How to Use GreenLean to Realize Hundreds of Thousands of Dollars. Pearson Lean & Green
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1 How to Use GreenLean to Realize Hundreds of Thousands of Dollars Pearson Lean & Green Helping Manufacturing Enterprises Grow Profitably
2 Background Pearson is a global company with over 40,000 employees in 70 countries Copyright 2011 Pearson Education, Inc. or its affiliates. All rights reserved. 2 2
3 Background Pearson prints over 2,000,000,000 scannable documents every year. 3 3
4 What is GreenLean Waste? Energy Defects G Water L Overproduction R Material E Waiting E Packaging Emission A Non-Utilized People Transportation E Landfill N Inventory N Discharge Motion Imbalance Excess Processing 4
5 Why GreenLean? Eliminate & minimize waste Standardize best practices Save money Stay competitive Meet customer needs Promote daily awareness 5
6 Why GreenLean? Pearson s GreenLean efforts are about business growth AND business survival. These are their weapons. 6
7 Global GreenLean Recognized by the EPA as a Power Purchaser 100% of Pearson electricity comes from renewable resources Solar panels supply 20% of power in Old Tappan, NJ plant Hybrid autos for Pearson s fleet Motion sensing light switches 7
8 Global GreenLean Invest in People Engagement Continuous improvement is built in GreenLean Champion support Invest in Process Standardization Employees develop, test & approve Employees update & improve Implement standards everywhere 8
9 Local GreenLean Owatonna consumes 4 million kilowatt hours of power annually... Their 95-kilowatt wind turbine offsets 119 metric tons of Co2; that s 5,540 barrels of oil over its 20-year life! 9
10 Local GreenLean Challenge: Identify a New Waste Stream for a Prize Winner: Shrink wrap recycling Additional results: Easy implementation Additional ideas generated Employee empowerment Continued awareness Green: new ways to recycle Lean: employee engagement to solve a problem Green Award 10
11 Local GreenLean Opportunity: Build a Rain Garden The City of Owatonna implemented a Rain Garden Cost Share Program (RGCS) to promote residential and commercial rain gardens. Cost share grants of 50% up to $500 Green: self-sustaining flowers that prevent erosion Lean: less time & money spent on lawn maintenance 11
12 Local GreenLean Full standardization of all critical production activities Robust and sustained 5S program Extensive cross-training Leadership Top 10 Strategy planning CI Idea System 12
13 A BILLION ACTS OF GREEN! Raising Awareness Planet Pearson Interactive community events Pearson Green Teams at all US facilities Future Projects Cylindrical solar energy generation in Cranberry, NJ facility 13
14 A BILLION ACTS OF LEAN! Raising Awareness Lean University Cross-functional & cross-facility events Identified Lean Leaders at all facilities Future Projects Shingo Prize assessment Hoshin planning for strategic alignment 14
15 GreenLean Projects Development of 25+ US Pearson GreenLean Teams On-demand print solutions with zero set-up waste (paper, ink, electricity, forced air, driers, time, money, staffing) In-line print solutions eliminate 50% of packaging waste (equipment electricity, shrink wrap, corrugate, labels, staffing) Electronic testing & ebooks (revisions, cost, staffing, shipping) Re-design of product flow (cost, overtime, staffing, trucking real estate) 15
16 Final Thoughts Pearson embodies the GreenLean philosophies in all areas of business. Both are critical elements in continued growth and sustainment We cannot become too busy mopping up the floor to turn off the faucet. ~ Author unknown 16
17 Questions? 17
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