Lean sustainability : creating safe, enduring, and profitable operations

212 Pages·2011·4.087 MB·English

by  Averill, Dennis

Lean Methods & Implementation
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The Japan Institute of Plant Maintenance defines safety as the maintenance of peace of v
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mind. Without peace of mind or serenity brought about by a safe working environment,
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employees will be unwilling and even unable to focus their energies on production i
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improvement. Thus, it can be said that all improvement begins with safety.
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.
The book is the result of the author’s two decades of experience implementing Lean;
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the Safety, Health, and Environmental (SHE) Pillar; and sustainability processes in the
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chemical, food, and consumer products industries. It unveils valuable lessons learned
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and little-known tips for eliminating waste and increasing process efficiency—while
reducing safety incidents and overall impact on the environment. N
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 S
and real-world advice, it introduces novel approaches for achieving safety and sustainability
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excellence, including
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• Autonomous Safety—supplying employees with the knowledge, skills,
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and motivation to work safely
• Triple Zero—the achievement of zero accidents, zero environmental incidents, A
and zero losses
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• Green Value Stream Mapping, the application of Value Stream Mapping N
to environmental and sustainability issues
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Although there are many books on Lean, sustainability, and SHE, few explain how to
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integrate these dynamic tools. Walking you through this process, this book supplies the
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tools to create a synergy that will boost efficiencies across all segments of your business.
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Follow its advice and you’ll be on your way to making your organization and employees
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more Lean, Green, and Serene.
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K12680
ISBN: 978-1-4398-5716-8
90000
www.crcpress.com
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K12680 cvr mech.indd 1 4/29/11 10:33 AM
Lean Sustainability
Creating Safe, Enduring,
and Profitable Operations

Lean Sustainability
Creating Safe, Enduring,
and Profitable Operations
Dennis Averill
CRC Press
Taylor & Francis Group
6000 Broken Sound Parkway NW, Suite 300
Boca Raton, FL 33487-2742
© 2011 by Taylor & Francis Group, LLC
CRC Press is an imprint of Taylor & Francis Group, an Informa business
No claim to original U.S. Government works
Version Date: 20110727
International Standard Book Number-13: 978-1-4398-9529-0 (eBook - PDF)
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To the giant, Ed Averill; it was only by
standing on his shoulders that I was able
to see farther and more clearly.

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