The Link between Lean and Green Manufacturing - A Way to Reach Sustainable Development

2014 ◽  
Vol 656 ◽  
pp. 534-541 ◽  
Author(s):  
Dana Iuliana Tilina ◽  
Miron Zapciu ◽  
Vasile Bendic
Keyword(s):  
Best Practices ◽  
Lean Manufacturing ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Environmental Problem ◽  
Sustainable Manufacturing ◽  
Green Manufacturing ◽  
First Century ◽  
Waste Minimization ◽  
Lean And Green

Today, manufacturing products in a sustainable way is increasingly becoming essential in the eyes of investors, authorities and customers. Failure leads to fines, penalties, and customers choosing to go to the competition. Success, on the other hand, can save money, helps build a reputation, attracts investment, spurs innovation, secures loyal customers and brings in repeat business. Taking into account the sustainable manufacturing is not just longer a caprice for the business.During the end of the twentieth century and into the twenty-first century two types of manufacturing systems that emphasize waste minimization have emerged: Lean and Green manufacturing. Despite the importance of Green manufacturing to the environmental problem, many companies are still skeptical about the business benefits. In the same time, however, a good many of them see the business benefits of Lean manufacturing. Several research efforts summarized in the literature review indicate how both systems share many of the same best practices to reduce their respective wastes. Yet, these two systems tend to operate independently.The aim of this research is to explore and to determine how the Lean manufacturing can include Green manufacturing system components in their overall strategy to reduce waste.

scholarly journals Technical, economic, and environmental performance assessment of manufacturing systems: The Multi-layer Enterprise Input-Output formalisation method

2021 ◽  
Author(s):  
Claudio Castiglione ◽  
Erica Pastore ◽  
Arianna Alfieri
Keyword(s):  
Environmental Performance ◽  
Lean Manufacturing ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Sustainable Manufacturing ◽  
Flow Analysis ◽  
Material Flow Analysis ◽  
Value Added ◽  
Economic Assessment ◽  
Input Output

In production planning and control, assessing the performance of a manufacturing system is a multi-dimensional problem, in which neglected dimensions may lead to hidden inefficiencies and missed opportunities for gaining a competitive advantage. This paper proposes a data formalisation method to model a manufacturing system by simultaneously considering value creation and technical, economic, and environmental performance. The proposed method combines the techno-economic assessment of lean manufacturing and sustainable manufacturing with the data-driven approach, typical of Industry 4.0, to overcome the limitations of the lean approaches in addressing complex systems. The method is based on integrating Multi-layer Stream Mapping and a combination of Enterprise Input-Output and Material Flow Analysis. It also considers non-value-added activities such as transport and inventories. Pen and papers and digital approaches can simultaneously exploit the method as a shared architecture for formal data integration. The implementation of the method is shown through a numerical example based on a recycled plastic pipeline manufacturing system.

Sustainable Manufacturing Through Lean and Green Approach: Best Practices and Indicators

2013 ◽  
Author(s):  
Brunilde Verrier ◽  
Bertrand Rose ◽  
Emmanuel Caillaud
Keyword(s):  
Literature Review ◽  
Best Practices ◽  
Lean Manufacturing ◽  
Sustainable Manufacturing ◽  
Social Dimensions ◽  
Maturity Level ◽  
Industrial Companies ◽  
Green Approach ◽  
Production Processes ◽  
Lean And Green

To become and remain competitive, companies must adopt evolution strategies. Lean Manufacturing is one such strategy used in several industrial companies. Lean Manufacturing is based on the identification and elimination of waste in various production processes. The originality of our work consists in proposing an approach which adds environmental and social dimensions to the consideration of economic earnings received through Lean actions. Adopting a case studies research methodology, we propose an extended literature review of lean and green paradigms and benchmark the practices of industrial companies in order to measure how Lean and Green actions can be enhanced when used together. We then highlight Lean and Green indicators and the associated best practices through the entire lifecycle corresponding to the maturity level of the company.

