Thesis Archive
Cleaner production with lean thinking : an application to the fish canning industry of the Philippines (2009)
Brillante, Jamica B.
Cabahug, Frances Isabel V.
Flores, Rozanne P.
Abstract:
-Philippine fish canning industry is responsible for several ill environmental impacts due to wastes from the whole production process, ranging from its inputs and high water consumption up to its high level of effluent wastewater discharge. The application of cleaner production and lean manufacturing had been explored for the first time in an industry setting to assuage its environmental impacts in order to bring the industry to the same decent levels as worldwide eco-friendly industries having new cleaner technologies. With this, an industry-wide survey dissemination was done to access the current system architecture of the fish canning companies in terms of their current environmental practices and lean tools used but only 17% of these companies agreed to participate in the survey. By conducting a case study, the cleaner production assessment identified the overall and per operation waste in the fish canning process where material balances showed six main waste streams namely spoiled fish, melted ice, damaged can, energy/heat loss, spilled sauces, and contaminated water. A comprehensive set of cleaner production options, gathered from related literature and focus group discussions, were proposed to eliminate the waste streams on receiving, at its source. To solve the production waste vis-a-vis the problem of decreasing raw fish supply and increasing tin can prices, a lean thinking approach was also conducted where overproduction, high inventories waiting and transport times are the non-value adding tasks shown in the current value stream map. To solve the production waste, inventory and demand level management, cellular manufacturing layout, work standardization, load-leveling, and 5s process were the lean tools and methodologies conformed to meet the proposed future state map.
The proposed cleaner production technologies and lean manufacturing tools were then integrated in the system architecture of the plant where overlapping solutions are evaluated lean-clean analysis heuristics. From the whole study, there is evidence to show that implementation of clean and lean technologies will reduce the environmental impact in the fish canning industries and the study estimate showed that water consumption decreased to 3 m³ /MT, BOD5 effluence reduced to 9 kg/MT and energy consumption was continuously improved.
Adviser:
Ms. Bella Manalang