Lean Sustainability: Creating Safe, Enduring, and Profitable Operations, 1st Edition (Paperback) book cover

Lean Sustainability

Creating Safe, Enduring, and Profitable Operations, 1st Edition

By Dennis Averill

Productivity Press

222 pages | 68 B/W Illus.

Shingo Award Winner
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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.

Table of Contents

Safety, Health, & Environmental (SHE) Pillar: Foundation of Lean Continuous Improvement

Beginnings of Lean & TPM

James Womack & Lean


The Safety, Health, & Environmental (SHE) Pillar

The Value of Safety, Health, & Environment

Zero Accident & Incident Vision

Strategy for Eliminating Accidents & Environmental Incidents

Autonomous SHE

The Path Towards Autonomous Safety / 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

Overview of the Integration of Autonomous Maintenance and SHE

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

About the Author

Dennis Averill CIH, CSP has over 25 years of management experience in the chemical, food, and consumer products industries leading corporate programs in the area of Safety, Health & Environment (SHE), Quality, and Manufacturing Improvement (Lean & TPM).

Mr. Averill was a Phi Beta Kappa, Bachelor of Science graduate of the University of Richmond. He has also earned Master of Health Science (Dept. Environmental Health Engineering) and Master of Administrative Science (Business Management) degrees from the Johns Hopkins University where he has served as an Associate of the Johns Hopkins Bloomberg School of Public Health. He is a Certified Industrial Hygienist (CIH), a Certified Safety Professional (CSP), and a Certified TPM Instructor.

He has lent his time and talents to various professional and community groups serving as; President of the American Industrial Hygiene Association Chesapeake Section, Vice President of the Community Coalition of Harford County, member of the Harford County Emergency Planning Committee, industry representative on the Maryland Governor’s Council on Toxic Substances, and member of the American Society of Safety Engineers Management Specialty Practice Group.

Mr. Averill was born and raised in New York City and now lives in Bel Air, Maryland with his wife, two children, and two dogs.

Subject Categories

BISAC Subject Codes/Headings:
BUSINESS & ECONOMICS / Quality Control
BUSINESS & ECONOMICS / Industries / Manufacturing Industries
TECHNOLOGY & ENGINEERING / Industrial Health & Safety