This article proposes a detailed calculation model for costing green manufacturing that incorporates concepts of industrial dynamics and product lifecycles. The model comprises a process-based cost model focusing on carbon emission costs and energy-saving activities, and a systems dynamics model that simulates dynamic metrics often ignored in traditional models. The findings show equipment costs and carbon emission costs are major cost components, and the total lifecycle cost of a green manufactured product is lower than a conventionally manufactured product. The model provides a tool for managers to accurately allocate resources for energy-saving activities based on appropriate cost drivers.
Three-quarters of US businesses reported using at least one green technology or practice in August 2011 according to a Bureau of Labor Statistics survey. The survey found around 855,000 jobs, representing 0.7% of total US employment, were held by workers who spent over half their time on green technologies and practices. Over a quarter of these green technology and practice jobs were in building maintenance and cleaning or installation, maintenance, and repair occupations. The survey defined green jobs as those involving making business production processes more environmentally friendly or using fewer natural resources.
This document presents a project report submitted by three students - Udbhav Datta, Rishabh Bhadhuria, and Aditya Singla - to fulfill the requirements for a Bachelor of Technology degree in Civil Engineering from The NorthCap University, Gurgaon. The report aims to rank the key drivers for adopting Green Supply Chain Management (GSCM) practices in the Indian construction industry using the Analytical Hierarchy Process (AHP) methodology. It begins with an introduction and literature review on GSCM and identifies a research gap around ranking important GSCM drivers for the Indian construction sector. The study then describes applying the AHP framework to survey construction companies in Delhi-NCR, shortlist relevant GSCM drivers
IRJET- Green Supply Chain Management in Construction Industry: A ReviewIRJET Journal
This document provides a literature review on green supply chain management (GSCM) practices in the construction industry. It first defines GSCM and discusses its importance and benefits. It then reviews several studies that have examined various aspects of GSCM in construction, including frameworks for implementation, key drivers and barriers, and the GSCM practices of different countries/regions. The document concludes that while construction activities can harm the environment, GSCM provides opportunities to reduce negative impacts and improve sustainability across the construction supply chain.
IRJET- Optimization of Machining Facility Layout by using Simulation: Cas...IRJET Journal
This document describes a case study of optimizing the facility layout of a machining facility through simulation. The existing layout is analyzed using FlexSim simulation software. An alternative layout is generated using Systematic Layout Planning methodology and also analyzed using FlexSim. Simulation results show the proposed layout reduces material handling distance by 40-65%, time to start first machining by 65-97%, and throughput time by 3-12% compared to the existing layout. This case study demonstrates how simulation can be used to evaluate facility layout alternatives and optimize performance.
Manual on material_flow_cost_accounting_iso 14051-2014zubeditufail
MFCA is a management accounting method that traces material flows and assigns costs in an organization. It quantifies materials used, waste generated, and their associated costs to identify improvement opportunities that reduce waste and costs. By highlighting full material costs, MFCA motivates organizations to improve environmental performance and profitability through more efficient material use. It serves as a tool to link environmental and economic goals.
Optimisation assessment model for selection of material and assembly for sust...IJMREMJournal
Sustainable Selection of Material and Assembly (SMA) constitutes a importants strategy in building design and
construction. Current sustainable SMA methods fail to provide adequate solutions for finding the optimum
improvement strategies and choosing the best alternative in a decision environment. To assist the decision-making
process, this study suggests the Multi objective Optimization (MO) approach utilization. However, process
improvements cannot be based only on environmental considerations, other factors like socio-economic must be
also being considered in parallel. As well, the study indicates that MO coupled with Life Cycle Assessment (LCA)
provides a tool for balancing process environmental and economic performance. The value of this approach in
environmental process analysis rests in providing an optimal option for process improvements which may be
optimal and suitable for a particular situation. A decision-aid tool – optimum Life Cycle Assessment Performance
(OLCAP) – is recommended. OLCAP is tested and demonstrated by application to case studies of an existing
traditional construction method and contemporary construction method of low cost housing projects. The MO
value in process analysis lies in allowing for an alternative option for process betterments, therefore able the
selection of the Best Available Technique not Entailing Excessive Cost (BATEEC) and Best Practicable
Environmental Option (BPEO).
THE EVALUATION OF FACTORS INFLUENCING SAFETY PERFORMANCE: A CASE IN AN INDUST...IJDKP
Safety has become a very important element in firms and organisations especially in Ghana. The impact of safety factors on a firm’s 3E’s (Employee, Environment and Equipment) can improve or deteriorate firm’s public image. This paper identified the key safety indicators and also provided a set of core factors that contribute meaningful in promoting safety performance in an Industrial Gas producer in Ghana using the Analytic Hierarchy Process. Organisational, Human, Technical and Environmental factors were identified as the safety indicators in relation to the study area. The studies revealed that organisational factor is the most important factor or criterion that could facilitate a better safety performance of the Industrial Gas
Company. In addition, employees was identified the best safety alternative, whilst environment and equipment followed sequentially.
This document contains information about Jae-Ho Bae, including his background, publications, awards, current and past positions, and consulting work. It provides details on various projects he has conducted related to overall equipment effectiveness (OEE), production improvement, algorithm design, and system implementations. The document is authored and copyrighted by Jae-Ho Bae in 2013. It aims to provide information on his expertise in OEE and related areas.
Three-quarters of US businesses reported using at least one green technology or practice in August 2011 according to a Bureau of Labor Statistics survey. The survey found around 855,000 jobs, representing 0.7% of total US employment, were held by workers who spent over half their time on green technologies and practices. Over a quarter of these green technology and practice jobs were in building maintenance and cleaning or installation, maintenance, and repair occupations. The survey defined green jobs as those involving making business production processes more environmentally friendly or using fewer natural resources.
This document presents a project report submitted by three students - Udbhav Datta, Rishabh Bhadhuria, and Aditya Singla - to fulfill the requirements for a Bachelor of Technology degree in Civil Engineering from The NorthCap University, Gurgaon. The report aims to rank the key drivers for adopting Green Supply Chain Management (GSCM) practices in the Indian construction industry using the Analytical Hierarchy Process (AHP) methodology. It begins with an introduction and literature review on GSCM and identifies a research gap around ranking important GSCM drivers for the Indian construction sector. The study then describes applying the AHP framework to survey construction companies in Delhi-NCR, shortlist relevant GSCM drivers
IRJET- Green Supply Chain Management in Construction Industry: A ReviewIRJET Journal
This document provides a literature review on green supply chain management (GSCM) practices in the construction industry. It first defines GSCM and discusses its importance and benefits. It then reviews several studies that have examined various aspects of GSCM in construction, including frameworks for implementation, key drivers and barriers, and the GSCM practices of different countries/regions. The document concludes that while construction activities can harm the environment, GSCM provides opportunities to reduce negative impacts and improve sustainability across the construction supply chain.
IRJET- Optimization of Machining Facility Layout by using Simulation: Cas...IRJET Journal
This document describes a case study of optimizing the facility layout of a machining facility through simulation. The existing layout is analyzed using FlexSim simulation software. An alternative layout is generated using Systematic Layout Planning methodology and also analyzed using FlexSim. Simulation results show the proposed layout reduces material handling distance by 40-65%, time to start first machining by 65-97%, and throughput time by 3-12% compared to the existing layout. This case study demonstrates how simulation can be used to evaluate facility layout alternatives and optimize performance.
Manual on material_flow_cost_accounting_iso 14051-2014zubeditufail
MFCA is a management accounting method that traces material flows and assigns costs in an organization. It quantifies materials used, waste generated, and their associated costs to identify improvement opportunities that reduce waste and costs. By highlighting full material costs, MFCA motivates organizations to improve environmental performance and profitability through more efficient material use. It serves as a tool to link environmental and economic goals.
Optimisation assessment model for selection of material and assembly for sust...IJMREMJournal
Sustainable Selection of Material and Assembly (SMA) constitutes a importants strategy in building design and
construction. Current sustainable SMA methods fail to provide adequate solutions for finding the optimum
improvement strategies and choosing the best alternative in a decision environment. To assist the decision-making
process, this study suggests the Multi objective Optimization (MO) approach utilization. However, process
improvements cannot be based only on environmental considerations, other factors like socio-economic must be
also being considered in parallel. As well, the study indicates that MO coupled with Life Cycle Assessment (LCA)
provides a tool for balancing process environmental and economic performance. The value of this approach in
environmental process analysis rests in providing an optimal option for process improvements which may be
optimal and suitable for a particular situation. A decision-aid tool – optimum Life Cycle Assessment Performance
(OLCAP) – is recommended. OLCAP is tested and demonstrated by application to case studies of an existing
traditional construction method and contemporary construction method of low cost housing projects. The MO
value in process analysis lies in allowing for an alternative option for process betterments, therefore able the
selection of the Best Available Technique not Entailing Excessive Cost (BATEEC) and Best Practicable
Environmental Option (BPEO).
