UNIVERSITY OF MUMBAI

LOKMANYA TILAK COLLEGE OF ENGINEERING

KOPARKHAIRANE , VASHI ,
NAVI MUMBAI – 400701
2004-2005

STATE LEVEL TECHNICAL PAPER PRESENTATION

PAPER

ON

GREEN MANUFACTURING

By
Ritesh Vernekar(B.E mechanical)
Archana Thombare(B.E mechanical)
 Green Manufacturing

Topic Overview

❂ What is green manufacturing?

❂ Goals

❂ Why green manufacturing.

❂ Benefits

❂ How it works?

❂ Different Aspects

❂ Example in the real world.

❂ Summary

What is green manufacturing?

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

Green Manufacturing’s Goal

*Its goal is to achieve sustainability.

*Every company when it comes to green manufacturing should be
conserving natural resources for future generations.

Why Green Manufacturing?

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

for it to become a law…………So GO GREEN.

Benefits Of Green Manufacturing

❂ Creates a great reputation to the public.

The reputation of a company to the public is always an important thing because it can
float or sink a company. If a company pollutes its neighborhoods, people would begin to
move away creating a lack of employees which might damage their production numbers.

❂ Saves useless cost.

Eliminating waste saves money because companies wouldn't have to figure out what to
do with parts in the end when it could be recycled.

❂ Promotes Research and Design

Firms that are using green manufacturing create 2x the products due to its research and
development. (Richard Florida in California Management Article)

Process of Green Manufacturing

❂ Companies move from traditional end-of-pipe control to new technologies.

Examples of new technologies would be things like pollution prevention, production
process modernization, materials substitution. etc.

❂ End-Of-Life Management
End of life management is the full life cycle starting from the virgin materials to the use
and disposal of the final product.

❂ Waste source reduction on the spot & Recycling.

Global environmental standards like ISO 14000 are being introduced that
emphasize management systems that address environmental concerns,
operations that consider energy and natural resource consumption, and systems
for measuring, assessing and managing waste streams.
Reduction of wastage has also helped in the cost reduction in the long-term
perspective. Wastage reduction directly deals with the minimization of residuals.
Any manufacturing process produces residuals and/or generates wastage.
Residuals are normally different from the input resources, while wastage is the
superfluous resources, which could not be tapped into the transformation
process.

Residuals can be reduced in manufacturing plants by three common methods.

They are reuse, remanufacture, and recycle. Reuse occurs when the component
has minor changes made before forming a part of the final product.
Remanufacture, results in considerable change in the component before it can
be taken back into the product. Recycle requires maximum transformation before
it can be taken back into the manufacturing cycle. Most of the times recycle
involves out-of-industry treatment for the component to be made useful. For
example, printing may use recycled paper, which becomes useful only after the
paper has been reprocessed in paper mills. Thus, reused, remanufactured and
recycled components are taken back into conversion process at different stages
with recycled being taken back at the earliest phase of production.

❂ Virgin Materials are recycled

Virgin materials can be recycled through the process of distillation and filtering. The
distilled or filtered materials could be reintroduced in the life cycle wherever new
materials aren't required.

❂ Invest in production process improvements rather than control technology.

"Corporate companies spent $7.2 billion in pollution abatement and control expenditure
of which $3.2 billion were on production process enhancement.

❂ Advanced manufacturing systems promotes green design and production

strategies.
Manufacturing systems promotes green design because both strategies are based on the
dedication to product improvement, cost reduction, and technology innovation.

❂ Development of innovative manufacturing systems.

Improving the manufacturing system simultaneously minimizes cost connected with
environmental compliance.

❂ Reduction in “leapfrogging from lily pad to lily pad.” (Bergstrom, 50)

Leapfrogging from lily to lily pad means not to jump on every chemical that initially
describes itself as more environmentally safe but later on it creates even more problems
than the original material.

❂ Substitute renewable sources for finite ones.

Substituting renewable sources for finite ones might not be completely safe as found in a
study between petroleum and plants. The study concluded that even though plants could
be used as a substitute the cost in the end might be more and more environmentally
dangerous. (Gerngross, Daily University Science News)

❂ Funding research facilities.

Companies can fund researches that includes finding substitute chemicals and materials
that will eliminate pollution at the top.

