Metal Finishing Guide Book

2012-2013

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Figure 1. Simple example of a lean value stream map with energy and environmental components added. a company to find significant waste across their entire manufacturing process by combining labor, materials, energy, and environmental components to each process step. For Company XYZ the primary focus of the LE2 was on the energy and waste aspect of their plating operation and less on the lean aspects of the operation since energy and environmental issues were dominant. Partial capital funding and engineering funding was provided by a combination of funds from the New York Department of Environmental Conservation (engineering funding) and the New York State Energy Research and Development Authority (capital funding assistance). Figure 1 is an example of two plating process steps using lean but also including energy and environmental items. Lean typically focuses on operator time, distance of part travel, lags between operations, scrap, etc. Figure 1 shows the energy and environmental opportunities in red. For energy, there are direct electrical costs associated with ventilation fans and tank heating. There are indirect costs associated with heating or cooling of make-up air from the exhaust ventilation. There are secondary energy costs not shown in this example for pumping wastewater to waste treatment, wastewater mixing, and sludge presses that would be typical of a plating operation. There are costs of hazardous materials used in the alkaline cleaning operation such as the purchase costs, protective equipment for operators, neutralization 716

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