SUSTAINABLE

MANUFACTURING:

EVALUATION AND MODELING

A SUSTAINABLE SUPPLY

CHAIN AND PRODUCT LIFE

CYCLE

Prasanna Sai Sammeta Student # 100914095

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Contents Introduction .................................................................................................................................................. 3

What is Sustainable Manufacturing? ........................................................................................................ 3

Sustainable Supply Chain Management ....................................................................................................... 4

What is Sustainable Supply Chain? ........................................................................................................... 4

The need for a Sustainable Supply Chain .................................................................................................. 4

Implementation of a Sustainable Supply Chain ........................................................................................ 5

Conformity approach ............................................................................................................................ 7

Life Cycle Analysis of Products ...................................................................................................................... 8

What is Life Cycle Analysis? ...................................................................................................................... 8

The Main Phases of a Life Cycle Analysis .................................................................................................. 8

Defining a Product Life Cycle .................................................................................................................... 9

Advantages of using a Life Cycle Analysis ............................................................................................... 10

Limitations of using a Life Cycle Analysis ................................................................................................ 11

Simulation ................................................................................................................................................... 12

Simulation in Manufacturing .................................................................................................................. 12

Lean manufacturing ................................................................................................................................ 12

Arena ................................................................................................................................................... 13

Simul8.................................................................................................................................................. 13

Witness ............................................................................................................................................... 14

Simter .................................................................................................................................................. 14

Technical features of Simter tool ............................................................................................................ 14

Development........................................................................................................................................... 15

Advantages of simter tool ....................................................................................................................... 15

Disadvantages of simter tool .................................................................................................................. 15

Waste Management ................................................................................................................................... 16

Waste Characteristics ............................................................................................................................. 16

Waste Streams ........................................................................................................................................ 16

Hazardous wastes ................................................................................................................................... 16

Non-hazardous wastes ............................................................................................................................ 17

Industrial Sector ...................................................................................................................................... 17

Integrated Waste Management (IWM) .................................................................................................. 17

Waste management framework ............................................................................................................. 18

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Additive Manufacturing .............................................................................................................................. 20

Sustainable Product Design .................................................................................................................... 20

Sustainable design benefits of AM ......................................................................................................... 21

AM as a sustainable alternative .............................................................................................................. 21

Reengineering ............................................................................................................................................. 22

Design ...................................................................................................................................................... 22

Analysis ................................................................................................................................................... 24

Synthesis ................................................................................................................................................. 25

Implementation ...................................................................................................................................... 25

Conclusion ................................................................................................................................................... 27

References .................................................................................................................................................. 27

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Introduction

What is Sustainable Manufacturing?

Sustainable manufacturing, according to Department of Commerce, USA, is,

"The creation of manufactured products that use processes that minimize negative

environmental impacts, conserve energy and natural resources, are safe for employees,

communities, and consumers and are economically sound."

A technical version of this definition is as follows:

"Sustainable manufacturing is a systems approach for the creation and distribution (supply

chain) of innovative products and services that: minimizes resources (inputs such as

materials, energy, water, and land); eliminates toxic substances; and produces zero waste

that in effect reduces greenhouse gases, e.g., carbon intensity, across the entire life cycle

of products and services."

In order to obtain sustainability, it is not only required for the operations of organization to fulfil

its functions and performance but also meet the challenges in environment, economy and social

issues too. Companies which intend to develop sustainable products should be well aware of

sustainability standards and design and manufacturing techniques and tools.

To obtain sustainability, integrating all the systems in the organization and working collectively

for sustainable future is required. All systems will also have to consider Social, economic,

ecological and environmental impacts of their specific functions and thus form the life cycle of

the product so that the product can be recycled and reused even after its life.

Fig 1: Sustainable Manufacturing A closed loop

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Sustainable Supply Chain Management

What is Sustainable Supply Chain?

There are many technical definitions of the term Sustainable Supply Chain. The following is the

most simplistic and practical:

Management of raw materials and services from suppliers to manufacturer/service provider to

customer and back with improvement of the social and environmental impacts explicitly

considered.

The interactions between a business and its customers and suppliers is known as supply chain.

The greatest benefits are derived by integrating environmentally and financially viable practices

in to supply chain management and extending the focus from raw materials to customers

including product design and development, material selection, manufacturing, transportation,

warehousing, distribution, consumption and then back again as the product and wastes are

recycled and disposed.

The need for a Sustainable Supply Chain

The supply chains of most of most of the organizations have far greater impact on environment

than any of their operations. A sustainable product is moreover in the corporate and public focus

as the product can be recycled and is financially viable.