An application of grey based decision making approach for the selection of manufacturing system

2014 ◽  
Vol 4 (3) ◽  
pp. 447-462 ◽  
Author(s):  
Om Ji Shukla ◽  
Gunjan Soni ◽  
G. Anand
Keyword(s):  
Decision Making ◽  
Lean Manufacturing ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Strategic Decision ◽  
Decision Matrix ◽  
Content Type ◽  
Manufacturing Organization ◽  
Decision Making Model ◽  
Selection Of

Purpose – In the current customer-driven market, the manufacturers have to be highly responsive and flexible to deliver a variety of products. Hence, to meet this dynamic and uncertain market changes, the production system, which enables the manufacturing of such variety of products should be able to meet such diverse, dynamic changes. Hence, selecting a suitable manufacturing system is a key strategic decision for today's manufacturing organization, which needs to survive in these uncertain market conditions. Hence, the purpose of this paper is to present a decision-making model for selecting the best manufacturing system and also discuss the criteria on the basis of which the management can select the same. Design/methodology/approach – A case of small- and medium-sized company is presented, in which the management is deciding to establish a most suitable manufacturing system. To supplement this, a suitable multi-criteria decision-making model (MCDM), the grey approach is used to analyze manufacturing system alternatives based on various decision criteria to arrive a comparative ranking. Findings – An extensive analysis of grey-based decision-making model described grey decision matrix, grey normalized decision matrix, grey weighted normalized decision matrix and grey possibility degrees for three alternatives revealed that lean manufacturing systems was found to be the most suitable manufacturing system among three alternatives for a given case. Research limitations/implications – The same study can be extended by including sub-criteria with main criteria for selection of manufacturing system by utilizing two MCDM techniques such as AHP or ANP with Grey approach. Practical implications – The Grey approach has been discussed in a detailed way and it will be useful for the managers to use this approach as a tool for solving similar type of decision-making problems in their organizations in the future. Originality/value – Although, the problem of selecting a suitable manufacturing system is often addressed both in practice and research, very few reports are available in the literature of Grey-based decision models that demonstrated its application for selecting a suitable manufacturing systems.

Energy Consumption Reduction for Sustainable Manufacturing Systems Considering Machines With Multiple-Power States

2011 ◽  
Author(s):  
Zeyi Sun ◽  
Stephan Biller ◽  
Fangming Gu ◽  
Lin Li
Keyword(s):  
Energy Efficiency ◽  
Manufacturing Systems ◽  
Large Scale ◽  
Manufacturing System ◽  
Production Systems ◽  
Sustainable Manufacturing ◽  
System Level ◽  
Model Estimate ◽  
Improve Energy Efficiency ◽  
Multiple Power

Due to rapid consumption of world’s fossil fuel resources and impracticality of large-scale application and production of renewable energy, the significance of energy efficiency improvement of current available energy modes has been widely realized by both industry and academia. A great deal of research has been implemented to identify, model, estimate, and optimize energy efficiency of single-machine manufacturing system [1–5], but very little work has been done towards achieving the optimal energy efficiency for a typical manufacturing system with multiple machines. In this paper, we analyze the opportunity of energy saving on the system level and propose a new approach to improve energy efficiency for sustainable production systems considering the fact that more and more modern machines have multiple power states. Numerical case based on simulation model of an automotive assembly line is used to illustrate the effectiveness of the proposed approach.

And The World Came To See: New Manufacturing System Designs and Industrial Revolutions

2002 ◽  
Author(s):  
J. T. Black ◽  
David S. Cochran
Keyword(s):  
System Design ◽  
Systems Engineering ◽  
Lean Manufacturing ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Job Shop ◽  
Flow Shop ◽  
The World ◽  
Industrial Revolutions ◽  
New System

AND THE WORLD CAME TO SEE. When a new manufacturing system design (MSD) is developed by a company or a group of companies, the rest of the world comes to those factories to learn about the new system. In the last 200 years, three new factory designs have evolved, called the job shop, the flow shop and the lean shop. Each is based on a new system design — a functional design, a product flow design and a linked cell design. New factory designs lead to new industrial leaders and even new industrial revolutions (IR’s). Two appendixes are included: One outlines the implementation strategy for the lean shop and the other is a discussion of lean manufacturing from the viewpoint of K. Hitomi, Japanese professor of manufacturing systems engineering.

