72nd International Technology and Engineering Educators Association Conference Green Technology: STEM Solutions for the 21st

Century Citizen Charlotte, North Carolina

Lean and Green Manufacturing in Wood Technology

11:00-11:50 AM
March 20, 2010
Presented by

Douglas R. Hague Jordan Clous Backs John L. Iley, Ph.D.

Pittsburg State University

Presentation Description & Presenters

Lean and Green Manufacturing in Wood Technology

Description:

addresses lean and green manufacturing practices in the wood industry. It features latest innovations in engineered wood materials, hardware, and processes; and educational activities.

Presenters: Douglas Doug R. Hague,

Assistant Professor, Wood Technology, PSU

Jordan Clous Backs,

Instructor, Wood Technology, PSU

Dr. John L. Iley,

Professor, Technology Education, PSU

AgendaTodays Presentation

Lean Manufacturing
Definition, origin, goals, implementing lean

Green Manufacturing
Definition and principles

Lean and Green Comparison

www.buker.com/images/Leanchart.gif

Lean and Green in the Wood Industry

Considerations Design, Material Selection, Production, and Conservation Case StudiesIndustry and PSU

Lean and Green-Implications for Educators

Suggestions, Activities, and Resources

Lean Manufacturing

Definition:
Lean Manufacturing refers to
manufacturing practices aimed at maximizing value and minimizing www.buker.com/images/Leanchart.gif waste in the manufacturing process. It considers expending resources for anything other than creation of value to the customer to be wasteful More value for less money

Origin and Key Figures of Lean

Ben Franklin (1733) Poor Richards Almanac Eli Whitney (1850s) interchangeable parts Frederick Taylor Principles of Scientific Management (1911) Frank Gilbreth process charts; motion study Henry Ford mass assembly manufacturing system (1915)

Kiichirio Toyota (1936) Kaizen improvement teams

W. Edwards Deming (WWII) SPC; TQM Taiichi Ohno Toyota Production System-TPS (1980) John Krafcik coined term Lean Manufacturing in 1988

History Timeline for Lean Manufacturing

Graphic from: Strategos www.strategosinc.com/images/lean_timeline.jpg

Goals of Lean Manufacturing

Continuously improve quality Eliminate waste-doesnt provide value

Waiting Transport Extra Processing

Overproduction
Inventory Motion Defects

www.sixthsigma.com/weblog/LeanManufacturingPa..

Reduce time-start to finish Reduce total costs

Going Lean in Manufacturing

Create simple manufacturing system

Decrease cycle times
Keep less inventory Increase productivity and efficiency

Increase equipment utilization

Recognize room for improvement Continuously improve

measure improvement
chohmann.free.fr/lean.gif

Green (or Sustainable) Manufacturing

Department of Commerce Definition:

Sustainable (Green) [sic] Manufacturing

is defined as the creation of manufactured products that use processes that are non-polluting, conserve energy and natural resources, and are economically sound and safe for employees, communities, and consumers.

From: Sustainable Manufacturing National Council for Advanced Manufacturing (http://www.nacfam.org/ ) - Definition http://nacfam02.dev.web.sba.com/PolicyInitiatives/SustainableManufacturing/tabid/64 /Default.aspx

Objectives for Green (Sustainable) Design in Mfg

Increase efficiency in the use of materials, energy and other resources Minimize damage or pollution from the chosen material Reduce to a minimum any long-term harm caused by use of the product Ensure that the planned life of the product is most appropriate in environmental terms and that the product functions efficiently for its full life Take full account of the effects of the end disposal of the product Ensure that the packaging and instructions encourage efficient and environmentally friendly use Minimize nuisances such as noise or smell Analyze and minimize potential safety hazards
Adapted from: Principles of Green Design http://www.slideshare.net/mschongkong/topic-3-principles-ofgreen-design

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Comparison of Lean to Green or Sustainable Manufacturing

Lean Manufacturing
Eliminate Waste Reduce time-start to finish Reduce total costs Continuously improve quality

Green Manufacturing
Conserve energy and natural resources Increase efficiency in time and resources Reduce pollution & damage to environment Product function properly throughout its life Minimize safety hazards

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Wood Industry Promotes Lean & Green

Certifications promote commitment
LEED

Leadership in Energy & Environmental Design U.S. Green Building Council (USGBC) Environmental Stewardship Program Kitchen Cabinet Manufacturers Assn (KCMA)
Forest Stewardship Council Sustainable Forest Initiative

ESP

FSC

SFI

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Wood Industry Responds to Lean & Green