Sustainable supply chain has much more benefits to organizations and consumers beyond the

obvious benefits like reducing the carbon footprint and thus contributing for environment and

saving energy and resource consumption and the following gives much more reasons for

organizations to follow sustainable supply chain management:

Research and experience has proven that practicing sustainable supply chain significantly

improves the financial results.

Consumers recognize the importance of green products and sustainability and thus

sustainable practices in organizations will improve its sales and share valuation.

Various government initiatives let organizations get many incentives and tax exemptions

for following sustainable supply chain and producing ecofriendly products which can be

recycled and disposed after its use.

Sustainability is one of the solution for organizations and corporate social responsibility

and stewardship and hence improve public relations and thus can yield numerous

benefits for companies.

The elimination of waste in supply chain is hallmark of sustainability.

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Implementation of a Sustainable Supply Chain

The social, economic and environmental impacts of the products and goods along the supply

chain is what makes a difference in sustainable development.

The following are few steps to implement a sustainable supply chain in various organizations with

various products and services along the supply chain.

Fig 2: Road map for sustainable supply chain strategy

Step 1: Inspecting the internal processes and mapping the risks

Organizations need to realize the importance of knowing their internal processes and to map

their own risks before they start collaborating with other organizations in supply chain and make

sure that they manage the issues successfully throughout.

These internal processes of the organizations include, but not limited to, tasks like procurement,

internal operations, product development and stewardess. The issues and risks in each of these

operations within the organization are traced and mapped based on environmental, social and

economic impacts and the level of risk is obtained. Then the organizations need to solve the

issues and minimize the risks, thus developing a sustainable model.

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Step 2: Identify the supply chain

Identification of what the supply chain means to the organization and where the organization

stands in other organizations supply chain is important. This, often becomes difficult for

organizations with complex supply chains. Such companies choose to appoint a supply chain

manager with overall responsibility for purchasing.

Step 3: Identifying sustainable development as an integral part of the business strategy

Appointing a sustainable development manager in the organizations and companies has its clear

benefits.

Making sustainable development as a key performance indicator (KPI) in the organization for all

levels from board level to junior level will also help for sustainable development within the

organization.

Step 4: Adopting decision and measurement tools that work for the organization

The written policies, communication materials, prequalification of suppliers, purchasing

guidelines and supplier partnerships are included in these.

Fig 3: Decision pyramid in supply chain management

Managers need tools to help them assess the risks and thus decide on the suppliers and hence

contributing to sustainable development. For most of the companies, there are few processes to

achieve regulatory compliance, through risk management, for a long term sustainable

development and the following is one of them:

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Conformity approach:

This is done by building a chain of custody right from raw materials and the resources to produce

the product and the initial conditions at the point of origin through manufacturing to delivering

to the customer. Systems like ISO 14001, SA8000, AA1000 and Envio-Mark help companies to

manage this process. These systems are integrated to regulations that are predefined, like Hazard

Analysis Control Critical Points (HACCP) and Occupational Health and Safety and Quality

Management Systems.

Step 5: Identifying initiatives throughout the organization and making everyone involve internally

and externally: Operationalization

Suppliers can include sustainable development by setting suppliers code of conduct and thus

influencing customers to reward sustainable suppliers.

Fig 4: Suggested model for decision making in supply chain

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Life Cycle Analysis of Products As environmental awareness expands, businesses and organizations are surveying how their

activities influence the nature. Society has gotten to be worried about the issues of natural

resource exhaustion and environmental degradation. Numerous organizations have reacted to

this mindfulness by giving "greener" products and utilizing "greener" processes. The

environmental performance of products and their courses of action has turned into a key issue,

which is the reason a few organizations are exploring approaches to minimize their consequences

for the environment. Numerous organizations have thought that it was beneficial to investigate

methods for moving past consistence utilizing pollution prevention methodologies and natural

administration frameworks to move forward their ecological execution. Thus, the Life cycle

analysis process had come into existence at a wider range.

What is Life Cycle Analysis?

Extensive environmental evaluation that distinguishes the vitality, energy, material, and the

waste streams of a product, and their effect on the environment. This life cycle assessment starts

with the design of the product and advances through the extraction and utilization of its raw

materials, manufacturing or processing with related waste stream, stockpiling, distribution,

usage, and its disposal or reusing. The target is to recognize changes, at each phase of the life

cycle that can prompt ecological profits and overall cost savings. Also known as the life cycle

assessment.

Life cycle assessment gives a satisfactory instrument to ecological choice backing. Reliable Life

cycle assessment execution is critical to accomplish a life-cycle economy.

The Main Phases of a Life Cycle Analysis

1. Goal and Scope Definition: Define and depict the product, process or action. Create the connection in which the appraisal is to be made and distinguish the boundaries and

environmental aspects to be looked into for the evaluation.

