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237 ENVIRONMENTAL CONSCIOUS MANUFACTURING AND USE OF ANALYTICAL NETWORK PROCESS (ANP) DECISION TOOL IN ECM Rajkumar Duhan 1 *, Manish Bansal 1 and Haripal Dhariwal 2 *Corresponding Author: Rajkumar Duhan, [email protected] Today the increasing industrialization creates huge pressure on environment and due to this industrialization many environmental related problems arises daily. The global warming, air, water and noise pollution, ozone layer depletion are some of the major problems. With the global awareness of environmental risk as well as market pressure to get maximum benefits, manufacturing system requires new development and Environmental Conscious Manufacturing (ECM) is the only solution for these problems. Multinational and domestic corporations all around the world are adopting environmental manufacturing. The Analytic Network Process (ANP) is a more general form of the Analytic Hierarchy Process (AHP) used in multi-criteria decision analysis. AHP structures a decision problem into a hierarchy with a goal, decision criteria, and alternatives, while the ANP structures it as a network. Both then use a system of pairwise comparisons to measure the weights of the components of the structure, and finally to rank the alternatives in the decision. ECM is also known as Green Manufacturing. Keywords: ANP software, Environmentally Conscious Manufacturing (ECM) parameters, Various decision tools, Planning and control, etc. INTRODUCTION Environmental Conscious Manufacturing (ECM) is a new way of thinking about manufacturing which focuses on the most efficient and productive use of raw materials and natural resources, and minimizes the adverse impacts on workers and the natural ISSN 2278 – 0149 www.ijmerr.com Vol. 1, No. 3, October 2012 © 2012 IJMERR. All Rights Reserved Int. J. Mech. Eng. & Rob. Res. 2012 1 Department of Mechanical Engineering, University Institute of Engineering & Technology, Rohtak, Haryana, India. 2 Department of Automobile Engineering, Government Polytechnic Manesar, Gurgaon. environment. In its most advanced form, a product’s entire life cycle is considered, from design, raw material and natural resource use to end use and disposal.In order to reach this goal, tools like Life Cycle Analysis (LCA) may be used. Concepts like pollution prevention, energy efficiency, material substitution and Research Paper

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Page 1: ENVIRONMENTAL CONSCIOUS MANUFACTURING AND USE · PDF fileENVIRONMENTAL CONSCIOUS MANUFACTURING AND USE OF ANALYTICAL NETWORK PROCESS (ANP) DECISION TOOL IN ECM ... Environmentally

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ENVIRONMENTAL CONSCIOUS MANUFACTURINGAND USE OF ANALYTICAL NETWORK PROCESS

(ANP) DECISION TOOL IN ECM

Rajkumar Duhan1*, Manish Bansal1 and Haripal Dhariwal2

*Corresponding Author: Rajkumar Duhan,[email protected]

Today the increasing industrialization creates huge pressure on environment and due to thisindustrialization many environmental related problems arises daily. The global warming, air,water and noise pollution, ozone layer depletion are some of the major problems. With theglobal awareness of environmental risk as well as market pressure to get maximum benefits,manufacturing system requires new development and Environmental Conscious Manufacturing(ECM) is the only solution for these problems. Multinational and domestic corporations all aroundthe world are adopting environmental manufacturing. The Analytic Network Process (ANP) is amore general form of the Analytic Hierarchy Process (AHP) used in multi-criteria decision analysis.AHP structures a decision problem into a hierarchy with a goal, decision criteria, and alternatives,while the ANP structures it as a network. Both then use a system of pairwise comparisons tomeasure the weights of the components of the structure, and finally to rank the alternatives inthe decision. ECM is also known as Green Manufacturing.

Keywords: ANP software, Environmentally Conscious Manufacturing (ECM) parameters,Various decision tools, Planning and control, etc.

