GREEN MANUFACTURING –

ITS TOOLS AND TECHNIQUES

FIROZ KHAN
B140845PE
 INTRODUCTION
• With rapid changes in technologies, customers' needs and globalizations manufacturing is itself
transforming and evolving
• In 19th century the production system adopted was mass production system without much giving
stress on green manufacturing
• In 1970s the concept adopted was flexible manufacturing system.
• As the manufacturing system kept progressing the environment started facing problems of
pollutions which lead to environmental degradation
• So the concept of Green Manufacturing was evolved.

Green Manufacturing is a method for manufacturing that minimizes waste and pollution. 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.
- Richard Cortellini

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GREEN!
• Manufacturing of 'green' products
• Greening of manufacturing reducing pollution and waste by minimizing usage of natural
resources.
• 92 percent of the companies surveyed are engaged in Green initiatives

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 WHY IS IT IMPORTANT?
• Rising emissions and associated climate change
• Fast depletion of scarce natural resources
• Growing waste generation and pollution

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GREEN MANUFACTURING TECHNIQUES

• Green purchasing

• procurement of products and services that have a lesser or reduced effect on human health and the
environment
• communities in the vicinity of your operations benefit from green purchasing practices through
cleaner air and water. In turn, this helps you avoid costs related to worker health and safety, and can
lower environmental risk costs
• purchasing just 6 cases of 100% postconsumer recycled content copy paper instead of virgin (non-
recycled) paper eliminates one metric ton of carbon dioxide equivalent (CO2e), an amount equal to
the emissions from burning 102 gallons of gasoline.

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GREEN MANUFACTURING TECHNIQUES
(Contd.)
• Green processes in operations
• Reverse logistics
• process of planning, implementing, and controlling the efficient, cost effective flow of
raw materials, in-process inventory, finished goods, and related information from the
point of consumption to the point of origin for the purpose of recapturing or creating
value or proper disposal.

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• Input – output analysis
• process map identifies material and natural resource inputs to the process and part and
waste stream outputs from the process.
• obtaining data for all of the inputs and outputs, and evaluating the resource
consumption of each process individually.
• Using resource consumption profiles, evaluating the environmental and economic
impacts of that resource consumption
• This allows to compare different process chain combinations with respect to resource
consumption and economic and environmental impacts

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• Green product design

• Designing of product which minimize the use of recyclable materials that clog landfills and
replacing them with materials that are reusable and have minimum negative impact on
the environment
• Designing of products that consumes less resources and therefore lots of waste can be
eliminated and the design team mainly focus on the customer requirement during the
design process of a product.
• Recycling allows to repurpose valuable materials that would otherwise have been wasted.
The more reduce, re-use, recycle and recover packaging, the greater the cost savings in
materials and energy

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 • circular economy, which means designing products so that resources are used in a cyclical
way. Materials can be regenerated and constantly flow round a ‘closed loop’ system, rather
than being used once and then discarded

• Green manufacturing
• Constantly focus on reduction of waste material
• Achieved using JIT(Just in Time manufacturing), which gives prime importance to reducing
waste and producing at minimum cost with more stress on green manufacturing.
• involves class of technologies that use cleaner fuels for generating Power.

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• Green distribution
• green packing-plastic returnable tray for packing is thus designed to hold the products for
shipment, and the packing density is improved so that more products can be shipped in one
cargo, which means unit transportation cost can be reduced.

• Distribution is most preferably channelized through rail and water and if needed through
using environmental friendly vehicle like solar vehicle with minimum environmental impact.

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• Training and employee involvement

• focuses on problem solving driven by ecofriendly measures thereby making them more
aware about green manufacturing concept. Seminar sections are arranged for the workers
and senior managers from the other industries are welcomed to give them training on green
practices.

• Customer awareness program

• Meetings are carried out for green purposes also interaction and feedback from customer is
taken on green product to create awareness about green concept and green manufacturing.

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Better housekeeping:
• refers to simple, routinized, non- resource intensive measures that keep a facility in good
working and environmental order.
• Segregating, reducing and eliminating wastes,
• minimizing waste inventories
• frequent inspections identifying environmental concerns and potential malfunctioning of
the production process.

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IMPLEMENTATION PROCESS
• Explaining how green considerations impact on design decisions relating to manufacturing processes
and products.
• Analyzing a technological outcome to determine its suitability for green manufacture
• Making design changes as required for the technological outcome guided by good design judgment
criteria
• Establishing specifications, required of the outcome that is to be manufactured within the constraints
and opportunities of the manufacturing location.

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IMPLEMENTATION PROCESS (Contd.)
• Selecting a green manufacturing process and quality control procedures to enable units to
meet the established specifications.
• Organizing resources and ensuring procedures are carried out accurately.
• Monitoring the manufacturing process and refining as required.
• Evaluation of manufacturing process in meeting green considerations
• Justifying the level of success the manufacturing process has attained in meeting green
considerations

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Result based on case study on Hindustan
Unilever Limited.
• Reduction in CO2 emissions from energy used for production by 43% per tonne of total production
• total footprint per consumer use reduced by 28% since 2010 as they use less materials
manufacture products that can be recycled
• Reducing disposal by 143,903 tonnes of total waste , a 96% reduction per tonne of production
• 32% reduction in energy (kWh) utilization per process.

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CONCLUSION
• GM play a significant role in reducing the environmental impact while
increasing the value of products.
• Techniques used in achieving GM helps in increasing the performance of
industry
• Elimination of waste represents the ultimate solution to pollution
problems that threaten ecosystems.
• Energy saving plays a prominent role in controlling the pollution there by
reduction in generation of greenhouse gases to atmosphere is controlled.

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 REFERENCES
• Moving Towards Green and Sustainable Manufacturing, David Alan Dornfeld.
• Green Manufacturing: Solution for Indian Climate Change Commitment and Make in
India Aspirations, Nikhil Sudhir Kothawade.
• The Techniques of Lean and Green Manufacturing Systems, Dr. Vasdev Malhotra and
2Sameer Kumar.
• IMPLEMENTATION OF GREEN MANUFACTURING IN INDUSTRY - A CASE STUDY Swapnil
V. Ghinmine, Dilip I. Sangotra.
• Green Manufacturing: It’s Tools and Techniques that can be implemented in
Manufacturing Sectors. Dilip Maruthia, Rashmi.

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