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SUSTAINABLE MANUFACTURING: AN INNOVATION AND NEED FOR FUTURE 1

PRIYANKA PATHAK, 2M. P. SINGH, 3DR. PANKAJ SHARMA

1

Research Scholar, 1Mechanical Engineering Department, Jagannath University, Jaipur (INDIA) 2 Professor, 3Principal Maharishi Arvind College of Engineering & Research Center, Jaipur Email: [email protected], [email protected], [email protected]

Abstract - Sustainable Manufacturing is integration of sustainability with Manufacturing. It deals with objectives of design, its functions, competitiveness, profitability and productivity. It is likely that in future sustainability and other environmental practices will have many considerations in manufacturing and designs and have influence on main priorities for advancing manufacturing operations and technologies. Designers, manufacturers and decision makers who need to practice and establish a sustainability culture in industries will surely remain successful in their fields as these are key requirements of today and future. Also extensive research and group work is needed to enhance and improve understanding of sustainability in manufacturing and its applications. Keywords - Sustainable Manufacturing, Sustainability, Sustainability culture.

Environmental Management [11], and Design for Environment [12], Product-Service Systems [13], and many others [14, 15].

I. INTRODUCTION Sustainability means meeting the needs of the present without compromising the ability of future generations to meet their own needs, (World Commission on Environment and Development, 1987). In the extensive discussion and use of the concept since then (see e.g. Holmberg, 1992; Reed, 1997; Harris et al., 2001), there has been a growing recognition of three essential aspects of sustainable development, which are Economic, Environmental, and Social aspects.

There are numerous factors playing a significant role in defining the requirements for a next-generation manufacturing paradigm, such as increased product and systems complexity, environmental concerns, lack of knowledge integration, technology advances in modelling and simulation techniques [16]. More recently, the concept of a Sustainable Manufacturing (SM) has been developed under various labels (e.g. Environmentally Conscious Manufacturing [17, 18] or Green Manufacturing [19]) as a sub-concept of Pollution Prevention (P2) [20]. The main objective of SM is to lower the environmental impact linked to manufacturing. Environmental activities have long been associated with a negative impact on business performance but this assumption has been proved wrong by many researchers [19, 21]. sustainability indicators reflect the relations among the three aspects of sustainability and the many factors that affect them. Fig 2.1 illustrates the relations, showing, for example, that:

Fig 1.1: The "three pillars" of sustainability bounded by the environment.

Manufacturing has traditionally been associated with undesirable environmental side effects [1] as manufacturers are responsible for the transformation of resource inputs into useful outputs (i.e. products with economic value) with limits on efficiency due to the laws of thermodynamics [2]. Over the last four decades, the environmental burden linked to industrial activities has become an increasingly important global issue [3–5] and a great challenge for society [6, 7]. Awareness about the impact of human activities on the global environment has promoted the implementation of environmental degradation prevention practices. These practices can be found under various labels and fields such as Industrial Ecology [8], Green Supply-Chain Management [9], Product Life-Cycle Management [10], Corporate

Fig 2.1: Relations between social, environmental and economic parts of sustainability, and some of the factors that comprise them.

Proceedings of International Conference on Recent Innovations in Engineering and Technology, Jaipur, India, 18th - 19th Feb’2017, ISBN: 978-93-86291-63-9 21

Sustainable Manufacturing: An Innovation and Need for Future

1.

The natural resource base provides the materials for production on which jobs and profits depend;

2.

Employment affects wealth creation, living standards and poverty rates;

3.

Poverty relates to crime and social unrest and instability;

4.

Resource, air and water quality affect health;

5.

Resources used for production affect profits.

Lowell Center for Sustainable Production: “Sustainable Production is the creation of goods and services using processes and systems that are:     

III. MANUFACTURING SUSTAINABILITY: NEED FOR FUTURE

II. SUSTAINABLE MANUFACTURING

Manufacturing industries account for a significant part of the world’s consumption of resources and generation of waste. Worldwide, the energy consumption of manufacturing industries grew by 61% from 1971 to 2004 and accounts for nearly a third of today’s global energy usage. Likewise, they are responsible for 36% of global carbon dioxide (CO2) emissions (IEA, 2007).

