DEVELOPMENT OF AN INTEGRATED SUSTAINABLE MANUFACTURING ASSESSMENT FRAMEWORK FOR TURNING PROCESS NEERAJ BHANOT

Transcription

1 DEVELOPMENT OF AN INTEGRATED SUSTAINABLE MANUFACTURING ASSESSMENT FRAMEWORK FOR TURNING PROCESS NEERAJ BHANOT DEPARTMENT OF MECHANICAL ENGINEERING INDIAN INSTITUTE OF TECHNOLOGY DELHI JULY 2017

2 Indian Institute of Technology Delhi (IITD), New Delhi, 2017

3 DEVELOPMENT OF AN INTEGRATED SUSTAINABLE MANUFACTURING ASSESSMENT FRAMEWORK FOR TURNING PROCESS by NEERAJ BHANOT DEPARTMENT OF MECHANICAL ENGINEERING Submitted In fulfillment of the requirement of the Degree of Doctor of Philosophy to the INDIAN INSTITUTE OF TECHNOLOGY DELHI JULY 2017

4 CERTIFICATE This is to certify that the thesis titled Development of an Integrated Sustainable Manufacturing Assessment Framework for Turning Process, submitted by Neeraj Bhanot, to the Indian Institute of Technology, Delhi, for the award of the degree of Doctor of Philosophy in Mechanical Engineering is a bonafide record of original research work carried out by him under our supervision in conformity with the rules and regulations of the institute. The results presented in this thesis have not been submitted, in part or full, to any University or Institute for the award of any degree or diploma. Prof. P. Venkateswara Rao Professor Department of Mechanical Engineering Indian Institute of Technology Delhi New Delhi , India Prof. S. G. Deshmukh Professor Department of Mechanical Engineering Indian Institute of Technology Delhi New Delhi , India

5 ACKNOWLEDGEMENTS I wish to express my sincere regards to my supervisors Prof. P. Venkateswara Rao and Prof. S.G. Deshmukh for their invaluable support throughout my PhD journey making me capable of pursuing research work with a focus on always exploring new dimesnions and providing insights into the domain. Their guidance and consistent academic and personal support have helped me to complete my research work smoothly and finally submission of my thesis. I also extend my gratitude towards my committee members Prof. M.S. Kulkarni, Prof. Sudarsan Ghosh, Prof. S.P. Singh and Prof. D. Ravi Kumar for their valuable comments and careful review of my work. I also want to thank all the staff members Mr. Subhash Chand, Mr. Manoj Kumar Tinnu, Mr. N.S. Negi, Mr. Naveen, Mr. Mangal, Mr. Sharma, Mrs. Rekha, Mr. Kadeem, Mr. Sandeep and Ms. Mohini of the Department of Mechanical Engineering at IIT Delhi, for their infinite enthusiasm and unreserved support throughout my time there. My research work included two important phases being survey between researchers and practitioners; and experimental work in order to develop a sustainability assessment framework for turning process. In order to conduct the survey, the initial support from supervisors helped alot in getting the responses from researchers around the world. In this phase, I also got an opportunity to interact with eminent researchers from USA, Germany, UK, Italy, Australia, etc. and helped in developing coordial relations with them. I am also really thankful to Prof. Jasmaninder Singh Grewal (GNDEC, Ludhiana), Mr. Amrinder Singh (my M.Tech student) and Mr. Dhaminder Singh (my B.Tech student) who helped me selflessly to collect the quality data from practitioners in order to complete the survey timely. I also wish to thank the industry colleagues who generously shared time and experience with me. In addition to this, the support from Prof. P.N. Rao (University of Northern Iowa, USA) and Prof. Sudarsan Ghosh is highly appreciable in finalising the sustainability assessment framework for turning process. I want to thank my peer research group seniors Dr. Avinash Samvedi, Dr. Gajanan Panchal, Dr. Mohammad Asjad, Mr. Vedpal, Mr. Ashutosh, Mr. Dinesh Setti, Mr. Anirban Kundu, Mr. Amit Upadhyay, Mr. Umang Soni, Mr. Manoj Sinha, Mr. Sumit i

