Carbon weight analysis for machining operation and allocation for redesign

The objective of this research paper is to explore and develop a new methodology for computing carbon weight (CW) – often referred to as carbon footprint, in manufacturing processes from part level to assembly level. In this initial study, we focused on machining operations, specifically turning and milling, for computing CW. Our initial study demonstrates that CW can be computed using either actual measured data from process level information or from initial material and manufacturing process information. In mechanical design, tolerance analysis principles extend from design to manufacturing and tolerances accumulate for parts and processes. By extending this notion to CW, we apply mechanical tolerancing principles for computing worst case and statistical case CW of a product. We call this the CW tolerance approach (CWTA). Two case studies demonstrate the computation of CW. Based on the tolerance allocation concepts; CW allocation is also demonstrated through specific redesign examples. CWTA helps in identifying carbon intensive parts/processes and can be used to make appropriate design decisions.     

A holistic approach to achieving energy efficiency for interoperable machining systems

In the twenty-first century, the continuous demand in energy resource has put sustainability on the agenda of many businesses. This is particularly true for the manufacturing industry, where a large amount of energy is consumed to sustain daily operations. This paper studies energy-efficient computer numerical control machining systems. To achieve overall energy efficiency in machining systems, several activities are involved as in the proposed research framework of a global energy-efficient machining system (GEMS). These activities are described as modules, i.e. energy monitoring, energy analysis and optimisation, energy-based optimal control and energy-enriched database. In a GEMS, one critical issue is data interoperability. Seamless data sharing enables collaboration for improving energy efficiency. Using the EXPRESS language, energy data models are proposed for each module in the GEMS, and integrated with the existing STEP-NC (STandard for Exchange of Produce-compliant Numerical Control) standards. Two case studies are presented to demonstrate how the proposed data models may be used. One study updates an existing production file to include general energy information for auditing or reviewing purposes; the other study maintains machine tool energy profiles in a database. Many other energy-efficient activities, e.g. online energy optimisation, can be realised with the proposed data models. The present study proved that interoperable energy information can enhance the energy-efficient performance of a machining system.     

State-of-the-art sustainability analysis methodologies for efficient decision support in green production operations

Over the last three decades, new concepts, strategies, frameworks and systems have been developed to tackle the sustainable development issue. This paper reviews the challenges, perspectives and recent advances in support of sustainable production operations decision-making. The aim of this review is to provide a holistic understanding of advanced scientific analysis methodologies for the evaluation of sustainability, to provide efficient decision support. Over 100 publications have been analysed, and a characterisation of state-of-the-art sustainability analysis methodologies has been produced, which includes life cycle assessment and multi-criteria decision analysis (MCDA), along with their applications to three key areas of production operations: sustainable design, sustainable manufacture and sustainable supply chain management. Distribution of existing work is discussed and future research directions are elicited from the literature. The paper finds three trends in supporting sustainable production operations decisions: (a) sustainability analysis has moved to whole life cycle assessment from single-stage assessment, (b) sustainability analysis has shifted away from single criterion to MCDA and (c) sustainability analysis has evolved from stand-alone approaches to integrated systematic methodologies. The paper concludes that integrated sustainability analysis can provide more efficient and effective support to complex decision-making in sustainable production operations.     

Social sustainability in supply chain decisions: Indian manufacturers

The purpose of the paper is to assess the inclusion of social sustainability in the decisions of supply chain in multinational manufacturing organisations in India. Indian organisations are resorting to sustainability-based reporting for greater transparency and for creation of brand value for their organisations. There are tremendous economic upheavals and changes across the complete value chain, and thus, responsible business practices are becoming a necessity for the long-term survival of organisations. Sustainability, as a strategy, is responsible utilisation of resources and is reported through social, economic and environmental factors in an organisation. For sustainability as a strategy, there has to be a complete organisational inclusion and employee engagement through decision making at operational levels along the value chain. The research paper is an empirical study done through a survey using a structured questionnaire to collect information to evaluate decision criteria particularly for social sustainability, from the middle and top level executives in Indian manufacturing organisations. Multinational manufacturing organisations in India are trying to be more responsible because of mandated CSR policy, and thus, sustainability through social factors is getting more prominence. A multiple linear regression analysis is used to explain the correlation and inclusion of social factors on the decision-making process in the supply chain of multinational manufacturing organisations in India. This study reveals that decision making in the supply chain of multinational manufacturing organisations in India specifically in manufacturing industry is incorporating social sustainability. The study highlights that decision making involving social sustainability needs larger frameworks for organisational preference. While the study provides evidence of social sustainability-based practices in multinational manufacturing organisations in India, it does not deal with social sustainability practices. The study also has limitation as has been limited to organisations which follow sustainability practices and make disclosures through GRI framework.     