What is sustainable manufacturing? Sustainable manufacturing is part of a larger concept, sustainable development, which emerged in the early 1980’s in response to increased awareness and concern over the environmental impact of economic growth and global expansion of business and trade. "Sustainable development is development that meets the needs of the present without compromising the ability of future generations to meet their own needs. It contains within it two key concepts: 

The concept of needs, in particular the essential needs of the world's poor, to which overriding priority should be given; and

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The idea of limitations imposed by the state of technology and social organization on the environment's ability to meet present and future needs."[22]

Non-polluting Conserving of energy and natural resources Economically viable Safe and healthful for workers, communities, and consumers Socially and creatively rewarding for all working people.”[24]

Manufacturing industries nevertheless have the potential to become a driving force for the creation of a sustainable society. They can design and implement integrated sustainable practices and develop products and services that contribute to better environmental performance. This requires a shift in the perception and understanding of industrial production and the adoption of a more holistic approach to conducting business (Maxwell et al., 2006). The environmental impact of industrial production has historically been dealt with by dispersing pollution in less harmful or less apparent ways (UNEP and UNIDO, 2004). Driven in part by stricter environmental regulations, industry has used various control and treatment measures to reduce the amount of emissions and effluents. More recently, its efforts to improve environ mental performance have moved towards thinking in terms of lifecycles and integrated environmental strategies and management systems, and companies have also begun to accept larger environmental responsibilities throughout their value chains.

At the 1992 UNCED conference held in Rio de Janeiro, sustainable production was introduced and adopted as one of the guiding principles for business and governments in transitioning towards and achieving sustainable development. As sustainability is becoming an expected business practice by companies, large and small, sustainable manufacturing is being defined, developed and implemented by manufacturing companies and their networks of suppliers and customers. There are several definitions of sustainable manufacturing to consider:

The adoption of more integrated and systematic methods to improve sustainability performance has laid the foundation for new business models or modes of provision which can potentially lead to significant environmental benefits. Efforts to create closed-loop, circular production systems have particularly focused on revitalising disposed products into new resources for production, for example by establishing ecoindustrial parks where economic and environmental synergies between traditionally unrelated industrial producers can be harnessed

US Department of Commerce: “For the purposes of Commerce's Sustainable Manufacturing Initiative, sustainable manufacturing is defined as 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.”[23]



2.

3.

4. Fig 4.1. The closed-loop production system

targeting the highest economic growth without assessing and mitigating the negative impacts outside the company’s boundaries The reality of climate change, its anthropomorphic causes and the need to reverse its trend, before the consequences on the human habitat are too serious The pressures from all categories of stakeholders: customers, investors, employees, suppliers, competitors, communities, local and national governments, international regulatory bodies, non-governmental organizations Scarcity of critical resources for operations: energy, raw materials, water and the price volatility caused, in part, by increased competition for and increased extraction costs of depleting virgin materials and nonrenewable resources.

IV. INNOVATION Much attention has recently been paid to innovation as a way for industry and policy makers to achieve more radical, systemic improvements in corporate environmental practices and performance. Many companies have started to use eco-innovation or similar terms to describe their contributions to sustainable development. A few governments are also promoting the concept as a way to meet sustainable development targets while keeping industry and the economy competitive. However, while the promotion of eco-innovation by industry and government involves the pursuit of both economic and environmental sustainability, the scope and application of the concept tend to differ. In the European Union (EU), eco-innovation is considered to support the wider objectives of its Lisbon Strategy for competitiveness and economic growth. The concept is promoted primarily through the Environmental Technology Action Plan (ETAP), which defines eco-innovation as “the production, assimilation or exploitation of a novelty in products, production processes, services or in management and business methods, which aims, throughout its lifecycle, to prevent or substantially reduce environmental risk, pollution and other negative impacts of resource use (including energy)”. Environmental technologies are also considered to have promise for improving environmental conditions without impeding economic growth in the United States, where they are promoted through various public-private partnership programmes and tax credits (OECD, 2008a). To date, the promotion of eco-innovation has focused mainly on environmental technologies, but there is a tendency to broaden the scope of the concept. In Japan, the government’s Industrial Science Technology Policy Committee defines eco-innovation as “a new field of techno-