6 Sakhuja and Mr. Pankaj Zine for their suggestions and support. I also want to thank my research group colleagues Mr. Bikash Behera, Mr. Anil, Mr. Umesh Khande, Mr. Chetan, Mr. Vishal, Mr. Habtamu Alemayehu, Mrs. Meenakshi and Mr. Khelraj Pandey for their timely help and support. Thanks are also expressed to graduate students Mr. Rakshit Gautam for helping me with python programming whenever I was stuck into it and Mr. Rajan for all the support in arranging last minute help for any issue relevant to hostel and personal work. I could not have enjoyed my research work without motivational and interdisciplinary friends. I want to express my heartiest thanks to Mr. Sandip Datta (Humanities), Mr. Sitakanta Panda (Humanities), Mr. Deep Kiran (Electrical), Mr. Gopinath Rangoli (Civil), Mr. Rituraj (Chemistry), Ms. Assia Kenbari (Exchange Student from France), Mr. Udayraj, Mr. Vipul Patel and Mr. Simranjit Singh for having spent such a wonderful time with me. In addition to this, I am also thankful to Mr. Rakesh Sharma (Station Superintendent at New Delhi Railway Station) for all his support in my PhD journey. I have no words to express my sincere gratitude to my father, Mr. Harsh V Bhanot; mother, Mrs. Shashi Bhanot; brother, Rishabh Bhanot; and my better half, Upasna Sharma for all their support without which I could not have completed my work. They happily permitted me to focus all my attention on my research work and continuously provided me the encouragement to complete my PhD. I also cherish my friendship with Manjit Singh, Bhawna and their baby iku for all the moments spent together. Last but certainly not the least, I am thankful to IIT Delhi, for providing me the academic environment where one feels motivated for learning. Neeraj Bhanot ii

7 ABSTRACT Sustainable Supply Chain Management has been well documented in the literature by various researchers in different contexts. However, it becomes a huge challenge for the working professionals when its implementation aspects are considered in the supply chain. India stands amongst the largest economies in the world and is expected to grow rapidly over the next two decades. But with the growth in the economy, India is bound to experience increase in demand for materials and energy, putting severe constraints on natural resources such as land, water, minerals, etc. Moreover, the increased burden on natural resources will increase waste and pollution level, which can ultimately restrict India s ability to grow, rendering its momentum unsustainable. This study hence focuses on Indian Manufacturing Sector and intends to propose a comprehensive sustainability assessment framework for turning process considering cost and quality issues in tooling, processes and material aspects. For this, the initial part of the study systematically analyzes the published sustainable supply chain literature from different perspectives. It further compiles and categorizes various published definitions of sustainability specifically concerning supply chain and its different facets (manufacturing, transportation, logistics, packaging, etc.). In particular, the review focuses on developing critiques of all the definitions to address critical research issues and develop a comprehensive definition for implementing sustainability aspects in the supply chain in the form of Sustainable Scenario. This study then presents the opinions of various researchers and practitioners on critical enablers, barriers, and manufacturing indicators based on the questionnaire survey and hence, analyze them using statistical techniques (Independent t-test) to highlight the differences in opinions of both groups for strategic implementation of SM. Ten critical enablers & barriers each and thirteen indicators of Sustainable manufacturing (SM) were identified from literature review and based on the interrelationships considering the responses from researchers and practitioners, Decision making Trial and Evaluation Laboratory (DEMATEL) approach has been applied to deal with the importance and causal relationships. A theoretical method, maximum mean de-entropy algorithm iii

8 (MMDE) based on the entropy approach has further been used to select the threshold value to integrate Interpretive Structural Modeling (ISM) approach to develop a hierarchical structure of the complex system. However, just before the application of ISM technique, Structural Equation Modeling (SEM) technique has been applied to provide a statistically valid causal model for both the groups to devise suitable mechanisms so that the differences in opinions of both the groups can be minimised to some extent. Based on the list of indicators developed above, this study presents a sustainability assessment framework for turning process and validates it using case study focussing one of the leading automobile manufacturing organization. Turning experiments to replicate the industrial process using carbide inserts and AISI-4140 Alloy steel have been conducted in the lab on CNC machine considering full tool-wear criteria under dry and wet cutting conditions to develop comprehensive sustainability assessment framework. It is clarified that some values of metrics such as insert cost, raw material cost, etc. have been considered from the case industry while others such as cutting forces, surface roughness, etc. have been assessed experimentally. However, indicators such as tooling cost, material cost, etc. per processed component incurred to the company have been derived using empirical relations for all the iterations of Taguchi s array design. Finally, Grey Relational Analysis (GRA) has been applied to convert multi-objective optimization problem into single objective to get optimal process parameters by particle swarm optimization (PSO). It also presents an interactive social sustainability assessment framework prepared after consultation with manufacturing industries to make it easy for them to implement and enhance their sustainable performance. Finally, this study identifies important measures from both groups to enhance the performance of turning process. An open-ended question had been put up to the respondents in both groups in the form of suggestions for initiatives by which sustainability issues can be implemented in turning process to which good number of responses had been received and suitably analyzed by data mining techniques (Python) and online word processing tool (Wordle) to highlight important suggestions put forth by both groups and simultaneously looking for difference in their opinions. iv

