ABSTRACT

Emerging surveys represent the vital role of small scale industries to cater the needs of the
country in terms of products are enormous. Productivity is a key drive and innovation is a fuel to run and
develop an industry. To reduce the burdens of industries towards the practicing of sustainable
development, a new best practice is a vital one. Based on the literature surveys, green products and
services are the need of country which is possible only by environment friendly, energy conserving
processes, optimum resource utilization. So GL is an elite way and upcoming practice to bring up small
scale industries development in a sustainable manner. This work is a pilot path toward sustainable
development with implementation of value streaming strategy which improve product value and as well
as its sustainability.
1. Introduction
Lean philosophy of manufacturing focuses on waste reduction. Toyota Production System is the
originator of Lean production techniques. Lean identifies some wastes namely over production,
Equipment breakdown, Material shortages, Yield loss, rework, and scrap, Non-optimal performance,
Changeover, Material transport, Material storage, Inspection, Delays, Walking, Overproducing, Idle
time or waiting, Excess inventory.
Green manufacturing is an emerging philosophy of manufacturing aims to reduce the
impact on environment. By using materials that are eco-friendly and by avoiding or reducing pollution to
the maximum extent Green Manufacturing can be ensured. Wherever possible Electric power can be
produced with renewable energy sources.
Sustainable practices combine Lean Green methodologies. Lean Green practices are successfully
applied to large industries. In India Small scale industries are more compared to large scale industries.
Hence the possibility of application of lean green techniques in small scale industries is to be studied.
2. Literature review
2.1 Lean Manufacturing
Ramamoorthy et all [1] [2011] suggest , to implement the lean manufacturing tools and techniques
in the pump manufacturing premises for taking necessary steps to fulfil the customer demand and
expectations.
Hudli Mohd et all [2][2010] describes the development of key areas which will be used to assess the
adoption and implementation of lean manufacturing practices.
Subha et all[3][2012] aim to evolve sector-specific Lean Manufacturing Practices (LMP) with
special reference to engineering goods manufacturing firms, duly validated to show how it would lead to
higher volumes of production through minimum use of resources and thus achieve competitive advantage
through operational benefits
Manoj Ade et all [4] [2012] suggest that Productivity improvement through Lean manufacturing
means optimization and co-ordination of the input resources to minimize the wastes to reduce total
production cost.
Ramesh et all [5] [2009] discusses the simulation study carried out for proposing one-piece lean
line layout with features of Lean Manufacturing. The lean initiatives that can be addressed are,
introducing Kanban replenishment system, better work-in-process, changing the layout, visual
management techniques, standardized work for the reduction of cycle time, number of workers, number
of setups

2.2 Green manufacturing

Adrian Vais et all [6][2006]discusses the implementation of three-year environmental project at
the Petrocart S.A. paper and board mill, through the Danish Support Programme for Eastern Europe
(DANCEE). The aim was to use Lean and Green Production to improve industrial compliance with the
effluent regulations
Virender Chahal [7][2012] states that effect of implementation of FMS, LMS and Green
Manufacturing.
Torielli1et all [8][2010] suggest that lean manufacturing is more than a set of lean tools that can
optimize manufacturing efficiencies; it is a process and mindset that needs to be integrated into daily
manufacturing systems to achieve sustainability.
Lean and Green manufacturing have a positive impact on operational performances when
implemented simultaneously. Geoff Miller et all [9][2010]explained this with a case study of a small
furniture manufacturing company.
P.Kumar et all [10][2013] explains the study to estimate the pollutants released from the foundries.
3. Problem Statement
Small scale industries are facing a lot of resource constraints. Due to power cut problems, labour
problems they need effective methods to cut down the cost and move towards pollution free
manufacturing. This research article tries to identify a simple method called as Eco-Value Stream
Mapping combining both lean and green techniques to reduce waste and impact on environment.
4. Methodology
The technique total green manufacturing combines lean and green practices. It ensures complete
utilization of all resources and a green product from design to recycling of the product.
Make to order concept is applied. All the processes are effective coordinated so that the customer
gets the product at the earliest time possible.
By elimination of all wastes leanness is practiced. Pull production, VSM, JIT and supplier
maintained d machines (SMM) are the techniques used. SMM is adapted to all machines bought for the
new plant. The machineries are maintained in good working condition by proper scheduled maintenance
methods. Whenever the new machines are installed the supplier takes care of complete maintenance for
10 years under automatically renewed annual maintenance contract.
Under this method all the spare parts, consumables for smooth running of the machineries are
supplied by the OEM.
By this method inventory will not wait for want of machine, operators are trained well.
Products are redesigned in such a way that materials selection, process parameters, easy
distribution, safe recycling of components of the product at the end of useful lifecycle are totally green.
From design, manufacturing, distribution to consumer, to the disposal of the product all are
decided after considering several alternating environmental impact index is calculated under each stage.