A comparison of four sustainable manufacturing strategies

Effective use of materials is one possible component of a sustainable manufacturing strategy. There are many such strategies proposed in the literature and used in practice, with confusion over what they are, what the differences among them may be and how they can be used by practitioners in design and manufacture to improve the sustainability of their product and processes. This paper reviews the literature on sustainable manufacturing strategies that deliver improved material performance. Four primary strategies were found: waste minimisation; material efficiency; resource efficiency; and eco‐efficiency. The literature was analysed to determine the key characteristics of these sustainable manufacturing strategies and 17 characteristics were found. The four strategies were then compared and contrasted against all the characteristics. While current literature often uses these strategy titles in a confusing, occasionally inter‐changeable manner, this study attempts to create clear separation between them. Definition, scope and practicality of measurement are shown to be key characteristics that impact upon the ability of manufacturing companies to make effective use of the proposed strategy. It is observed that the most actionable strategies may not include all of the dimensions of interest to a manufacturer wishing to become more sustainable, creating a dilemma between ease of implementation and breadth of impact.     

Integrated Simulation and Modelling Approach to Decision Making and Environmental Protection

This paper's objective is first to test the application of computer simulation and modelling tools in investigating the effects of applying sustainable manufacturing practices in a smelter plant, and second, to prove quantitatively and visually that 'sustainibility is free'. A simulation model is built to test and capture two different operating polices, 'Policy 1' and 'Policy 2', of an industrial system. In the case study, the simulation model is designed to reflect the effects of decision making in the activites found in a smelter plant, and to quantify the cost, sustainable and environmental consequences based on the decisions. Apart from providing a means of accurately measuring a system's performance, the purpose of using simulation tools is also to link the economic factors, such as productivity and total costs, as well as the sustainable factors, such as natural resource and energy consumption of a system. The simulation results prove quantitatively and visually that sustainability is not only 'free' but is, in fact, a far better proposition for economic growth in the medium to longer term than traditional forms of management.     

Performance evaluation of lean sustainable systems using adaptive neuro fuzzy inference system: a case study

The modern manufacturing organisations have been adopting both lean and sustainable manufacturing paradigms to survive in the competitive environment. Lean and sustainable strategies aim at achieving productivity improvement by streamlined processes and waste elimination. The performance of such integrated lean sustainable system has to be assessed to ensure whether the strategic objectives are in line with customer value and to identify improvement opportunities that enable and enhance the competitive advantage of an integrated lean sustainable system. This paper presents the formulation of conceptual performance evaluation model to assess lean sustainable systems. Appropriate performance indicators have been identified and adaptive neuro fuzzy inference system approach is used to evaluate lean sustainability. A case of automotive component manufacturing firm in Indian scenario is exemplified. Based on the evaluation, lean sustainability index was computed and the firm was found to be ‘Averagely Lean Sustainable’. Further improvement actions to enhance the lean sustainable performance were planned and implemented. The developed performance evaluation model is capable of effectively evaluating the lean sustainable performance of manufacturing firms and has more practical relevance.     

Exploring the need for more radical sustainable innovation: what does it look like and why?

