1st Edition

Lean Sustainability Creating Safe, Enduring, and Profitable Operations

By Dennis Averill Copyright 2011
    222 Pages 68 B/W Illustrations
    by Productivity Press

    222 Pages
    by Productivity Press

    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
    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


    Dennis Averill