Environmental impact should be minimum. By good quality raw quality raw materials and sub
components, recyclability without dumping as waste after the life of the product is achieved.
TOTAL GREEN MANUFACTURING

Plan, Design

Manufacturing

E
Distribution

I
I

Utilization by customer

Recycling
Zero defects and rework, [through high quality tools, reliable machineries and processes trained
operators], single piece flow, SMED leads to continuous flow. Process chain analysis, eco route map are
applied
A value stream Map is drawn by finding the cycle time for each process. Along with this for each
process environmental effect also noted. By identifying the wastes future state map is drawn with
improved processes to reduce the wastes. Different ideas are generated to develop ideas for reducing
wastes by Brain storming technique.
A survey is conducted to find the methods for reducing the pollution by Benchmarking Method. The
methodology
is
tried
with
a
small
scale
workshop.

Study the product flow

Walkthroug Observe the process
h the line

Time study
Find the Determine the cycle time

cycle time

Find out the wastes

Identify the Identify the ways to reduce waste

wastes

Calculate
the TAKT
Time

Determine the total Time

Calculate thw TAKT TIME

Mention the Impact on environment for each process

Draw the By Survey Method Benchmarking Process to reduce
Pollution
VSm
Future
state Eco-

VSM

Planed Effect after the improvement process

Checking about the practical Application of EcoVSm

Research Methodology Block Diagram

5. Case Study
A small scale fabrication shop is taken for study. There are five employees. One person does the
marking and gas cutting. Two persons are deployed for drilling, setting and welding. Two persons are
working for grinding and painting.
Generally all the materials come in the morning. Products are produced and despatched in the
evening of the same day. The factory follows Just-in-Time already. Goods are manufactured only to the
customer order. During the change of product setting time takes more time.
A questionnaire [Attached in the Annexure] is circulated among the local small scale industries of
this similar type to get ideas for Green Manufacturing. From the Questionnaire survey all the knowledges
are gathered and Bench marking is done to find the best idea followed by the leading competitor.
Table for Survey responding Consolidation
S.N
o
1

Type of the Industry

No of respondents

Suggestions

Remarks

Mechanical Fabrication

Economic analysis
to be done

Textile Industries

3
4

Service Workshops
Food industries

3
2

To use welding
Booths to control
Pollution
To train operators
for
creating
awareness
about
Green
Manufacturing
To use Painting
Booths
with
pollution
control
Equipments

Cost
to
estimated

be

Viability Study to
be conducted

Welding process is advised to do in a closed chamber with proper exhaust control system instead of
in a open area .A paint booth to reduce the air pollution is recommended. Some of the respondents shared
their ideas for using eco friendly paints. Also for producing electric power it is suggested to provide 300
KW Photo voltaic Power Plant in the roofs of the industry.
6. Results and Discussions

