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Lean Sustainability
Creating Safe, Enduring, and Profitable Operations




ISBN 9781439857168
Published June 6, 2011 by Productivity Press
222 Pages - 68 B/W Illustrations

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Book Description

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
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
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

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Author(s)

Biography

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.