Sustainable Green Development and Manufacturing Performance through Modern Production Techniques

377 Pages·2021·24.087 MB·English

by  Chandan Deep Singh, Harleen Kaur

Sustainable Green Development
and Manufacturing Performance through
Modern Production Techniques

Sustainable Green
Development and
Manufacturing
Performance through
Modern Production
Techniques
Chandan Deep Singh
Harleen Kaur
First edition published 2022
by CRC Press
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and by CRC Press
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© 2022 Chandan Deep Singh and Harleen Kaur
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Library of Congress Cataloging‑in‑Publication Data
Names: Singh, Chandan Deep, author. | Kaur, Harleen, author.
Title: Sustainable green development and manufacturing performance through
modern production techniques / Chandan Deep Singh, Harleen Kaur.
Description: First edition. | Boca Raton, FL : CRC Press, 2022. | Includes
bibliographical references and index.
Identifiers: LCCN 2021030341 (print) | LCCN 2021030342 (ebook) | ISBN
9781032038834 (hbk) | ISBN 9781032038858 (pbk) | ISBN 9781003189510 (ebk)
Subjects: LCSH: Lean manufacturing. | Manufacturing
processes--Environmental aspects. | Sustainable engineering.
Classification: LCC TS155.7 .S56 2022 (print) | LCC TS155.7 (ebook) | DDC 658.408--dc23
LC record available at https://lccn.loc.gov/2021030341
LC ebook record available at https://lccn.loc.gov/2021030342
ISBN: 978-1-032-03883-4 (hbk)
ISBN: 978-1-032-03885-8 (pbk)
ISBN: 978-1-003-18951-0 (ebk)
DOI: 10.1201/9781003189510
Typeset in Times
by SPi Technologies India Pvt Ltd (Straive)
Contents
Preface .......................................................................................................................xi
Author’s Biography .................................................................................................xiii
Chapter 1 Sustainable Development .....................................................................1
1.1 Introduction ...............................................................................1
1.2 Sustainability .............................................................................3
1.3 Sustainable Development ..........................................................3
1.4 Competition and Consolidation in Manufacturing ..................17
1.5 Raw Material ...........................................................................19
1.6 Ergonomics ..............................................................................24
1.7 Lean Manufacturing ................................................................27
Chapter 2 Green Engineering ..............................................................................43
2.1 Green Engineering ...................................................................43
2.2 Green Manufacturing ...............................................................45
2.2.1 Transformation to Green Manufacturing ....................53
2.2.1.1 Green Energy ..............................................53
2.2.1.2 Green Products ............................................53
2.2.1.3 Green Processes in Business Operations ....54
2.2.2 Forces Driving Green Manufacturing ........................54
2.2.3 Technologies for Green Manufacturing......................55
2.3 Challenges in Adopting Green .................................................56
2.4 Economic Assessment and Making Strategic Choices ............57
2.5 Implementation Framework.....................................................57
2.6 Consumer Perspective .............................................................58
2.7 Green Supply Chain Management ...........................................59
2.7.1 SCM to GSCM ...........................................................76
2.7.2 Advantages and Limitations of GSCM ......................77
2.7.2.1 Advantages of GSCM .................................77
2.7.2.2 Limitations of GSCM .................................78
2.7.3 Environmental and Economic Benefits of GSCM ......78
2.7.4 GSCM Throughout Product Life Cycle .....................80
2.7.5 Activities in GSCM ....................................................82
2.7.5.1 Green Design of Product and Process ........82
2.7.5.2 Life Cycle Assessment ................................82
2.7.5.3 Green Design Methods and Tools ...............82
2.7.5.4 Green Procurement of Product and
Process ........................................................83
v
vi Contents
2.7.6 Green Operations of Product and Processes...............83
2.7.6.1 Logistics ......................................................84
2.7.6.2 Green Distribution of Product and
Process ........................................................90
2.7.6.3 Green Packaging .........................................90
2.7.6.4 Green Logistics ...........................................90
2.7.6.5 Reverse Logistics ........................................90
2.7.7 Operations of GSCM ..................................................91
2.7.7.1 Collaboration with Customers ....................91
2.7.7.2 Eco-design and Packaging ..........................91
2.7.7.3 Warehousing and Green Building ...............91
2.7.8 Need of Top Management in GSCM ..........................91
2.7.9 Role of GSCM in Improving Production and
Cost .............................................................................93
2.7.10 Role of Employees in Promoting GSCM ...................94
2.8 Maintenance Repair and Operations (MRO) ...........................94
2.9 Waste Management ..................................................................94
Chapter 3 Modern Production Techniques ..........................................................97
