Transcript GLRPPR Spring Meeting Chicago, IL
Green Suppliers Network
Office Furniture Industry participant GLRPPR Spring Meeting, March 13, 2007
Mary Ellen Mika Supply Chain Management Steelcase Inc.
616.246.9787
A program of the U.S. Dept of Commerce
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GSN – Lean and Clean Opportunity
We contacted Dubois Johnson-Diversey regarding: Green Suppliers Network &
Cost-savings ideas for our paint pretreatment systems.
They offered a ‘green CUSTOMER’ solution to address both.
A program of the U.S.Dept of Commerce
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What is the benefit?
How does Steelcase benefit?
Labor Energy
Water Chemical …cost savings and environmental impact reduction.
A program of the U.S.Dept of Commerce
Great Lakes/Great Plains
- P2Conference US EPA Building, 77 Jackson St. Chicago, IL March 13-14, 2007 Total Cost of Ownership: a Business Case from the Supply Chain Perspective
Case study was conducted in a STEELCASE Systems Plant metal pretreatment washer in Grand Rapids, MI Steelcase Representatives:
– MaryEllen Mika – Mike Warners
DuBois Representatives:
– Keith Lane – Jerry Harrington
Steelcase facts
*
:
• Global Leader – Office Furniture Industry • $2.9 Billion in Global Sales • Mfg. space consolidation ( 13MM to 5.5MM ft 2 ) • Environmental Leadership • Sustainable growth via “industrial reinvention” • Strong set of Core Values
* 2006 Annual Report @ steelcase.com
STEELCASE and the Environment:
• 2006 Awards and Recognition*: – MBDC’s C2C (cradle to cradle) product certification – Only International C2C Certification – Gold achievement, WasteWise – 2nd year – prod stewardship – Honorable mention, WasteWise – 5 th year – waste minimization – MVP2 (Most Valuable Pollution Prevention) from NPPR – International Innovation Award – Steelcase Canada – 2006 Neighborhood Envr. Partners Gold award – by MDEQ – Habitat for Humanity – Kent County Donor of the Year award – Riverkeeper Annual Benefit Honors – only company so honored – Steelcase joins EPA’s Climate Leaders Program – reduce GHG – Just to name a few . . . . .
* 2006 Environmental Reports @steelcase.com
Facts about DuBois Chemical:
• Parent company: S. C. Johnson Racine, WI (retail/distribution) • Operating Divisions of JohnsonDiversey Inc. – H & H, Food & Beverage, BG&E, Industrial (Commercial/Ind’l) • DuBois Chemical- Headquartered in Cincinnati, Ohio – 80 year history of helping customers – ISO 14001 Certified – Markets include: Surface Finishing, Food, Paper, Transportation, other Specialty markets – Applications include: Food C&S, Water & Wastewater treatment, Facilities Maintenance, Lubrication, MWF Fluids, Processing of Metals, Plastics prior to paint, PSB’s etc.
Green Suppliers Network
:
• What is the
Green Suppliers Network ?
– Collaborative venture among industry, US EPA and US Dept of Commerce’s National Institute of Standards and Technology Manufacturing Extension Partnership (NIST MEP). cost technical reviews that employ
GSN
manufacturers to engage their small to medium-sized suppliers in low-
Lean and Clean
works with large methodologies to increase productivity, reduce waste, and boost profitability.
• What is
Lean and Clean ?
– Lean and Clean expands the traditional definition of Lean
(eliminating non value added time, labor and capitol)
to one that includes environmental wastes
(e.g., reducing energy, water, waste, and emissions).
This targets the root causes of wasteful practices and provides a framework for achieving specific, measurable business and environmental goals.
Focus of Lean and Clean
• Lean
Eliminates:
– Defects – Overproduction – Waste – Non-utilized people – Transportation – Inventory – Motion – Extra processing • Clean – O – W
Strives for :
– Nature-friendly subs
ptimized material and energy efficiency aste elimination
– A – S
ir / water emission reduction olid / Hazardous waste reduction
– Toxic material reduction or substitution – Efficient packaging
GSN – Lean and Clean
Started our project down the path of . . .
• LCA or “Life Cycle Analysis” • COO or “Cost of Ownership”
Mid-way into our project discovered the “TCO for Metalworking” reference @ the WMRC web site.
• TCO or “Total Cost of Ownership” has been defined as
“the sum of all expenses and costs associated with the purchase and use of equipment, materials, and services.”
(Monczka 1998)
Steelcase and the
GSN
:
• Steelcase signed on as an OEM Champion and has been an active member in the
GSN
process since ~2004.
– Steelcase’s GSN Champion; Mary Ellen Mika • An opportunity to bring
“Lean & Green”
concepts into Steelcase’s supply chain of small to medium suppliers • Candidate companies are invited to attend a
GSN
session by their sponsoring OEM company.
• DuBois Reps were invited by Steelcase and did attend a
GSN
focused session sponsored by the Office Furniture Manufacture’s Association in Western Michigan (Oct 2005).
