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Development of collaborative green lean production systems
Mälardalen University, School of Innovation, Design and Engineering, Innovation and Product Realisation.ORCID iD: 0000-0001-9068-3527
2014 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

This thesis deals with development of lean and green production systems from an action research point of view. The studies focus on Swedish-based automotive and vehicle industries and their aims to integrate sustainable thinking and environmental care into their operations management.

Starting from operations management in manufacturing and corporate sustainable development, the research is built on how to integrate these two views into one production system. The systematic structure of a multiple-target improvement process with methodologies and tools designed to achieve the sustainability vision has been studied. Since lean as well as green production is based on the entire value chain, the research has gone beyond legal company limits and included the collaborative efforts between suppliers and customers in the value chain.

The thesis includes six papers and describes approaches on how to implement integration, how to structure and integrate improvement management systems, how to set up an integrated monitoring and control system for the business and how to organise and redesign green lean tools and methodologies to support collaboration towards common targets.

The results can be used for exploration and hypothesis formulation for further studies and development of integrated production systems and collaboration systems. The thesis helps answering how to integrate and implement company-specific green lean production systems.

Place, publisher, year, edition, pages
Eskilstuna/Västerås: Mälardalens Högskola , 2014.
Series
Mälardalen University Press Dissertations, ISSN 1651-4238 ; 162
Keyword [en]
Operations management, Lean manufacturing, Sustainable production, Environmental management, Swedish manufacturing
National Category
Environmental Management
Research subject
Innovation and Design
Identifiers
URN: urn:nbn:se:mdh:diva-25605ISBN: 978-91-7485-157-1 (print)OAI: oai:DiVA.org:mdh-25605DiVA: diva2:734280
Public defence
2014-09-19, Filen, Smedjegatan 37, Eskilstuna, 10:00 (English)
Opponent
Supervisors
Available from: 2014-07-16 Created: 2014-07-05 Last updated: 2014-12-12Bibliographically approved
List of papers
1. Lean and green integration into production system models – experiences from Swedish industry
Open this publication in new window or tab >>Lean and green integration into production system models – experiences from Swedish industry
2014 (English)In: Journal of Cleaner Production, ISSN 0959-6526, E-ISSN 1879-1786, Vol. 85, 180-190 p.Article in journal (Refereed) Published
Abstract [en]

This paper focuses on integration of operations management, specifically production system models with environmental management and related issues such as quality and safety. Based on knowledge concerning lean-based improvement programmes for company-specific production systems (XPS) and integration between formal management systems, such as ISO 9001 and 14001, industrial practices from integrating management systems with the XPS were studied. A literature-based comparison between formal management systems and XPS is made, indicating integration potentials. The empirical research is an analysis of five vehicle and automotive companies in which various efforts have been made to integrate their management systems with their XPS. The results show that although conscious steps have been taken since the introduction of ISO 14001 in integrating environmental management into everyday operations, there are still obstacles to overcome. To fully include sustainability aspects, the characteristics of the improvement systems have to be adapted and extended. One barrier to extended integration is the lack of integration strategy. There is further a lack of sustainability metrics and adaptation of improvement methods to push companies' operational performance. In addition, organisational issues still arise concerning the responsibility and ownership of environmental management in relation to operations. Based on these results it is concluded that processes for integration are recommended; however, each organisation needs to consider its operations, corporate culture and business opportunities of its environmental management. Still, incorporating environmental management systems into XPS is seen as an effective way of establishing company commonality in continuous improvement, resulting in holistic understanding and improved organisation performance.

National Category
Engineering and Technology Environmental Management
Identifiers
urn:nbn:se:mdh:diva-25246 (URN)10.1016/j.jclepro.2014.04.013 (DOI)000346551500015 ()2-s2.0-84922449345 (Scopus ID)
Available from: 2014-06-14 Created: 2014-06-14 Last updated: 2016-02-25Bibliographically approved
2. Green performance map: visualizing environmental KPI’s
Open this publication in new window or tab >>Green performance map: visualizing environmental KPI’s
2013 (English)In: EurOMA conference: At the Heart of Recovery, 2013Conference paper, (Refereed)
Abstract [en]

This paper analyse the current practice in environmental key performance indicator (KPI) allocation and presents an industrially applicable tool, focusing on the link between KPIs and environmental sustainability. The empirical base for the paper is a study of operational KPIs and environmental performance control within two Swedish manufacturing companies, on corporate, plant, and workstation level. It is concluded that the presented Green Performance Map gives managers, environmental specialists and improvement teams a common but comprehensive view of the manufacturing’s environmental performance and a method to collect, visualize and prioritize improvement efforts.

