GREEN MANUFACTURING : A LITERATURE REVIEW

Frenky Soegijapranata Catholic University Semarang Indonesia Frenky13292@gmail.com Lysia Hanjaya Soegijapranata Catholic University Semarang Indonesia Lysia_92@yahoo.com Dr. Rustina Untari Soegijapranata Catholic University Semarang Indonesia r.untari@gmail.com Abstract The current environmental damage often occurs intentionally or unintentionally. Human is now less concerned about the environmental damage that has occurred. Actually nature and all that is in the earth is entrusted by God to our children and Grandchildren (Descendant). This is what should make us concerned and thinking about green technology, not just a green phobia, but about how green manufacturing and green product itself. Green Manufacturing actually offers a lot of benefits, not just from the economical point of view but from other aspects as well. This paper will present Green Manufactyring a Literature Review Keywords green manufacturing, eco
efficiency, clean production, a literature

because of the benefits obtained internally and externally. Green manufacturing is not just a form of marketing for the company, but it is a must that be seen as an investment for the company. As the description above, that Green Manufacturing is a method for manufacturing that minimizes waste and pollution. (Waste = Cost) In Green Manufacturing, environmental impact of all stages of production is considered. The manufacturer will not use any materials which are harmful to the ecosystem in the design, production, field application and end of life disposal stages of the product 1. The goal of Green Manufacturing is to support future generations by attaining sustainability by preserving natural resources Why Green Manufacturing is so important? Due to the recent global climate, humans have started to realise the vulnerability of nature and the disasters it may bring as are sponse of our negligence. The following are the recent stresses on our environment: As much fresh water has been withdrawn in the last 30 years as in the last three centuries.

I. INTRODUCTION Green manufacturing is a method for manufacturing that minimizes waste and pollution. These goals are often achieved through product and process design.(Foster, S. Thomas. Managing Quality: An Integrative Approach. Upper Saddle River: Prentice Hall, 2001.) Green manufacturing is actually not a new thing that is in the use of current technology. There have been many companies thatutilizegreen technology

Globally, there is a 160 billion cubic meter overdraft of groundwater per year. The rate of increase in atmospheric carbon dioxide between 1970 and 2000 isnearly double that between 1960 and 1970 (1.5 ppm vs. 0.88 ppm per year). Carbon emissions have increased by more than 1.5 times since 1970. The U.S., EU and Japan are by far the worlds biggest producers of solid waste,with the U.S. at about 14 times that of Japan and the EU combined. Solid waste strategies: In Japan, its "Minimize at source"; In Europe, its"Producer responsibility"; In the U.S., its "Theres always more space."

include scheduling and process optimization, advanced fabrication techniques, minimization of waste stream volume and toxicity, and improved energy efficiency3. As stated by Manufacturing & Technology News2 , Green Manufacturing will become one of industrys greatest strategic challenges, not only from an engineering perspective, but from a business and marketing perspective as well. II. GREEN MANUFACTURING REVIEW 1. Clean Production Cleaner production is a preventive, company-specific environmental protection initiative. It is intended to minimize waste and emissions and maximize product output. Clean Production Approach more focuses in preventive action from pollutan, include solid, liquid, or gas.7

Today is time to reflect and take environmental effects of company activity intoconsideration. Examples of Green Manufacturing sub disciplines

Figure 1.1 Clean Production Approach

Cleaner Production is defined as the continuous application of an integrated preventive environmental strategy applied to processes,products and services to increase overall efficiency and reduce risks to humans and the environment.8 For production processes, Cleaner Production involves theconservation of raw materials and energy, the elimination of toxicraw materials,

and the reduction in the quantities and toxicity ofwastes and emissions. For product development and design, Cleaner Production involvesthe reduction of negative impacts throughout the life cycle of theproduct: from raw material extraction to ultimate disposal. For service industries, Cleaner Production involves theincorporation of environmental considerations into the design anddelivery of services.