THE EVALUATION OF FACTORS INFLUENCING SAFETY PERFORMANCE: A CASE IN AN INDUST...IJDKP
Safety has become a very important element in firms and organisations especially in Ghana. The impact of safety factors on a firm’s 3E’s (Employee, Environment and Equipment) can improve or deteriorate firm’s public image. This paper identified the key safety indicators and also provided a set of core factors that contribute meaningful in promoting safety performance in an Industrial Gas producer in Ghana using the Analytic Hierarchy Process. Organisational, Human, Technical and Environmental factors were identified as the safety indicators in relation to the study area. The studies revealed that organisational factor is the most important factor or criterion that could facilitate a better safety performance of the Industrial Gas
Company. In addition, employees was identified the best safety alternative, whilst environment and equipment followed sequentially.
This document contains information about Jae-Ho Bae, including his background, publications, awards, current and past positions, and consulting work. It provides details on various projects he has conducted related to overall equipment effectiveness (OEE), production improvement, algorithm design, and system implementations. The document is authored and copyrighted by Jae-Ho Bae in 2013. It aims to provide information on his expertise in OEE and related areas.
This document discusses Lean Six Sigma and resources available through Knovel to support Lean Six Sigma implementation. It provides an overview of the Lean Six Sigma implementation process including strategic leadership and vision, deployment planning, and execution and results. It describes Knovel's Lean Six Sigma resources such as handbooks, case studies, templates, and guides covering tools like DMAIC, DOE, SPC etc. that can help with the different belts and project phases from Define to Control. Other resources discussed include those for Design for Six Sigma and practical applications/case studies.
Presently most electrical/electronic equipment (EEE) is not designed for recycling, let alone for circulation. Plastics in these products account for 20% of material use, and through better design, significant environmental and financial savings could be gained.
Technological solutions and circular design opportunities already exist, but they haven’t been implemented yet.
Some challenges, such as ease of disassembly, could be resolved through better communication and by sharing learnings across the value chain.
Instead of WEEE, we should focus on developing CEEE: Circular Electrical and Electronic Equipment.
The case examples of this report show how different stages of the lifecycle can be designed so that plastics circulation becomes possible and makes business sense.
I am pursuing masters in Industrial Engineering. During the course of my degree I have taught many concepts of Industrial Engineering and I am confident that I can apply all the concepts in real time environment. With the great knowledge of Fundamentals of 6 sigma, statistics, MRP, JIT and Deterministic Optimization, I am confident to apply those concepts for production procedures, production standards and costs. I have come from the mechanical background so I have pretty good knowledge about mechanical procedures and applying industrial concepts to enhance overall system. While working in industries, I realized the impact of applying industrial concepts in Industries. My knowledge is well defined and I take pride working in sync with people and resources at every stage of production cycle.
This document discusses MnTAP's efforts to help Minnesota businesses reduce solvent usage for degreasing operations while maintaining effectiveness. MnTAP evaluated products at 23 facilities to identify alternatives that reduce VOC emissions and human health risks. Some successful substitutions included replacing lacquer thinner containing HAPs with acetone at one company, and replacing three solvents with a single water-based cleaner at another company. These changes helped businesses reduce pollution while lowering costs. The document provides additional examples of facilities that achieved VOC and waste reductions through alternative brake cleaners and degreasing products recommended by MnTAP.
Go Green to Save Green – Embracing Green Energy PracticesLindaWatson19
Green is not just media/technology hype. IT organizations can reduce their carbon footprint, reduce energy consumption and drive cost out of the data center. This paper examines the costs and strategies that can be deployed to reduce Tier 1 storage in production and reduce the overall storage and servers required for data management.
Improving energy efficiency in SMEs – an interdisciplinary perspectiveLeonardo ENERGY
Research however states that there is still large untapped energy efficiency potential which deployment is hindered by the existence of various barriers to energy efficiency. The complexity of improved energy efficiency in manufacturing industry calls for an interdisciplinary approach to the issue. The book “Improving Energy Efficiency in Industrial Energy Systems” applies: “an interdisciplinary perspective in examining energy efficiency in industrial energy systems, and discusses how “cross-pollinating” perspectives and theories from the social and engineering sciences can enhance our understanding of barriers, energy audits, energy management, policies, and programmes as they pertain to improved energy efficiency in industry.”
This document proposes a model for organizing the production of energy-efficient products in 3 steps:
1) It begins with determining customer requirements and product ideas.
2) It then recommends developing a customized flowchart to guide the product development and manufacturing process.
3) The flowchart should incorporate principles of quality management and energy efficiency throughout the product's lifecycle from design to recycling.
The model is intended to help companies systematically produce energy-efficient products by outlining the key phases and considerations.
Energy efficiency of Industrial Utilities-Pratap Jung RaiPratap Jung Rai
The document discusses energy efficiency in industrial utilities. It outlines the objectives of energy efficiency as minimizing costs and environmental impacts without reducing productivity. An effective methodology for conducting energy audits is described, including preliminary, targeted, and detailed audits. The types of industrial utilities covered include electric motors, boilers, pumps, compressors, and HVAC systems. Monitoring equipment needed for energy audits is also discussed, such as electrical meters, combustion analyzers, thermometers, flow meters, and lux meters.
IRJET- Review Study on a Green Building based on the Rating SystemIRJET Journal
This document provides an overview of green buildings and their benefits compared to conventional buildings. It discusses green building features like energy efficiency, water conservation, and use of renewable energy and non-toxic materials. The document also examines the GRIHA rating system for green buildings in India and highlights various design techniques used in the GAIL Jubilee Tower, a green building in India that achieved a platinum rating from IGBC. In conclusion, the document emphasizes that green buildings can help reduce environmental impacts and promote sustainable development.
Process design synthesis, intensification, and integration of chemical processesUp Seven
This document discusses process design methodology for chemical processes. It introduces concepts of complexity and uncertainty in process design due to changing business environments. A holistic process design methodology is needed to efficiently handle uncertainty and complexity. The goal of process design is to create a blueprint that converts raw materials to products. Process design defines the process structure and parameters based on input of product quantity and quality goals. The document outlines the overall process from idea to plant, noting that process design plays a key role in selecting the best process technologies and structure to optimize profitability.
IRJET- Value Engineering: Better Way of Implementing Conventional MethodsIRJET Journal
This document discusses value engineering and its application in various fields. It begins with an introduction to value engineering, defining it as a creative, organized effort to analyze projects to achieve essential functions cost-effectively. It then provides examples of value engineering being used in waste management, residual value analysis of vehicles, and machine-based optimization. The document concludes that value engineering can reduce production costs through techniques like reducing cycle times, optimizing materials and weights, and improving product life cycles and sustainable development.
This document provides an overview of training modules on value stream mapping (VSM) and how to incorporate environmental considerations. It discusses how VSM can help identify environmental waste opportunities and new ways to improve operational and environmental results. Specific strategies covered include using icons to identify high environmental impact processes, recording environmental metrics in VSMs, analyzing material use versus needs with a "materials line," expanding VSM to natural resources, and finding opportunities in future state maps. The purpose is to help "see" environmental issues in VSMs and reduce costs, save time and improve workplace health and safety.
IRJET- Study of Forced Convection Evacuatedtube Solar Grape DryerIRJET Journal
This document discusses a study on the use of nanofluids in forced convection evacuated tube solar grape dryers. It begins with background on nanofluids and their applications in heat exchange. The document then describes the design and testing of a solar dryer for grapes using evacuated tubes. Experiments showed drying of grapes was faster with forced convection compared to natural convection. The dryer design aimed to use inexpensive, locally available materials suitable for developing areas. In conclusion, the solar collector and dryer design were found to improve drying effectiveness over previous designs.
This document discusses an empirical study of green supply chain management (GSCM) practices adopted by electrical and electronic companies in Taiwan in response to international environmental regulations. It finds that Taiwanese OEM and ODM manufacturers have implemented green procurement and manufacturing practices like establishing control lists for hazardous substances and assessing supplier environmental management. These practices positively impact companies' environmental and financial performance. The study uses literature reviews, interviews and surveys of ISO 14001 certified companies to analyze the relationship between regulations, stakeholders, GSCM practices and organizational performance.
The document discusses how sustainable business practices can benefit companies' bottom lines. It argues that implementing sustainability strategies like efficiently using resources and investing in renewable energy can help reduce costs and legal risks for businesses. Monitoring resource usage and emissions allows companies to identify ways to cut expenses and comply with increasingly stringent regulations. Case studies show companies saving millions through sustainability measures like installing solar panels and converting to natural gas. The document concludes that sustainable practices are cost-effective and good for both business and the environment.