2. Inventory Analysis: Identify and evaluate energy, water and materials utilization and natural discharges (e.g., air outflows, solid waste disposal, waste water releases).

3. Impact Assessment: Assess the potential human and environmental impacts of energy, water, and material use and the ecological discharges recognized in the inventory

examination.

4. Interpretation: Evaluate the consequences of the inventory analysis and effect assessment to select the favored product or process with an agreeable understanding of

the instability, uncertainty and the assumptions used to generate the results.

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Fig 5: Life Cycle Analysis Phases

Defining a Product Life Cycle

Generally, a Product life cycle is characterized as linear progression. The main stages of a product

life cycle are as below.

Raw materials are concentrated from the earth. A few examples are metal ore, water and

oil.

Raw materials are processed into completed materials. Like, bauxite metal is handled into

aluminum and oil is prepared into plastics.

The materials are manufactured or amassed into a final product. This stage can regularly

be considered in two sections: first materials are made into parts (for instance, an

aluminum sheet is produced into an auto body board). At that point the parts are

gathered into a last item (for instance, the body board alongside the windows, motor, and

a lot of more parts are amassed into an automotive vehicle).

The utilization stage when a customer has total control over the product.

The waste administration stage or end-of-life stage when the product is broken down into

component materials for remanufacturing or reusing, or is disposed of.

Some include a sixth phase of appropriation as the materials and products are

transported between stages.

Amid each of these stages, the exercises that happen oblige material and energy assets,

and produce wastes, squanders and outflows. Material and energy assets incorporate

things, for example, minerals, water, coal, natural gas, or power.

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Wastes incorporate solid wastes (garbage) or hazardous wastes. Discharges incorporate

pollutants discharged to the air, for example, sulfur dioxide or carbon dioxide or residue, or to

the water, for example, sewage or solids. Life cycle appraisal assembles data about the amount

of these resources and wastes at every life cycle stage.

The Fig: 2 illustrates the Life cycle stages along with the typical inputs and outputs.

Fig 6: Product Life Cycle Stages

Advantages of using a Life Cycle Analysis

It helps the chiefs select the product or process that brings about the slightest effect to

the environment. This data can be utilized with different elements, for example, expense

and execution information to choose an item or product or procedure.

Life cycle assessment, information distinguishes the exchange of ecological effects from

one media to an alternate (e.g., killing air discharges by making a waste water emanating

rather) and/or from one life cycle stage to an alternate (e.g., from utilization and reuse of

the product to the raw material procurement stage).

In the event that an LCA were not performed, the exchange may not be perceived and

appropriately included in the examination since it is outside of the common degree or

focus of product selection processes.

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Create a deliberate assessment of the ecological outcomes connected with a given

Product.

Analyze the natural exchange offs connected with one or more particular

products/processes.

To help acquire stakeholder (state, group, and so on.) acknowledgement for an arranged

activity.

Quantify natural discharges to air, water, and land in connection to every life cycle stage

also/or real helping methodology.

Assist in recognizing critical moves in natural effects between life cycle stages and

ecological media.

Compare the wellbeing and biological effects between two or more opponent

products/processes or recognize the effects of a particular product or procedure.

Identify effects on one or more particular ecological territories.

Limitations of using a Life Cycle Analysis

Performing a Life Cycle Analysis can be resource and time escalated.

Based on how intensive a Life Cycle Analysis the client wishes to direct, assembling the

information can be difficult, and the accessibility of information can extraordinarily affect

the exactness of the final comes about.

Consequently, it is advisable to measure the accessibility of information, the time

constraint, and the money related assets needed against the anticipated profits of the

Life Cycle Analysis.

Life Cycle Analysis does figure out which product or procedure is the most practical or

works the best.

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Simulation

Simulation is a process where a prototype of an actual or a real-world system has been developed

and operated over a period of time. This operation is conducted to test the efficiency of the actual

system. The prototype represents the system itself.

Simulation process is used in many sectors such as computer technology, common user

interactive systems, clinical healthcare, entertainment and manufacturing.

Simulation in Manufacturing

Most of the Manufacturing industries are reliable on the simulation process for the perfect

output of the capital investments on the raw materials, equipment and warehouses. Using the

simulation technique one can estimate the life of the product and look for an alternative solution

for the design problems. Material flow or factory simulations are used in the design phase before

the investments.

Manufacturing simulation is performed using some of the digital engineering tools, which

provides positive impact on the manufacturing industry. For designing a sustainable

manufacturing system, different departments of the system should be jointly optimized.