❂ Employee Recycling.

❂ Companies must decide whether to make-or-buy.

Little things like recycling paper and soda cans can reduce a lot of waste cost. Companies
that produces materials can decide whether or not they want to contract another company
to make certain parts because those companies might have better equipment and higher
vertical control technology
Different Aspects in green manufacturing:

❂ JIT Manufacturing

❂ Zero Emission Strategy

❂ ISO 9000 and ISO 14000

What is JIT Manufacturing?

❂ JIT Manufacturing
• Aspect of Supply Chain Management
Collaboration between companies and their suppliers creates opportunities for new design
products and processes that are more efficient and environmentally friendly.
• Emphasis on continuous cost reduction and quality improvement
Continuous improvement creates an incentive for waste reduction and cost saving.

What is Zero Emission?

❂ Zero Emission
• “Elimination of all environmentally damaging by products from the production
process.”
• 16% of companies actively pursuing zero emission.

• 85% of companies are pursuing reduced emission strategies.

What is ISO 9000 and ISO 14000?

❂ International Quality Standards used by companies on a voluntary basis.

❂ Motivates changes
❂ Companies is following quality standards that are recognized.
Study done on National US Manufacturing firms found that most companies were
moving from ISO 9000 to ISO 14000 such as Sony Corp and Safety Kleen.

Example of Green Manufacturing

❂ Murray Ohio Manufacturing Company

*produces lawn mowers and bicycles
❂ Wanted to develop ways of reducing scrap metal.
Scrap metal was created because of the depth of the draw on the metal sheets and since
the machines created severe deep draws it would tear and mar the metal sheets.

Murray Ohio Manufacturing

❂ Used a chlorinated oil with an additive of graphite to create heightened
lubricity.
*Oil was used as a stamping lubricant
❂ Looked at two different chemicals
*Dry Coating Product
*Coldkote
❂ Dry Coating Product
• Required machinery needed 400ft in length.
• Teflon coating that the product left made the sheets more slippery.
• Cost of machinery was high.

❂ ColdKote
• System was 10ft in length.
• Non-oil lubricant
• Cost of machinery had a payback of six months.

Coldkote the winner

❂ The benefits of Coldkote
• scrap metal went from 9% to 1/10 of 1%.

• Tool life increased 30-50%.

• Polish time went from 3-4days to once a day.

Green Manufacturing
❂ Coldkote Green Manufacturing
• The removal of Coldkote was used with a warm alkaline bath.

• Coldkote becomes a solid compound once its applied therefore reducing the
amount of spilling and dripping.
• Non-oil lubricant reduces toxicity of company’s waste stream.
A warm alkaline bath eliminates the need for any hazardous cleaning agents.
Decreased spilling and dripping allowed for cleaner facilities.

Are you an expert on Green Manufacturing?

❂ What is one of the benefit for green manufacturing?
❂ One of the benefits of green manufacturing would be reducing cost because in the
end the company may not have to shell out money to remove the waste when waste has
already been eliminated on the first step. ( Zero Emission Strategy )
❂ Green manufacturing includes employees. True or False. Explain.
Employees are included in every step of the green manufacturing process. In order to
have better quality which is linked to better manufacturing services, employees must be
involved from the designing of the process to just recycling office materials.

❂ Why should your company even think about green manufacturing?

A company should consider green manufacturing because it makes their standards a little
higher in quality than others. Saving cost and increasing production could also be an
incentive for a company to even think about green manufacturing.

Summary

❂ Green manufacturing is the elimination of waste through the production process.

❂ Companies must step up and take responsibility for their actions.
❂ End-of-life management used more often then end-of-pipe control.
❂ Green manufacturing promotes innovative design.
❂ Processes such as JIT and zero emission should be exercised by all companies.
❂ Green manufacturing saves cost but more importantly it saves valuable resources.
--------------------------------------------------------------------------------------------
Reference:
❂ Bergstrom, Robin. “Fighting the Good Fight at Northrop,”
Manufacturing Management
❂ Bergstrom, Robin. “On Giving Due Thought to Afterthought,”
Manufacturing Management
❂ Bergstrom, Robin. “Stamping Made Cleaner, “ Manufacturing
Management