M. Puviarasu, P. Asokan, S. Umar Sherif, K. Mathiyazhagan and P. Sasikumar
Increased demand for new batteries and strict government protocols have stressed the battery industries to collect and recycle used batteries for economic and environmental…
Abstract
Purpose
Increased demand for new batteries and strict government protocols have stressed the battery industries to collect and recycle used batteries for economic and environmental benefits. This scenario has forced the battery industries to collect used batteries and establish the formal battery recycling plant (BRP) for effective recycling. The starting of BRP includes several strategic decisions, one of the most critical decisions encountered is to find the best sustainable location for BRP. Hence, this paper aims to address the complexity of the issues faced during the BRP location selection through a hybrid framework.
Design/methodology/approach
In this study, the criteria are identified under socio-cultural, technical, environmental, economic and policy and legal (STEEP) dimensions through literature review and experts' opinions. Then, the hybrid methodology integrating fuzzy decision making trial and evaluation laboratory (DEMATEL), best worst method (BWM) and technique for order preference by similarity to an ideal solution (TOPSIS) has been proposed to find the inter-relationship between criteria, the weights of criteria and the best alternative.
Findings
The identified five main criteria and 26 sub-criteria have been analyzed through fuzzy DEMATEL, and found that the policy and legal criteria have more inter-relationship with other criteria. Then from BWM results, it is found that the support from government bodies has attained the maximum weightage. Finally, the second alternative has been identified as a more suitable location for establishing BRP using TOPSIS. Further, it is found from the results that the support from government bodies, the impact of emissions, availability of basic facilities and community health are the essential criteria under STEEP dimensions for establishing BRP.
Originality/value
In addition to the various existing sustainable criteria, this study has also considered a set of policy and legal criteria for the evaluation of locations for BRP. Further, the hybrid MCDM method has been proposed in this study for selecting the best alternative. Thus, this study has yielded more insights to the decision-makers in choosing a sustainable location for BRP.
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B.G. Aadithya, P. Asokan and S. Vinodh
This research aims to identify lean tools and techniques that are needed to be implemented to improve the performance in the fabrication industry. The objective is to find the…
Abstract
Purpose
This research aims to identify lean tools and techniques that are needed to be implemented to improve the performance in the fabrication industry. The objective is to find the wastes in manufacturing processes using value stream mapping (VSM) and prioritize the lean tools suitable to enable the attainment of leanness and streamline the processes.
Design/methodology/approach
VSM tool is applied in the industry to construct the current state map, identify improvement proposals and implement in future state. Fuzzy technique for order performance by similarity to ideal solution (TOPSIS), a multi-criteria decision-making technique (MCDM), is used to prioritize the identified improvement proposals. This study observed that mistake-proof processing and layout organization are the two techniques with the top priority that needs further improvement to enhance the leanness of the organization.
Findings
Upon successful implementation, the cycle time is reduced by 14.97%, and total inventory is reduced by 45.67% which leads to the improvement of value addition from 5.88 to 9.21%. Although lean has been adopted for many years, implementation of lean in the fabrication industry has been limited.
Practical implications
This study addresses the challenges in terms of implementing lean in fabrication industries and practical implications of lean tools and techniques and the prioritization of lean concepts against various lean criteria to enable leanness.
Originality/value
The deployment of improvement prioritization tool integrated with VSM in the context of a fabrication industry is the original contribution of the authors.
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Ben Ruben R., S. Vinodh and Asokan P.
The study aims to describe the development of a structural measurement model using structural equation modeling technique to validate the association that exists between Lean Six…
Abstract
Purpose
The study aims to describe the development of a structural measurement model using structural equation modeling technique to validate the association that exists between Lean Six Sigma (LSS) and sustainable manufacturing strategies.
Design/methodology/approach
Both LSS and sustainable manufacturing aim at improving the firm’s business competitiveness which forms a strategic link that benefits the manufacturing organizations. The study aims to investigate the relationship among constructs that leads to operational excellence while deploying LSS and sustainable manufacturing strategies in organizations.
