Search results for: Cleaner production

Authors: Shao-lun Zeng, Yu-long Ren

Abstract:

Benchmarking cleaner production performance is an effective way of pollution control and emission reduction in coal-fired power industry. A benchmarking method using two-stage super-efficiency data envelopment analysis for coal-fired power plants is proposed – firstly, to improve the cleaner production performance of DEA-inefficient or weakly DEA-efficient plants, then to select the benchmark from performance-improved power plants. An empirical study is carried out with the survey data of 24 coal-fired power plants. The result shows that in the first stage the performance of 16 plants is DEA-efficient and that of 8 plants is relatively inefficient. The target values for improving DEA-inefficient plants are acquired by projection analysis. The efficient performance of 24 power plants and the benchmarking plant is achieved in the second stage. The two-stage benchmarking method is practical to select the optimal benchmark in the cleaner production of coal-fired power industry and will continuously improve plants- cleaner production performance.

Keywords: benchmarking, cleaner production performance, coal-fired power plant, super-efficiency data envelopment analysis

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Authors: Sawarni Hasibuan, Juliza Hidayati

Abstract:

Competitiveness and sustainability issues not only put pressure on big companies, but also small and medium enterprises (SMEs). SMEs Batik Bogor is one of the local culture-based creative industries in Bogor city which is also dealing with the issue of sustainability. The purpose of this research is to develop framework of sustainability at SMEs Batik Indonesia case of SMEs Batik Bogor by integrating innovation of cleaner production in its supply chain. The approach used is desk study, field survey, in-depth interviews, and benchmarking best practices of SMEs sustainability. In-depth interviews involve stakeholders to identify the needs and standards of sustainability of SMEs Batik. Data analysis was done by benchmarking method, Multi Dimension Scaling (MDS) method, and Strength, Weakness, Opportunity, Threat (SWOT) analysis. The results recommend the framework of sustainability for SMEs Batik in Indonesia. The sustainability status of SMEs Batik Bogor is classified as Moderate Sustainable. Factors that support the sustainability of SMEs Batik Bogor such is a strong commitment of top management in adopting cleaner production innovation and creativity approach. Successful cleaner production innovations are implemented primarily in the substitution of dye materials from toxic to non-toxic, reducing the intensity of non-renewable energy use, as well as the reuse and recycle of solid waste. “Mosaic Batik” is one of the innovations of solid waste utilization of batik waste produced by company R&D center that gives benefit to three pillars of sustainability, that is financial benefit, environmental benefit, and social benefit. The sustainability of SMEs Batik Bogor cannot be separated from the support of Bogor City Government which proactively facilitates the promotion of sustainable innovation produced by SMEs Batik Bogor.

Keywords: Cleaner production innovation, creativity, SMEs Batik, sustainability supply chain.

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Authors: Frantisek Bozek, Pavel Budinsky, Ignac Hoza, Alexandr Bozek, Magdalena Naplavova

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A cleaner production project was implemented in a bakery. The project is based on the substitution of the best available technique for an obsolete leaven production technology. The new technology enables production of durable, high-quality leavens. Moreover, 25% of flour as the original raw material can be replaced by pastry from the previous day production which has not been sold. That pastry was previously disposed in a waste incineration plant. Besides the environmental benefits resulting from less waste, lower consumption of energy, reduction of sewage waters quantity and floury dustiness there are also significant economic benefits. Payback period of investment was calculated with help of static method of financial analysis about 2.6 years, using dynamic method 3.5 years and an internal rate of return more than 29%. The supposed annual average profit after taxationin the second year of operation was incompliance with the real profit.

Keywords: Bakery, best available technology, cleaner production, costs, economic benefit, efficiency, energy, environmental benefit, investment, savings.