9 स र व व न न स द म व व न न श धकर ओ द व र सर र आप वर श र खल प रब धन स व त य म अच छ र र स प रल वखर वकय गय ल वक, य क म कर र प श र क वलए एक बड च न र बन ज र जब इसक क य न यन क प ल ओ क आप वर श र खल म म न ज र रर द वनय क सबस बड अर व य स र ओ म स एक और अगल द दशक म र ज स बढ न क उम म द ल वकन अर व य स र म रव क स र, रर स मव य और ऊज क म ग म रव क अन करन क वलए ब ध य, प र कर वर क स स धन ज स जम न, प न, खवनज आवद पर ग र ब ध ए ड लर इसक अल, प र कर वर क स स धन पर बढ ए ब झ अपवशष ट और प रद षण म रव ग स र र, ज अ र र बढ न क रर क क षमर क स वमर कर सकर, वजसस इसक गवर वस र र न सकर इसवलए य अध ययन रर य व वनम ण क ष त र पर क व र और ट वल ग, प रव य ओ और वर क प ल ओ म ल गर और ग ण त त क म द द पर प रव य क बदलन क वलए एक व य पक वस र रर म लय कन ढ च क प रस र करन च र इसक वलए, अध ययन क प र र व क ग अलग-अलग द वष टक ण स प रक वशर वटक ऊ आप वर श र खल स व त य क व य वस र र र प स व श ल षण करर य आग क आप वर श र खल और इसक व व न न प ल ओ (व वनम ण, परर न, रसद, प क वज ग, आवद) स स ब वधर व श ष र प स वस र रर क व व न न प रक वशर परर ष ओ क स कवलर और श ण ब करर व श ष र प स, सम क ष स म त प ण परर ष ओ क आल चक क व कवसर करन क वलए म त प ण अन स ध न म द द क स ब वधर करन और "सर र पररद श य" क र प म आप वर श र खल म वस र रर प ल ओ क ल ग करन क वलए एक व य पक परर ष व कवसर करन पर क व र य अध ययन प रश न ल स क षण क आध र पर म त प ण समर क, ब ध ओ और व वनम ण स क र क पर व व न न श धकर ओ और वचवकत सक क र य प रस र र करर और इसवलए उन स मररक र कन क क वलए द न सम क व च र म मर द क उज गर करन क वलए स वययक य र कन क (स र त र ट -पर क षण) क व श ल षण करन एसएम क क य न यन स र ई वनम ण (एस.एम.) क प रत य क और र र स क र क क स व वत यक सम क ष स और श धकर ओ और वचवकत सक क प रवर व य ओ पर व च र करन ल अ र स ब ध क आध र पर दस म त प ण समर क और ब ध ए, वनण य ल न क पर क षण और म लय कन प रय गश ल (ड म टल) द वष टक ण ल ग वकय गय म त और

10 क रण स ब ध एक स वर क व वध, ए ट र प द वष टक ण क आध र पर अवधकर म अर ड -एन ट र प एलग ररथ म (एमएमड ई) जवटल प रण ल क पद न वमर ढ च क व क स करन क वलए व य यय त मक स ट रक चरल म डवल ग (आईएसएम) द वष टक ण क एक कर र करन क वलए थ र श लड म न क चयन करन क वलए आग क उपय ग वकय गय ल वक, आईएसएम र कन क क प रय ग स प ल, स रचन त मक सम करण म डवल ग (एसईएम) र कन क द न सम क वलए उपय क त र त र र य र करन क वलए एक स वययक य र प स उवचर क रण म डल प रद न करन क वलए ल ग वकय गय र वक द न सम क व च र म मर द क क छ कम वकय ज सक उपर क त व कवसर स क र क क स च क आध र पर, इस अध ययन म प रव य क बदलन क वलए एक वस र रर म लय कन ढ च प रस र र वकय गय और य म मल क एक अ ण ऑट म ब इल म न य फ क चरर ग स गठन पर ध य न क व र कर अध ययन क म ध यम स प वष ट करर प रय गश ल म प रय गश ल म क ब इड आ षण और एआईएसआई-4140 वमश ध र स ट ल स एनस मश न क उपय ग करक स ख और ग ल क टन क वस र वर क र र प र उपकरण क व सन क म पद ड पर व च र करन क वलए व य पक वस र रर म लय कन ढ च क व क स वकय गय य स पष ट वकय ज र वक ड लन क ल गर, कच च म ल क ल गर आवद ज स म वट रक क क छ म लय क म मल क उद य ग स म न गय जबवक अन य ज स वक क टन ल बल, सर ख रदर पन आवद क प रय ग प र य वगक र प स वकय गय ल वक, कम पन क वलए प रस स कर र टक प रवर ट वल ग ल गर, स म ल गर इत य वद ज स स क र क क ट ग च क सर चन वडज इन क स प नर रवत तय क वलए अन जन य स ब ध क उपय ग करक प र प त वकय गय अ र म, ररल शनल एन वलवसस (ज आरए) क ब -उद द श य अन क लन समस य क कण झ ड ऑवटटम इज शन (प एसओ) द व र इष टर म प रव य प र म टर प र प त करन क वलए एकल उद द श य म परर वर र करन क वलए ल ग वकय गय य एक इ टर वक ट स म वजक वस र रर आकलन क ब द व वनम ण उद य ग क स र पर मश स ल ग करन और उनक स र य प रदश न क बढ न क वलए बन न क वलए र य र र पर ख प रस र र करर अ र म, य अध ययन प रव य क म ड क प रदश न क बढ न क वलए द न सम स म त प ण उप य क प च न करर एक ओपन ए ड ड प रश न प छ गय वजसक द व र प रव य क वलए वस र रर क म द द क प च न ज सकर, ज अच छ स यय म प रवर व य ओ और ड ट खनन र कन क द व र वकय गय उवचर व श ल षण (द न सम क उत तरद र ओ क र प म प यर न द व र स झ ) और ऑनल इन शब द प र स वस ग ट ल ( ड ल) द न सम क स र उनक र य म म त प ण अ र र द न क वलए प र प त वकय गय र

