Lean applied to the sorting of waste - Experience feedback in industrial environment

The waste treatment sector is characterized by the absence of "pull flows", as well as the absence of batches, since we are rather in continuous, push flows at certain stages of the process. For some, this effectively disqualifies lean approaches. Faced with these objections, our approach was pragmatic. We didn't spend months "arguing" about concepts and theory, but sought to transpose them to our business reality. We believe that the most important thing for our industries in France is already to take action and become high-performance, learning companies.

We recognize that the characteristics of the sector call for an intellectual adaptation of lean methods, and even of the purpose of certain tools. For example: on an incineration plant, SMED (Single Minute Exchange Die – rapid tool change) may be considered, not to reduce batch sizes, but to increase equipment availability (reduction of technical downtime), and thus avoid diverting volumes to competitors/subcontractors. This also avoids a certain number of truck round-trips, which contributes to reducing the carbon footprint. Likewise, a VSM can be used to analyze flows and limit the number of machine and personnel movements.

In this case, we're talking about the implementation of a TPM (Total Productive Maintenance) approach applied to a waste sorting center. While the financial and technical benefits of the approach are obvious, so is the managerial contribution. Organization and skills development, and easier communication from the field to the technical departments, are the main human gains achieved.

We are therefore convinced that this sector of activity can draw inspiration from the best operational excellence practices of other industrial sectors (automotive, etc.). This case study is just one example.