Findings
Empirical data needed for the study are collected from experts belonging to various industries that are implementing both LSS and sustainable manufacturing practices. Later statistical estimates (hypotheses) are being formulated to confirm the developed measurement model. Based on the obtained results after analysis of the structural model, the statistical estimate is either being accepted or rejected. Results of this study reveal that there exists a strong correlation between LSS and sustainable manufacturing factors that leads to organizational performance.
Research limitations/implications
Additional indicators could be included to deal with technological advancements in sustainable manufacturing.
Practical implications
The study has been done with regard to Indian automotive component manufacturing organizations scenario. Hence, the inferences derived have practical relevance.
Originality/value
The development of structural model for the Lean Six Sigma system with sustainability considerations is the original contribution of the authors.
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Rohit Agrawal, P. Asokan and S. Vinodh
The purpose of this paper is to present a study that is focused on application of fuzzy logic and adaptive neuro-fuzzy inference system (ANFIS) approaches for leanness evaluation…
Abstract
Purpose
The purpose of this paper is to present a study that is focused on application of fuzzy logic and adaptive neuro-fuzzy inference system (ANFIS) approaches for leanness evaluation in an Indian small- and medium-size enterprise (SME).
Design/methodology/approach
Lean manufacturing concepts are being adopted by SMEs to sustain in the competitive manufacturing landscape. Performance of lean system needs to be assessed using appropriate methods. A model for measuring lean performance is proposed with five enablers, 30 criteria and 90 attributes. Leanness index is computed using fuzzy logic approach and benchmarked with ANFIS approach.
Findings
Leanness index computed using fuzzy logic approach is found to be (4.47, 5.97, 7.55) and that of ANFIS approach is found to be 5.84 to facilitate benchmarking of leanness evaluation. After finding weaker areas, certain improvement initiatives are being deployed.
Research limitations/implications
The developed model for leanness evaluation has been test implemented in an SME. In future, the model could be test implemented in several SMEs.
Practical implications
A case study conducted in an SME involved in heavy engineering fabrication is presented. Therefore, the inferences derived from the study has practical propensity.
Originality/value
The development of leanness evaluation model for SMEs and deployment in an industrial scenario are the original contributions of the authors.
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Aadithya B.G., Asokan P. and S. Vinodh
The purpose of the paper is to depict a study on analysis of barriers to lean adoption in fabrication industry using interpretive structural modelling (ISM).
Abstract
Purpose
The purpose of the paper is to depict a study on analysis of barriers to lean adoption in fabrication industry using interpretive structural modelling (ISM).
Design/methodology/approach
From the literature review, 22 barriers to lean adoption in fabrication industry have been recognized . Self-structure interaction matrix has been developed based on expert opinion. Computational steps of ISM are being done to develop the structural model. cross-impact matrix multiplication applied to classification (MICMAC) analysis is being done to group the barriers into four types.
Findings
Based on the study, it has been found that “lack of knowledge about lean (philosophy, principles, tools)”, “lack of top management support and commitment” and “poor leadership” are found to be the principal barriers. MICMAC analysis indicated that number of driving, dependent, linkage and autonomous barriers are 9, 8, 4 and 1, respectively.
Practical implications
The study has been executed based on the inputs from industrial practitioners and hence the inferences are found to have practical relevance.
Originality/value
The study is an attempt to analyze the barriers for lean concepts adoption in fabrication kind of industry.
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S. Umar Sherif, P. Sasikumar, P. Asokan and J. Jerald
Due to the economic benefits and environmental awareness, most of the battery manufacturing industries in India are interested to redesign their existing supply chain network or…
Abstract
Purpose
Due to the economic benefits and environmental awareness, most of the battery manufacturing industries in India are interested to redesign their existing supply chain network or to incorporate the effective closed loop supply chain network (CLSCN). The purpose of this paper is to develop CLSCN model with eco-friendly distribution network and also enhance recycling to utilize recycled lead for new battery production. The existing CLSCN model of a battery manufacturing industry considered for case study is customized for attaining economic benefit and environmental safety. Hence, single objective, multi-echelon, multi-period and multi-product CLSCN model with centralized depots (CD) is developed in this work to maximize the profit and reduce the emission of CO2 in transportation.