It has been argued in recent years that Western economies need to increase their resource productivity by 90% over the next 50 years. This is a radical aim. This paper draws on design for sustainability (DfS) thinking to scope interventions that encourage greater levels of resource productivity through reconfiguring concepts of growth and well‐being within organisational strategies, structures, systems, processes and outputs. Based on research from a UK EPSRC funded project Design Dialogues (2005–2008), this paper links together sustainable design and innovation literatures and dialogue‐based primary research that together inform the development of an approach to innovation for sustainability. The emphasis on sustainable innovation is to understand what is designed (the outputs of business) and why (the inputs: the values, beliefs, visions and objectives) within a context of ecological limits. The foundations of this approach are introduced here in order to demonstrate the potential to provoke a new way of thinking about longer‐term organisational innovation through making explicit the intrinsic connections between natural and human capitals. This paper explores the need to think differently in order to create sustainability and presents the outcome of this research: a methodology for innovation for sustainability.     

An enhanced sustainable approach for design and manufacturing with an application to fuselages for mono-seat civil sailplanes

Abstract

A number of tools and software systems have been developed in order to reduce the time for the design and manufacturing of industrial products. Nowadays, virtual modelling by Computer Aided Design (CAD) systems and process simulation by the application of Finite Element Method (FEM) software is a standard routine in order to compress product design activities and to achieve the optimal solution before producing any real components. These developments provided not only a reduction in the time to market but a higher complexity of the project and an improved quality of the industrial products. With the aim to further improve the sustainability of this activity, the implementation of a tool that adds automatic operations into the design activity is demonstrated. This software can interact with any CAD and helps designers when the object dimension and shape can be affected by limits and constraints deriving from different features and targets, such as the spatial collocation of the component and the interaction with other limiting items, for examples the material and the manufacturing issues. The concept was developed into the software SFIDA (Sailplane Fuselage Integrated Design Application) that is a first attempt to automatically manage multiple relations and optimise their combination.     

"Reference Biospheres" for solid radioactive waste disposal: the BIOMASS methodology

The BIOMASS Theme 1 project has developed a methodology for the logical and defensible construction of 'assessment biospheres': mathematical representations of biospheres used in the total system performance assessment of radioactive waste disposal. The BIOMASS Methodology provides a systematic approach to decision making, including decisions on how to address biosphere change. The BIOMASS Methodology was developed through consultation and collaboration with many relevant organisations, including regulators, operators and a variety of independent experts. It has been developed to be practical and to be consistent with recommendations from ICRP and IAEA on radiation protection in the context of the disposal of long-lived solid radioactive wastes. The five main steps in the methodology are described in this paper. The importance of a clear assessment context, to clarify intentions and to support a coherent biosphere assessment process within an overall repository performance assessment, is strongly emphasised. A well described assessment context is an important tool for ensuring consistency across the performance assessment as a whole. The use of interaction matrices has been found to be helpful in clarifying the interactions between different habitats within the biosphere system and the significant radionuclide transfer pathways within the biosphere system. Matrices also provide a useful means of checking for consistency.     

Environmental impact assessment of manufacturing processes using a combinatorial mathematics based decision making method

This paper presents a methodology for environmental impact assessment of manufacturing processes using a combinatorial mathematics based decision making method. An ‘environmental impact assessment index’ is proposed that evaluates and ranks the manufacturing processes for producing a given engineering product or component. The index is obtained from an ‘environmental impact assessment factors function’ considering environmental impact assessment factors and their relative importance for the considered application. An example is included to illustrate the approach.     

A Graph Theory approach to measure the performance of sustainability enablers in a manufacturing organization

In a manufacturing organization, the term sustainability deals with the impact of production process and products on the environment and society, laying emphasis on preservation of scarce resources. In this article, the study concentrates on developing a Graph Theory model to measure the performance and inter-relationship between the sustainability enablers in an organization, thereby to quantitatively measure the extent to which ‘sustainable manufacturing’ practices are being followed in the organization. The objective of this study was to identify a set of sustainability enablers and attributes that impact a manufacturing organization. Digraphs were developed for the whole system and sub-systems depicting the inter-relationships and dependencies between various enablers and attributes to interpret the performance of the sustainability enablers in the case organization. Using the best case and worst case values, the level of sustainable manufacturing practices of the organization was found by Comprehensive Assessment Index. Based on the best case values, the relative significance of individual sustainability enablers are found and compared with worst case situations. The impacts of individual enablers on the overall sustainability level of the organization were also studied.     

