A systematic approach for identifying lean and green improvements related to packaging material in assembly

One significant environmental impact from assembly operations includes packaging material use and subsequent waste generation. Although current practice involves reduction of unnecessary materials handling, there is potential to adapt packaging material in order to simultaneously improve the environmental performance and reduce cost in a “lean and green” mindset. Hence, with increased emphasis on sustainable and efficient production systems, there is a growing need for analysis and decision support tools to be used by operators and engineers as well as management. This paper approaches the gap by presenting an industrial application in the form of a set of simplistic analysis methods, as a systematic approach for identifying lean and green improvement potentials for packaging material in assembly. The methodology uses the advantages of eco-mapping, waste sorting analysis and material handling analysis and combines them with the systematic prioritisation of the five-step waste hierarchy and Bill of Material (BOM) structure. A pilot test indicates that a systematic use of these tools can be an efficient decision support for implementing focused improvements, providing cost reductions, productivity improvements and resource savings. Hence, the methodology adds to the general assembly optimisation toolbox, providing rapid answers for packaging decisions, including materials usage, handling and disposal processes.