Leong, Wei Dong and Teng, Sin Yong and How, Bing Shen and Ngan, Sue Lin and Lam, Hon Loong and Tan, Chee Pin and Ponnambalam, S. G. (2019): Adaptive Analytical Approach to Lean and Green Operations. Published in: Journal of Cleaner Production , Vol. 235, (20 October 2019): pp. 190-209.
PDF
AAA_manuscript.pdf Download (2MB) |
Abstract
Recent problems faced by industrial players commonly relates to global warming and depletion of resources. This situation highlights the importance of improvement solutions for industrial operations and environmental performances. Based on interviews and literature studies, manpower, machine, material, money and environment are known as the foundation resources to fulfil the facility's operation. The most critical and common challenge that is being faced by the industrialists is to perform continuous improvement effectively. The needs to develop a systematic framework to assist and guide the industrialist to achieve lean and green is growing rapidly. In this paper, a novel development of an adaptive analytic model for lean and green operation and processing is presented. The development of lean and green index will act as a benchmarking tool for the industrialist. This work uses the analytic hierarchy process to obtain experts opinion in determining the priority of the lean and green components and indicators. The application of backpropagation optimisation method will further enhance the lean and green model in guiding the industrialist for continuous improvement. An actual industry case study (combine heat and power plant) will be presented with the proposed lean and green model. The model is expected to enhance processing plant performance in a systematic lean and green manner.
Item Type: | MPRA Paper |
---|---|
Original Title: | Adaptive Analytical Approach to Lean and Green Operations |
English Title: | Adaptive Analytical Approach to Lean and Green Operations |
Language: | English |
Keywords: | Lean & green manufacturing; Lean and green index; Back-propagation; Machine learning; Process optimisation |
Subjects: | C - Mathematical and Quantitative Methods > C1 - Econometric and Statistical Methods and Methodology: General C - Mathematical and Quantitative Methods > C1 - Econometric and Statistical Methods and Methodology: General > C10 - General C - Mathematical and Quantitative Methods > C8 - Data Collection and Data Estimation Methodology ; Computer Programs C - Mathematical and Quantitative Methods > C8 - Data Collection and Data Estimation Methodology ; Computer Programs > C80 - General C - Mathematical and Quantitative Methods > C8 - Data Collection and Data Estimation Methodology ; Computer Programs > C83 - Survey Methods ; Sampling Methods L - Industrial Organization > L6 - Industry Studies: Manufacturing L - Industrial Organization > L7 - Industry Studies: Primary Products and Construction L - Industrial Organization > L8 - Industry Studies: Services L - Industrial Organization > L9 - Industry Studies: Transportation and Utilities M - Business Administration and Business Economics ; Marketing ; Accounting ; Personnel Economics > M0 - General O - Economic Development, Innovation, Technological Change, and Growth > O3 - Innovation ; Research and Development ; Technological Change ; Intellectual Property Rights |
Item ID: | 95449 |
Depositing User: | Dr Sin Yong Teng |
Date Deposited: | 22 Aug 2019 22:10 |
Last Modified: | 26 Sep 2019 12:28 |
