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Lean and Green Production Development -Examples of Industrial Practices in China and Turkey

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Lean and Green Production Development -Examples of Industrial Practices in China and Turkey School of Innovation, Design and Engineering Lean and Green Production Development -Examples of Industrial Practices in China and Turkey Master thesis work 30 credits, D-level Product and Process Development Master Thesis Programme in Production and Logistics Authors Haiyan Wang Mesut Bora Sezen Report code: Commissioned by: Mälardalen University Tutor (university): Mats Jackson, Mälardalen University Examiner: Sabah Audo, Mälardalen University Abstract This master thesis project was initiated in connection to the research project “Green Production Systems”, which is being conducted at Mälardalen University with involvement of academics and Swedish automotive and manufacturing industries. This thesis is prepared in guidance of “Development of guidelines for environmental value improvement and cost decrease” work package and the work package associated “Lean and Green Production Systems” master thesis proposal (see Appendix I). The aim of the thesis is to provide the work package with an international aspect under the given master thesis proposal scoping. The main objective of this thesis has been to contribute to a further understanding of how approaches to lean and green can be used to develop competitive production systems. A theoretical frame of reference has been presented in order to provide the research with a theoretical foundation. Further, empirical studies of four companies from China and Turkey have been carried out to investigate how companies perceive and work with their production systems in terms of applications of lean and green approaches. The empirical studies also aimed at identifying good examples of current practices that the companies achieved within the area. Keywords: Lean Production/Manufacturing, Green Production/Manufacturing, Lean and Green Production/Manufacturing, Clean Production/Manufacturing Acknowledgements First of all, we would like to express our gratitude to our supervisor Mats Jackson. Thank you for providing us with initial “Lean and Green Production Systems” master thesis proposal information and the “Green Production Systems” research project information. The information enabled us to initiate our research studies within lean and green production field and take the right direction to shape our project objective and research questions. Dear Mats, your support and guidance has been invaluable; thank you for all the feedback that you provided us with, for your advices, and especially for the time that you have spared for us, in such short notices. The project would not be possible without the support of the companies that we handled interviews to form our results in regards to lean and green production. We would like to thank to Karsan and Tofas (Turkey); Dongfeng and Jinxiang Badge (China) automotive industry companies for sparing time for us to handle interviews and all the support provided before, during, and after the interviews. We also would like to thank to Sabah Audo, our master program coordinator and thesis examiner. Thank you for all your guidance and support when we had the needs and questions regarding procedures of initiating, handling, and submitting a master thesis. Västerås, November, 2011 Bora Sezen & Haiyan Wang Table of Content 1. INTRODUCTION ........................................................................................................................ 1 1.1 BACKGROUND ................................................................................................................................. 1 1.2 AIM OF PROJECT .............................................................................................................................. 1 1.3 RESEARCH QUESTIONS .................................................................................................................... 2 1.4 EXPECTED OUTCOMES ..................................................................................................................... 3 1.5 DELIMITATIONS ............................................................................................................................... 3 2. METHODOLOGY ....................................................................................................................... 4 2.1 LITERATURE STUDY ........................................................................................................................ 4 2.2 CHOICES OF DATA COLLECTION ...................................................................................................... 5 2.3 COMPANY STUDIES: DELIMITATION AND SELECTION ....................................................................... 6 2.4 VALIDITY AND RELIABILITY ............................................................................................................ 8 2.4.1 VALIDITY .................................................................................................................................. 9 2.4.2 RELIABILITY .............................................................................................................................. 9 3. THEORETICAL FRAMEWORK ............................................................................................. 10 3.1 LEAN PRODUCTION ....................................................................................................................... 10 3.1.1 DEFINITION OF LEAN PRODUCTION ...................................................................................... 10 3.1.2 PRINCIPLES OF LEAN PRODUCTION ....................................................................................... 12 3.1.3 LEAN ‘MUDA’ WASTES ........................................................................................................... 13 3.1.4 THE HOUSE OF LEAN PRODUCTION....................................................................................... 15 3.1.5 LEAN TOOLS, METHODS AND TECHNIQUES .......................................................................... 16 3.2 GREEN PRODUCTION ..................................................................................................................... 31 3.2.1 DEFINITION OF GREEN MANUFACTURING ............................................................................ 31 3.2.2 GREEN (ENVIRONMENTAL) WASTES DEFINITION .................................................................. 32 3.2.3 KEY ELEMENTS OF GREEN MANUFACTURING ....................................................................... 34 3.3 “LEAN AND GREEN PRODUCTION” ................................................................................................ 53 3.3.1 WASTE PERSPECTIVE ............................................................................................................. 53 3.3.2 LEAN AND ENGERGY USE RELATION ...................................................................................... 55 3.3.3 LEAN AND CHEMICAL WASTE RELATION ............................................................................... 61 4. RESULTS .................................................................................................................................... 70 4.1 COMPANY 1 - KARSAN ............................................................................................................. 70 4.2 COMPANY 2 - TOFAS ................................................................................................................. 79 4.3 COMPANY 3 - DONGFENG ....................................................................................................... 91 4.4 COMPANY 4 - JINXIANG BADGE ............................................................................................ 99 5. DISCUSSIONS ......................................................................................................................... 108 6. CONCLUSIONS & FUTURE STUDY..................................................................................... 119 6.1 CONCLUSIONS ........................................................................................................................ 119 6.2 FUTURE STUDY ...................................................................................................................... 120 7. REFERENCES ......................................................................................................................... 121 8. APPENDICES ........................................................................................................................... 124 APPENDIX I MASTER THESIS PROPOSAL ........................................................................................... 124 APPENDIX II GUIDING INTERVIEW QUESTIONS .................................................................................. 126 Figure list FIGURE 1 THE HOUSE OF LEAN PRODUCTION [1] .................................................................................. 16 FIGURE 2 TPM STRUCTURE [7] ............................................................................................................... 19 FIGURE 3 THE SEVEN-STEP LADDER [7] .................................................................................................. 20 FIGURE 4 VALUE STREAM MAPPING [7]. ................................................................................................ 23 FIGURE 5 LOADING A MACHINE WITH ONE PIECE OF WIP [11] ............................................................. 25 FIGURE 6 HIGH-VARIETY PRODUCTION [11] ........................................................................................... 26 FIGURE 7 LIFE CYCLE STAGES [23] .........................................................................................................
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