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Authors: N. Clavijo Buriticá, L. M. Correa Lópezand J. R., Sánchez Rodríguez

Abstract:

The environmental impact caused by industries is an issue that, in the last 20 years, has become very important in terms of society, economics and politics in Colombia. Particularly, the tannery process is extremely polluting because of uneffective treatments and regulations given to the dumping process and atmospheric emissions. Considering that, this investigation is intended to propose a management model based on the integration of Lean Supply Chain, Green Supply Chain, Cleaner Production and ISO 14001-2004, that prioritizes the strategic components of the organizations. As a result, a management model will be obtained and it will provide a strategic perspective through a systemic approach to the tanning process. This will be achieved through the use of Multicriteria Decision tools, along with Quality Function Deployment and Fuzzy Logic. The strategic approach that embraces the management model using the alignment of Lean Supply Chain, Green Supply Chain, Cleaner Production and ISO 14001-2004, is an integrated perspective that allows a gradual frame of the tactical and operative elements through the correct setting of the information flow, improving the decision making process. In that way, Small Medium Enterprises (SMEs) could improve their productivity, competitiveness and as an added value, the minimization of the environmental impact. This improvement is expected to be controlled through a Dashboard that helps the Organization measure its performance along the implementation of the model in its productive process.

Keywords: Integration, environmental impact, management, systemic organization.

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Authors: Edison Muzenda, Freeman Ntuli, Tsietsi Jefrey Pilusa

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This paper highlights some interesting facts on South African-s waste situation and management strategies, in particular the Integrated Waste Management. South Africa supports a waste hierarchy by promoting cleaner production, waste minimisation, reuse, recycling and waste treatment with disposal and remediation as the last preferred options in waste management. The drivers for waste management techniques are identified as increased demand for waste service provision; increased demand for waste minimisation; recycling and recovery; land use, physical and environmental limitations; and socio-economic and demographic factors. The South African government recognizes the importance of scientific research as outlined on the white paper on Integrated Pollution and Waste Management (IP and WM) (DEAT, 2000).

Keywords: Cleaner production, demographic factors, environmental quality, integrated waste management, hierarchy, recycling

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Authors: Nabil A. Ibrahim, Nabil M. Abdel Moneim, Mohamed A. Ramadan, Marwa M. Hosni

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As the Textile Industry is the second largest industry in Egypt and as small and medium-sized enterprises (SMEs) make up a great portion of this industry therein it is essential to apply the concept of Cleaner Production for the purpose of reducing pollution. In order to achieve this goal, a case study concerned with ecofriendly stone-washing of jeans-garments was investigated. A raw material-substitution option was adopted whereby the toxic potassium permanganate and sodium sulfide were replaced by the environmentally compatible hydrogen peroxide and glucose respectively where the concentrations of both replaced chemicals together with the operating time were optimized. In addition, a process-rationalization option involving four additional processes was investigated. By means of criteria such as product quality, effluent analysis, mass and heat balance; and cost analysis with the aid of a statistical model, a process optimization treatment revealed that the superior process optima were 50%, 0.15% and 50min for H2O2 concentration, glucose concentration and time, respectively. With these values the superior process ought to reduce the annual cost by about EGP 105 relative to the currently used conventional method.

Keywords: Cleaner Production, Eco-friendly of jeans garments, Stone washing, Textile Industry, Textile Wet Processing.

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Authors: S. Homrossukon, D. Aromstain

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The simple methods used to plan and measure non patterned production system are developed from the basic definition of working efficiency. Processing time is assigned as the variable and used to write the equation of production efficiency. Consequently, such equation is extensively used to develop the planning method for production of interest using one-dimensional stock cutting problem. The application of the developed method shows that production efficiency and production planning can be determined effectively.

Keywords: Production Planning, Parallel Machine, Production Measurement, Cutting and Packing.

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Authors: Stefan Schmidt

Abstract:

Lean production (or lean management respectively) gained popularity in several waves. The last three decades have been filled with numerous attempts to apply these concepts in companies. However, this has only been partially successful. The roots of lean production can be traced back to Toyota-s just-in-time production. This concept, which according to Womack-s, Jones- and Roos- research at MIT was employed by Japanese car manufacturers, became popular under its international names “lean production", “lean-manufacturing" and was termed “Schlanke Produktion" in Germany. This contribution shows a review about lean production in Germany over the last thirty years: development, trial & error and implementation as well.

