Lean sustainability : creating safe, enduring, and profitable operations

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Title:

Personal Author:

Averill, Dennis.

Publication Information:

Boca Raton, FL : CRC Press, c2011.

Physical Description:

xv, 206 p. : ill. ; 26 cm.

ISBN:

9781439857168

Subject Term:

Lean manufacturing.

Industrial safety.

Industrial hygiene.

Industrial management -- Environmental aspects.

The Japan Institute of Plant Maintenance defines safety as the maintenance of peace of mind. Without peace of mind, or the serenity brought about by a safe working environment, employees will be unwilling and even unable to focus their energies on production improvement. Thus, it can be said that all improvement begins with safety.

Winner of a 2013 Shingo Research and Professional Publication Award!

A how-to manual on the proper integration of safety and environmental sustainability with Lean implementations, Lean Sustainability: Creating Safe, Enduring, and Profitable Operations provides a proven recipe for achieving safety and sustainability excellence. This book is the result of the author's two decades of experience implementing Lean; Safety, Health, and Environmental (SHE); and sustainability processes in the chemical, food, and consumer products industries. It unveils valuable lessons learned and little-known tips for eliminating waste and increasing process efficiency--while reducing safety incidents andnbsp;the overall impact on the environment.

The text illustrates how to use the SHE Pillar as a gateway to continuous improvement, regardless of the improvement methodology you use. Bolstered with proven methodologies and real-world advice, it introduces novel approaches for achieving safety and sustainability excellence, including:

Autonomous Safety--supplying employees with the knowledge, skills, and motivation to work safely Triple Zero--the achievement of zero accidents, zero environmental incidents, and zero losses Green Value Stream Mapping--the application of Value Stream Mapping to environmental and sustainability issues

Although there are many books on Lean, sustainability, and SHE, few explain how to integrate these dynamic tools. Walking you through this process, this book supplies the tools to create a synergy that will boost efficiencies across all segments of your business. Follow its advice and you'll be on your way to making your organization and employees Lean, green, and serene.

Author Notes

Dennis Averill CIH, CSP has over 25 years of management experience in the chemical, food, and consumer products industries leading corporate programs in the area of Safety, Health & Environment (SHE), Quality, and Manufacturing Improvement (Lean & TPM).

Mr. Averill was a Phi Beta Kappa, Bachelor of Science graduate of the University of Richmond. He has also earned Master of Health Science (Dept. Environmental Health Engineering) and Master of Administrative Science (Business Management) degrees from the Johns Hopkins University where he has served as an Associate of the Johns Hopkins Bloomberg School of Public Health. He is a Certified Industrial Hygienist (CIH), a Certified Safety Professional (CSP), and a Certified TPM Instructor.

He has lent his time and talents to various professional and community groups serving as; President of the American Industrial Hygiene Association Chesapeake Section, Vice President of the Community Coalition of Harford County, member of the Harford County Emergency Planning Committee, industry representative on the Maryland Governor's Council on Toxic Substances, and member of the American Society of Safety Engineers Management Specialty Practice Group.

Mr. Averill was born and raised in New York City and now lives in Bel Air, Maryland with his wife, two children, and two dogs.