Keyword
Performance measurement, Environment Management Systems, Productionsystem
National Category
Engineering and Technology
Identifiers
urn:nbn:se:mdh:diva-22898 (URN)
Conference
EurOMA 2013, The 20th EurOMA conference 7-12 June 2013, Dublin
Projects
XPRESLean and Green Production Navigator
Available from: 2013-11-20 Created: 2013-11-19 Last updated: 2014-07-16Bibliographically approved
3. Sustainable metalworking fluid systems: Best and common practice for metalworking fluid maintenance and system design in Swedish industry
Open this publication in new window or tab >>Sustainable metalworking fluid systems: Best and common practice for metalworking fluid maintenance and system design in Swedish industry
2012 (English)In: International Journal of Sustainable Manufacturing  (IJSM), ISSN 1742-7223, E-ISSN 1742-7231, Vol. 2, no 4, 276-292 p.Article in journal (Refereed) Published
Abstract [en]

This paper investigates the function of metal working fluid (MWF) emulsions in automotive industries in Sweden and looks at how the negative environmental and health impact of their use can be reduced through means of monitoring and system design. Major input to this study has been collected from several of the large companies in Sweden, through a literature review, interviews, questionnaires, findings from workshops and comparisons with other countries. The mapping of this data was carried out, firstly by defining several concepts and terms related to MWFs in order to give an unambiguous terminology. The MWF system design, with its impact on economical, environmental and health and safety parameters, is then described more in detail. Finally, applied monitoring methodologies are reviewed and analysed in terms of common and best practices. Insights gained were formulated as general recommendations for designing a state-of-the-art sustainable MWF system. The article gives examples of how these recommendations translate into practical design features and requirements of monitoring, and maybe of interest for professionals and researchers working with machining technology, process fluid system design and control methodology.

Place, publisher, year, edition, pages
Sweden: , 2012
Keyword
metalworking fluids, automotive MWFs, fluid monitoring, process fluids, fluid system design, fluid reuse, fluid waste minimisation, sustainable metalworking, Sweden, sustainable manufacturing, automobile industry, economics, environmental impact, health and safety.
National Category
Engineering and Technology
Identifiers
urn:nbn:se:mdh:diva-23403 (URN)10.1504/IJSM.2012.048582 (DOI)2-s2.0-84865254440 (Scopus ID)
Projects
XPRES
Available from: 2013-12-10 Created: 2013-12-10 Last updated: 2015-04-27Bibliographically approved
4. Chemical Management Services: Safeguarding Environmental Outcomes
Open this publication in new window or tab >>Chemical Management Services: Safeguarding Environmental Outcomes
2009 (English)In: Environmental Management Accounting (EMA) as a Support for Cleaner Production / [ed] Stefan Schaltegger (2) Martin Bennett (3) Roger L. Burritt (4) Christine Jasch, Springer Netherlands , 2009, 209-229 p.Chapter in book (Other academic)
Abstract [en]

Every year hundreds of new chemicals with uncertain life-cycle impacts on our health and the environment are being developed and introduced to the market. Reducing the amount and volume of chemicals in use is seen as an important option for reducing associated environmental effects. Chemical management services (CMS) is seen by environmental experts as a business strategy that may allow reduction in the volume of chemicals sold, while maintaining profits from use of chemicals for suppliers. In traditional business the user would try to achieve the same reduction with less support from the supplier. The goal of this paper is to investigate how common performance indicators can be used to monitor the environmental performance of different chemical management strategies and how CMS customers and suppliers can safeguard environmental improvements. The paper draws on experiences from implementing CMS in one of Sweden’s automotive companies and meetings with European CMS providers.

