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Top1. Introduction
The major part of energy exploitation lies in the production of a rejected product. So it has been use the combination of six sigma, green manufacturing, lean methodology and value stream mapping to reduce wastage of energy and create energy saving processes. Value stream mapping is a paper and pencil tool that helps us to see and understand the flow of material and information as a product or service makes its way through the value stream. It has been use this to map the various processes in a small scale industry and study the processes in detail where the maximum energy wastage is taking place. After observing those processes and suggest the major steps that should be followed in order to minimize the energy wastage and hence contribute towards the clean; green and less energy consuming manufacturing processes.
The concept of Lean Manufacturing is widely applied by leading manufacturing companies today. It is basically a concept of getting the right things, to the right place, at the right time and in the right quantity so as to minimize waste. A pull production concept wherein the flow on the factory floor is driven by demand from downstream pulling production upstream, enabling production in the only sum of its value added work content time. A typical Lean manufacturing model is characterized by the following features: one unit at a time production, non-value added time away with, production restricted only to work content time and repositioning and relocation of requisite resources to the point of usage.
It was observed that an ideology of lean manufacturing is basically a systematic method for waste minimization within a manufacturing system, without sacrificing productivity. It has at its core laser-sharp focus on the elimination of waste from all processes and aspects of organization’s operations like design, manufacturing, distribution, customer services etc. i.e. it reduces waste of any activity process that consumes resources without adding value. In various industrial processes such non-vale added activity comprises more than 90% of the factory’s total activity. All over the country, various companies, big or small, have implemented the lean production system, mainly in the manufacturing and service sectors. And reports say that the adoption of the lean manufacturing is accelerating. Three basics reasons why the companies prefer lean manufacturing (Sahu et al., 2017a; Sahu et al., 2017b; Sahu et al., 2017c; Sahu et al., 2017d; Sahu et al., 2017d; Sahu et al., 2017e; Sahu et al., 2017f; Sahu et al., 2018a; Sahu et al., 2018b; Sahu et al., 2016; Sahu et al., 2015):
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To minimize the production resource requirements and costs.
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To optimize customer responsiveness, and
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To improve the product quality, so as to escalate the profits and competitiveness.
In gradual findings about reduction of industrial pollution, it is found that this can be done through waste minimization strategies and this scheme aims at encouraging the small and medium scale industries to adopt cleaner production practices.
Green manufacturing (GM) is a manufacturing practice that does not harm the environment during any part of the manufacturing process. It is completely harmless process that causes no harm to the environment, to the consumers, employees or other members of community (Ejim-eze & Emeka, 2013) GM emphasises on reducing parts, rationalizing materials, and reducing components to help make products more efficient to produce through sustainable development and its impact of organizational competitive outcomes along with, the strength and weaknesses of sustainable development practices.
“Introduction to Green Manufacturing” defines Green Manufacturing as “elimination of waste by re-defining existing production process or system.” Balan (2008) stated that green manufacturing concept does not only address the social and environmental impact of pollution-centric process but also process redundancy, ergonomics and cost implications due to inefficient methods of producing goods.
“A system model for Green manufacturing” emphasises the need to move towards green manufacturing. To this into practise it develops a system model for new green manufacturing paradigm.