OVERVIEW OF TOOLS & TECHNIQUES: GREEN PRODUCTIVITY R. C. Monga 2nd World Conference on Green Productivity 10 December 2002

MANILA DECLARATION ENVIRONMENT PROTECTION SHOULD BE PROMOTED WITHOUT SACRIFICING PRODUCTIVITY

GP Concept The concept of GP is drawn from integration of two important developmental strategies viz. Productivity Improvement Environmental Protection

Productivity PROVIDES THE FRAMEWORK FOR CONTINUOUS IMPROVEMENT. Environmental Protection PROVIDES THE FOUNDATION FOR SUSTAINABLE DEVELOPMENT.

SPECIAL FEATURES OF THE GREEN PRODUCTIVITY CONCEPT Green Productivity: HOLISTIC COMPLIANCE INFORMATION DRIVEN CONTINUES IMPROVEMENT PREVENTIVE APPROACH PEOPLE INTENSIVE Top Management Involvement

VALUE FOR ALL STAKEHOLDERS QUALITY OF PRODUCTS & PROCESSES (INPUT, PROCESSES, OUTPUT OWNERS CUSTOMERS EMPLOYEES COMMUNITY SUPPLIERS Survival, Profits, Environment Compliance Better & Cheaper Products Working Conditions, Health & Safety Quality of Life, Less Resources Environmental Compliance, Lower Costs ENHANCES GREEN PRODUCTIVITY

Methodology Integrates all these concepts for SYSTEMATIC APPLICATION SPECIAL FEATURES OF GREEN PRODUCTIVITY

Overview of GP Methodology

PLAN DO CHECK ACTION PDCA CYCLE

PDCA cycle is the most basic principle –Plan includes selection of area for improvement, analysis and goal setting & action plan –DO INVOLVES EXECUTION –CHECK MEANS RECONFIRMATION OF RESULTS –ACT INVOLVES STANDARDIZATION

PDCA/SDCA CYCLE A P CD A P C D A S CD A S CD STANDARDIZATION KAIZEN STANDARDIZATION KAIZEN IMPROVEMENT

GP Tools & Techniques DATA COMPILATION ANALYSIS & INTERPRETATION FINANCIAL IMPLICATIONS OPTIONS GENERATION IMPLEMENTATION VISUAL PRESENTATION

Tools facilitate CAPTURING BASELINE INFORMATION IDENTIFICATION OF PROBLEMS & CAUSES PRIORITIZATION OF PROBLEMS SETTING TARGETS & OBJECTIVES GENERATION OF NEW IDEAS

Techniques Techniques HELP IN GENERATING OPTIONS THESE ARE THE METHODS OF PERFORMANCE OR WORK IMPROVEMENT APPLICABLE TO WASTE,PROCESSES, EQUIPMENT, MATERIAL, ENERGY, PRODUCTS AND PEOPLE,

TASKS 1.Form a GP Team 2.Walk through survey & information collection 3.Identification of problems & causes 4.Setting Objectives & Targets 5.Generating GP Options 6.Screening & Evaluation of GP Options 7.Preparation of Implementation Plan TOOLS & TECHNIQUES STEP - I: GETTING STARTED CHECKLISTS, TALLY CHARTS PLANT LAYOUT, FLOW CHARTS & PROCESS FLOW DIAGRAMS MATERIAL BALANCE BENCH MARKING, BRAINSTORMING, ATTRIBUTE ANALYSIS, RESPONSIBILITY ANALYSIS STEP - II: PLANNING BRAINSTORMING CAUSE & EFFECT ANALYSIS CRITICAL PATH ANALYSIS, GANTT CHART FORCE FIELD ANALYSIS ECO – MAPPING STEP - III: GENERATION & EVALUATION OF GP OPTIONS BRAINSTORMING COST BENEFIT ANALYSIS ECO – MAPPING FAILURE MODE & EFFECT ANALYSIS PARETO CHART PROGRAMME EVALUATION REVIEW TECHNIQUE

8.Implementation of selected Options 9.Training, Awareness building & developing competence 10.Monitoring & Evaluation of Results 11.Management Review 12.Incorporate changes 13.Identify/additional problem areas for continuous improvement STEP - IV: IMPLEMENTATION OF GP OPTIONS TRAINING NEED ANALYSIS TEAM BRIEFING RESPONSIBILITY MATRIX CRITICAL PATH ANALYSIS GANTT CHART SPIDERWEB DIAGRAMS STEP - V: MONITORING & REVIEW SOLUTION EFFECT ANALYSIS ECO – MAPPING FAILURE MODE & EFFECT ANALYSIS CHARTS (CONTROL, TALLY ETC.) / SPIDERWEB DIAGAM STEP - VI: SUSAINING GP SOME OF THE TOOLS ARE REPEATED HERE, SINCE THE ACTIVITIES ARE LOOPED BACK TO THE PREVIOUS STEPS

GP Techniques Waste Prevention 1. Improved Operating Procedures 2. Waste Segregation 3. Good Housekeeping 4. 5S Program 5. 7 Wastes RESOURCE CONSERVATION RECYCLE, REUSE, & RECOVERY OFF/ON SITE RECYCLING PROCESS MODIFICATION INPUT MATERIAL CHANGES PROCESS/EQUIPMENT CHANGES

PRODUCT IMPROVEMENT QUALITY IMPROVEMENT COST BENEFIT ANALYSIS

GP Techniques GP Techniques, Cost and Level of Effort Cost and Level of Effort Process and Equipment Change GP Techniques GP Techniques, Cost and Level of Efforts Design for Environment Input Material Changes Resource Conservation Recycle, Reuse and Recovery Improved Operating Procedures Housekeeping (5S) and 7 Wastes Pollution Control

1.Brainstorming Idea 1 Supporting Idea 1 Extension to Idea 1 Opposing Idea 1 Idea 2 Idea 3 based on 1 and 2 Supporting Idea 3 Idea 4

2.Eco-maps (to identify problem areas)

3.Material Balance Inputs Process Outputs Wastes Raw materials Energy Water Chemicals Air emissions Effluents Solid waste Heat losses Off-spec products Byproducts Products, Useful byproduct s Steps in developing a Material Balance 1. Determining Inputs Recording raw material procurement, water and energy usage, 2. Quantifying Outputs Accounting for wastewater, gaseous emissions, solid wastes, energy 3. Selecting a Tie compound 4. Preparing a preliminary material balance 5. Evaluating and refining material balance Preliminary material balance Refined material balance OutputsInputs

4.Cause-Effect Analysis : Ishikawa (Fishbone) Diagram

SPIDER WEB ANALYSIS

Thank you for your kind attention