INTRODUCTIONEnvironmental Conscious Manufacturing(ECM) is a new way of thinking aboutmanufacturing which focuses on the mostefficient and productive use of raw materialsand natural resources, and minimizes theadverse impacts on workers and the natural

ISSN 2278 – 0149 www.ijmerr.comVol. 1, No. 3, October 2012

© 2012 IJMERR. All Rights Reserved

Int. J. Mech. Eng. & Rob. Res. 2012

1 Department of Mechanical Engineering, University Institute of Engineering & Technology, Rohtak, Haryana, India.2 Department of Automobile Engineering, Government Polytechnic Manesar, Gurgaon.

environment. In its most advanced form, aproduct’s entire life cycle is considered, fromdesign, raw material and natural resource useto end use and disposal.In order to reach thisgoal, tools like Life Cycle Analysis (LCA) maybe used. Concepts like pollution prevention,energy efficiency, material substitution and

Research Paper

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maximization of recycled content guide theprocess. Environmentally ConsciousManufacturing is also known by plethora ofdifferent names: Clean manufacturing, GreenManufacturing, environmentally benignmanufacturing, environmentally responsiblemanufacturing and Sustainable manufacturing.Irrespective of the various acronyms, theprimary goal remains the same—designingand delivering products that minimize negativeeffects on the environment through theirproduction, use, and disposal. There are manyinterpretations of green manufacturing and allconvey similar meaning. According to Melnykand Smith, it is a system that integrates productand process design issues with issues ofmanufacturing, planning and control in such amanner as to identify, quantify, assess, andmanage the flow of environmental waste withthe goal of reducing and ultimately minimizingenvironmental impact while also trying tomaximize resource efficiency. Figure 1 showsgreen manufacturing helps in recycling theprocess.

SELECTION OF TOOLThe Analytical Network Process (ANP) isselected here for solving the present problem.The ANP is used because there isinterdependency between the factors and tomake the necessary computation. As there isnumber of factors on which environmentconscious manufacturing depends and it isvery confusing to select or priorities themdepending upon some criteria and to also ittakes lots of time to find out correct prioritywithout any using any tool so ANP is used hereto solve the present problem. The process andmethod to priorities the factors is discussedin the next part of the study.

FACTORS DESCRIPTIONAs the ultimate goal here is to achieve theenvironment conscious manufacturing and forachieving this target, the factors which affectsthe ECM have to known and their impact onthe environment have to be known, so theselection and classification of the factor is thefirst basic step to advance the study further.Also the selection of factor for ECM affectsthe whole efficiency of the plant so selectionof factors plays a very crucial role in ECM andone should have to select and choose the factortactfully and carefully otherwise the efficientresult can’t be achieved. The factor are chosenfrom the research papers after studying themand it is found that there are numerous factorswhich affects the environment and then a totalof 31 factors are selected from all availablefactors and their brief description is given hereone by one. These factors are divided into fivemajor categories which are further divided into31 other factors and all of them are listed inTable 1 shown below and these factors are

Figure 1: Meaning of EnvironmentConscious Manufacturing

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GreenManufacturing Research and Design Process Energy Savings of Products ESOP

Health and Safety HS

Proportion of Product Reuse POPR

Proportion of Product Recycling POPRC

Conformity with Eco-Concept CWEC

Simplification and Standardization SS

Reliability and Durability RD

Staff with Eco-Awareness SWEA

Waste Control Pollution from Product PFP

Proportion of Waste Renewable Products POWRP

Ability to Minimize Waste and Maximizethe Utility ATMWAMTU

Management of Waste Classification MOWC

Waste Reduction Rate of ProductionFacilities WRRPF

Application of Foolproof Devices AOFD

Production Automation PA

Packaging Control Packaging Simplification PS

Ease of Disintegration EODI

Application of Product Intensified Packaging AOPIP

Proportion of Non-Packaging PONP

Additional Processing of Packaging Materials APOPM

Inspection Pass Rate of Green Part IPROGP

Green Procurement Capabilities GPC

Manufacturing Control Environmental Pollution During Production EPDP

Environmental-Related Injury to Operator ERITP

Capabilities of Pollution PreventionDuring Production COPPDP

Waste Reduction Capabilities WRC

Energy Efficiency During Production EEDP

Quality Control Ability to Obtain Green Certification ATOGC

Customer Satisfaction with Respect to GreenDemand CSWRTGD

Ability to Identify Flawed Green Product ATIFGP

Compliance with Outsourcing Regulationsfor Green Products CWORFGD

Table 1: Factors Description

Goal Dimensions Assessment Factors Code

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coded into short form to make themcompactable with the software used.

MODEL DEVELOPMENT/DESCRIPTIONFor developing the ANP model first of all weshould have some know goal which we wantto achieve and over aim here is environmentalconscious manufacturing evaluation andsecond thing we have to know is the factorson which the aim depends so here a total of31 factors are selected for ECM evaluationand these factors are categories into five maincategories. Now after getting all these usefulinformation we use the ANP software anddevelop the basic model. The Figure 2 belowshows the basic ANP model which isdeveloped and all the computation work isdone based on this ANP model.

