes expects to see natural gas cost savings of nearly $360,000 annually upon the completion of all the EES projects. "

Walmart Product ecoRatings Initiative for Manufacturers

Walmart suppliers will be required to provide eco information on products so that an eco-rating can be created for consumers. ...

... "WalMart's demand in recent years that suppliers reduce their packaging to reduce their environmental impact has rippled throughout the retail and manufacturing industries. " ...

Via Associated Press: WalMart product eco-ratings

Xerox Brazil uses Lean Six Sigma to Reduce Landfill Waste

Xerox recognizes its employees with Earth Awards for achievements in reducing waste, energy, and costs. The various teams and manufacturing sites targeted waste through process improvements, capital investments, and optimizations. ...

... "Rio, Brazil: This team established a goal of 20 percent reduction in waste generated and in doing so eliminated more than 10 tons of toner waste from landfills with the help of Lean Six Sigma. Things like one-time use cloths were replaced with washable cloths. Metal barrels were replaced with reusable bags and toner was used as product for roadways. They even composted cafeteria waste for use onsite. " ...

Via Xerox: Earth Awards Create Business Results

Kodak Lean Process Drives Environmental Performance and Beyond

Eastman Kodak resets its three-year Sustainability Goals, as its adoption of lean principles have accelerated the company's performance to date. ...

... "The prevention of 1.1 million metric tons of carbon dioxide emissions since 2002, the equivalent of taking more than 190,000 cars off the road, is a hallmark of Kodak’s progress. A portion of this progress is attributable to Kodak’s digital transformation. However, roughly half of the overall progress is the result of applying the principles of lean manufacturing and process design, as well investments in energy-efficient equipment. " ...

Via Kodak: New Worldwide Sustainability Goals

Kodak lean focuses on energy via 2007 Sustainability Report (PDF): "Continued the use of multi-disciplinary employee teams and lean manufacturing methodology to aggressively improve energy efficiency. "

Kodak reduced its methylene chloride emissions via 2006 Sustainability Report (PDF): "Efficiency gains included application of lean manufacturing techniques, changes in air handling systems and procedural improvements. "

In 2005, Kodak exceeded its 2008 environmental goals via 2007 Kodak Park Environmental Annual Report (PDF): "Kodak 2008 Health Safety and Environmental (HSE) goals surpassed through efficiency gains from lean manufacturing practices, improved emission controls, and significant reductions of manufacturing assets. "

Kodak is recognized for its contributions by the US EPA. ...

Lean Manufacturing and the Environment via US EPA: "EPA’s Lean and energy partners include Baxter International, California Manufacturing Technology Consulting (CMTC), Eastman Kodak Corporation, Eaton Corporation, General Electric (GE) ... "

Lean kaizen is used to identify improvement opportunities. ...

The Lean and Energy Toolkit techniques via US EPA: "Eastman Kodak Company conducted energy kaizen events that significantly reduced energy use and resulted in overall savings of $15 million between 1999 and 2006. "

Kodak's lean methods have been implemented globally across its manufacturing footprint. ...

Printing Plate Manufacturing Facility in Xiamen, China: "The team in Xiamen is experienced and highly qualified. Many of our employees come from Kodak’s other operations in Xiamen. They are skilled in the process manufacturing required for high quality plate production, as well as in Kodak’s quality standards and LEAN manufacturing practices. "

Kodak makes the case for lean business process workflow in the print industry. ...

Lean Graphic Arts Business (PDF): "With a track record of success at non-graphic arts customers, the Kodak Operating System has recently been implemented at two print providers with very promising results ... "

Six Sigma Environmental Performance

What role can lean and Six Sigma play in the environmental process? Lower variability and effective processes can prevent real waste that must be disposed of. ...

... "By removing variation from production processes, fewer defects inherently result. A reduction in defects can, in turn, help eliminate waste from processes in three fundamental ways: (1) fewer defects decreases the number of products that must be scrapped; (2) fewer defects also means that the raw materials, energy, and resulting waste associated with the scrap are eliminated; (3) fewer defects decreases the amount of energy, raw material, and wastes that are used or generated to fix defective products that can be re-worked. " ...

Via EPA: Lean and the Environment

Bluefinder Manufacturing Design

Environmental-Friendly Lean Manufacturing

Experts see synergy between lean manufacturing and environmental stewardship. And, the EPA agrees. ...

... "Environmental concerns are a part of the lean concept. Emissions to air and water, as well as the generation of solid/hazardous waste, represent a waste of production " ...

Via GreenBiz: Lean Manufacturing Environmental Impact