A simulation based approach to realize green factory from unit green manufacturing processes

Guidelines for systematic analysis of manufacturing facilities, specifically the unit manufacturing processes are necessary to identify improvement opportunities. This work developed a practical approach to mathematically describe relationships between various process variables to energy consumption, waste reduction, and worker environment. Four unit manufacturing processes, viz., grinding, drilling, milling, and micro-EDM were modeled and their corresponding process parameters were optimized using Artificial Bee Colony algorithm (ABC) to improve the 'greenness' of these processes. A hypothetical flow shop facility comprising of these four optimized green unit manufacturing processes was modeled using Technomatix Simulation software. This flowshop was numerically simulated to realize a target throughput while minimizing environmental impacts, energy, and waste. The milling, drilling, grinding, and μ-WEDG process operating at green parameter settings demonstrated 29%, 16%, 31%, and 42% savings in energy respectively; resulting in a total saving of 28% in the variable energy of the overall factory. Also, the results demonstrated around 92% reduction in the usage of cutting fluids. Further, complete substitution of the non-biodegradable cutting fluids without compromising process parameters was also demonstrated.