1st Edition
Lean Sustainability Creating Safe, Enduring, and Profitable Operations
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 and 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.
Safety, Health, & Environmental (SHE) Pillar: Foundation of Lean Continuous Improvement
Beginnings of Lean & TPM
James Womack & Lean
TPM
The Safety, Health, & Environmental (SHE) Pillar
The Value of Safety, Health, & Environment
Zero Accident & Incident Vision
Strategy for Eliminating Accidents & Environmental Incidents
Autonomous SHE
Proactively Removing SHE Risk
Integrating the SHE Pillar with the Other Pillars
Preparation Phase: Laying the Foundation for SHE Excellence
Management Commitment & Living Leadership
Assessing Organizational Readiness
SHE Vision and Values
Zero Accident & Incident Education
SHE Loss Tree
SHE Governance: Form Follows Function
SHE Targets & the Balanced Scorecard
6 S (5S for SHE)
Lockout Tagout / Zero Energy State (LOTO/ZES)
Integrating SHE into the Autonomous Maintenance Pillar
AM Step 1: Initial Clean & SHE
AM Step 2: Countermeasures to Sources of Contamination & SHE
AM Step 3: Tentative AM & SHE
AM Step 4: General Inspections & SHE
AM Step 5: Autonomous Inspection & SHE
AM Step 6: Standardization & SHE
AM Step 7: All – Out AM Management & SHE
Integrating SHE, Planned Maintenance, & Early Management
Rationale Behind the Integration of Planned Maintenance and SHE
Safety Permit Systems
Planned Maintenance Support for AM & SHE
PM Safety Checklists
Early Management & SHE
Hazard and Operability Reviews
FEMA & Start-Up Checklists
30 -60-90 Day Reviews
Focused Improvement, Training & Education, and SHE
The Rationale behind Integrating Focused Improvement and SHE
SHE Kaizens
5S for SHE/6S: Condition-Based Kaizens
People-Centered Safety: Behavior-Based Kaizens
Integrating SHE into the Training and Education Pillar
Shu Ha Ri
One-Point Lessons (OPLs)
SHE Training Plan & the Kaizen Gym
SHE Pillar Activities
SHE & Lean
SHE Pillar Master Plan & SHE Management Systems
SHE Pillar Self-Assessment
SHE Control Charting
SHE Visual Mapping & Charting
SHE Pillar Activity Board
Lean & Green: Applying Lean to the Environment
Lean and Environmental Sustainability
The Lean & Green Sustainability Roadmap
Applying Value Stream Mapping to The Environment
Applying Visual Controls to the Environment
Lean & Energy
Biography
Dennis Averill