Keywords: Application, JIT, lean production, review, trial and error.

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Authors: R. Knizek, D. Karhankova

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The production of nanofibers and the machinery for their production is a current issue. The pioneer, in the industrial production of nanofibers, is the machinery with the sales descriptions Nanospider^TM from the company Elmarco, which came into being in 2008. Most of the production facilities, like Nanospider^TM, use electrospinning. There are also other methods of industrial production of nanofibers, such as the centrifugal spinning process, which is used by FibeRio Technology Corporation. However, each method and machine has its advantages, but also disadvantages and that is the reason why a new machine called as Nanomachine, which eliminates the disadvantages of other production facilities producing nanofibers, has been developed.

Keywords: Nanomachine, nanospider, spinning slat, electrospinning.

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Authors: Ben Muenzberg, Prof. Peter Nyhuis

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The logistical requirements placed on industrial manufacturing companies are steadily increasing. In order to meet those requirements, a consistent and efficient concept is necessary for production control. Set up properly, production control offers considerable potential with respect to achieving the logistical targets. As experience with the many production control methods already in existence and their compatibility is, however, often inadequate, this article describes a systematic approach to the configuration of production control based on the Lödding model. This model enables production control to be set up individually to suit a company and the requirements. It therefore permits today-s demands regarding logistical performance to be met.

Keywords: Production, planning, control, configuration.

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Authors: Kambiz Tahvildari, Shakila ila Motamedi

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Presently and in line with the United Nations (EPA), human thinking system has shifted towards clean fuels so as to maintain a cleaner environment and to save our planet earth. One of the most successful studies in order to achieve new energies includes the use of animal wastes and their organic residues, and the result of these researches has been represented in the form of very simple and cheap methods called biogas technology. Biogas technology has developed a lot in the recent decades; its reason is the high cost of fossil fuels and the greater attention of countries to the environmental pollutions due to the consumption of this kind of fuels. IRAN is ready for the optimized application of renewable energies, having much enriched resources of this kind of energies; so a special place could be considered for it when making programs. The purpose of biogas technology is the recovery of energy and finally the protection of the environment, which is much appropriate for the third world farmers with respect to their technical abilities and economic potentials. Studies show that the production and consumption of biogas is appropriate and economic in IRAN, because of the high amount of waste in the agriculture sector, the significant amount of animal and human excrement production, the great volume of garbage produced and the most important the specific social, climatic and agricultural conditions in IRAN, in order to proceed towards the reduction of pollution due to the use of fossil fuels.

Keywords: Agriculture, Biogas, Energy, Environment.

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Authors: Seongcheol Kwon, Jeongmin Kim, Kwang Ryel Ryu

Abstract:

We assume an IoT-based smart-home environment where the on-off status of each of the electrical appliances including the room lights can be recognized in a real time by monitoring and analyzing the smart meter data. At any moment in such an environment, we can recognize what the household or the user is doing by referring to the status data of the appliances. In this paper, we focus on a smart-home service that is to activate a robot vacuum cleaner at right time by recognizing the user situation, which requires a situation-aware model that can distinguish the situations that allow vacuum cleaning (Yes) from those that do not (No). We learn as our candidate models a few classifiers such as naïve Bayes, decision tree, and logistic regression that can map the appliance-status data into Yes and No situations. Our training and test data are obtained from simulations of user behaviors, in which a sequence of user situations such as cooking, eating, dish washing, and so on is generated with the status of the relevant appliances changed in accordance with the situation changes. During the simulation, both the situation transition and the resulting appliance status are determined stochastically. To compare the performances of the aforementioned classifiers we obtain their learning curves for different types of users through simulations. The result of our empirical study reveals that naïve Bayes achieves a slightly better classification accuracy than the other compared classifiers.

Keywords: Situation-awareness, Smart home, IoT, Machine learning, Classifier.

