Greening the canned peach production

Transcription

1 Greening the canned peach production Dimitris Folinas a, Dimitrios Aidonis b, Panayotis D. Karayannakidis c a,b,c,d Department of Logistics, Technological Educational Institute of Central Macedonia, Katerini Branch, Greece,

2 Background 2 This study is a one of the deliverables of a national research project under the Research Project Thales titled Implementation of green development in agrifood supply chains It is a three year project that was launched in April 2012, running until April 2015 This project will design implementation models and a respective green performance measurement toolset for assessing environmental sustainability of agrifood products on a supply chain level

3 Background 3 Agrifood Supply Chain: a complex network that consists of a number of entities linked from farm to fork, such as farmers, suppliers, cooperatives, packhouses, transporters, exporters, importers, wholesalers, retailers, and finally consumers Past: minimize costs while enhancing the quality of the end product Now: identify the factors that have environmental impacts in the targeted supply chain by decreasing waste Lean Thinking: allows the identification of the various sources of waste in the supply chains Value Stream Mapping: a visual representation of processes aiming identifying and removing non value add steps and therefore eliminate waste

4 Background 4 Agrifood Supply Chain: a complex network that consists of a number of entities linked from farm to fork, such as farmers, suppliers, cooperatives, packhouses, transporters, exporters, importers, wholesalers, retailers, and finally consumers Past: minimize costs while enhancing the quality of the end product Now: identify the factors that have environmental impacts in the targeted supply chain by decreasing waste Lean Thinking: allows the identification of the various sources of waste in the supply chains Value Stream Mapping: a visual representation of processes Overproduction, Waiting, Transportation, Processing, Inventories: raw material, aiming work in process, identifying and finished and removing goods, Moving: non value add both operator and steps machine, and and therefore eliminate Defects: defective waste products or process outputs

5 Background 5 Agrifood Supply Chain: a complex network that consists of a number of entities linked from farm to fork, such as farmers, suppliers, cooperatives, packhouses, transporters, exporters, importers, wholesalers, retailers, and finally consumers Past: minimize costs while enhancing the quality of the end product Now: identify the factors that have environmental impacts in the targeted supply chain by decreasing waste Lean Thinking: allows the identification of the various sources of waste in the supply chains Value Stream Mapping: a visual representation of processes aiming identifying and removing non value add steps and therefore eliminate waste

6 Aim 6

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8 Aim 8 Propose a systematic approach for measuring the environmental performance of supply chains in agrifood sector based on the Value Stream Mapping (VSM) technique for determining waste The suggested approach includes specific steps and tasks which are presented and analysed Each of the tasks / steps aimed at eliminating non value adding steps in order to reduce on the length of the value stream which subsequently would contribute to the reduction of the total process, lead and customer query cycle times and consequently the energy consumption and emissions

9 Proposed approach based on Value Stream Mapping 9 Step 1: Selection of agrifood supply chain processes to be value streamed Step 2: Development of the Current State Map (CSM) of the selected logistics processes in the agrifood supply chain Step 3: Development of the Future State Map (FSM) Step 4: Development of the Action Plan (AP)

10 Proposed approach based on Value Stream Mapping 10 Step 1: Selection of agrifood supply chain processes to be value streamed Selection of processes that would be studied in depth in the next steps Based on the following six (6) criteria: Processes that require significant amounts of inputs / resources, such as pounds of materials used, pounds of hazardous materials used, gallons of water used, gallons of water consumed, watts of energy used, etc. Processes that emit significant amounts of outputs, such as pounds of solid waste generated, pounds of hazardous waste generated, pounds of air pollution emitted, etc. Processes requiring environmental permits or reporting to environmental agencies. Processes that include special pollution control equipment and/or specialized infrastructure. Processes that potentially affect the environmental consciousness and sensitiveness of the producers. Processes that potentially affect the environmental consciousness and sensitiveness of the consumers.

11 Proposed approach based on Value Stream Mapping Step 2: Development of the Current State Map (CSM) of the selected logistics processes in the agrifood supply chain 11 CSM depicts diagrammatically how the selected processes performed at the time (snapshot of the current practices and materials usage rates for these processes) and collect and record information where environmental impacts occur in the agrifood product line Both qualitative and quantitative data can be collected for the identification of waste. The data are categorized into two groups: General information: cycle time, processing time for each of the logistics tasks performed, average waiting time for each order, number of operators, etc. Specific information: pounds of materials and hazardous materials used, gallons of water and energy used, pounds of solid waste and hazardous waste generated, pounds of air pollution emitted and gallons of wastewater treated

12 Proposed approach based on Value Stream Mapping Step 3: Development of the Future State Map (FSM) 12 FSM symbolizes the starting point for the improvement activities. Therefore, specific questions can be used for the identification of improvements: What is the energy consumption (electricity, etc.) of each machine, conveyer or any other tools during the running of the processes? What is the energy consumption during the logistics activities (such as transportation, distribution or inventory?) How often are orders marshaled for the production of an agrifood product? What are the constraints in the above operations? What other improvement are required regarding the environmental impacts?

