Lean manufacturing principles were introduced to several western companies at 80's [1]. Since them, those who want to implement lean principles focus mainly on building a robust lean process [2], becoming excellence models within their corporate group.
But frequently they face an obstacle when trying to implement a lean process, even when the organization has a clear purpose and engaged people: the lack of Lean designed equipment, which avoids obtaining the maxim benefits of a real lean process.
In parallel, LEED (Leadership in Energy and Environmental Design) rating systems with 1.6 million feet certifying per day around the world is growing significantly each year, delivering more sustainable design constructions [3]. Companies such as Volkswagen plant, in Chattanooga; American Honda Finance Corporation (AHFC) office, in Charlotte, North Carolina and General Motors' new Lansing Delta Township (Mich.) assembly plant are some of those companies that received a certification from the U.S. Green Building Council's Leadership in Energy and Environmental Design (LEED) program.
But recently, a research entitled “Identification of Safety Risks for High Performance Sustainable Construction Projects” [4] shows that LEED certified constructions sites led to a one-third higher risk of workplace injury compared to traditional construction counterparts.
The L2 Engineering is a methodology based on LEAN (1st L) principles, in one side to design Lean equipment, to design Lean processes and consequently, designs a Lean plant. In other side, those Lean plants and buildings are also designed with LEED (2nd L) certification norms.
This paper describes the key principles and design methodology of L2 Engineering to deliver a Lean plant and buildings that work efficiently, effectively with lower energy consumption and production cost. It also provides safe standard conditions required to build a LEED certified factories. The companies designed with L2 Engineering will be the next leap to become a Lean and Green organization.