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Authors: G. Reinhart, J. Pohl

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Manufacturing companies are facing a broad variety of challenges caused by a dynamic production environment. To succeed in such an environment, it is crucial to minimize the loss of time required to trigger the adaptation process of a company-s production structures. This paper presents an approach for the continuous monitoring of production structures by neurologic principles. It enhances classical monitoring concepts, which are principally focused on reactive strategies, and enables companies to act proactively. Thereby, strategic aspects regarding the harmonization of certain life cycles are integrated into the decision making process for triggering the reconfiguration process of the production structure.

Keywords: Continuous Factory Planning, Production Structure, Production Management.

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Authors: Tomas Duranik, Juraj Ruzbarsky, Markus Stopper

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CONWIP (constant work-in-process) as a pull production system have been widely studied by researchers to date. The CONWIP pull production system is an alternative to pure push and pure pull production systems. It lowers and controls inventory levels which make the throughput better, reduces production lead time, delivery reliability and utilization of work. In this article a CONWIP pull production system was simulated. It was simulated push and pull planning system. To compare these systems via a production planning system (PPS) game were adjusted parameters of each production planning system. The main target was to reduce the total WIP and achieve throughput and delivery reliability to minimum values. Data was recorded and evaluated. A future state was made for real production of plastic components and the setup of the two indicators with CONWIP pull production system which can greatly help the company to be more competitive on the market.

Keywords: CONWIP, constant work in process, delivery reliability, hybrid production planning, PPS.

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Authors: Pavel Vazan, Pavol Tanuska, Michal Kebisek

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The paper gives the pilot results of the project that is oriented on the use of data mining techniques and knowledge discoveries from production systems through them. They have been used in the management of these systems. The simulation models of manufacturing systems have been developed to obtain the necessary data about production. The authors have developed the way of storing data obtained from the simulation models in the data warehouse. Data mining model has been created by using specific methods and selected techniques for defined problems of production system management. The new knowledge has been applied to production management system. Gained knowledge has been tested on simulation models of the production system. An important benefit of the project has been proposal of the new methodology. This methodology is focused on data mining from the databases that store operational data about the production process.

Keywords: data mining, data warehousing, management of production system, simulation

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Authors: B. Fahimnia, L.H.S. Luong, R. M. Marian

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The Aggregate Production Plan (APP) is a schedule of the organization-s overall operations over a planning horizon to satisfy demand while minimizing costs. It is the baseline for any further planning and formulating the master production scheduling, resources, capacity and raw material planning. This paper presents a methodology to model the Aggregate Production Planning problem, which is combinatorial in nature, when optimized with Genetic Algorithms. This is done considering a multitude of constraints of contradictory nature and the optimization criterion – overall cost, made up of costs with production, work force, inventory, and subcontracting. A case study of substantial size, used to develop the model, is presented, along with the genetic operators.

Keywords: Aggregate Production Planning, Costs, and Optimization.

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Authors: R. Usubamatov, M. Z. Abdulmuin

Abstract:

Automated production lines with so called 'hard structures' are widely used in manufacturing. Designers segmented these lines into sections by placing a buffer between the series of machine tools to increase productivity. In real production condition the capacity of a buffer system is limited and real production line can compensate only some part of the productivity losses of an automated line. The productivity of such production lines cannot be readily determined. This paper presents mathematical approach to solving the structure of section-based automated production lines by criterion of maximum productivity.

Keywords: optimization production line, productivity, sections

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Authors: Marco Kennemann, Steffen C. Eickemeyer, Peter Nyhuis

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An increasingly dynamic and complex environment poses huge challenges to production enterprises, especially with regards to logistics. The Logistic Operating Curve Theory, developed at the Institute of Production Systems and Logistics (IFA) of the Leibniz University of Hanover, is a recognized approach to describing logistic interactions, nevertheless, it reaches its limits when it comes to the dynamic aspects. In order to facilitate a timely and optimal Logistic Positioning a method is developed for quickly and reliably identifying dynamic processing states.