Schlank und ressourceneffizient produzieren*/Lean and Green Manufacturing

2015 ◽  
Vol 105 (04) ◽  
pp. 231-237
Author(s):  
S. Greinacher ◽  
E. Moser ◽  
H. Hermann ◽  
G. Lanza
Keyword(s):  
Carbon Dioxide ◽  
Economic Efficiency ◽  
Carbon Dioxide Emissions ◽  
Manufacturing Systems ◽  
Green Manufacturing ◽  
Decision Criterion ◽  
Manufacturing Companies ◽  
Lean And Green ◽  
The Common ◽  
Common Target

Neben den klassischen Zielgrößen Kosten, Zeit und Qualität sind Unternehmen zunehmend mit Forderungen nach Ressourceneffizienz (Energie, Material) und Verringerung von CO2-Emissionen konfrontiert. In aller Regel stellt die Wirtschaftlichkeit jedoch weiterhin das entscheidende Kriterium bei der Einführung „grüner“ Maßnahmen dar. Der Fachbeitrag beschreibt eine Methodik zur Planung und Bewertung von Maßnahmen zur wirtschaftlichen Gestaltung von Produktionssystemen unter Berücksichtigung „grüner“ Grenzwerte.   Resource efficiency and reduction of carbon dioxide emissions gain increasing importance for manufacturing companies alongside the common target dimensions cost, time and quality. Nevertheless, economic efficiency remains the primary decision criterion for the implementation of „green“ strategies. This approach presents a methodology for planning and assessment of strategies for the economic configuration of manufacturing systems with regard to „green“ limits.

Implementation of Lean Manufacturing System in Bogie Assembly in Railway Coach Factory

2012 ◽  
Vol 248 ◽  
pp. 511-515 ◽  
Author(s):  
P. Arunagiri ◽  
A. Gnanavelbabu
Keyword(s):  
Lean Manufacturing ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Low Cost ◽  
Value Added ◽  
Layout Design ◽  
Design Calculation ◽  
Assembly Shop ◽  
Cost Calculations ◽  
Two Stages

Elimination of the non-value added activities in the bogie assembly shop during bogie assembly process. The various non-value added activities are found in the assembly shop such as excess distance between each assembly stages, excess cost to flow of material from one stage to another stage, waste of time and non-flexibility of shop. These types of non-value added activities occur due to the improper arrangement of bogie assembly stages. Implementation of lean manufacturing systems through layout design by the conversion of existing layout of bogie assembly shop into proposed layout. Analysing the existing layout by using the CRAFT method to find out the best optimized layout .Interchanges are made between each stages that help to correct the present layout. Design calculation are done for various stages .Interchanging of stages of different section are considered by distant matrix and total cost calculations .Various cost of all the pair wise interchanged stages are estimated to find the best low cost interchange. As per the design calculation best interchange between the two stages are considered and that lead to the development of new proposed layout in which all the non-value added activities are eliminated

scholarly journals Simulation Modeling Approach for Collaborative Workplaces’ Assessment in Sustainable Manufacturing

2020 ◽  
Vol 12 (10) ◽  
pp. 4103 ◽  
Author(s):  
Robert Ojstersek ◽  
Borut Buchmeister
Keyword(s):  
Energy Consumption ◽  
Simulation Modeling ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Block Diagram ◽  
Operation Mode ◽  
Sustainable Manufacturing ◽  
Electrical Energy ◽  
Modeling Approach ◽  
The Impact

The presented manuscript represents a new simulation modeling approach, which evaluates the impact of collaborative workplaces on manufacturing sustainability in terms of workplaces’ cost, flow times and electrical energy consumption. The impact of collaborative workplaces on the manufacturing system and on its sustainable viability as a whole has not yet been explored, despite the fact that collaborative workplaces are increasingly present in different manufacturing systems. In the past, researchers have devoted a lot of time to research individually examining the collaborative machines, workplaces and various aspects of Sustainable Manufacturing. Investigating the impact of collaborative workplaces on an enterprise’s financial, social and environmental points of view is a very complex task, since we are talking about a multicriteria evaluation of manufacturing systems. The simulation approach is based on a newly proposed block diagram structure that allows for an evaluation of the impact of collaborative workplaces on Sustainable Manufacturing in its entirety. Using the input data of the real-world manufacturing system characteristics and Eurostat statistical values, numerical and graphical results of the proposed simulation evaluation are given, which, with a high degree of evaluation credibility, influences the introduction of collaborative workplaces in manual workplaces. The results obtained show a 20% reduction in the cost of collaborative workstations compared to manual assembly workstations, a 13.2% reduction in order throughput times, a negligible increase in energy consumption in operation mode of 3.28% and a 4.57% reduction in the idle mode. The new evaluation approach allows for a comprehensive consideration of the influence of the collective workplace when developing new or modernizing existing manufacturing systems from a financial, social and environmental point of view.