Figure 1.2 - Types of Cleaner Production options8 :

Figure 1.3 - Some reasons to invest in Cleaner Production8 :

2. Eco-Efficiency Eco-efficiency is increasingly becoming a key requirement for success in business. The World Business Council for Sustainable Development (WBCSD) describes eco - efficiency as a management strategy of doing more with less. In practice, eco-efficiency is achieved through the pursuit of three core objectives 10 : Increasing product or service value; Optimizing the use of resources; and, Reducing environmental impact. Because of the opportunity for cost savings associated with each of these objectives, addressing them makes good business sense. In fact, case studies of companies that have adopted ecoefficient technologies and practices demonstrate that eco-efficiency stimulates productivity and innovation, increases competitiveness and improves environmental performance. Eco-efficiency offers a number of practical benefits for your business, including 9 : Reduced costs - through more efficient use of energy and materials; Reduced risk and liability - by "designing out" the need for toxic substances; Increased revenue by developing innovative products and increasing market share Enhanced brand image - through marketing and communicating your improvement efforts Increased productivity and employee morale - through closer alignment of company values with the personal values of the employees Improved environmental performance - by reducing toxic emissions, and increasing the

recovery and reuse of "waste" material. Achieving the benefits listed above requires a commitment to ecoefficiency throughout the various divisions, departments and functions of your business. The return on investment is achievable benefits in all areas of your business, including: Management viewing your company's activities through an eco-efficient lens can reveal hidden costs and unexploited opportunities. Better information supports better decisions, which can lead to competitive advantage in the marketplace. Design and development reducing material and energy intensity of your products and services, and increased product durability results in cost savings for your business and your customers. Purchasing working with other business functions to reduce hazardous and/or toxic materials used in processes and facilities, reduces costs associated with employee health and safety, and waste disposal. Accounting tracking costs and benefits of managing your environment impacts and improvements, results in more informed decision-making and strategic planning. Marketing and Communications providing your customers, stakeholders and investors with updates on your productivity improvements and innovations

improves brand image, and can attract new customers and financing. Production and Distribution optimizing the use of materials and resources, minimizing waste, and offering remanufacturing/ refurbishing services provides your company with cost savings opportunities and opens new markets. Facilities Management implementing recycling programs, improving building efficiency and site management processes motivates employees and improves the company image while reducing operational costs. 3. Benefits a) Environmental Benefits Green Manufacturing will make a lot of substantial impact on the environment. Nearly 80%of toxic waste is from the electrical and electronics industry. The goal of GreenManufacturing is to reduce waste to zero. This will definitely improves the ecologyand stop pollution, especially the green house effect that is affecting the Earth moreand more as a result of 50 years of manufacturing without taking any environmentalconsideration b) Company Benefits A company that practises Green Manufacturing creates a great image to the public. With the public getting more and more aware of the green house effects, going greenis an action much appreciated and supported by the public. In the viewers eyes, the company is said to have social responsibility and this reputation means a lot to the company. The society now is fonder to environmental friendly products. According to Manufacturing & Technology News 2, this is the current market trend.

A company which could develop a similar, greener product will certainly have the competitive edge. For example, car users now are more interested in buying energy efficient carsthat emit less carbon monoxide rather than energy consuming high powered vehicles. Therefore, the company that is able to produce the greener car will record better sales. While it is costly to change from the present manufacturing method to a greener method, practising Green Manufacturing may actually be cost saving. Zero waste policy means companies can optimise their resource and save their money on wastemanagement later on. There will also be a cost reduction resulted from improved energy efficiency and better process control c) Technological Benefits Green Manufacturing spins off a lot of research and development projects. Each of this projects enhances our technology. For example, the car industry. With theincreasing development of hybrid cars, it is bound to replace all fuel powered cars.The need for a greener product has produced a more advanced technology. As thesaying goes, necessity is the mother of all inventions. 4. Implementation a) Production Process Production process here involves the product design and process design. Both playsvital role in implementing Green Manufacturing. Manufacturers have to developgreener product design. This means that manufacturers have to consider the life cycleof the product and also the virgin material used. To reduce waste, biodegradable andrecyclable materials should be used. Materials must also be non-toxic. Besides that, product must be designed for disassembly and remanufacturing.