References: | 5ME, 2019. The 5 M’s of Efficiency & Lean Manufacturing. http://5me.com/the-5ms-of-efficiency/explore-the-5ms/ (accessed 4.19.19). Abadie, R., 2012. Infrastructure development in emerging markets: Closing the talent gap. http://www.pwc.com/gx/en/capital-projects-infrastructure/assets/gridlines_talent1210.pdf (accessed 4.19.19). Ahuja, I.P.S., Khamba, J.S., 2008. Total productive maintenance: Literature review and directions. Int J Qual Reliab Manag. https://doi.org/10.1108/02656710810890890 Amasuomo, E., Baird, J., 2016. The Concept of Waste and Waste Management. J Manag Sustain 6, 88. https://doi.org/10.5539/jms.v6n4p88 Baba, D., Mohd Yusof, S., Azhari, S., 2006. A benchmarking implementation framework for automotive manufacturing SMEs. Benchmarking An Int J. https://doi.org/10.1108/14635770610676272 Baby, S., 2013. AHP Modeling for Multicriteria Decision-Making and to Optimise Strategies for Protecting Coastal Landscape Resources. Int J Innov Manag Technol 4. https://doi.org/10.7763/ijimt.2013.v4.395 Batumalay, K., Santhapparaj, A.S., 2009. Overall Equipment Effectiveness (OEE) through Total Productive Maintenance (TPM) practices - A study across the Malaysian industries, in: International Conference for Technical Postgraduates 2009, TECHPOS 2009. https://doi.org/10.1109/TECHPOS.2009.5412049 Blazewicz, J., Breit, J., Formanowicz, P., Kubiak, W., Schmidt, G., 2001. Heuristic algorithms for the two-machine flowshop with limited machine availability. Omega. https://doi.org/10.1016/S0305-0483(01)00048-2 BP, 2018. 67 th edition Contents is one of the most widely respected. Stat Rev World Energy 1–56. Braglia, M., Frosolini, M., Zammori, F., 2008. Overall equipment effectiveness of a manufacturing line (OEEML): An integrated approach to assess systems performance. J Manuf Technol Manag. https://doi.org/10.1108/17410380910925389 Chan, S.W., Tasmin, R., Nor Aziati, A.H., Rasi, R.Z., Ismail, F.B., Yaw, L.P., 2017. Factors Influencing the Effectiveness of Inventory Management in Manufacturing SMEs. IOP Conf Ser Mater Sci Eng 226, 012024. https://doi.org/10.1088/1757-899X/226/1/012024 Chen, Q., Grossmann, I.E., 2017. Recent Developments and Challenges in Optimization-Based Process Synthesis. Annu Rev Chem Biomol Eng. https://doi.org/10.1146/annurev-chembioeng-080615-033546 Chong, T.T.L., Wong, K.M., 2015. Does Monetary Policy Matter For Trade?. https://mpra.ub.uni-muenchen.de/63502/ (accessed 4.23.19). Christodoulou, D., Mcleay, S., 2014. The double entry constraint, structural modeling and econometric estimation. Contemp Account Res. https://doi.org/10.1111/1911-3846.12038 Chryssolouris, G., Mavrikios, D., Mourtzis, D., 2013. Manufacturing systems: Skills & competencies for the future, in: Procedia CIRP. https://doi.org/10.1016/j.procir.2013.05.004 Chui, M., Manyika, J., Miremadi, M., George, K., 2017. The great re-make: Manufacturing for modern times. Čuček, L., Klemeš, J.J., Kravanja, Z., 2012. A review of footprint analysis tools for monitoring impacts on sustainability. J Clean Prod. https://doi.org/10.1016/j.jclepro.2012.02.036 Dadashnejad, A.A., Valmohammadi, C., 2019. Investigating the effect of value stream mapping on overall equipment effectiveness: a case study. Total Qual Manag Bus Excell. https://doi.org/10.1080/14783363.2017.1308821 Daisyme, P., 2018. Understanding the Financial Cost of Downtime in Manufacturing - Due. https://due.com/blog/understanding-the-financial-cost-of-downtime-in-manufacturing/ (accessed 4.23.19). Dallasega, P., Rauch, E., Frosolini, M., 2018. A Lean Approach for Real-Time Planning and Monitoring in Engineer-to-Order Construction Projects. Buildings 8, 38. https://doi.org/10.3390/buildings8030038 Dessault, 2016. KEYS TO IMPROVING MANUFACTURING EFFICIENCY. White Pap 1–8. Dieste, M., Panizzolo, R., Garza-Reyes, J.A., Anosike, A., 2019. The relationship between Lean and environmental performance: practices and measures. J Clean Prod. https://doi.org/10.1016/j.jclepro.2019.03.243 Dilip Maruthi, G., Rashmi, R., 2015. Green Manufacturing: It’s Tools and Techniques that can be implemented in Manufacturing Sectors, in: Materials Today: Proceedings. https://doi.org/10.1016/j.matpr.2015.07.308 Dües, C.M., Tan, K.H., Lim, M., 