11 TABLE OF CONTENTS ACKNOWLEDGEMENTS ABSTRACT LIST OF TABLES LIST OF FIGURES ABBREVIATIONS NOTATIONS i iii xiv xvii xvii xx 1 INTRODUCTION Sustainable Supply Chain Management: A Bibliometric Analysis Sustainable Manufacturing and Its Importance in Supply Chain Motivation for Research Organization of Thesis Summary LITERATURE REVIEW Introduction Literature in Review Category Literature in Theory Building: Indicators and Frameworks Category Literature in Performance Evaluation and Optimization Category Global Reporting Initiative s Framework Observations from Literature Research Gaps Objectives of Research Flowchart of Proposed Research Work Summary v

12 3 SUSTAINABLE SUPPLY CHAIN MANAGEMENT: REVIEW PERSPEC- TIVES AND AGENDA FOR RESEARCH Introduction Review Methodology Analysis of Sustainability Literature through Systematic Review Analysis of Sustainable Supply Chain Definitions in various contexts General Definitions of Sustainability Insights Gained from General Definitions Specific Definitions of Sustainability relevant to Supply Chain Insights Gained from Specific Definitions Research Issues Need for a conceptual model Summary IDENTIFYING CRITICAL ENABLERS, BARRIERS, AND INDICA- TORS OF SUSTAINABLE MANUFACTURING Introduction Technological Initiatives and Policy Analysis for Sustainable Manufacturing Literature for critical Enablers, Barriers, and Indicators of Sustainable Manufacturing Enablers of Sustainable Manufacturing Barriers of Sustainable Manufacturing Indicators (and Metrics) of Sustainable Manufacturing Economic Dimension Environmental Dimension Social Dimension Remarks Hypothesis Testing Based on Responses of Researchers and Practitioners Survey Methodology Survey Analysis for Enablers and Barriers Descriptive Statistics vi

13 Independent t-test for Comparison of Means Effect Size to assess Mean Differences Enablers and Barriers with No Significant Difference Enablers and Barriers with Significant Difference Survey Analysis for Sustainable Manufacturing Indicators (and Metrics) Related Literature on Application of Structural Equation Modeling in Manufacturing Domain Hypothesis Formation Structural Equation Modeling Reliability Analysis Hypothesis Testing for Significant Relations for Sustainable Turning Process Discussion on Researcher s Scenario Discussion on Practitioners Scenario Remarks Causal Models for Enablers, Barriers, and Indicators Based on Responses of Researchers and Practitioners Methodology Decision making Trial and Evaluation Laboratory Maximum Mean De-Entropy Algorithm Structural Equation Modeling Analysis Interpretive Structural Modeling Causal Models for Enablers of Sustainable Manufacturing Comparative Analysis for Enablers between Researchers and Practitioners Discussion on Similar Significant Relationships Between Enablers in both groups Discussion on Different Significant Relationships Between Enablers in both groups Causal Models for Barriers of Sustainable Manufacturing Comparative Analysis for Barriers between Researchers and Practitioners Discussion on Similar Significant Relationships Between Barriers in both groups vii

14 Discussion on Different Significant Relationships Between Barriers in both groups Causal Models for Indicators of Sustainable Manufacturing Comparative Analysis for Indicators between Researchers and Practitioners Discussion on Similar Significant Relationships Between Indicators in both groups Discussion on Different Significant Relationships Between Indicators in both groups Remarks Summary DEVELOPING A SUSTAINABILITY ASSESSMENT FRAMEWORK FOR TURNING PROCESS Introduction Methodology for Sustainability Assessment Framework Dimension-wise Sustainability Assessment for Turning Process Assessment for Economic Dimension Assessment for Environmental Dimension Assessment for Social Dimension Grey Relational Analysis Particle Swarm Optimization Illustration of Economic and Environmental models Results and Discussion Economic Index for Turning Process in Wet and Dry Machining Scenario s Results of Economic Indicators in both Machining Scenario s Grey Relational Analysis of Economic Indicators in both Machining Scenario s Comparative Analysis Between both Machining Scenarios for Economic Indicators Environmental Index for Turning Process in Wet and Dry Machining Scenario s Results of Environmental Indicators in both Machining Scenario s viii