It is evident that there exists a tremendous scope for the implementation of the Lean Green
Methodologies in industries to save the resources and Earth. By analysing the impact on environment
simultaneously with lean Value Stream Mapping wastes and pollution are reduced. The improvement is a
continuous process. Other tools of lean like Kaizen, kanban, SMED also can be combined together.
The study can be further explored to service industries. Implications on Inventory Turnover and
Profitability also can be studied.
References
1.Ramamoorthy.C.1 *, Dr.V.Selladurai 2, Dr.Rajesh Ranganathan - Economical Growth in pump
manufacturing industries through lean manufacturing system using Brainstorming technique: A case
study International journal of advanced economics and business management Vol No. 2, Issue No. 1,
001 008
2. Hudli Mohd. Rameez, K.H.Inamdar-Areas of Lean Manufacturing for Productivity Improvement in a
Manufacturing Unit World Academy of Science, Engineering and Technology, Vol: 4 2010-09-20.
3. M. V. Subha, S. Jaisankar Balanced Adoption of Lean Manufacturing Practices in Engineering Goods
Manufacturing Firms European Journal of Social Sciences, Vol.28 No.2 (2012), pp. 271-277.
4. Manoj Ade, V.S.Deshpande Lean Manufacturing and Productivity Improvement in Coal Mining
Industry International Journal of Engineering Research and Development Volume 2, Issue 10 (August
2012), PP. 35-43.
5. V.Ramesh, K. V. Sreenivasa Prasad, T. R. Srinivas Study on implementation of one-piece lean line
design using simulation techniques: A practical approach Journal of Industrial Engineering, January
2009, Vol. 5, No. 8, 20-36.
6. Adrian Vais , Viorel Miron , Morten Pedersen , Jens Folke Lean and Green at a Romanian
secondary tissue paper and board millputting theory into practice Resources, Conservation and
Recycling 46 (2006) 4474.
7. Virender Chahal An Advance Lean Production System In Industry To Improve Flexibility And
Quality In manufacturing By Implementation Of FMS & Green Manufacturing International Journal of
Emerging Technology and Advanced Engineering, Volume 2, Issue 12, December 2012,405-408.
8. R. M. Torielli1, R. A. Abrahams, R.W. Smillie and R.C. Voigt Using lean methodologies
forveconomically and environmentally sustainable foundries China Foundry ,Vol.8 No.1.
9. Geoff Miller1, Janice Pawloski2, Charles Standridge A case study of lean, sustainable manufacturing
Journal of Industrial engineering and Management, vol.3n1.p11-32
10. P.Kumar 1 & Dr. N. Mohan Das Gandhi Green Manufacturing in Foundry International Journal of
Engineering Research & Technology,Vol. 2 Issue 11, November 2013.
Annexure
Survey Questionnaire for Empirical Study of Green Manufacturing / Sustainable
Manufacturing in India
Part I: Company Profile and Competitiveness

1. Name of the Organization

2. Name of respondent and Designation
3. Plant location (City)
4. Address of the Organization
Address of
the
Organization
i
ii
iii
5. What is your organizations manufacturing domain?
6. Major products
7. Total Turnover
8. Please indicate the growth of organization in terms of revenue in the last three
years
Please indicate the growth of organization in terms of revenue in the last three years over 20%
between 10-20%
between 1-10%
negative growth
9. Please indicate the growth of organization in terms of profit in the last three
years
Please indicate the growth of organization in terms of profit in the last three years over 20%
between 10-20%
between 1-10%
loss

10. What is the vision statement of your organization?

11. What is the mission statement of your organization?

12. Please indicate the number of employees in your organization

0-50
51-499
500-2,000
2,001-4,999
Over 5,000
13. Please indicate the region of parent company
An Indian parent company
An European parent company
A Japanese parent company
A US parent company
Other foreign parent company
14. Does your company have ISO 9000 certification?
Yes
No
15. Does your company have ISO 14000 certification?
Yes
No
16. Does your organization have the significant environment policy?
Yes
No

If yes, for how long it existed?

17. What is the extent of Research & Development in your organization?

Very strong
Strong
Effective
Slightly
Not at all
18. Please indicate your organizations performance over the last 3 years
compared to your competitors:

Excellent
Good
Average
Below Average
Poor
19. Does your organization follow a green/environmentally conscious strategy?
Yes
No
20. Please indicate the rank of priority for the Organization / Corporate objectives
of your organization (1 for highest and 6 for lowest). Please add any additional
objective and its rank of priority if not included below:
Profit
Growth
Survival
Global focus
Maintain
competitive
advantage
Social
responsibilit
y
21. Please indicate the rank for the competitive priorities of your organization (1
for highest and 10 for lowest). Please add any additional competitive priority and
its rank if not included below
Cost
Flexibility
Environmenta
l

consciousness
Quality and
reliability
Innovation
Delivery
Morale
Customer
relations
Productivity
Sustainability