Certifications & policies promote commitment EPP

Environmentally Preferable Purchase Government stimulates buy green Science-based environmental certification standards GREENGUARD Environmental Institute ANSI standards developer-indoor air quality Scientific Certification Systems Certification of sustainability & environmental claims

Green Seal - 1989

GEI

SCS

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Keys to Implementing Lean and Green

Philosophy Facility Considerations Product Design Material Selection Production Techniques Finishing Hardware Selection Minimize and Eliminate Waste Reduce-Reuse-Recycle

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Lean & Green: Philosophy and Commitment

Example: Dimensional Innovations

We utilize digital fabrication to eliminate waste and increase yield of materials. We maintain strict standards for proper disposal of batteries, paint solids and other hazardous materials. A high percentage of our post-production product is recycled and donated to local art school programs including, the Kansas City Art Institute and the University of Kansas. We utilize a solvent recycling machine that reduces our solvent waste by 95 percent. This system reduces 220 gallons of solvent waste per year. Dimensional Innovations interior architectural designer is a LEED AP and has completed several recent exhibits in facilities seeking LEED certification. We are currently exploring supplemental options for recycling Sintra and EPS foam.

From: Dimensional Innovations Environmental Stewardship http://www.dimin.com/?page=about_environment

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Lean & Green: Facility Considerations

Location Environmentally-friendly construction; renovation; resource conservation Energy Efficiency

Less fossil fuel alternate energy Energy efficient motors, etc. Less transportation

Efficient flow of materials and product Clean environment indoor air quality

Space efficiency less to heat, cool

Dust collection, air filtration & dust extraction; incorporate eco-gates EPA adherence - finishing

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Lean & Green: Product Design

Incorporate green design principles

Efficiency in use of materials, energy, resources Minimize damage or pollution Reduce long-term harm of product Planned life of productfull life efficiently Effects of end disposal biodegradable, recyclable

Specify materials with environmental certificationsLEED, EPS, SFI, FSC, etc. More panel construction with veneers and laminate Use CADD-CAM software and optimization features Simulate production

Minimize material waste, and production time and cost consider standard stock material and machine capacity
Weight reduction and modular reduced shipping costs Reduce, Reuse, Recycle

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Lean and Green: Material Selection

Cabinet box materials

Composite panels (95% of tree [lumber 63%]

Panels with low formaldehyde certifications (e.g., Composite panel association (CPA) EPP specification CPA 2-06 = formaldehyde levels less than 0.18 per million parts of air
Core material with EPP specification for being manufactured with 100% recycled and/or recovered fiber Use high percentage of hardwoods with SFI and/or FSC certification Medite II wood fibers combined w/ formaldehde free synthetic resin; no commercially viable tree (scrag wood) fiber used Dur-A-Tek Hardwood Composite - ultra low VOC = woods Wheat board composites low VOCs (volatile organic compounds); alternative to MDF and particle board

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Lean and Green: Material Selection (cont-)

Doors, drawers, cabinet component materials

Bamboo a grass; highly renewable and recyclable Wood veneers - applied to doors and drawer front base materialsMDF or wheat board SFI or FSC Certified Wood little environmental pressure Lyptus Wood (Lyptus) Weyerhauser product from eucalyptus; excellent quality, beauty and environmental attributes; excellent choice when selecting exotic hardwood specie Reconstituted veneers veneer replicates wood species under environmental pressure; ; engineered and harvested from African hardwood trees and Italian plantation grown poplar trees. Recycled and reclaimed wood http://www.greenbuildingsherpa.com/categories/recycled-woodand-reclaimed-wood-products.html 19

Lean and Green: Material Selection (cont-)

Laminates and veneer adhesives

Use low VOC glues
Water-borne PVA (polyvinyl acetate) adhesive is preferred over contact cement--no VOCs

Edgebanding
Edgebanding substitute ABS edge banding for PVC; no chlorine in material and its processing

Finishing

- see slide #22

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Lean and Green: Production Techniques

Consider material and product flow Optimization & optimization software

Optimizing rip saws and cut-off saws CNC for optimizing panel construction
Optimizing features Simulations can prevent waste Nested parts Decrease production times and cycles

Panel optimization maximum cutting patterns & yield Panel utilization visual scanning systems; reduce scrap Solid wood yield high speed material handling & yield

Flexible assembly tables; z-lifts more efficient time and motion Control dust and waste by-products
Down-draft sanding tables

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Lean and Green: Finishing

Material selection
Natural finishes e.g., Tung oil Low or ultra low VOC finishes Waterborne finishes and sealants (e.g.,

Vermont Natural Coatings non toxic finish; durable water-based finish from cheese whey Sherwin-Williams Kem Aqua Waterborne Finishing System