15 Grey Relational Analysis of Environmental Indicators in both Machining Scenario s Comparative Analysis Between both Machining Scenarios for Environmental Indicators Social Index Summary IDENTIFYING PERSPECTIVES FOR SUSTAINABILITY ENHANCE- MENT: A TEXT MINING APPROACH Introduction Literature on Text Mining techniques in Manufacturing Domain Research Methodology Data Collection Data Preparation for Text Analysis Text Mining Approaches Principal Component Analysis K-Means Clustering Algorithm Data Visualization Results and Discussions Analysis on the basis of Researcher s Measures Analysis on the basis of Practitioners Measures Summary SUSTAINABLE MANUFACTURING ASSESSMENT MODEL: TEM- PLATES FOR PRACTITIONERS Template for Enhancing Knowledge on Various Aspects of Sustainable Manufacturing Template for Assessing Sustainability of Turning Process Summary SUMMARY AND CONCLUSIONS Summary of the Work Done Novelty of Research Work Limitations and Scope for Future Work Concluding Remarks ix

16 APPENDIX A First and Second Stage Questionnaire Surveys 302 APPENDIX B Survey Responses for Researchers and Practitioners 316 APPENDIX C Survey Data Results for Enablers, Barriers, and Indicators 324 C.1 Researchers based analysis of Enablers C.2 Practitioners based analysis of Enablers C.3 Researchers based analysis of Barriers C.4 Practitioners based analysis of Barriers C.5 Researchers based analysis of Indicators C.6 Practitioners based analysis of Indicators APPENDIX D Economic and Environmental Analysis for Turning Process 348 D.1 Experimental Operating Conditions D.2 Experiment for Validating Framework D.3 Analysis of Economic Indicators for Wet and Dry Turning Process. 353 D.4 Analysis of Environmental Indicators for Wet and Dry Turning Process 355 D.5 Plots for Economic Variables D.6 Plots for Environmental Variables APPENDIX E Feature Vectors of different Words for both groups 362 APPENDIX F List of Publications Based on Thesis 365 APPENDIX G Biography of Researcher 367

17 LIST OF TABLES 1.1 Publication Count with Highest Citation Record in Different Journals Metrics used by some Manufacturing Companies Manufacturing - Value Added (% of GDP) Summary of Review Category Summary of Theory Building Category Summary of Optimization Category Category-wise Observations from Literature Identified Gaps from Literature Categories Methodologies for Addressing Various Gaps Research Publications in Different Subject Areas ( ) Key Findings based on analysis of Top 10 cited Review Articles Journals referred for Sustainability Definitions General Definitions of Sustainability Specific Definitions of Sustainability Enablers of Sustainable Manufacturing Barriers of Sustainable Manufacturing Manufacturing Parameters in Economic Dimension Manufacturing Parameters in Environmental Dimension Manufacturing Parameters in Social Dimension Group Statistics of Enablers and Barriers for Sustainable Manufacturing Comparing Enablers in both groups by Independent t-test Comparing Barriers in both groups by Independent t-test Discussion on Enablers with No Significant Difference Discussion on Barriers with No Significant Difference Discussion on Enablers with Significant Difference Discussion on Barriers with Significant Difference SEM Based Significant Relations for Sustainable Turning Process. 115 xi

18 4.14 MMDE and SEM Results for Enablers by Researchers and Practitioners Goodness-of-Fit Statistics for Enablers of S.M MMDE and SEM Results for Barriers by Researchers and Practitioners Goodness-of-Fit Statistics for Barriers of S.M MMDE and SEM Results for Indicators by Researchers and Practitioners Goodness-of-Fit Statistics for Indicators of S.M Experimental Set-up used for Machining Analysis Illustration for calculating Economic and Environmental Indicators Optimizing Economic Performance Without Constraint Optimizing Economic Performance With Constraint Optimizing Environmental Performance Without Constraint Optimizing Environmental Performance With Constraint Assessment of Social Indicators for Turning Process Social Sustainability Index based on GRA values for Turning Process Literature Summary for Text Mining Applications Eigen values for Principal Components as per Researchers Words and Labels for Researcher s Clusters Eigen values for Principal Components as per Practitioners Words and Labels for Practitioners Clusters Features of Integrated Sustainable Manufacturing Model Template for Enhancing Practitioner s Knowledge on SM Aspects Empirical Relations for Economic and Environmental Indicators (T 1 ) Template for Assessing Economic Sustainability (T 2 ) Template for Assessing Environmental Sustainability (T 3 ) Template for Collecting Responses on Social Indicators (T 4 ) Template for Assessing Social Sustainability (T 5 ) Hierarchy-Wise use of Templates for Sustainability Assessment An Overview of the Research Work Done An Overview of Tools and Techniques Used in Research xii

