Uitic 18th congress session 2 1 sergio dulio presentation

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Lean , green and clean: a new paradigm for footwear manufacturing Sergio DULIO Consultant November 15th, 2013


LEAN, GREEN AND CLEAN A « comprehensive » definition: “to produce only what is needed, minimizing wastes and inefficiency throughout the entire manufacturing process, with the lowest possible energy consumption, respecting and protecting the environment” It is more than just lean, it goes beyond green , it expands sustainability: it’s a manifesto for footwear production in the years to come ..

Sergio Dulio, Consultant , October 15th, 2013


LEAN, THE CLASSICAL DEFINITION LEAN MANUFACTURING definition: Lean manufacturing is a production practice that considers the expenditure of resources for any goal other than the creation of value for the customer to be wasteful and then targets for their elimination. Value is defined as any action or service the customer would be willing to pay for

LEAN IS CENTERED ON PRESERVING VALUE WITH LESS WORK

Sergio Dulio, Consultant , October 15th, 2013


A ÂŤ LEAN Âť APPROACH TO THE MARKET ON DEMAND PRODUCTION: what can be leaner than producing ONLY what a customer has ordered and has already paid for? Internet is changing the traditional purchase patterns and the whole retail structure. The manufacturing systems of the future will have to be very reactive and highly flexible so to receive a customer order and to deliver the product within two or three days Sergio Dulio, Consultant , October 15th, 2013


A « LEAN » APPROACH TO THE MARKET CUSTOMIZATION OF GOODS; if we can produce unit orders on demand why not eliciting the customer even more by producing shoes customized according to his desires and wishes? Placing the customer back at the centre of the sale and manufacturing process unleashes a full potential to learn from ..

Sergio Dulio, Consultant , October 15th, 2013


GREEN: A CLASSICAL DEFINITION GREEN PRODUCTION: more sustainable consumption patterns and more sustainable products will require new production sites able to produce more sustainable products with minimal consumptions and emissions. What we need is resource conscious machines ..

Sergio Dulio, Consultant , October 15th, 2013


BEYOND GREEN RESOURCE CONSCIOUS MACHINES Machines which consume a minimum of energy, with a minimum use of materials and a minimum input of human capital We can learn from other industries and adjust their findings to our needs ..

Sergio Dulio, Consultant , October 15th, 2013


BEYOND GREEN # EXAMPLE 1 Learn from other industries Like in a modern car with a start and stop ECO function the new MGT EVAlution machine can automatically reduce its power consumption when idle and supply power to its devices only when needed and where needed Sergio Dulio, Consultant , October 15th, 2013


BEYOND GREEN # EXAMPLE 2 Re-think energy hungry machines A new generation of heat setters and other thermal conditioning units adopts a combination of new radiating systems and control electronics to reduce power consumptions

Sergio Dulio, Consultant , October 15th, 2013


BEYOND GREEN # EXAMPLE 3 Revise process to rethink the machine Moving from thermoplastic cements to water based, fluid ones in a toe lasting machine has several advantages; it reduces power consumption as well as pollution and the risks for the operators’ health Sergio Dulio, Consultant , October 15th, 2013


BEYOND GREEN MACHINES Resource conscious processes; the machine approach must be extended to the entire process, to the manufacturing system, the facilities in which it is installed , the entire enterprise.

Sergio Dulio, Consultant , October 15th, 2013


BEYOND GREEN A SYSTEM APPROACH EMfIEE – Energy Management for Increasing Energy Efficiency for the footwear factories of the future

Sergio Dulio, Consultant , October 15th, 2013


EXPAND CLEAN PRODUCTION Clean is a philosophy that should embrace the entire value chain: Raw materials: clean , biodegradable leather tanned in clean tanneries. Shoe manufacturing process that don’t use polluting or dangerous substances and that don’t generate wastes. Products designed according to LCA principles and that can be recycled at the and of their life.

Sergio Dulio, Consultant , October 15th, 2013


EXPAND CLEAN PRODUCTION Consider the entire lifecycle; it can become a business TIMBERLAND Earthkeepers TM A green recyclable product ; brands begin to appreciate a green market

Sergio Dulio, Consultant , October 15th, 2013


LEAN, GREEN AND CLEAN The synthesis of three worlds: lean processes and organization, using power conscious machines processing clean materials to produce clean products The GREEN domain: : machines, energy , power saving

The LEAN domain: : processes, organization, business models

The CLEAN domain: : materials, substances, chemicals Sergio Dulio, Consultant , October 15th, 2013


CONCLUSION Consumers are becoming more attentive to environmental impact, healthy products and to a careful use of energy resources. This should turn into a "value" for the products we buy and this requires companies to innovate products and processes in order to minimize their environmental impact, to optimize the use of resources (of all kinds) and to adopt organizational schemes (in the broad sense) to reduce such wastes to a minimum. An apparent burden should be transformed into a new challenge and a market opportunity.

Sergio Dulio, Consultant , October 15th, 2013


LEAN, GREEN AND CLEAN

SERGIO DULIO Via San Giacomo 17/2 27029 Vigevano (PV) Italy Telephone: +39 0381 71702 Mobile: +39 335 6664251 Email: dulio@tin.it Skype address: sdulio Sergio Dulio, Consultant , October 15th, 2013