Green Manufacturing of Electricity for Stationary Industrial Applications

2008 ◽  
Author(s):  
Zulfiqar Ali-Qureshi
Keyword(s):  
Renewable Energy ◽  
Manufacturing System ◽  
Sustainable Manufacturing ◽  
Peak Load ◽  
Electricity Consumption ◽  
Green Manufacturing ◽  
Industrial Applications ◽  
Complete Analysis ◽  
Prototype Model ◽  
Synthetic Natural Gas

On-site power generation in industrial plants are desirable, however, this may not contribute as a significant source of pollution to the environment. In order to lower the potential impact on the environment in terms of less toxic emissions, to save useless cost and the sustainability, manufacturer’s responsibilities become more than end-of-pipe control and includes end-of-life management. Green manufacturing is the method that minimizes waste and pollution achieved through product and process life cycle design. The cradle to grave analysis in green manufacturing system provides the complete analysis in every aspect of the sustainable manufacturing system for policy makers to take decisions. In this paper the renewable source of alternate energy manufacturing system has been analyzed for production of power. The renewable energy from hydrogen and (green gas synthetic natural gas) for generation of electricity focusing large stationary application set up has been studied. A prototype model has been developed in order to draw analogy for establishing future Industrial power parks of mega energy productions in order to meet the peak load requirements of the electricity consumption. The results has been analyzed and comparison have also been made for the purpose to apply green industrial manufacturing process in renewable energy sector as much as possible for reducing waste and with zero potential environmental burden on our Eco-system.

Design for Lean Manufacturing: Incorporating Lean Considerations During Product Development

2006 ◽  
Author(s):  
S. J. Pavnaskar ◽  
D. Weaver ◽  
J. K. Gershenson
Keyword(s):  
System Design ◽  
Continuous Improvement ◽  
Lean Manufacturing ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Manufacturing Operations ◽  
Manufacturing System Design ◽  
Lean Engineering ◽  
Product And Process ◽  
Lean Operations

Lean has become a “must-use” philosophy for businesses today. Lean manufacturing focuses on the elimination of waste in manufacturing operations. Similarly, companies have started using lean engineering to eliminate wastes from their engineering processes. Both lean manufacturing and lean engineering yield dramatic improvements in quality, cost, and delivery. However, the philosophy of lean (manufacturing and engineering) revolves around the continuous improvement of existing processes. Costs associated with continuous improvement can be significantly reduced by incorporating “lean” considerations when designing a product, process, or manufacturing system. This is known as design for lean manufacturing (DfLM). DfLM guides the design of a product, process, or a manufacturing system to enable lean operations when in production, just as design for assembly (DFA) guides the design of a product to allow easier assembly during production. Currently, there are no guidelines that would help a product or process designer in considering to lean operations during design. Note that usage of the word “product” in this paper must be interpreted in a literary sense and not as a “widget.” The “product” of a manufacturing engineering process is a complete manufacturing system. In this paper, we consider manufacturing system design and propose a novel set of structured DfLM guidelines for designing a manufacturing system. These guidelines will be a valuable resource for manufacturing engineers to guide manufacturing system design for new products to enable lean operations once the system is in production. DfLM guidelines for system design also will help plant engineers and rapid continuous improvement managers to assess existing manufacturing systems and identify and prioritize improvement efforts. The proposed DfLM guidelines are then validated for accuracy, completeness, and redundancy by using them to evaluate an existing benchmark manufacturing system. The initial DfLM guidelines show promise for use in designing manufacturing systems that are easy to manage, flexible, safe, build quality into the products, optimize material flow, fully utilize all resources, maximize throughput, and continuously produce what the customer wants just in time. Similar guidelines can be proposed for product and process design to further enhance the efficiency of operations and reduce the overhead of continuous improvement efforts.

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