The main goals of manufacturing industry is to aggregate production planning and the master

production schedule, maximize the capacity , to make the best use of the inventory, schedule the

delivery and production of the parts and products on time. Simulation process helps the industry

to achieve these goals within the deadline and satisfy the consumer.

Manufacturing system design is involved with the following subjects:

Tooling strategy

Material requirements planning

Enterprise resource planning

Capacity planning

Material handling system

Process flow configuration

Inventory control

Lean manufacturing

One of the most effective ways for gaining profits in a business is waste elimination. During the

production the operations performed might add value or waste of a good. Seven most common

wastes in a firm are

Over production

Unnecessary inventory

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Excess motion

Waiting

Transportation

Over processing

Initial failures

Designing a sustainable manufacturing system means considering both economic and ecological

factors. These two factors are the biggest and growing concerns in business industry. Ecological

constraint is the major issue where a firm has to deal with, because of the amount of fossil fuels

used and carbon dioxide released is really high in manufacturing industry. In particular, fuels are

used to generate the electricity which increases the cost of energy. So this factor should be

understood well during the manufacturing design phase.

To eradicate all these issues, energy efficient solutions should be adopted which leads to huge

savings in the lifetime of an equipment.

Simulation tool is nothing but software which can be called as an analytical tool used to optimize

a wide range of manufacturing systems with some expert intervention.

Some of the tools which are used for a manufacturing simulation are:

Arena

Simul8

Witness

Simter

Arena

It is a high level graphical tool in which all the work parts are placed on a drawing board and then

these work parts are connected together for the required model.

Simul8

In this simulation software the programming involves five of the basic points in the

manufacturing system. They are

Work entry point

Storage cabin

Work center

Work complete

Resource

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Witness

It is a simulation package with individual and distinct events which is mainly used to carry out the

manufacturing simulation. The witness concept is based on the queuing theory in which the work

parts are placed on the conveyors and moved in a queue to the work stations. Human workers

are also needed in this type of simulation. This tool is used to generate the breakdown timings

and activity timings.

Simter

This tool is kind of approach where building a sustainable manufacturing system is the main goal.

This tool helps in analyzing environmental impacts with some individual and unique simulation

and level of automation is analyzed virtually. The levels of automation are collaborated with

ergonomics and productivity.

Simter tool is total computer based system which helps the decision makers to use the data and

models for identifying and solving the problems and move forward in developing a human and

environmental free sustainable manufacturing system.

Fig 7: Simter tool covers the system planning phase

The simter tool highly covers manufacturing system planning phase. Assuming that a

manufacturing system has upper and lower levels, in the upper level the simter tool simulates

the distinct events according to the production flow and efficiency and other major factors. At

the lower level this tool concentrates on simulating the operations, tasks, process steps.

Technical features of Simter tool

A simter tool is processing unit which works with number of input and output parameters. At the

input, there will be different set of manufacturing process layouts with different coupling of

manual and machine operations. These process layouts are designed based on the type of work

requirements. Each layout is designed with different sets of tasks, energy and material flow. At

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the output the simter tool provides the engineer with solution which consists of total information

about the work piece such as its efficiency, productivity and lifetime.

Development

A simter tool has been developed with commercial software which includes factory and robotic

information for easy access and to reduce the total cost. Because of this we can avoid usage of

several small pieces of software.

A simter tool has three subsets which are

Ergonomics sub tool

Level of automation sub tool

Environmental sub tool

Advantages of simter tool

It provides the user with higher understanding on how the changes affect the different

elements in the system

The tasks performed will be more human friendly

Using this technique we can identify the area where we perform an operation to improve

the green performance

The simter tool is tested and implemented in real industrial cases

Disadvantages of simter tool

Its biggest challenge is getting environmental data

Inaccuracy of the models

While integrating the sub tools identifying the set of shared variables will be an issue.

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Waste Management Waste management is the methodology of treating robust squanders and offers assortment of

answers for reusing things that don't fit in with garbage. It is about how trash can be utilized as

an issue asset. Waste administration is something that every single family and entrepreneur on

the planet needs. Waste management discards the items and substances that you have use in a

sheltered and effective way.

Waste Characteristics

A typical misinterpretation is that natural insurance and supportable activities must take a swing

at the cost of monetary advancement. This is especially valid for overseeing squanders, a

methodology which drains regular assets and contaminates the nature's turf if not done

effectively. Fitting waste administration can be immoderate as far as time and assets along these

lines it is vital to comprehend what alternatives exist for overseeing waste in a successful,

sheltered and feasible way.

Waste Streams

Civil strong squanders is regularly portrayed as the waste that is created from private and

mechanical, business and institutional sources except for hazardous and general squanders,

development and decimation squanders, and fluid squanders .