Factors Affecting the Implementation of Green Manufacturing- A Case Study Ana...IRJET Journal
This document presents a case study analysis of factors affecting the implementation of green manufacturing in an automotive industry in India. It first provides background on green manufacturing and its goals. A literature review identifies common green factors studied, such as ISO 14001 certification, employee support, environmental projects, training, and supplier/customer collaboration. The methodology examines these factors through interviews at multiple plant lines to determine importance scores. Results found reverse logistics and waste minimization were most important, while environmental purchasing was least. The study aims to identify key success factors for automakers seeking to adopt green manufacturing practices.
This document discusses green manufacturing and sustainable development practices. It begins with an abstract that outlines how green manufacturing aims to conserve natural resources for future generations through improvements in production processes and recycling. The document then covers several key aspects of green manufacturing including cleaner production, using renewable resources like solar energy to generate steam, and utilizing waste materials from industries like sugarcane processing. Overall, the document promotes applying green technologies and innovative systems to manufacturing to reduce resource depletion, waste generation, and pollution while also improving economic outcomes.
Assessment and Analysis of GSCM Barriers using AHPIRJET Journal
This document discusses barriers to implementing green supply chain management (GSCM) in plastic industries using analytical hierarchy process (AHP). 47 potential barriers were identified from literature and interviews. A survey was conducted to determine the most important barriers. AHP was then used to prioritize the key barriers based on their calculated values. The top barriers included lack of human resources, technical expertise, and government support for adopting environmental policies. Identifying and addressing the primary barriers can help plastic industries more easily implement GSCM and improve their environmental performance.
This document discusses Lean Six Sigma and resources available through Knovel to support Lean Six Sigma implementation. It provides an overview of the Lean Six Sigma implementation process including strategic leadership and vision, deployment planning, and execution and results. It describes Knovel's Lean Six Sigma resources such as handbooks, case studies, templates, and guides covering tools like DMAIC, DOE, SPC etc. that can help with the different belts and project phases from Define to Control. Other resources discussed include those for Design for Six Sigma and practical applications/case studies.
Presently most electrical/electronic equipment (EEE) is not designed for recycling, let alone for circulation. Plastics in these products account for 20% of material use, and through better design, significant environmental and financial savings could be gained.
Technological solutions and circular design opportunities already exist, but they haven’t been implemented yet.
Some challenges, such as ease of disassembly, could be resolved through better communication and by sharing learnings across the value chain.
Instead of WEEE, we should focus on developing CEEE: Circular Electrical and Electronic Equipment.
The case examples of this report show how different stages of the lifecycle can be designed so that plastics circulation becomes possible and makes business sense.
I am pursuing masters in Industrial Engineering. During the course of my degree I have taught many concepts of Industrial Engineering and I am confident that I can apply all the concepts in real time environment. With the great knowledge of Fundamentals of 6 sigma, statistics, MRP, JIT and Deterministic Optimization, I am confident to apply those concepts for production procedures, production standards and costs. I have come from the mechanical background so I have pretty good knowledge about mechanical procedures and applying industrial concepts to enhance overall system. While working in industries, I realized the impact of applying industrial concepts in Industries. My knowledge is well defined and I take pride working in sync with people and resources at every stage of production cycle.
This document discusses MnTAP's efforts to help Minnesota businesses reduce solvent usage for degreasing operations while maintaining effectiveness. MnTAP evaluated products at 23 facilities to identify alternatives that reduce VOC emissions and human health risks. Some successful substitutions included replacing lacquer thinner containing HAPs with acetone at one company, and replacing three solvents with a single water-based cleaner at another company. These changes helped businesses reduce pollution while lowering costs. The document provides additional examples of facilities that achieved VOC and waste reductions through alternative brake cleaners and degreasing products recommended by MnTAP.
Go Green to Save Green – Embracing Green Energy PracticesLindaWatson19
Green is not just media/technology hype. IT organizations can reduce their carbon footprint, reduce energy consumption and drive cost out of the data center. This paper examines the costs and strategies that can be deployed to reduce Tier 1 storage in production and reduce the overall storage and servers required for data management.
Improving energy efficiency in SMEs – an interdisciplinary perspectiveLeonardo ENERGY
Research however states that there is still large untapped energy efficiency potential which deployment is hindered by the existence of various barriers to energy efficiency. The complexity of improved energy efficiency in manufacturing industry calls for an interdisciplinary approach to the issue. The book “Improving Energy Efficiency in Industrial Energy Systems” applies: “an interdisciplinary perspective in examining energy efficiency in industrial energy systems, and discusses how “cross-pollinating” perspectives and theories from the social and engineering sciences can enhance our understanding of barriers, energy audits, energy management, policies, and programmes as they pertain to improved energy efficiency in industry.”
This document proposes a model for organizing the production of energy-efficient products in 3 steps:
1) It begins with determining customer requirements and product ideas.
2) It then recommends developing a customized flowchart to guide the product development and manufacturing process.
3) The flowchart should incorporate principles of quality management and energy efficiency throughout the product's lifecycle from design to recycling.
The model is intended to help companies systematically produce energy-efficient products by outlining the key phases and considerations.
Energy efficiency of Industrial Utilities-Pratap Jung RaiPratap Jung Rai
The document discusses energy efficiency in industrial utilities. It outlines the objectives of energy efficiency as minimizing costs and environmental impacts without reducing productivity. An effective methodology for conducting energy audits is described, including preliminary, targeted, and detailed audits. The types of industrial utilities covered include electric motors, boilers, pumps, compressors, and HVAC systems. Monitoring equipment needed for energy audits is also discussed, such as electrical meters, combustion analyzers, thermometers, flow meters, and lux meters.
IRJET- Review Study on a Green Building based on the Rating SystemIRJET Journal
This document provides an overview of green buildings and their benefits compared to conventional buildings. It discusses green building features like energy efficiency, water conservation, and use of renewable energy and non-toxic materials. The document also examines the GRIHA rating system for green buildings in India and highlights various design techniques used in the GAIL Jubilee Tower, a green building in India that achieved a platinum rating from IGBC. In conclusion, the document emphasizes that green buildings can help reduce environmental impacts and promote sustainable development.
Process design synthesis, intensification, and integration of chemical processesUp Seven
This document discusses process design methodology for chemical processes. It introduces concepts of complexity and uncertainty in process design due to changing business environments. A holistic process design methodology is needed to efficiently handle uncertainty and complexity. The goal of process design is to create a blueprint that converts raw materials to products. Process design defines the process structure and parameters based on input of product quantity and quality goals. The document outlines the overall process from idea to plant, noting that process design plays a key role in selecting the best process technologies and structure to optimize profitability.
IRJET- Value Engineering: Better Way of Implementing Conventional MethodsIRJET Journal
This document discusses value engineering and its application in various fields. It begins with an introduction to value engineering, defining it as a creative, organized effort to analyze projects to achieve essential functions cost-effectively. It then provides examples of value engineering being used in waste management, residual value analysis of vehicles, and machine-based optimization. The document concludes that value engineering can reduce production costs through techniques like reducing cycle times, optimizing materials and weights, and improving product life cycles and sustainable development.
This document provides an overview of training modules on value stream mapping (VSM) and how to incorporate environmental considerations. It discusses how VSM can help identify environmental waste opportunities and new ways to improve operational and environmental results. Specific strategies covered include using icons to identify high environmental impact processes, recording environmental metrics in VSMs, analyzing material use versus needs with a "materials line," expanding VSM to natural resources, and finding opportunities in future state maps. The purpose is to help "see" environmental issues in VSMs and reduce costs, save time and improve workplace health and safety.
IRJET- Study of Forced Convection Evacuatedtube Solar Grape DryerIRJET Journal
This document discusses a study on the use of nanofluids in forced convection evacuated tube solar grape dryers. It begins with background on nanofluids and their applications in heat exchange. The document then describes the design and testing of a solar dryer for grapes using evacuated tubes. Experiments showed drying of grapes was faster with forced convection compared to natural convection. The dryer design aimed to use inexpensive, locally available materials suitable for developing areas. In conclusion, the solar collector and dryer design were found to improve drying effectiveness over previous designs.
This document discusses an empirical study of green supply chain management (GSCM) practices adopted by electrical and electronic companies in Taiwan in response to international environmental regulations. It finds that Taiwanese OEM and ODM manufacturers have implemented green procurement and manufacturing practices like establishing control lists for hazardous substances and assessing supplier environmental management. These practices positively impact companies' environmental and financial performance. The study uses literature reviews, interviews and surveys of ISO 14001 certified companies to analyze the relationship between regulations, stakeholders, GSCM practices and organizational performance.
The document discusses how sustainable business practices can benefit companies' bottom lines. It argues that implementing sustainability strategies like efficiently using resources and investing in renewable energy can help reduce costs and legal risks for businesses. Monitoring resource usage and emissions allows companies to identify ways to cut expenses and comply with increasingly stringent regulations. Case studies show companies saving millions through sustainability measures like installing solar panels and converting to natural gas. The document concludes that sustainable practices are cost-effective and good for both business and the environment.