Design/methodology/approach
The proposed CD has the facility to store new batteries (NB), scrap batteries (SB) and lead ingot. The objective of the proposed research work is to identify potential location of CD using K-means clustering algorithm, to allocate facilities with CD using multi-facility allocation (MFA) algorithm and to minimize overall travel distance by allowing bidirectional flow of materials and products between facilities. The proposed eco-friendly CLSCN-CD model is solved using GAMS 23.5 for optimal solutions.
Findings
The performance of the proposed model is validated by comparing with existing model. The evaluation reveals that the proposed model is better than the existing model. The sensitivity analysis is demonstrated with different rate of return of SB, different proportion of recycled lead and different type of vehicles, which will help the management to take appropriate decision in the context of cost savings.
Originality/value
This research work has proposed single objective, multi echelon, multi period and multi product CLSCN-CD model in the battery manufacturing industry to maximize the profit and reduce the CO2 emission in transportation, by enhancing the bidirectional flow of materials/products between facilities of entire model.
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Ben Ruben R., S. Vinodh and Asokan P.
The contemporary manufacturing organizations recognize the importance of lean manufacturing as a tool to eliminate wastes, streamline processes and improve value addition. On the…
Abstract
Purpose
The contemporary manufacturing organizations recognize the importance of lean manufacturing as a tool to eliminate wastes, streamline processes and improve value addition. On the other hand, such organizations also focus on the development of ecofriendly products and processes. In this context, lean manufacturing concepts provide a pathway for attaining sustainable benefits. This paper aims to present the state of art review on lean and sustainable manufacturing.
Design/methodology/approach
A total of 80 research papers on lean and sustainable manufacturing from various perspectives have been reviewed and their contributions are being presented. The perspectives include origin, definition, decision-making, performance measurement, product development and application for both lean and sustainable manufacturing.
Findings
Findings from the literature prove that both lean and sustainable manufacturing systems aim at improving the organizational performance and provide both operational and sustainable benefits. Also based on the studies, it has been found that integrated lean sustainable manufacturing system can be defined as a system that creates value for the customers by eliminating wastes consistently and adopting processes that are ecofriendly, economically viable and safe for the employees to produce green products that enhance the social performance.
Research limitations/implications
The present review considers the papers on lean and sustainable manufacturing based on certain perspectives. Peer-reviewed journal articles, and books are only being considered and reviewed. Articles and information from dissertation thesis, unpublished working papers and conference proceedings were excluded. In future, the study can be enhanced by considering more such perspectives that reflect the ideology and applicability of the selected themes. The practical perspectives of lean and sustainable manufacturing and their integration are also being presented.
Originality/value
This paper presents a review of lean and sustainable manufacturing and provides insights from different perspectives. The scope for their integration is also discussed. The contributions are original.
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B.G. Aadithya, P. Asokan and S. Vinodh
The purpose of this paper is to report a review of various perspectives of lean in heavy engineering and fabrication industries and to propose a framework.
Abstract
Purpose
The purpose of this paper is to report a review of various perspectives of lean in heavy engineering and fabrication industries and to propose a framework.
Design/methodology/approach
Lean manufacturing (LM) earlier known as Toyota Production System (TPS) was mainly used by automobile industries where the operations occur in sequence and the adoption of LM was easier. When it comes to heavy engineering industries, the concept of lean can be adopted in a versatile operating environment to have more advantages by waste elimination thereby having higher profit. Thus, an effort is made to consolidate various lean perspectives, namely, barriers, principles, tools and performance measures and a framework was proposed on how various lean perspectives can be adopted in a systematic way.
Findings
A comprehensive analysis of lean from various perspectives from viewpoint of the fabrication industry are done and the review is presented. Also, the framework linking barriers, principles, tools and performance measures is being contributed as an outcome of the review.