In Nova Scotia, MSW is characterized through the Solid Waste-Resource Management

Regulations (1996) which express that MSW ". incorporates rubbish, can't, muck, refuse, tailings,

flotsam and jetsam, litter and other disposed of materials coming about because of private,

business, institutional and mechanical exercises which are regularly acknowledged at a

metropolitan robust waste administration office, yet bars squanders from modern exercises

directed by an approbation issued under the Nova. Materials which are natural or recyclable are

prohibited from this definition, along these lines MSW in Nova Scotia is essentially not the same

as that in numerous different wards. This meaning of MSW cooperates with an enacted landfill

forbid which disallows certain materials from landfill to guarantee that just certain materials are

entering landfills. Banned materials can't be discarded and are prepared through option

techniques; regularly reusing, reuse, or composting. The assignment of materials into particular

classifications, for example, organics, recyclables, and waste can contrast by district, in this way

associations must guarantee that waste is divided as indicated by neighborhood laws.

Hazardous wastes

Substances hazardous to utilize financially, modernly, horticulturally, or monetarily are

dispatched, brought from the nation of starting point for dumping or transfer in, or in travel

through, any piece of the Country.

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Non-hazardous wastes

Substances sheltered to utilize industrially, modernly, horticulturally, or financially that are

delivered, transported from the nation of inception for dumping or transfer in, or in travel

through, any piece of the nation.

Fig 8: Waste Generation by Country

Industrial Sector

Associations from all ranges inside the ICI division are obliged to oversee customary strong waste,

private waste, and that which is not normally delivered in private settings. This reasons

noteworthy contrasts and presents special difficulties in waste administration inside the ICI area

versus civil level robust waste administration. With metropolitan squanders, general attributes

can be regular crosswise over different areas. The ICI segment in any case, creates a wide scope

of potential waste streams, including city and mechanical robust squanders, clinical squanders,

development and decimation squanders, unsafe squanders, and all inclusive waste which vary

broadly in the middle of associations and can make examinations troublesome . Business and

institutional firms ordinarily create squander as an issue of leading exchange and business (Smith

& Scott, 2005), while the waste streams of mechanical firms (assembling, repair, generation) are

normally portrayed as fluid squanders, robust squanders, or air toxins with every regularly being

overseen and managed diversely . Mechanical settings likewise deliver MSW. Besides managing

exceedingly changing waste streams, there is likewise the issue that numerous firms put a high

esteem on organization protection and may not impart data eagerly.

Integrated Waste Management (IWM)

Waste management methods cannot be uniform across regions and sectors because individual

waste management methods cannot deal with all potential waste materials in a sustainable

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manner. Conditions vary; therefore, procedures must also vary accordingly to ensure that these

conditions can be successfully met. Waste management systems must remain flexible in light of

changing economic, environmental and social conditions. In most cases, waste management is

carried out by a number of processes, many of which are closely interrelated; therefore it is

logical to design holistic waste management systems, rather than alternative and competing

options. A variety of approaches have been developed to tackle waste issues. A well designed

framework can help managers address waste management issues in a cost-effective and timely

manner. It can spur the improvements of existing plans or aid in the design of new ones.

Waste management framework

Structure to obviously recognize key objectives and qualities.

Flexibility to casing and examine quantitative and subjective data crosswise over diverse

scales.

logic to consider the potential likelihood and results identified with a specific alternative

Coordinated waste administration has developed as an issue methodology to overseeing waste

by joining and applying a scope of suitable procedures, innovations and administration projects

to accomplish particular destinations and objectives. The idea of coordinated waste

administration emerged out of distinguishment that waste administration frameworks are

contained a few interconnected frameworks and capacities, and now be known as "a schema of

reference for planning and actualizing new waste administration frameworks and for breaking

down and improving existing frameworks. Generally as there is no individual waste

administration system which is suitable for handling all waste in a maintainable way, there is no

impeccable IWM framework. Individual IWM frameworks will shift crosswise over locales and

associations, however there are some key peculiarities which describe IWM:

Employing a comprehensive methodology which surveys the general natural loads and

monetary expenses of the framework, considering vital arranging;

Using a scope of gathering and treatment systems which concentrate on delivering less

waste and inadequately overseeing waste which is still created;

Handling all materials in the strong waste stream as opposed to concentrating exclusively

on particular materials or wellsprings of materials (Hazardous materials ought to be

managed inside the framework, however in a separate stream)

Being naturally compelling through decreasing the ecological troubles, for example,

outflows to air, land and water;

Being financially reasonable by driving expenses out and receiving a business sector

situated methodology by creating client supplier associations with waste items that have

end utilizes and can create wage;

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Social worthiness by fusing open investment and guaranteeing people understand their

part in the waste administration framework.

