Modelling, assessment and deployment of strategies for ensuring sustainable shielded metal arc welding process – a case study

Abstract The welding process is viewed as an environmentally vulnerable due to its energy intensive nature, human hazards and environmental burden. But, the deployment of sustainable manufacturing strategies (SMSs) can improve the sustainability of the welding processes. In this study, shielded metal arc welding (SMAW) process is considered as a candidate process for which the influence of implementing SMSs on sustainable performance was studied. Using the graph theory approach, interdependence among the Sustainable Manufacturing Measures (SMMs) was modelled to assess the SMSs. Based on the study, two SMSs, namely, employee skill training and involvement program, and waste minimization and disposal strategies were resorted to. The waste minimization and disposal strategy resulted in improved environmental performance and conservation of materials. Based on the findings, manufacturing organizations will be motivated to initiate sustainable manufacturing practices in their processes. This study also appreciates the application of modelling approach in sustainability studies from an economic point of view. Further, the study extends the scope of welding research to sustainable process optimization and redesigning.

[1]  Ming-Lang Tseng,et al.  Using QFD and ANP to analyze the environmental production requirements in linguistic preferences , 2010, Expert Syst. Appl..

[2]  Sami Kara,et al.  Towards Energy and Resource Efficient Manufacturing: A Processes and Systems Approach , 2012 .

[3]  S. Sikdar.  Sustainable development and sustainability metrics , 2003 .

[4]  H. Walker,et al.  Drivers and barriers to environmental supply chain management practices: lessons from the public and private sectors , 2008 .

[5]  S. P. Sivapirakasam,et al.  Multi-attribute decision making for green electrical discharge machining , 2011, Expert Syst. Appl..

[6]  Wei-Wen Wu,et al.  Choosing knowledge management strategies by using a combined ANP and DEMATEL approach , 2008, Expert Syst. Appl..

[7]  Manoj Kumar Tiwari,et al.  Modeling the metrics of lean, agile and leagile supply chain: An ANP-based approach , 2006, Eur. J. Oper. Res..

[8]  Ming-Lang Tseng,et al.  Evaluating firm's sustainable production indicators in uncertainty , 2009, Comput. Ind. Eng..

[9]  Lin Li,et al.  Multi-objective optimization of milling parameters – the trade-offs between energy, production rate and cutting quality , 2013 .

[10]  Toolseeram Ramjeawon,et al.  Life Cycle Assessment (LCA) of PET bottles and comparative LCA of three disposal options in Mauritius , 2008 .

[11]  H. Ryser,et al.  Matrix factorizations of determinants and permanents , 1966 .

[12]  Ivan Tengbjerg Herrmann,et al.  Does it matter which Life Cycle Assessment (LCA) tool you choose? – a comparative assessment of SimaPro and GaBi , 2015 .

[13]  Larry W. Canter,et al.  Environmental Impact Assessment , 1995 .

[14]  Yong Geng,et al.  Role of behavioural factors in green supply chain management implementation in Indian mining industries , 2013 .

[15]  R. Venkata Rao,et al.  Rapid prototyping process selection using graph theory and matrix approach , 2007 .

[16]  Wim Dewulf,et al.  Combining Machine Tool Builder and Operator Perspective towards Energy and Resource Efficiency in Manufacturing , 2013 .

[17]  Shahin Rahimifard,et al.  A framework for modelling energy consumption within manufacturing systems , 2011 .

[18]  Gang Li,et al.  Multiple criteria data envelopment analysis for full ranking units associated to environment impact assessment , 2006 .

[19]  Tarek Kasah,et al.  LCA of a newsprint paper machine: a case study of capital equipment , 2014, The International Journal of Life Cycle Assessment.

[20]  S. H. Yeo,et al.  Inclusion of environmental performance for decision making of welding processes , 1998 .

[21]  Fernando César Almada Santos,et al.  Relationships between human resource dimensions and environmental management in companies: proposal of a model , 2008 .

[22]  Konstantinos Salonitis,et al.  Environmental impact of ship hull repair , 2009 .

[23]  V. P. Agrawal,et al.  Structural modelling and integrative analysis of manufacturing systems using graph theoretic approach , 2008 .