Factors Affecting the Implementation of Green Manufacturing- A Case Study Ana...IRJET Journal
This document presents a case study analysis of factors affecting the implementation of green manufacturing in an automotive industry in India. It first provides background on green manufacturing and its goals. A literature review identifies common green factors studied, such as ISO 14001 certification, employee support, environmental projects, training, and supplier/customer collaboration. The methodology examines these factors through interviews at multiple plant lines to determine importance scores. Results found reverse logistics and waste minimization were most important, while environmental purchasing was least. The study aims to identify key success factors for automakers seeking to adopt green manufacturing practices.
This document discusses green manufacturing and sustainable development practices. It begins with an abstract that outlines how green manufacturing aims to conserve natural resources for future generations through improvements in production processes and recycling. The document then covers several key aspects of green manufacturing including cleaner production, using renewable resources like solar energy to generate steam, and utilizing waste materials from industries like sugarcane processing. Overall, the document promotes applying green technologies and innovative systems to manufacturing to reduce resource depletion, waste generation, and pollution while also improving economic outcomes.
Assessment and Analysis of GSCM Barriers using AHPIRJET Journal
This document discusses barriers to implementing green supply chain management (GSCM) in plastic industries using analytical hierarchy process (AHP). 47 potential barriers were identified from literature and interviews. A survey was conducted to determine the most important barriers. AHP was then used to prioritize the key barriers based on their calculated values. The top barriers included lack of human resources, technical expertise, and government support for adopting environmental policies. Identifying and addressing the primary barriers can help plastic industries more easily implement GSCM and improve their environmental performance.
Minimising waste in construction by using lean six sigma principleIAEME Publication
This document discusses how lean six sigma principles can be applied to minimize waste in construction projects. It first provides background on lean production and six sigma methods. It then discusses how the 5S methodology (seiri, seiton, seiso, seiketsu, shitsuke) can help identify and eliminate waste at various construction stages through improved organization, cleanliness and standardization. The benefits of applying 5S principles in construction include improved safety, productivity and quality. Key lean principles like reducing non-value adding activities, continuous improvement and flexibility are also important for efficient construction. Overall waste can be minimized through proper planning, material management and applying lean six sigma techniques.
Minimising waste in construction by using lean six sigma principleIAEME Publication
This document discusses how lean six sigma principles can be used to minimize waste in construction projects. It first provides background on lean six sigma and its goals of eliminating waste and defects. It then discusses how the 5S methodology (sort, set in order, shine, standardize, and sustain) can be applied to construction processes to establish order and cleanliness. Some benefits of implementing 5S in construction include improved safety, productivity, quality and reduced lead times. The document provides examples of how lean principles like just-in-time delivery and visual management can help minimize waste in construction material management, planning and work execution.
DEMATEL (siglas en inglés de Decision Making Trial and Evaluation Laboratory) es una técnica desarrollada en 1972 por Fontela y Gabus en el Centro de Investigación de Ginebra del Battelle Memorial Institute. Se utiliza para analizar la interdependencia (relación o influencia) entre componentes, variables o atributos de un sistema complejo, identificar aquellos que son críticos y estudiar sus relaciones causa-efecto, utilizando un diagrama de relaciones de
DEMATEL (siglas en inglés de Decision Making Trial and Evaluation Laboratory) es una técnica desarrollada en 1972 por Fontela y Gabus en el Centro de Investigación de Ginebra del Battelle Memorial Institute. Se utiliza para analizar la interdependencia (relación o influencia) entre componentes, variables o atributos de un sistema complejo, identificar aquellos que son críticos y estudiar sus relaciones causa-efecto, utilizando un diagrama de relaciones de DEMATEL (siglas en inglés de Decision Making Trial and Evaluation Laboratory) es una técnica desarrollada en 1972 por Fontela y Gabus en el Centro de Investigación de Ginebra del Battelle Memorial Institute. Se utiliza para analizar la interdependencia (relación o influencia) entre componentes, variables o atributos de un sistema complejo, identificar aquellos que son críticos y estudiar sus relaciones causa-efecto, utilizando un diagrama de relaciones de DEMATEL (siglas en inglés de Decision Making Trial and Evaluation Laboratory) es una técnica desarrollada en 1972 por Fontela y Gabus en el Centro de Investigación de Ginebra del Battelle Memorial Institute. Se utiliza para analizar la interdependencia (relación o influencia) entre componentes, variables o atributos de un sistema complejo, identificar aquellos que son críticos y estudiar sus relaciones causa-efecto, utilizando un diagrama de relaciones de
EMATEL (siglas en inglés de Decision Making Trial and Evaluation Laboratory) es una técnica desarrollada en 1972 por Fontela y Gabus en el Centro de Investigación de Ginebra del Battelle Memorial Institute. Se utiliza para analizar la interdependencia (relación o influencia) entre componentes, variables o atributos de un sistema complejo, identificar aquellos que son críticos y estudiar sus relaciones causa-efecto, utilizando un diagrama de relaciones de
DEMATEL (siglas en inglés de Decision Making Trial and Evaluation Laboratory) es una técnica desarrollada en 1972 por Fontela y Gabus en el Centro de Investigación de Ginebra del Battelle Memorial Institute. Se utiliza para analizar la interdependencia (relación o influenci
A Holistic Approach to Yield Improvement in the Semiconductor Manufacturing I...yieldWerx Semiconductor
Semiconductor manufacturing is one of the most complex and competitive industries, heavily driven by innovation and cost-efficiency. It is continuously grappling with increasing cost pressures while concurrently working to meet the demands of rapidly advancing technology. Yield optimization, a multifaceted process aimed at improving the number of usable chips produced from raw materials, is an integral part of reducing manufacturing costs. This process involves taking into account several elements, such as equipment performance, operator capability, and the complexity of the design.
IRJET- Improving Productivity in a Mechanical Industry using Industrial Engin...IRJET Journal
This document summarizes a study conducted to improve productivity at a mechanical industry in India using industrial engineering tools and techniques. The study focused on a paint manufacturing process and identified areas for improvement through time studies, method studies, and layout studies. Observations of standard operating procedures and the existing process flow were made. Issues identified included unnecessary worker and material movement, long machine idle times, and an inefficient packaging method. Suggestions were proposed to redesign the process flow and material handling to reduce idle times and incorporate more efficient packaging. The goal was to eliminate non-value added activities and improve overall productivity through comprehensive analysis and minimization of waste.
Waste Minimization in Die Cutting Industry Through Implementation of Green Ma...IRJET Journal
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Industrial management & data systems
1. Industrial Management & Data Systems
A detailed calculation model for costing of green manufacturing
Ifeyinwa Orji Sun Wei
Article information:
To cite this document:
Ifeyinwa Orji Sun Wei , (2016),"A detailed calculation model for costing of green manufacturing",
Industrial Management & Data Systems, Vol. 116 Iss 1 pp. 65 - 86
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http://dx.doi.org/10.1108/IMDS-04-2015-0140
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3. major problem for engineering managers is to ascertain the costs of embarking on green
manufacturing. At the design stage of manufacturing processes, the machines, materials,
machining parameters, cutting tools and operation sequences can be harnessed for
efficient resource consumption and reduction of carbon dioxide emissions at a
competitive price. Thus, a planning and control methodology for costing of green
manufacturing at the early design stage is important for engineering managers.
Green manufacturing can be defined as an efficient approach required in the design
and production activities necessary for new product development and production
system operations aimed at minimizing environmental impact. Reducing hazardous
emissions, eliminating wasteful resources consumption and recycling are examples of
green manufacturing activities (Deif, 2011). It is a manufacturing strategy that is
conscious of the impact of operation/product on the environment and resources and
incorporates such in its detailed planning and control.
In recent years, there has been a significant growth in research activities directed at
reducing carbon intensity and green manufacturing. The green design and operation
strategy of milling machines was studied based on the analysis of their energy
consumption (Diaz et al., 2010). Tridech and Cheng (2008) modeled the characteristics of
low-carbon manufacturing by expanding the carbon emission analysis. An integrated
low-carbon product design system based on bill of materials and embedded greenhouse
gas emissions of product parts has been proposed (Song and Lee, 2010). A life cycle
approach-based assessment method was proposed to characterize the carbon emissions of
machine tools (Cao et al., 2011). The concept of electricity carbon emission factor was
introduced to establish the link between energy consumption and carbon emissions of
manufacturing (Jeswiet and Kara, 2008). A thermodynamic framework to study the
characteristics of the resource consumption and the environmental impact of
manufacturing processes has been established (Gutowski et al., 2009). The detailed
breakdown of energy required to produce a single product on which energy inefficiencies
were easily identified and improved has been modeled (Rahimifard et al., 2010). The analysis
of no-load energy characteristics of CNC machines has been researched (Hu et al., 2012). An
analytical method for quantifying carbon emissions generated from different processes
associated with a CNC-based machining system was presented (Li et al., 2013). A process
planning method for reduced carbon emissions has been developed (Yin et al., 2014).