Because of the shifting needs and difficulties confronted by association in the ICI area, an

adaptable yet complete methodology is required to oversee squander appropriately. Utilizing an

extensive variety of waste administration alternatives as a component of a far reaching

coordinated waste administration framework takes into account enhanced capacity to acclimate

to evolving natural, social and monetary conditions.

Structuring an IWM arrangement can be a complex undertaking. Those in charge of planning

IWM frameworks must have an acceptable understanding of their objectives and targets and

guarantee that wording and exercises are unmistakably characterized in the arrangement. The

following step obliges distinguishing the scope of potential choices that are suitable for

overseeing waste with expense assessments, hazard appraisals, accessible transforming offices

and potential accomplices, and the item models which exist for the reusing of specific squanders.

Open criticism in this step can help to guarantee the exactness of presumptions made, and help

to assemble open acknowledgement. The last step includes inspecting the tradeoffs which exist

among the accessible choices given what is thought about the danger, expense, waste volumes,

and potential future conduct changes. When these points of interest are known, an extensive

IWM methodology can be shaped.

Frameworks investigation can give data and input that is helpful in serving to characterize, assess,

enhance and adjust waste administration frameworks. There are two fundamental sorts of

frameworks examination procedures significant to waste administration frameworks: -

frameworks designing models, for example, expense advantage investigation, gauging models,

reenactment models, streamlining models, incorporated demonstrating frameworks -

framework appraisal devices, for example, administration data frameworks, choice emotionally

supportive networks, master frameworks, situation advancement, material stream examination,

life cycle evaluation, hazard evaluation, ecological effect evaluation, key natural appraisal,

financial evaluation.

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Additive Manufacturing Most of the conventional manufacturing processes were classified in to casting and moldings,

these two methods are literally dominating the world since the Stone Age. However according to

time there is a rapid development in the technology a new type of manufacturing called Additive

Manufacturing (AM) came in to existence where the manufacturing can be done by particle to

particle using Computer Aided Design i.e., 3D software, Indeed have compromised a designers

ability to make the product they imagined, almost eliminating the conventional tools and the

supply chain constraints typically associated in the process. AM is the most sensational topic

hitting the headlines in the recent times prompting the debate of risks in the environment and

also the options evolving around this technology, now the most burning question is that will AM

drive through sustainability through increased efficiency in manufacturing processes, by

diminishing the waste material ? Yes, AM is being used widely in used in manufacturing the end

use products such as medical implants in materials like titanium and also like hearing shells, and

is also being used in aerospace and defense, automotive components. Since the decades

sustainability is rapidly emerging as an issue that designers and engineers must engage with and

embrace to survive in a more sustainability conscious world. On examining what is meant by

sustainable products, a plethora of definitions and methodologies emerge, some of which

contain generally its the endurance of systems and processes and which are interconnected to

main domains such as environment, economics, utilization and culture. We shall now discuss

something in deep about

Sustainable product design.

AM as a sustainable alternative.

Sustainable design benefits of AM.

Sustainable Product Design

Sustainable product design may include environmental imperatives, ecology and also economic

dimensions of sustainability, and adopts environmental principles as methods of improving the

design. A product can be rated as good one if it is safer for the environment and obtains a financial

benefit to the company and also something good for the society. So while designing a product

one must follow some principles in order to make the product sustain.

Products must not show such a great impact on the environment like must be non-toxic,

easily recyclable, sustainably produced.

Must be more energy efficient while using.

Design must be durable i.e., reducing the consumption and waste resources

management.

Design for reuse and recycling.

Emission of carbon must be reduced.

Should maintain product sustainability

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Should follow robust eco principle design.

At the time of buildings must reduce the collective environmental impacts from the

components.

Sustainable design benefits of AM

Additive manufacturing enables the sustainability as it authorizes to address of each elements

from minimizing the raw materials usage, and also increasing the reusability, geometric

flexibilities of the design, and supply chain management potential of the present technology.

Here are some of the benefits of the sustainable design.

Reduction of raw material consumption

Minimization of wastage

Can obtain better optimistic products through better design

Decrease in the weightage of the products i.e., light weight products can be gained.

Increases the geometric flexibility which helps in more appropriate design.

Elimination of secondary level production operations like electrical circuits and wires can

be replaced with sensors.

Flexibility of remanufacturing.

AM as a sustainable alternative

Although Additive manufacturing doesnt remove all the restrictions of manufacturing but it

replaces them with a different set of designs and designers must take into consideration if the

wish to use the technology successfully. However these design considerations are much easier

for designers to understand and comply without affecting any design that intended in a major

way. Some of the major principal major design considerations while designing the AM include.

