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Environment and energy pillar 90-day model area plan
An environment and energy pillar model area plan is a 90-day plan for proving, on one area of the plant, that waste and energy can be measured, cut at the source and kept down with simple standards, before the method spreads to other areas. The team maps every waste stream and energy user, checks the legal register for the area, rates the environmental aspects, hunts energy losses such as idle running and air leaks, works down the waste hierarchy (refuse, reduce, reuse, recycle) for the top streams, segregates waste at the source and writes the area standards. This template has the 13-week plan as a Gantt chart in three phases with the owner, deliverable and done-when of each activity, a scoring table to choose the model area from loss data, the team, a KPI board, the day-90 gate, and the expansion plan for months 4 to 12 in three waves, with a worked example.
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
When to use it
When to use an environment and energy pillar 90-day plan
- When a plant wants to cut waste and energy with its own people and prove the method in one area before every area is asked to do it.
- When waste and energy are only known as one figure for the whole site and nobody owns them area by area.
- When a permit, a customer or a target asks for less waste to landfill or less energy per unit, and the plant needs a plan it can show.
- When leaders want an environment plan they can review every week: who does what, by when, and what done looks like.
How to fill it in
- 1
Choose the model area from loss data
Score up to three candidate areas (five in Excel) on loss data, visibility, team willingness and repeatability, from 1 to 3. Loss data here means waste by stream, energy, water and spills by area. Pick the highest total; on a tie, the higher loss data score wins.
- 2
Name the team and write day 1
Sponsor, pillar lead, the environment coordinator, a utilities technician, and the area supervisor and operators. In Excel, day 1 and the status date set the dates and status of every activity.
- 3
Set the baseline and the day-90 targets
Waste and energy per unit of output, the share of waste to landfill, air leaks fixed and legal requirements with evidence. Per unit of output keeps a busy week from looking like a failure.
- 4
Run the 13 weeks and update the plan every week
Move a bar if your area needs it, write the week each activity really finished, and add one actual per KPI each week. Late activities turn red in the Excel version.
- 5
Pass the day-90 gate
The sponsor and pillar lead check the six gate items with evidence. If one is not met, fix it before any other area starts.
- 6
Plan the expansion waves
Wave 1 goes to the areas with the same machines, materials or utilities, with the model area team running the first waste and energy walk in each. Each new area runs its own 13 weeks against its own baseline.
The 90-day plan
Week by week: from waste and energy maps to area standards
The standard plan printed on page 1 and in the Excel version. Days 1 to 30 are weeks 1 to 4, days 31 to 60 weeks 5 to 9 and days 61 to 90 weeks 10 to 13. Move the weeks to fit your area.
| Weeks | Activity | Owner | Deliverable | Done when |
|---|---|---|---|---|
| 1 | Choose the model area and form the team (Setup) | Pillar lead | Team list; area chosen with the selection table | Team named, sponsor agreed, first meeting held |
| 1 to 3 | Map the waste streams (Measure) | Environment coordinator | Each stream: source, kg per week, where it goes (landfill, recycling, reuse) | Every stream weighed or counted for two weeks |
| 1 to 3 | Map the energy users (Measure) | Utilities technician | Motors, compressed air, heating, lighting: use when running and when idle | Baseline energy per unit of output set |
| 2 to 4 | Check the legal register for the area (Compliance) | Environment coordinator | Permits, waste rules and reporting duties that apply, with the evidence | Every requirement has an owner and evidence on file |
| 3 to 5 | Rate the area's environmental aspects (Aspects) | Environment coordinator | Aspects and impacts register for the area | Every aspect rated and the significant ones marked |
| 4 to 6 | Find energy losses: idle running, air leaks, heat loss (Energy) | Utilities technician | Leak tags from a quiet-time leak hunt; idle-running list | Each loss listed with an estimate of the energy it wastes |
| 5 to 9 | Cut the top waste streams by the waste hierarchy (Waste) | Model area team | Action per stream: refuse, reduce, reuse, then recycle | Each top stream has an action at the highest level that works |
| 6 to 9 | Fix leaks and start switch-off routines (Energy) | Area supervisor | Leak repairs; switch-off checklist for breaks, shift ends and weekends | Leaks fixed or planned and the checklist used every shift |
| 7 to 10 | Segregate waste at the source (Waste) | Area supervisor | Labelled bins by stream, a color standard and training | The right waste goes in the right bin at every check |
| 9 to 12 | Write the area standards (Standards) | Pillar lead | Segregation, switch-off and spill response standards with one point lessons | Standards posted where the work is done and the team trained |
