leanand green manufactruing need of day.pptx

Lean and gran manufacturing for advane manufactring system

1. Lean and Green manufacturing

2. Lean Manufacturing: Lean Manufacturing can be defined as: a systematic approach to identifying and eliminating waste through continuous improvement by flowing the product at the pull of the customer in pursuit of perfection. Lean is philosophy that seeks to eliminate waste in all aspect of a firm’s product activities: human relation, vendor relation, technology, and management of material and invent.

3. Lean manufacturing is simply the elimination of waste in the manufacturing process. Waste can be in the form of material, time, ideal equipments, or inventory. Lean manufacturing helps to improve material handling, inventory, quality, scheduling, and personal and customer satisfaction. A lean manufacturing process is one that continuously strives to eliminate waste, thereby increase the percentage of time devoted to value adding activities. Waste in Lean Manufacturing: There are 7 different kinds of waste identified in lean manufacturing

4. Wastes Descriptions Over-production Product that is produced without or beyond demand. Over-production is described as the main waste that will trigger and contribute to the remaining of 7 wastes. Waiting Waiting occurred between two different processes when the product is not being processed. Poor communication and uneven workstation loading can contribute to the waiting factor. In traditional manufacturing, manpower is one of the contributors to waiting waste. Interruption of production flow is considered as waiting waste. Inventory Inventory is an essential part of every manufacturing factory. Excessive inventory will lead to cash flow constraint, longer lead time in obtaining items or storage of the obsolete product. It will cause a hidden operation problem that can lead to higher better plant performance. Motion Motion is defined as an excessive movement of employee or machine that does not add value to the product Excessive motion might result from lack of standard operating procedure (SOP), poor layout design, etc. This will relate to employee health issue. Transportation Transportation is deemed as waste if it does not add value to the product, it might cause damage to the product or extra manpower to manage transportation. Transportation factor is normally caused by poorly designed layout, improvement can be done by simplifying the process and improve the layout.

5. Principles of Lean Manufacturing: To achieve the lean level, industries have to follow some principles. These principles are as follow: Perfect first time quality: Quest for zero defects, revealing and solving problems at the source. Waste minimization: Eliminating all activities that do not add value and safety nets, maximize use of scare resource. Continuous improvement: Reducing cost, improving quality, increasing productivity and information sharing. Pull processing: products are pulled from the consumer end, not pushed from the production end. Flexibility: producing different mixes or greater diversity of products quickly, without sacrificing efficiency at lower volume of production. Building and maintaining a long term relationship with supplier through collaborative risk sharing, cost sharing and information sharing arrangements .

6. Techniques Used for Lean Manufacturing: Few techniques are used for lean manufacturing as under: Work Flow Analysis Kanban Kaizen

7. Advantages of Lean Manufacturing: the benefits derived by adopting the lean manufacturing system are given as: Increased productivity and asset utilization. Increase flexibility in variety an design of product Significant cost reduction in short span time. Significant improvement in delivery time of product Stronger focus on performance of product Reduces waste and inventory managment Reduction in cycle time and lead time for prodduct Reduces unplanned maintenance. Reduction in scrap and wastage Greater sensitivity to market change and demand Improve buyer supplier relationship. Increased customer satisfaction with lean Lesser setup time in shop for prduct Better communication between departments. Increased and improve competitiveness.

8. Green Manufacturing Green stands for ecological sustainability and encompasses many different concerns including, but not limited to, air, water and land pollution, energy usage and efficiency, and waste generation and recycling Green initiatives aim to minimize the impact of human activities on the environment Green manufacturing activities form the basis for making green and environmentally friendly goods. In particular, industrial companies face several challenges in adopting and enforcing renewable manufacturing practices through SMEs . Green technology is the regeneration of production processes and the creation within the industrial sector of environmentally friendly operations. Environmental developmentincludes three methods of changing manufacturing activities: utilizing green energy, producing and marketing renewable goods and, using green

9. Forces Driving Green Manufacturing A number of companies have started adopting Green initiatives as an integral part of their operations. These initiatives are driven by five factors:  Rising energy and input costs of product material  Growing consumer pull for Green products  Increasing regulatory pressures as policy makers introduce new and stricter environmental and waste management laws of different country  Technological advances which open up new attractive business opportunities  The need to enhance competitive differentiation, particularly for first movers or those who are able to break the compromise between short–term higher costs and numerous benefits (example: brand premium, new customer segments)

10. . Principle Definitions Descriptions Principle 1 A comprehensive systems approach must be used to evaluate and improve manufacturing process from a green perspective. Principle 1 takes environmental impact into consideration as the impact may have resulted from the process itself. Principle 2 The system should be wholly viewed across both the vertical and horizontal directions. Vertical refers to system varying level of detail from the enterprise down to the process while horizontal refers to the system at the same level of detail. This approach is important as environmental impact can occur depending on the level of detail. Principle 3 Harmful input and output of the system to the environment and humans should be reduced or removed. Identify harmful input and output to be replaced with material that has a lower impact. An alternative way is to implement recycle, reuse and remanufacture to reduce harmful input required. Principle 4 Net resource use should be lowered. Ideally, net resources should be zero so that resources may be used at a rate equal to the rate of replenishment in the environment. Aside from being practically impossible, the system will be deemed as inefficient in minimizing environmental impact. Principle 5 Temporal effect on the system should always be considered. Temporal effect is referred to effect that is time-based. Environmental impact should be considered in the design stage to allow better ability to consider for an alternative in reducing the future effect Simplified 5 principles of Green Principles

11. Reference Helu , M. and Dornfeld , D. (2012). Principles of Green Manufacturing. Green Manufacturing , pp.107 -115.) Reference :- Leong, W.D. , Lam, H.L., Ng, W.P.Q. , Lim, C.H. , Tan, C.P. , Ponnambalam , S., 2019. Lean and Green Manufacturing—a Review on its Applications and Impacts. Process Integr Optim Sustain. https://doi.org/10.1007/s41660-019-00082-x Helu , M. and Dornfeld , D. (2012). Principles of Green Manufacturing. Green Manufacturing , pp.107 -115.