2013. Green as the new Lean: how to use Lean practices as a catalyst to greening your supply chain. J Clean Prod 40, 93–100. https:/ /doi.org/10.1016/J.JCLEPRO.2011.12.023 EPA, 2017. Understanding Global Warming Potentials. https://www.epa.gov/ghgemissions/understanding-global-warming-potentials (accessed 4.4.19). Fairris, D., Tohyama, H., 2002. Productive efficiency and the lean production system in Japan and the United States. Econ Ind Democr. https://doi.org/10.1177/0143831X02234004 Ferreira, A.C., Nunes, M.L., Martins, L.B., Teixeira, S.F., 2014. Technical-Economic Evaluation of a Cogeneration Unit Considering Carbon Emission Savings. Int J Sustain Energy Plan Manag. Field, H.L., Solie, J.B., 2007. Equipment Efficiency and Capacity, in: Introduction to Agricultural Engineering Technology. Springer US, Boston, MA, pp. 118–128. h ttps://doi.org/10.1007/978-0-387-36915-0_9 Ghosh, S.N., 2014. Advances in cement technology : critical reviews and case studies on manufacturing, quality control, optimization and use, 1st ed. Pergamon, London. https://doi.org/https://doi.org/10.1016/C2013-0-06042-2 Gibbons, P.M., 2006. Improving overall equipment efficiency using a Lean Six Sigma approach. Int J Six Sigma Compet Advant 2, 207. https://doi.org/10.1504/IJSSCA.2006.010110 Gori, M., Maggini, M., 1996. Optimal convergence of on-line backpropagation. IEEE Trans Neural Networks. https://doi.org/10.1109/72.478415 Govindan, K., Kaliyan, M., Kannan, D., Haq, A.N., 2014. Barriers analysis for green supply chain management implementation in Indian industries using analytic hierarchy process. Int J Prod Econ 147, 555–568. https://doi.org/10.1016/J.IJPE.2013.08.018 Griewank, A., 2012. Who Invented the Reverse Mode of Differentiation? Doc Math Extra Vol ISMP, 389–400 . Hajmohammad, S., Vachon, S., Klassen, R.D., Gavronski, I., 2013. Lean management and supply management: Their role in green practices and performance. J Clean Prod 312–320. https://doi.org/10.1016/j.jclepro.2013.06.038 Hines, P., 2009. Lean and Green. Source Mag Home Lean Thinking, 3rd Ed, sapartners. Hong, B.H., How, B.S., Lam, H.L., 2016. Overview of sustainable biomass supply chain: from concept to modelling. Clean Technol Environ Policy. https://doi.org/10.1007/s10098-016-1155-6 Hou, Y., Wang, B., Ouyang, G., Shen, H., He, Y., 2011. An analytic hierarchy process to evaluate PEM fuel cell engine performance. Int J Hydrogen Energy. https://doi.org/10.1016/j.ijhydene.2011.02.119 How, B.S., Lam, H.L., 2017. Integrated Palm Biomass Supply Chain toward Sustainable Management. Chem Prod Process Model. https://doi.org/10.1515/cppm-2017-0024 Huang, S.H., Dismukes, J.P., Shi, J., Su, Q., Razzak, M.A., Bodhale, R., Robinson, D.E., 2003. Manufacturing productivity improvement using effectiveness metrics and simulation analysis. Int J Prod Res. https://doi.org/10.1080/0020754021000042391 Huang, S.H., Dismukes, J.P., Shi, J., Su, Q., Wang, G., Razzak, M.A., Robinson, D.E., 2002. Manufacturing system modeling for productivity improvement. J Manuf Syst. https://doi.org/10.1016/S0278-6125(02)80165-0 IEA, 2018. CO2 Emissions. https://www.iea.org/statistics/co2emissions/ (accessed 4.28.19). Kamaruzzaman, S.N., Lou, E.C.W., Wong, P.F., Wood, R., Che-Ani, A.I., 2018. Developing weighting system for refurbishment building assessment scheme in Malaysia through analytic hierarchy process (AHP) approach. Energy Policy 112, 280–290. https://doi.org/10.1016 /J.ENPOL.2017.10.023 Kar, S., 2018. 