Application of fuzzy QFD for enabling sustainability

Contemporary manufacturing organisations recognise sustainability as an important concept for survival. Environmental awareness and recycling regulations have been compelling manufacturers and consumers to evolve sustainable strategies. The modern customers' voices need to be translated with care into technical requirements. Quality function deployment (QFD) is a technique extensively used for this purpose. In order to cope with the vagueness associated with relationships and correlations in QFD, fuzzy numbers have been integrated within a QFD framework and fuzzy QFD has been used in this study. The study is concerned with the application of fuzzy QFD for enabling sustainability in an Indian modular switches manufacturing organisation. The approach is effective in the identification of sustainable competitive bases, sustainable decision domains, sustainable attributes and sustainable enablers for the organisation. The improvement in sustainability has been measured from three perspectives. The results gained as a result of the study indicated that fuzzy QFD could be used as an enabler of sustainability.     

Sustainable supplier selection criteria classification for Indian iron and steel industry: a fuzzy modified Kano model approach

ABSTRACT

The aim of this work is to provide a systematic approach for sustainability criteria clustering into different useful categories. For this purpose, a methodology has been proposed with the following three steps. (i) A comprehensive set of the sustainability criteria in economic, environmental and social dimension has been extracted from the literature and have been customised for the iron and steel industry. (ii) A fuzzy Kano methodology has been used to classify these sustainability criteria into useful Kano cluster like must-be, one-dimensional, and attractive cluster (iii) further, must-be and attractive criteria derived from the second step were further sub-classified into three categories using Type IV Kano model. All steps have been examined in the iron and steel industry of India and findings indicate that quality and delivery criteria are classified as high must be criteria in the economic realm. Further, environmental and energy management system in the environmental dimension and social responsibility and right of stakeholders criteria in the social dimension are classified as high must be criteria. Prioritising must be and attractive criteria enable decision makers of other industries to select the appropriate criteria to adopt sustainability.     

Relative Assessment of Indicators in Sustainability Enhancement (RAISE): a first approach in the manufacturing stage of products

The estimation of the sustainability performance of products requires tools to provide systematic approaches to the definition of impacts, indicators and comparative scenarios from early design stages. This paper illustrates the Relative Assessment of Indicators in Sustainability Enhancement (RAISE) methodology that is based on the measure of negative impacts generated during any product life cycle stage. This approach includes a systematic process for the definition and evaluation of indicators to compare the sustainability performance of products considering each indicator individually and using a holistic index of sustainability to entail an overall comparison between products from manufacturing scenarios. The RAISE method is developed with the aim of assessing sustainability performance of product life cycle stages and incorporating this assessment into the decision-making process when comparing different manufacturing scenarios. A guitar capo manufactured in polymeric material is used as case study to demonstrate the use of the method. In this paper, only the manufacturing stage is considered; however, the method can also be employed in other stages of the life cycle.     

Sustainable outsourcing: a practice survey and research opportunities

This paper addresses the issue of the sustainability imperative and its influence on outsourcing practice. The research initially finds that there is currently little or no work that explores sustainable or green outsourcing, other than in an information technology context. This lack of research on sustainable outsourcing practice in the industrial organisation sector led to the development of this research study. This exploratory study used a qualitative survey tool to investigate current industrial practice. Manufacturing managers in 57 organisations formed the survey sample. The data were analysed by comparison and clustering of responses of survey participants. This study contributes five key findings that demonstrate current industrial practice which includes: 32% of respondents state that sustainability is not a factor in their outsourcing decision making and 65% of small- and medium-sized enterprises had never heard of the ‘triple bottom line’ concept. Future research needs are identified and proposed highlighting that urgent development of research is required in outsourcing performance measurement and also in considering sustainability as a new manufacturing competitive priority.     

Risk communication and sustainability science: lessons from the field

Sustainability science aims to help societies across the globe address the increased environmental and health crises and risks that range from poverty to climate change to health pandemics. With the increased magnitude and frequency of these large-scale risks to different societies, scientists and institutions have increasingly recognized the need for improved communication and collaboration among researchers, governments, businesses, and communities. This article argues that risk communication has fundamentally important contributions to make to sustainability science’s mission to create use-inspired, “actionable science” that can lead to solutions. Risk communication research can advance the mission of sustainability science to engage a wide range of stakeholders. This kind of engagement is especially important in the context of addressing sustainability problems that are characterized by high levels of uncertainty and complexity. We introduce three core tenets of risk communication research that are fundamental to advancing sustainability science. Risk communication specifically offers an increased understanding of how system feedbacks, human perceptions, and levels of uncertainty influence the study and design of solutions within social ecological systems.     