Most past works as stated above target energy consumption and carbon dioxide
emissions at the process level concentrating on individual equipment, machinery and
work stations within a production system without considering costs. Most importantly,
no study has been found which addresses how reduced costs will be achieved through
green manufacturing considering the life cycle of machined product features.
The process-based cost modeling is a cost modeling approach for estimating cots
more accurately and providing detailed cost consumption of products in their
manufacturing process for detailed analysis. A typical process-based cost estimation
method is the activity-based costing (ABC) approach. Various surveys have also
indicated that the ABC approach has been used to analyze different kinds of
management decisions in manufacturing firms (Lockamy, 2003; Comelli et al., 2008;
Lea, 2007; Tsai et al., 2007; Kee, 2007, 2008; Qian and Ben-Arieh, 2008; Da Silva and
Amaral, 2009; Tsai and Hung, 2009a, b; Ruiz-de-Arbulo-Lopez et al., 2013). The basic
assumptions in applying process-based costing (PBC) model are the homogeneity and
proportionality assumptions. These assumptions limit the feasibility of the result in the
presence of certain important metrics which exists in more than one category
(e.g. capacity expansion and price elasticity) in manufacturing firms.
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4. In efforts toward ensuring more reliable decision making, researchers have begun to
apply soft operation research modeling techniques; these interprets, defines and
explore various perspectives of the problem under scrutiny by employing
predominantly qualitative, rational, interpretative and structured techniques (Orji
and Wei, 2015). A good example of a soft operations research modeling technique is
systems dynamics (SD). SD has a distinct advantage in analyzing, improving and
managing the system characterized by long development cycle and complex feedback
effects (Li et al., 2012).
There exist in the literature many applications of SD (Ansari and Seifi, 2012, 2013;
Aslani et al., 2014; Feng et al., 2013; Li et al., 2012; Qudrat-Ullah, 2013; Shen et al., 2009;
Shih and Tseng, 2014; Thompson and Bank, 2010; Zhang et al., 2014). Various
necessary metrics (e.g. capacity expansion and price elasticity) which exist in more
than one category during costing can be fully incorporated using SD. Therefore, SD can
be applied during costing of green manufacturing.
In this work, concepts of SD, “green manufacturing,” and product life cycle are
integrated to develop a methodology for cost calculation. The relevant entire life
cycle of the product are incorporated within a PBC decision methodology and both
low-carbon manufacturing method and carbon emission costs analyzed
simultaneously. Additionally, the SD approach is employed to incorporate capacity
expansion and price elasticity into the costing process. The remaining parts of this
paper will discuss a novel approach which is capable of: estimating the total carbon
emissions and costs resulting from the life cycle assessment of machined product
within a manufacturing facility; providing insight into capacity expansion and other
important metrics often neglected in static modeling.
It is believed that this work can provide cost justifications of green manufacturing.
2. Background
Manufacturing firms are facing intense pressures to embark on green manufacturing.
It is therefore imperative to ascertain cost of green manufacturing at an early stage.
The PBC model can assist managers to become aware of design parameters that cause
demands on optional and indirect resources. Through using PBC model, non-value-
adding activities can be removed during design for carbon emission cost reduction thus
minimizing resource depletion.
Orji et al. (2015) states that designing a PBC model involve the following steps:
• Step 1: identify the different overhead activities;
• Step 2: assign the overhead costs to the different activities using a resource
driver;
• Step 3: identify the activity driver for each activity;
• Step 4: determine the activity driver rate by dividing the total activity costs by
the practical volume of the activity driver; and
• Step 5: multiply the activity driver rate by the activity driver consumption to
trace costs to orders, products or customers.
ABC provides information about a product’s cost based on the resources used in its
production (Tsai et al., 2012). The problem of allocating indirect costs to products is
solved by ABC through estimating the cost of activities that consumes resources and
by linking these costs to the products (services) that are provided (Cao et al., 2006; Lin
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5. et al., 2007). ABC can be applied in a wide range of activities involving environmental
metrics (Da Silva and Amaral, 2009).
With increased awareness of corporate social responsibility, manufacturing firms
must consider carbon emission costs to help accurately predict manufacturing costs
and reduce impact on the environment. Manufacturing companies must pay huge
emphasis to environmental costs during the entire life cycle of green manufacturing
assessment, such as carbon emission costs. Carbon emission costs are usually
quantified through carbon tax policy. Even though the carbon tax would be regarded
as an additional cost borne by companies, enhancement of occupant health and
comfort, and productivity as well as a reduction in pollution levels would provide
long-term benefits to people and society (Tsai et al., 2014). An evidence from microdata
in UK industries shows that carbon tax can reduce energy intensity and electricity use
(Martin et al., 2014). Thus, it is crucial for manufacturing firms to understand carbon
emission cost policies and also consider carbon emission costs as part of the cost
planning methodology for green manufacturing.
Green manufacturing is a sustainable form of manufacturing that integrates the
life cycle concept, including green designs, production and distribution of raw
materials, maintenance and disposal processes which minimize resource depletion.
Some researchers have employed the life cycle assessment approach in green
manufacturing; the life cycle assessment methodology has been widely applied in
assessing the environmental burden of products and services during their life
cycle (Tsai et al., 2014). A life cycle approach-based assessment method
was proposed to characterize the carbon emissions of machine tools (Cao et al.,
2011). An environmental burden analysis for machining operation was carried out
using life cycle assessment (Narita et al., 2008). The life cycle thinking becomes
important in green manufacturing as renewable materials and efficient energy
systems are employed to achieve sustainable development. Till date to the best our
knowledge, not much attention has been given to the research of providing cost
justifications of green manufacturing by employing life cycle thinking. This work
pioneers the integration of green manufacturing, SD concept and product life cycle to
develop a cost calculation model for green manufacturing; thus it comprises of
an assessment of the energy consumption of machines and carbon emissions
during manufacturing process. Six main stages in the life cycle of manufactured
products are studied including development stage, manufacturing/production stage,
operation/use stage, maintenance stage, decoupling stage and waste collection stage
for recycling and reuse.
3. Methodology
The longitudinal and cross-wise designs were adopted to collect data on carbon
emissions based on the activities in the relevant life cycle of manufactured product
features. A manufacturing facility in China was used as the sample population.
The case company is active in gear technology/manufacturing, and designs and
produces components in partnership with their suppliers and customers. The company
is situated in southern China and is fast expanding its china manufacturing footprint.
In this study, the main gear manufacturing site is considered that is co-located with the
product development site. This main manufacturing site has around 1,500 employees.
The manufacturing facility includes more than 180 machines distributed in about
25 departments and provides maintenance operations to its coupled base of products in
China. The manufacturing produces new gear part prototypes using collaborations
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6. from the designers at the development site. The engineering managers are faced with
pressures to implement green manufacturing. However, they are unable to ascertain the
costs of embarking on green manufacturing.
The conventional manufacturing is embarked upon by the company since its
inception about a decade ago. The conventional manufacturing involves the use of
cutting fluids, virgin steel material and high energy consumption fuel. This implies
higher carbon emission quantities and carbon tax. In this work, energy-saving
activities are introduced and carbon emission quantities minimized to reduce carbon
tax which could lead to subsequent reduction of total cost of green manufacturing.
The information applied in the study was gathered from observations, archival records
and personnel interviews. The personnel considered in this study were technicians,
coordinators and design engineers. Questionnaires were issued to personnel for data
collection. Data collection was carried out over a period of two years commencing in 2013
to provide information on energy consumption drivers in the life cycle stages
(development, production, operation/use, maintenance, decoupling and waste collection) of
the manufactured product. Information on the number of drawings and time for design
and fuel for material transport were sourced from design engineers for the development
stage. The information on the production process parameters were sourced from
technicians and coordinators for the manufacturing stage. Fuel data, years of operation
data and machine energy consumption data were collected for the use/operation stage
from technicians and coordinators. Data on frequency of maintenance, distance to
recycling plant, fuel type and electric power were collected for the maintenance, decoupling
and waste collection stages from technicians. A simple average method was employed to
estimate the average score of sourced data of a particular variable from different personnel.
It is assumed that accurate cost information can be acquired by engineering personnel
from the finance department to be applied in the decision methodology.
3.1 Model formulation
A planning methodology based on PBC techniques is formulated to calculate the costs
of machined products in its relevant life cycle. Specific to the methodology, costs
associated with machined products in green manufacturing environment include
material costs, labor costs, equipment costs, energy-saving activity costs and carbon
emission costs. It should be noted that capacity expansions, purchasing discounts and
carbon emission costs were preliminarily factored into the PBC model. A SD was
presented to further investigate dynamic behavior of capacity expansion and other
important metrics often ignored in static mathematical modeling. The following
assumptions are incorporated in the process-based planning methodology:
(1) Purchasing discounts will be offered if material order exceeds a minimum order
quantity. Also capacity can be expanded using overtime work or additional
night shifts as well as hiring temporary workers at a higher wage rate for a
short term.