This means modular product design and snap fit or push fit instead of glue and screws.In the process design, manufacturers have to move from the traditional end-of-pipecontrol to new technologies such as pollution prevention, production process modernization and materials substitution. Process optimization should beimplemented to minimize losses and wastes in energy and materials throughout the production process 3.Virgin materials can be recycled through the process of distillation and filtering. The distilled or filtered materials could be reintroduced inthe life cycle wherever new materials aren't required. Waste will be reduced on thespot. Manufacturers must also improve the end-of-life management of the products.Some of the choices are repair, refurbishment and reuse; remanufacturing; recyclewith disassembly; recycle without disassembly; and disposal to landfill. As stated by Richard Florida in California Management [6], companies should investin 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. Besides that, according to Robin Bergstorm 4, companies should quit leap frogging from lily to lily pad. It means that they should not jump on every chemical thatinitially describes itself as more environmentally safe but later on it creates even more problems than the original material. They should conduct more research to validate its effectiveness in protecting the environment before deciding on its usage b) International Organization for Standardization

The ISO 14000 environmental management standards exist to help organizationsminimize how their operations negatively affect the environment (cause adversechanges to air, water, or land), comply with applicable laws, regulations, and other environmentally oriented requirements, and continually improve on the above. ISO14000 is similar to ISO 9000 quality management in that both pertain to the process(the comprehensive outcome of how a product is produced) rather than to the productitself. The overall idea is to establish an organized approach to systematically reducethe impact of the environmental aspects which an organization can control. Effective tools for the analysis of environmental aspects of an organization and for thegeneration of options for improvement are provided by the concept of Cleaner Production. ISO 14001 is an internationally accepted specification for an environmentalmanagement system (EMS). It specifies requirements for establishing anenvironmental policy, determining environmental aspects and impacts of products/ activities /services, planning environmental objectives and measurabletargets, implementation and operation of programs to meet objectives and targets,checking and corrective action, and management review. In order to obtain ISO14001 certification, the following criteria have to be fulfilled: reduced release of pollutants; energy saving; resources saving such as water saving and paper recycling;and prevention of potential hazards to the environment c) Regulations Here are some of the regulations of green production around the globe: - EU - Waste Electrical and Electronic Equipment (WEEE), Restriction

5. a)

b)

c)

of Hazardous Substances (RoHS), End of Life Vehicle (ELV) directives Japan - Japanese Home Electronics Recycling Law USA - Some state activities, nothing federal China - WEEE directives (under preparation), RoHS like law (InformationElectronics Production pollution control and management) Waste Electrical and Electronic Equipment (WEEE) Directive establishes criteria for collection, recovery and recycling of waste electrical and electronic equipment.Restrictions of Hazardous Substances (RoHS) Directive bans a variety of hazardous materials from use in manufacturing process. End of Life Vehicle (ELV) Directive establishes a framework to ensure that vehicles are designed and manufactured in away that optimizes opportunities for reuse, recycling and recovery Challenges Long Term Effort In realizing Green Manufacturing, it requires a lot of determination from themanufacturer. Green Manufacturing is not just a short term effort as results will notshow in a short period. Essential and proper education and training must be providedto ensure the success of Green Manufacturing.4.2 Investment Companies must invest a large amount of cash in water treatment, waste treatmentand emission control. As these field increases production cost, setting a higher allocation for them might result in a lower profit margin. Green Manufacturing alsorequires expenditure in testing, capital equipment and certification of ISO.4.3 Increase in Production Cost With all the spending in the above mentioned field, there will surely be

an increase in production cost. Besides that, since green material is not widely accepted yet by theindustry, there will be less choice to choose from and few suppliers. This resultshigher material cost which consequently increases the production cost.4.4 d) Engineers The real challenge is posed to the engineers. They have to weigh between productreliability and disassembly/assembly during the designing of the product. Besides that,they have to figure out methods to increase component by two times to improve itslife cycle. Engineers will experience a tight process management under the GreenManufacturing policy and have to monitor the supply chain. Engineers will not only bear the responsibility given by their company but the social responsibility as well. III. CONCLUSION Green Manufacturing is vital in preserving our natural resources for future generations. Itmay be costly and requires a lot of determination but many companies have taken theinitiative to go green. With Green Manufacturing, companies that truly is green, will prove thecompanies strength, capability and reliability
ACKNOWLEDGMENTS

This manuscript is fully granted by MP3EI Project on 2012 from the Directorate General of Higher Education of the Ministry of National Education of the Republic of Indonesia under contract no. 270/SP2H/PL/Dit.Litabmas/V/2012

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