Enclosed voids

Surface finish

Strength and flexibility

Machine and material cost.

Freedom of design

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Reengineering Design and Redesign of a Production Control Model are methods for business process

reengineering of manufacturing companies. It is a practical approach to assist companies that

want to make the way they control their manufacturing processes a competitive advantage in

meeting future market and customer demands. It is based on application of a mixture of

techniques and methods from well-known control principles. It has been developed and tested

in a dozen Norwegian companies.

In order to compete successfully, firms must achieve excellence in managing their manufacturing

operations. Companies need to change the role of manufacturing from being internal neutral

to externally supportive. The best known is probably "Made in America" (Dertouzos, et. al,

1989) which studied how the US industry should change in order to regain competitiveness over

Europe and Japan. A stronger focus on manufacturing was one of the major findings. In the

Norwegian TOPP project a study of the performance of 50 Norwegian industrial companies was

performed. This study showed that product development, quality management, production

control, procurement and internal material flow all had a higher relative importance than

performance, Bredrup et. al (1994). From Bredrup (1994), we also know that traditional

accounting and performance measurement systems are not adequate to measure customer

satisfaction. Neither has the focus on ISO 9000 seemed to improve the performance of those

companies being certified by it. Many ISO certified companies experience less flexibility in

adapting to new customer demands. There is also a clear new focus on the total value chain view,

introduced by Porter (1985), which requires a new way of thinking when designing manufacturing

systems. A practical method Design of a Production Control Model for manufacturing business

process redesign.

Design

The basic idea of designing a Production Control Model is to make the way you organize and

control your production and logistic system a competitive advantage for the company. It is a fact

that products have shorter and shorter life cycles. The customers ask for specific designs with

extremely short delivery times. The competition is global, making the price margins smaller. The

first examples of requirements of 100 % recyclable products are seen.

This challenge can be met by a redesign of the manufacturing business processes by developing

a Production Control Model (PCM) based on;

A vision of the future market (pull)

An analysis of the existing system

Knowledge and experience of existing theories, methods and techniques

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When the scenarios of the future market are defined, the challenge is then in a systematic, but

yet creative, way to analyze the current situation, identify potentials and limitations, synthesize

the solution into a model, and implement it. The different topics to consider when analyzing the

existing system are the following processes and aspects;

Production planning and control

Material flows

Inbound and outbound logistics

Organization

A proposed definition of a Production Control Model is;

A Production Control Model is a description of how a production and logistic system is organized

and controlled. It contains information about layout and material flows. It is used in redesign of

a manufacturing system, as an operative control document, and for training purposes. The model

defines a set of customer focused measurements to be used in the company.

The term model is used in the meaning as a description of a real world system, used to

communicate and explain how the system should be organized and controlled. The following

figure illustrates the process for redesign of a Production Control Model. The process is outlined

as three streams, one for analysis and synthesis, one for education and training, and one for

management discussions and decisions. The following sections will describe the analysis and

synthesis in detail.

Fig 9: Production Control Model

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Analysis

The analysis phase can be characterized by three main activities; data collection & investigation,

establish visions for the future company, and define performance measurements. It is of course

important to aim for a systematic approach. The objective of the activity is to ensure

understanding of the basic features of what is to be controlled. If the collection of data becomes

too much oriented towards a specific solution, there is a tendency to concentrate on the first

solutions that came up. Other possibilities may thus be left unexplored. Therefore a structure

that is independent of the solutions, is applied. In short words, the following stepwise approach

is recommended. Each of these steps are explained in the next sections:

Identify what is important to achieve in the market - the visions of the future: The whole idea

of a business process redesign is to improve competitiveness. It is therefore necessary to

investigate how the future income can be increased by better performance on delivery terms.

Collect data and analyze the current situation in the company: The most resource demanding

activity in this first phase is probably the collection of data and information to describe the

current situation in the company, and how the company performs today. This means how the

market recognizes the companys services, the efficiency of the production system, and how well

prepared the company is to meet future challenges.

Identify the characteristics of the production system: On the basis of this information, the next

step is to identify the key characteristics of the production system and its surroundings.

Questions to be asked are;

Does the company sell products or production capacity?

Is there an even or uneven workload throughout the year?

How many product types and variants of products?

What are the typical number of processing stages?

What is the degree of use of common components?

Use cause/effect analysis: Disclosing possibilities of improvement and outlining of a PCM is just

a part of the process.

