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OVERVIEW OF TOOLS & TECHNIQUES:
GREEN PRODUCTIVITY
R. C. Monga
2nd World Conference on Green Productivity10 December 2002
MANILA DECLARATION
ENVIRONMENT PROTECTION SHOULD BE
PROMOTED
WITHOUT SACRIFICING PRODUCTIVITY
GP Concept
The concept of GP is drawn from integration of two important developmental strategies
viz.
Productivity Improvement Environmental Protection
ProductivityPROVIDES THE FRAMEWORK FOR CONTINUOUS IMPROVEMENT.
Environmental Protection
PROVIDES THE FOUNDATION FOR SUSTAINABLE DEVELOPMENT.
SPECIAL FEATURES OF THE GREEN PRODUCTIVITY
CONCEPT
Green Productivity:
HOLISTIC
COMPLIANCE
INFORMATION
DRIVEN
CONTINUES
IMPROVEMENT
PREVENTIVE APPROACH
PEOPLEINTENSIVE
Top ManagementInvolvement
•VALUE FOR ALL STAKEHOLDERS•QUALITY OF PRODUCTS & PROCESSES
(INPUT, PROCESSES, OUTPUT
OWNERSCUSTOMER
SEMPLOYEE
SCOMMUNIT
YSUPPLIERS
Survival, Profits, Environment Compliance
Better & Cheaper ProductsWorking Conditions, Health &
SafetyQuality of Life, Less ResourcesEnvironmental Compliance,
Lower Costs
ENHANCES
GREEN PRODUCTIVITY
Methodology Integrates all these concepts for
SYSTEMATIC APPLICATION
SPECIAL FEATURES OF GREEN PRODUCTIVITY
Getting StartedGetting Started
PlanningPlanningPlanning
Generation and Evaluation
of GP Options
Generation andEvaluation ofGP Options
Generation andEvaluation ofGP Options
Sustaining GPSustaining GP
Monitoring and Review
Monitoring and Review
Implementation of GP Options
Implementation ofGP Options
Implementation ofGP Options
I
II
IIIIV
V
VI
Overview of GP Methodology
PLAN
DOCHECK
ACTION
PDCA CYCLE
PDCA CYCLE• PDCA cycle is the most basic principle
– Plan includes selection of area for improvement , analysis and goal setting & action plan
– DO INVOLVES EXECUTION
– CHECK MEANS RECONFIRMATION OF RESULTS
– ACT INVOLVES STANDARDIZATION
PDCA/SDCA CYCLE
A P
C D
A P
C D
A S
C D
A S
C D
STANDARDIZATION
KAIZEN
STANDARDIZATION
KAIZEN
IMPROVEMENT
GP Tools & Techniques
• DATA COMPILATION
• ANALYSIS & INTERPRETATION
• FINANCIAL IMPLICATIONS
• OPTIONS GENERATION
• IMPLEMENTATION
• VISUAL PRESENTATION
Tools facilitate Tools facilitate CAPTURING BASELINE INFORMATIONCAPTURING BASELINE INFORMATION
IDENTIFICATION OF PROBLEMS & CAUSESIDENTIFICATION OF PROBLEMS & CAUSESPRIORITIZATION OF PROBLEMSPRIORITIZATION OF PROBLEMS
SETTING TARGETS & OBJECTIVESSETTING TARGETS & OBJECTIVESGENERATION OF NEW IDEAS GENERATION OF NEW IDEAS
TechniquesTechniques HELP IN GENERATING OPTIONS
THESE ARE THE METHODS OF PERFORMANCE OR WORK IMPROVEMENT
APPLICABLE TO WASTE ,PROCESSES,
EQUIPMENT,MATERIAL, ENERGY,
PRODUCTS AND PEOPLE,
TASKS
1. Form a GP Team
2. Walk through survey & information collection
3. Identification of problems & causes
4. Setting Objectives & Targets
5. Generating GP Options
6. Screening & Evaluation of GP Options
7. Preparation of Implementation Plan
TOOLS & TECHNIQUES
STEP - I: GETTING STARTED
CHECKLISTS, TALLY CHARTSPLANT LAYOUT, FLOW CHARTS & PROCESS FLOW DIAGRAMSMATERIAL BALANCEBENCH MARKING,BRAINSTORMING, ATTRIBUTE ANALYSIS, RESPONSIBILITY ANALYSIS