19 B.1 Responses for Enablers by Researchers B.2 Responses for Enablers by Practitioners B.3 Responses for Barriers by Researchers B.4 Responses for Barriers by Practitioners B.5 Responses for Economic Indicators by Researchers B.6 Responses for Economic Indicators by Practitioners B.7 Responses for Environmental Indicators by Researchers B.8 Responses for Environmental Indicators by Practitioners B.9 Responses for Social Indicators by Researchers B.10 Responses for Social Indicators by Practitioners C.1 Enablers Cause and Effect analysis for Researchers C.2 Level Partitioning of Enablers for Researchers C.3 SEM Model for Enablers by Researchers C.4 Enablers Cause and Effect analysis for Practitioners C.5 Level Partitioning of Enablers for Practitioners C.6 SEM Model for Enablers by Practitioners C.7 Barriers Cause and Effect analysis for Researchers C.8 Level Partitioning of Barriers for Researchers C.9 SEM Model for Barriers by Researchers C.10 Barriers Cause and Effect analysis for Practitioners C.11 Level Partitioning of Barriers for Practitioners C.12 SEM Model for Barriers by Practitioners C.13 Indicators Cause and Effect analysis for Researchers C.14 Level Partitioning of Indicators for Researchers C.15 SEM Model for Indicators by Researchers C.16 Indicators Cause and Effect analysis for Practitioners C.17 Level Partitioning of Indicators for Practitioners C.18 SEM Model for Indicators by Practitioners D.1 Data used in Machining Calculations D.2 Surface Roughness Factors for Wet and Dry Turning Process D.3 Comparison between Experimental and Empirical Results xiii

20 D.4 Results for Economic Variables in Wet Turning D.5 Results for Economic Variables in Dry Turning D.6 Grey Relational Values for Economic Variables in Wet Turning D.7 Grey Relational Values for Economic Variables in Dry Turning D.8 Results for Environmental Variables in Wet Turning D.9 Results for Environmental Variables in Dry Turning D.10 Grey Relational Values for Environmental Variables in Wet Turning 357 D.11 Grey Relational Values for Environmental Variables in Dry Turning 357 E.1 Feature Vectors of Words for Researchers E.2 Feature Vectors of Words for Practitioners xiv

21 LIST OF FIGURES 1.1 SSCM Publications during Trend in Literature Review Categories Sustainability Assessment Framework by Global Reporting Initiative Summary of Literature Review Proposed Research Work SSCM Publication Count for Different Research Methodologies SSCM Publication Trend within Research Methodologies during Methodology for Developing Conceptual Model of Sustainability Implementation Evolution of Sustainability Theory Conceptual Model for Implementing Sustainability Indicators (and Metrics) for Economic Dimension Indicators (and Metrics) for Environmental Dimension Indicators (and Metrics) for Social Dimension Structural Equation Model for Economic Dimension Structural Equation Model for Environmental Dimension Structural Equation Model for Social Dimension Methodology for Identifying Critical Enablers, Barriers, and Indicators of Sustainable Manufacturing Average Matrix Plot for Enablers Causal Diagram for Enablers Digraph Plots for Enablers ISM Models for Enablers Average Matrix Plot for Barriers Causal Diagram for Barriers Digraph Plots for Barriers ISM Models for Barriers xv

22 4.16 Average Matrix Plot for Indicators Causal Diagram for Indicators Digraph Plots for Indicators ISM Models for Indicators Results for Important Economic Indicators Grey Relational Analysis for Economic Indicators Results for Important Environmental Indicators Grey Relational Analysis for Environmental Indicators Tentative Mapping of Total Respondents around the World D Scatter Plot of Words for Researchers Elbow Chart for Clustering Researchers results Cluster Results for Researchers Visualizing Reseachers opinions using Wordle D Scatter Plot of Words for Practitioners Elbow Chart for Clustering Practitioners results Cluster Results for Practitioners Visualizing Practitioners opinions using Wordle An Integrated SM Framework for Turning Process Flowchart for Implementing Integrated Sustainability Assessment Model Pictorial View of Research Work done D.1 Surface Roughness (R a ) Chart for Confirmatory Experiment D.2 Tool Wear Trend for Confirmatory Experiment D.3 Cutting insert at end of Tool life criteria for Confirmatory Experiment 352 D.4 Tool Life per Cutting Edge (in minutes) D.5 Quality of machined surface i.e. Surface Roughness (in µm) D.6 Production Rate per edge of insert (in number of components) D.7 Production Cost per component (in Rupees) D.8 Energy Consumption per component (in kwh) D.9 Carbon Emissions per component (in kg CO 2 ) D.10 Theoretical Cutting Temperature during Machining xvi

