Improving Profitability Through Green Manufacturing

"I highly recommend the holistic and knowledge building book Improving Profitability Through Green Manufacturing: Creating a Profitable and Environmentally Compliant Manufacturing Facility by David R. Hillis, Ph.D. and J. Barry DuVall, Ph.D., to any business leaders, manufacturers, design specialists, building and plant builders, public policy makers, environmental groups, practicing engineers, engineering and manufacturing students, elected officials, and anyone interested in green manufacturing who are seeking a clear and concise road map to establishing and maintaining a complete system that is profitable and environmentally sustainable. This book will change your mind forever about profit and the environment as green manufacturing works for both goals." (Money Talks, 4 November 2012) "I highly recommend the holistic and knowledge building book Improving Profitability Through Green Manufacturing: Creating a Profitable and Environmentally Compliant Manufacturing Facility by David R. Hillis, Ph.D. and J. Barry DuVall, Ph.D., to any business leaders, manufacturers, design specialists, building and plant builders, public policy makers, environmental groups, practicing engineers, engineering and manufacturing students, elected officials, and anyone interested in green manufacturing who are seeking a clear and concise road map to establishing and maintaining a complete system that is profitable and environmentally sustainable. This book will change your mind forever about profit and the environment as green manufacturing works for both goals." (Blog Business World, 4 November 2012)

DAVID R. HILLIS, PhD, has more than thirty-five years of experience in academia and private industry. Currently he is an independent consultant who works with manufacturers to maximize productivity and minimize waste. Hillis is coauthor of Manufacturing Processes: Materials, Productivity, and Lean Strategies; Manufacturing Processes: Automation, Materials, and Packaging; and Waste Reduction Strategies for Fiberglass Fabricators. J. BARRY DuVALL, PhD, has more than forty years of experience in industry and academia. He is currently a full Professor in the Department of Technology Systems at East Carolina University. He has taught courses in many areas including productivity improvement, manufacturing processes and materials, digital communication, and technology management. Dr. DuVall is the author or coauthor of Contemporary Manufacturing Processes; Manufacturing Processes: Materials, Productivity, and Lean Strategies; Manufacturing Processes: Automation, Materials, and Packaging; and Getting the Message: the Technology of Communications.

PREFACE xi ACKNOWLEDGMENTS xv 1 MANUFACTURING 1 Introduction 1 Manufacturing Sequence 2 Product Life Cycles-There's More Than One 3 Life Cycle Analysis 4 Potential for Waste and Value Added in Manufacturing 9 Vertically versus Horizontally Integrated Manufacturing 11 Waste and Its Unexpected Sources 13 The First Source of Waste 14 The Second Source of Waste 17 The Third Source of Waste 19 A New Product-First Phase for Waste Reduction 20 Existing Products-Second Phase for Waste Reduction 22 Regeneration 24 Life Cycle of the Manufacturing Facility 25 Creating a Classifi cation System for a Compliant and Profitable Manufacturing System 27 Summary 29 Selected Bibliography 31 2 BUILDING A DECISION-MAKING MODEL 33 Introduction 33 Industrial Production and Manufacturing 34 Classifying Manufacturing Industries 38 Major Product Groups from NAICS 40 Material Stocks 51 Major Material Families 52 Basic Process Classifi cations 53 Forming Processes 55 Separating Processes 56 Joining Processes 57 Conditioning Processes 58 Finishing Processes 59 Design Template for Classifying Manufacturing Processes 60 It All Began in Sally's Garden 60 The Analysis 62 Next Steps 67 Selected Bibliography 68 3 ENVIRONMENTAL REGULATIONS, STANDARDS, AND PROFITABILITY 69 Introduction 69 Organizing to Comply-The Management Foundation 71 Formalizing the Management Approach-The ISO Standards 73 ISO 14000 Series of Standards 74 Overview of Major Environmental Regulations 75 Clean Air Act Overview 77 Clean Water Act Overview 79 Solid and Hazardous Waste Management Overview 81 Summary-Compliance Can Mean Profits 82 Selected Bibliography 84 4 CASE STUDIES 85 Introduction 85 Case Study 1 88 Introduction 88 Waste Minimization Programs 91 Reuse and Recycling Activities in the Office 92 Reduction and Reuse of Packaging 92 Comment 93 Case Study 2 93 Introduction 93 The Study and Methods Used 94 Conclusion 97 Comment 97 Case Study 3 98 Introduction 98 Description of the Manufacturing Operation 98 Manufacturing Operations and Sequence 99 Steps Taken to Lessen the Environmental Impact of the Manufacturing Facility 102 Material Waste Reduction 102 Resource Reduction 103 Methods the Company Uses to Identify and Make Improvements 104 Summary 105 Comment 106 Case Study 4 106 Introduction 107 Manufacturing Operations and Sequence 109 Steps Taken to Lessen the Environmental Impact of the Facility 111 Methods Used to Make Improvements 112 Examples of Waste Reduction 114 Comment 115 Case Study 5 115 Introduction 115 Singapore Packaging Agreement 117 The "Three Rs" Approach to Solid Waste Minimization 118 Comment 120 Conclusion 120 Selected Bibliography 121 5 AN OVERVIEW OF TOOLS USED TO IMPROVE MANUFACTURING OPERATIONS 123 Introduction 123 Waste Reduction: The Profi table and Compliant Process Chart-A Collaborative Tool for Both Groups and All Functions 128 Training and Development 129 Operator Self-Control 129 Culture Change 130 Manufacturing Engineering and Operations 131 Lean Manufacturing 132 Kaizen 135 Pareto Principle 136 Process Control 136 Certifi ed Management Systems 137 Design of Experiments 137 Poka-Yoke 138 Finding the Root Cause of a Problem 139 Fishbone or Ishikawa Diagram 139 Situational Awareness 140 Product Design 142 Design for Assembly 142 Human Resources 143 The Life Cycle 143 A Just-in-Time Workforce 144 Summary 147 Selected Bibliography 148 6 THE FACILITY 149 Introduction 149 Making a Building That Can Be Regenerated 152 Plant Location 152 Sustainable Design 154 A Sustainable Building 157 Construction Sequence 159 Life Cycle and Life Cycle Cost Analysis 160 Cost Analysis Software 163 The eQUEST (R) Program 164 The eVALUator Program 164 Building for Environmental and Economic Sustainability 166 Energy Star 167