13 Proposed approach based on Value Stream Mapping Step 4: Development of the Action Plan (AP) 13 This step involve the design or drafting of the plan based on the Future State Map. The AP includes the following information: Information regarding the project of the application of the suggested improvements, such as the title and description of the project, its goals and objectives, the responsible process managers, scheduling Information regarding the examined logistics processes, such as the title, description, status (not started, in progress, completed), impact, and priority

14 Case Study 14 Value Stream Mapping (VSM) diagrams is used in order to develop visual representations of the canned peach production First, the Current State Map (CSM) is developed to represent the production as is in order to identify the highest sources of waste (non value added activity) in the value stream of the examined process, as well as, to develop an implementation plan for lean techniques with the development of the Future State Map (FSM)

15 Case Study Proposed approach based on Value Stream Mapping 15 Step 1: Selection of agrifood supply chain processes to be value streamed Step 2: Development of the Current State Map (CSM) of the selected logistics processes in the agrifood supply chain Step 3: Development of the Future State Map (FSM) Step 4: Development of the Action Plan (AP)

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17 Step 1: Selection of agrifood supply chain processes to be value streamed 17 Based on the above description of the canned peach production the following discrete processes are identified: factory reception, washing, cutting in halves and removing the kernels, peeling (removal of residual chemicals), washing, sorting, cup up, cup down, filling with fruit, addition of syrup, degassing, closing, pasteurizing, cooling pelletizing and labeling But, are all these processes potentially waste sources?

18 Step 1: Selection of agrifood supply chain processes to be value streamed 18 A number of interviews were arranged with key persons in the Production and Quality Assurance departments Respondents took into account the effects, causes and environmental impact of the seven wastes and evaluated the processes using four values: Not significant, Low, Medium and High (significance) Data extracted from both departments and referred to the production line of the last 3 years were collected and analyzed A number of reports were created and given to employees / respondents to make a more reliable evaluation

19 Step 1: Selection of agrifood supply chain processes to be value streamed 19

20 Step 2: Development of the Current State Map (CSM) of the selected logistics processes in the agrifood supply chain The study was focused on the environmental aspects of the targeted procedure and was referred to: Electricity used (kwh/per production line) and Steam used (% of the total use) 20

21 Step 2: Development of the Current State Map (CSM) of the selected logistics processes in the agrifood supply chain 21 According to the estimations some processes that were measured have some of the environmental impacts But all have time and labour inputs such as the number of employees / shifts, cycle time (c/t), operation time (o/t), set up time, scrap rate, rework rate, etc. Current State Map (CSM) Daily schedule

22 Step 2: Development of the Current State Map (CSM) of the selected logistics processes in the agrifood supply chain 22

23 Step 2: Development of the Current State Map (CSM) of the selected logistics processes in the agrifood supply chain 23 Inventory, Transportation and motion waste, as well as, the Waiting waste are not critical Furthermore, according to the historical data maintained by the Quality Control company s department, the Defect level (caused by scrap rate, design error, machine setup, wrong process production and quality protocol assessment) is very low (~0.5% per lot) so this waste is also not critical There are two processes that have significant environmental impact in terms of water and energy used: Peeling and subsequent washing and pasteurizing

24 Step 3: Development of the Future State Map (FSM) 24 Peeling and pasteurizing are the most energy consuming The use of chemical compounds during peeling, such as potassium and sodium hydroxide, will increase the chemical load of wastes, and the production cost Peeling by steaming instead of chemical peeling, automatically minimizes the amount of water during the second washing for removing any residual chemicals, having great benefits regarding water consumption Another point to be made is that most of the holding tanks and piping, in the peach canning industries in Greece, are lacking insulation and this is of significant importance for minimizing the energy losses, especially in the stages where heating and cooling are involved Peach kernels may be exploited by the industries for energy production (biomass boilers) to cover the energy requirements of other small production lines

25 Step 3: Development of the Future State Map (FSM) 25 First: Insulation of holding tank and piping

26 Step 3: Development of the Future State Map (FSM) 26 Second: Utilization of peach kernels for energy production

27 Step 3: Development of the Future State Map (FSM) 27 Third: Substitute the current chemical peeling process with steam peeling

28 Step 3: Development of the Future State Map (FSM) 28 Third, Substitute the current chemical peeling process with steam peeling

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30 30 Step 4: Development of the Action Plan (AP)

31 Step 4: Development of the Action Plan (AP) 31 After the deployment of the Action Plan (AP) the following achievements have been realized: Today, canned peach production is achieved by peeling with sodium hydroxide solution at 95oC. However, peeling by steam, which is an alternative peeling process, may have great benefits regarding water consumption and energy usage Insulation of piping and vessels, where heating or cooling is involved can further reduce steam consumption and therefore energy usage The kernels formed during the cutting in halves process can also be used for the production of energy Finally, the wastes (peels) that derive after peeling can be used for animal feed and if steam peeling instead of chemical peeling is used, then no neutralization step is necessary

32 Conclusions 32 A step by step approach for determining the waste in the agrifood supply chain was proposed based on the Value Stream Mapping, which is a basic Lean Thinking tool The proposed systematic approach was deployed in the canned peach production The main objective aims to assess the current status of the selected agrifood supply chains, in the context of environmental sustainability (green) practices focusing on SMEs, so as to improve the understanding of the supply chains and to identify areas of potential improvement

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