Preface	p. xi
Acknowledgments	p. xiii
About the Author	p. xv
1 Safety, Health, and Environmental (SHE) Pillar: Foundation of Lean Continuous Improvement	p. 1
1.1 Beginnings of Lean and TPM	p. 1
1.2 James Womack and Lean	p. 3
1.3 TPM	p. 4
1.4 The Safety, Health, and Environmental (SHE) Pillar	p. 6
1.5 The Value of Safety, Health, and Environment	p. 10
1.6 Zero Accident and Incident Vision	p. 14
1.7 Strategy for Eliminating Accidents and Environmental Incidents	p. 16
Endnotes	p. 20
2 Autonomous SHE	p. 23
2.1 The Path toward Autonomous Safety/Autonomous SHE	p. 23
2.2 Proactively Removing SHE Risk	p. 31
2.3 Integrating the SHE Pillar with the Other Pillars	p. 33
Endnotes	p. 34
3 Preparation Phase: Laying the Foundation for SHE Excellence	p. 35
3.1 Management Commitment and Living Leadership	p. 35
3.2 Assessing Organizational Readiness	p. 39
3.3 SHE Vision and Values	p. 41
3.4 Zero Accident and Incident Education	p. 43
3.5 SHE Loss Tree	p. 46
3.6 SHE Governance: Form Follows Function	p. 49
3.7 SHE Targets and the Balanced Scorecard	p. 51
3.8 6S (5S for SHE)	p. 54
3.9 Lockout/Tagout and Zero Energy State (LOTO and ZES)	p. 62
Endnotes	p. 64
4 Integrating SHE into the Autonomous Maintenance Pillar	p. 67
4.1 Overview of the Integration of Autonomous Maintenance and SHE	p. 67
4.2 AM Step 1: Initial Cleaning and SHE	p. 68
4.2.1 Danger Anticipation and Experiential Training	p. 70
4.2.2 SHE F-Tags	p. 72
4.2.2.1 One-Point Lessons (OPLs)	p. 73
4.2.3 Incorporating Safety into Cleaning and Inspection Plans	p. 73
4.3 AM Step 2: Countermeasures to Sources of Contamination and SHE	p. 76
4.3.1 Elimination of Sources of Leaks, Spills, and Dust	p. 76
4.3.2 Elimination of Hard-to-Access Areas	p. 76
4.3.3 Zero Leak and Spill Campaign	p. 77
4.4 AM Step 3: Tentative AM and SHE	p. 78
4.4.1 Including SHE in Provisional Standards	p. 78
4.4.2 Use of SHE Visual Indicators and Controls	p. 78
4.4.3 Pointing and Naming Drills	p. 96
4.5 AM Step 4: General Inspections and SHE	p. 96
4.5.1 Incorporating Real-Life Safety Examples into AM Training	p. 97
4.6 AM Step 5: Autonomous Inspection and SHE	p. 97
4.6.1 S Points (Safety or SHE Points)	p. 98
4.6.2 SHE Mistake-Proofing or Poka Yoke	p. 99
4.7 AM Step 6: Standardization and SHE	p. 99
4.7.1 SHE Standards	p. 100
4.7.2 Zero Accident and Zero Incident Lines	p. 100
4.8 AM Step 7: All-Out AM Management and SHE	p. 100
4.8.1 Comprehensive SHE Inspection and Auditing	p. 100
Endnotes	p. 103
5 Integrating SHE, Planned Maintenance, and Early Management	p. 105
5.1 Rationale behind the Integration of Planned Maintenance and SHE	p. 105
5.2 Safety Permit Systems	p. 106
5.3 Planned Maintenance Support for AM and SHE	p. 107
5.4 PM Safety Checklists	p. 110
5.5 Early Management and SHE	p. 111
5.6 Hazard and Operability Reviews	p. 111
5.7 FMEA and Start-Up Checklists	p. 112
5.8 30-60-90 Day Reviews	p. 116
Endnotes	p. 116
6 Focused Improvement, Training and Education, and SHE	p. 117
6.1 Rationale behind Integrating Focused Improvement and SHE	p. 117
6.2 SHE Kaizens	p. 118
6.3 5S for SHE/6S: Condition-Based Kaizens	p. 122
6.4 People-Centered Safety Behavior-Based Kaizens	p. 123
6.5 Integrating SHE into the Training and Education Pillar	p. 125
6.6 Shu Ha Ri	p. 125
6.7 One-Point Lessons (OPLs)	p. 127
6.8 SHE Training Plan and Kaizen Gym	p. 128
Endnotes	p. 134
7 SHE Pillar Activities	p. 135
7.1 SHE and Lean	p. 135
7.2 SHE Pillar Master Plan and SHE Management Systems	p. 136
7.3 SHE Pillar Self-Assessment	p. 145
7.4 SHE Control Charting	p. 148
7.5 SHE Visual Mapping and Charting	p. 154
7.5.1 Dot Distribution Mapping	p. 154
7.5.2 Body Mapping	p. 154
7.5.3 Fishbone Mapping	p. 156
7.5.4 Discharge Mapping	p. 158
7.5.5 Process Flow Mapping	p. 159
7.5.6 Contour Mapping	p. 160
7.6 SHE Pillar Activity Board	p. 162
Endnotes	p. 165
8 Lean and Green: Applying Lean to the Environment	p. 167
8.1 Lean and Environmental Sustainability	p. 167
8.2 The Lean and Green Sustainability Roadmap	p. 172
8.2.1 Phase 1: Recognize	p. 173
8.2.2 Phase 2: Visualize	p. 174
8.2.3 Phase 3: Organize	p. 174
8.2.4 Phase 4: Strategize	p. 175
8.2.5 Phase 5: Conceptualize	p. 175
8.2.6 Phase 6: Prioritize	p. 175
8.2.7 Phase 7: Operationalize	p. 176
8.2.8 Phase 8: Synthesize	p. 176
8.2.9 Phase 9: Integrate	p. 176
8.2.10 Phase 10: Synergize	p. 177
8.3 Applying Value Stream Mapping to the Environment	p. 177
8.4 Applying Visual Controls to the Environment	p. 181
8.5 Lean and Energy	p. 182
Endnotes	p. 185
Bibliography	p. 187
Index	p. 195

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