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