STEP - II: PLANNING
BRAINSTORMINGCAUSE & EFFECT ANALYSISCRITICAL PATH ANALYSIS, GANTT CHARTFORCE FIELD ANALYSISECO – MAPPING
STEP - III: GENERATION & EVALUATION OF GP OPTIONS
BRAINSTORMINGCOST BENEFIT ANALYSISECO – MAPPINGFAILURE MODE & EFFECT ANALYSIS PARETO CHARTPROGRAMME EVALUATION REVIEW TECHNIQUE
8. Implementation of selected Options
9. Training, Awareness building & developing competence
10. Monitoring & Evaluation of Results
11. Management Review
12. Incorporate changes
13. Identify/additional problem areas for continuous improvement
STEP - IV: IMPLEMENTATION OF GP OPTIONS
TRAINING NEED ANALYSISTEAM BRIEFING RESPONSIBILITY MATRIXCRITICAL PATH ANALYSISGANTT CHARTSPIDERWEB DIAGRAMS
STEP - V: MONITORING & REVIEW
SOLUTION EFFECT ANALYSISECO – MAPPINGFAILURE MODE & EFFECT ANALYSISCHARTS (CONTROL, TALLY ETC.) / SPIDERWEB DIAGAM
STEP - VI: SUSAINING GP
SOME OF THE TOOLS ARE REPEATED HERE, SINCE THE ACTIVITIES ARE LOOPED BACK TO THE PREVIOUS STEPS
GP Techniques•Waste Prevention
1. Improved Operating Procedures
2. Waste Segregation 3. Good Housekeeping 4. 5S Program5. 7 Wastes
•RESOURCE CONSERVATION• RECYCLE, REUSE, & RECOVERY
•OFF/ON SITE RECYCLING
•PROCESS MODIFICATION•INPUT MATERIAL CHANGES•PROCESS/EQUIPMENT CHANGES
•PRODUCT IMPROVEMENT
•QUALITY IMPROVEMENT
•COST BENEFIT ANALYSIS
GP TechniquesGP Techniques, Cost and Level of Effort
Cost
and
Level
of
Effort
Process and Equipment Change
GP Techniques
GP Techniques, Cost and Level of Efforts
Design for Environment
Input Material Changes
Resource Conservation
Recycle, Reuse and Recovery
Improved Operating Procedures
Housekeeping (5S) and 7 Wastes
Pollution Control
1. Brainstorming
Idea 1
Supporting Idea 1
Extension to Idea 1
Opposing Idea 1
Idea 2
Idea 3 based on 1 and 2
Supporting Idea 3
Supporting Idea 3
Idea 4
2. Eco-maps
MC Panel
Buffing /Polishing
RawMaterialStoragesolutions,metal
Plating Section
Finished productstorageProposed ETP
Drain piping
Bad Practice
Bad Practice
Nodrains
Drains
High waterconsumption
Office
Spillage
Water
Solid waste
Energy
(to identify problem areas)
3. Material Balance
Inputs Process Outputs
Wastes
Raw materialsEnergyWaterChemicals
Air emissionsEffluentsSolid wasteHeat lossesOff-spec productsByproducts
Products,Useful byproducts
Steps in developing a Material Balance
1. Determining InputsRecording raw material procurement, water and energy usage, 2. Quantifying OutputsAccounting for wastewater, gaseous emissions, solid wastes, energy3. Selecting a Tie compound4. Preparing a preliminary material balance5. Evaluating and refining material balance
Preliminarymaterial balance
Refined material balance
OutputsInputs
4. Cause-Effect Analysis : Ishikawa (Fishbone) Diagram
SPIDER WEB ANALYSISSpider web Chart
0
20
40
60
8060% Water conservation
30% Minimisation of solidw aste
30% Reuse of process liquor
% Time taken
% target achieved
Thank you for your kind attention
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