GREEN MANUFACTURING

GREEN MANUFACTURING

ABSTRACTGreen Manufacturing is a method for manufacturing that minimizes waste and pollution achieved through product and process design. It slows the depletion of natural resources as well as lowering the extensive amounts of trash that enter landfills. Its emphasis is on reducing parts, rationalizing materials, and reusing components, to help make products more efficient to buildGreen Manufacturing is a philosophy rather than an adopted process because it motivates ongoing improvement efforts even though it may be impossible to achieve. It is a holistic endeavor intended to result in less waste, cleaner products and processes, a better and safer working environment, improved relationships between companies and local communities, compliance with government regulations, and enhancement of profitability.The reason it is such an important tool is because it intertwines with todays manufacturing strategies of global sourcing, concurrent engineering, and total quality.

TABLE OF CONTENTSChapter 1 IntroductionChapter 2Green manufacturings goalChapter 3Necessity of green manufacturingChapter 4Process of green manufacturingChapter 5different aspects in green manufacturing5.1 Jit manufacturing5.2 Zero emission strategy5.3 Iso 9000 and iso 14000Chapter 6Benefits of green manufacturingChapter 7 Examples Chapter 8 Area of applicationsChapter 9 Conclusion References

Chapter 1INTRODUCTIONGreen Manufacturing is generically defined as elimination of waste by re-defining the existing production process or system. Several other jargons such as end-of-line management mean the same thing. We have all come across company examples that take their problem solving approach to the next level and develop innovative techniques towards effective solutions. Such solutions result in cost savings from reduced work handling, effluent control, process automation, etc. All these efforts are applications of green manufacturing. This manufacturing concept is not just restricted to addressing the social and environmental impact of a pollution-centric process. Green manufacturing addresses process redundancy, ergonomics and cost implications due to faulty methods of producing goods. Faster and cheaper are no longer the only two criteria in manufacturing a product or evaluating an existing process line. Several other factors such as materials used in manufacture, generation of waste, effluents and their treatment (or possible elimination), life of the product and finally, treatment of the product after its useful life are all important considerations. How does this relate to the blast cleaning and shot peening industries? Surprisingly, in many important ways! Right from the early days of blast cleaning components, this process has unfailingly generated dust. Every responsible blast equipment manufacturer and operator has, with a great deal of concern, adopted traditional and innovative means to contain, filter and dispose off this dust. This, at the grassroots level, has been our initiation into green manufacturing. History has shown the effectiveness of this process and its implementation in several industry sectors to clean, etch, de-burr and strengthen metal components. Further development of the technique of blast cleaning resulted in the creation of standards of cleaning and parameters of peening, eventually increasing the application base. There are very few manufactured components that, at one time during their manufacturing process, have not been through a blast machine!

Chapter 2GREEN MANUFACTURINGS GOAL*Its goal is to achieve sustainability. *Every company when it comes to green manufacturing should be conserving natural resources for future generations.

Chapter 3NECESSITY OF GREEN MANUFACTURINGTo answer the above question one has to ask questions about the Manufacturers Responsibilities, so as to, Where does a manufacturers responsibility end? What is an acceptable level of toxic emission? The questions further lead to more questions to be answered, as to, Responsibility, does it end at the sale? Does a customer's responsibility end at the landfill when they are finished using the product? Who should decide on the toxic level? The people that live in the neighborhood of the government? In the end no one really knows where anything stops and so therefore companies and individuals must take it upon themselves to help eliminate waste. They should not wait for it to become a law............So GO GREEN.

Chapter 4PROCESS OF GREEN MANUFACTURING Companies move from traditional end-of-pipe control to new technologies.Examples of new technologies would be things like pollution prevention, production process modernization, materials substitution. etc. End-Of-Life ManagementEnd of life management is the full life cycle starting from the virgin materials to the use and disposal of the final product. Waste source reduction on the spot & Recycling.Global environmental standards like ISO 14000 are being introduced that emphasize management systems that address environmental concerns, operations that consider energy and natural resource consumption, and systems for measuring, assessing and managing waste streams.Reduction of wastage has also helped in the cost reduction in the long-term perspective. Wastage reduction directly deals with the minimization of residuals. Any manufacturing process produces residuals and/or generates wastage. Residuals are normally different from the input resources, while wastage is the superfluous resources, which could not be tapped into the transformation process.Residuals can be reduced in manufacturing plants by three common methods. They are reuse, remanufacture, and recycle. Reuse occurs when the component has minor changes made before forming a part of the final product. Remanufacture, results in considerable change in the component before it can be taken back into the product. Recycle requires maximum transformation before it can be taken back into the manufacturing cycle. Most of the times recycle involves out-of-industry treatment for the component to be made useful. For example, printing may use recycled paper, which becomes useful only after the paper has been reprocessed in paper mills. Thus, reused, remanufactured and recycled components are taken back into conversion process at different stages with recycled being taken back at the earliest phase of production. Virgin Materials are recycled Virgin materials can be recycled through the process of distillation and filtering. The distilled or filtered materials could be reintroduced in the life cycle wherever new materials aren't required. Invest in production process improvements rather than control technology. "Corporate companies spent $7.2 billion in pollution abatement and control expenditure of which $3.2 billion were on production process enhancement. Advanced manufacturing systems promotes green design and production strategies.Manufacturing systems promotes green design because both strategies are based on the dedication to product improvement, cost reduction, and technology innovation. Development of innovative manufacturing systems.Improving the manufacturing system simultaneously minimizes cost connected with environmental compliance. Reduction in leapfrogging from lily pad to lily pad. (Bergstrom, 50)Leapfrogging from lily to lily pad means not to jump on every chemical that initially describes itself as more environmentally safe but later on it creates even more problems than the original material. Substitute renewable sources for finite ones.Substituting renewable sources for finite ones might not be completely safe as found in a study between petroleum and plants. The study concluded that even though plants could be used as a substitute the cost in the end might be more and more environmentally dangerous. (Gerngross, Daily University Science News) Funding research facilities.Companies can fund researches that includes finding substitute chemicals and materials that will eliminate pollution at the top. Companies must decide whether to make-or-buy.Little things like recycling paper and soda cans can reduce a lot of waste cost. Companies that produces materials can decide whether or not they want to contract another company to make certain parts because those companies might have better equipment and higher vertical control technology

