Kata for the Environment. Lean Educators Conference 2016 Professor Pauline Found

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1 Kata for the Environment Lean Educators Conference 2016 Professor Pauline Found

2 WHAT IS THE PROBLEM WE ARE TRYING TO SOLVE?

3 What is the problem?

4 WHAT IS THE PROBLEM WE ARE STILL TRYING TO SOLVE?

5 Since Rachel Carson wrote Silent Spring in 1962 we have known there is a problem in the way that we have treated the environment

6 Over the last 40 years legislation in EU and UK has tried to solve the problem Control of Pollution Act, 1974 & 1989; Single European Act, 1986; Environmental Protection Act, 1990; Controlled Waste (Registration of Carriers & Seizure of Vehicles) Regulations, 1991; Water Resources Act, 1991; Water Industry Act, 1991; Environmental Act, 1995; Special Waste Regulations, 1996; Air Quality Framework Directive, 2008 Integrated Pollution, Prevention and Control (IPPC) Directive, 2008 Waste Electrical and Electronic Equipment (WEEE) Directive, 2012 Packaging Essential Requirements, 1997, 2015

7 We have known about the problem for decades Yet this still happens. We don t change our habits either as an organisation or as individuals We ignore signs We tolerate excess packaging

8 Packaging Essential Requirements, 1996, The essential requirements are, in summary: i) Packaging volume and weight must be the minimum amount to maintain the necessary levels of safety, hygiene and acceptance for the packed product and for the consumer. ii) Packaging must be manufactured so as to permit reuse or recovery in accordance with specific requirements. iii) Noxious or hazardous substances in packaging must be minimised in emissions, ash or leachate from incineration or landfill. These were established 20 years ago

9 WHAT CAN WE DO ABOUT IT?

We need to change our habits Goals first influence habits by setting cues to motivate people to respond Goals energise and direct action towards an outcome People act on habit

10 We need to change our habits Goals first influence habits by setting cues to motivate people to respond Goals energise and direct action towards an outcome People act on habit by tailoring their behaviour according to the reward +/- of the response Once habits form, context cues trigger automatic responses Habit = Cue -> Response -> Reward (H=C+R+R)

11 We need to change our habits and our behaviours Habits are automatic behavioural responses to environmental cues, thought to develop through repetition of behaviour in consistent contexts. When habit is strong, deliberate intentions have been shown to have a reduced influence on behaviour.

12 Theory of Planned Behavior/Theory of Reasoned Action Habit Habit Fishbein and Aizen (1975) Aizen, 1991

13 MOTIVATION Fogg s Behavioural Model High Motivation Triggers Succeed Here Low Motivation Triggers Fail Here Hard to Do ABILITY Easy to Do

15 We need to set our direction Sustainable Development by 2030

16 Improvement Kata Supported by Coaching Kata

17 Kata for Environment KATA AND LEAN CAN HELP WITH REDUCING OUR ENVIRONMENTAL IMPACT Some case studies of companies who are making a difference

18 Case 1 GKN LEAN AND GREEN BUSINESS MODEL ANDREA PAMPANELLI REGIONAL ENVIRONMENTAL MANAGER GKN DRIVELINE AMERICAS - PHD

19 Lean and Green Business Model Source: Pampanelli, 2013

20 GKN Driveline: Brazilian operations mass and energy flows Source: Pampanelli, 2013 Source: Pampanelli, 2013

21 5-Step Lean and Green Business Model (L&GBM) process Source: Pampanelli, 2013

22 Lean and Green Business Model (L&GBM) at 3 Levels of Flow Cell, Plant and Supply Chain Source: Pampanelli, 2013

23 Source: Pampanelli, 2013

24 Systems Approach - To build into the CI Culture Source: Pampanelli, 2013

25 Case 2 ACCOLADE WINES CIRCULAR ECONOMY MODEL ALI BEARD-GUNTHER CI MANAGER ACCOLADE WINES

26 The Circular Economy Why the circular economy? the industrial revolution-inherited, linear, extractive model of take, make, dispose MAKE MORE WITH LESS Taiichi Ohno Courtesy Ali Beard-Gunther, 2016

27 Ellen MacArthur Foundation & Model The Ellen MacArthur Foundation works with business, government and academia to build a framework for an economy that is restorative and regenerative by design. A circular economy is restorative and regenerative by design, and aims to keep products, components, and materials at their highest utility and value at all times. The concept distinguishes between technical and biological cycles.

28 Accolade Wines are developing a model that will show how they embrace this and integrate this into their DNA. Accolade Wines

29 Circular Economy Waste Hierarchy Model Design Waste Out Maintain As new Prevent Reduce Re-use Re-furbish Re-purpose Re-manufacture Recycle Recovery Dispos al Accolade Wines

30 Accolade Wines What are we doing? 1. Working with SevernNet and UWE on CE in Avonmouth. 3. Strategy Creation Include: Renewables, Obsolescence, Energy, Water Reduction. 2. Art of the Possible Workshop in the innovations room with Suppliers. Pet Bottles, Labels made of Grape pomice, Wine from a protected area.

1 E - Training of Revised Waste heirachy Model Strategy Creation July 2014 2 Obselete

All of these are either underway or will be included in the 2016/17 projects.

