By Grainger Editorial Staff 1/17/22
The manufacturing environment is rapidly evolving, and new technology is impacting every corner of the way the industry does business.
While the pandemic could have resulted in a setback for manufacturers, it acted as a reset button instead, giving the industry a chance to rethink processes and approaches as teams had to quickly adapt to new ways of working. A main focus was sustainability. In fact, a July 2021 report from The Sustainability Consortium revealed that, since 2016, manufacturers have increased their sustainable practices by 38 percent—even through the pandemic. The challenges of the past two years taught manufacturers valuable lessons that can help further improve the way products are made.
In the past, sustainability may have been considered a competitive edge. Today, it’s becoming a necessity. Establishing best practices that focus on green manufacturing efforts and eco-friendly factories is not only good for people but also the planet and your bottom line.
As you plan for 2022 and beyond, consider these sustainable manufacturing trends.
Additive manufacturing, another term for 3D printing, is a computer-controlled process that creates objects from successive layers of polymers, ceramics and metals. Think of it like this: traditional manufacturing creates a shape or object by removing material from a stock piece, while additive manufacturing adds layers of material to create a shape or object. The latter consumes less material, produces less waste, can be faster and can be more cost efficient.
A Metal Powder Industries Federation report highlights the advantages of additive manufacturing with this real-world example: with traditional manufacturing, 17 steps are required to produce a piece of truck gear, but additive manufacturing requires only six steps to create that same gear. This reduction in steps saves time, money and energy.
Industries such as aerospace, medical, transportation and consumer packaged goods are already putting this technology to work—mostly in lower-volume parts production. A survey cited by Deloitte revealed that 63 percent of plants using additive manufacturing processes rely on it for prototyping while another 21 percent use it to manufacture goods that can’t be made using other technologies.
According to nonprofit Polaris MEP, since this approach is different than what the industry is used to, it requires a shift in mindset and skillset.
When plants follow traditional bulk manufacturing processes, they run the risk of over-producing and creating unsold inventory that takes up valuable space. Eventually, these products must be disposed of, whether that involves sending them to the landfill, incineration or recycling, which negatively impacts sustainable manufacturing practices.
While on-demand manufacturing can help reduce this problem, it isn’t the right fit for every application. Compared to bulk manufacturing, the approach means that goods are produced only when they’re needed. They are manufactured in a specific quantity based on what consumers order, eliminating the possibility of them sitting on shelves.
Using a combination of bulk and on-demand manufacturing processes—a hybrid manufacturing approach, as described by Global Trade magazine—can help manufacturers assess specific products before they move into mass production. Putting a SKU through an on-demand manufacturing cycle tests viability so manufacturers can see how sales go. Then, a move to mass production can be made if or when the time is right.
When COVID-19 hit the U.S. in March 2020, many plants realized how quickly they could pivot to adopt remote manufacturing and collaboration practices.
Monitoring facilities, emissions, manufacturing processes and maintenance remotely in real-time reduces travel and carbon footprints. A labor force that has the ability to work remotely can also apply its expertise to more than one location, helping plants make the most of the technical workers on staff.
Through continued evolution of the Industrial Internet of Things (IIoT) and Industry 4.0, remote monitoring and operation can help efficiently control and access equipment and processes from anywhere at any time.
Instead of spreading supply chains throughout the globe, sustainable manufacturing processes will focus on regional supply chains. From raw material sourcing and material processing to manufacturing, more activities will happen within a smaller geographic area
As information services company Wolters Kluwer points out, some manufacturers may decide to increase reliance on neighboring countries that have friendly trade agreements with the U.S. This move not only helps ease supply chain issues and support faster lead times but also lowers costs, reduces environmental impact, decreases travel and infuses money into local economies.
Green manufacturing needs to factor in all facets of the manufacturing process—right down to the facility where the goods are produced.
There are basic steps that can be taken to reduce plant energy usage, such as upgrading old incandescent and HID lamps to energy-efficient LEDs or using variable frequency drives (VFDs) to match the speed of an electric motor with an application’s voltage requirements. However, there are also other practices to consider, such as implementing solar power, recovering heat waste or adjusting maintenance plans.
Instead of making guesses about where and how to reduce energy usage, an energy assessment can identify ways you can make the biggest impact based on current energy usage, facility location and potential areas of waste. From there, you’ll have a roadmap that leads you down a sustainable path.
Get more tips and trends on sustainable operations to help your business thrive.
The information contained in this article is intended for general information purposes only and is based on information available as of the initial date of publication. No representation is made that the information or references are complete or remain current. This article is not a substitute for review of current applicable government regulations, industry standards, or other standards specific to your business and/or activities and should not be construed as legal advice or opinion. Readers with specific questions should refer to the applicable standards or consult with an attorney.