The development of model helps tounderstand the work and to progress the study.In the model there are basically three levelstop, middle and bottom. In the hierarchy of themodel aim (environment consciousmanufacturing) is situated at top of the modeland in the hierarchy of the model middle levelconsists of dimensions on which the aimdepends and these are research and designprocess, waste control, packaging control,manufacturing control and quality control. Afterthat at last or at bottom level of the modeldifferent factors on which major dimensiondepends are shown or it is the base of themodel on which the whole ECM processdepends. In the AHP model the process starsfrom bottom to top that is in AHP theimportance of bottom factor decides theimportance of top factor on which it depends.

Figure 2: ANP Basic Model

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COMPUTATION WORK ANDRESULT SYNTHESISNow after developing the model with the helpof software different computation work isdone to synthesis the result. It consists offollowing step.

DATA INPUTThe first step after the model development isto do the comparison and to progress the

comparison process we have to fill thequestionnaire first and it should be donecarefully keeping in mind about the relativeimportance of different factors and the Figure3 shows the basic type of questionnaire. Thequestionnaire shown here is just for onecategory but actually such questionnaires aredeveloped for entire group and all of them haveto be fill accurately to make the computationwork for the model developed. This

Figure 3: Questionnaire for Computational Data

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comparison is done for all the 31 factorsdepending upon the effect of these factors onECM and this comparison is basically basedon these questionnaires.

There is other form of date input alsoavailable that are matrix, graph and verbalform. But the questionnaire type data input isbest method as it make easy to understandthe process and we have to simply make therelationship between different factors andthese relation or relative importance is basedon some knowledge base and Table 2 isused to fill the questionnaire depending uponthe relative importance and ranking of thefactors.

is better to do the work right at first time ratherthan increasing it at later stage.

RESULTAs it is well known that different factorspossess different priorities with relation to theenvironmental conscious manufacturing so inorder to have a wider reach over them, thepriorities are easily predicted using the superdecisions software. The inputs to the prioritiesare filled by various questionnaire preparedduring our course of study. Their inconsistencyindex is also mentioned in the fig with desiredvalue. This priority table help the researchersto judge the relative importance between allthese factors and based on the judgement thedecision is made for environmentalmanufacturing. The priority defer from categoryto category as the expectation/desires differsfrom person to person, category to categorytherefore the priorities for the differentcategories are discussed below one by one.Also the priority for entire group/model isdiscussed.

Result/Priority for Research andDesign Process

The result for the research and design processis shown in the Figure 4 shown below and it isobserve from the result that Proportion ofProduct Recycling (POPRC) is most importantfactor among this cluster and Simplificationand Standardization (SS) is second mostimportant factor while Energy Savings ofProducts (ESOP) is least importance factoramong the research and design processes.

Result/Priority for Waste Control

The Figure 5 shows the result for this categoryand it is observed from the result thatApplication of Foolproof Devices (AOFD) is

The numerical value is used to rank thefactor and this should be done based on somescientific approach that is the value shouldsatisfy the relation. If the relative importancein the questionnaire is done without thinkingthis will make error in the computation workand consistency is not achieved. Then thisinconsistency is to be removed to synthesisthe result and this removal is done by changingthe numerical values in the questionnaire so it

1. Equal

2. Between Equal and Moderate

3. Moderate

4. Between Moderate and Strong

5. Strong

6. Between Strong and Very Strong

7. Very Strong

8. Between Very Strong and Extreme

9. Extreme

Table 2: Ranking for Questionnaire

Note: Decimal judgments, such as 3.5, are allowed for fine tuning,and judgments greater than 9 may be entered, though it issuggested that they be avoided.

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most important factor in this category and thanProportion of Waste Renewable Products(POWRP) is second most important factorwhile Ability to Minimize Waste and Maximizethe Utility (ATMWA MTU) is least important asat this stage the product is manufactured andit is tough to reduce its impact on theenvironment. Also the importance for otherfactor can be easily calculated from the resultand these factors can also be rankedaccordingly.

