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“SAFE AND SUSTAINABLE INDUSTRIAL
DEVELOPMENT”
for better future
G Rajan Kumar
Why is manufacturing becoming more
environmentally conscious?
Sustainable manufacturing has both benefits and costs, but it can help make every company more
competitive. Let’s discuss sustainability in manufacturing in more detail.
Is any company trying to cope with increasing environmental regulation?
Are the customers demanding better environmental performance and data?
Do we want to lower your energy and materials costs?
Are we interested in producing and marketing greener products?
Common questions for everyone
Every Manufacturing Firm needs
 Raw materials
 Energy
 Manpower
 Machinery
 Market
Unwanted outputs
 Waste
 Scrap
 Hazardous materials
What is Sustainability?
A common definition of sustainable development is that of the UN
Brundtland Commission:
“Sustainable development is development that meets the needs of
the present without compromising the ability of future generations to
meet their own needs.”
This concept suggests that, in addition to its economic
performance, a company must also account for and focus on its
environmental and social performance to be truly sustainable.
Another common way of saying this is “people, planet, profit”
Sustainability is the intersection of these three concepts.
Environmental
(Planet)
Economic
(Profit)
Social
(People)
Sustainability
Designing our product to be
reusable,
remanufacturable,
recyclable, or
biodegradeable
Working with stakeholders
like customers and retailers
to reduce the
environmental impact of
sales and distribution
Expanding the life of the
product, making it easier
to repair or designing it to
use fewer resources
during use
Using less
packaging, lowering
product weight,
using more efficient
transportation and
logistics
Modifying
production
processes to use
less energy, water,
and materials and
to produce less
waste
Using fewer
materials and inputs
and materials that
are non-hazardous
or recycled
Using renewable
materials that don’t
deplete the natural
environment
So What does Sustainable Manufacturing Mean in
Practice?
Then: Pollution Control and
Treatment
• End-of-pipe pollution abatement (wastewater
treatment, air scrubbers and filters)
• Benefits include better environmental performance
and regulatory compliance
• Not likely to produce direct financial benefits
Now: Cleaner
Production
• Pollution prevention at the source (i.e. energy
efficiency, waste reduction)
• Benefits include environmental performance,
regulatory compliance, lower energy and material
costs, increased marketability of products and
brand, employee recruitment and retention,
innovation, etc.
For many years, the main environmental focus with regards to manufacturing was pollution abatement—preventing the pollution that
has been created from getting into the environment.
The attention has shifted to cleaner production and pollution prevention. With cleaner production, there are many opportunities for cost
savings and other financial benefits for companies.
Evolution of Sustainable Manufacturing
How do you Implement Sustainable Manufacturing?
It can be overwhelming to think about all the work that would be required to make your company more sustainable.
However, there is a spectrum of efforts you can make towards sustainable manufacturing. Some involve more effort and investment than
others.
Raw Material
Substitution
Shifting to more
environmentally sound
inputs
Generally easier More Difficult
Process Optimization
• Process optimization involves changing your manufacturing process to minimize waste,
conserve raw materials, and capture and reuse waste materials.
• There may be simple things we can do to change our production process to become more
sustainable.
• Maybe we can collect metal savings for recycling, change the steps in a painting process
to use less paint, or rearrange your machines to minimize movement.
• Although it is challenging, you may be able to find ways to substitute greener materials for hazardous
materials, chemicals with high environmental or health impacts, materials that are non-renewable, or
those that are scarce.
• We may also be able to find ways to eliminate materials that are used during your production process
but don’t remain in the final product.
• Example: use water-based solvents rather than chemical solvents.
• If the materials we are eliminating are considered hazardous, this can help you avoid regulatory costs
associated with storage and disposal of materials.
Raw Material Substitution
New Product Design
• Design our product to be greener from the ground up. This concept touches on all of the previous sustainable
manufacturing concepts. It can even include redesign involving rethinking how your product is used, and may
involve:
– Using recycled materials instead of new ones
– Using renewable materials
– Designing for easy disassembly, for recycling, or for remanufacturing
– Using less packaging and more recycled or recyclable packaging
• Green product design can have the same benefits as other aspects of sustainable manufacturing, including
improved resource efficiency.
Example
• A famous company used design-for-the-environment
principles when it redesigned its well known Aeron chair.
