Aluminium Green Supply Chain Ashwin Thottumkara Full Ppt

INTRODUCTION The supply chain has been traditionally defined as a one way, integrated

manufacturing process wherein raw materials are converted into final products, then delivered to customers.

Nowadays due to recent changing environmental requirements affecting

manufacturing operations, increasing attention is given to developing environmental management (EM) strategies for the supply chain.

GSCM is an integrating environment thinking into supply chain

management, including product design, material sourcing and selection, manufacturing processes, delivery of the final product to the consumers, and end-of-life management of the product after its useful life.

Flow chart: MANUFACTURES

DISTRIBUTORS

RETAILERS

CUSTOMERS

FACTORS DRIVE A COMPANY TO ADOPT GSCM Government Environmentally aware customer Market and competitor Company

DESIGNING THE GREEN SUPPLY CHAIN Distribution consumer

supplier

Manufacturer

Retailer

STAGES OF ENVIRONMENTAL MANAGEMENT 1. PROBLEM SOLVING

TRADITIONAL APPROACHES. VIEW

REGULATORY

COMPLIANCE

AS

A

BURDENSOME CAUSE OF DOING BUSINESS

2.MANAGING COMPLIANCE

FORPRIMITIVE ATTEMPT AT EM COORDINATION AND INTEGRATION, COMPLIANCE ORIENTED

3. MANAGING FOR ASSURANCE

VISIONARY/LONG RANGE PLANNERS UTILIZE

RISK

MANAGEMENT

TO

BALANCE

POTENTIAL FUTURE LIABILITIES VERSUS COSTS

4.

MANAGING

FOR

ECO-POLLUTION

PREVENTION

INSTEAD

EFFICIENCY

POLLUTION CONTROL

5. FULLY INTEGRATED

ENVIRONMENTAL QUALITY VIEWED ASPECT

OF

TOTAL

OF

AS AN QUALITY

MANAGEMENT(TQM) GLOBAL CONCERN ABOUT PROCESSES AND ENTIRE PRODUCT LIFE CYCLE

The Extended Supply Chain

THE EXTENDED SUPPLY CHAIN •

Environmental targets are to be added to economical targets .

•

The company target is to find the right balance between these two different dimensions, which often seem to be in contrast.

• The aim of the seminar is to show how these

two goals could be perceived simultaneously, driving the traditional business practice into new opportunities

ALUMINIUM SUPPLY CHAIN

INGOT  The costs that will be taken into account have been

attributed to the two different parties The refiner (r)  the component producer (p).  Different

cost

components

have

been

separated Costs for the aluminium alloy production (pr),  aluminium ingots solidification (is),  aluminium transport (tr),  aluminium ingots holding (ih),  aluminium ingots melting (im),  molten aluminium warm-up (wu)  , molten aluminium keeping (kp),  additional equipments depreciation (d)

considered

TRANSPORTATION For maximum delivery distance of 200 km in

numerical example, a distance of 100km determines a cost saving between 4% and 5% on the aluminium selling price (one ladle per day, i.e. 1500 ton/year) and 3–4% on the aluminium selling price (four ladles per day, i.e. 6000 ton/year). But, beyond the costs, the environmental impact needs to be taken into account

Environmental impact The environmental impact of the two alternative chains has been computed considering the following main pollutants: In the case examined, two main causes contribute to pollution: transport (T) and the re-melting (M) process in the component producer furnace. As far as the former is concerned, both levels and type of transport pollution depend on the combination of two additional factors: The type of transportation, i.e. the truck and its load, and the distance travelled

THE EMISSIONS (E) PRODUCED IN 1 YEAR FOR EACH POLLUTANT k.

D −3 Ek = eTk d + eFK D(120X 10 ) q

EMISSION LEVEL OF MOLTEN ALUMININUM

D −3 E k = eTk ' d + eFK D(10 X 10 ) q '

EMISSION LEVEL

ALUMINIUM MELTING EMISSION

PRODUCTION COST Production costs (the differential component considers only the ingot solidification process):

CIS = ∑i =1 ∑J =1 ∑t =1[ Ingotijt cIS ] N

M

T

TRASPORTATION COST Total transportation cost (both for molten and solid metal supply): Ingotijt T molten(ij ) CTR = ∑i =1 ∑ J =1 ( Tdij cTR + ∑t =1[ dij cTR]) q' q N

M

GREEN SUPPLY CHAIN

RESULTS

RESULTS

The green supply chain and product design 

Energy Efficiency



Product Packaging



Design for Upgradeability



Design for Recyclability



Materials Innovation

Bibliography • Bourke,

Richard and Kempfer, Lisa. “Achieving Success with Mass Customization: The Vital Contribution of Engineering.” Computer – Aided Engineering. (Oct 1999).

• Ham, Inyoung, Katsundo, Hitomi and Teruhiko,

Yoshida. Group Technology: Application to Production Management. Boston, MA: Hingham, 1985.

• Kroll, Denis and Wang, Xiaoli. “Using group

technology to improve quality and response time.” Industrial Management. (July 1994).

• Manocher, Djassemi. “An efficient CNC

programming approach based on group technology.” Journal of Manufacturing Systems. (2000).