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Figure 8.1 separates this 11-step process as it relates to the Six Sigma approach. By applying Six Sigma and the systems approach, waste minimization alternatives can be developed and evaluated in a standardized manner to reduce the organization s environmental impact and improve nancial performance. With this approach, alternatives are fully described, environmental impacts are quanti ed, a feasibility analysis is conducted, a nancial justi cation analysis is performed, and feedback is collected from all stakeholders before making a nal decision to implement. To aid in describing the 11-step process, a case study is utilized as an example to discuss the real-world application of each step. The case study involves a company in Northwest Ohio that is a leading manufacturer of original equipment batteries, specializing in parts for Chrysler, Ford, Jeep, Nissan, and Mazda. Approximately 18,000 to 20,000 batteries are produced per day in a plant that was opened in 1980. The basic components in battery construction are the case, positive plates, negative plates, separators, plate straps, electrolyte, and terminals. At the company, the separator is made of microporous rubber while the case is made of polypropylene. Other components are lead oxide and acid electrolyte. Waste is generated from each of these components and these waste streams along with the process ow diagrams are discussed in this chapter.

After identifying the need to minimize solid waste and gaining top management support, the rst step involves establishing the team and de ning goals. The key outcomes and deliverables of this step are

must have a few leadership players, several role players, and several doers. A typical team, depicted in Figure 5-3, has three membership tiers. Level 0 establishes the expectations, level 1 provides the guidance and direction, and level 2 executes the strategy at the process level. The level 0 responsibility is assigned to a leadership-quality executive, the level 1 responsibility is assigned to a team consisting of key executives, and the level 2 responsibility is assigned to the process or department managers. The department managers then develop a series of measurements according to the Six Sigma Business Scorecard guidelines.

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Again, we will end up with a graph with three lines. Make a prediction now! How do you expect this graph to differ from the one when we connected solar cells in series The solar cells will be connected in accordance with Figure 10-25. First connect one cell, then two in parallel, then three! Now plot the graph from the points that you obtained (Figure 10-26) and compare it to Figure 10-24.

Measure 2. Review existing solid waste and recycling records 3. Create process flowcharts and conduct throughput analyses 4. Conduct the solid waste sorts at the facility

Analyze 5. Analyze the data to determine annual generation by work unit or area and establish baseline data

Improve 6. Identify major waste minimization opportunities 7. Determine, evaluate, and select waste minimization process, equipment, and method improvement alternatives. 8. Develop the waste minimization deployment and execution plan 9. Execute and implement the waste minimization plan and timeline

Remember that business is a collection of processes. The processes might be office or production, sales or purchasing,

Control 10. Validate the program versus established goals 11. Monitor and continually improve performance

How do the two graphs differ Well, it can be seen that in the parallel plots, the voltage remains the same throughout, and it is the current that changes contrast this to the series experiment where it was the voltage that changed.

A letter of support from top management to all employees Team leader and member identi cation Initial training for the team Project goal identi cation including metrics Team charter Project timeline Project budget

Upper management support is one of the most important components for any successful project. A letter, memo, or e-mail from the organization president, CEO, or facility manager to all employees is a great way to set the tone of the project and to create awareness among all employees. A clear message must be sent that solid waste minimization is an important focus of the company and that all employees are requested to take part and contribute. Figure 8.2 shows a sample letter that may be used.

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