Result/Priority for PackagingControl

The result for the packaging control cluster isshown in the Figure 6 and it is observed herethat Green Procurement Capabilities (GPC)is most importance factor in this cluster andthen inspection pass rate of green parts(IPROGP) and Packaging Simplification (PS)comes next in the priority while Proportion ofNon-Packaging (PONP) is least importancefactor in this cluster.

Figure 4: Result for Research and Design Process

Figure 5: Result for Waste Control

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Result/Priority for ManufacturingControlThe result for manufacturing control is shownin the Figure 7 and it is seen here that EnergyEfficiency During Production (EEDP) andwaste reduction capabilities (WRC) is mostimportant factor and all other factor are havingalmost equal importance.

Result/Priority for Quality ControlThe result of quality control is shown in theFigure 8 and it is observed here Customer

Figure 6: Result for Packaging Control

Satisfaction With Respect to Green Demand

(CSWRTGD) is most important factor here

and all other factors are almost equally

important.

Result/Priority for Entire Model

The result for the entire model can be

measured based upon the priority of all the

factors and it is shown in the Figure 9 and the

priority of the entire category can be judged

from the figure.

Figure 7: Result for Manufacturing Control

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The priority Table 3 shown below for theentire sample is based on the result obtainedfrom the software and it is used to give relativeimportance between different factors. The

percentage importance of different factors isalso shown in the table and it can be used togive relative importance/priority between thefactors selected.

Figure 8: Result for Quality Control

Figure 9: Combined Results

Category Rank Percentage Importance

Manufacturing Control 1st 41.66%

Waste Control 2nd 24.35%

Quality Control 3rd 17.05%

Research and Design Process 4th 09.02%

Packaging Control 5th 07.89%

Table 3: Relative Importance

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CONCLUSIONBased on considerable data from ECMpractices and feasible industrial methods,while incorporating comments from experts inrelevant fields, this work here developedassessment model and evaluate factors,followed by a calculation the weights ofevaluating factors via ANP. Finally, the modelis used for extracting successful factors ofimplementing ECM in any organizationalsystem. Based on the results of this study, thefollowing conclusion points can be drawn:

• The proposed model contains 5 strategicfactors, i.e., research and design process,waste control, packaging control,manufacturing control and quality control and31 assessment factors/sub factors.

• For strategic subjects, based on evidential

analysis, the importance of assessmentfactors from each category can be seenjudged from the result and the relativeimportance for five main categories canbe judged from the Figure 10 shownbelow.

• It is observed that Manufacturing Controlprocess plays most important role forenvironment conscious manufacturing

and then Waste Control comes next in thepriori ty while Quali ty Control andResearch and Design Process comesnext in hierarchy and Packaging Controlis least important among the factorsselected.

Figure 10: Priority for Different Categories

REFERENCES1. Ahmed M Dief (2011), “Industrial System

Engineering-University of Regina ASystem Model for Green Manufacturing”.

2. Baoju H and Jian L (2011), “Virtual GreenManufacturing and its Application in

Manufacturing”, International Conference onAdvanced Manufacturing Technology New

Requirements to China’s Manufacturing,Vol. 11, No. 5, June, pp. 244-248.

3. Gencer C and Gurpinar D (2006),

“Analytic Network Process in Supplier

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Selection: A Case Study in an ElectronicFirm, Applicable Math Model, Vol. 31,No. 11, May, pp. 2475-2486.

4. Liang D H (2012), “Cloud Computing andGreen Management”, InternationalConference on Intelligent System Designand Engineering Application, Vol. 7,January 6-7, pp. 639-642.

5. Manish Bansal (2012), “Research Paperon Green Manufacturing and Use ofAnalytical Network Process (ANP)Decision Tool in Green Manufacturing”,Vol. 1, No. 3, October, ISSN 2278-0149,www.ijmerr.com

6. Zhang Y (2010), “Research onDevelopment & Application of InformationResources of Green Manufacturing

Enterprise”, International Conference onInformation Management, InnovationManagement and Industrial Engineering,Vol. 3, March, pp. 130-134.

7. Zhongling Z and Xiwen F (2010), “TheResearch and Practice of GreenProduction and Recycling Economy inGold Mine Enterprise”, InternationalConference on Information Managementand Engineering, Vol. 5, April 16-18,pp. 518-522.

8. Zhou M (2011), “Simulation BasedAnalysis for Selection and Evaluation ofGreen Manufacturing Strategies,International Conference on ServiceSystems and Service Management,Vol. 10, June 25-27, pp. 1-6.