(2) The manufacturing firm highly emphasizes on corporate responsibility; thus
carbon emissions will be calculated from the entire life cycle of machined
products and increasing carbon emissions will increase taxation.
(3) Material costs, wage costs, equipment costs, energy-saving costs and carbon
emissions costs are the costs associated with the entire life cycle of machined
products. Other costs were excluded from this study.
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7. (4) Energy-saving activity costs were categorized into four levels namely unit level,
batch level, process level and environmental level. Two types of manufacturing
processes are considered: conventional manufacturing and green manufacturing.
(5) Due to budgetary restrictions, total costs should remain constant. Engineering
managers can acquire accurate cost information from the firm’s finance
department to apply to the decision methodology.
3.2 Material costs
The material costs of the machined product Mc can be computed with the following
equations:
Mc ¼ NxPx þ
X
xAd
NxPx þNdxPdxð Þ (1)
Xn
i¼1
TixYi pPx; xAd0
(2)
Px pQx; xAd0
(3)
Xn
i¼1
TixYi pPx þPdx; xAd (4)
Pdx XMdxSdx; xAd (5)
Px pMdxIdx; xAd0
(6)
Pdx XQxSdx; xAd (7)
Idx þSdx ¼ 1 (8)
Px X0 (9)
where Nx is the unit cost of material x without purchase discount, Px is the quantity of
material x without purchase discount, Ndx is the unit cost of material x with purchase
discount, Pdx is the quantity of material x without purchase discount, Txy is the
requirement of xth material for machined product y, Mdx is the minimum order quantity
of xth material to obtain purchase discount, Qx is the available quantity of xth material,
Sdx is 0/1 variable; when 1, means quantity of xth material satisfies threshold discount
and when 0, otherwise, Idx is 0/1 variable; when 1, means quantity of xth material
dissatisfies threshold discount and when 0, otherwise, Sy is a 0/1 variable; when 1,
firm executes manufacturing process and when 0, otherwise, and d' is without discount
while d is with discount.
Thus, the quantity of material should satisfy the demands of the machined product
as stated in Equation (4). The terms in which a purchase discount qualified or not is
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8. stated in Equations (5) and (6). The limit condition of order quantity for purchase
of material with discount is given by Equation (7). Equation (8) ensures singularity
of conditions.
3.3 Wage costs
The wage costs for the machined products Wc are computed as follows:
Wc ¼ W1 þ W2 – W1ð Þb1 þ W3 – W1ð Þb2 (10)
H ¼ W1 þ W2 – W1ð Þb1 þ W3 – W1ð Þb2
 Ã
(11)
b0 – m1 p0 (12)
b1–m1 – m2 p0 (13)
b2 – m2 p0 (14)
b0 þb1 þb2 ¼ 1 (15)
m1 þm2 ¼ 1 (16)
where H is the total manpower time requirement for the process, W1 is the available
manpower time to carry out work in manufacturing environment, W2 is the
overtime manpower time required for work, W3 is the additional manpower hire time to
complete work, b0-b2 is a set of non-negative variables, in which two consecutive
variables at the most can be non-zero, Wc1-Wc3 represent the total wage cost in W1-W3
conditions, respectively, m1, m2 are 0/1 variables, in which only one must be non-zero.
Equation (11) states that the process requires overtime work time and additional
hire time for completion of process.
3.4 Equipment costs
The equipment costs Ec of machined products can be computed as follows:
Ec ¼
Xk
h¼0
EChJh (17)
Xn
y¼1
ZygSyÀ
Xt
e¼1
OeJe p1 (18)
Xt
e¼1
Je ¼ 1 (19)
where Eh is the total equipment costs, Oe is the available equipment time, Zyg is the
requirement time of equipment g for process, Je is a 0/1 variable; when 1, capacity
demands of equipment can be expanded to eth level and when 0, otherwise.
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9. 3.5 Energy-saving activity costs
The energy-saving costs of machined products are categorized into four types namely
unit level, batch level, environmental and process level.
The batch-level energy saving costs Bc is computed as follows:
Bc ¼
Xn
i¼1
X
jABs
ajfijBij (20)
Xn
y¼1
fyjByj ¼ Cj; Vj ABs (21)
Sy pa
;
yjByj; I ¼ 1; 2; . . .; n; Vj ABs (22)
where aj is the actual activity cost per activity driver for activity j, Byj is the summation
of batches during batch-level activity j, Fyj is the requirement expected of activity
driver of batch-level activity j, Cj is the available/limit of capacity of activity driver of
batch-level activity j, a
;
yj is the number of materials used for batch-level activity j.
The process-level activity costs can be computed as follows:
Xn
y¼1
X
jAqz
ajbyjHy (23)
Sy pHy; y ¼ 1; 2; 3; . . .::n (24)
Xn
y¼1
byjHy pKj; Vj AQ (25)
where Βyj is the requirement expected of activity driver of process-level activity j, Kj is
the available/limit of capacity of activity driver of process-level activity j, aj is the
actual activity cost per activity driver for activity j, Vj ∈ Q is the process-level activities.
The environmental-level activity costs can be computed as follows:
Xn
y¼1
X
jAPR
ajyyjĐy (26)
Sy pWy (27)
Xn
y¼1
yyjWy pPj; V AR (28)
where θyj is the requirement expected of activity driver of environmental-level activity
j, Pj is the available/limit of capacity of activity driver of environmental-level activity j,
aj is the actual activity cost per activity driver for activity j, and Vj ∈ R is the
environmental-level activities.
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10. 3.6 Life cycle carbon emission costs
The carbon emission costs LCCE in the entire life cycle of machined products are
computed as follows:
Lc ¼ Lš1 þLš2 þLš3 (29)
Tc ¼ Tš1 þTš2 þTš3 (30)
š0 – o1 p0 (31)
š1 – o1 – o2 p0 (32)
š2 – o2 – o3 p0 (33)
š3 – o3 p0 (34)
š0 þš1 þš2 þš3 ¼ 1 (35)
o1 þo2 þo3 ¼ 1 (36)
where Tc is the total life cycle carbon emissions quantities, š1-š3 is a set of non-negative
variables, in which two consecutive variables at the most can be non-zero, Lš1-Lš3
represent the total carbon emission costs in Tš1-Tš3 quantities, respectively, ω1-ω3 are
0/1 variables, in which only one must be non-zero.
It is assumed that documenting the quantities of carbon emissions in the life cycle
of machined products would support carbon taxation policy and reduction of
emission costs.
3.7 Total life cycle carbon emissions
The total life cycle carbon emissions can be defined as the sum of carbon emissions
generated from various stages in the relevant entire life cycle of manufactured
products. It is given by the following equation:
Tc ¼ Cdc þCma þCop þCmt þCde þCwc (37)
where Cdc is the carbon emissions in the development stage, Cpr is the carbon emissions
in the production/manufacturing stage, Cop is the carbon emissions in the use/operation
stage, Cmt is the carbon emissions in the maintenance/refurbishing stage, Cdc is the
carbon emissions in the decoupling stage, Cwc is the carbon emissions in the waste
collection for reuse/recycling stage.
3.7.1 Manufacturing stage. The carbon emission in the manufacturing stage of
machined products is given by the following equation:
Cpr ¼ Cel þCto þCco þCma þCch (38)
where Cel is the carbon emissions caused by the generation of electricity, Cto is the
carbon emissions caused by the production of cutting tools, Cco is the carbon emissions
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11. caused by the production of cutting fluid, Cma is the carbon emissions caused by raw
materials harvesting, Cchy is the carbon emissions generated from chip removal.
Cel can be calculated as follows:
Cel ¼ FelEma (39)
where Fel is the electricity carbon emission factor, Ema is the energy consumption of the
machine.
Usually, machining process involves the interaction between the cutting tool, the
material to be cut and the cutting fluid. Thus, the total power consumption Pt of a
machine tool consists of idle power Pi, cutting power Pc and additional load loss Pa
(Hu et al., 2012). Thus the total power consumption required for the manufacturing is
given in the following equation:
Pt tð Þ ¼ Pi tð ÞþPc tð ÞþPa tð Þ (40)
where t is time.
In this work, a product is denoted as y. Thus, the energy consumption of a machine
tool required to manufacture a product is given in the following equation:
Emy ¼
Z T
0
Pt tð Þdt ¼
Z ti þtc
0
Pi tð Þdtþ
Z tc
0
Pc tð Þdtþ
Z ti þta
0
Pa tð Þdt (41)
ta is the summation of loading time, cleaning time and unloading time. Given that
idle/passive power is defined as the power consumed by the machine when the system of
its spindle is rotating with the necessary cutting speed before the process of manufacturing
and is often constant. The idle time is the sum of handling (rapid axis movement, spindle
motor, coolant, tool changer) time and cutting time. The cutting/machining power is power
consumed during the machining process while additional loss/feed power is the power loss
generated by the spindle of the machine.