6 Challenges for HR in the Manufacturing Industry. https://blog.gethyphen.com/blog/challenges-hr-manufacturing-industry (accessed 4.28.19). Knop, K., Mielczarek, K., 2018. Using 5W-1H and 4M Methods to Analyse and Solve the Problem with the Visual Inspection Process - case study. MATEC Web Conf 183, 03006. https://doi.org/10.1051/matecconf/201818303006 leanproduction.com, 2017. Top 25 Lean Manufacturing Tools | Lean Production. https://www.leanproduction.com/top-25-lean-tools.html#continuous-flow (accessed 4.28.19) . Lecun, Y., 1988. A theoretical framework for back-propagation. Leong, W.D., Lam, H.L., Ng, W.P.Q., Lim, C.H., Tan, C.P., Ponnambalam, S., 2019. Lean and Green Manufacturing—a Review on its Applications and Impa cts. Process Integr Optim Sustain. https://doi.org/10.1007/s41660-019-00082-x Leong, W.D., Lam, H.L., Tan, C.P., Ponnambalam, S.G., 2018. Development of multivariate framework for lean and green process. Chem Eng Trans. https://doi.org/10.3303/CET1870366 Liliana, L., 2016. A new model of Ishikawa diagram for quality assessment, in: IOP Conference Series: Materials Science and Engineering. https://doi.org/10.1088/1757-899X/161/1/012099 Matteo, M., Wiktor, N., Rafael, P., Sree, R., 2017. Global growth, local roots: The shift toward emerging markets | McKinsey. https://www.mckinsey.com/business-functions/operations/our-insights/global-growth-local-roots-the-shift-toward-emerging-markets (accessed 5.2.19). McBride, D., 2003. 7 Wastes Muda Article on the Seven Wastes of Lean Manufacturing. https://www.emsstrategies.com/dm090203article2.html (accessed 4.28.19). MITI, 2017. MALAYSIA AND THE UNITED NATIONS FRAMEWORK CONVENTION ON CLIMATE CHANGE (UNFCCC) – THE PARIS AGREEMENT. Myhre, G., Shindell, D., Bréon, F.-M., Collins, W.,Fuglestvedt, J., Huang, J., Koch, D., Lamarque, J.-F., Lee, D., Mendoza, B., Nakajima, T., Robock, A., Stephens, G., Takemura, T., Zhan, H., 2013. IPCC (2013): Anthropogenic and Natural Radiative Forcing In: Climate Change 2013: The Physical Science Basis. Contribution of Working Group I to the Fifth Assessment Report of the Intergovernmental Panel on Climate Change, Climate Change 2013: The Physical Science Basis. Contribution of Working Group I to the Fifth Assessment Report of the Intergovernmental Panel on Climate Change. https://doi.org/10.1017/ CBO9781107415324.018 Nakajima, S., 1988. Introduction to TPM: Total Productive Maintenance. http://www.plantmaintenancecomarticlestpmintros.html (accessed 4.28.19). Nasir, S.Z., 2017. Emerging Challenges of HRM in 21 st Century: A Theoretical Analysis. Int J Acad Res Bus Soc Sci 7. https://doi.org/10.6007/IJARBSS/v7-i3/2727 Ng, W.P.Q., Lam, H.L., Ng, F.Y., Kamal, M., Lim, J.H.E., 2012. Waste-to-wealth: Green potential from palm biomass in Malaysia. J Clean Prod. https://doi.org/10.1016/j.jclepro.2012.04.004 Ng, W.P.Q., Lam, H.L., Varbanov, P.S., Klemeš, J.J. , 2014. Waste-to-Energy (WTE) network synthesis for Municipal Solid Waste (MSW). Energy Convers Manag 85, 866–874. https://doi.org/10.1016/J.ENCONMAN.2014.01.004 Ngan, S.L., Promentilla, M.A.B., Yatim, P., Lam, H.L., 2018. A Novel Risk Assessment Model for Green Finance: the Case of Malaysian Oil Palm Biomass Industry. Process Integr Optim Sustain. https://doi.org/10.1007/s41660-018-0043-4 OECD, 2017. ENHANCING THE CONTRIBUTIONS OF SMEs IN A GLOBAL AND 7–8. Oedewald, P., Gotcheva, N., Kaupo Viitanen, |, Wahlström, M., 2015. Safety culture and organisational resilience in the nuclear industry throughout the different lifecycle phases. Ong, S.A.C.T.I.O.N.S.V.; H.Y., Pang, B.H.Y., Wan, Y.S., Yap, J.Y., Ng, A.K.S., Foo, W.P.Q., 2015. Water network optimisation with consideration of network complexity, in: Chemical Engineering Transactions. pp. 13–18. https://doi.org/10.3303/CET1545003 Owen, D.G., 2002. Manufacturing Defects. Patel, C., Deshpande, V.A., 2016. A Review on Improvement in Overall. Peters, G.P., Marland, G., Le Quéré, C., Boden, T.Canadell, J.G., Raupach, M.R., 2012. Rapid growth in CO 2 emissions after the 2008-2009 global financial crisis. Nat Clim Chang. https://doi.org/10.1038/nclimate1332 Razavi, R., Perrot, J.