[24]  S. Vinodh,et al.  Development of checklist for evaluating sustainability characteristics of manufacturing processes , 2013 .

[25]  Ming-Lang Tseng,et al.  Modeling sustainable production indicators with linguistic preferences , 2013 .

[26]  P. T. Anastas,et al.  Chapter 2 The twelve principles of green engineering as a foundation for sustainability , 2006 .

[27]  P. Reddy,et al.  New trends in globalization of corporate R&D and implications for innovation capability in host countries: A survey from India , 1997 .

[28]  Kevin Fong-Rey Liu,et al.  A Qualitative Decision Support for Environmental Impact Assessment Using Fuzzy Logic , 2009 .

[29]  Craig R. Carter,et al.  Purchasing's Role in Environmental Management: Cross-Functional Development of Grounded Theory , 2001 .

[30]  Paul Mativenga,et al.  Sustainable machining: selection of optimum turning conditions based on minimum energy considerations , 2010 .

[31]  Jc Johan Wortmann,et al.  Fuzzy sustainability incentives in new product development: An empirical exploration of sustainability challenges in manufacturing companies , 2014 .

[32]  Toshiyuki Sueyoshi,et al.  Measurement of a linkage among environmental, operational, and financial performance in Japanese manufacturing firms: A use of Data Envelopment Analysis with strong complementary slackness condition , 2010, Eur. J. Oper. Res..

[33]  Pratim Biswas,et al.  Characterization of the aerosols resulting from arc welding processes , 2001 .

[34]  Maryam Darvish,et al.  Application of the graph theory and matrix methods to contractor ranking , 2009 .

[35]  I. S. Jawahir,et al.  Sustainable manufacturing: Modeling and optimization challenges at the product, process and system levels , 2010 .

[36]  Athanasios C Karmperis,et al.  Decision support models for solid waste management: review and game-theoretic approaches. , 2013, Waste management.

[37]  Michael J. Ellenbecker,et al.  Indicators of sustainable production: framework and methodology , 2001 .

[38]  Athulan Vijayaraghavan,et al.  Evaluating the relationship between use phase environmental impacts and manufacturing process precision , 2011 .

[39]  G. Anand,et al.  A mathematical model for the evaluation of roles and responsibilities of Human Resources in a Lean Manufacturing environment , 2010 .

[40]  R. Venkata Rao,et al.  Decision Making in Manufacturing Environment Using Graph Theory and Fuzzy Multiple Attribute Decision Making Methods , 2013 .

[41]  Dennis Brandão,et al.  Utilization of Life Cycle Assessment methodology to compare two strategies for recovery of copper from printed circuit board scrap , 2014 .

[42]  Sami Kara,et al.  Sustainable product development and manufacturing by considering environmental requirements , 2003 .

[43]  S. Vinodh,et al.  Leanness evaluation using IF–THEN rules , 2012 .

[44]  G. Azzone,et al.  Identifying effective PMSs for the deployment of “green” manufacturing strategies , 1998 .

[45]  J T Sanderson,et al.  Toxic constituents of welding fumes. , 1966, The Annals of occupational hygiene.

[46]  N. Prasanna Kumar.  Human Resource Management in Future An Obstacle of Champion of Globalization , 2014 .

[47]  Thomas J. Dean,et al.  Stepping Towards Sustainable Business: An Evaluation of Waste Minimization Practices in US Manufacturing , 2000, Interfaces.

[48]  L. V. Wassenhove,et al.  Sustainable Operations Management , 2005 .

[49]  T. Warren Liao,et al.  A shielded metal arc welding expert system , 1993 .

[50]  Vesela Veleva,et al.  Indicators of sustainable production , 2001 .

[51]  Christoph Herrmann,et al.  Process chain simulation to foster energy efficiency in manufacturing , 2009 .

[52]  Ernst Worrell,et al.  An approach for analysing the potential for material efficiency improvement , 1995 .

[53]  R. Klassen,et al.  The Impact of Environmental Technologies on Manufacturing Performance , 1999 .

[54]  Yo-Han Choi,et al.  Application of the integrated ecodesign method using the GHG emission as a single indicator and its GHG recyclability , 2016 .

[55]  Ma Ga Yang,et al.  Impact of lean manufacturing and environmental management on business performance: An empirical study of manufacturing firms , 2011 .