| 10 to 13 | Measure again against the baseline (Measure) | Environment coordinator | Waste and energy per unit of output, week by week | Thirteen weeks of data on the KPI board |
| 13 | Day-90 review and decision to expand (Gate) | Sponsor | Day-90 gate sheet, KPIs against baseline, lessons | Gate signed by the sponsor and the pillar lead |
1
- Activity
- Choose the model area and form the team (Setup)
- Owner
- Pillar lead
- Deliverable
- Team list; area chosen with the selection table
- Done when
- Team named, sponsor agreed, first meeting held
1 to 3
- Activity
- Map the waste streams (Measure)
- Owner
- Environment coordinator
- Deliverable
- Each stream: source, kg per week, where it goes (landfill, recycling, reuse)
- Done when
- Every stream weighed or counted for two weeks
1 to 3
- Activity
- Map the energy users (Measure)
- Owner
- Utilities technician
- Deliverable
- Motors, compressed air, heating, lighting: use when running and when idle
- Done when
- Baseline energy per unit of output set
2 to 4
- Activity
- Check the legal register for the area (Compliance)
- Owner
- Environment coordinator
- Deliverable
- Permits, waste rules and reporting duties that apply, with the evidence
- Done when
- Every requirement has an owner and evidence on file
3 to 5
- Activity
- Rate the area's environmental aspects (Aspects)
- Owner
- Environment coordinator
- Deliverable
- Aspects and impacts register for the area
- Done when
- Every aspect rated and the significant ones marked
4 to 6
- Activity
- Find energy losses: idle running, air leaks, heat loss (Energy)
- Owner
- Utilities technician
- Deliverable
- Leak tags from a quiet-time leak hunt; idle-running list
- Done when
- Each loss listed with an estimate of the energy it wastes
5 to 9
- Activity
- Cut the top waste streams by the waste hierarchy (Waste)
- Owner
- Model area team
- Deliverable
- Action per stream: refuse, reduce, reuse, then recycle
- Done when
- Each top stream has an action at the highest level that works
6 to 9
- Activity
- Fix leaks and start switch-off routines (Energy)
- Owner
- Area supervisor
- Deliverable
- Leak repairs; switch-off checklist for breaks, shift ends and weekends
- Done when
- Leaks fixed or planned and the checklist used every shift
7 to 10
- Activity
- Segregate waste at the source (Waste)
- Owner
- Area supervisor
- Deliverable
- Labelled bins by stream, a color standard and training
- Done when
- The right waste goes in the right bin at every check
9 to 12
- Activity
- Write the area standards (Standards)
- Owner
- Pillar lead
- Deliverable
- Segregation, switch-off and spill response standards with one point lessons
- Done when
- Standards posted where the work is done and the team trained
10 to 13
- Activity
- Measure again against the baseline (Measure)
- Owner
- Environment coordinator
- Deliverable
- Waste and energy per unit of output, week by week
- Done when
- Thirteen weeks of data on the KPI board
13
- Activity
- Day-90 review and decision to expand (Gate)
- Owner
- Sponsor
- Deliverable
- Day-90 gate sheet, KPIs against baseline, lessons
- Done when
- Gate signed by the sponsor and the pillar lead
What's on the gates
The day-90 gate and the wave gate for the environment and energy pillar
The day-90 gate decides whether the model area is ready to be copied; the wave gate is checked for each new area before the next wave starts. Both are on page 3 of the PDF and on the Excel version's Day-90 gate and Expansion sheets.
Day-90 gate
All met before the first expansion wave starts
- 1Every waste stream and energy user in the area is measured against the baseline
- 2Every legal requirement for the area has an owner and evidence on file
- 3The top waste streams have actions at the highest level of the waste hierarchy that works
- 4Segregation, switch-off and spill response standards are posted and followed
- 5The KPI board has 13 weeks of data against the baseline
- 6The maps, standards and lessons are written up so another team can copy them
Wave gate
For each new area, before the next wave starts
- 7The area passed the same day-90 gate as the model area
- 8Its KPIs are measured against its own baseline, not the model area's
- 9The waste and energy standards were copied and adapted, and the copy is recorded
- 10Coaches for the next wave are named and have run a session with the pillar lead watching
- 11The model area was audited again and still holds its standard
A filled-in example
Illustrative, not a benchmarkAn example: a printing and converting plant (illustrative, with made-up numbers; the same as page 4 of the PDF and the Excel example sheets). Not a benchmark.
- Model area choice, loss data, visibility, team willingness and repeatability scored 1 to 3: Press hall scored 11, Finishing scored 9 and Ink room scored 7. The press hall made the most waste (paper trim and make-ready sheets) and used the most compressed air, sits on the visitor route, and its team asked for better bins.
- Waste per unit of output: baseline 38 kg per 1,000 units, day-90 target 28 kg per 1,000 units, week 13 actual 31 kg per 1,000 units, 70% of the gap closed.
- Share of waste to landfill: baseline 55%, day-90 target 30%, week 13 actual 35%, 80% of the gap closed.
- Energy per unit of output: baseline 210 kWh per 1,000 units, day-90 target 190 kWh per 1,000 units, week 13 actual 192 kWh per 1,000 units, 90% of the gap closed.