Place, publisher, year, edition, pages
Springer Netherlands, 2009
National Category
Engineering and Technology
Identifiers
urn:nbn:se:mdh:diva-23405 (URN)10.1007/978-1-4020-8913-8_11 (DOI)978-1-4020-8912-1 (ISBN)
Projects
XPRES
Available from: 2013-12-10 Created: 2013-12-10 Last updated: 2014-07-16Bibliographically approved
5. Use of environmental value stream mapping and environmental loss analysis in lean manufacturing work at Volvo
Open this publication in new window or tab >>Use of environmental value stream mapping and environmental loss analysis in lean manufacturing work at Volvo
Show others...
2011 (English)In: Proceedings of the 4th Swedish Production Symposium, Lund, Sweden, 2011Conference paper, (Refereed)
Abstract [en]

ABSTRACT Green production systems requires efficient production and low use of resources such as energy, material etc. To achieve this, there is a need for further development of continuous improvement tools in the “lean and green” area. This work deals with environmental value stream mapping (Environmental-VSM), which has been applied in two case studies at Volvo Penta Vara and Volvo Construction Equipment Braas. In the performed studies Environmental-VSM, as described by the US-Environmental Protection Agency, has been extended by the introduction of a loss model to show environmental losses. The combination of methods provides the user with hands-on tools supporting strategic as well as operational management. Examples of practical improvement actions that were found include reduction of energy use trough minimising idling losses and floor space as well as reduced waste flow through lowered packaging material usage. Keywords: Green Lean, Green production systems, Competitiveness, Manufacturing industry, Production management

Place, publisher, year, edition, pages
Lund, Sweden: , 2011
National Category
Other Engineering and Technologies
Research subject
Innovation and Design
Identifiers
urn:nbn:se:mdh:diva-13513 (URN)
Conference
4th Swedish Production Symposium, May 3-5th 2011, Lund University, Sweden
Projects
xpres
Funder
XPRES - Initiative for excellence in production research
Available from: 2011-12-15 Created: 2011-12-15 Last updated: 2016-01-11Bibliographically approved
6. Waste flow mapping to improve sustainability of waste management: A case study approach
Open this publication in new window or tab >>Waste flow mapping to improve sustainability of waste management: A case study approach
Show others...
2015 (English)In: Journal of Cleaner Production, ISSN 0959-6526, E-ISSN 1879-1786, Vol. 98, no 1, 304-315 p.Article in journal (Refereed) Published
Abstract [en]

Innovative, resource-efficient solutions and effective waste management systems capture value in business and contribute to sustainability. However, due to scattered waste management responsibilities in the vehicle industry and the orientation of operations management and lean tools, which mostly focus on lead-time and labour-time improvements, the requirement of a collaborative method to include material waste efficiency in operational development is identified. The main purpose of this research is to study how operations management and environmental management can be integrated on an operational level and include the waste management supply chain. Based on a literature review of environmental and operational improvement tools and principles, the gaps and needs in current practice were identified. A large case study implementing a waste flow mapping (WFM) method on a set of manufacturing sites revealed potentials in terms of reducing material losses and inefficiencies in the handling of materials and waste. Finally, the integrated WFM method was analysed with respect to the gaps and needs identified in the existing body of tools for operational and environmental improvement. The method combines lean manufacturing tools, such as value stream mapping with cleaner production and material flow cost accounting strategies. The empirical data showed that the WFM method is adequate for current state analysis of waste material efficiency potentials, especially when multiple organisations are involved. However, further development and specific methods are needed such as, for example, logistics inefficiencies, root cause analysis, implementation guidelines for best practice and systems for performance monitoring of actors.

Place, publisher, year, edition, pages
Elsevier, 2015
Keyword
material efficiency;waste flow mapping; waste management services; manufacturing industry; environmental system analysis
National Category
Other Materials Engineering
Research subject
Energy- and Environmental Engineering
Identifiers
urn:nbn:se:mdh:diva-25265 (URN)10.1016/j.jclepro.2014.06.076 (DOI)000356194300031 ()2-s2.0-84929944699 (Scopus ID)
Projects
Memiman
Funder
Mistra - The Swedish Foundation for Strategic Environmental Research
Available from: 2014-07-05 Created: 2014-06-16 Last updated: 2016-12-22Bibliographically approved

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Citation style
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Output format
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