-F., Guelfi, N., 2010. Adaptive Modeling: An Approach and a Method for Implementing Adaptive Agents 6, 136–148. https://doi.org/10.1007 /11512073_10 Roosevelt, 2011. Six Reasons Manufacturing is Central to the Economy - Roosevelt Institute. http://rooseveltinstitute.org/six-reasons-manufacturing-central-economy/ (accessed 4.23.19). Rumelhart, D.E., Hinton, G.E., Williams, R.J., 1986. Learning representations by back-propagating errors. Nature. https://doi.org/10.1038/323533a0 Saaty, T.., 1980. The Analytic Hierarchy Process. McGraw-Hill, New York. Saaty, T.L., 2008. Decision making with the analytic hierarchy process, Int. J. Services Sciences. Sasidhar, T., Nandan, A., Sharma, M., 2015. Assessment and Improvement of Safety Culture in a Sugar Industry in India. Res J Eng Tech 6. https://doi.org/10.5958/2321-581X.2015.00057.4 Schmidt, G., 2000. Scheduling with limited machine availability. Eur J Oper Res. https://doi.org/10.1016/S0377-2217(98)00367-1 SDG, 2019. Sustainable Development Goals : Sustainable Development Knowledge Platform. https://sustainabledevelopment.un.org/?menu=1300 (accessed 4.29.19). Septiawan, D.B., Bekti, R., 2016. Analysis of Project Construction Delay Using Fishbone Diagram At Pt . Rekayasa Industri 5, 634–650. Sezen, B., Çankaya, S.Y., 2013. Effects of Green Ma nufacturing and Eco-innovation on Sustainability Performance. Procedia - Soc Behav Sci. https://doi.org/10.1016/j.sbspro.2013.10.481 Silver, E.A., Peterson, R., Pyke., D.F., 1998. Inventory Management and Production Planning and Scheduling, 3rd ed. Wiley, New York. Sim, K.L., Curatola, A.P., Banerjee, A., 2015. Lean Production Systems and Worker Satisfaction: A Field Study. Adv Bus Res 2015 6, 79–100. Singh, R., Shah, D.B., Gohil, A.M., Shah, M.H., 2013. Overall equipment effectiveness (OEE) calculation - Automation through hardware & software development, in: Procedia Engineering. https://doi.org/10.1016/j.proeng.2013.01.082 Skibniewski, M.J., Chao, L., 2007. Evaluation of Advanced Construction Technology with AHP Method. J Constr Eng Manag. https://doi.org/10.1061/(asce)0733-9364(1992)118:3(577) Sonneborn, J., 2016. The Efficiency, Cost Savings and Sustainability Equation. https://www.sdcexec.com/home/article/12193183/the-efficiency-cost-savings-and-sustainability-equation (accessed 4.29.19). Teng, S.Y., How, B.S., Leong, W.D., Teoh, J.H., Siang Cheah, A.C., Motavasel, Z., Lam, H.L., 2019. Principal component analysis-aided statistical process optimisation (PASPO) for process improvement in industrial refineries. J Clean Prod 225, 359–375. https://doi. org/10.1016/J.JCLEPRO.2019.03.272 Touš, M., Pavlas, M., Putna, O., Stehlík, P., Crha, L., 2015. Combined heat and power production planning in a waste-to-energy plant on a short-term basis. Energy. https://doi.org/10.1016/j.energy.2015.05.077 Verrier, B., Rose, B., Caillaud, E., 2016. Lean and Green strategy: The Lean and Green House and maturity deployment model. J Clean Prod. https://doi.org/10.1016/j.jclepro.2015.12.022 Vyas, K.C., 2011. Toyota production system. The University of Texas at Austin. Wilson, D.R., Martinez, T.R., 2002. The need for small learning rates on large problems, in: IJCNN’01. International Joint Conference on Neural Networks. Proceedings (Cat. No.01CH37222). IEEE, pp. 115–119. https://doi.org/10.1109/IJCNN.2001.939002 Womack, J.P., Jones, D.T., 1996. Lean thinking: banish waste and create wealth in your corporation, Journal of the Operational Research Society. https://doi.org/10.1057/palgrave.jors.2600967 World Bank, 2019. Manufacturing, value added (current US$) | Data . https://data.worldbank.org/indicator/NV.IND.MANF.CD?end=2016&start=1997&view=chart (accessed 4.29.19). Yadav, A., Jayswal, S.C., 2013. Using geometric mean method of analytical hierarchy process for decision making in functional layout. Int J Eng Res Technol. |
URI: | https://mpra.ub.uni-muenchen.de/id/eprint/95449 |