The Eco Lean Method – A Combined Approach for Low Cost Economic and Ecologic Optimization in the Manufacturing Industry☆

Abstract Rising resource efficiency is essential for a future green economy. Research and business activities in this field have thus increased dramatically during the past decades. While most environmentally oriented methods suffice to provide deep transparency, few have the ability to depict optimization potential and/or provide procedural methods of improvement. The general approach of ecological amendments in industries thus often is investment intensive. Numerous companies however do not dispose of appropriate savings. These companies strongly depend on low cost improvements, a field that has yet been neglected in research. In this paper we present a tailored approach for low cost economic and ecologic optimization of manufacturing processes. Therefore, we discuss conflicts and links between characteristic ecological and Lean principles in order to develop a greater Eco Lean mindset. Adopting the Lean philosophy, to do more with less, we introduce a four step approach. Therefore, we expand the traditional understanding of lean waste categories by adding ecologically relevant problem areas. In a first step, the orbit view, economic and ecologic wastage is determined via advanced Gemba walk that consists of visual testing and selective interrogation. We use a plant layout and specific characters to map areas of waste within a production facility. Hereupon, a weighting of problems is executed based on expected effort for implementation and impact on waste reduction. A single problem then is analyzed extensively in order to determine its value adding, organizational and waste tasks. In a final step we chose an appropriate method for optimization based on the specific problem.