Search

It is possible to create value with less environmental impact through the adoption of Lean and Green manufacturing concepts and tools. This paper proposes a Lean-Green model based on the application of the Single Minute Exchange of Die (SMED) combined with Carbon Footprint (CF) to analyze eco-efficiency of a machining center in a case study in Brazil. The novelty of this paper was the proposal of a Lean-Green model based on ecoefficiency indicators to measure performance of production systems toward a cleaner production. The developed Lean-Green model should be used by companies with low-capacity of production due to restrictions of machine availability. The case study was organized in five different scenarios by varying machine tools, workers and workpieces. First, the SMED tool was applied in the setup activities and gains of reduced idle times were up to 88%. CF results were reduced up to 81% after applying the SMED tool on each scenario. Lastly, an eco-efficiency set of indicators were used to combine results of SMED and CF, and results of eco-efficiency were 3% higher even with higher CF values after converting setup saved time into productive time. To achieve such results simple improvements were performed in the machining center, through the standardization of work and the study of time and methods for setup activities, showing that the proposed Lean-Green model could be also adopted by other companies to create value with less impact. [ABSTRACT FROM AUTHOR]

The utilization of cutting fluids in metalworking industries causes health issues and environmental impacts. Owing to eco-friendly apprehensions and rising regulations over pollution and contamination, the need for a greener approach is increasing to diminish the employment of cutting fluids and dwindle the ecological impact. Therefore, special attention should be focused on clean and sustainable machining processes. Foremost, the optimal setting for multiple response problems in the manufacturing sectors must be acknowledged to reduce energy consumption. Even though machining industries established mist lubrication with vegetable oil and cryogenics as a substitute for mineral oils-based flooding, its meager lubrication and cooling property at elevated speed lead to a hunt for a new hybrid approach that offers adequate cooling/lubrication (C/L). Moreover, as of now, no information concerning the effects of hybrid cooling on milling of Nimonic-80A is existing. In this holistic investigation, machining of Nimonic-80A under hybrid C/L was compared with other cooling strategies (flood, MQL, and cryogenic) to determine the viability of employing cryogenics and hybrid cooling method. Complex Proportional Assessment (COPRAS) technique was applied to select the optimum cutting conditions to get the ideal surface trait. Besides improving the surface quality, the hybrid condition is treated as a trendsetter which is in legitimate agreement with the latest global swing for sustainable means of production. The optimization result indicated that machining at a cutting speed of 60 m/min and a feed rate of 0.04 mm/rev under the hybrid cooling strategy provides the optimal value, that controls the energy requirement. Pugh matrix method has been deployed to establish the sustainability assessment among the distinct cooling conditions. The research verdict illustrates the suitability of the hybrid cooling strategy and explains the process of going green. [ABSTRACT FROM AUTHOR]