BDMA, Bharuch

Lean in Chemical & Process Industries

Nital Zaveri

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BDMA, Bharuch

Common Myths

1. Lean is for Automotive2. Lean is for Discrete Industries3. Lean is means productivity

improvement4. Lean is cost reduction 5. Lean is Less Employees Are

Needed6. Lean cannot work in regulatory

environment.

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Ideas to implement Lean in Process Ind.1. Drive out chemical waste with Lean Events

a. VSM Eventsb. Kaizen Events

2. Lean Chemical Management a. JIT and Chemical Management Services b. Right sizing c. Applying Lean to Waste Management d. POUSe. Visual Management

3. Stabilize Processes a. Daily Work Management b. AM

4. Designing Products and Process that use less hazards a. Green Chemistry b. Use 3P c. DFMA

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1. Drive out chemical waste with Lean Events

• A chemical factory was able to reduce amount of chemical on shop floor by 30% with Kanban and Lean Inventory Management.

• Process industry was able to reduce use of Hazardous waste by 20% due to lean waste walk.

• Reduction of chemical storage space from 64,000 square feet to 1,200 square feet through 6S (5S + Safety)

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BDMA, Bharuch

Comparison of Tools applicable to Process Ind

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6S *****Kaizen *****Visual Management *****Kanban **VSM ***Poka Yoke *****Standardization *****TPM *****Why-Why / RCA *****Gemba Boards *****JIT **Right Sizing ***Line Balancing NACell Manufacturing NA

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“Toxics Team” conducted a value stream mapping workshop and three kaizen events on the finishing department, where products are stained and coated.

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• The Team analyzed environmental wastes alongside other production wastes, and implemented process changes that improved process efficiency, cut costs, and reduced wastes.

• Reduced hazardous substances used by 68,700 lbs per year by installing dedicated pumps for each solvent-based stain color.

• Decreased hazardous wastes by 84,400 lbs per year by reducing wastes from changeover of aqueous and solvent-based stains.

• Cut volatile organic compound (VOC) emissions by 55,100 lbs per year, primarily by employing a new unicoat product to replace the existing sealant and topcoat. These changes allowed the facility to increase production capacity up to 70 percent.

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Right Sizing

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Point-of-Use Storage

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6S (5S + Safety)

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Visual Controls, Standard Work and Chemical Management

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Total Productive Maintenance and Chemical Management

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