A number of problems has to be dealt with before the production system has become

controllable. When solving a problem, one must aim at attacking the root causes and not the

symptoms. An important part of the analyses is the use of cause/effect diagrams (Kume, 1985),

and the involvement of operators in the problem solving process. The cause/effect diagram

shows the connections and dependencies in the problem complex. In addition to giving a survey,

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it is used to choose hypotheses regarding causes. The hypotheses are checked out by data

collection and data analysis.

Perform training and education of key personnel: The whole idea of the method is that the

PCM is the company's own solution to their challenge. To be able to take part in creating the

solution, a substantial amount of training must be performed. The training is a mixture of

practical examples and theory, where explanations and solutions are supposed to pop up during

the training seminars.

Define performance measurement system: It is a common finding in the projects we have

performed that many of the performance indicators that are applied, are not related to customer

satisfaction nor profitability. And they are not indicators that are used to evaluate and improve,

but simply to measure. An important aspect in improving performance is to identify indicators

that are directly related to customer satisfaction or the ability to satisfy customers. Delivery

performance is an example of the first, flexibility being an example of the second. To evaluate

the production system indicators that cover the productions ability to produce the right

products, at the right time, at the right quality and with a minimum use of resources, must be

identified. They must cover this ability both in the present time and in the future.

Synthesis

The analysis phase should already have initiated some ideas of possible solutions. But now the

highly iterative synthesis phase is where these and constantly new solutions are merged,

discussed and revised.

Identify basic principles and solutions that are applicable

Make rough outline of Production Control Model

Test of solutions

Merge and integrate solutions

Make complete Production Control Model

Implementation

A few remarks and some advice about the implementation process are needed. The emphasis on

training and education is already mentioned. Another aspect is the need for top management

involvement. The whole idea is to make production control a competitive advantage in meeting

future customer and market demands, making it a strategic issue.

The change-over process is critical. The change from old to new conditions has its own problems.

It is of great importance to identify problem areas and to take preventive actions.

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These can include extraordinary limitations in delivery program, full stocks, and extra crew on

expected bottlenecks, etc. There is a need for a specific plan to cover the change-over

preparations and the change-over period. For some people every change is a fear. They struggle

against all new. For others the new PCM entails that they lose importance and position. Some of

them will struggle against too. It has to be taken into consideration that somebody will use

implementation problems to prove they are right. The new PCM is not robust yet; small problems

can grow big. Management has to ensure that positive and loyal people cover all positions of

importance. The production capacity will possibly suffer during the change-over period. This

possibility has to be coordinated with the sales department and even with customers. Buildup of

stocks and/or avoidance of sales campaigns just in this critical period can reduce risk for delivery

problems.

This method has been applied with success in more than a dozen Norwegian manufacturing

companies. They have all experienced radical improvements in performance. A major criticism to

the method is that it is still very dependent on consultants assistance. The method should also

be developed further with supporting methods for identification of problems and creating

solutions. One example is the future area is integrating modelling tools, from traditional SADT

diagrams to the enterprise modelling techniques, in the method.

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Conclusion Sustainability is an integral part of an organization and hence is an integral part of manufacturing too. The

importance of sustainable development and sustainable manufacturing has been established and by

implementing a sustainable supply chain, it will benefit the organization and customers as well apart from

resolving various social, economic and environmental issues.

Though the report gives us the brief summary of how to execute and implement sustainable development,

there is a still research going on sustainable development to improve the implementations and to make

sustainability an integral part of the companies from junior levels to executive levels.

By implementing the sustainable supply chain and analyzing the product life cycles, it becomes easy for

the organization to estimate the risks at all levels including environmental, social and economic risks,

and thus one can build strategies to eliminate the risks and achieve sustainability.

Waste management, being an important challenge in the supply chain, using the methods and

techniques like waste resource management etc., the organizations will able to recycle and re use the

products for further manufacturing and thus manufacturing various other products.

Adopting latest technologies and methods like running simulations, adopting Re-engineering methods

and techniques like Additive manufacturing and 3D printing can benefit the organizations and

companies to achieve sustainability and also improved product in standards.

Hence, the necessity of obtaining sustainable development and implementing sustainable methods

should be understood and prioritized in the organizations and thus help making the Earth a better place.

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measurement method. In: International Journal of Production Research, Vol. 40, No. 15, pp.

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Chopra S, Meindl P (2004): Supply chain management. Strategy, planning, and operation. 2nd

edition. Upper Saddle River, NJ: Prentice Hall

Christopher M (2005): Logistics and supply chain management. Creating value-adding networks.

3rd edition. Horlow: Financial Times/Prentice Hall

Davidson, G.(2011)."Waste Management Practices".

Shannon, R. E. (1998) Introduction to the Art and Science of Simulation. IEEE, USA