Originality/value
The review of lean from various perspectives for the fabrication industry and the development of a framework is the original contribution of the authors.
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Ben Ruben R., Vinodh S. and Asokan P.
The purpose of this study is to prioritize and analyze the barriers that affect Lean Six Sigma (LSS) adoption with environmental considerations.
Abstract
Purpose
The purpose of this study is to prioritize and analyze the barriers that affect Lean Six Sigma (LSS) adoption with environmental considerations.
Design/methodology/approach
To find interrelationships and mutual influences among the identified barriers, an integrated interpretive structural modeling (ISM) and Fuzzy MICMAC (Matrice d’Impacts Croisés Multiplication Appliqués à un Classement approach was applied). In total, 20 crucial barriers that affect LSS adoption with environmental considerations have been derived from the literature and in consultation with experts hailing from the industry and academia.
Findings
Based on the analysis, the most dominant and dependent barriers that affects LSS adoption with environmental considerations have been identified. The barriers, namely, “lack of top management commitment”, “lack of training and education” and “lack of funds for green projects”, occupy the base segment of the ISM hierarchy; the barriers, namely, “difficulty in adopting environmental strategies”, “stringent government policies”, “negative attitude towards sustainability concepts”, “improper communication” and “lack of defect monitoring analysis”, occupy the top level of the ISM hierarchy.
Practical implications
The analysis helped in identifying and prioritizing the barriers that affect LSS adoption with environmental considerations using a mathematical approach. This approach is also helpful for practitioners to focus on removing the key dominant barriers and to enable LSS adoption with environmental considerations smoothly.
Originality/value
The analysis helped in identifying and prioritizing the barriers that affect LSS adoption with environmental considerations using the Fuzzy MICMAC approach which has not been attempted in the past. The structural model is developed holistically based on the inputs gathered from practitioners and academicians to ensure practical validity. Also, this approach is helpful for practitioners to focus on removing the key dominant barriers and enabling them to deploy LSS concepts with environmental considerations smoothly.
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Aissa Boucedra and Madani Bederina
This study aims to the framework of the development of a new sand concrete, essentially manufactured with river/dune sand and recycled plastic aggregates (PAs; 0/3.15 mm). This…
Abstract
Purpose
This study aims to the framework of the development of a new sand concrete, essentially manufactured with river/dune sand and recycled plastic aggregates (PAs; 0/3.15 mm). This new concrete may have a great interest, as it can enable us to achieve the best economical, technical and ecological solutions for local construction problems. Given the high abundance of dune sand (DS) and the large quantities of plastic waste, plastic–mineral sand concrete can be a good alternative to the ordinary building materials available on the local market.
Design/methodology/approach
A replacement of sand by PAs is made by volume substitution. The plastic percentages laid down are 0%, 25%, 50% and 100%. Indeed, after a general experimental characterization of the studied composites, the investigation mainly concentrated on the study of the effect of the addition of plastic particles on the accelerated carbonation of river sand (RS) concrete and DS concrete, separately.
Findings
The density of the composites and consequently their compressive strength are slightly reduced; but their thermal insulation is significantly improved. Their structure seems to be homogeneous, the plastic grains are well distributed in the matrix and the adhesion “plastic–matrix” is good. At small plastic contents, the RS concrete is slightly better. As regards the carbonation results, the PAs significantly contribute to the improvement of the resistance of the composite against carbonation effect. It can be observed that increasing the proportion of plastic particles in sand concrete considerably decreases the thickness of the carbonated concrete.
Originality/value
The studies led on the behavior of plastic concrete, particularly in arid zones, are very limited. Moreover, for sand concrete, there are no similar studies. Therefore, the characterization of such materials is necessary. In addition of thermo-mechanical characterization, this work aims at studying the durability of the material, especially its resistance to carbonation. On the other hand, this work has a significant positive impact on both environment and economy, since it focuses on the recycling of industrial waste, and the valorization of DS, which is available in great quantities in south of Algeria.