The Green Factory : Creating Lean and Sustainable Manufacturing book cover
1st Edition

The Green Factory
Creating Lean and Sustainable Manufacturing

ISBN 9781498707855
Published August 22, 2015 by Productivity Press
192 Pages 30 B/W Illustrations

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Book Description

This book proposes a new model, the Lean and Green Business Model (L&GBM), where the environmental aspect of sustainability is integrated with Lean thinking in order to create a way of thinking that contributes to and balances the three sustainability dimensions of people, profit, and planet. The model presented uses a kaizen approach that will help readers improve mass and energy flows in manufacturing environments that already possess a deployment level in applying Lean.

The Green Factory: Creating Lean and Sustainable Manufacturing tells the story of how GKN, a major British multinational corporation with operations in more than 30 countries, developed and implemented a Lean and Green Business Model in two of its automotive facilities in Brazil. It provides practical insight into how GKN was able to develop and deploy Lean and Green in a manner that resulted in environmental and cost benefits in the automotive facilities that operated in Brazil’s high-inflation environment.

Detailing proven concepts and sustainable models derived from the first-hand experiences, the book supplies information against the backdrop of GKN’s automotive manufacturing environment. The authors take an inside-out approach, describing the real issues Environmental Health & Safety professionals face when implementing sustainable manufacturing policies.

The book covers the corporate issues of balancing profit with environmental concern and the behavioral issues of engaging the workforce to identify and reduce environmental waste. All the concepts and models presented in the book have come about through the authors’ real life experiences in live kaizen events as well as their extensive academic research in the subject area.

Table of Contents

Foreword by John Bicheno
Foreword by Robert W. "Doc" Hall
Prologue: A New Way of Thinking

Introduction to the Lean and Green Business Model Concept behind the Model
Inputs from Operations Management
Power of Lean Production
Four Dimensions of a Lean Enterprise
Sustainable Development and "Green" Thinking
Connecting the Concepts: Operations, Lean, Green, and Sustainability
How Lean and Green Thinking Can Be Combined into One Conceptual Business Model
Analysis of Lean and Green through Operations Lenses
Analysis of Lean and Green Taking a Sustainability Perspective
Analysis of Green Taking a Lean Perspective
Analysis of Lean Taking a Green Perspective
Understanding the Connections

Lean and Green Business Model and Operational Implementation
Purpose of the L&GBM
Principles of the L&GBM
Ways of Working of the L&GBM
L&GBM Is Different from Pure Lean and Green Thinking
Consolidating the L&GBM
Understanding the L&GBM Kaizens
L&GBM for a Cell
Pilot Testing: L&GBM for a Cell
Rollout the L&GBM for a Cell

L&GBM for Sister Cells
Applying the L&GBM to Sister Cells
L&GBM for a Value Stream
Applying the L&GBM to a Value Stream
Reverse Testing: Applying the L&GBM to a Cell in Different Manufacturing Environments
L&GBM Ways to Save Mass and Energy

Lean and Green Business Model Strategic Implementation
Key Lessons from Implementation
Positioning the L&GBM
Confirming L&GBM Key Characteristics: Identifying Preconditions for Success
20 Questions and 20 Answers for the L&GBM


Andrea’s Real-Life Story behind the Research and the Book
The Beginning
Year One
Year Two
Year Three: The End

Glossary of Terms



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Dr. Andrea Pampanelli has more than 15 years of environmental and 5 years of Lean experience working for GKN Driveline. During her career in GKN, Dr. Pampanelli developed more than 100 EHS & Lean research projects applied to GKN in partnership with Brazilian local universities and won more than 15 excellence awards from GKN Driveline, GKN Group, and OEM customers. She has a bachelor’s degree in chemical engineering, an MBA in environmental management, a master’s degree in production engineering from UFRGS in Brazil, and a specialization degree in safety engineering by Unisinos in Brazil.

Neil Trivedi is a highly experienced strategy and transformation consultant and qualified Lean expert, with broad experience across global platforms within the automotive, aerospace, food, FMCG, transportation, biomedical, and public sectors. He has been instrumental in helping organizations improve their performance by collaboratively tackling complex business problems and in designing and implementing solutions that demonstrate tangible benefits to businesses.

Dr. Pauline Found is a course director for MSc in continuous improvement in public services and a senior lecturer in Lean operations at the University of Buckingham. She was previously senior research fellow of the Lean Enterprise Research Centre (LERC) at Cardiff University, where she worked for nine years and was involved in a range of research, knowledge transfer, and engagement and executive education projects and initiatives, as well as writing books and papers on Lean. She is coauthor of Staying Lean: Thriving Not Just Surviving, for which she holds a Shingo Research and Professional Publication Prize (2009).


"In this book, the authors add a great deal of experiential insight into a subject that should be attracting much more attention—the merging of Lean process improvement with environmental process improvement. ... A strength of this book is that it characterizes failed and mediocre projects as well as the kind that proponents like to toot."
—Robert. W. "Doc" Hall, Chairman, Compression Institute; Professor Emeritus, Indiana University, Bloomington, USA

"The book extends the ‘adjacent possible’ of Lean and Green to develop the Lean and Green Business Model, taking as it does the best from ‘planet, people, and profit’ and showing the application at cell, factory, and ‘extended product’ areas. Of particular importance is the eminently practical guidance material on how to do kaizen activities in such areas. Extending the already great value of the book, the authors have gone further to include key implementation lessons, and an extremely valuable section on preconditions for success."
—John Bicheno, MSc Lean Enterprise Course Director, Buckingham Lean Enterprise Unit, University of Buckingham

"A very useful hands-on, ground-up methodology for addressing Lean and Green issues in your operations. Well worth doing."
—Daniel T. Jones, Chairman, Lean Enterprise Academy, UK