6 Residual packaging standardisation and review 7 Direct Electricty supply from waste

8 All Cleaning water is now grey water - rinser from Bottling Lines.

31 1 E - Training of Revised Waste heirachy Model Strategy Creation July Obselete packaging Reduction of X 3 SIC of Wine Usage Action and alert level. All of these are either underway or will be included in the 2016/17 projects. 4 SIC on Glass Usage 5 Mapping of Avon Mouth with Severn net - opportunities to re-use. 6 Residual packaging standardisation and review 7 Direct Electricty supply from waste reprocessing plant waste heat project. 8 All Cleaning water is now grey water - rinser from Bottling Lines Boilers fed by grey water RO and Carbon filters. Gray water top up of rain water system in summer. 11 Potential for Nitrogen Generation. 12 Circular Economy Product and Packaging

Residual Packaging Challenge As well as actual packaging we have the packaging the packaging is delivered in, on and with. This is a hierarchy analysis of the packaging that comes in with wine labels.

32 Residual Packaging Challenge As well as actual packaging we have the packaging the packaging is delivered in, on and with. This is a hierarchy analysis of the packaging that comes in with wine labels. Where are the opportunities? Residual Packaging Assessment: Collotype Type of packaging/ Plastic Stretch on the pallet Pallet Corner Protector Box No of boxes. Divider Core in reel Core 2 to hold Label backing Red Pallets Bag from BIB New Bags Boxes for cores Material of the packaging. How many? Weight Grams Current State Onwards handling: Current state Opportunity for Improvement from Supplier LDPE Wood Cardboard Cardboard Cardboard Cardboard Cardboard Wood Cardboard ( 126g ) 1 Whole Pallet Current State Current State Current State Current State Various Customosed to the size of the box Recycle Energy Recover Recycle Recycle Recycle Recycle Recycle Recycle Energy Recovery Reuse Recycle Recycle Recycle Currently stock is delivered to put euro pallets into the racking the Currently stock is delivered to put euro pallets into the racking the Changing to plastic cores - these would need Changing to plastic cores - these would need to be made to specific sizes, there would to be made to specific sizes, there would need to be many more in the system, they need to be many more in the system, they woul dneed to be segreagtred and sorted by woul dneed to be segreagtred and sorted by size and sent back. Given the variation of the size and sent back. Given the variation of the reels the two locations and the increased reels the two locations and the increased cost this is not feasible cost this is not feasible Current actions: Change to LPR Lightweight Lightweight Rewind Units Future State Recycle Recycle Recycle ( Light weighted Card ) Recycle ( Light weighted Card ) Recycle Recycle ( Light weighted Card ) Re - use Re - use Recycle Reuse Recycle Recycle Recycle AP Opportunity for improvement We incur extra handling and wasted space in the cages due to putting cores in with flat boxes. These then need to be emptied and are sorted in the waste area. 1. Can we find bins to segragate cores in the cages - either hang the bin on the cage or put one inside. We incur extra handling and wasted space in the cages due to putting cores in with flat boxes. These then need to be emptied and are sorted in the waste area. 1. Can we find bins to segragate cores in the cages - either hang the bin on the cage or put one inside. Revenue/Cost/Neutral Supplier/Service provider Per tonne REVENUE Neutral REVENUE REVENUE Neutral REVENUE REVENUE REVENUE COST COST COST COST COST Biffa Somerlap Biffa Biffa Biffa Biffa Biffa Accolade Wines

Accolade Wines Mapping the flow of residual packaging Process Euro Pallet Arrives Slaved onto Standard pallet Sent to line Label reels waits on pallet until required.

33 Accolade Wines Mapping the flow of residual packaging Process Euro Pallet Arrives Slaved onto Standard pallet Sent to line Label reels waits on pallet until required. Reel loaded onto Agg Labels go onto bottles Waste Standard WHITE pallet Standard RED pallet White Euro pallet Plastic Shroud Plastic Wrap Box Divider Reel Core Box Core Backing Handling 1 Blue Cage - Plastic Blue Cage - Plastic Line 2/3 in to plastic bags Line 1 - Re wound - Handling 2 Flat Boxes Sorted Cores Sorted Plastic Bag Soft cheeses - Red small bin Processing at AP Compactor 1 Dedicated Plastic ( Can do both) Compactor 2 Dedicated Plastic ( Can do both) Put in boxes into a container Compactor A Label Backing only Big Blue Wheelie bin Processing by onward LR Somerlap Biffa - Pick up as required. Biffa - Pick up as required. Sorted as Outsize Cardboard Biffa Biffa - Pick up as required.

Last word to the Future Generation 15,674,019,386 trees pledged 14,195,107,561 trees planted 1 st August 2016 We children think we can plant a trillion trees

34 Last word to the Future Generation 15,674,019,386 trees pledged 14,195,107,561 trees planted 1 st August 2016 We children think we can plant a trillion trees in 10 years. I don t have much hope that adults will do something. So we children will do it ourselves. Felix Finkbeiner. A 13-year-old calls for climate action.

35 Felix Finkbeiner addresses United Nations in 2011

36 THANK YOU VERY MUCH

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