[56]  Yong Geng,et al.  Improving performance of green innovation practices under uncertainty , 2013 .

[57]  R M Miranda,et al.  Characterization of airborne particles generated from metal active gas welding process , 2014, Inhalation toxicology.

[58]  O. P. Gandhi,et al.  Digraph and matrix methods for the machinability evaluation of work materials , 2002 .

[59]  Stephen Evans,et al.  A comparison of four sustainable manufacturing strategies , 2008 .

[60]  Cathy A. Rusinko,et al.  Green Manufacturing: An Evaluation of Environmentally Sustainable Manufacturing Practices and Their Impact on Competitive Outcomes , 2007, IEEE Transactions on Engineering Management.

[61]  Angela W. Little,et al.  Successful Globalisation, Education and Sustainable Development , 2009 .

[62]  Wim Dewulf,et al.  Methodology for systematic analysis and improvement of manufacturing unit process life cycle inventory (UPLCI) Part 1: Methodology Description , 2011 .

[63]  William Faulkner,et al.  Sustainable Value Stream Mapping (Sus-VSM): methodology to visualize and assess manufacturing sustainability performance , 2014 .

[64]  S. Vinodh,et al.  A mathematical model to evaluate the role of agility enablers and criteria in a manufacturing environment , 2013 .

[65]  Anand Gurumurthy,et al.  Graph theoretic approach for analysing the readiness of an organisation for adapting lean thinking , 2013 .

[66]  F. Pil,et al.  LEAN, GREEN, AND THE QUEST FOR SUPERIOR ENVIRONMENTAL PERFORMANCE , 2001 .

[67]  Ravi Shankar,et al.  Evaluation of supply chain collaboration: a case of apparel retail industry in India , 2011 .

[68]  Alvin B. Culaba,et al.  A methodology for the life cycle and sustainability analysis of manufacturing processes , 1999 .

[69]  M. Taisch,et al.  Sustainable manufacturing: trends and research challenges , 2012 .

[70]  Lennart Y. Ljungberg,et al.  Materials selection and design for development of sustainable products , 2007 .

[71]  S. Feng,et al.  Categorization of indicators for sustainable manufacturing , 2013 .

[72]  Vivian W. Y Tam,et al.  A checklist for assessing sustainability performance of construction projects , 2007 .

[73]  Vimal Dhokia,et al.  Energy efficient process planning for CNC machining , 2012 .

[74]  Sunil Pandey,et al.  Recycling of slag to act as a flux in submerged arc welding , 2009 .

[75]  Warit Jawjit,et al.  Assessing environmental performance by combining life cycle assessment, multi-criteria analysis and environmental performance indicators , 2007 .

[76]  Sandeep Grover,et al.  Digraph and matrix method to evaluate the machinability of tungsten carbide composite with wire EDM , 2011 .

[77]  Sandeep Grover,et al.  Role of human factors in TQM: a graph theoretic approach , 2006 .

[78]  Adisa Azapagic,et al.  The application of life cycle assessment to process optimisation , 1999 .

[79]  S. Vinodh,et al.  An approach for evaluation of process sustainability using multi-grade fuzzy method , 2015 .

[80]  S. Vinodh,et al.  Thirty criteria based leanness assessment using fuzzy logic approach , 2012 .

[81]  Mahesh Gupta,et al.  Environmental management and its impact on the operations function , 1995 .

[82]  J. Antonini,et al.  Health Effects of Welding , 2003, Critical reviews in toxicology.

[83]  Eric Vigoda,et al.  A polynomial-time approximation algorithm for the permanent of a matrix with nonnegative entries , 2004, JACM.

[84]  Jeanette M. Schwarz,et al.  Use Sustainability Metrics to Guide Decision-Making , 2002 .

[85]  Kevin F. R. Liu,et al.  Decision-support for environmental impact assessment: A hybrid approach using fuzzy logic and fuzzy analytic network process , 2009, Expert Syst. Appl..

[86]  P. Butelli,et al.  Environmental performance, indicators and measurement uncertainty in EMS context: a case study , 2008 .

[87]  Huan-Jyh Shyur,et al.  COTS evaluation using modified TOPSIS and ANP , 2006, Appl. Math. Comput..