CLEANER PRODUCTION ASSESSMENT_2019/asb.pptx

cleaner production Assessement for tailoring shop

1. CLEANER PRODUCTION ASSESSMENT - For tailoring shop in Trincomalee - 2019/ASB/38 ENS 4122

2. TABLE OF CONTENTS Introduction Study area Pre-assessment Process flow diagram Types of waste generated Assessment Root cause analysis Material & energy flow analysis Opportunity identification Option generation and screening Feasibility analysis Conclusion Recommendations References

3. 1. INTRODUCTION Adopting strategies and techniques to minimize waste, optimize resource use, and reduce environmental impacts during garment production. Benefits: Reduces production costs Enhances product quality and consistency Improves the shop's environmental and social responsibility Attracts eco-conscious customers, boosting market reputation.

4. 2. STUDY AREA Location: Jothi tailoring shop. Address: No 415, first lane, Anpuvalipuram, Trincomalee .

5. 3. PRE-ASSESSMENT Raw materials as input Energy usage as input Fabrics Threads Buttons Zippers Scissors Measurement tape Sewing machine Pattern paper Electricity for, Sewing machine Bulbs Fans

6. Process flow diagram Inputs Measurement tape Fabrics, pattern paper Fabric pieces, thread, buttons, zippers, electricity for sewing machine Additional fabric & accessories Outputs Measurement records Cut fabric pieces, fabric off-cuts Assembled garment, scrap threads, leftover materials Altered garment, scrap materials Processes

7. Process Raw materials Production Wastes 8

8. Fabric remnants Threat waste Paper pattern Polythene waste Pins & needles Buttons, zippers & fasteners Worn-out tools Dust and lint Types of waste generated

9. Root cause analysis Poorly maintained or malfunctioning equipment. Using substandard or inappropriate materials. Inadequate training or lack of motivation among workers. Inefficient operational procedures. 01. Technical Status of Equipment 02. Process Efficiency 04. Personnel Skills and Motivation 03. Choice and Quality of Input Materials 04. ASSESSMENT

10. Outdated or inefficient technology Complex or unclear product requirements Poor planning and communication. Lack of proper waste management systems. 05. Choice of Production Technology 06. Product Specifications 08. Wastes and Emissions 07. Management Planning and Information Systems

11. Material & energy flow analysis

12. Total outputs per month, Frocks = 20 units Fabric waste = 6.74 m Thread waste = 200 m Energy cost = 21.6 MJ Fabric waste are highly emitted to the environment.

13. Opportunity identification Brain storming Use CAD (Computer-Aided Design) software or pattern-making tools Implement collection and management system Invest in or explore technologies like 3D knitting machines, which create knitted fabrics directly from digital files Introduce well experienced workers Waste convert as products

14. Screening of ideas Criteria Idea I Idea II Idea III Idea IV Idea V Poor (1) Fair (2) Good (3) V. Good (4) Excellent (5) Poor (1) Fair (2) Good (3) V. Good (4) Excellent (5) Poor (1) Fair (2) Good (3) V. Good (4) Excellent (5) Poor (1) Fair (2) Good (3) V. Good (4) Excellent (5) Poor (1) Fair (2) Good (3) V. Good (4) Excellent (5) Investment (40%) X X X X X Rate of return (20%) X X X X X Likely profit (10%) X X X X X Expected life (30%) X X X X X

15. Scoring of ideas Idea I (5*0.4 + 2*0.2 + 5*0.1 + 5*0.3 = 4.4) Idea II (2*0.4 + 4*0.2 + 3*0.1 + 4*0.3 = 3.1) Idea III (5*0.4 + 1*0.2 + 5*0.1 + 4*0.3 = 3.9) Idea IV (1*0.4 + 5*0.2 + 5*0.1 + 4*0.3 = 3.1) Idea V (3*0.4 + 4*0.2 + 5*0.1 + 5*0.3 = 4.0) Selection of ideas I, III, V

16. 05. FEASIBILITY ANALYSIS Criteria CAD Software & Pattern-Making 3D Knitting Machines Waste Conversion into Products Economic Feasibility High initial investment; high ROI through reduced waste and material costs High initial cost; high potential for profit due to speed and efficiency Moderate to high initial cost; potential for long-term cost savings and revenue generation Environmental Feasibility Significant waste reduction through optimized design Minimal waste generation, sustainable production Significant reduction in landfill waste; supports circular economy Social Feasibility Increases skillsets of workers; may reduce manual labor Creates new job opportunities; appeals to eco-conscious consumers Creates new jobs; raises awareness of sustainability among consumers Technical Feasibility Widely used; easy integration with existing machinery Established technology; requires specialized training Established recycling technology; ongoing advancements in product quality

17. 06. CONCLUSION Implementing cleaner production is essential for the tailoring industry to enhance sustainability and efficiency. Converting fabric waste into products like pillow covers and bed covers aligns with cleaner production principles. Reduces waste generation and environmental impact, ensuring resource optimization. Increases profitability through value-added products while minimizing raw material costs. Promotes a sustainable, eco-friendly, and economically viable business model for the industry.

18. 07. REFERENCES 1- Industrial carbon footprint of several typical Chinese textile fabrics. (2016).  Acta Ecologica Sinica , [online] 36(3), pp.119–125. doi:https ://doi.org/10.1016/j.chnaes.2015.09.002. ‌ https://www.ceb.lk/front_img/1662019801English-Electricity-Tariffs-2022.pdf http://article.sapub.org/10.5923.j.textile.20180704.02.html