The chairs are now made up of up to 53% recycled
materials and are 94% recyclable. They are easily
disassembled, contain no PVC, and emit very low levels of
VOCs.
Environmental Waste
• Environmental waste can be described as “any
unnecessary use of resources or a substance released into
the air, water, or land that could harm human health or the
environment.”
• Environmental Waste includes:
– Any energy, water, or other materials used that are
more than what is really needed to meet the customer’s
needs
– Hazardous materials and substances
– Pollutants, residuals, and other material wastes
released into the environment (air emissions,
wastewater discharges, hazardous wastes, solid
wastes)
• As mentioned previously, adding “clean” to lean can result
in significantly greater returns for any company.
Traditional Wastes Addressed by
Lean:2
DOWNTIME
•D efects
•O verproduction
•W aiting
•N on-utilized Resources
•T ransportation
•I nventory
•M otion
•E xtra Processing
Adding Clean to Lean
• Energy and materials are consumed to make defective
products, and defective products need to be disposed of.
Defective Products or
Components
• Materials and energy are consumed to make
unnecessary products. Products may spoil or become
obsolete. Products may require hazardous materials
Overproduction of
Components or Final Products
• Materials may spoil or become damage. Downtime
wastes energy for heating, cooling, and lighting.
Waiting
Lean Waste Environmental Impact
Adding Clean to Lean (Cont.)
• Energy is used for transport and produces emissions.
Transport can cause damage or spills. More space is needed
for additional motion, requiring heating and cooling.
Unnecessary Transport or
Motion
• More packaging and space is needed for excess inventory.
Storage could cause deterioration of products and waste.
Requires energy to heat, cool, and light inventory space.
Excess Inventory
• If processing is unnecessary, increases waste and energy
use. Consumes more parts and raw materials.
Extra Processing
Lean Waste Environmental Impact
Challenges to Sustainable Development
• Environmental degradation
• Lack of technology in harnessing Renewable energy sources
• Financial problems
• Change in consumption patterns
• Policy and Frameworks
• Population
• Energy management
Industries Should focus on
• Renewable energy sources
• Improving process efficiency
• Design parameters
• Reducing wastage
• Using of recycled products
• Increasing product life
• Energy management
• Usage of Non-hazardous materials
• Waste management
Safe and sustainable development for Industry

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Safe and sustainable development for Industry

  • 1. “SAFE AND SUSTAINABLE INDUSTRIAL DEVELOPMENT” for better future G Rajan Kumar
  • 2. Why is manufacturing becoming more environmentally conscious? Sustainable manufacturing has both benefits and costs, but it can help make every company more competitive. Let’s discuss sustainability in manufacturing in more detail. Is any company trying to cope with increasing environmental regulation? Are the customers demanding better environmental performance and data? Do we want to lower your energy and materials costs? Are we interested in producing and marketing greener products? Common questions for everyone
  • 3. Every Manufacturing Firm needs  Raw materials  Energy  Manpower  Machinery  Market Unwanted outputs  Waste  Scrap  Hazardous materials
  • 4. What is Sustainability? A common definition of sustainable development is that of the UN Brundtland Commission: “Sustainable development is development that meets the needs of the present without compromising the ability of future generations to meet their own needs.” This concept suggests that, in addition to its economic performance, a company must also account for and focus on its environmental and social performance to be truly sustainable. Another common way of saying this is “people, planet, profit” Sustainability is the intersection of these three concepts. Environmental (Planet) Economic (Profit) Social (People) Sustainability
  • 5. Designing our product to be reusable, remanufacturable, recyclable, or biodegradeable Working with stakeholders like customers and retailers to reduce the environmental impact of sales and distribution Expanding the life of the product, making it easier to repair or designing it to use fewer resources during use Using less packaging, lowering product weight, using more efficient transportation and logistics Modifying production processes to use less energy, water, and materials and to produce less waste Using fewer materials and inputs and materials that are non-hazardous or recycled Using renewable materials that don’t deplete the natural environment So What does Sustainable Manufacturing Mean in Practice?
