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More Henkel Corporate Reporting 2014
We have developed optimization programs that identify best operating practices and promote continuous improvement across our entire production network. Our business units develop both general and specific optimization programs for their locations, as the various production processes involved in making products such as household cleaners, skin creams or tile adhesives allow different approaches to improvements.
The Adhesive Technologies business unit is using a combination of lean production principles, workshops and structured problem-solving techniques to create customer value. Through Value Stream Mapping (VSM) workshops, we identify inefficiencies (e.g., waiting times or excess production) and develop corresponding improvement projects, which often have sustainability benefits. In 2014, the business unit also launched sustainability workshops focused on energy, water and waste and will extend them gradually to major production sites. We also began training Supply Chain and Operations managers on an eight-step methodology used to improve processes and eliminate waste, so that they can drive efficiency within their own areas of responsibility.
Employees in Seabrook, New Hampshire, USA, developed a comprehensive plan to eliminate waste, beginning with a Value Stream Mapping workshop in 2014. The roadmap is essential to optimizing processes and achieving operational excellence. Johnny Tong (right), Vice President Operations & Supply Chain Adhesive Technologies in North America, explains our lean production philosophy to Harvard Professor Dr. Ananth Raman.
The Laundry & Home Care business unit uses its Manufacturing Excellence Program to monitor best practices in the areas of sustainability and efficiency. Standardized scorecards are used to define targets and track continuous improvement measures for each site on a quarterly basis. Moreover, a global internet-based energy measurement system enables us to track our energy use in real time. In 2014, the business unit implemented energy recovery and efficiency programs that will lead to carbon dioxide savings of 20,000 metric tons per year. In recognition of these efforts, the Econique Network presented the business unit with the 2014 Energy Masters Award.
The Beauty Care business unit continues using its Total Productive Management Plus program to identify optimization potential and implement continuous improvement measures. The business unit also introduced a state-of-the art software system in Europe to monitor its performance in real time and steer processes more effectively. The system will be rolled out further in 2015. Finally, Beauty Care focuses on sharing best operating practices across its production network. The goal is to encourage sites to continue improving in all areas of sustainability by developing improvement plans specific to their needs.
In 2015, we will begin rolling out the Henkel Production System (HPS), a new continuous improvement program on a common platform, across all three business units. HPS will enable us to better leverage best practices across business units, standardize processes and harmonize production processes further.
In 2014, our cosmetics production site in Maribor, Slovenia, installed a new system that reuses process water for cleaning purposes. By collecting the process water in tanks and warming it through heat-recovery measures, we save up to 7,000 cubic meters of fresh water and 200,000 kilowatt hours of energy per year. Pictured: Technician Romana Florjančič and Project Manager Srečko Habjanič.
|Chelghoum Laïd, Algeria|
The laundry detergent plant reduced its annual energy use by six percent by replacing existing lighting fixtures with more efficient LED lighting.
A multi-million-euro investment in new manufacturing equipment for the automotive industry helped the Adhesives site turn an intermittent production system into a continuous manufacturing process. The new process reduces waste and increases ease-of-use for employees.
West Hazelton, Pennsylvania, United States
By optimizing the handling of coloration materials between the product mixing and packaging steps, the cosmetic plant reduced waste by nearly 2,000 kilograms per year.
|Seven Hills, New South Wales, Australia|
The adhesives plant began using a high-pressure cleaner to sterilize its seven tanks. By using this technique instead of boiling water to generate steam daily, the factory reduced its process wastewater by 50 percent.
Adhesives plants in Balakleya, Vyshgorod and Mykolayiv modernized their sand drying lines in 2014. The upgrades have reduced annual energy consumption by approximately 4 million kilowatt hours and related carbon dioxide emissions by 800 metric tons.