Finishing equipment and process

Flat panel coating with recovery systems reduce waste requiring disposal (e.g., Cefla) Transfer efficiency; flexibility and productivity

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Finishing Integration and Green Mfg

from M&M Solutions, WMS, September 2009
http://m-mwoodsolutions.com/knowledge/M+M-WMS_October_2009.pdf

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Lean and Green: Hardware Selection

Specialty designed hardware components for lighter panel materials and composites (e.g., Hafele)

Green door and cabinet hardware

Recycled glass Varia eco-resin -40% post-industrial reclaimed material Cork Inlay Fused glass layers of glass fired in a kiln Recycled aluminum Stainless steel

Recycled hardware
Recommended Resource: Rustica Hardware http://www.rusticahardware.com/GREEN-HARDWARE-sp1.html 24

Lean and Green: Minimize & Eliminate Waste

Waste utilization
Biomass furnace burns sawdust and wood waste

Briquetting wood waste can provide a fuel source Dust collection system captures dust to silo

Packing material

VOC Abatement
VOC emissions used as fuel

Reduce, Recycle, Reuse

Resource: Stiles MachineryGreen Manufacturing -

http://www.stilesmachinery.com/Equipment/Showroom/green-mfg.aspx

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Case Study #1 Mark Richey Woodworking and Design

Philosophy

Facility Considerations

Environmentally-responsible company since founding in 1980 Cut energy usage Renovate existing structures Combine natural and energy-efficient lighting Insulate, seal building envelope Operate wind turbine to generate electricity

Product Design

Material Selection

Design products for material savings Design to make products that last Specify wood from sustainable sources FSC certified Use veneered product with particleboard or MDF cores recycled cores Use advanced equipment to cut and machines materials efficiently

Production Techniques

Finishing Hardware Selection Minimize and Eliminate Waste - Reduce-Reuse-Recycle

Burn wood waste in biomass furnace to heat plant Use post-industrial or recycled product for packing materials
From: Taking the Lead in Green Manufacturing by George Lausch http://www.fdmonline.com/richeyinterview.aspx

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Case Studies: Four Additional Wood Industries

Case Green Cabinetry
Environmentally Friendly or Green Cabinet Options http://www.casegreen.com/process/GreenCabinet Options.html

Pacific Crest Industries

Amero Cabinet Collection Builds responsibly as steward of environment
http://amerocabinetcollection.com/environment.html

Industrial Woodworking Corporation

IWC leads the way to a sustainable future
http://www.industrialwoodworking.com/HTML/environment/index.htm

Fimbel Architectural Door Specialties

Well documented policies concerning green
http://www.fimbelads.com/green_manufacturing.html

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Pittsburg State University Wood Technology: Addressing Lean and Green

Facility Considerations Product Design Material Selection Production Techniques Hardware Selection Finishing Minimize and Eliminate Waste
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PSU: Lean & Green Lab Considerations

Production Equipment
Optimizing Rip Saw CNC Router Horizontal Beam saw Shop Layout Production and Material Flow

Assembly Tables Dust Collection

Dust collection system and downdraft tables

Finishing Lab

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PSU: Lean & Green: Product Design

Design to use standard stock sizes Design for production and efficiency
CAD/CAM and CNC Machine capacity and capability

Use optimization software and/or features get most out of material Design to minimize waste of material, energy, and time Keep end-use and end-user in mind

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PSU: Lean & Green Material Selection

Composite Materials
MDF TruPan

Extensive Use of Veneers Solid Lumber Saw Mill

Local species readily available Logs provided by tree removal services

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PSU: Lean & Green Production Techniques

CNC
optimization nested production

Vacuum Bag
Veneer to substrate (MDF)

Tiger Stop
Save time Minimize waste caused by operator error

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PSU: Lean & Green Finishing

Flash Tunnel
Reduces Dry Time

Recycle Waste Spray Guns

High transfer rate spray guns

Low VOC Finishes Water Borne Finishes

Make students aware Experiment with finishes

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PSU: Lean & Green Hardware Selection

Hardware for Composite Material

Specialty hardware is needed for use in some composite materials that are used.