3.1 Advanced Manufacturing Techniques .....................................97
3.1.1 Implementation of AMTs .........................................104
3.1.2 AMTs and Strategic Success ....................................106
3.1.3 Application of AMTs ...............................................113
3.1.4 Future Prospects of New Technologies ....................113
3.2 Advanced Maintenance Techniques ......................................114
3.2.1 Maintenance Types ...................................................132
3.2.2 Maintenance Performance and Measurement ..........133
3.2.3 Computerized Maintenance Management
System (CMMS) ......................................................133
3.2.4 Maintenance Strategies .............................................140
3.2.4.1 Applications of Maintenance
Strategies ...................................................140
3.2.4.2 Types of Maintenance Strategies ..............141
3.2.5 Reliability-centred Maintenance (RCM) ..................142
3.2.5.1 Principles of RCM ....................................142
3.2.5.2 Role of RCM in Improving the
Manufacturing Performance .....................143
3.2.6 Computer-Aided Facility Management (CAFM) .....144
3.2.7 New Generation Strategic Asset Management
(eXSAM) ..................................................................144
3.3 Condition-Based Maintenance and Residual
Life Prediction .......................................................................145
3.3.1 Advantages ...............................................................145
3.3.2 Disadvantages ...........................................................145
3.3.3 Examples of Condition-based Maintenance .............146
Contents vii
Chapter 4 Competency and Performance of Manufacturing Industry ..............149
4.1 Competency ...........................................................................149
4.1.1 Competency Development .......................................149
4.1.2 Competency Management ........................................150
4.1.3 Core Competency .....................................................151
4.1.4 Resource-based Perspective .....................................152
4.1.5 Economic Effects .....................................................153
4.1.6 Technological Competency ......................................153
4.1.7 Competition ..............................................................154
4.2 Strategy ..................................................................................155
4.2.1 Strategy Agility .........................................................155
4.2.2 Strategy and Business Performance .........................156
4.2.3 Management .............................................................157
4.2.3.1 Strategy Management ...............................158
4.2.4 Knowledge Transfer Management ...........................158
4.2.5 Strategy Management and Technology ....................159
4.3 Competency and Performance ...............................................160
4.3.1 Manufacturing Competency .....................................161
4.3.1.1 Competency-based Business Performance ...162
4.3.2 Performance..............................................................163
4.3.2.1 Competitiveness ........................................163
4.3.2.2 Company Enactment .................................164
4.4 Need .......................................................................................166
4.5 Aim ........................................................................................166
4.6 Issues Explored ......................................................................166
4.7 Methodology Adopted ...........................................................166
4.8 Scope .....................................................................................167
4.9 Phases ....................................................................................167
4.10 Research Framework .............................................................169
4.11 Reliability and Validity ..........................................................173
4.11.1 Validity .....................................................................173
4.12 Pilot Study .............................................................................173
4.13 Statistical Framework ............................................................174
4.13.1 Chi-square Test .........................................................174
4.13.2 Analysis of Variance (ANOVA) ...............................174
4.13.3 Factor Analysis .........................................................175
4.13.4 Type of Factoring .....................................................176
4.13.4.1 Principal Component Analysis (PCA) ......176
4.13.4.2 Factor Loadings ........................................176
4.13.4.3 Communality ............................................176
4.13.4.4 Eigen Values ..............................................176
4.13.4.5 Factor Scores.............................................177
4.13.4.6 Criteria for Determining the Number
of Factors ..................................................177
4.13.4.7 Reliable Measurements .............................177
4.14 Scoring of the Variables .........................................................177
viii Contents
Chapter 5 Reliability and Factor Analysis of Preliminary Data ........................179
5.1 Croanbach Alpha ...................................................................179
5.2 Demographic Profile ..............................................................179
5.2.1 Turnover ...................................................................180
5.2.2 Number of Employees ..............................................180