  • 6. Then: Pollution Control and Treatment • End-of-pipe pollution abatement (wastewater treatment, air scrubbers and filters) • Benefits include better environmental performance and regulatory compliance • Not likely to produce direct financial benefits Now: Cleaner Production • Pollution prevention at the source (i.e. energy efficiency, waste reduction) • Benefits include environmental performance, regulatory compliance, lower energy and material costs, increased marketability of products and brand, employee recruitment and retention, innovation, etc. For many years, the main environmental focus with regards to manufacturing was pollution abatement—preventing the pollution that has been created from getting into the environment. The attention has shifted to cleaner production and pollution prevention. With cleaner production, there are many opportunities for cost savings and other financial benefits for companies. Evolution of Sustainable Manufacturing
  • 7. How do you Implement Sustainable Manufacturing? It can be overwhelming to think about all the work that would be required to make your company more sustainable. However, there is a spectrum of efforts you can make towards sustainable manufacturing. Some involve more effort and investment than others. Raw Material Substitution Shifting to more environmentally sound inputs Generally easier More Difficult
  • 8. Process Optimization • Process optimization involves changing your manufacturing process to minimize waste, conserve raw materials, and capture and reuse waste materials. • There may be simple things we can do to change our production process to become more sustainable. • Maybe we can collect metal savings for recycling, change the steps in a painting process to use less paint, or rearrange your machines to minimize movement. • Although it is challenging, you may be able to find ways to substitute greener materials for hazardous materials, chemicals with high environmental or health impacts, materials that are non-renewable, or those that are scarce. • We may also be able to find ways to eliminate materials that are used during your production process but don’t remain in the final product. • Example: use water-based solvents rather than chemical solvents. • If the materials we are eliminating are considered hazardous, this can help you avoid regulatory costs associated with storage and disposal of materials. Raw Material Substitution
  • 9. New Product Design • Design our product to be greener from the ground up. This concept touches on all of the previous sustainable manufacturing concepts. It can even include redesign involving rethinking how your product is used, and may involve: – Using recycled materials instead of new ones – Using renewable materials – Designing for easy disassembly, for recycling, or for remanufacturing – Using less packaging and more recycled or recyclable packaging • Green product design can have the same benefits as other aspects of sustainable manufacturing, including improved resource efficiency. Example • A famous company used design-for-the-environment principles when it redesigned its well known Aeron chair. The chairs are now made up of up to 53% recycled materials and are 94% recyclable. They are easily disassembled, contain no PVC, and emit very low levels of VOCs.
  • 10. Environmental Waste • Environmental waste can be described as “any unnecessary use of resources or a substance released into the air, water, or land that could harm human health or the environment.” • Environmental Waste includes: – Any energy, water, or other materials used that are more than what is really needed to meet the customer’s needs – Hazardous materials and substances – Pollutants, residuals, and other material wastes released into the environment (air emissions, wastewater discharges, hazardous wastes, solid wastes) • As mentioned previously, adding “clean” to lean can result in significantly greater returns for any company. Traditional Wastes Addressed by Lean:2 DOWNTIME •D efects •O verproduction •W aiting •N on-utilized Resources •T ransportation •I nventory •M otion •E xtra Processing
  • 11. Adding Clean to Lean • Energy and materials are consumed to make defective products, and defective products need to be disposed of. Defective Products or Components • Materials and energy are consumed to make unnecessary products. Products may spoil or become obsolete. Products may require hazardous materials Overproduction of Components or Final Products • Materials may spoil or become damage. Downtime wastes energy for heating, cooling, and lighting. Waiting Lean Waste Environmental Impact
  • 12. Adding Clean to Lean (Cont.) • Energy is used for transport and produces emissions. Transport can cause damage or spills. More space is needed for additional motion, requiring heating and cooling. Unnecessary Transport or Motion • More packaging and space is needed for excess inventory. Storage could cause deterioration of products and waste. Requires energy to heat, cool, and light inventory space. Excess Inventory • If processing is unnecessary, increases waste and energy use. Consumes more parts and raw materials. Extra Processing Lean Waste Environmental Impact
  • 13. Challenges to Sustainable Development • Environmental degradation • Lack of technology in harnessing Renewable energy sources • Financial problems • Change in consumption patterns • Policy and Frameworks • Population • Energy management
  • 14. Industries Should focus on • Renewable energy sources • Improving process efficiency • Design parameters • Reducing wastage • Using of recycled products • Increasing product life • Energy management • Usage of Non-hazardous materials • Waste management