Fig 4.2. The evolution of sustainable manufacturing concepts and practices

How is it different from other concepts, such as green, eco-manufacturing? Sustainable manufacturing is more comprehensive and systemic than green, eco-manufacturing, ecomachining, clean production by dealing with all three components of sustainability: environment, economy and society. While it includes all the environmental concerns, such as pollution, material toxicity, GHG emissions, it is not limited to those concerns, nor is it a component of an environmental management system. Sustainable manufacturing uses both technological and non-technological solutions, from selection of materials and production processes to organizational mission, structure and performance reporting. It shifts the focus from “end-of-pipeline” solutions, disposal of waste, clean-up, recovery, a liability approach, to the very beginning, at product or process design stage, an opportunity approach. Why is it important? There are several significant drivers for adopting sustainable manufacturing into the company’s strategic initiatives: 1. The current global economics crisis has exposed the fragility and, in some cases, non- viability of existing business models



social innovations [that] focuses less on products’ functions and more on [the] environment and people” (METI, 2007). Eco-innovation is thus seen as an overarching concept which provides direction and vision for pursuing the overall societal changes needed to achieve sustainable development. This extension of eco-innovation’s scope corresponds to the more integrated applicationof sustainable manufacturing described above.

3. Impacts, which are how the eco-innovation affects environmental conditions. Experience shows that more radical changes in methods, such as alternatives and creation, usually result in higher environmental benefits.

Fig 5.2: Three main facets of eco-innovation

Sustainable manufacturing calls for multi-level eco-innovations Both industry and government need to better understand and determine how to move towards a sustainable future. Innovation plays a key role in moving manufacturing industries towards sustainable production. Evolving sustainable manufacturing initiatives – from traditional pollution control through cleaner production initiatives, to a lifecycle view, to the establishment of closed-loop production – can be viewed as facilitated by eco-innovation.

Fig 5.1 The scope of Japan’s eco-innovation concept

Eco-innovation has three dimensions: targets, mechanisms and impacts The OECD defines innovation as “the implementation of a new or significantly improved product (good or service), or process, a new marketing method, or a new organisational method in business practices, workplace organisation or external relations”. Eco-innovation is generally the same as other types of innovation but with two important distinctions:  Eco-innovation represents innovation that results in a reduction of environmental impact, no matter whether that effect is intended or not.  The scope of eco-innovation may go beyond the conventional organisational boundaries of the innovating organisation and involve broader social arrangements that trigger changes in existing socio-cultural norms and institutional structures.

Fig 5.3 provides a simple illustration of the general conceptual relations between sustainable manufacturing and eco-innovation. The steps in sustainable manufacturing are depicted in terms of their primary association with respect to eco innovation, i.e. with innovation targets on the left and mechanisms at the bottom. The waves spreading towards the upper right corner indicate the path dependencies of different sustainable manufacturing concepts.

1. Targets, which are the basic focus areas of ecoinnovation. These are products, processes, marketing methods, organisations, and institutions. Ecoinnovation in products and processes tends to rely on technological development, while eco innovation in marketing, organisations and institutions relies more on non-technological changes. 2. Mechanisms, which are how changes in the target areas are made. They can involve modification of practices, re-design of practices, alternatives to existing practices, or the creation of new practices.

Fig 5.3 Conceptual relationships between sustainable manufacturing and eco-innovation



mind researches could be enhanced for sustainable manufacturing as it is the most innovative and importantly required issue in todays scenario specially for the industrial sector.

Current eco-innovations focus mostly on technological development but are facilitated by non-technological changes To better understand current applications of ecoinnovation in manufacturing industries, a small sample of sector-specific examples were reviewed in light of the above framework. The sectors chosen were: i) the automotive and transport industry; ii) the iron and steel industry; and iii) the electronics industry. The examples draw mainly on a questionnaire survey and focus group meetings conducted among leading companies in OECD countries as part of this project (Table 1).

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[2]

[3]

Eco-innovation seems best examined and developed using an array of characteristics ranging from modifications to creations across products, processes, organisations and institutions.

[4]

Table 1. Eco-innovation examples examined in this project Industry and company/association Eco-innovation example

[7]

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[8]

[9]

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Fig 5.4 Mapping the primary focus of example of ecoinnovation

[15]

CONCLUSION

[16]

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