Strengths and weaknesses of common sustainability indices for multidimensional systems

Sustainability is rapidly moving from an abstract concept to a measurable state of dynamic human-ecological systems. The large number of economic, social, and environmental indicators currently available provides an unwieldy view of system sustainability. To aid policy decisions, these indicators are therefore either presented in the context of a conceptual framework, or quantitatively aggregated into indices. Due to the quantitative nature of sustainability indices, their results may be given more weight by scientists and policy-makers. However, policy decisions can be ineffective or even counterproductive if they do not consider factors which influence index behavior: the scale of the available data and choice of system boundaries; the inclusion, transformation, and weighting of indicator data; and the aggregation method used. As previous reviews have demonstrated, sustainability indices do not rank countries consistently, even when using some of the same indicator data. Several improvements would increase the utility of sustainability indices for policy decisions, particularly the identification of biases introduced by the index methodology and data inclusion. The discrepancy of current sustainability indices due to theoretical or methodological differences supports the use of several complementary indices.     

Eco-efficiency in Portuguese companies of marble sector

The activities developed within an eco-efficiency project in mineral industries located in the largest area for marble extraction in Portugal, in Alentejo region, in the Estremoz – Borba and Vila Viçosa anticline are presented in this paper. The project was designed to apply the sustainability concept in seven companies of marble extraction and transformation. The adopted strategy used new cleaner production models together with sustainable value (SV) improvement, leading to the rationalization of the industrial process, the involvement of economic agents and the orientation of the management of production processes towards eco-efficiency. The challenge was to have the mineral industry managing efficiently the resources on which the business depends, according to sustainability principles. Different opportunities for improvement, related to the minimization of materials, water and energy use, were identified in the companies. Some proposals mainly related to social improvement and small and medium-sized enterprise competitiveness benefits were also selected and discussed. This approach allows the integration of sustainability at company's and region's levels by combining in the entrepreneurial activity the creation of wealth together with the environment protection and the achieving of social benefits. Highlights: The involvement of different stakeholders in the project (Eco-efficiency in Portuguese companies of marble sector) was positive in the discussion and search of solutions for companies. It is possible to involve marble extraction and processing companies in eco-efficiency improvement towards sustainability. Companies from the marble sector improved environmental and social performance and reduced the costs of their production processes by applying SV methodology.     

A methodology for assessing urban sustainability: Aalborg commitments baseline review for Riga, Latvia

Both the Aalborg Commitments and the guidance on integrated urban environmental management and sustainable urban transport plans proposed by the EU Thematic Strategy on the Urban Environment foresee a baseline review as the first step in developing integrated urban management plans and systems. A baseline review of urban sustainability undertaken in Riga reveals significant discrepencies between the sustainability criteria of the Aalborg Commitments and the: responsibilities and competencies of the municipal government and administration as defined by statutes; policy goals and measures defined in municipal planning documents; policy goals and measures defined in the Riga Development Plan. To better orient the mandate of the municipality towards sustainable development, municipal statutes should be supplemented to more fully reflect the issues defined by the Aalborg Commitments and should include sustainability as a goal. In order to strengthen the implementation of sustainable development specific policy goals, measures and targets should be formulated for all the Aalborg Commitments issues when revising existing municipal planning documents or developing a municipal sustainable development management plan. An analysis of the European Common Indicators and the State of the Environment in Riga 2001 indicators indicates that they can only partially fulfill a monitoring function for the implementation of the Aalborg Commitments. This highlights a need to better coordinate sustainable development initiatives at the European level. The methodology used for the baseline review in Riga is useful for assessing the status of urban sustainability when preparing integrated urban management plans or systems, but requires testing elsewhere. Readers should send their comments on this paper to BhaskarNath@aol.com within 3 months of publication of this issue.