5.2.3 Market Share ............................................................181
5.3 Response Analysis .................................................................181
5.4 Factor Analysis ......................................................................188
5.4.1 Results of Factor Analysis ........................................189
5.5 Correlation Analysis ..............................................................191
5.6 Regression Analysis ...............................................................203
5.6.1 Regression Analysis for Production Capacity ..........204
5.6.2 Regression Analysis for Production Time ................204
5.6.3 Regression Analysis for Lead Time ..........................205
5.6.4 Regression Analysis for Quality ...............................205
5.6.5 Regression Analysis for Reliability ..........................205
5.6.6 Regression Analysis for Productivity .......................205
5.6.7 Regression Analysis for Growth and Expansion ......205
5.6.8 Regression Analysis for Competitiveness ................211
5.6.9 Regression Analysis for Sales ..................................211
5.6.10 Regression Analysis for Profit ..................................211
5.6.11 Regression Analysis for Market Share .....................211
5.6.12 Regression Analysis for Customer Base ..................211
Chapter 6 Qualitative Analysis ..........................................................................217
6.1 Modified DEMATEL .............................................................217
6.2 Weighted Sum Model ............................................................218
6.3 Weighted Product Model .......................................................220
6.4 Weighted Aggregated Sum Product Assessment ...................227
6.5 Grey Relational Analysis .......................................................227
6.6 Simple Multi-attribute Rating Technique ..............................233
6.7 Criteria Importance Through Intercriteria Correlation ..........234
6.8 Entropy ..................................................................................235
6.9 Evaluation Based on Distance from Average Solution ..........238
6.10 Multi-Objective Optimization Ratio Analysis (MOORA) ....241
6.11 Analytical Hierarchy Process (AHP) .....................................246
6.11.1 Comparison Scale for Pairwise Comparison ............246
6.11.2 Pairwise Comparison of Attributes ...........................247
6.11.3 Analysis Using AHP .................................................247
6.12 Technique for Order of Preference by Similarity to
Ideal Solution (TOPSIS) ........................................................248
6.13 VIKOR Method .....................................................................250
Contents ix
Chapter 7 Fuzzy Techniques .............................................................................255
7.1 Fuzzy MDEMATEL ..............................................................255
7.2 Modified Fuzzy TOPSIS........................................................256
7.3 Modified Fuzzy VIKOR ........................................................267
7.4 Fuzzy AHP .............................................................................272
7.5 Fuzzy Logic ...........................................................................273
7.5.1 Fuzzy Evaluation Rules and Solution ......................279
Chapter 8 Model Development Techniques ......................................................283
8.1 Interpretive Structural Modelling ..........................................283
8.1.1 Structural Self-interaction Matrix (SSIM) ...............284
8.1.2 Final Reachability Matrix .........................................284
8.1.3 Level Partition ..........................................................284
8.1.4 MICMAC Analysis ...................................................285
8.2 Structural Equation Modelling ..............................................289
Chapter 9 Case Studies in Manufacturing Industries ........................................295
9.1 Case Study in a 2-wheeler Manufacturing Industry ..............295
9.1.1 Company Strategy ....................................................296
9.1.2 Initiatives Taken towards Technological
Advancement ............................................................298
9.1.3 Management Initiatives ............................................299
9.1.4 Sustainable Development Goals ...............................301
9.1.5 Growth Framework with Customer Needs ...............305
9.1.6 Vision for the Future.................................................305
9.2 Case Study in a 4-wheeler Manufacturing Unit ....................306
9.2.1 Company Principles .................................................306
9.2.2 Company Objectives ................................................306
9.2.3 Company Strategy and Business Initiatives .............307
9.2.4 Technology Initiatives ..............................................307
9.2.5 Management Initiatives ............................................308
9.2.6 Quality ......................................................................309
9.2.7 Sustainable Development Goals ...............................310
9.2.8 Future Plan of Action ...............................................314
Chapter 10 Sustainable Green Development Model ...........................................315
10.1 Summary ................................................................................315
10.2 Implications ...........................................................................316
10.2.1 Reliability Analysis ..................................................317
10.2.2 Demographic Analysis .............................................317