Optimizing Carbon Footprint and Operational Productivity of Horizontal Boring Machines: An EFBA-Based Approach

Abstract

Abstract In modern-day industries, the presence of bottleneck processes, where the throughput capacity falls short of the workload, can result in reduced efficiency, increased energy consumption, and higher production costs. Such inefficiencies are deemed unacceptable in today’s highly competitive market, coupled with stringent environmental regulations. To address these challenges, many industries have adopted lean and green manufacturing concepts to enhance workflow and environmental performance. This research paper integrates bottleneck analysis with carbon footprinting, specifically employing the EFBA (Energy Focussed Bottleneck Analysis) approach, to identify and eliminate bottlenecks and high energy consumption within the machining section of a press manufacturing industry. The study focuses on improving the setup time, machining time, and carbon footprint associated with the boring operation of the journal head. By implementing the proposed approach, significant improvements were achieved, with setup time reduced by 108 min, machining time reduced by 64 min, and carbon dioxide emissions reduced by 32.2 kg. These outcomes highlight the effectiveness of the integrated EFBA-based methodology in enhancing operational efficiency and reducing the environmental impact of the manufacturing process. The findings of this study offer valuable insights and practical implications for other industries seeking to optimize their production systems, reduce energy consumption, and minimize carbon emissions. By identifying and addressing bottlenecks through a combined bottleneck analysis and carbon footprinting approach, companies can enhance their operational productivity while promoting sustainability in line with environmental regulations and market demands.