Keywords: Dynamics, Logistic Operating Curves, Production Logistics, Production Planning and Control

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Authors: Govind Sharan Dangayach, Himanshu Bhatt

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The paper attempts to overcome the fluctuations occurring in demand of the components in an automotive sector company. Resource and time being the strict constraints, the production is not able to match the pace of the fluctuating demand. So, we introduce some production schedules that help in meeting out the required demand. The merits and demerits of the approaches are also highlighted.

Keywords: Production scheduling, Demand rise, Capacity constrained resource (CCR), Overtime.

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Authors: G. Schuh, T. Potente, D. Kupke, S. Ivanescu

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As German companies roll out their standardized production systems to offshore manufacturing plants, they face the challenge of implementing them in different cultural environments. Studies show that the local adaptation is one of the key factors for a successful implementation. Thus the question arises of where the line between standardization and adaptation can be drawn. To answer this question the influence of culture on production systems is analysed in this paper. The culturally contingent components of production systems are identified. Also the contingency factors are classified according to their impact on the necessary adaptation changes and implementation effort. Culturally specific decision making, coordination, communication and motivation patterns require one-time changes in organizational and process design. The attitude towards rules requires more intense coaching and controlling. Lastly a framework is developed to depict standardization and adaption needs when transplanting production systems into different cultural environments.

Keywords: Culture, influence of national culture on production systems, lean production, production systems.

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Authors: J. Ranogajec, O. Rudic, S. Pasalic, S. Vucetic, D. Cjepa

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The paper involves a chain of activities from synthesis, establishment of the methodology for characterization and testing of novel protective materials through the pilot production and application on model supports. It summarizes the results regarding the development of the pilot production protocol for newly developed self-cleaning materials. The optimization of the production parameters was completed in order to improve the most important functional properties (mineralogy characteristics, particle size, self-cleaning properties and photocatalytic activity) of the newly designed nanocomposite material.

Keywords: Cultural heritage. Materials compatibility. Pilot production. Self-cleaning.

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Authors: F. Keller, G. Reinhart

Abstract:

The efficient and economic allocation of resources is one main goal in the field of production planning and control. Nowadays, a new variable gains in importance throughout the planning process: Energy. Energy-efficiency has already been widely discussed in literature, but with a strong focus on reducing the overall amount of energy used in production. This paper provides a brief systematic approach, how energy-supply-orientation can be used for an energy-cost-efficient production planning and thus combining the idea of energy-efficiency and energy-flexibility.

Keywords: Production planning and control, energy, efficiency, flexibility.

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Authors: Seung Woo Lee, So Jeong Nam, Jai-Kyung Lee

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It can be said that the business sector is faced with a range of challenges–a rapidly changing business environment, an increase and diversification of customers- demands and the consequent need for quick response–for having in place flexible management and production info systems. As a matter of fact, many manufacturers have adopted production info management systems such as MES and ERP. Nevertheless, managers are having difficulties obtaining ever-changing production process information in real time, or responding quickly to any change in production related needs on the basis of such information. This is because they rely on poor production info systems which are not capable of providing real-time factory settings. If the manufacturer doesn-t have a capacity for collecting or digitalizing the 4 Ms (Man, Machine, Material, Method), which are resources for production, on a real time basis, it might to difficult to effectively maintain the information on production process. In this regard, this paper will introduce some new alternatives to the existing methods of collecting the 4 Ms in real time, which are currently comprise the production field.

Keywords: 4M, Acquisition of Data on shop-floor, Real-time machine interface

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Authors: S. Kreitlein, N. Eder, A. Syed-Khaja, J. Franke

Abstract:

The importance of energy efficiency within the production processes increases steadily. For a comprehensive assessment of energy efficiency within the production process, unfortunately no tools exist or have been developed yet. Therefore the Institute for Factory Automation and Production Systems at the Friedrich-Alexander-University Erlangen-Nuremberg has developed two methods with the goal of achieving transparency and a quantitative assessment of energy efficiency namely EEV (Energy Efficiency Value) and EPE (Energetic Process Efficiency). This paper describes the basics and state-of-the-art as well as the developed approaches.

Keywords: Energy efficiency, energy efficiency value, energetic process efficiency, production.

