Improving Profitability Through Green Manufacturing: Creating a Profitable and Environmentally Compliant Manufacturing Facility

Manufacturers can be green and highly profitable at the same time Profits do not have to be sacrificed to environmental responsibility, or vice versa. Following this book's tested and proven approach, readers discover how to create and operate manufacturing facilities that are highly profitable while meeting or exceeding the environmental standards of their local community, state, and federal governments. The authors' approach is broad in scope, setting forth the roles and responsibilities of organizational functions such as marketing, product design, manufacturing technology, management, and human resources. The book begins with an overview explaining why profitability and green manufacturing must be viewed as a single objective. Next, the book becomes a "how to" guide to creating and maintaining an environmentally compliant and profitable manufacturing operation, with chapters covering: * Manufacturing, waste, and regeneration* Building a decision-making model* Environmental regulation, standards, and profitability* Case studies* Tools used to improve manufacturing operations* The facility* Applying the profitable and compliant process chart The final chapter is dedicated to a step-by-step approach in the application and use of the profitable and compliant process chart, a core working tool discussed in the book. In this chapter, several actual manufacturing applications, along with their worksheets, are presented to illustrate how this approach can minimize resources and waste. Armed with this comprehensive systems approach, readers will no longer view profitability and green manufacturing as two opposing goals. Instead, they'll have the tools and knowledge needed to create and maintain a manufacturing operation that is both profitable and green.

Table of Contents:
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 Energy Management Program 169 Steps to Establish an Energy Management Program 170 International Standards for an Energy Management System 173 Leadership in Energy and Environmental Design 174 Summary 177 Selected Bibliography 178 7 APPLYING THE PROFITABLE AND COMPLIANT PROCESS CHART 181 Introduction 181 PCPC Worksheets 182 Using the Data Collection Worksheets 189 Step 1: Material Selection 189 Step 2: Process Identifi cation 190 Step 3: Outsourcing Manufacturing Processes 195 Summary 195 Industrial Applications of the PCPC 197 Application 1: Avionic Systems, Incorporated 198 Comment 198 Application 2: American Automotive Corporation 200 Comment 200 Application 3: NAVAC Logistics Center 202 Comment 202 Application 4: Custom Machine Builders 204 Comment 207 Observations 209 Constructing the Virtual PCPC 209 Conclusion 211 Selected Bibliography 212 GLOSSARY 213 INDEX 223

About the Author :
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.

Review :
"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)