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PSU: Lean & Green Minimize and Eliminate Waste

Chipper/ Wood Grinder

Experimented and tested the benefits of a wood grinder

Tiger Stop
Capabilities of optimizing

CNC & Horizontal Beam Saw

Increase of material yield

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Lean and Green Implications for Educators

Suggestions for Educators Activities Resources

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Lean and Green: Suggestions for Educators

Note: Many of the following are not new, but have been used by teachers for years to conserve limited resources and fundsLean Teaching

Organize lab (shop) for material & production flowsave time and energy Purchase materials locally & regionally Design custom and mass produced products to optimize standard stock material
CAD/ Cam software Optimizing software and/or features

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Lean and Green: Suggestions for Educators (cont-)

Material selection
Local, more plentiful solid lumber species Recycled wood Composite materials & veneers

Urea-free MDF Formaldehyde-free plywood

Finishing and laminate projects

Natural finishes e.g., tung oil Finishes low in VOCs and HAPs

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Lean and Green: Suggestions for Educators (cont-)

Hardware Selection

Environmentally-friendly new
Materials recycled glass and aluminum; cork; fused-glass; eco-resin (e.g., Varia); lead-free pewter and stainless steel

Recycled hardware
Specialty stores

Sample Resources
Rustic Hardware - Hardware http://www.rusticahardware.com/GREENHARDWARE-sp-1.html Hafele www.hafele.com ?

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Lean and Green: Suggestions for Educators

(cont-)

Minimize and Eliminate WasteReduce, Reuse, Recycle

Recycle or reuse abrasivesabrasive belts, sand paper, etc. Sawdust

Packing material Cage bedding-Biology animals Mulch for acid-loving plants (e.g., blueberries) Note: Walnut harmful to plants Specialty Projects wood flour molded knobs, coasters, etc.

Solid wood waste

Kindling for wood stoves, etc.

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Lean and Green: Suggestions for Educators (cont-)

Rough Lumber or S2S surface and edge joint whole board to eliminate having small pieces that cant be machines safely and become scrap Create Standard Stock instead of lots of odd sized shorts, create standard sizes (t x w) for small projects Small Filler Projects several small projects
Use up leftover material Students do these during idle times Examples: wood puzzles; cutting boards; key holders; salad fork & spoon re-saw project; etc.

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Lean and Green: Activities for Educators: Green Design Brief #1: Bird House

Scenario: Local Audubon

Society needs a large quantity of bird houses built for local wildlife area

Design Brief: Design and mass

produce a large number of ecofriendly, solid wood bird houses, as efficiently as possible for the lowest cost.
This image is from: www.birdingessentials.com/page/birdhouses

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Lean and Green: Activities for Educators: Green Design Brief #1: Bird House (cont-)

Considerations for evaluating solution:

Material Selection appropriate for application; standard stock; proper hardware Design - appropriate size for bird; optimizes use of standard stock material; minimum number of T x W x L Production manufacturabilityease of making; material & production flow; minimum number of cuts, fasteners, assemblies; surface preparation; etc. Finish none; environmentally friendly; exterior application Installation ease of installation Aesthetics craftsmanship; appearance

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Lean and Green: Activities for Educators: Green Design Brief #1: Bird House (cont-)

Comparison of cut lists of two solutions for a given type of house with one-piece roof:

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Lean and Green: Activities for Educators: Green Design Brief #2: Recycle Bins

Scenario: The school district

needs 20 special recycle container bins (10 for cans; 10 for plastic bottles) built.

Design Brief: Design and mass

produce a large number of ecofriendly, composite- panel recycle container bins, as efficiently as possible for the lowest cost.

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Lean and Green: Activities for Educators: Green Design Brief #2: Recycle Bins (cont-)

Considerations for evaluating solution:

Material selection appropriate for application; standard stock; proper hardware Design - appropriate openings for containers; optimizes use of standard stock material; minimum number of W x L Production manufacturabilityease of making; material & production flow; minimum number of cuts, fasteners, assemblies; etc. Finish environmentally friendly; appropriate for application Aesthetics craftsmanship; appearance

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Green Activities & Resources for Educators-Activity: Green Manufacturing Terminology

Directions:
Complete the Green (or Sustainable) Manufacturing Crossword Puzzle. Handout: Glossary of Green Terms Related to Wood Manufacturing Compiled by Pittsburg State University Wood Technology ______________________________________ Going Green in the Woodworking Industry

Presentation Resources on CD:

PowerPoint/PowerPoint Handout (48 slides/4-pages f/b) Glossary of Green Terms Related to Wood Manufacturing Crossword Puzzle & Answer Key Outline of Presentation with Website Resources

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Questions and Answers

Thank You for Your Attention to this Presentation: Going Green in the Woodworking Industry
Contact Information: Douglas R. Hague Jordan Clous Backs John L. Iley, Ph.D., Chairman Department of Technology and Workforce Learning Pittsburg State University Pittsburg, KS 66762 TWL Phone: 620-235-4371 Emails: drhague@pittstate.edu jcbacks@gus.pittstate.edu jiley@pittstate.edu

Kansas Technology Center

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