23 ABBREVIATIONS BASF CC CD CE CFI CT CQ DEMATEL EC EI ER EVA EVNA FDI FSC GoI GDP GMM GR GRA GRC GRG GRI GSCM HI ICT INR ISM Badische Anilin und Soda Fabrik Coolant Consumption Coefficient of Determination Carbon Emissions Comparative Fit Index Cutting Temperature Cutting Quality Decision Making Trial and Evaluation Laboratory Energy Consumption Energy Intensity Environmental Regulations Equal Variances Assumed Equal Variances Not Assumed Foreign Direct Investment Forest Stewardship Council Government of India Gross Domestic Product Gaussian Mixture Model Government Rules and Regulation Grey Relational Analysis Grey Relational Coefficients Grey Relational Grades Global Reporting Initiative Green Supply Chain Management Health Issues Information and Communications Technology Indian Rupee Interpretive Structural Modeling xvii

24 LI LR MC MEW ML MLE MMDE MO MP MRR NMCC NNFI PC PCA PE PI PEFC PM PR PSO RD RMSEA RPM RSM RQ SCM SEM SI SM SMEs SRMR SSC SSCM Labor Issues Labor Relations Manufacturing Cost Material, Energy, and Waste Materials Maximum Likelihood Estimation Maximum Mean De-Entropy Algorithm Multiobjective Optimization Machining Performance Material Removal Rate National Manufacturing Competitiveness Council Non-Normed Fit Index Production Cost Principal Component Analysis Production Efficiency Process Improvement Programme for the Endorsement of Forest Certification Process Management Production Rate Particle Swarm Optimization Research and Development Root Mean Square Error of Approximation Revolutions Per Minute Response Surface Methodology Research Question Supply Chain Management Structural Equation Modeling Safety Issues Sustainable Manufacturing Small and Medium Enterprises Standardized Root Mean Squared Residual Sustainable Supply Chain Sustainable Supply Chain Management xviii

25 TL TLI TR WC WCED WH WI WLS WM WOS WP WS WT Tool Life Tucker-Lewis Index Training and Education Water Consumption World Commission on Environment and Development Worker Health Water Intensity Weighted Least Squares Waste Management Web of Science Waste and Pollution Worker Safety Workforce Training xix

26 NOTATIONS E 1 E 2 E 3 E 4 E 5 E 6 E 7 E 8 E 9 E 10 B 1 B 2 B 3 B 4 B 5 B 6 B 7 B 8 B 9 B 10 pc pc1 pc2 pc3 pc4 pc5 pc6 cq Pressure from market Government promotions and regulations Economic Benefits Investment in Innovation & Technology Lowering Manufacturing Cost Improving Quality Education and Training System Attracting Foreign Direct Investment Infrastructure facilities in Transportation sector Development in E-Economy Lack of awareness of sustainability concepts Lack of awareness programs conducted locally Lack of awareness of local customers in green products Negative attitudes towards sustainability concepts Lack of funds for green projects Lack of standardized metrics or performance benchmarks Lack of support from senior leaders Cost too high Power Shortage Low Availability of Credit Production Cost Actual Machining Cost Machine Idle Cost Cutting and Lubrication Fluid Cost Cost of by-product treatment Governmental Policies Machine Tool Usage Cost Cutting Quality xx

27 cq1 cq2 cq3 pr pr1 pr2 pm pm1 pm2 pm3 wi wi1 wi2 ei ei1 ei2 ml ml1 ml2 ml3 ml4 ml5 ml6 ml7 wm wm1 wm2 wm3 wm4 wm5 wm6 wm7 wm8 Cutting Temperature Machining Induced Variations Surface Roughness Production Rate Cutting Power Material Removal Rate Process Management Continuous improvements of existing processes Improvement of material/energy consumption Performance Measurement Water Intensity Consumption of water per unit of output Source of water for the process Energy Intensity Energy consumed per unit of output Renewable proportion of energy consumed Materials Hazardous materials Chemicals Raw materials Material composition Packaging re-usability Packaging recyclability Distance from source Waste Management Weight of releases into air from production process Weight of releases into surface water from production process Weight of releases into land from production process Weight of transfers into disposal from production process Weight of transfers for treatment from production process Weight of transfers to recycling from production process Weight of transfers for energy recovery from production process Consumables reuse ratio xxi