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Authors: Sebastian Bertsch

Abstract:

In the past decades, the environment of production companies showed a permanent increase in dynamic and volatility in the form of demand fluctuations, new technologies or global crises. As a reaction to these new requirements, changeability of production systems came into attention. A changeable production system can adapt to these changes quickly and with little effort. Even though demand for changeable production exists for some time, the practical application is still insufficient.

To overcome this deficit, a three year research project at the Department of Production Systems and Logistics at the Leibniz University of Hanover/ Germany was initiated. As a result of this project, different concepts have been developed to design production changeable. An excerpt of the results will be presented in this paper. An eight step procedure will be presented to design the changeability of production logistics. This procedure has been applied at a German manufacturer of high demanding weighing machines. The developed procedure, their application in industry, as well as the major results of the application will be presented.

Keywords: Changeability, Change Drivers, Production Logistics.

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Authors: K. Knüppel, G. Meyer, P. Nyhuis

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The increasing interconnectedness and complexity of  production processes raise the susceptibility of production systems to  failure. Therefore, the ability to respond quickly to failures is  increasingly becoming a competitive factor. The research project  "Sustainable failure management in manufacturing SMEs" is  developing a methodology to identify failures in the production and  select preventive and reactive measures in order to correct failures  and to establish sustainable failure management systems.

 

Keywords: Failure categorization, failure management, logistic performance, production optimization.

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Authors: Michael Grigutsch, Marco Kennemann, Peter Nyhuis

Abstract:

Due to the recovering global economy, enterprises are increasingly focusing on logistics. Investing in logistic measures for a production generates a large potential for achieving a good starting point within a competitive field. Unlike during the global economic crisis, enterprises are now challenged with investing available capital to maximize profits. In order to be able to create an informed and quantifiably comprehensible basis for a decision, enterprises need an adequate model for logistically and monetarily evaluating measures in production. The Collaborate Research Centre 489 (SFB 489) at the Institute for Production Systems (IFA) developed a Logistic Information System which provides support in making decisions and is designed specifically for the forging industry. The aim of a project that has been applied for is to now transfer this process in order to develop a universal approach to logistically and monetarily evaluate measures in production.

Keywords: Measures in Production, Logistic Operating Curves, Transfer Functions, Production Logistics

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Authors: Baby Joseph, Sankarganesh Palaniyandi

Abstract:

The enzyme alkaline protease production was determined under solid state fermentation using the soil bacteria Serratia marcescens sp7. The maximum production was obtained from wheat bran medium than ground nut shell and chemically defined medium. The physiological fermentation factors such as pH of the medium (pH 8), Temperature (40oC) and incubation time (48 hrs) played a vital role in alkaline protease production in all the above. 100Mm NaCl has given better resolution during elution of the enzymes. The enzyme production was found to be associated with growth of the bacterial culture.

Keywords: Alkaline protease, Wheat bran, Ground nut shell, Serratia marcescens

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Authors: Mehmet Savsar

Abstract:

This paper presents a model for an unreliable production line, which is operated according to demand with constant work-in-process (CONWIP). A simulation model is developed based on the discrete model and several case problems are analyzed using the model. The model is utilized to optimize storage space capacities at intermediate stages and the number of kanbans at the last stage, which is used to trigger the production at the first stage. Furthermore, effects of several line parameters on production rate are analyzed using design of experiments.

Keywords: Production line simulator, Push-pull system, JIT system, Constant WIP, Machine failures.

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Authors: Behrouz Afshar Nadjafi

Abstract:

Extensive research has been devoted to economic production quantity (EPQ) problem. However, no attention has been paid to problems where production period length is constrained. In this paper, we address the problem of deciding the optimal production quantity and the number of minor setups within each cycle, in which, production period length is constrained but a minor setup is possible for pass the constraint. A mathematical model is developed and Iterated Local Search (ILS) is proposed to solve this problem. Finally, solution procedure illustrated with a numerical example and results are analyzed.

Keywords: EPQ, Inventory control, minor setup, ILS.

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