Thus, Equation (41) is transformed to the following equation:
Emay ¼ Pi ti þtcð ÞþPctc þPa ta þtið Þ (42)
The total power consumption Pt and the passive power Pi can be measured by power
testing instruments. The idle time on the machine during the manufacture of product y
ti can be determined from historical data and observations.
The cutting time tc is a function of the cutting speed, cutting depth, feed rate,
product length, cutting edges, product diameter and machining allowance.
The following equation shows the factors affecting the cutting time during the
manufacture of product y:
tc ¼
Q
dLyg
1; 000vcf zap
(43)
where vc is cutting speed, ap is cutting depth, f is feed rate, L is product length, Z is
cutting edges, d is product diameter, g is machining allowance.
The chip emissions CEchy considered in this work are caused by the energy required
for re-melting of chip material.
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12. Hence, the following equation shows the carbon emissions generated from
chip removal:
Cch ¼ FchWch (44)
where Fch is the carbon emission factor of chips. Wch is the mass of removed material
and is calculated in the following equation:
Wch ¼
MRRtcyr
103
¼ vcapf ztcyr (45)
where ρ is the density of material expressed in (kg/cm3
). MRR is the removal rate and is
determined by multiplying the cutting speed vc, cutting depth ap, number of cutting
edges z and feed rate f as shown in the following equation:
MRR ¼ vcapfz (46)
The carbon emissions Cco caused by the production of cutting fluid is comprised of two
parts: Coil and Cwc.
Coil is the carbon emissions generated through the production of pure mineral oil.
Cwc is the carbon emissions generated by the disposal of cutting fluid waste.
The various compositions of the carbon emissions caused by the production of
cutting fluid are given in Equation (47):
Cco ¼
t Coil þCwcð Þ
Tco
(47)
t ¼ tc þti þta (48)
where t is the machining throughput time, Tco is the life cycle of cutting fluid, Coil is
the carbon emission factors for the production of cutting fluid during machining, Cwc
is the carbon emission factors for the disposal of cutting fluid.
In this work, Coil is 2.895 kgCO2/L while Cwc is 0.2 kgCO2/L.
The carbon emissions of raw material harvesting Cma is given by the following
equation:
Cma ¼ FmaMma (49)
where Fma is the carbon emission factor of the raw material which comprises of its
embodied energy, Mma is the mass of work piece material required for production.
The carbon emissions caused by the production of cutting tools CEto is calculated in
the following equation:
Cto ¼
tcFtoMto
Lto
(50)
where Mto is the mass of cutting tool, Fto is the carbon emission factor of cutting tool,
Ltois the life cycle of the cutting tool.
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13. The carbon emission factor of cutting tools is dependent on its embodied energy
which comprises of the embodied tool material energy and the further manufacturing
steps of the cutting tool.
4. Results and discussion
In this study, carbon emission quantities are evaluated using carbon emission factors
according to IPCC (2006). The machining activities are carried out on CNC machines
based on a typical high-production scenario for the gear part shown in Figure 1.
Two types of manufacturing processes namely conventional and green
manufacturing were considered in this work as stated in the methodology for
machining the gear part to the same cutting standard. The parameters of conventional
and green manufacturing are shown in Table I.
80.83
84.29
20
40.5
10
42.5
Figure 1.
Gear part
Parameter
Conventional
manufacturing
Green
manufacturing
Number of teeth 46 46
Cutting speed (m/min) 39 44
Thickness of tooth (mm) 20 20
Pressure angle (degrees) 30 30
Feed rate (mm/min) 73.5 83
Spindle speed (rpm) 147 166
Volume removal rate (mm3
/min) 315,290 356,041
Cutting time per cut (sec) 35 22
Volume of chips (mm3
) 85,793 85,793
Machining power (kW) 15.65 17.68
Cutting energy (kJ) 547.75 389.03
Idle power (kW) 10 15
Idle time (sec) 39 25
Energy consumption of machine (kJ) 1,792.75 1,514
Weight of cutting tool (kg) 1.50 2.70
Life cycle of cutting tool (min) 208 420
Cutter material Cemented carbide Cemented carbide
Replacement cycle 1 month –
Rapid traverse (horizontal, X, Y ) (m/min) 30 30
Rapid traverse (vertical, Z ) (m/min) 24 24
Initial amount of mineral oil (L) 22 –
Additional amount of oil in replacement cycle (L) 0.09 –
Mass of work piece (kg) 3.50 2.54
Work piece material Steel Recycled steel
Table I.
Process parameters
for machining
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14. The carbon emissions of the gear part during the manufacturing stage were calculated
as shown in Table II.
The carbon emissions generated from various stages in the relevant entire life cycle of
the manufactured product are calculated based on Equation (37) as shown in Table III.
The various costs associated with the manufactured product are calculated based on
Equations (1)-(28) as shown in Table IV.
As shown in Table IV, eight energy-saving activities are namely production,
maintenance, material transport, product transport, waste collection, operation activity,
waste reuse/recycling and design/development.
Three materials were considered for manufacturing as shown in material costs
constraints. The supplier of materials 1 and 3 allows a purchase discount if a minimum
order quantity of PD1 ¼ 1,000 kg and PD3 ¼ 2,300 kg is exceeded as shown in Table IV.
The available man-hours is denoted by WO1 and has a cost which increases when
man-hours increases due to overtime work/additional night-shifts. Capacity of
machines can also be expanded from EO1 ¼ 3,000 hr to EO3 ¼ 6,000 hr through
machine rental from vendor which is at an increased cost. It is assumed that
engineering managers can choose energy-saving activities depending on cost and
quality requirements of the manufacturing process. Also the tax rate of carbon
emissions depends on the quantity of carbon emissions. Increasing carbon emission
quantity form TLCCE1 ¼ 2,000 kg to TLCCE3 ¼ 7,000 kg increases the tax rate to about
twice. The life cycle cost of product in green manufacturing is less than cost of same
product in conventional manufacturing.
A SD model is developed to examine the dynamic behavior of capacity (manpower
and machine) expansion, purchasing discounts and carbon emission quantities and
their relationship to costs. Figure 2 shows the SD model in Vensim.
The SD model presented shows the costs associated with the entire manufactured
product life cycle which exist in more than one category and ignored during
mathematical modeling. The costs considered as shown are material costs, wage costs,
equipment costs and carbon emissions costs. The various costs are estimated by using
capacity expansion and purchasing discounts to reach net requirement. The various
costs are influenced by their respective rates and quantities. The aggregation of all the
considered costs gives the total costs.
For a proper understanding of the dynamic behavior of capacity (manpower and
machine) expansion, purchasing discounts and carbon emission quantities, an analysis
of the variables has been carried out by simulations in Vensim. Simulation runs were
carried out using data presented on Table IV.
Figure 3 shows the behavior of manpower. Figure 4 shows the behavior of
manpower costs in manufacturing. Figures 5 and 6 shows the behavior of carbon
emission costs and material costs, respectively. The behavior of machine capacity
Conventional manufacturing (gCO2) Green manufacturing (gCO2)
Carbon emissions of electricity 266 225.4
Carbon emissions of raw materials 9,415 1,882.14
Carbon emission of chips 243 176.5
Carbon emissions of cutting tools 124.5 69.8
Carbon emissions of coolant 3.91 –
Total carbon emissions 10,052.4 2,353.84
Table II.
Carbon emissions in
manufacturing stage
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15. and machine costs are shown in Figures 7 and 8, respectively. Thebehaviors depicted
by the costs as shown in Figures 4-6 and 8 are due to the respective target
requirements. In Figure 4, manpower costs remain constant over a period of time after
which it increases due to capacity expansion resulting from overtime labor. A further
increase in labor hours also leads to increase in manpower costs. The effect of carbon
Life cycle stage Carbon emission factor
Energy consumption
driver
Conventional
manufacturing
Green
manufacturing
Development
Product design
planning
0.536 kgCO2 Drawings 6 6
Days 200 100
Material
transport
2.2631 kgCO2/L Motor gasoline 0.0315 0.0187
2.606 kgCO2/L Diesel oil 0.35 L 0.254 L
Carbon emissions in the development stage 1.555 kgCO2 1.026 kgCO2
Production
Electricity
consumption
0.536 kgCO2 of electric
power
Energy consumption
of machine
1,792 kJ 1,514 kJ
Chip production 0.361 kgCO2 of chip Mass of chips 0.673 kg 0.488 kg
Cutting tool
production
29.6 kgCO2 of cutting
tool
Mass of cutting tool 1.50 kg 2.70 kg
Cutting tool life cycle 208 minutes 420 minutes
Cutting time 35 seconds 22 seconds
Raw material
harvesting
0.741 kgCO2 of steel Mass of steel material 3.50 kg –
2.69 kgCO2 Mass of recycled steel – 2.54 kg
Cutting fluid
production
0.2 kgCO2/L of cutting
fluid waste
Total time 114 seconds 100 seconds
2.895 kgCO2/L of oily
substances
Replacement time of
coolant
1 month –
Carbon emissions in the production stage 10,052.4 gCO2 2,353.84 gCO2
Use/operation
Product
coupling
0.536 kgCO2 Electric power 0.0166 hours 0.0166 hours
Product
transportation
2.2631 kgCO2/L Motor gasoline 0.0424 L 0.03076 L
Operation 0.536 kgCO2 Machine energy
consumption
0.0975 kJ 0.0707 kJ
Years of operation 10 10
Carbon emissions in the use/operation stage 1.5 kgCO2 1.16 kgCO2
Maintenance
Product
maintenance
0.536 kgCO2 Electric power 0.00694 hours 0.00694 hours
Frequency 240 240
Carbon emissions in the maintenance/ refurbishing stage 0.89 kgCO2 0.89 kgCO2
Decoupling
Product
decoupling
0.536 kgCO2 Electric power 0.0166 hours 0.0166 hours
Carbon emissions in the decoupling stage 0.0088 kg CO2 0.0088 kgCO2
Waste collection for reuse/recycling
Waste transport 2.2631 kgCO2/L Motor gasoline 0.0424 L 0.03076 L
Carbon emissions in the waste collection for reuse/recycling stage 0.0959 kgCO2 0.0696 kgCO2
Total life cycle carbon emissions 14.10 kgCO2 5.498 kgCO2
Table III.