28 wm9 Weight of transfers to sewage from production process wm10 Pollution impact on ozone layer wm11 Wastage and Spill over during production wm12 Mass of coolant loss er Environmental Regulations wh Worker Health wh1 Chemical Contamination of working environment wh2 Mist/dust level wh3 Physical Load Index wh4 Noise Level wh5 Health related absenteeism rate wh6 Compliance with regulatory requirements imposed on industry wh7 Admitted level of emissions and waste from machining operations ws Worker Safety ws1 Exposure to toxic chemicals ws2 Exposure to high energy components ws3 Number of occupational accidents ws4 Near Misses ws5 Operator Risk Level ws6 Ergonomic Design of human interface lr Labor Relations lr1 Hourly Wages lr2 Working Hours lr3 Workload lr4 Community Engagement lr5 Local Employment tr Training and Education tr1 Average Number of Hours of training per operator tr2 Required Skill Level H 0 H 1 Null Hypothesis Alternate Hypothesis µ Res Mean of Researchers Responses µ Ind Mean of Practitioners Responses xxii

29 x Sample Mean s 2 n x k ij h A Res A Ind D T R i + C j Pooled Variance Survey Sample Size Pairwise Comparisons between any two factors Number of respondents for causal matrix Average Causal matrix by Researchers Average Causal matrix by Practitioners Direct Influence Matrix Total Relation Matrix Prominence shows total effects given and received by factor i R i C j Relation represents net effect that factor i contributes to the system I.R. Res Modified Initial Reachability Matrix by Researchers I.R. Ind Modified Initial Reachability Matrix by Practitioners F.R. Res Final Reachability Matrix by Researchers F.R. Ind Final Reachability Matrix by Practitioners Res Original Fit statistics for Researchers models prior to SEM application Res Modified Fit statistics for Researchers models after SEM application Ind Original Fit statistics for Practitioners models prior to SEM application Ind Modified Fit statistics for Practitioners models after SEM application v Cutting Speed (m/min) f Feed (mm/rev) d Depth-of-Cut (mm) T.L. wet Tool Life in wet machining T.L. dry Tool Life in dry machining N p T c/comp. L N R a R a,th r ai r C 1 Number of components turned/edge Cutting Time per component Length of component to be turned Number of R.P.M Surface Roughness Theoretical Surface Roughness Ratio of Actual to Theoretical Surface Roughness Nose Radius of cutting insert Programming Cost over six months for complete batch/component xxiii

30 C 2 C 3 C 4 T l,u,cl T toolchange C L C M.R. C 5 C 6 Water Cost/component Oil Cost/component Labour Part Handling Cost/component Time spent in loading and unloading the part and cleaning off the chips Tool Change Time after the insert wears out Cost of Labour Charges per minute Cost of machine running per minute Labour Machining Cost/component Labour Idle Cost/component T air cut Time taken for total air-travel made by tool path before and after cutting C 7 T downtime C 8 C insert N edges/insert C 9 C /kw h C 10 C 11 C 12 C 13 C treatment/ltr C m/comp. D i L E 1 K p C Q W E 2 P basic Labour Downtime Cost/component Time involving no machining activity Tooling Cost/component Cost of 1 insert Number of cutting edges per insert Cutting Energy Cost/component Cost of electricity per kwh Basic Energy Cost/component Idle Energy Cost/component Downtime Energy Cost/component Coolant Disposal Cost/component Cost incurred in treating the waste coolant Cost of material/component Initial diameter of component Length of component Density of component Cutting Energy/component Power Constant Feed factor Metal Removal Rate Tool Wear Factor Basic Energy/component Amount of Basic Power consumed in non productive activities xxiv

31 E 3 P coolant P spindle P axis E 4 CE 1 CEF elect. CE 2 CEF tool M tool CE 3 CEF m CE 4 M chip CEF chip CE 5 CEF oil CEF wc T coolant Temp Idle Energy/component Power consumed by Coolant motor Power consumed by Spindle motor Power consumed by Axis motor Downtime Energy/component Carbon Emissions due to electricity/component Carbon Emission factor for electricity generation Carbon Emissions due to tool/component Carbon Emission Factor of tools Mass of the tool Carbon Emissions due to material/component Carbon Emission Factor per kg of raw material produced Carbon Emissions due to chips/component Mass of the chips produced Carbon Emission Factor of chips produced Carbon Emissions due to coolant/component Carbon Emission Factor in producing cutting fluid Carbon Emission Factor in disposing waste cutting fluid Predetermined Cutting Fluid Concentration Time Period after which cutting fluid is replaced Cutting Temperature T Mean Temperature rise at tool-chip interface in C U Specific Cutting Energy C Volumetric Specific Heat of work material t o K PC n C j Chip Thickness before cut Principal Cutting Edge Angle of insert Thermal Diffusivity of work material Principal Components Cluster Identity in Text Analysis xxv