- Air leaks found and fixed: baseline 0%, day-90 target 100%, week 13 actual 90%, 90% of the gap closed.
- Legal requirements with evidence: baseline 70%, day-90 target 100%, week 13 actual 100%, 100% of the gap closed.
The team passed the day-90 gate in week 13. Wave 1 (months 4 to 6) went to Finishing, cutting room, wave 2 (months 7 to 9) to Ink room, plate making, and wave 3 (months 10 to 12) to Offices, canteen, yard, with a model area team member coaching each wave 1 area.
Common mistakes
Starting with recycling
Recycling is near the bottom of the waste hierarchy. Ask first whether the waste can be refused or reduced at the source, then reused, and recycle what is left.
Measuring totals instead of per unit
Waste and energy rise and fall with output. Divide by units made, or a busy week looks like a failure and a quiet week like a success.
Hunting air leaks while the plant is loud
Leaks are easier to hear and tag when production is stopped. Plan the leak hunt for a break, a weekend or a shutdown.
Leaving the legal register to head office
The area needs to know which permits and waste rules apply to it and where the evidence is kept. Give each requirement an owner.
Spreading before the gate
Copying bins and checklists to every area before the model area holds its numbers spreads habits that have not stuck yet. Hold the gate, then expand in waves.
Download the template
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
Run this template in LeanSuite
In LeanSuite anyone can flag spills, waste, air and water issues as environment tags on the spot, route each one to an owner and close it with an audit trail.
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Environment and energy pillar 90-day model area plan: common questions
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- Toyota Production System (TPS) house templateThe TPS house for one plant or value stream: roof, two pillars and foundation, with what you do today, the evidence, a status and the next step for each element.
- EPEI and batch size calculatorHow often each part can come round on a shared machine (EPEI) and how big each batch must be, from demand, cycle times and changeovers, now and after SMED.
- People, process, technology (PPT) assessmentCheck one change before go-live: 18 people, process and technology statements scored 1 to 4 by the people who will use it, the lowest element and the actions.
- Process capacity sheet templateEach machine in a part's routing with manual, auto and tool change time, its capacity per shift, and the step that limits the cell against demand.
- Jidoka worksheet (stop at abnormality)For one line or cell, every abnormality that should stop the work: how it is detected, how the work stops, who is called, the immediate fix and the root cause step, plus a log of real stops.
- Team charter templateA one-page charter for a standing team: purpose, scope, roles, the KPIs it owns, which decisions it makes itself, norms and cadence.
- Chaku-chaku line plannerPlan a load-load cell: time each machine, load and walk, check that every machine is ready when the operator comes back, compare the cell cycle with takt and size the crew.
- Standard operating procedure (SOP) templateA full SOP in the hierarchical step format, from purpose and scope to the steps, records, revision history and approvals, with review checks and an SOP register.
- Process improvement method selectorEight questions about one problem, an example rule that suggests a method and a matrix of nine methods: when each fits, the usual team and time, and the template to start with.
- X-bar and R control chart template25 subgroups with means and ranges, control limits from A2, D3 and D4, signal flags, both charts and a reaction log.
- Gage R&R study sheet10 parts, 2 or 3 appraisers, 2 or 3 trials: EV, AV, GRR, PV, %GRR and ndc by the average and range method.
- Root cause analysis templateOne report from problem statement to proof: containment, evidence, analysis, verified causes, actions and the effectiveness check.
- Safety pillar 90-day model area planThirteen weeks from the incident pyramid to safety standards on one model area, a KPI board, the day-90 gate and expansion waves.
- Quality control pillar 90-day model area planThirteen weeks from the QA matrix to the QM matrix on one model area, a KPI board, the day-90 gate and expansion waves.
- Autonomous maintenance 90-day model area planAM steps 0 to 3 on one model machine in 13 weeks, a KPI board, the day-90 gate and expansion waves for months 4 to 12.
- Professional maintenance (PM) 90-day model area planThirteen weeks from breakdown analysis to a running PM calendar on one model machine, a KPI board, the day-90 gate and expansion waves.
- Focused improvement 90-day model area planThirteen weeks from the loss Pareto to standardized fixes on one model line, a KPI board, the day-90 gate and expansion waves.
- Logistics and customer service pillar 90-day model area planThirteen weeks from the current-state map to pull on one model value stream, a KPI board, the day-90 gate and expansion waves.
- People development pillar 90-day model area planThirteen weeks from the skills matrix to trained cover on critical tasks in one model area, a KPI board, the day-90 gate and expansion waves.
- Early equipment management 90-day model area planThirteen weeks from lessons on current machines to a tracked start-up on one model equipment project, a KPI board, the day-90 gate and expansion waves.
- Cost deployment pillar 90-day model area planThirteen weeks from the loss map to costed, ranked projects in one model area, a KPI board, the day-90 gate and expansion waves.
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A shift handover sheet, a red tag log, a changeover checklist for one machine: if your team uses it on the floor, ask.