Steelcase/DuBois
– background info:
• DuBois Rep had an established relationship in the Wood Plant • Interaction with MaryEllen Mika & the
GSN Focus
• Steelcase Paint Engineering Team decided to look for vendors with potential solutions to ongoing QC issues and for general process improvements.
• DuBois was one of six suppliers to be invited to engage the project by being subjected to Steelcase’s “Toll Gate” selection process
“We saw the opportunity to implement a
GSN focused solution
deliver much more; via “TCO” improvements.”
Keith Lane
and
Steelcase –
Project goals
:
• Must pass an initial process qualification • Energy reduction by lowering operating temps.
• Lower operating costs for process chemicals – Tank-life extensions / Innovative chemistry • Document trial via on-site presence/data collection • Water use/reuse & Labor reductions were added on
by DuBois Team as achievable goals Next - a few “basic concept” slides
A few basic concepts – 1 of 3
• Hardness salts: – Inverse solubility of calcium and magnesium – Base component of scale and sludge – Aids in grease formation – with oils and/or soils – Negative impact on quality . . . Over time – Negative impact on cleanliness (nozzles & screens) – Negative impact on tank life . . . Over time – 1MM lbs water @ 150 ppm Hardness carries 150 lbs salts – 1MM lbs water @ 8.33#/gal = 120,000 gallons of water – 30 GPM flow into a process will introduce about 150 / 180 lbs of salt every 72 hours of operation.
– This is generally the basis for 2 to 10 week dump cycles
TYPICAL WATER HARDNESS
WA OR CA NV ID UT AZ MT WY CO NM ND SD NE KS TX OK MN IA MO AK ME WI IL IN KY TN MI OH WV VA NC SC PA NY VT NH MA CT NJ DE MD RI MS MS AL GA LA FL < 80 80-125 125-200 > 200 ppm SOFT Grains < 4.5
4.5-7.5
7.5-12 > 12 ppm HARD Grains
Basic concepts – 2 of 3
• Purified water like RO or DI: – Advantages: Removes > 95% of all impurities Extends the life of chemical baths Provides for high quality rinsing Will not “artificially” consume chemicals Will not load a bath with by products (re: calcium phosphate) Will not promote the formation of “sticky” residues Will keep the internal wetted surfaces much cleaner – Disadvantages: Cost more than city water Can promote bacteria if not pro-actively managed
A few basic concepts – 3 of 3
• “Skimming” counter-flows: – Advantages: Constantly removes surface scum Simple . . . Yet effective Promotes the “reuse” of water Minimizes “total” water volume used Reduces discharge flows and points of discharge Keeps rinses clean Lowers conductivities in the final rinses Promotes “hydraulic balancing” and water minimization Promotes high quality / high volume rinsing on parts
DuBois – process audits:
• Performed “process audits” on pretreatment processing lines to . . .
– Document “current state” of process variables • “S W A T C H E D” principles – Produce “flow diagrams” • Water flow rates . . . inputs and discharge points – Produce “process timing charts” – Identify heated stage(s) and operating temperatures – Evaluate overall washer cleanliness • As a result of our efforts . . . We were offered an
opportunity for a 6 week trial in a production washer at the Systems Plant in Grand Rapids, MI
DuBois – process audits:
“S W A T C H E D” is an acronym for: S – soils and substrates W – water source(s) A - action T - time C - chemical H - heat E – environmental impact D - dollars
“Current State” - flow diagram
the DuBois’ approach included:
• Use of innovation chemistry – Secure TEC ES – Low temperature formulation – Energy reduction potential – Low sludging – side benefits when coupled with RO water • Focus on 100% use / reuse of RO water – Reduce environmental footprint (
GSN focused activity
– Main driver of “cleanliness” and “water reduction” ) – TDS reduction / hardness salt elimination / scale reduction • Stabilization of chemical processing bath – Match product addition to consumption/depletion rate – Control board methodology – “plug-n-play” • On-site Reps to track
“Life Cycle Analysis”
– And implement “skimming counter-flows”
“Future State” - flow diagram
“TCO” Results (after 5 months)
Energy reduction
–
60% reduction in BTU’s required
Water usage reduction
–
80% less water required
Innovative chemistry
–
20% to 30% less volume
Waste stream reduction
–
85% to 95% less discharge
Labor to maintain washer
– >
50% reduction
“AAR” – Lesson’s Learned!
• Purified water offers value and consistency • Skimming counter-flows reduce water volume • Washer stays cleaner
(screens, nozzles, tanks)
• Processing results are very consistent • Water, energy, labor, and chemical reductions
offer “TCO” improvements.
Thoughts going forward . . .
• Lean & Green
in the industrial marketplace has value!
• “TCO” concepts
offer economic growth opportunities and environmental enhancements.
• Shrinking of the industrial specialty chemical market
going to happen . . . . with us . . . .or . . . . without us.
is
• “Leaning & Greening”
of our industrial markets could be a solid sales growth strategy . . . “Let’s be the first
to pro-actively go there and take the additional “market share” that comes with it.”
J. Harrington