• Table of Contents
  • Boxes
  • Figures
  • Tables
• Acknowledgements

Table of Contents

• Executive Summary
• Preface
• Chapter 1: Introduction
  • Learning to See Chemical Wastes
  • Benefits of Addressing Chemicals with Lean
  • Getting Started with Lean and Chemicals
• Chapter 2: Chemicals Overview
  • Definition of Chemical Waste
  • Understanding the Dangers of Chemicals
  • Examples of Hazardous Chemicals
  • How to Learn More about Chemicals
  • The Chemical Lifecycle
• Chapter 3: Driving Out Chemical Waste with Lean Events
  • Value Stream Mapping Events
  • Kaizen Events
• Chapter 4: Chemical Management in the Lean Organization
  • Lean Strategies and Chemical Use
  • Lean Approaches to Chemical and Hazardous Waste Management
• Chapter 5: Managing Chemicals in Lean Workspaces
  • Point-of-Use Storage Best Practices
  • Visual Management of Chemicals in the Workplace
• Chapter 6: Lean Product and Process Design Methods
  • Introduction to Lean Product and Process Design
  • Add Environmental Design Criteria to Lean Design Methods
  • Draw on Design for the Environment Tools and Resources to Find Safer Alternatives
  • Use Green Chemistry Principles When Designing Chemical Processes
  • A Vision for Lean and Chemicals Efforts
• Chapter 7: Conclusion
  • Getting Started with Lean and Chemicals
  • Partners for Success
• Appendix A: Chemical Resources
• Appendix B: Material Safety Data Sheet Template Example
• Appendix C: Point-of-Use Storage Request Form Example

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Boxes

• Key Benefits of Addressing Chemicals with Lean (Box 1)
• Example Results From Lean and Chemical WasteReduction Efforts (Box 2)
• Benefits of Coordinating Lean and Chemical Management Activities (Box 3)
• The European Union’s RoHS and REACH Directives Are Influencing Businesses’ Use of Chemicals (Box 4) 
• Example of Chemical Wastes (Box 5)
• Value Stream Mapping at Woodfold Manufacturing, Inc. (Box 6)
• Processes with Chemical Wastes (Box 7)
• Common Operational Changes That Trigger EHS Involvement (Box 8)
• Key Questions for Identifying Chemical and Hazardous Waste Reduction Opportunities (Box 9)
• Asking Why Five Times (Box 10)
• Canyon Creek Cabinet Company “Toxics Team” (Box 11)
• Eliminating the Need to Address Risk Management Planning Requirements – Goodrich Aerostructures Example (Box 12)
• Point-of-Use Storage Cabinets at Robins Air Force Base (Box 13)
• Benefits of Chemical Management Services (Box 14)
• Chemical and Hazardous Waste Management Process Improvement at Lockheed Martin (Box 15)
• Regulatory Compliance under a Lean Chemical Management Strategy (Box 16)
• Point-of-Use Storage Request Form Questions (Box 17)
• POUS Situations to Look for and Promptly Address (Box 18)
• Key Questions for Improving Chemical Labeling (Box 19)
• Managing Chemicals Safely – Nine Simple Steps (Box 20)
• Product Design Criteria (Box 21)
• Process Evaluation Questions from a Chemical Perspective (Box 22)
• EPA’s Sustainable Futures Program (Box 23)

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Figures

• Chemical Warning Signs (Figure 1)
• National Fire Protection Association Chemical Label Example (Figure 2)
• Chemical Lifecycle (Figure 3)
• Process Boxes Showing Environmental Wastes (Figure 4)
• Current State Map with Chemical Metrics (Figure 5)
• Conceptual Outline of Adding Environmental Inputs and Outputs on Value Stream Maps (Figure 6)
• Photo of Modified Value Stream Map (Figure 7)
• Value Stream Map Incorporating Environmental Inputs and Outputs (Figure 8)
• Right-Sized Containers (Figure 9)
• Point-of-Use Storage Cabinets (Figure 10)
• The Six Pillars of 6S (5S + Safety) (Figure 11)
• 6S (5S + Safety) Applied to a POUS Station (Figure 12)
• Visual Control Examples (Figure 13)

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Tables

• Example Persistent Bioaccumulative Toxic (PBT) Chemicals Covered by the TRI Program (Table 1)
• Methods Used in Lean Design (Table 2)
• Product Design Stages and Appropriate Lean Tools (Table 3)

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Acknowledgements

The U.S. Environmental Protection Agency (EPA) is grateful for the valuable assistance of the organizations and individuals who helped develop this toolkit and shared experiences, tools, and techniques for integrating Lean manufacturing and chemical waste reduction. EPA’s National Center for Environmental Innovation, Office of Pollution Prevention and Toxics, and Office of Resource Conservation and Recovery participated in the development of this toolkit.

This toolkit has benefited from the collective expertise and ideas of many individuals. In particular, EPA would like to thank the following individuals for their thoughtful contributions:

• Dave Bury, Energy Engineer, Energy Office, Robins Air Force Base
• Caitlin Callaghan, PhD Chemical Engineering, JD and Masters Environmental Law and Policy, Vermont Law School
• Casey Connolly, Continuous Improvement & Reliability Manager, Gulf Chemical & Metallurgical Corporation
• John Earl, Environmental Manager & Special Projects, Canyon Creek Cabinet Company
• Hal Ehrhardt, Principal Environmental, Health & Safety Engineer, Corporate Office, Lockheed Martin
• Kevin Emerick, EHS Manager, Woodfold Manufacturing, Inc.
• Michelle Gaither, Environmental Engineer, Pacific Northwest Pollution Prevention Resource Center
• Dave Gunnarson, Senior Staff Environmental Engineer, Manassas, Virginia facility, Lockheed Martin
• Carole LeBlanc, Special Expert, Emerging Contaminants, Office of Deputy Under Secretary of Defense
• Becky McCoy, P.E., Chief, Environmental Division, Robins Air Force Base
• Charlie Martin, Consultant, Oregon Manufacturing Extension Partnership

This toolkit was prepared for the U.S. Environmental Protection Agency by Ross & Associates Environmental Consulting, Ltd. (http://www.ross-assoc.com) in association with Industrial Economics, Inc. (EPA Contract # EP-W-04-023).

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