Carbon emissions in
the product life cycle
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16. tax rate is shown in Figure 5. As shown, tax rate increases with increased
carbon emission quantities. Figure 6 depicts the effect of purchasing discounts.
As shown, a material vendor offers discounts for if the purchasing quantity exceeds a
particular threshold.
Conventional
manufacturing
Green
manufacturing
Unit level
Production Machining time (s) 149 114
Unit cost ($/hr) 180 170
Maintenance Labor time (minutes) 0.416 0.416
Technician cost ($/hr) 1 1
Batch level
Material transport Transportation
distance (km) 1,000 980
Number of order 1 1
Activity cost ($/km) 0.005 0.005
Product transport Transportation
distance (km) 1,200 1,200
Cost per product
($/km) 0.005 0.005
Waste collection Transportation
distance (km) 1,200 1,200
Batch size 1 1
Activity cost ($/km) 0.005 0.005
Environment level
Operation activity Energy cycle (years) 10 10
Unit cost ($/yr) 12 12
Waste reuse/recycling Recycled waste (kg) – 2.54
Unit cost ($/kg) – 3
Process level
Design/development Drawings/sketches 6 6
Unit cost ($/cutter) 3 3
Material costs constraints
N1 ¼ $2/kg Nd1 ¼ $1.5/kg Pd1 ¼ 1,000 kg
N2 ¼ $5/kg
N3 ¼ $7/kg Nd3 ¼ $5.5/kg Pd3 ¼ 2,300 kg
Wage costs constraints
W1 ¼ 1,000 hr b1 ¼ $1/hr
W2 ¼ 1,600 hr b2 ¼ $1.8/hr
W3 ¼ 2,900 hr b3 ¼ $2.5/hr
Equipment costs constraints
E1 ¼ 2,000 hr E2 ¼ 3,500 hr E3 ¼ 5,000 hr
J1 ¼ $180/hr J2 ¼ $290/hr J3 ¼ $350/hr
Carbon emission costs
Tc1 ¼ 2,000 kg, Tc2 ¼ 4,000 kg,
Tc3 ¼ 7,000 kg
14.10 kgCO2 5.498 kgCO2
s1 ¼ $2, s2 ¼ $3, s3 ¼ $4 $2 $2
Total costs ($) 190.65 179.22
Table IV.
Activity-based
costs of product
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17. The dynamic behavior of machine capacity is depicted in Figure 7. Machine capacity is
increased through rental form vendors. With increased machine capacity, cost also
increases as shown in Figure 8. From the Vensim simulation results, equipment costs
and carbon dioxide emission costs are the major cost components influencing the
product costs in manufacturing. Green manufacturing lowers carbon emission to
provide environmentally friendly manufacturing thereby decreasing carbon emission
costs. Thus, life cycle costs in manufacturing can be reduced through green
manufacturing.
Manpower
requirement
Time to adjust
manpower
Manpower
Net hire rate
Target
manpower costs
Manpower
costs
Rate of
manpower costs
Time to adjust
manpower costs
Time to adjust
machine capacity
Machine capacity
requirement
Time to adjust
equipment costs
Target
equipment costs
Equipment
costs
Rate of
equipment costs
Machine
capacity
Net rental rate
Material
Net purchasing rate
Time to adjust
material
Target material
requirement
Material costs
Rate of material costs
Time to adjust
material costs
Target material costs
Carbon
emissions
quantity
Emission
adjustment time
Target carbon
emissions
Net emission rate
Carbon
emissions
costs
Rate of carbon
emissions costs
Carbon costs
adjustment time
Target carbon
emissions costs
Total costs
Energy-saving costs
Figure 2.
Systems dynamics
model for costs in
green manufacturing
Manpower
3,000
2,250
1,500
750
0
1 1 1 1 1
1
1 1 1 1 1 1
1
1
1
0 10 20 30 40 50 60 70 80 90 100
Time (Month)
hours
Manpower : Manufacturing 1 1 1 1 1 1 1 1 1 1
Figure 3.
Vensim simulation
results for manpower
in manufacturing
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19. 5. Conclusion, managerial implications and recommendations
This paper integrates “green manufacturing,” concepts of industrial dynamics, and product
lifecycle aiming at developing a methodology for cost calculation. The methodology
comprises of a process-based cost model and a SD model. The process-based cost model
focusses mainly on carbon emission costs and energy-saving activities. SD model was
applied to incorporate important metrics usually ignored in traditional static modeling.
The study provides a decision-making tool which will assist management in implementing
green manufacturing by incorporating a life cycle assessment measurement into
manufacturing cost management.
It is possible to reduce the manufacturing costs by incorporating “green issues”
at the unit level and batch level. At the unit level, production and maintenance activities
are carried out. The cost reduction can be achieved through minimizing wastes during
production and employing electric power. Waste minimization during production can
be achieved through the use of recycled material and avoidance of cutting fluids.
The carbon emissions of virgin materials accounts for the highest percentage of carbon
emissions during production due to their high carbon emission factor. Using recycled
materials which are characterized by low carbon emission factor can lead to a
significant reduction in total carbon emission during production. Minimizing total
Machine capacity
5,000
3,750
2,500
1,250
0
1 1 1 1 1
1
1 1 1 1 1 1
1
1 1
0 10 20 30 40 50 60 70 80 90 100
Time (Month)
hours
Machine capacity : Manufacturing 1 1 1 1 1 1 1 1 1
Figure 7.
Vensim simulation
results for
machine capacity
Equipment costs
2 M
1.5 M
1 M
500,000
0
1 1 1 1 1
1
1 1 1 1 1
1
1
1
0 10 20 30 40 50 60 70 80 90 100
Time (Month)
dollars
Equipment costs : Manufacturing 1 1 1 1 1 1 1 1 1
Figure 8.
Vensim simulation
results for
equipment costs
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20. carbon emission during production can cause a reduction in carbon emission tax which
constitutes a larger part of total life cycle cost of product. Lengthened tool life,
increased dimensional accuracy and reduced power consumption are some of the
advantages of using cutting fluids during manufacturing. However, cutting fluid can
pose a huge threat to the environment by emitting high carbon dioxide. Thus, it is
recommended to management to use recycled materials and avoid use of cutting fluid
during manufacturing. At the batch level, material and finished/used product are
transported to the manufacturing facility, customer and waste reuse/recycling center.
Costs at the batch level can be minimized through employing low energy consumption
fuel type (e.g. motor gasoline) and electric power. Thus, engineering mangers are
recommended to use electric power and low energy consumption fuel having low
carbon emission factor. At the process level, design and development activities are
carried out using drawings. Engineering managers are recommended to minimize cost
through reducing number of drawings and design time for a new product prototype.
The specific results of this study are limited to the case company, but can hopefully
contribute to further research on ascertaining cost of implementing “green issues”
in manufacturing. The proposed cost calculation model can be efficiently applied in any
manufacturing firm on the basis of accessibility of real cost data thus necessitating a
comprehensive cost database. At the development of the model and database
management system, time and cost resources could be demanding, but once installed,
use of the model becomes less demanding.
The results of the application show that the proposed detailed cost model can be
effective in ascertaining costs of implementing green manufacturing. Manufacturing
firms are recommended to adopt energy-saving activities mainly at the unit level and
batch level based on the proposed detailed cost calculation model. This work provides
costs justification of green manufacturing.
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Corresponding author
Ifeyinwa Orji can be contacted at: ifindustrial@yahoo.com
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