Chapter 5DIFFERENT ASPECTS IN GREEN MANUFACTURING JIT Manufacturing Zero Emission Strategy ISO 9000 and ISO 14000

5.1JIT MANUFACTURING Aspect of Supply Chain Management Collaboration between companies and their suppliers creates opportunities for new design products and processes that are more efficient and environmentally friendly. Emphasis on continuous cost reduction and quality improvement Continuous improvement creates an incentive for waste reduction and cost saving.5.2 Zero Emission Strategy Elimination of all environmentally damaging by products from the production process. 16% of companies actively pursuing zero emission. 85% of companies are pursuing reduced emission strategies5.3 ISO 9000 and ISO 14000International Quality Standards used by companies on a voluntary basis. Motivates changes Companies is following quality standards that are recognized.Study done on National US Manufacturing firms found that most companies were moving from ISO 9000 to ISO 14000 such as Sony Corp and Safety Kleen.

Chapter 6BENEFITS OF GREEN MANUFACTURING Creates a great reputation to the public.The reputation of a company to the public is always an important thing because it can float or sink a company. If a company pollutes its neighborhoods, people would begin to move away creating a lack of employees which might damage their production numbers. Saves useless cost.Eliminating waste saves money because companies wouldn't have to figure out what to do with parts in the end when it could be recycled. Promotes Research and DesignFirms that are using green manufacturing create 2x the products due to its research and development. (Richard Florida in California Management Article)

Chapter 7EXAMPLES OF GREEN MANUFACTURING Murray Ohio Manufacturing CompanyWanted to develop ways of reducing scrap metal. Scrap metal was created because of the depth of the draw on the metal sheets and since the machines created severe deep draws it would tear and mar the metal sheets. Murray Ohio ManufacturingUsed a chlorinated oil with an additive of graphite to create heightened lubricity. Oil was used as a stamping lubricant

Chapter 8AREAS OF APPLICATIONS

Chapter 9CONCLUSIONGreen manufacturing is a relatively new concept about which there is currently significant confusion and misunderstanding regarding its components, costs, benefits, and implementation. Its future trends, therefore, are also uncertain. It is likely; however, that customers will increasingly demand low-cost, quickly produced and designed, high-quality products characterized by extensive variety. They will also demand that such products be produced by processes that are environmental responsible.Whether green manufacturing is good business or a bad investment is being argued. On one hand, eliminating waste has potential for reducing cost and increasing value. On the other hand, investments can result in negative returns, decreasing dividends for shareholders. Middle managers are often focused on quality and productivity rather than environmental or marketing issues. This perspective can hinder development and implementation of green manufacturing.To ensure success in green manufacturing, corporate cultures need to be developed in which the organization clearly defines its vision of green manufacturing and defines its objectives for implementation, establishes a plan for achieving the objectives, and recognizes the consequences and costs of not achieving these objectives. Along with support of top management, a team approach with representation from engineering, production, purchasing and human resources has been found to be necessary, rather than reliance on plant-level environmental experts or consultants.Training of the team in the techniques of total quality management would certainly help. Green manufacturing is likely to be an increasingly important issue because it is a crucial component in the international trend towards sustainable development. Sustainable development has been a long term goal to meet the needs of the current generation by developing systems and processes that do not compromise the needs of future generations. Achieving this will require interdisciplinary cooperation between politicians, economists, scientists and engineers.

REFERENCE Bergstrom, Robin. Fighting the Good Fight at Northrop,Manufacturing Management Bergstrom, Robin. On Giving Due Thought to Afterthought,Manufacturing Management Bergstrom, Robin. Stamping Made Cleaner, Manufacturing Management http://www.ce.cmu.edu/GreenDesign/ http://csspub.snre.umich.edu/css_proj/ http://www.enme.umd.edu/greenmfg/links.html http://www.leidenuniv.nl/interfac/cml/ http://www.indiainfoline.com/bisc/mdigm04.html Green,inc. by francescairncross,Publisher: Island Press (September 1, 1995) Business Transformation Through ISO 14000, By Lt Gen H LalDirector General, FICCI Quality Forum www.northland.edu/studentlife/ELLC/index.html http://www.environmental-center.com/articles/article684/.htm

Dept. of Mechanical Engineering, Belgaum.Page 14